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[HJIRLEYDAYIDSOK]

SOFTAIL® MODELS
2022 HARLEY-DAVIDSON® SERVICE MANUAL

94000936
 IMPORTANT NOTICE

Harley-Davidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards and U.S.A. En-
vironmental Protection Agency regulations effective on the date of manufacture.

To maintain the safety, dependability, and emission and noise control performance, it is essential that the procedures,
specifications and service instructions in this manual are followed.

Any substitution, alteration or adjustment of emission system and noise control components outside of factory spe-
cifications may be prohibited by law.

Harley-Davidson Motor Company

 SOFTAIL® MODELS
2022 HARLEY-DAVIDSON® SERVICE MANUAL
©2021 H-D.
ALL RIGHTS RESERVED
PRINTED IN THE USA
94000936

VISIT THE HARLEY-DAVIDSON WEB SITE

https://^^.harley-davidson.com
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94000936

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2022 HARLEY-DAVIDSON® SERVICE MANUAL - SOFTAIL® MODELS

• Return this form to:
Harley-Davidson Motor Company
Department 625 Service Communications
P.O. Box 653
Milwaukee WI 53201 USA
PLEASE ADD ANY OTHER COMMENTS HERE
NOTES
FOREWORD

GENERAL
This manual has been created to inform Harley-Davidson Table 1. Symbols
technicians about the construction of Harley-Davidson products Symbol Description
and the latest tested and approved maintenance and repair Apply Lubricant: Indicates a part that should be
techniques. lubricated during installation.

MANUAL LAYOUT _______ ______________ Discard/Do Not Reuse: Indicates a part that must
be replaced with a new part during installation.
Safety
Apply Sealant: Indicates a part that must be in-
Refer to the Safety section before performing any procedures on stalled with a threadlocker or sealant.
a vehicle.
Special Tool: Indicates that a special tool is re-
Sections commended.
$
This service manual is organized into chapters, sections and
Measure: Indicates a part that should be measured
topics. Each section is laid out in the following manner:
or gauged to verify that it is within specification.
• Prepare
• Remove HOW TO USE THIS SERVICE MANUAL
• Install
• Disassemble (if applicable)
Cross-References and Page Numbers
• Clean/Inspect (if applicable) A cross-reference shown as 2.2 SPECIFICATIONS refers to
chapter 2 CHASSIS, heading 2.2 SPECIFICATIONS.
• Assemble (if applicable)
All pages contain a chapter number followed by a page number.
• Complete
For example, page 3-5 refers to page 5 in Chapter 3.

Topics

FOREWORD
Item References and Quantities
The purpose of the Prepare topics is to to provide an outline of
procedures required before beginning a specific task. Links to the In figure legends and tables, the number in parentheses that
necessary procedures are provided in the topic. follows the part name indicates the quantity of that part
necessary for one complete assembly.
The Remove and Install topics allow the technician to only
remove and install the component - which may be all that is Example:
required. If a component can be repaired, Disassemble, 2. Screw (4)
Assemble and Clean/Inspect topics are provided as
appropriate. In a procedure step or paragraph, the number in parentheses
that follows a part name indicates the legend item of the part in
Complete topics provide a list of procedures that need to be the figure referenced by the text.
performed to return the vehicle to ride-ready condition. If
additional removal procedures need to be performed, move to Example:
the next section without performing the Complete topics in the
1. Remove screws (2).
current section.
Acronyms and Abbreviations
Procedural Steps
Acronyms and abbreviations are used in this document. See the
Each topic contains steps to complete the procedure. These
Acronyms and Abbreviations (Page B-1) for a list of acronyms,
steps are laid out in numeric and alpha steps.
abbreviations and definitions.
The purpose of the numeric steps is to provide the experienced
technician with high-level information to complete the procedure.
PREPARATION FOR SERVICE ____________

The alpha steps provide a less-experienced technician with step- • Start each job with a clean work area.
by-step instructions to perform the procedure.
• Clean the motorcycle before work begins.
Symbol Identification • Gather any tools, instruments and parts needed for the job
before work begins.
Symbols are used in some graphics to provide information about
parts. Refer to Table 1 for symbol definitions. • Carefully read all related service information, including service
bulletins, before service work begins.

94000936 I
USE GENUINE REPLACEMENT PARTS parts inspection. Strip rusted paint areas to bare metal before
priming and repainting.
A WARNING Always clean around lines or covers before they are removed.
When cleaning parts:
Harley-Davidson parts and accessories are designed for Harley-
Davidson motorcycles. Using non-Harley-Davidson parts or • Plug, tape or cap holes and openings to keep out dirt, dust
accessories can adversely affect performance, stability or and debris.
handling, which could result in death or serious injury. (00001 b)
• Clean and inspect all parts as they are removed.

To achieve satisfactory and lasting repairs, carefully follow the • Cover all clean parts with clean lint-free cloth, paper or other
service manual instructions and use only genuine Harley- material.
Davidson replacement parts. • Verify that the part is clean when installed.
SHOP PRACTICES
Cleaning Threads and Threaded Holes
Always verify cleanliness of blind holes before assembly.
CONSUMABLE PART NUMBER Tightening a screw with dirt, water or oil in the hole can cause
LOCTITE 243 99642-97 castings to crack or break.
MEDIUM
To attain proper clamp load, always clean fastener threads and
STRENGTH
threaded holes prior to assembly.
THREADLOCKER
AND SEALANT NOTE
(BLUE)
Never use a thread-cutting tap or die to clean threads.
Removing Parts
• Clean all threadlocking material from fastener threads and
Always use blocking or proper stands to support the part that has threaded holes.
been hoisted. If a part cannot be removed, verify that all bolts
• Use a wire brush or thread-chasing die to clean fastener
and attaching hardware have been removed. Verify that no parts
threads.
are in the way of the part being removed.
• Use a thread chaser to clean threaded holes.
Always tag hoses, wiring or tubes to verify proper installation.
• Use a mixture of 50 percent isopropyl alcohol and 50 percent
distilled water or equivalent to remove all traces of oil and
Cleaning
contaminants from threads.
Thoroughly clean all parts to be reused before assembly. Clean • Clear all threaded holes with low-pressure compressed air.
parts promote better component operation and longer life. Seals,
filters and covers used in this vehicle keep out extraneous dirt Cleaning Plastic and Rubber Parts
and dust. Keep these items in good condition to guarantee
satisfactory operation. See Cleaning (Page II). Never use cleaners containing chlorine or ammonia on plastic
parts. Chlorine will cause parts to become distorted and brittle
resulting in cracks. Ammonia will cause cloudiness and
Checking Torques on Fasteners and
brittleness in windshields and cause non-painted parts to form a
Threadlocking Agents
white haze.
Check torque using a torque wrench set to the minimum Before cleaning, protect rubber parts (such as hoses, boots and
specification for that fastener. If the fastener does not rotate, the
electrical insulation) from cleaning solutions. Use a grease-proof
torque has been maintained. If the fastener rotates, remove it to
barrier material. Remove the rubber part if it cannot be properly
determine if it has a threadlocking agent.
protected.
If it has a threadlocking agent, clean all material from the
threaded hole. See Cleaning Threads and Threaded Holes later Rust or Corrosion Removal
in this section. Replace the fastener with a new one or clean the
Remove rust and corrosion with a wire brush, abrasive cloth,
original fastener threads. Use the threadl ocker stated in the
sand blasting, vapor blasting or rust remover. Use buffing crocus
appropriate procedure. If no threadlocker is indicated, use
cloth on highly polished parts that are rusted.
LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (BLUE) (99642-97) or equivelent. Install and tighten
the fastener to specification. Bearings
Wash bearings in a non-flammable petroleum cleaning solution.
If the fastener does not use a threadlocking agent, install and
Never use a solution that contains chlorine. Knock out packed
tighten it to specification.
lubricant by tapping the bearing against a wooden block. Wash
CLEANING _____________________________ bearings again.
A WARNING
General Using compressed air to "spin dry" bearings can cause bearing to
fly apart, which could result in death or serious injury. (00505b)
Any cleaning method may be used as long as it does not result in
parts damage. Thorough cleaning is necessary for proper

2 94000936
Cover bearings with a clean shop towel. Allow bearings to air dry. Gunk, Heli-Coil, Hydroseal, Hylomar, iPhone, iPod, Kevlar,
Do not spin bearings while they are drying. Never use Lexan, Loctite, Lubriplate, Keps, K&N, Magnaflux, Marson
compressed air to dry bearings. Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin, MPZ,
Mulitilock, nano, NGK, Novus, Packard, Pirelli, Permatex, Philips,
When dry, coat bearings with clean oil. Wrap bearings in clean PJ1, Pozidriv, Road Tech, Robinair, S100, Sems, Siri, SiriusXM,
paper. Snap-on, Teflon, Threadlocker, Torca, Torco, TORX, Tufoil,
Tyco, Ultratorch, Velcro, X-Acto and XM Satellite Radio are
DISPOSAL AND RECYCLING _ among the trademarks of their respective owners.

Many communities maintain facilities for recycling used fluids, H-D U.S.A., LLC TRADEMARK INFORMATION
plastics and metals. Dispose of or recycle used oil, lubricants, __________________________________
fuel, coolant, brake fluid and batteries in accordance with local
regulations. Bar & Shield, Boom!, Cross Bones, Cruise Drive, CVO, Digital
Tech, Digital Technician, Digital Technician II, Dyna, Electra
TOOLS AND MATERIALS
Glide, Evolution, Fat Bob, Fat Boy, Forty-Eight, Glaze, Gloss, H-
D, H-Dnet.com, Harley, Harley-Davidson, HD, Heritage Softail,
A WARNING Iron 883, Low Rider, Milwaukee-Eight, Night Rod, Nightster,
Read and follow warnings and directions on all products. Failure Night Train, Profile, Reflex, Revolution, Road Glide, Road King,
to follow warnings and directions can result in death or serious Road Tech, Rocker, Screamin' Eagle, Seventy-Two, Softail,
injury. (00470b) Sportster, Street Glide, Street Rod, Sun Ray, Sunwash, Super
Glide, SuperLow, Supersmart, Switchback, SYN3, TechLink,
TechLink II, TechLink Ill, Tour-Pak, Tri Glide, Twin Cam 88, Twin
Some service procedures require the use of tools designed for a
Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam 103, Twin
specific purpose. These tools should be used when and as
Cam 103B, Twin Cam 110, Twin Cam 110B, Twin-Cooled, Ultra
recommended.
Classic, V-Rod, VRSC and Harley-Davidson Genuine Motor
When reference is made in this manual to a brand name product, Parts and Genuine Motor Accessories are among the trademarks
tool or instrument, an equivalent product, tool or instrument may of H-D U.S.A., LLC.
be substituted.
CONTENTS________ _______
Special Tools
All photographs, illustrations and procedures may not necessarily
Special tools mentioned in this manual with a part number that depict the most current model or component, but are based on
begins with an "HD", "J" or "B" must be purchased, serviced or the latest production information available at the time of
warrantied through a Harley-Davidson dealer. publication.

Specific use of special tools is not discussed in this manual. Since product improvement is our continual goal, Harley-
Refer to the tool instruction sheet for instructions. If the tool Davidson reserves the right to change specifications, equipment
instructions are misplaced, a copy can be obtained online at H- or designs at any time without notice and without incurring
Dnet.com > My Toolbox > Edit > Bosch Tool Site. obligation.

LOCTITE Sealing and Threadlocking Products Content Applicability

Some procedures in this manual call for the use of LOCTITE Certain areas within this manual may have tables designating
products. If you have any questions regarding LOCTITE product model or feature applicability. Refer to Table 2.
usage or retailer/wholesaler locations, contact Loctite Corp. at
Table 2. Sample Applicability Table
www.loctite.com. APPLICABILITY
PRODUCT REGISTERED MARKS • Content applies to model or feature listed
0

□
• Content does not apply to model or feature listed
Apple, Alcantara S.p.A., Allen, Amp Multilock, Android Auto,
Bluetooth, Brembo, CarPlay, City Navigator, Delphi, Deutsch,
Dunlop, Dynojet, Fluke, G.E. Versilube, Garmin, Googel LLC,

94000936 Ill
NOTES
 TABLE OF CONTENTS
SAFETY 2.9 LUBRICATE CABLES AND
CHASSIS
1.1 SAFETY General ................................................................................. 2-16
Safety. .......... ......................................................................... 1-1 Lubrication Points ................................................................. 2-16
Safety Messages ........................................................... 1-1
Customer Safety .............................................................. 1-1
2.10 INSPECT BRAKES
Inspect .................................................................................. 2-17
Personal Protection ......................................................... 1-1 Brake Pads .................................................................. 2-17
Tool Safety ...................................................................... 1-1 Brake Disc ..................................................................... 2-17
Product Safety ................................................................. 1-1 Replace Front Brake Pads .................................................... 2-18
Hazardous Materials ........................................................ 1-2 Remove ......................................................................... 2-18
Electrical Systems ......................................................... 1-2 lnstall ............................................................................. 2-18
Replace Rear Brake Pads .................................................... 2-19
MAINTENANCE Remove ......................................................................... 2-19
lnstall ............................................................................. 2-19
2.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter ................................. 2-1 2.11 CHECK AND REPLACE BRAKE
2.2 GENERAL FLUID
Servicing a Motorcycle ........................................................... 2-2 Check Brake Fluid Level ....................................................... 2-21
Drain and Replace Fluid ....................................................... 2-22
Secure the Motorcycle for Service .......................................... 2-2
Set Motorcycle Upright .................................................... 2-2 2.12 CHECK AND ADJUST CLUTCH
Raise Front or Rear Wheel for Service ............. .............. 2-2 Check and Adjust.................................................................. 2-23
Adjust .......................................................................... 2-23
2.3 MAINTENANCE SCHEDULE Clutch Cable Only Check ............................................... 2-24
General .................................................................................. 2-3
Regular Service Intervals ................................................. 2-3 2.13 REBUILD FRONT FORK AND REPLACE

TABLE OF CONTENTS
2.4 FUEL AND OIL OIL
Fuel ........................................................................................ 2-5 Rebuild and Replace Fork Oil ............................................... 2-26
Gasoline Blends ..................................................................... 2-5
2.14 ADJUST AND LUBRICATE
Engine Lubrication.................................................................. 2-5
Winter Lubrication .................................................................. 2-6 STEERING HEAD BEARINGS
Prepare .............................................................................. ...2-27
2.5 REPLACE ENGINE OIL AND FILTER Check and Adjust.................................................................. 2-27
Check Engine Oil Level .......................................................... 2-7 Measure ..... ... .............................................................. 2-27
Oil Level Cold Check ....................................................... 2-7 Adjust .......................................................................... 2-27
Oil Level Hot Check ......................................................... 2-7 Lubricate ............................................................................... 2-28
Change Oil and Oil Filter ........................................................ 2-7 Complete .............................................................................. 2-28

2.6 REPLACE PRIMARY CHAINCASE 2.15 INSPECT FUEL LINES AND FIT-
LUBRICANT TINGS
Change Primary Chaincase Lubricant .................................... 2-9 Inspect .................................................................................. 2-29
2.7 REPLACE TRANSMISSION LUBRIC 2.16 INSPECT AND LUBRICATE JIFFY STAND
ANT Inspect and Lubricate............................................................ 2-30
Check Transmission Lubricant ............................................. 2-11
Change Transmission Lubricant ........................................... 2-11 2.17 INSPECT AND ADJUST DRIVE
BELT AND SPROCKETS
2.8 INSPECT TIRES AND WHEELS lnspect .................................................................................. 2-31
General .......................................................................... 2-31
General ............................................................................... 2-13 Cleaning ........................................................................ 2-31
Tire Pressure ................................................................. 2-13
Sprockets.............................................. . ....................... 2-31
Tread ............................................................................. 2-13
Drive Belt ....................................................................... 2-31
Tires ..................................................................................... 2-14
Measure Drive Belt Deflection............................................... 2-32
lnspect .......................................................................... 2-14
Adjust Belt ............................................................................ 2-33
When to Replace Tires .................................................. 2-14
Screw Style:................................................................... 2-33
Wheel Bearings .................................................................... 2-14
Wheel Spokes ...................................................................... 2-14 2.18 ADJUST SUSPENSION
Identify Wheel Spoke Groups ...................................... 2-15 Adjust Shock Absorber ......................................................... 2-35
Adjust Wheel Spokes ................................................ .....2-15

TABLE OF CONTENTS V
 TABLE OF CONTENTS
Calculate Preload Setting .............................................. 2-35 Clutch Slips ................................................................... 2-52
Adjustment ..................................................................... 2-37 Clutch Drags Or Does Not Release ............................... 2-52
Clutch Chatters .............................................................. 2-52
2.19 INSPECT EXHAUST SYSTEM
Leak Check ......................................................................... 2-39 Handling ............................................................................... 2-52
Irregularities ................................................................... 2-52
2.20 INSPECT AIR FILTER Brakes .............................................................................. 2-52
Remove and Install: Round ................................................. 2-40 Brake Does Not Hold Normally ...................................... 2-52
REMOVE ....................................................................... 2-40
INSTALL ........................................................................ 2-40 CHASSIS _________________
Remove and Install: Oval ...... .............................................. 2-40
REMOVE ....................................................................... 2-40 3.1 FASTENER TORQUE VALUES
INSTALL ........................................................................ 2-41
Fastener Torque Values in this Chapter .................................. 3-1
Remove and Install: Cone ................................................... 2-41
Remove ......................................................................... 2-41 3.2 SPECIFICATIONS
lnstall ............................................................................. 2-41
Clean and Inspect ................................................................ 2-42 Chassis ................................................................................... 3-8
Chassis Specifications ..................................................... 3-8
2.21 INSPECT BATTERY Tire Specifications ........................................................... 3-9
Prepare ................................................................................ 2-43
Remove .............................................................................. 2-43 3.3 VEHICLE IDENTIFICATION NUM
lnstall .................................................................................... 2-44 BER (VIN)
Clean and Inspect ................................................................ 2-44
Voltage Test ......................................................................... 2-44 Vehicle Identification Number (VIN) ..................................... 3-1O
Storage................................................................................. 2-44 General ........................................................................ 3-10
Complete .............................................................................. 2-45 Location ........................................................................ 3-1O
Abbreviated VIN............................................................. 3-10
2.22 CLEAN, INSPECT, REPLACE
3.4 FRONT WHEEL
SPARK PLUGS
Prepare ................................................................................ 2-46 Prepare ................................................................................. 3-12
Remove ............................................................................... 2-46 Remove ................................................................................ 3-12
Clean and Inspect ................................................................ 2-46 lnstall .................................................................................... 3-12
Spark Plugs ................................................................... 2-46 Disassemble ......................................................................... 3-13
Spark Plug Cables ......................................................... 2-46 Clean and lnspect ................................................................. 3-13
lnstall .................................................................................... 2-46 Assemble .............................................................................. 3-13
Complete .............................................................................. 2-47 Complete .............................................................................. 3-15
2.23 STORAGE 3.5 REAR WHEEL
Place in Storage ................................................................... 2-48
Remove from Storage .......................................................... 2-49 Prepare ................................................................................. 3-16
Remove ................................................................................ 3-16
2.24 TROUBLESHOOTING
lnstall .................................................................................... 3-16
Engine .................................................................................. 2-50
Disassemble ......................................................................... 3-18
Starter Motor Does Not Operate or Does Not Turn Engine
Clean and Inspect ................................................................. 3-18
Over ............................................................................... 2-50
Assemble .............................................................................. 3-18
Engine Turns Over But Does Not Start .......................... 2-50
Complete .............................................................................. 3-18
Starts Hard .................................................................... 2-50
Starts But Runs Irregularly or Misses ............................. 2-50 3.6 WHEEL LACING
A Spark Plug Fouls Repeatedly ..................................... 2-50
Pre-Ignition or Detonation (Knocks or Pings) ................. 2-51 Wheel Lacing: Angle Flange Hub .......................................... 3-19
Overheating ................................................................... 2-51
3.7 CHECKING AND TRUING WHEELS
Valve Train Noise .......................................................... 2-51
Excessive Vibration ..................................................... 2-51 General ................................................................................. 3-21
Check Engine Light Illuminates During Operation .......... 2-51 Checking Wheel Runout ....................................................... 3-21
Lubrication System ............................................................... 2-51 Checking Radial Runout ................................................ 3-21
Oil Does Not Return To Oil Reservoir ............................ 2-51 Checking Lateral Runout ............................................... 3-21
Engine Uses Too Much Oil Or Smokes Excessively....2-51 Laced Wheel Rim Offset ....................................................... 3-22
Engine Leaks Oil From Cases, Pushrods, Hoses, True Laced Wheels ............................................................... 3-23
Etc ................................................................................. 2-51 Adjust Radial Runout ..................................................... 3-23
Low Oil Pressure ........................................................... 2-51 Adjust Lateral Runout ........ ...................................... ....3-24
High Oil Pressure ........................................................... 2-52
Electrical System ................................................................ 2-52 3.8 SEALED WHEEL BEARINGS
Alternator Does Not Charge .......................................... 2-52
Prepare ................................................................................ 3-25
Alternator Charge Rate Is Below Normal ....................... 2-52 Inspect ...... ....................................................................... ...3-25
Speedometer Operates Erratically................................. 2-52 Remove ................................................................................3-25
Transmission ....................................................................... 2-52 lnstall ....................................................................................3-26
Shifts Hard .................................................................... 2-52 Complete ..............................................................................3-27
Jumps Out Of Gear ....................................................... 2-52

TABLE OF CONTENTS VI
 TABLE OF CONTENTS
3.9 TIRES Removing Caliper for Service ......................................... 3-46
General ................................................................................ 3-28 Remove Rear Caliper Mounting Bracket ........................ 3-46
Prepare .............................................................................. 3-28 lnstall ......... .......................................................................... 3-46
Remove ..... ................................................................ .....3-28 Install Rear Caliper Mounting Bracket ............................ 3-47
Clean, Inspect and Repair .................................................... 3-29 Installing Caliper from Service ........................................ 3-47
lnstall .................................................................................... 3-29 Installing Caliper from Removing Rear Brake Pads........3-47
Tube-Type Tires ............................................................ 3-29 Installing Caliper from Remove Rear Wheel ................... 3-47
Tubeless Tires: Cast Wheels ......................................... 3-30 Install All......................................................................... 3-47
Check Tire Runout ............................................................. 3-30 Disassemble ......................................................................... 3-48
Lateral Runout ............................................................... 3-30 Caliper............................................................................ 3-48
Radial Runout ................................................................ 3-30 Rear Caliper Mounting Bracket ...................................... 3-49
Balance ............................................................................... 3-31 Clean and lnspect ................................................................. 3-49
Static vs Dynamic .......................................................... 3-31 Assemble .............................................................................. 3-49
Weights ......................................................................... 3-31 Rear Caliper Mounting Bracket ...................................... 3-49 •
Complete ......................................................................... ...3-32 Caliper............................................................................ 3-49
Complete .............................................................................. 3-50
3.10 WHEEL ALIGNMENT
3.15 BRAKE LINES
Prepare ................................................................................ 3-33
Inspect.............................................................................. 3-33 Front Brake Line: Non-ABS .................................................. 3-51
Measure: Rear Fork Flat ............... ................................ 3-33 Prepare .......................................................................... 3-51
Measure: Rear Fork Pivot Shaft ................................ ...3-34 Remove......................................................................... 3-51
Adjust ........................................................................... .....3-34 lnstall ............................................................................. 3-51
Complete ....................................................................... .....3-34 Complete........................................................................ 3-51
Rear Brake Line: Non-ABS ................................................... 3-51
3.11 FRONT BRAKE MASTER CYLIN- Prepare .......................................................................... 3-51
DER Remove........................................................................ 3-51
Prepare ................................................................................ 3-35 lnstall .............................................................................. 3-52
Remove ............................................................................... 3-35 Complete........................................................................ 3-52
lnstall ................................................................................... 3-36 Brake Line: Front Master Cylinder (ABS) .............................. 3-52
Disassemble ..................... ....... — ....... ..... .......................... 3-36 Prepare .......................................................................... 3-52
Clean and lnspect....... ...................................................... 3-36 Remove.......................................................................... 3-52
Assemble .......................................................................... 3-37 lnstall .............................................................................. 3-53
Complete .......................................................................... 3-37 Complete...................................................................... 3-53
Brake Line: Front Caliper (ABS)............................................ 3-53
3.12 FRONT BRAKE CALIPER Prepare .......................................................................... 3-53
Remove.......................................................................... 3-54
Prepare ................................................................................ 3-38
Install ........................................................................... 3-54
Remove ................................................................................ 3-38
Complete........................................................................ 3-54
Remove Caliper to Remove Front Wheel ................. 3-38
Front ABS Lines.................................................................. 3-54
Remove Caliper to Remove Front Brake Pads ............. 3-38
Prepare ........ ..... .......................................................... 3-54
Remove Caliper for Service ........................................... 3-38
Remove.......................................................................... 3-54
lnstall .................................................................................... 3-38
Install ............................................................................. 3-55
Install Caliper After Service............................................ 3-38
Complete....................................................................... 3-56
Install Caliper After Installing Front Brake Pads ............. 3-39
Brake Line: Rear Master Cylinder to ABS Module ................ 3-56
Install Caliper After Installing Front Wheel ..................... 3-39
Prepare .......................................................................... 3-56
Disassemble ..................................................................... 3-39
Remove........ ................................................................. 3-56
Clean and Inspect ...... ........................................................ 3-40
lnstall .............................................................................. 3-56
Assemble ............................................................................. 3-41
Complete........................................................................ 3-57
Complete .............................................................................. 3-41
Brake Line: Rear Caliper to ABS Module .............................. 3-57
3.13 REAR BRAKE MASTER CYLINDER Prepare .......................................................................... 3-57
Remove.......................................................................... 3-58
Prepare ............................................................................... 3-42 Install ........................................................................... 3-58
Remove ................................................................................ 3-42 Complete........................................................................ 3-58
lnstall .................................................................................... 3-42
Disassemble and Assemble: Master Cylinder ...................... 3-43
Disassemble .................................................................. 3-43
Clean and Inspect ..................................................... 3-44
Assemble ....................................................................... 3-44
Complete .............................................................................. 3-45

3.14 REAR BRAKE CALIPER

Prepare ................................................................................ 3-46
Remove ................................................................................ 3-46
Removing Caliper to Remove Rear Wheel .................... 3-46
Removing Caliper to Removing Rear Brake Pads ......... 3-46

TABLE OF CONTENTS
VII
TABLE OF CONTENTS
3.16 ABS MODULE 3.23 REAR FORK
General................................................................................. 3-59 Prepare ................................................................................ 3-81
Prepare................................................................................. 3-59 Remove and lnstall............................................................... 3-81
Remove ................................................................................ 3-59 Remove ........................................................................ 3-81
Install .................................................................................... 3-59 lnstall............................................................................. 3-81
Complete .............................................................................. 3-60 Disassemble and Assemble: Standard ................................. 3-82
Disassemble ................................................................. 3-82
3.17 BLEED BRAKES Clean and Inspect ......................................................... 3-82
Drain ..................................................................................... 3-61 Assemble ........ ............................................................. 3-83
Fill and Bleed ........................................................................ 3-61
Complete.............................................................................. 3-84
3.18 LEFT SIDE COVER 3.24 BELT GUARDS
Remove ................................................................................ 3-63
Install .................................................................................... 3-63 Prepare ................................................................................ 3-85
3.19 RIGHT SIDE COVER Remove and Install: Standard .............................................. 3-85
Remove ................................................................................ 3-64 REMOVE ...................................................................... 3-85
Install .................................................................................... 3-64 INSTALL ....................................................................... 3-85
Complete.............................................................................. 3-86
3.20 FRONT FORK
Check For Oil Leak ............................................................... 3-65 3.25 REAR SHOCK ABSORBER
Fork Oil Seals ................................................................ 3-65
Prepare ................................................................................ 3-87
Check Oil Leak............................................................... 3-65
Remove................................................................................ 3-87
Prepare................................................................................. 3-65
lnstall .................................................................................... 3-87
Remove ................................................................................ 3-65
Disassemble and Assemble: Rear Shock Adjuster .............. 3-89
Remove ......................................................................... 3-65
Remove shock adjuster knob ........................................ 3-89
lnstall .................................................................................... 3-66
Install shock adjuster knob ............................................ 3-89
lnstall ............................................................................. 3-66
Complete.............................................................................. 3-90
Disassemble and Assemble: Standard ................................. 3-66
Disassemble .................................................................. 3-66 3.26 CLUTCH CONTROL
Clean and Inspect .......................................................... 3-69
Assemble ....................................................................... 3-69 Prepare ................................................................................ 3-91
Disassemble and Assemble: Inverted, Left Side ................... 3-70 Remove................................................................................ 3-91
Disassemble .................................................................. 3-70 Clutch Cable Disconnect. ..... ....................................... 3-91
Clean and lnspect .......................................................... 3-72 Clutch Cable: Lower End .......................................... 3-92
Assemble ....................................................................... 3-72 Clutch Cable: Upper End .......................................... 3-92
Disassemble and Assemble: Inverted, Right Side ................ 3-73 Clutch Hand Control ...................................................... 3-92
Disassemble .................................................................. 3-74 Clean and Inspect ................................................................ 3-93
Clean and lnspect .......................................................... 3-76 lnstall .................................................................................... 3-93
Assemble ....................................................................... 3-76 Clutch Cable: Lower End .......................................... 3-93
Complete .............................................................................. 3-77 Clutch Cable: Upper End .......................................... 3-93
Clutch Cable Connect ................................................... 3-93
3.21 STEERING HEAD/FORK STEM Clutch Hand Control ...................................................... 3-93
AND BRACKET ASSEMBLY Disassemble ........................................................................ 3-94
Prepare................................................................................. 3-78 Lock Button ................................................................... 3-94
Remove ................................................................................ 3-78 Housing......................................................................... 3-94
Upper Fork Bracket ........................................................ 3-78 Assemble ............................................................................. 3-94
Lower Fork Bracket ........................................................ 3-78 Lock Button ................................................................... 3-94
Clean and lnspect ................................................................. 3-78 Housing......................................................................... 3-94
lnstall .................................................................................... 3-78 Complete.............................................................................. 3-95
Lower Fork Bracket ........................................................ 3-79 3.27 HEADLAMP NACELLE
Upper Fork Bracket ........................................................ 3-79
Complete .............................................................................. 3-79 Prepare ................................................................................ 3-96
PREPARE ..................................................................... 3-96
3.22 FORK LOCK Remove............................................................................... 3-96
Prepare................................................................................. 3-80 HORIZONTAL ............................................................... 3-96
Remove ................................................................................ 3-80
STANDARD ROUND .................................................... 3-96
lnstall .................................................................................... 3-80
NACELLE MOUNTED ................................................... 3-96
Complete .............................................................................. 3-80
lnstall .................................................................................... 3-96
HORIZONTAL ............................................................... 3-96
STANDARD ROUND .................................................... 3-96
NACELLE MOUNTED ................................................... 3-97
Complete.............................................................................. 3-98
COMPLETE .................................................................. 3-98

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TABLE OF CONTENTS
3.28 FAIRING 3.33 MIRRORS
Remove and Install: Screw-On ............ ............................... 3-99 Remove ............................................................................. 3-112
Fairing ........................................................................... 3-99 Remove ...................................................................... 3-112
Brackets ........................................................................ 3-99 lnstall.................................................................................. 3-112
Remove ........................................................................ 3-99 lnstall ........................................................................... 3-112
Install.... ...................................................................... 3-99
Remove and Install: Clamp-On .......................................... 3-100 3.34 FRONT FENDER
Removal ..................................................................... 3-100
Remove ............................................................................. 3-113
lnstallation ................................................................... 3-100
Install ................................................................................. 3-113
Disassemble and Assemble ............................................... 3-100
Inverted Fork ............................................................... 3-113
Disassemble ............................................................... 3-100
FXBBS, FXST ............................................................. 3-113
Assemble ..................................................................... 3-101
FXLRS, FXLRST ......................................................... 3-113
3.29 FAIRING: FRAME MOUNTED Standard Fork (Typical) ............................................... 3-113
Disassemble ...................................................................... 3-114
Remove and Install: Windshield ......................................... 3-102 Full Fender .................................................................. 3-114
Remove ....................................................................... 3-102 Assemble .......................................................................... 3-114
Install .......................................................................... 3-102 3.35 REAR FENDER
Remove and Install: AirDeflector .................................. 3-102 Prepare............................................................................... 3-116
Remove ...................................................................... 3-102 Remove and Install: Standard............................................. 3-116
Install .......................................................................... 3-102 Remove ....................................................................... 3-116
Remove and Install:Outer Fairing Shell .............................. 3-102 Install ........................................................................... 3-116
Prepare ....................................................................... 3-102 Disassemble and Assemble: Full Fender ....... ................... 3-116
Remove .................................................................... ...3-102 Disassemble ................................................................ 3-116
lnstall........................................................................... 3-103 Disassemble and Assemble: Chopped Fender Without License
Complete ................. .......... ........................................3-103 Plate Bracket Lighting ......................................................... 3-117
Remove and Install:Inner Fairing Shell ............................... 3-103 Disassemble ................................................................ 3-117
Prepare ....................................................................... 3-103 Assemble ..................................................................... 3-118
Remove ...................................................................... 3-103 Disassemble and Assemble: Chopped Fender With License
lnstall........................................................................... 3-103 Plate Bracket Lighting ......................................................... 3-120
Complete .................................................................... 3-103 Disassemble ................................................................ 3-120
Disassemble and Assemble:Inner Fairing Shell ................. 3-104 Assemble ..................................................................... 3-120
Disassemble ........................................ .................. ....3-104 Complete ............................................................................ 3-121
Assemble .................................................................... 3-104 COMPLETE ................................................................. 3-121
Remove and Install: FairingSupports ............................... 3-104
Prepare.. .................. ... ............. .................................3-104 3.36 REAR FENDER WIRE CONDUIT
Remove ...................................................................... 3-104 Prepare............................................................................... 3-122
Install .......................................................................... 3-105 Remove .............................................................................. 3-122
Complete .................................................................... 3-105 lnstall .................................................................................. 3-122
Complete ............................................................................ 3-123
3.30 WINDSHIELD
3.37 SAREE GUARD
Remove ............................................................................. 3-106 Remove... ........................................................................... 3-124
lnstall................................................................................. ..3-106 lnstall .................................................................................. 3-124
Disassemble .................................................................. ....3-106
Assemble ........................................................................... 3-106 3.38 FRONT LICENSE PLATE BRACKET
Remove .............................................................................. 3-125
3.31 HAND GRIPS lnstall .................................................................................. 3-125
Two hole bracket......................................................... 3-125
Remove ............................................................................. 3-108 One hole bracket...... .... ............................................. 3-125
Left .............................................................................. 3-108 Clamp brackets .......................................................... 3-125
Right ........................................................................... 3-108
lnstall.................................................................................. 3-108 3.39 REAR LICENSE PLATE BRACKET
Left .............................................................................. 3-108 General............................................................................... 3-126
Right ......... ................................................................ 3-108 Standard ............................................................................. 3-126
Remove ....................................................................... 3-126
3.32 HANDLEBAR Install ........................................................................... 3-126
Prepare .............................................................................. 3-109 Disassemble ................................................................ 3-126
Remove and Install: Standard .......... ... ............................ 3-109 Assemble ..................................................................... 3-126
Remove ..................................................................... 3-109 Center Mount ...................................................................... 3-126
Install .......................................................................... 3-109 Disassemble .............................................................. ..3-126
Disassemble and Assemble:Standard................................ 3-11O
Disassemble .............................................................. 3-11O
Assemble .................................................................... 3-110
Complete............................................................................ 3-111

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9
 TABLE OF CONTENTS
Assemble ..................................................................... 3-126 Solo Seat..................................................................... 3-142
Center Mount With Lighting ................................................ 3-127 lnstall ..................................................................................3-142
Disassemble ................................................................ 3-127 Two-up One-piece Seat.. 3-142
Assemble ..................................................................... 3-127 Two-up Two-piece Seat.. .3-142
Solo Seat .................................................. . ...............3-142
3.40 LEFT FOOT CONTROLS
3.45 FRAME CROSSMEMBER
Prepare .............................................................................. 3-128 Prepare .............................................................................. 3-144
Remove .............................................................................. 3-128 Remove ..............................................................................3-144
install .................................................................................. 3-128 Install .................................................................................3-144
Remove and Install: ForwardFoot Controls......................... 3-128 Complete ............................................................................3-144
Prepare ...................................................................... 3-128
Remove ...................................................................... 3-128 3.46 SADDLEBAGS
lnstall ........................................................................... 3-128
Complete ..................................................................... 3-129 Remove and Install: Standard .............................................3-145
Remove and Install: Mid Foot Controls .............................. 3-129 Remove ...................................................................... 3-145
Prepare ........................................................................ 3-129 lnstall ............................................................................3-145
Remove .................................................................... 3-129 Remove and Install: Quick Disconnect ................................3-146
lnstall ................................................... ... —............... 3-129 Remove ........................................................................3-146
Remove and Install: Footboards ......................................... 3-129 Install............................................................................3-146
Prepare ........................................................................ 3-129 Disassemble and Assemble: Standard ...............................3-148
Remove ....................................................................... 3-129 Disassemble.................................................................3-148
Install ........................................................................... 3-129 Assemble .....................................................................3-149
Complete .................................................................... 3-129 Disassemble and Assemble: Quick Disconnect ..................3-150
Disassemble and Assemble: Footboard............................. 3-130 Disassemble.................................................................3-151
Disassemble .......................... ...... .............................. 3-130 Assemble..... ................................................................3-151
Assemble .................................................................... 3-130
Disassemble and Assemble: Footpeg.... ............................ 3-131
3.47 MEDALLIONS, BADGES, TANK
Disassemble ................................................................ 3-131 EMBLEMS AND ADHESIVE
Assemble ..................................................................... 3-131 STRIPS
Complete ............................................................................ 3-132 Remove .................................................. ...........................3-156
lnstall ..................................................................................3-156
3.41 RIGHT FOOT CONTROLS
Remove and Install: ForwardFoot Controls.................... .....3-133 ENGINE
Remove ....................................................................... 3-133
Install ........................................................................... 3-133
4.1 FASTENER TORQUE VALUES
Remove and Install: Mid Foot Controls .............................. 3-133 Fastener Torque Values in this Chapter ..................................4-1
Remove ....................................................................... 3-134
Install .......................................................................... .3-134 4.2 SPECIFICATIONS
Remove and Install: Footboards ......................................... 3-134 Engine . ... .4-4
Prepare ........................................................................ 3-134 SERVICE WEAR LIMITS ........................................................4-5
Remove ....................................................................... 3-134
lnstall ........................................................................... 3-135
4.3 ENGINE OIL FLOW
Disassemble and Assemble: Footboard............................. 3-135 Operation ................................................................................4-7
Disassemble ................................................................ 3-135 Internal Oil Distribution: All ...............................................4-8
Assemble ..................................................................... 3-135 External Oil Distribution: Air Cooled Only .........................4-9
Disassemble and Assemble: Footpeg .............................. 3-136
Disassemble ................................................................ 3-136 4.4 OIL PUMP OPERATION
Assemble ..................................................................... 3-136 General .................................................................................4-10
Operation ................... ..... .............. . ......4-10
3.42 PASSENGER FOOTRESTS 4.5 BREATHER OPERATION
General .................................................................................4-11
Remove .............................................................................. 3-138
Install .................................................................................. 3-138 4.6 OIL PRESSURE
Operation ..............................................................................4-12
3.43 JIFFY STAND Oil Pressure Check ...............................................................4-12
Prepare .............................................................................. 3-140 4.7 TROUBLESHOOTING
Remove .............................................................................. 3-140 Typical Symptoms.................................................................4-14
Install .................................................................................. 3-140 Typical Symptoms ..........................................................4-14
Disassemble ....................................................................... 3-140 Compression Test .................................................................4-14
Assemble............................................................................ 3-140 Cylinder Leakdown Test........................................................4-15
Complete... ........................................................................ 3-141 Measure Crankshaft Runout .................................................4-15
3.44 SEAT Crankshaft lnstalled ........................................................4-15
Remove .............................................................................. 3-142 Crankshaft Removed ......................................................4-16
Two-Up One-Piece Seat. ............................................ 3-142 Diagnose Valve Train Noise ..................................................4-16
Two-Up Two-Piece Seat... . ..... 3-142 Diagnose Smoking Engine or High Oil Consumption ........... 4-17

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TABLE OF CONTENTS
Check Before Cylinder Head Removal: ......................... 4-17 Prepare................................................................................ .4-32
Check After Cylinder Head Removal: ............................ 4-17 Remove ............................................................................... .4-32
Clean and Inspect................................................................ .4-32
4.8 CRIMP CLAMPS lnstall .................................................................................... 4-32
Remove ............................................................................... 4-18 Complete .............................................................................. 4-33
Removal ........................................................................ 4-18
lnstall.................................................................................. .4-18 4.18 PUSHRODS, LIFTERS AND COV-
Installation ..................................................................... 4-18 ERS
Prepare................................................................................. 4-34
4.9 OIL COOLER Remove ................................................................................ 4-34
Prepare ................................................................................ 4-19
Clean and Inspect................................................................. 4-35
Remove ............................................................................... 4-19
Inspect Lifters ....................................................................... 4-35
Oil Cooler Cover ........................................................... .4-19
Assemble Pushrod Cover ..................................................... 4-35
Oil Cooler ...................................................................... 4-19
lnstall .................................................................................... 4-36
lnstall.................................................................................. 4-19
Complete .............................................................................. 4-37
Oil Cooler ..................................................................... .4-19
Oil Cooler Cover .......................................................... .4-19 4.19 CYLINDER HEADS
Complete.............................................................................. 4-20 Prepare................................................................................ .4-38
Remove ............................................................................... .4-38
4.10 OIL CHECK VALVE Clean ................................................................................... .4-38
Prepare ............................................................................... .4-21
lnstall .................................................................................... 4-39
Remove .............................................................................. 4-21
Disassemble ........................................................................ .4-39
lnstall................................................................................... .4-21
Clean and Inspect................................................................ .4-41
Complete............................................................................. .4-21
Cylinder Head ................................................................ 4-41
4.11 OIL COOLANT LINES Valve Guides ................................................................. 4-41
Prepare ............................................................................... .4-22 Valves and Valve Seats ................................................. 4-41
Remove ............................................................................... 4-22 Valve Springs ................................................................. 4-41
lnstall.................................................................................... 4-22 Tapered Keepers ........................................................... 4-41
Complete............................................................................. .4-22 Valve Seats.................................................................... 4-41
Valve and Seat Repair .......................................................... 4-41
4.12 FRONT ENGINE MOUNT Assemble.............................................................................. 4-42
Complete ............................................................................. .4-43
Prepare ............................................................................... .4-24
Remove and Install: Lower Front Engine Mount ................... 4-24 4.20 CYLINDERS
Remove ........................................................................ .4-24 Prepare.............................................................................. .4-44
Install ............................................................................ .4-24 Remove ................................................................................ 4-44
Remove and Install: Upper Front Engine Mount .................. .4-24 Install ....... .... ..................................................................... .4-44
Remove ........................................................................ .4-24 Clean and Inspect................................................................. 4-45
Install ............................................................................. 4-25 Deglaze Cylinder ................................................................. .4-46
Complete.............................................................................. 4-25 Complete .............................................................................. 4-46

4.13 LEFT SIDE ENGINE MOUNT 4.21 PISTONS

Prepare................................................................................ .4-47
Prepare ............................................................................... 4-26 Remove ............................................................................... .4-47
Remove ............................................................................... 4-26 lnstall ................................................................................... .4-48
lnstall................................................................................... .4-26 Disassemble ......................................................................... 4-49
Complete............................................................................. 4-26 Clean and Inspect................................................................. 4-49
Clean ............................................................................ .4-49
4.14 UPPER ROCKER COVERS Inspect ........................................................................... 4-49
Prepare .............................................................................. .4-27 Check Piston Ring Gap ........................................................ 4-50
Assemble.............................................................................. 4-51
Remove ............................................................................. 4-27
Complete .............................................................................. 4-51
lnstall.................................................................................... 4-27
Complete............................................................................. .4-27 4.22 CAM COMPARTMENT AND COM-
4.15 BREATHERS PONENTS
Prepare ............................................................................... .4-29 Prepare................................................................................ .4-53
Remove ............................................................................... 4-29 Remove and Install: Camshaft Cover ................................... 4-53
lnstall.................................................................................... 4-29 Remove ......................................................................... 4-53
Complete.............................................................................. 4-29 lnstall ............................................................................. 4-53
Remove ............................................................................... .4-54
4.16 LOWER ROCKER COVERS Inspect Cam Component ...................................................... 4-55
Prepare ................................................................................ 4-30 Camshaft ...................................................................... .4-55
Remove ............................................................................... 4-30 Cam Support Plate ........................................................ 4-55
lnstall.................................................................................... 4-30 Cam Drive Components ................................................ 4-55
Complete.............................................................................. 4-30 lnstall .................................................................................... 4-55
Complete ............................................................................. 4-57
4.17 ROCKER ARMS Camshaft Needle Bearings ................................................... 4-57

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11
 TABLE OF CONTENTS
Remove ......................................................................... 4-57 Complete ............................................................................. 4-77
lnstall ............................................................................ .4-57

4.23 OIL PUMP DRIVE AND TRANSMISSION

Prepare ................................................................................ 4-59 5.1 FASTENER TORQUE VALUES
Remove ................................................................................ 4-59 Fastener Torque Values in this Chapter ................................. 5-1
Disassemble and lnspect ...................................................... 4-59
Assemble.............................................................................. 4-60
5.2 SPECIFICATIONS
Install ................................................................................... .4-60 Drive Specifications ............................................................... 5-3
Complete ............................................................................. .4-61 Transmission Specifications ................................................... 5-3
4.24 REPLACE ENGINE SERVICE WEAR LIMITS....................................................... 5-3

Prepare ................................................................................ 4-62 5.3 TRANSMISSION OPERATION

Prepare ......................................................................... 4-62
Power Flow ............................................................................ 5-5
Remove ................................................................................ 4-62
Neutral ........................................................................... .5-5
Remove ......................................................................... 4-62
First Gear ........................................................................ 5-5
lnstall .................................................................................... 4-63
Second Gear ................................................................... 5-5
lnstall ............................................................................ .4-63
Third Gear ....................................................................... 5-5
Complete .............................................................................. 4-63
Fourth Gear ..................................................................... 5-5
Complete ....................................................................... 4-63
Fifth Gear ........................................................................ 5-5
4.25 CRANKCASE Sixth Gear ....................................................................... 5-5

Prepare ................................................................................ 4-65 5.4 DRIVE BELT

Disassemble ......................................................................... 4-65
Clean and lnspect ................................................................. 4-66 Prepare .................................................................................. 5-7
Assemble.............................................................................. 4-66 Remove ................................................................................. 5-7
Repair Right Crankcase Half ................................................ 4-68 lnstall ..................................................................................... 5-7
Remove Main Bearing ................................................... 4-68 Complete ............................................................................... 5-8
Install Main Bearing ....................................................... 4-68
5.5 SHIFTER LINKAGE
Remove Balancer Bearing ............................................. 4-69 Shifter Rod ............................................................................. 5-9
Install Balancer Bearing................................................. 4-69 Replace .......................................................................... .5-9
Remove Piston Jets ...................................................... 4-69 Adjust .............................................................................. 5-9
Install Piston Jets .......................................................... 4-70 Foot Shift Lever.................................................................... 5-10
Repair Left Crankcase Half................................................... 4-70 Removal ........................................................................ 5-10
Remove Main Bearing ................................................... 4-70 Repair ........................................................................... 5-10
Install Main Bearing ....................................................... 4-70 Installation ..................................................................... 5-10
Remove Balancer Bearing ............................................. 4-71 Shifter Rod Lever, Front ...................................................... 5-10
Install Balancer Bearing................................................. 4-71 Removal ........................................................................ 5-10
Sprocket Shaft Bearing Inner Race ...................................... 4-71 lnstallation ..................................................................... 5-11
Remove ........................................................................ .4-71
Install ............................................................................. 4-72
Cylinder Studs ...................................................................... 4-73
Remove ......................................................................... 4-73
lnstall ............................................................................. 4-73
Plugs and Oil Fittings ............................................................ 4-73
Remove ........................................................................ .4-73
lnstall ............................................................................ .4-73
Complete .............................................................................. 4-73

4.26 FLYWHEEL AND CONNECTING

RODS
Symptoms ............................................................................ 4-75
Overview........................................................................ 4-75
No Oil Pressure .......................................................... .4-75
Vibration ......... .............................................................. 4-75
Prepare ................................................................................ 4-75
lnspect ................................................................................. 4-75
Complete .............................................................................. 4-76

4.27 OIL PAN

Prepare ............................................................................... .4-77
Remove ................................................................................ 4-77
lnstall .................................................................................... 4-77

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12
TABLE OF CONTENTS
5.6 CLUTCH RELEASE COVER 5.13 TRANSMISSION SPROCKET
Prepare .............................................................................. 5-12 Prepare................................................................................. 5-32
Remove ............................................................................... 5-12 Remove ............................................................................... 5-32
Install ................................................................................... 5-12 Clean and Inspect................................................................. 5-32
Disassemble ........................................................................ 5-12 Install .................................................................................. 5-32
Clean and lnspect ................................................................ 5-13 Complete ............................................................................ 5-34
Assemble ............................................................................. 5-13
Complete............................................................................ 5-14 5.14 TRANSMISSION
Prepare................................................................................. 5-35
5.7 CLUTCH RELEASE PUSH ROD Remove ................................................................................ 5-35
COMPONENTS lnstall .................................................................................. 5-36
Prepare ................................................................................ 5-15 Disassemble ....................................................................... 5-36
Remove ............................................................................... 5-15 Remove Shift Cam and Shifter Forks ............................ 5-36
Right Side ........... ........................................................ 5-15 Remove Mainshaft........................................................ 5-38
Left Side........................................................................ 5-15 Remove Countershaft ................................................... 5-38
lnstall.................................................................................... 5-15 Remove Bearing Housing Bearings ............................... 5-39
Left Side........................................................................ 5-15 Clean and Inspect................................................................. 5-40
Right Side ..................................................................... 5-15 Assemble.............................................................................. 5-40
Complete.............................................................................. 5-16 Install Bearing Housing Bearings ................................... 5-40
Install Countershaft........................................................ 5-41
5.8 PRIMARY CHAINCASE COVER Install Mainshaft ............................................................ 5-41
Prepare ................................................................................ 5-17 Install Shifter Cam/Shifter Forks ................................... 5-42
Remove ............................................................................... 5-17 Complete .............................................................................. 5-43
lnstall.................................................................................... 5-17
Complete...... .... ................................................................ 5-17 5.15 MAIN DRIVE GEAR AND BEARING
Prepare............................................................................... 5-45
5.9 DRIVE COMPONENTS Remove .............................................................................. 5-45
Prepare ........ ....................................................................... 5-18 Clean and Inspect................................................................. 5-46
Remove.............................................................................. 5-18 Install .................................................................................... 5-46
lnstall.................................................................................. 5-18 Replace Needle Bearings ..................................................... 5-47
Complete............................................................................. 5-21 Replace Mainshaft Seal ........................................................ 5-48
Complete ............................................................................. 5-49
5.10 CLUTCH
Prepare ................................................................................ 5-22
5.16 TRANSMISSION CASE
Disassemble and Assemble: Clutch Pack ............................ 5-22 Prepare................................................................................. 5-50
Disassemble ................................................................. 5-22 Remove ............................................................................... 5-50
Clean and lnspect ........ ............................................... 5-22 lnstall .................................................................................... 5-51
Assemble ...................................................................... 5-22 Disassemble ........... ............................................................. 5-51
Disassemble and Assemble: Hub......................................... 5-25 Remove Shifter Pawl Lever ........ ..... ............................ 5-51
Disassemble ................................................................. 5-25 Remove Oil Return Tube ............................................... 5-51
Assemble ...................................................................... 5-25 Clean and lnspect ................................................................. 5-52
Complete............................................................................ 5-26 Assemble.............................................................................. 5-52
5.11 PRIMARY CHAINCASE HOUSING Install Oil Return Tube ................................................... 5-52
Replace Countershaft Needle Bearing .......................... 5-53
Prepare ................................................................................ 5-27 Install Shifter Pawl Lever ............................................... 5-53
Remove ............................................................................... 5-27 Complete ....... ................................................................... 5-54
lnspect ................................................................................. 5-27
Install ................................................................................... 5-27 FUEL AND EXHAUST
Mainshaft Bearing and Seal..... ....................................... 5-28
Remove ........................................................................ 5-28 6.1 FASTENER TORQUE VALUES
Install ............................................................................ 5-28 Fastener Torque Values in this Chapter ................................ 6-1
Mainshaft Bearing Inner Race ............................................. 5-29
Remove ........................................................................ 5-29
6.2 SPECIFICATIONS
Specifications ................................. .... ................................. 6-3
Install .......................................................................... 5-29
Shifter Shaft Bushing .......................................................... 5-29 6.3 AIR CLEANER BACKPLATE AS
Complete............................................................................ 5-30 SEMBLY
Prepare................................................................................... 6-4
5.12 ENGINE OIL FILL SPOUT Remove and Install: Round ............................................... 6-4
Prepare ................................................................................ 5-31 Remove ........................................................................... 6-4
Remove ............................................................................... 5-31 lnstall ............................................................................... 6-4
lnstall.................................................................................... 5-31 Remove and Install: Oval ................................................... 6-5
Complete............... ........................................................ 5-31

TABLE OF CONTENTS
13
 TABLE OF CONTENTS
Remove .......................................................................... .6-5 Complete ............................................................................. 6-19
Install .............................................................................. .6-5
Remove and Install: Cone .................................................... .6-6 6.10 VENT TUBE
Prepare .............................................................................. 6-20
Remove ............................................................. ........... .6-6
Remove ............................................................................... 6-20
lnstall .............................................................................. .6-6
lnstall ................................................................................... 6-20
Complete ................................................................................ 6-7
Complete ............................................................................. 6-21
6.4 CONSOLE
6.11 VAPOR VALVE
Prepare ................................................................................. 6-8 Prepare ............................................................................... .6-22
Remove and Install: No lnstrument ......................................... 6-8 Remove .............................................................................. .6-22
Remove ........................................................................... 6-8 lnstall .................................................................................. .6-22
lnstall ............................................................................... 6-8 Complete ............................................................................. 6-22
Remove and Install: Single Instrument with Panel .................. 6-8
Remove ...... .................................................................... 6-8 6.12 TEMPERATURE MANIFOLD ABSO
lnstall .................... ........................................................ ..6-8 LUTE PRESSURE (TMAP)
Remove and Install: Single Instrument without Panel ........... 6-9 SENSOR
Remove ........................................................................... 6-9 Prepare ................................................................................ 6-23
lnstall ............................................................................... 6-9 Remove ............................................................................... 6-23
Complete .............................................................................. 6-10 lnstall .................. .. ............................................................. 6-23
Complete ................................. ........................................... 6-23
6.5 FUEL PRESSURE TEST
Prepare ................................................................................ 6-11 6.13 TWIST GRIP SENSOR (TGS)
Prepare ................................................................................ 6-24
Test ...................................................................................... 6-11
Remove ............................................................................. 6-24
Complete .............................................................................. 6-11
Install ................................................................................... 6-24
6.6 PURGE FUEL LINE Complete ............................................................................. 6-25

Prepare ............................................................................... .6-12 6.14 FUEL INJECTORS

Lift Rear Of Fuel Tank ............................... .......................... .6-12
Purge................................................................................... .6-12 Prepare ............................................................................... .6-26
Secure Fuel Tank ................................................................. 6-12 Remove .............................................................................. 6-26
Complete .............................................................................. 6-12 lnstall ................................................................................... 6-26
Complete ............................................................................. 6-26
6.7 FUEL LINE
6.15 INDUCTION MODULE
Prepare ................................................................................ 6-13
Remove ................................................................................ 6-13 Prepare .............................................................................. 6-27
Remove ........................................................................ .6-13 Remove ............................................................................. 6-27
lnstall .................................................................................... 6-13 Install ................................................................................... 6-28
Complete .............................................................................. 6-13 Disassemble ........................................................................ 6-29
6.8 FUEL TANK Throttle Body ................................................................. 6-29
Induction Manifold .......................................................... 6-29
Prepare ................................................................................ 6-14 Assemble ............................................................................. 6-29
Remove ................................................................................ 6-14 Induction Manifold .......................................................... 6-29
lnstall ................................................................................... 6-14 Throttle Body ............................................................... 6-29
Complete .............................................................................. 6-14 Complete ............................................................................. 6-30
6.9 FUEL PUMP
Prepare ................................................................................. 6-16 Tester Assembly ............................................................ 6-31
Remove ................................................................................ 6-16 Tester Adjustment ......................................................... 6-31
Clean and lnspect ................................................................. 6-16 Procedure ............................................................................ 6-31
lnstall ................................................................................... .6-16
Disassemble ......................................................................... 6-17 6.17 HEATED OXYGEN SENSORS
Level Sender .................................................................. 6-17 (HO2S)
Pressure Regulator ........................................................ 6-17 Prepare ............................................................................... .6-32
Filter ............................................................................... 6-17 Remove ............................................................................... 6-32
Pump ............................................................................ .6-17 lnstall.................................................................................... 6-32
Inlet Strainer................................................................... 6-17 Complete............................................................................ 6-33
Assemble .............................................................................. 6-17
Level Sender .................................................................. 6-17
Pressure Regulator ........................................................ 6-17
Filter .............................................................................. .6-17
Pump ............................................................................ .6-18
Inlet Strainer.................................................................. .6-18
6.16 INTAKE LEAK TEST
Leak Tester.......................................................................... 6-31
Parts List ....................................................................... 6-31

TABLE OF CONTENTS
14
TABLE OF CONTENTS
6.18 MUFFLERS 7.4 POWER DISCONNECT
Prepare ........... ... ................................................... 6-34 Main Fuse .............................................................................. 7-7
Remove ................................................................................ 6-34 Remove Main Fuse ......................................................... 7-7
Muffler ........................................................................... 6-34 Install Main Fuse ............................................................. 7-7
End Cap ........................................................................ 6-34 Negative Battery Cable .......................................................... 7-7
Install .................................................................................... 6-34 Disconnect Negative Battery Cable ................................ 7-7
Muffler ........................................................................... 6-34 Connect Negative Battery Cable ..................................... 7-7
End Cap ....................................................................... 6-34
Complete ............................................................................ 6-35 7.5 STARTER
Prepare .................................................................................. 7-9
6.19 EXHAUST SYSTEM Remove ................................................................................. 7-9
Prepare .............................................................................. 6-36 lnstall ..................................................................................... 7-9
Remove ............................................................................... .6-36 Complete ............................................................................... 7-9
Install .............................................................................. 6-36
Disassemble and Assemble: Standard ................................. 6-37 7.6 ALTERNATOR
Disassemble .................................................................. 6-37 Prepare ................................................................................ 7-10
Assemble ...................................................................... 6-37 Remove ............................................................................... 7-10
Disassemble and Assemble: Upswept.................................. 6-38 lnstall ................................................................................... 7-10
Disassemble .................................................................. 6-38 Complete ....................................................................... ..7-11
Assemble ...................................................................... 6-39
Disassemble and Assemble: Two Into One .......................... 6-40
7.7 VOLTAGE REGULATOR
Prepare ................................................................................ 7-12
Disassemble .................................................................. 6-40
Remove ............................................................................... 7-12
Assemble .................................................................... 6-41
lnstall ................................................................................... 7-12
Complete ............................................................................ 6-42
Complete ............................................................................. 7-12
6.20 PURGE SOLENOID: EVAPORATIVE 7.8 SPARK PLUG CABLES
EMISSIONS Remove ............................................................................... 7-13
Prepare ................................................................................ 6-43 lnstall ................................................................................... 7-13
Remove ................................................................................ 6-43
lnstall ................................................................................... 6-43 7.9 IGNITION COIL
Complete .............................................................................. 6-43 Prepare ................................................................................ 7-14
Remove ............................................................................... 7-14
6.21 CHARCOAL CANISTER: EVAPORATIVE lnstall ................................................................................... 7-14
EMISSIONS Complete ............................................................................. 7-14
Remove ................................................................................ 6-44
lnstall ................................................................................... 6-44 7.10 HANDLEBAR CONTROL MOD-
ULES
6.22 PURGE LINES: EVAPORATIVE General ................................................................................ 7-15
EMISSIONS Solder Procedure ................................................................. 7-15
Prepare ................................................................................ 6-45
Remove ................................................................................ 6-45 7.11 LEFT HAND CONTROL MODULE (LHCM)
lnstall .................................... ............................................. .6-45 Prepare ................................................................................ 7-16
Remove .............................................................................. 7-16
Complete .............................................................................. 6-46
lnstall ................................................................................... 7-17
Switch Caps ......................................................................... 7-18
ELECTRICAL Rocker Switch Caps...................................................... 7-18
Cruise Switch Cap ........................................................ 7-18
7.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter.... ............................. 7-1 Clutch Switch Replacement ................................................. 7-19
Complete ............................................................................. 7-19
7.2 SPECIFICATIONS
7.12 RIGHT HAND CONTROL MODULE
Specifications ......................................................................... 7-5 (RHCM)
7.3 FUSES Prepare ................................................................................ 7-20
Remove ............................................................................... 7-20
Prepare .................................................................................. 7-6 Install ................................................................................... 7-21
Remove ................................................................................ 7-6 Switch Caps ......................................................................... 7-22
Primary Fuses ................................................................. 7-6 Rocker Switch Caps............. ........................................ 7-22
lnstall ..................................................................................... 7-6 Front Brake Switch Replacement ......................................... 7-22
Primary Fuses ...... ... ...................................................... 7-6 Complete ............................................................................. 7-23
Complete ................................................................................ 7-6

TABLE OF CONTENTS
15
 TABLE OF CONTENTS
7.13 INSTRUMENT MODULE (IM) Assemble ....................................................................... 7-35
General ................................................................................ 7-24 Remove and Install: Nacelle Mounted .................................. 7-36
Prepare ................................................................................ 7-24 Remove ...................................................................... 7-36
Remove and Install: Handlebar Mount ................................. 7-24 lnstall ............................................................................. 7-36
Handlebar mounted, rectangular ................................... 7-24 Remove and Install: Oblong ................................................. 7-36
Handlebar mounted, round ............................................ 7-24 Remove ......................................................................... 7-36
Remove and Install: Console With Panel ............................. 7-25 lnstall ............................................................................. 7-36
Remove ......................................................................... 7-25 Remove and Install: Horizontal ............................................. 7-37
Install............................................................................. 7-25 Remove ....................................................................... 7-37
Remove and Install: Console Without Panel ........................ 7-25 Install ............................................................................. 7-38
Remove ......................................................................... 7-25 Remove and Install: Fixed Fairing ........................................ 7-38
lnstall ............................................................................. 7-26 Remove ......................................................................... 7-38
Complete ............................................................................ 7-26 lnstall ............................................................................. 7-38
Align ..................................................................................... 7-39
7.14 INDICATOR LAMPS Prepare .......................................................................... 7-39
Check Alignment ............................................................ 7-39
Prepare ................................................................................ 7-27
Adjust ................................................................................... 7-40
Remove ............................................................................... 7-27
Round ..................... ................... ...... ........................... 7-40
Install ................................................................................... 7-27
FXBRS, FXFBS ............................................................. 7-40
Complete ............................................................................. 7-27
FLFBS ........................................................................... 7-41
7.15 OIL PRESSURE SWITCH FXLRST ......................................................................... 7-41
Prepare ................................................................................ 7-28 Complete .............................................................................. 7-41
Remove ............................................................................... 7-28
7.19 FRONT LIGHT BAR
Install ................................................................................... 7-28
Complete ........................................................................... 7-28 Prepare ................................................................................ 7-43
Prepare .......................................................................... 7-43
7.16 NEUTRAL INDICATOR SWITCH Remove and Install: Standard Lighting ................................. 7-43
Prepare ................................................................................ 7-29
Remove ......................................................................... 7-43
Remove.. ............................................................................. 7-29
Disassemble ......................................................... ... .... 7-43
Install ................................................................................... 7-29
Assemble ....................................................................... 7-43
Complete ............................................................................. 7-29
lnstall ............................................................................. 7-44
7.17 HORN Complete ........................................... ...... .. ........................ 7-44
Complete ................................................. ..................... 7-44
Prepare.... ............................................................................ 7-30
Remove... ............................................................................ 7-30 7.20 AUXILIARY LAMPS
Install ................................................................................... 7-30
Bulb Replacement .................................... ... ....................... 7-45
Disassemble ........................................................................ 7-30 Bulb ............................................................................... 7-45
Assemble ............................................................................. 7-30 Remove ......................................................................... 7-45
Complete ............................................................................. 7-30 Install ............................................................................. 7-45
7.18 HEADLAMP Prepare .......................................................... ..................... 7-45
Remove and Install: Standard Lighting ................................. 7-45
Bulb Replacement: Standard Round .................................... 7-31 Remove ......................................................................... 7-45
Prepare ......................................................................... 7-31 Install ............................................................................. 7-45
Remove ........................................................................ 7-31 Align ................... ................................................................. 7-46
Install............................................................................. 7-31 Check Alignment ............................................................ 7-46
Complete ....................................................................... 7-31 Adjust ............................................................. .. .................. 7-46
Bulb Replacement: LED Round ........................................... 7-31 Auxiliary Lamp Adjustment ......... .................................. 7-46
Remove ......................................................................... 7-32 Complete .............................................................................. 7-46
lnstall ............................................................................. 7-32
Bulb Replacement: Nacelle Mounted ................................... 7-32
7.21 FRONT TURN SIGNAL LAMPS
Remove ......................................................................... 7-32 Bulb Replacement ......... .................................................... 7-48
Install............................................................................. 7-32 Incandescent .......... ...................................................... 7-48
Bulb Replacement: Oblong .................................................. 7-33 Prepare ................................................................................ 7-48
Remove ..................................................................... ....7-33 Prepare .................................................... ... ................. 7-48
Install............................................................................. 7-33 Remove and Install: Handlebar Mount.................................. 7-48
Bulb Replacement: Horizontal .............................................. 7-33 Remove ......................................................................... 7-48
Bulb Replacement: Fixed Fairing ......................................... 7-33 lnstall ............................................................................. 7-48
Prepare ................................................................................ 7-33 Remove and Install: FixedFairing Mount .............................. 7-50
Remove and Install: Standard Round................................... 7-33 Remove ........................................... .... ........................ 7-50
Remove ........................................................................ 7-33 Install .......... .... ............................................................. 7-50
Install............................................................................. 7-34 Complete ............................. .. ............................................. 7-51
Remove and Install: LED Round ...........................................7-34 Complete.... ................................................................... 7-51
Remove ..........................................................................7-34
lnstall ..............................................................................7-34 7.22 REAR TURN SIGNAL LAMPS
Disassemble...................................................................7-34

TABLE OF CONTENTS
16
TABLE OF CONTENTS
Bulb Replacement ................................................................ 1-52 Prepare ................................................................................ 7-69
Incandescent ................................................................. 1-52 Remove ............................................................................... 7-69
LED Puck....................................................................... 7-52 lnstall ................................................................................... 7-69
Remove ......................................................................... 7-52 Complete .............. .............................................................. 1-69
lnstall ............................................................................. 7-52
Prepare ................................................................................ 7-52 7.27 ELECTRONIC CONTROL MODULE (ECM)
Prepare ................................................................................ 7-70
Remove and Install: Fender Mount ............................... .... .. 7-52
Remove ......................................................... ..................... 7-70
Remove ......................................................................... 7-52
lnstall ................................................................................... 7-70
Install ............................................................................. 7-53
Complete ................................................................ ............ 7-70
Remove and Install: Rear Lighting Assembly ....................... 7-54
Remove ................ ........................................................ 7-54 7.28 BODY CONTROL MODULE (BCM)
lnstall ............................................................................. 7-54 Prepare .......................................................... ..................... 7-71
Remove and Install: Light Bar Mount .................................... 7-54 Remove ............................................................................... 7-71
Remove ......................................................................... 7-55 lnstall ................................................................................... 7-71
lnstall ............................ ... ...................... ....... ............. 7-55 Complete ............................................................................. 7-71
Remove and Install: Center Mount ....................................... 7-55
Remove ........................................... .. .......................... 7-55 7.29 SECURITY SYSTEM ACTIVATION
Install .......... .................................................... ............ 7-55 Activation ............................................................................. 7-72
Fob Assignment ................................................................... 7-72
Complete .............................................................................. 7-56
7.30 PERSONAL IDENTIFICATION NUMBER
7.23 TAIL LAMP
(PIN)
Bulb Replacement .................................................. ... ......... 1-51 General ................................................................................ 7-73
Bulb Replacement ......................................................... 1-51 Changing the PIN................................................................. 7-73
Standard .......................................................... ............. 7-57 Modifying an Existing PIN.............................................. 7-73
Prepare ............................................................................... .7-57
Remove and Install: Rear Lighting Assembly ....................... 7-57
7.31 SECURITY SYSTEM MAINTEN-
Remove ........................ ................................................ 7-57 ANCE
Install ............... ...... ...................................................... 7-58 Service Mode ...................................................................... 7-7*4
Remove and Install: Standard .............................................. 7-58 Transport Mode................................ ... ............................... 7-7*4
Base Replacement ........................................................ 7-58 To Enter Transport Mode ............................................. 1-7*4
Remove and Install: License Plate Bracket Mount ................ 7-60 To Exit Transport Mode ................................................ 7-7*4
Remove ........................................................... ............. 7-60 Fob Battery ......................................................................... 7-7*4
lnstall ............................................................... ............. 7-60 Battery Replacement Schedule .................................... 7-7*4
Remove and Install: Center Mount ....................................... 7-61 Battery Replacement ........................................ ............ 1-7*4
Remove... ...................................................................... 7-61 Security Siren Battery ......................................................... 7-7*4
lnstall ............................................................................. 7-62 Battery Replacement Schedule .................................... 7-7*4
Complete ........................................................................... ...1-62 Battery Replacement .................................................... 7-7*4

7.24 REAR STOPLAMP SWITCH 7.32 SECURITY SIREN

Prepare ................................................................................ 7-76
Prepare ................................................................................ 7-63 Remove ......................................................................... .7-76
Remove .......................................... ..... ......... .... .. ............. 7-63 lnstall ................................................................................... 7-76
lnstall ................. .... .. ......... ..... ............ ..... ............... ....... 7-63 Complete ............................................................................. 7-76
Complete ..................... .................. .. ............ .... ... ............ 7-63
7.33 SECURITY SYSTEM ANTENNA
7.25 LICENSE PLATE LAMP Prepare ................................................................................ 7-77
Remove ............................................................................... 7-77
Bulb Replacement ............................................................... 7-6*4 lnstall ................................................................................... 7-77
Bulb Replacement... ..................................................... 1-6*4 Complete ............................................................................. 7-77
Incandescent Bulb Center Mount: ................................. 7-6*4
Prepare..., ......... .... ............................................................. 7-65 7.34 CRANKSHAFT POSITION SENSOR (CKP)
Remove and Install: Center Mount ....................................... 7-65 Prepare ................................................................................ 7-78
Remove ........................ .... ..... ..................................... 7-65 Remove ............................................................................... 7-78
lnstall ........................................................................... 7-65 lnstall ................................................................................... 7-78
Remove and Install: License Plate Bracket Mount ................ 7-66 Complete ............................................................................. 7-78
Remove ......................................................................... 7-66
lnstall ............................................................................. 7-66 7.35 ENGINE TEMPERATURE (ET)
Remove and Install: Side Mount ............. ............................. 7-67 SENSOR
Remove ......................................................................... 7-67 Assemble ............................................................................ 7-91
lnstall ............................................................................. 7-67 Complete ..................... ... .................................................. 7-91
Complete .............................................................................. 7-68
7.44 ECM CADDY
7.26 TERMINATING RESISTOR
Prepare ................................................................................ 7-79 Complete ........................................................................... 7-79
Remove ................................................................................ 7-79
Install.................................................................................... 7-79 7.36 KNOCK SENSOR (KS)
Prepare ................................................................................ 7-80

TABLE OF CONTENTS
17
 TABLE OF CONTENTS
Remove ............................................................................... 7-80 7.47 BATTERY TRAY
lnstall.................................................................................... 7-80 Prepare ................................................................................ 7-97
Complete ........ ... .............................................................. 7-80 Remove ............................................................................... 7-97
lnstall .................................................................................... 7-97
7.37 AUTOMATIC COMPRESSION RELEASE Complete .............................................................................. 7-97
(ACR)
Prepare ............................................................................. 7-81 7.48 ENGINE GROUND CABLE
Remove ............................................................................ 7-81
lnstall.................................................................................. 7-81 Prepare ............................................................................... 7-98
Complete ............................................................................. 7-82 Remove ................................................................................ 7-98
lnstall .................................................................................. 7-98
7.38 VEHICLE SPEED SENSOR (VSS) Complete .............................................................................. 7-98
Prepare ................................................................................ 7-83
Remove ............................................................................... 7-83 7.49 ENGINE WIRE HARNESS
Prepare .............................................................................. 7-99
lnstall.................................................................................... 7-83
Remove ............................................................................... 7-99
Complete ........................................................................... 7-83
lnstall .................................................................................. 7-100
7.39 FRONT WHEEL SPEED SENSOR (WSS) Complete ........................................................................... 7-101
Prepare ................................................................................ 7-84
Remove ............................................................................... 7-84 7.50 BACKBONE WIRE HARNESS
InstalI ................................................................................... 7-84 Prepare .............................................................................. 7-102
Complete ........ .................................................................... 7-84 Remove ............................................................................ 7-102
7.40 REAR WHEEL SPEED SENSOR lnstall .................................................................................. 7-102
Complete ............................................................................ 7-103
(WSS)
Prepare .......................................................................... ....7-85 7.51 FAIRING WIRE HARNESS
Remove and Install: Standard Fork ...................................... 7-85 Remove and Install: Frame Mounted Fairing ...................... 7-104
Remove ......................................................................... 7-85 Prepare ........................................................................ 7-104
lnstall ............................................................................. 7-85 Remove ....................................................................... 7-104
Complete ...................................................................... ....7-85 Install ........................................................................... 7-104
Complete ..................................................................... 7-104
7.41 JIFFY STAND SENSOR (JSS)
Prepare ................................................................................ 7-86 7.52 MAIN WIRE HARNESS
Remove .......... .................................................................... 7-86 Prepare ............................................................................. 7-105
lnstall.................................................................................... 7-86 Remove .......... ... ............................................................. 7-105
Complete ............................................................................. 7-86 lnstall .................................................................................. 7-106
Complete ............................................................................ 7-106
7.42 FRONT ELECTRICAL CADDY
WIRING
Prepare ................................................................................ 7-87
Remove ............................................................................... 7-87 A.1 WIRING DIAGRAMS
Install ................................................................................... 7-89
General .................................................................................. A-1
Complete ............................................................................. 7-89
Wire Color Codes ............................................................ A-1
7.43 USB CADDY Wiring Diagram Symbols ............................................... A-1
Prepare ................................................................................ 7-90 Wiring Diagrams ..................................................................... A-2
Remove ............................................................................. 7-90
A.2 WIRE HARNESS CONNECTORS
lnstall.................................................................................. 7-90
Disassemble ........................................................................ 7-91 General ................................................................................A-29
Prepare ................................................................................ 7-93 Function/Location .......................................................... A-29
Remove ............................................................................... 7-93 Place and Color ............................................................. A-29
lnstall.................................................................................... 7-93 Connector Number......................................................... A-29
Complete ............................................................................. 7-93 Repair lnstructions ......................................................... A-29
7.45 BCM CADDY Connector End Views ........................................................... A-31
Prepare ............................................................................... 7-95 REFERENCE ______________________
Remove ............................................................................... 7-95
lnstall................................................................................... 7-95 B.1 GLOSSARY
Complete ............................................................................. 7-95
Acronyms and Abbreviations ................................................. B-1
7.46 REAR LIGHTING CADDY B.2 METRIC CONVERSION
Prepare .......... ..................................................................... 7-96 Conversion Table .................................................................. B-4
Remove .............................................................................. 7-96
lnstall................................................................................... 7-96 B.3 FLUID CONVERSION
Complete ............................................................................ 7-96 United States System ............................................................ B-5
Metric System........................................................................ B-5

TABLE OF CONTENTS
18
TABLE OF CONTENTS
British Imperial System ...........................................................B-5
REFERENCE MATERIAL

TOOLS ................................................................I
Torque Values .................................................. V
lndex .............................................................. XIX

TABLE OF CONTENTS
19
NOTES
SUBJECT PAGE NO.
1.1 SAFETY ..................................................................................................................................... 1-1

SAFETY
NOTES
SAFETY 1.1

SAFETY

Customer Safety
Harley-Davidson service manuals are intended for use by A WARNING
professional, qualified and experienced technicians. Attempting
The rider's safety depends upon proper motorcycle service
the procedures found within this manual without the proper
and maintenance. If a procedure in this manual is not within
training, tools and equipment could result in death or injury to you
your capabilities or you do not have the correct tools, have a
or others. This could also damage the vehicle, or cause the
Harley-Davidson dealer perform the procedure. Improper
vehicle to operate improperly.
service or maintenance could result in death or serious
Safety is always the most important consideration when injury. (00627b)
performing any job.
Proper service and repair is important for the safe, reliable
• Always have a complete understanding of the task. operation of all mechanical products. The service procedures
• Use common sense. recommended and described in this manual are effective
methods for performing service operations and are essential to
• Use proper tools for the task. your customer's safety and the reliable and safe operation of
• Protect yourself and bystanders with approved eye protection. your customer's vehicle.
Harley-Davidson does not evaluate or advise the technicians of
every way in which service might be performed, or all possible Personal Protection
hazardous consequences of every method, or undertaken such a
A WARNING
broad evaluation. Before using a tool not recommended by
Harley-Davidson, make sure that technician or rider safety will • Always wear safety glasses or goggles when performing
not be jeopardized as a result. service or maintenance procedures. Flying objects or
materials can cause serious eye injury or death.
Warnings against the use of specific service methods which
could damage the motorcycle or render it unsafe are stated in • Wear protective gear that is appropriate to the situation.
this manual. These warnings are not all-inclusive. Inadequate Helmets, gloves, boots and other protective clothing can
safety precautions could result in death or serious injury. prevent serious injury or death.

Safety Messages • Wear ear protection when loud noises are present. Loud
noises can damage ears and cause hearing loss.
Statements in this manual preceded by the following words are of
(00628b)
special significance.

A DANGER
Tool Safety
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury. (08704a) Some of these service operations require the use of tools
specially designed for the purpose. Follow the manufacturer's
A WARNING suggested usage and safety instructions. If using a tool other
WARNING indicates a potentially hazardous situation which, than that recommended by Harley-Davidson, be sure that the
if not avoided, could result in death or serious injury. tool is appropriate for the service or maintenance procedure and
(00119a) is being used in accordance with the tool's safety instructions.

A WARNING
Product Safety
A CAUTION
CAUTION indicates a potentially hazardous situation which, Read and follow warnings and directions on all products.
if not avoided, may result in minor or moderate injury. Failure to follow warnings and directions can result in
(00139a) death or serious injury. (00470b)

NOTICE • When reference is made to a specific brand name product,

NOTICE indicates a potentially hazardous situation which, if tool or instrument, an equivalent product, tool or instrument
may be substituted.
not avoided, may result in property damage. (00140b)
• Some referenced or recommended products contain
NOTE chemicals known to the State of California to cause cancer
Refers to important information. It is recommended that you and birth defects or other reproductive harm as indicated on
take special notice of these items. the product label or at the point of purchase.

94000936 1-1
Hazardous Materials known to the State of California to cause cancer, and birth
defects or other reproductive harm. Wash hands after
A WARNING handling.
Read and follow warnings and directions on all products. Coolant
Failure to follow warnings and directions can result in
death or serious injury. (00470b) • Coolant contains toxic chemicals which could cause death or
serious injuries if ingested. Do not induce vomiting. Call a
physician immediately.
- Keep hazardous products out of the reach of children.
• Many products (oils, lubricants, solvents, sealants and • Irritation to skin or eyes can occur from vapors or direct
cleaners, etc.) can cause death or serious injury if inhaled, contact. Flush thoroughly with water if contact is made.
absorbed, injected, ingested or improperly contacted. If • Use in a well ventilated area.
hazardous contact is made with a product, follow the
instructions on the product label and, if necessary, contact Hydraulic (Brake) Fluid
poison control or a medical facility. • Direct contact with brake fluid to the eyes can cause irritation.
• Some products are flammable and/or explosive as indicated Flush thoroughly with water if contact is made.
on the product label or at the point of purchase. Keep these • Do not swallow brake fluid. Swallowing brake fluid can cause
products away from flame and intense heat. digestive discomfort. Call a physician immediately.
• Some products are corrosive as indicated on the product label. • Brake fluid will cause cosmetic damage to painted surfaces.
Wear appropriate protective gear to prevent skin contact. Use Always use caution and protect surfaces from spills whenever
service covers to prevent damage to cosmetic surfaces on brake work is performed.
the motorcycle.
Engine Oil
• Some products contain chemicals known to the State of
California to cause cancer and birth defects or other • Prolonged or repeated contact with used motor oil may be
harmful to skin and could cause skin cancer. Promptly wash
reproductive harm as indicated on the product label or at the
affected areas with soap and water.
point of purchase.
Fuel • Do not swallow oil. If swallowed, do not induce vomiting.
Contact a physician immediately.
A WARNING • Direct contact with eyes can cause irritation. Flush thoroughly
Keep gasoline away from ignition sources. Gasoline is with water if contact is made. Contact a physician if irritation
extremely flammable and highly explosive and, if ignited, persists.
could result in death or serious injury. (00634b)
Electrical Systems
• Stop the engine when refueling or servicing the fuel system.
A WARNING
• Do not allow open flame, sparks, radiant heat or other ignition
Improper service or maintenance of the electrical system can
sources near gasoline.
cause damage to the electrical system. This may result in
• Do not store motorcycle with gasoline in tank within the home component failure. In certain situations, a component failure
or garage where ignition sources, such as open flames, pilot during operation could lead to a loss of control, which could
lights, sparks or electric motors are present. result in death or serious injury. (00637b)

• Do not overfill fuel tank. Allow for fuel expansion .

• Always use replacement fuses that are of the specified type
• Do not use gasoline as a cleaner or solvent. and amperage rating.
• Gasoline can leak or drain from loosened or improperly • Do NOT pull on electrical wires. Pulling on electrical wires may
tightened fuel fittings or from removed fuel components. damage wire conductivity.
• Clean spilled gasoline immediately. Dispose of waste • Route wires and harnesses properly to prevent chafing,
materials properly. stripping, pinching, crimping or cutting wires. Damaged wires
Battery can cause short circuits and component damage or failure.

• Do NOT overload the vehicle's charging system. If the

A WARNING electrical accessories consume more electrical current than
Read and follow warnings and directions on all products. the charging system can produce, the battery may be
Failure to follow warnings and directions can result in discharged and cause damage to the motorcycle's electrical
death or serious injury. (00470b) 1 system.
• Batteries, battery posts, terminals and related accessories
■ Do NOT exceed the maximum amperage rating of the fuse or
contain lead and lead compounds, and other chemicals
circuit breaker protecting a modified circuit.

• Avoid directly heating electrical system components other than

1 Batteries contain sulfuric acid, which could cause severe burns the connectors on which heat shrink work is being performed.
to eyes and skin. Wear a protective face shield, rubberized
gloves and protective clothing when working with batteries.
Keep batteries out of the reach of children.
' Do not remove warning label attached to top of battery.

1-2 94000936
SUBJECT PAGE NO.
2.1 FASTENER TORQUE VALUES ................................................................................................ 2-1
2.2 GENERAL .................................................................................................................................. 2-2
2.3 MAINTENANCE SCHEDULE .................................................................................................... 2-3
2.4 FUEL AND OIL .......................................................................................................................... 2-5
2.5 REPLACE ENGINE OIL AND FILTER ....................................................................................... 2-7
2.6 REPLACE PRIMARY CHAINCASE LUBRICANT ...................................................................... 2-9
2.7 REPLACE TRANSMISSION LUBRICANT ............................................................................... 2-11
2.8 INSPECT TIRES AND WHEELS ............................................................................................. 2-13
2.9 LUBRICATE CABLES AND CHASSIS ..................................................................................... 2-16
2.10 INSPECT BRAKES ................................................................................................................ 2-17
2.11 CHECK AND REPLACE BRAKE FLUID ................................................................................ 2-21
2.12 CHECK AND ADJUST CLUTCH ........................................................................................... 2-23
2.13 REBUILD FRONT FORK AND REPLACE OIL ...................................................................... 2-26
2.14 ADJUST AND LUBRICATE STEERING HEAD BEARINGS .................................................. 2-27
2.15 INSPECT FUEL LINES AND FITTINGS ................................................................................ 2-29
2.16 INSPECT AND LUBRICATE JIFFY STAND .......................................................................... 2-30
2.17 INSPECT AND ADJUST DRIVE BELT AND SPROCKETS ................................................... 2-31
2.18 ADJUST SUSPENSION ........................................................................................................ 2-35
2.19 INSPECT EXHAUST SYSTEM ............................................................................................ 2-39
2.20 INSPECT AIR FILTER ........................................................................................................... 2-40
2.21 INSPECT BATTERY.............................................................................................................. 2-43
2.22 CLEAN, INSPECT, REPLACE SPARK PLUGS ..................................................................... 2-46
2.23 STORAGE ............................................................................................................................. 2-48
2.24 TROUBLESHOOTING .......................................................................................................... 2-50

MAINTENANCE
NOTES
FASTENER TORQUE VALUES 2.1

FASTENER TORQUE VALUES IN THIS

CHAPTER. _ _______ _
FASTENER TORQUE VALUE NOTES
Air filter cover screw, cone 18-24 in-lbs 2-2.7 N-m 2.20 INSPECT AIR FILTER, Remove and Install:
Cone
Air filter cover screw, single screw cover 50-65 in-lbs 5.6-7.3 N-m
2.20 INSPECT AIR FILTER, Remove and Install:
Round
Apply LOCTITE 243 (blue) to the threads of screw.
Air filter cover screws, five-screw cover 48-72 in-lbs 5.4-8.1 N-m 2.20 INSPECT AIR FILTER, Remove and Install:
Round
Apply LOCTITE 243 (blue) to the threads of screw.
Tighten in a star pattern.
Air filter cover screws, oval cover 50-60 in-lbs 5.7-6.8 N-m 2.20 INSPECT AIR FILTER, Remove and Install:
Oval
Air filter element screws, round cover 48-72 in-lbs 5.4-8.1 N-m 2.20 INSPECT AIR FILTER, Remove and Install:
Round
Air filter trim insert screws 27-32 in-lbs 3-3.6 N-m 2.20 INSPECT AIR FILTER, Remove and Install:
Oval
Axle nut, rear 95-105 ft-lbs 128.8-142.4 N-m
2.17 INSPECT AND ADJUST DRIVE BELT AND
SPROCKETS, Adjust Belt
Battery, positive cable, screw 60-70 in-lbs 6.78-7.91 N-m 2.21 INSPECT BATTERY, Install

Brake master cylinder, front, reservoir 9-18 in-lbs 1-2 N-m 2.11 CHECK AND REPLACE BRAKE FLUID, Check
cover screws Brake Fluid Level
Brake master cylinder, rear, reservoir 9-18 in-lbs 1-2 N-m 2.11 CHECK AND REPLACE BRAKE FLUID, Check
cover screws Brake Fluid Level
Clutch hub jamnut 72-120 in-lbs 8.1-13.6 N-m 2.12 CHECK AND ADJUST CLUTCH, Check and
Adjust
Clutch inspection cover screws 25-35 in-lbs 2.8-3.9 N-m 2.6 REPLACE PRIMARY CHAINCASE LUBRICANT,
Change Primary Chaincase Lubricant
Torque sequence
Engine oil drain plug 14-21 ft-lbs 19-28.5 N-m 2.5 REPLACE ENGINE OIL AND FILTER, Change
Oil and Oil Filter
Fork stem pinch bolt - 16-20 ft-lbs 21.7-27.1 N-m 2.14 ADJUST AND LUBRICATE STEERING HEAD
BEARINGS, Check and Adjust
Front brake pad hanger pin 11-14 ft-lbs 14.7-19.6 N-m 2.10 INSPECT BRAKES, Replace Front Brake Pads

Lower fork bracket pinch bolt 16-20 ft-lbs 21.7-27.1 N-m 2.14 ADJUST AND LUBRICATE STEERING HEAD
BEARINGS, Check and Adjust
Primary chaincase drain plug 14-21 ft-lbs 19-28.5 N-m 2.6 REPLACE PRIMARY CHAINCASE LUBRICANT,
Change Primary Chaincase Lubricant
Spark plug 86-108 in-lbs 9.7-12.2 N-m 2.22 CLEAN, INSPECT, REPLACE SPARK PLUGS,
Install
Spoke nipple 55 in-lbs 6.2 N-m 2.8 INSPECT TIRES AND WHEELS, Wheel Spokes

Transmission drain plug 14-21 ft-lbs 19-28.5 N-m 2.7 REPLACE TRANSMISSION LUBRICANT,
Change Transmission Lubricant
Transmission filler plug/dipstick 25-75 in-lbs 2.8-8.5 N-m 2.7 REPLACE TRANSMISSION LUBRICANT, Check
Transmission Lubricant
Transmission filler plug/dipstick 25-75 in-lbs 2.8-8.5 N-m 2.7 REPLACE TRANSMISSION LUBRICANT, Change
Transmission Lubricant

94000936 2-1
GENERAL 2.2
SECURE THE MOTORCYCLE FOR SERVICE
SERVICING A MOTORCYCLE

A WARNING PART NUMBER TOOL NAME

HD-45968 FAT JACK
Perform the service and maintenance operations as
indicated in the regular service interval table. Lack of regular A WARNING
maintenance at the recommended intervals can affect the
safe operation of your motorcycle, which could result in Be sure to check capacity rating and condition of hoists,
death or serious injury. (00010a) slings, chains and cables before use. Exceeding capacity
ratings or using lifting devices that are in poor condition can
Perform necessary set-up tasks before customer delivery. See lead to an accident, which could result in death or serious
applicable model year predelivery and set-up instructions. injury. (00466c)

The performance of new motorcycle initial service is required to

Always use blocking or proper stands to support motorcycle.
keep warranty in force and to verify proper emissions systems
operation. See MAINTENANCE SCHEDULE (Page 2-3).
Set Motorcycle Upright
Inspect motorcycle regularly for additional maintenance needs.
1. Place motorcycle upright on a level surface or suitable lift if
Routinely check components between regular maintenance
available.
intervals. Always inspect motorcycle after periods of storage
before riding. 2. Verify that motorcycle is level.
3. Secure with tie-downs.
Perform all of the checks in the PRE-RIDING CHECKLIST in the
owner's manual following any service procedure. Operate the
motorcycle to perform any final check or adjustments. If all is Raise Front or Rear Wheel for Service
correct, the vehicle is ready to return to the customer. 1. Verify that motorcycle is level.
2. Use a FAT JACK (PART NUMBER: HD-45968) or similar to
raise the motorcycle to service a front or rear wheel.
3. Secure with tie-downs.

2-2 94000936
MAINTENANCE SCHEDULE 2.3
Table 2-1. Regular Service Intervals: Harley-Davidson Softail Models
COMPONENT ACTION NOTES
GENERAL • Some countries, such as Brazil, may require all regular

16000 KM

24000 KM

32000 KM

40000 KM

48000 KM

56000 KM

64000 KM

72000 KM

80000 KM
10000 Ml

15000 Ml

20000 Ml

25000 Ml

30000 Ml

35000 Ml

40000 Ml

45000 Ml

50000 Ml
1600 KM

8000 KM
maintenance to be performed by an authorized Harley-

1000 Ml

5000 Ml
Davidson dealer for your limited warranty to remain in
Regular Service Intervals effect. Check with your authorized Harley-Davidson
Service must be performed at specified intervals to keep your dealer.
Service Intervals
Harley-Davidson motorcycle operating at peak performance. • Some countries, such as Brazil, may require additional
Electrical equipment and switches Inspect X X X X X X X X X X X
See the Regular Service Intervals table below. annual (or semi-annual) regular maintenance steps to be
Front tire pressure and tread Check X X X X X X X X X X X 1
X X performed
X to keep your
X limited warrantyX in2.4.
effect and/or
Front wheel spoke tightness (if NOTECheck comply with vehicle regulations. Check with your
3
equipped)
• The use of parts and service procedures other than Harley- authorized Harley-Davidson dealer as well as the
Front brake fluid level Inspect X X X X X X X X X X X 7
Davidson approved parts and service procedures
Check X X may
X X motorcycle
X X regulations
X X in your
X country
X X
1. 2
DOT4 front brake fluid moisture
void the limited warranty. Any alterations to the emission
content
system components, such as the intake and exhaust • After completing the final service interval, repeat the
Steering head bearings Adjust X X X
service X
schedule starting X at the 8000
X 2
km (5000 mi)
system,
Steering may be in violation of
head bearings motor vehicle laws.
Lubricate X
2
interval.
Windshield bushings (if applicable) Inspect X X X X X

Upper and lower switch housing Tighten X X • Whenever

X a vehicle
X is in for
X maintenance,
X always
1,2, 5 check
screw torque for and complete recalls and open product programs.
X X X X X X
Clutch lever handlebar clamp screw Tighten 1,2, 5
• Whenever a vehicle is in for maintenance, always verify
torque
Tighten X X that
X the latest calibration
X is Xinstalled. X
1,2, 5
Master cylinder handlebar clamp
screw torque
X X X X X X
Front brake handlebar clamp screw Tighten 1,2, 5
torque
Air cleaner filter Inspect X X X X X X X X X X 3
Engine oil and filter Replace X X X X X X X X X X X 1, 3
Oil cooler Clean X X X X X X X X X X X

X X X X X X
Primary chaincase lubricant Replace 3, 2
X X X
Transmission lubricant Replace 3,2
Oil and brake lines Inspect X X X X X X X X X X X 1,2, 6
Fuel lines and fittings Inspect X X X X X X X X X X X 1,2, 6
Rear brake fluid level Inspect X X X X X X X X X X X 7
X X X X X X X X X X X
DOT4 rear brake fluid moisture Check 1,2
content
NOTES
1. Perform annually or at specified intervals, whichever comes first.
2 Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified.
3. Perform maintenance more frequently in severe riding conditions. This includes extreme temperatures, dusty environments, mountainous or rough roads, long storage
conditions, short runs, heavy stop/go traffic or poor fuel quality.
4 Perform spoke tension check at 1,000 mi (2,000 km). 5,000 mi (8,000 km), 20,000 mi (32,000 km) services and every 15,000 mi (24,000 km) interval thereafter. Not all
vehicles have spoked wheels. Consult appropriate topic in the service manual
5 For torque instructions, see Shop Practices in the service manual.
6. Check for leaks, contact or abrasion.
7. Brake fluid level drops as brake pads wear.
8. Use HARLEY LUBE.

94000936 2-3
 Table 2-1. Regular Service Intervals: Harley-Davidson Softail Models
ACTION NOTES

ii ll - :E — ii is o§
2 s.
§8 1 :E s§
S2 i
GO 2
H 1 :E §8
is

Brake systems Replace __ Flush brake systems and replace DOT 4 hydraulic brake fluid every two years or 2
sooner if moisture content is 3 percent or greater.
Brake pads and discs Inspect X X X X X X X X X X X

Front axle nut torque Tighten X X X X X X 1, 2, 5

Jiffy stand Lubricate X X X X X X X X X X X 2, 3
Clutch system Adjust X X X X X X X X X X X 2,3
Brake and clutch controls Lubricate X X X X X X X X X X X 2,8
X X X X X
Rear wheel spoke tightness (if Check 2,3,4
equipped)
Rear tire pressure and tread Check X X X X X X X X X X X 1
Drive belt and sprockets Inspect X X X X X X X X X X X 2
Drive belt Adjust X X X X X X X X X X X 2
Rear axle nut torque Tighten X X X X X X 1, 2, 5
X X X X X X X X X X X
Exhaust system, fasteners and Inspect 1,3
shields
12 volt battery Check Check battery, terminal torque and clean connections annually. Lubricate terminals with
1
ELECTRICAL CONTACT LUBRICANT.
Spark plugs Replace
. Replace spark plugs every two years or every 30,000 mi (48,000 km), whichever comes first. .
Front forks Rebuild iiiiiiiii 2,3
Fuel filter Replace Replace fuel filter element every 100,000 mi (161,000 km). 2,3
Component and system functions Road Test X X X X X X X
X [ X 1 X
X

NOTES
1. Perform annually or at specified intervals, whichever comes first.
2. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified.
3. Perform maintenance more frequently in severe riding conditions. This includes exlreme temperatures, dusty environments, mountainous or rough roads, long storage
conditions, short runs, heavy stop/go traffic or poor fuel quality.
4. Perform spoke tension check at 1,000 mi (2,000 km), 5,000 mi (8,000 km), 20,000 mi (32,000 km) services and every 15,000 mi (24,000 km) interval thereafter. Not all
vehicles have spoked wheels. Consult appropriate topic in the service manual.
5. For torque instructions, see Shop Practices in the service manual.
6. Check for leaks, contact or abrasion.
7. Brake fluid level drops as brake pads wear.
8. Use HARLEY LUBE.

2 Gasoline/METHYL TERTIARY BUTYL ETHER (MTBE) blends are a mixture of gasoline and as much as 15 percent MTBE.
Gasoline/MTBE blends use in your motorcycle is approved.
• ETHANOL fuel is a mixture of ethanol (grain alcohol) and unleaded gasoline and can have an impact on fuel mileage. Fuels with
an ethanol content of up to 10 percent may be used in your motorcycle without affecting vehicle performance. U.S. EPA
regulations currently indicate that fuels with 15 percent ethanol (E15) are restricted from use in motorcycles at the time of this
publication. Some motorcycles are calibrated to operate with higher ethanol concentrations to meet the fuel standards in certain
countries.
2-4 94000936
FUEL AND OIL 2.4

FUEL • REFORMULATED OR OXYGENATED GASOLINES (RFG)

describes gasoline blends that are specifically designed to
burn cleaner than other types of gasoline. This results in
Always use a good quality unleaded gasoline. Octane ratings are fewer tailpipe emissions. They are also formulated to
usually found on the pump. Refer to Table 2-2. evaporate less when filling the tank. Reformulated gasolines
use additives to oxygenate the gas. Your motorcycle will run
A WARNING
normally using this type of fuel. Harley-Davidson recommends
Avoid spills. Slowly open fuel filler cap. Do not fill above using it whenever possible as an aid to cleaner air in our
bottom of filler neck insert, leaving air space for fuel environment.
expansion. Secure filler cap after refueling. Gasoline is
• Do not use racing fuel or fuel containing methanol. Use of
extremely flammable and highly explosive, which could
these fuels will damage the fuel system.
result in death or serious injury. (00028b)
• Using fuel additives other than those approved for use by
A WARNING Harley-Davidson may damage the engine, fuel system and
other components.
Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is Some gasoline blends might adversely affect starting,
extremely flammable and highly explosive, which could performance or fuel efficiency. If any of these problems are
result in death or serious injury. (00029a) experienced, try a different brand of gasoline or gasoline with a
higher octane blend.
Modern service station pumps dispense a high flow of gasoline
into a motorcycle fuel tank. This can cause air entrapment and ENGINE LUBRICATION ___________________
pressurization.
A CAUTION
Table 2-2. Octane Rating
SPECIFICATION RATING Prolonged or repeated contact with used motor oil may be
Pump Octane (R+M)/2 91 (95 RON) harmful to skin and could cause skin cancer. Promptly wash
affected areas with soap and water. (00358b)
GASOLINE_BLENDS A CAUTION
Harley-Davidson motorcycles are designed to get the best If engine oil is swallowed, do not induce vomiting. Contact a
performance and efficiency using unleaded gasoline. Most physician immediately. In case of contact with eyes,
gasoline is blended with alcohol and/or ether to create immediately flush with water. Contact a physician if irritation
oxygenated blends. The type and amount of alcohol or ether persists. (00357d)
added to the fuel is important.
NOTICE
NOTICE
Do not switch lubricant brands indiscriminately because
Do not use gasoline that contains methanol. Doing so can some lubricants interact chemically when mixed. Use of
result in fuel system component failure, engine damage inferior lubricants can damage the engine. (00184a)
and/or equipment malfunction. (00148a) •
Engine oil is a major factor in the performance and service life of
the engine. Use the proper grade of oil for the lowest temperature
expected before the next oil change. Refer to Table 2-3.

This motorcycle was originally equipped with GENUINE

HARLEY-DAVIDSON H-D 360 MOTORCYCLE OIL 20W50. If
operation under extreme cold or heat are expected, refer to Table
2-3 for alternative choices.

If H-D 360 or SYN3 is not available, add oil certified for diesel
engines. Acceptable designations include: CH-4, Cl-4 and CJ-4.
The preferred viscosities, in descending order are: 20W50,
15W40 and 10W40.

At the first opportunity, see an authorized dealer to change back

to 100 percent Harley-Davidson oil.

94000936 2-5
 Water vapor is a normal by-product of combustion . During cold-
Table 2-3. Recommended Engine Oils
TYPE VISCOSITY LOWEST AMBIENT COLD-WEATHER
TEMPERATURE STARTS BELOW
50 °F (10 °C)
Screamin' Eagle SYN3 Full Synthetic Motor- SAE 20W50 Above 30.2 °F (-1 °C) Excellent
cycle Lubricant
Genuine Harley-Davidson H-D 360 Motorcycle SAE 20W50 Above 39.2 °F (4 °C) Good
Oil
Genuine Harley-Davidson H-D 360 Motorcycle SAE 50 Above 60.8 °F (16 °C) Poor
Oil
Genuine Harley-Davidson H-D 360 Motorcycle SAE 60 Above 80.6 °F (27 °C) Poor
Oil
WINTER LUBRICATION weather operation, some water vapor condenses to liquid form
on the cool surfaces inside the engine. In freezing weather, this
Change engine oil often in colder climates. If motorcycle is water becomes slush or ice. If the engine is not warmed to
frequently ridden less than 15 mi (24 km), in ambient operating temperature, accumulated slush or ice blocks the oil
temperatures below 60 °F (16 °C), reduce oil change intervals to lines and causes engine damage. Over time, water will
1500 mi (2,400 km). accumulate, mix with the engine oil and form a sludge that is
harmful to the engine.
NOTE
Lower ambient temperatures require more frequent oil If the engine is allowed to warm to normal operating temperature,
changes. most of the water evaporates and exits through the crankcase
breather.

2-6 94000936
REPLACE ENGINE OIL AND FILTER 2.5

CHECK ENGINE OIL LEVEL 3. See Figure 2-1. Check oil level.
a. Remove filler plug/dipstick.
A CAUTION b. Wipe off the dipstick.
Prolonged or repeated contact with used motor oil may be c. Insert the dipstick and tighten into the fill spout.
harmful to skin and could cause skin cancer. Promptly wash
d. Remove filler plug/dipstick.
affected areas with soap and water. (00358b)
e. See Figure 2-2. Check oil level. Oil level must register
NOTICE between the ADD QT and FULL HOT marks on the
dipstick.
Do not overfill oil. Doing so can result in oil carryover to the air
cleaner leading to equipment damage and/or equipment 4. If oil level is at or below the ADD QT mark, add only enough
malfunction. (00190b) oil to bring the level to the FULL HOT mark. Do not overfill.
NOTE
Check engine oil level at each complete fuel refill.

Oil Level Cold Check

1. Place vehicle on level ground resting on the jiffy stand.

NOTE
Oil level on a cold engine should never be above the midway
point.

2. See Figure 2-1. Check engine oil level.

a. Remove filler plug/dipstick.

b. Wipe off the dipstick.
c. Insert the dipstick and tighten into the fill spout.
d. Remove filler plug/dipstick.
e. See Figure 2-2. Check oil level. The correct cold oil level
is midway (2) between the ADD QT (1) and FULL HOT
(3) marks on the dipstick.

3. If oil level is at or below the ADD QT mark, add only enough

oil to bring the level to the ADD QT mark.

4. Start and idle engine on jiffy stand for two minutes. Turn off
engine.

5. Check oil level. Add only enough to bring level midway

between the ADD QT (1) and FULL HOT (3).

Oil Level Hot Check

NOTICE

Do not allow hot oil level to fall below Add/Fill mark on dipstick.
Doing so can result in equipment damage and/or equipment
malfunction. (00189a)

NOTE CHANGE OIL AND OIL FILTER

Perform engine oil level hot check only with engine oil at
normal operating temperature.

1. Ride motorcycle until engine oil reaches at least 200 °F (93 PART NUMBER TOOL NAME
°C) or higher.
94686-00 OIL FILTER WRENCH
2. Allow engine to idle for 1-2 minutes on jiffy stand. Turn off 94863-10 OIL FILTER WRENCH
engine.
FASTENER TORQUE VALUE
Engine oil drain plug | 14-21 ft-lbs 19-28.5 N-m

94000936 2-7
 A WARNING 8. Install engine oil drain plug and new O-ring.

Be sure that no lubricants or fluids get on tires, wheels or Torque: 14-21 ft-lbs (19-28.5 N-m) Engine oil drain plug
brakes when changing fluid. Traction can be adversely NOTE
affected, which could result in loss of control of the Use the proper grade of oil for the lowest temperature
motorcycle and death or serious injury. (00047d) expected before the next oil change. Refer to Table 2-3
for recommended oil.
NOTICE

Do not switch lubricant brands indiscriminately because 9. Add an initial volume of engine oil. Refer to Table 2-4.
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a) Table 2-4. Initial Oil Fill
ITEM QUANTITY
• Change engine oil at the first 1000 mi (1,600 km) for a new
engine. After the initial service, change oil at regular intervals Engine oil initial fill 4.0 qt (3.8 L)
in normal service at warm or moderate temperatures. Refer to 10. Verify proper oil level. See Check Engine Oil Level (Page 2-
General (Page 2-3). 7).

• Change oil at more frequent intervals in cold weather or severe a. Perform engine oil level cold check.
operating conditions. See FUEL AND OIL (Page 2-5). b. Start engine and carefully check for oil leaks around
drain plug and oil filter.
1. Run motorcycle until engine is at normal operating
temperature. Turn off engine. c. Perform engine oil level hot check.

2. Remove filler plug/dipstick.

NOTE
Replace drain plug O-ring.

3. See Figure 2-3. Remove the oil drain plug (2) and O-ring.
Allow oil to drain completely.

NOTE
Use P&A Oil Catcher (Part No. 62700199) or equivalent to
keep drain oil off crankcase when removing oil filter.
Residual drain oil could falsely appear as a crankcase oil
leak at a later time.

4. Remove the oil filter using oil filter wrench and hand tools. Figure 2-4. Lubricating New Oil Filter Gasket
Do not use with air tools.

Special Tool: OIL FILTER WRENCH (94863-10)

Figure 2-3. Engine Oil Drain Plug
Special Tool: OIL FILTER WRENCH (94686-00)

5. Clean the oil filter mount flange.

6. Clean any residual oil for crankcase and transmission

housing.

7. See Figure 2-4. Install new oil filter.

a. Lubricate gasket with a thin film of clean engine oil.

b. Install new oil filter.

c. Hand-tighten oil filter one-half to three-quarters of a

turn after gasket first contacts filter mounting surface.
Do NOT use oil filter wrench for installation.

2-8 94000936
REPLACE PRIMARY CHAINCASE LUBRICANT 2.6

CHANGE PRIMARY CHAINCASE 9. Add lubricant.

LUBRICANT
a. Pour specified amount of FORMULA-
TRANSMISSION AND PRIMARY CHAINCASE
FASTENER TORQUE VALUE
LUBRICANT or SCREAMIN EAGLE SYN3 FULL
Clutch inspection cover screws 25-35 in-lbs 2.8-3.9 N-m SYNTHETIC MOTORCYCLE LUBRICANT 20W50
through clutch inspection cover opening. Refer to
Primary chaincase drain plug 14-21 ft-lbs 19-28.5 N-m Table 2-5.
1. Run motorcycle until engine is at normal operating
b. See Figure 2-6. Proper level is approximately at
temperature. Turn off engine.
bottom of pressure plate OD.
A WARNING
Be sure that no lubricants or fluids get on tires, wheels or brakes
when changing fluid. Traction can be adversely affected, which ITEM
could result in loss of control of the motorcycle and death or DRY FILL1'1 WET FILL''1
Oz L Oz L
serious injury. (00047d)
Amount'’' 40 1.18 36 1.06
2. Secure motorcycle upright (not leaning on jiffy stand) on a (1) Amount is approximate. Fill to bottom of pressure plate OD with
level surface. vehicle upright.
(2) Cover was removed and installed.
(3) Lubricant was drained through the drain plug only.
3. See Figure 2-5. Drain primary chaincase.

4. Clean drain plug magnet. If plug has excessive debris,

inspect the condition of chaincase components.

5. Install drain plug and new O-ring. Tighten.

Torque: 14-21 ft-lbs (19-28.5 N-m) Primary chaincase

drain plug

Figure 2-6. Primary Chaincase Lubricant Level

Table 2-5. Primary Chaincase Lubricant

10. See Figure 2-7. Install new seal (1):

11. Install clutch inspection cover (2).

12. Install screws (3). Tighten finger tight.

Figure 2-5. Removal/Installation of Chaincase Drain Plug

6. See Figure 2-7. Remove screws (3). 13. See Figure 2-8. Tighten screws in sequence.
Torque: 25-35 in-lbs (2.8-3.9 N-m) Clutch inspection cover
7. Remove clutch inspection cover (2). screws

8. Remove seal (1). Wipe oil from primary cover and O-ring
groove.

NOTICE

Do not overfill the primary chaincase with lubricant. Overfilling

can cause rough clutch engagement, incomplete disengagement,
clutch drag and/or difficulty in finding neutral at engine idle.
(00199b)

94000936 2-9
Figure 2-8. Clutch Cover Tightening Sequence

2-10 94000936
REPLACE TRANSMISSION LUBRICANT 2.7
CHECK TRANSMISSION LUBRICANT

FASTENER TORQUE VALUE

Transmission filler plug/dip- 25-75 in-lbs 2.8-8.5 N-m
stick
NOTE
Check transmission fluid with the motorcycle at ambient
temperature. Inspect transmission dipstick 0-ring. Replace if
necessary.

1. Park motorcycle on a level surface on jiffy stand.

2. Remove right side cover. See Remove (Page 3-64).

3. See Figure 2-9. Remove transmission filler plug/dipstick.

Wipe dipstick clean.

4. Install filler plug/dipstick until O-ring contacts the case. Do

Table 2-6. Transmission Lubricant
not tighten.
MODEL LUBRICANT
All FORMULA- TRANSMISSION AND PRIMARY
5. See Figure 2-10. Remove filler plug/dipstick. Check lubricant CHAIN LUBRICANT or SCREAMIN' EAGLE
level on dipstick. Proper oil level is between the Add (A) (1) SYN3 FULL SYNTHETIC MOTORCYCLE
and Full (F) (2) marks. LUBRICANT 20W50
when changing fluid. Traction can be adversely affected, which
NOTICE could result in loss of control of the motorcycle and death or
Mixing mineral-based lubricants with SYN-3 in the transmission
can damage the transmission. (00452b) FASTENER TORQUE VALUE
Transmission drain plug 14-21 ft-lbs 19-28.5 N-m
6. If lubricant level is low, add recommended Harley-Davidson Transmission filler plug/dip- 25-75 in-lbs 2.8-8.5 N-m
lubricant to bring level to between the A mark and the F stick
marks. Refer to Table 2-6. 1. See Figure 2-9. Remove transmission filler plug/dipstick.
serious injury. (00047d)
7. Install filler plug/dipstick. Tighten.

Torque: 25-75 in-lbs (2.8-8.5 N-m) Transmission filler 2. See Figure 2-11. Remove transmission drain plug. Drain
plug/dipstick transmission.

8. Install right side cover. See Install (Page 3-64). 3. Clean and inspect drain plug and O-ring.

NOTICE
Do not over-tighten filler or drain plug. Doing so could result in a
lubricant leak. (00200b)

4. Install drain plug with new O-ring. Tighten. Do not over-

tighten.

Torque: 14-21 ft-lbs (19-28.5 N-m) Transmission drain

plug

5. Fill the transmission with recommended Harley-Davidson

lubricant. Refer to Table 2-6.

Volume: 28 fl oz (0.83 L)

Figure 2-9. Transmission Filler Plug/Dipstick Location

CHANGE TRANSMISSION LUBRICANT

A WARNING
Be sure that no lubricants or fluids get on tires, wheels or brakes

94000936 2-11
6. Check lubricant level. Add enough lubricant to bring the level
between the add (A) and full (F) marks. See Figure 2-10.

7. Install filler plug/dipstick. Tighten.

Torque: 25-75 in-lbs (2.^^.5 N-m) Transmission filler
plug/dipstick

Figure 2-11. Transmission Drain Plug

2-12 94000936
INSPECT TIRES AND WHEELS 2.8
GENERAL 2. See Figure 2-12, Figure 2-13 and Figure 2-14.
Inspect each tire for wear. Replace tires before they
A WARNING
reach the tread wear indicators.
Match tires, tubes, rim strips or seals, air valves and caps to
the correct wheel. Contact a Harley-Davidson dealer.
Mismatching can lead to tire damage, allow tire slippage on
the wheel or cause tire failure, which could result in death or
serious injury. (00023c)

A WARNING
Harley-Davidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure,
which could result in death or serious injury. (00026a)

NOTE
• Tubeless tires are used on all Harley-Davidson cast
wheels.
• Tire sizes are molded on the tire sidewall. Inner tube sizes
are printed on the tube.

• Store new tires on a horizontal tire rack. Avoid stacking

new tires in a vertical stack. The weight of the stack
compresses the tires and crushes the beads.

Tire Pressure Figure 2-12. Tread Wear Indicator: Michelin Tires

A WARNING
Be sure tires are properly inflated, balanced, undamaged,
and have adequate tread. Inspect your tires regularly and
see a Harley-Davidson dealer for replacements. Riding with
excessively worn, unbalanced, improperly inflated,
overloaded or damaged tires can lead to tire failure and
adversely affect stability and handling, which could result in
death or serious injury. (00014b)

Check tire pressure:

• As part of the pre-ride checklist.
• At every scheduled service interval.
1. Check tire pressures when tires are cold. Compare with
specifications. Refer to Table 2-7.

NOTE
Harley-Davidson does not perform any testing with only
nitrogen in tires. Harley-Davidson neither recommends nor
discourages the use of pure nitrogen to inflate tires.
Figure 2-13. Dunlop Sidewall Tread Wear Indicator Bar
Locator
Tread

A WARNING

Replace tire immediately with a Harley-Davidson specified

tire when wear bars become visible or only 1/32 in (1 mm)
tread depth remains. Riding with a worn tire could result in
death or serious injury. (00090c)

Check tire tread:

• As part of the pre-ride checklist.

• At every scheduled service interval.

1. Inspect each tire for punctures, cuts and breaks.

94000936 2-13
 1. Replace when bearings exceed end play service wear limit
of 0.002 in (0.051 mm).
2. Inspect any time the wheels are removed.
a. Inspect the play of the wheel bearings by hand while they
are in the wheel.

b. Rotate the inner bearing race and check for abnormal

noise.

c. Make sure that bearing rotates smoothly.

3. Check wheel bearings and axle spacers for wear and

corrosion. Excessive play or roughness indicates worn
bearings.
WHEEL SPOKES _________________________

Figure 2-14. Dunlop Tread Wear Indicator Bar Appearance

Table 2-7. Specified Tires

MODEL MOUNT SIZE SPECIFIED TIRE PRESSURE(COLD 68.0 °F
(20 °C))
psi kPa
FLFBS front 18 in Michelin Scorcher 11 160/60R18 70V BW 36 248
FLHCS front 16 in Dunlop D401F 130/90B16 73H BW 36 248
FXBBS,FXST front 19 in Dunlop D401F 100/90B19 57H BW 36 248
FXBRS front 21 in Michelin Scorcher 11 130/60B21 63H BW 36 248
FXFBS front 16 in Dunlop D429F 150/80B16 71H BW 36 248
FXLRS,FXLRST front 19 in Michelin Scorcher 31 110/90B19 62H BW 32 221
FLSB front 18 in Michelin Scorcher 31 130/70B18 63H BW 36 248
FLFBS,FXBRS rear 18 in Michelin Scorcher 11 240/40R18 79V BW 42 290
FLHCS, FXBBS, FXST rear 16 in Dunlop D401 150/80B16 77H BW 40 276
FXFBS rear 16 in Dunlop 180/70B16 77H BW 40 276
FLSB,FXLRS,FXLRST rear 16 in Michelin Scorcher 31 180/70B16 77H BW 40 276
TIRES

Inspect
Tread wear indicators appear on tire tread surfaces when
0. 031 in (0.8 mm) or less of tire tread remains. Always
replace tires before the tread wear indicators appear on the
surface of the tire.

See Figure 2-12 or Figure 2-13 . The locations of tread wear

indicators are identified by the marks on the tire sidewalls.

When to Replace Tires

New tires are needed if:

• Tread wear indicators become visible on the tread surfaces.

• Tire cords or fabric become visible through cracked sidewalls,
snags or deep cuts.
PART NUMBER TOOLNAME
• A bump, bulge or split in the tire.
HD-48985 SPOKE TORQUE WRENCH
• A puncture, cut or other damage to the tire that cannot be HD-94681-80 SPOKE WRENCH
repaired.

WHEEL BEARINGS ______________________ FASTENER TORQUE VALUE

Spoke nipple 55 in-lbs 6.2 N-m

NOTE
Replace bearings in sets only. See SEALED WHEEL
BEARINGS (Page 3-25).

2-14 94000936
 A WARNING 3. Repeat previous two steps for spoke (4) in the same group.
Spokes that are too tight can draw nipples through the rim or 4. Continue around the wheel checking spokes 1 and 4 until all
distort hub flanges. Spokes that are too loose can continue to groups are done.
loosen when put in service. Either condition can adversely affect
5. Repeat procedure for spokes (2, 3) in each group.
stability and handling, which could result in death or serious
injury. (00286a) NOTE

A WARNING When checking any spokes that were labeled, make sure to
use the original alignment mark.
Do not over-tighten spoke nipples. Protruding spoke nipples can
damage rim seal, resulting in rapid tire deflation, which could 6. Check spokes, if any, that were labeled as not reaching the
cause death or serious injury. (00611c) proper torque value after tightening one-quarter turn past
alignment mark.
NOTICE
a. Loosen spoke one-quarter turn past original alignment
When llfting a motorcycle using a jack, be sure jack contacts both
mark using SPOKE WRENCH (PART NUMBER: HD-
lower frame tubes where down tubes and lower frame tubes
94681-80).
converge. Never lift by jacking on cross-members, oil pan,
mounting brackets, components or housings. Failure to comply b. While tightening, if the torque wrench clicks before the
can cause serious damage resulting in the need to perfonn major alignment marks align, continue to turn the spoke nipple
repair work. (00586d) until the marks align.

c. If the marks align and torque specification has not been

Identify Wheel Spoke Groups reached, tighten the spoke nipple until the correct torque
is achieved. Do not turn spoke nipple more than one-
NOTE quarter turn past alignment mark.
Spokes are grouped in sets of four.
7. True the wheel. See CHECKING AND TRUING WHEELS
1. Raise the wheel. (Page 3-21).

2. See Figure 2-15. Starting at the valve stem, identify the first Table 2-8. Spoke Nipple Torque Specification
group of four spokes (1-4). RIM TYPE MINIMUM TORQUE
3. Using a different color for each spoke in the group, draw an All 55 in-lbs (6.2 N-m)
alignment mark across the spoke nipple and onto the rim.

4. Continue around the wheel marking the rest of the spokes

the same as they were marked in the previous steps.

Adjust Wheel Spokes

NOTE
• Do not tighten spake mare than one-quarter turn past
alignment mark. If more tension is needed, label spoke
and check after completing rest of wheel.

• Do not use the spoke torque wrench to loosen spokes.

Use SPOKE WRENCH (PART NUMBER: HD-94681-80) to
loosen spokes.

1. See Figure 2-15. Starting with the first group of spokes,

loosen spoke (1) one-quarter turn using SPOKE WRENCH
(PART NUMBER: HD-94681-80).

2. Using SPOKE TORQUE WRENCH (PART NUMBER: HD-

48985) tighten spoke (1) to the value listed in Table 2-8.

a. While tightening, if the torque wrench clicks before the

alignment marks align, continue to turn the spoke nipple
until the marks align. Figure 2-15. Tightening Laced Wheels (typical)
b. If the marks align and torque specification has not been
reached, tighten the spoke nipple until the correct torque
is achieved. Do not turn spoke nipple more than one-
quarter turn past alignment mark.

94000936 2-15
LUBRICATE CABLES AND CHASSIS 2.9
GENERAL Consumable: CCI #20 BRAKE GREASE (42830-05)

Inspect and lubricate the following items according to 2. NOTE

MAINTENANCE SCHEDULE (Page 2-3). HARLEYLUBE (94968-09) is formulated to be compatible
with clutch cable lining. Use of other lubricants could
If service is on muddy or dusty roads, clean and lubricate at damage clutch cable lining.
shorter intervals.
Clutch cable. See CLUTCH CONTROL (Page 3-91).
LUBRICATION POINTS ___________________
Consumable: HARLEY LUBE (94968-09)

CONSUMABLE PART NUMBER 3. Clutch hand lever. See CLUTCH CONTROL (Page 3-91).
CCI #20 BRAKE 42830-05 Consumable: HARLEY LUBE (94968-09)
GREASE
HARLEY LUBE 94968-09 4. Jiffy stand: Lubricate clevis pin and spring hook groove.
See JIFFY STAND (Page 3-140).
ANTI-SEIZE 98960-97
LUBRICANT Consumable: ANTI-SEIZE LUBRICANT (98960-97)
SPECIAL 99857-97A
5. Steering head bearings: Lubricate steering head bearings.
PURPOSE
See ADJUST AND LUBRICATE STEERING HEAD
GREASE
BEARINGS (Page 2-27).
See Figure 2-16 for general location of lubrication points.
Consumable: SPECIAL PURPOSE GREASE (99857-97A)
1. Front brake hand lever: Use grease on front brake lever pivot
pin hole and end of piston that contacts brake lever. See 6. Fork lock: Lubricate lock internal components.
FRONT BRAKE MASTER CYLINDER (Page 3-35).
Consumable: HARLEY LUBE (94968-09)

1. Front brake hand lever 4. Jiffy stand

2. Clutch cable 5. Steering head bearings
3. Clutch hand lever 6. Fork lock
Figure 2-16. Lubrication Points

2-16 94000936
INSPECT BRAKES 2.10

INSPECT A WARNING
Clean if necessary.
PART NUMBER TOOL NAME
a. Rinse area with warm soapy water.
HD-48497-A DOT 4 BRAKE FLUID MOISTURE
TESTER
b. Dry using low-pressure compressed air.
CONSUMABLE PART NUMBER
2. NOTE
Harley-Davidson 41800xxx
Platinum Label Always replace both pads in a caliper as a set.
DOT 4 Brake Fluid
NOTICE See Figure 2-17. Measure brake pad thickness.

Contact with DOT 4 brake fluid can have serious health

effects. Failure to wear proper skin and eye protection could
result in death or serious injury.
• If inhaled: Keep calm, remove to fresh air, seek medical
attention.

• If on skin: Remove contaminated clothing. Rinse skin

immediately with plenty of water for 15-20 minutes. If
irritation develops, seek medical attention.
• If in eyes: Wash affected eyes for at least 15 minutes
under running water with eye lids held open. If irritation
develops, seek medical attention.

• If swallowed: Rinse mouth and then drink plenty of water.

Do not induce vomiting. Contact Poison Control.
Immediate medical attention required.

• See Safety Data Sheet (SDS) for more details available at

sds.harley-davidson.com
(00240e)
NOTICE
DOT 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is
performed. Failure to comply can result in cosmetic damage.
(00239c)

1. Inspect for grit and debris buildup at caliper piston areas.

Brake Pads a. Replace brake pads (3) if friction material thickness

^ — — — — — i s equal to or less than dimension.
A WARNING
0. 016 in (0.4 mm)
Always replace brake pads in complete sets for correct
b See INSPECT BRAKES (Page 2-17)
and safe brake operation. Improper brake operation could - .
result in death or serious injury. (00111a)
Brake Disc
NOTE
Minimum acceptable thickness is stamped on side of disc.

1. Measure thickness.

a. Measure thickness with a micrometer.

b. Replace disc if disc is scored or measured thickness

is less minimum.

94000936 2-17
2. Measure runout. 3. Remove brake pads.
a. Measure runout near the outside diameter of the disc NOTE
using a dial indicator. Loosening the reservoir cap allows air to escape and
helps prevent contamination. It also helps prevent fluid
b. Replace disc if runout meets or exceeds dimension. from squirting out of reservoir.
0. 008 in (0.2 mm)
Replace disc if warped, badly scored or worn beyond service 4. Remove brake pad spring (4).
limit. See FRONT WHEEL (Page 3-12) or REAR WHEEL (Page
3-16). 5. Loosen front master cylinder reservoir cap.
Front brake caliper (viewed from below) Brake disc Brake
NOTE
,4s pistons are pushed back into caliper, verify that fluid
does not overflow reservoir. Remove fluid if necessary.

6. Using the old brake pad and a C-clamp, retract the pistons
fully into the caliper.

Install
A WARNING

Always replace brake pads In complete sets for correct

and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

1. Install new pads into caliper.

NOTE
See Figure 2-18. Brake pad spring (4) must be installed
with the stamped arrow facing up.

2. Loosely install new brake pad hanger pins (3) and new brake
pad spring (4).

3. Install front caliper. See FRONT BRAKE CALIPER (Page 3-

38).

4. Tighten brake pad hanger pins.

Torque: 11-14 ft-lbs (14.7-19.6 N-m) Front brake pad

hanger pin

5. Pump brakes to move pistons out until brake pads contact

rotor. Verify piston location against pads. If the front wheel
is off the ground, rotate wheel to check for excessive brake
1. pads Backplate pad drag.
2. Rear brake caliper (viewed from above) Rear brake
3. caliper mounting bracket 6. Check fluid level in brake master cylinder reservoir. See
4. Figure 2-17. Brake Pad Inspection CHECK AND REPLACE BRAKE FLUID (Page 2-21).
5. REPLACE FRONT BRAKE PADS
6.
A WARNING
Remove
After repairing the brake system, test brakes at low speed. If
1. Remove front caliper. See FRONT BRAKE CALIPER (Page brakes are not operating properly, testing at high speeds can
cause loss of control, which could result in death or serious injury.
FASTENER TORQUE VALUE
(00289a)
Front brake pad hanger pin 11-14 ft-lbs 14.7-19.6 N-m
3-38). 7. Test brakes.

NOTE
Avoid making hard stops for the first 100 mi (160 km) in
order to wear in the brakes properly

2. See Figure 2-18. Remove brake pad hanger pins (3). a. Turn ignition switch ON. Check operation of rear lamps.

2-18 94000936
 b. Test ride motorcycle. If brakes feel spongy, bleed brakes REPLACE REAR BRAKE PADS
. See CHECK AND REPLACE BRAKE FLUID (Page
2-21).

Install

1. See Figure 2-19. Install brake pad retaining spring (5).

A WARNING
Remove in death or serious injury. (00111a)

1. See Figure 2-19. Remove rear caliper (1). See REAR

2. Install new brake pads (4).
BRAKE CALIPER (Page 3-46).

3. Install brake pad hanger pin (2). Hand tighten.

2. Remove brake pad hanger pins (2).
NOTE
a. Inspect brake pad hanger pins for damage or wear, Hanger pins are torqued after caliper is installed on vehicle.
replace if needed.
4. See Figure 2-19 and Figure 3-50. Install new retainer clip (3)
3. Remove brake pads (4). onto rear caliper mounting bracket.

4. NOTE 5. Install rear caliper. See REAR BRAKE CALIPER (Page 3-

Loosening the reservoir cap allows air to escape and 46).
helps prevent contamination. It also helps prevent fluid
from squirting out of reservoir.
6. Pump brakes to move pistons out until brake pads contact
rotor. Verify piston location against pads. If the rear wheel is
Loosen rear master cylinder reservoir cap. off the ground, rotate wheel to check for excessive brake
pad drag.
5. NOTE
As pistons are pushed back into caliper, verify that fluid
does not overflow reservoir. Remove fluid if necessary. 7. Check fluid level in rear brake master cylinder reservoir. See
CHECK AND REPLACE BRAKE FLUID (Page 2-21).
Using the old brake pad and a C-clamp, retract the pistons
fully into the caliper. A WARNING

After repairing the brake system, test brakes at low speed. If

6. Inspect brake pad retainer spring (5). Replace if needed. brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
7. See Figure 2-19 and Figure 3-50. Remove retainer clip (3) serious injury. (00289a)
from rear caliper mounting bracket.
Always replace brake pads in complete sets for correct and
safe brake operation. Improper brake operation could result

8. NOTE
Avoid making hard stops for the first 100 mi (160 km) in
order to wear in the brakes properly.

94000936 2-19
Test brakes. b. Test ride motorcycle. If brakes feel spongy, bleed
brakes. See BLEED BRAKES (Page 3-61 ).
a. Turn ignition switch ON. Check operation of rear brake
lamps.

2-20 94000936
CHECK AND REPLACE BRAKE FLUID 2.11

CHECK BRAKE FLUID LEVEL • Flush brake system and replace DOT 4 BRAKE FLUID
(41800219) fluid every two years or sooner if brake fluid
PART NUMBER TOOL NAME test shows moisture content is 3% or greater.
HD-48497-A DOT 4 BRAKE FLUID MOISTURE • Fluid should never need to be added or removed from the
TESTER system during normal wear; except for fluid replacement
as specified in the maintenance schedule.
FASTENER TORQUE VALUE
• Fluid level in reservoir will decrease with brake wear.
Brake master cylinder, front, 9-18 in-lbs 1-2 N-m Reservoir volume is adequate to provide fluid to the wear
reservoir cover screws limits of the pads and rotors.
Brake master cylinder, rear, 9-18 in-lbs 1-2 N-m
reservoir cover screws 1. Front brake: Check fluid level.

CONSUMABLE PART NUMBER a. Set motorcycle upright and turn handlebar to level
DOT 4 BRAKE 41800219 reservoir.
FLUID
A WARNING b. See Figure 2-20. Check low-level mark on reservoir
sight glass. See Figure 2-21. If necessary, add brake
Clean reservoir filler cap or cover before removing. Use only DOT fluid to reservoir.
4 brake fluid from a sealed container. Contaminated fluid can
DOT 4 BRAKE FLUID (41800219)
adversely affect braking or clutch disengagement, which could
result in death or serious injury. (00504d)
2. Rear brake: Check fluid level.
A WARNING
a. Stand motorcycle upright (not leaning on jiffy stand) on
Contact with DOT 4 brake fluid can have serious health effects.
a level surface.
Failure to wear proper skin and eye protection could result in
death or serious injury.
b. See Figure 2-20. Check low-level mark on reservoir
• If inhaled: Keep calm, remove to fresh air, seek medical sight glass. See Figure 2-22. If necessary, add brake
attention. fluid to reservoir.

• If on skin: Remove contaminated clothing. Rinse skin DOT 4 BRAKE FLUID (41800219)
immediately with plenty of water for 15-20 minutes. If irritation
develops, seek medical attention. 3. If fluid level was below minimum mark:

• If in eyes: Wash affected eyes for at least 15 minutes under a. Check for brake system fluid leaks.
running water with eye lids held open. If irritation develops,
seek medical attention. b. Check that brake pads and rotors are properly
• If swallowed: Rinse mouth and then drink plenty of water. Do installed and not worn beyond service wear limits. See
not induce vomiting. Contact Poison Control. Immediate INSPECT BRAKES (Page 2-17).
medical attention required.
4. NOTE
• See Safety Data Sheet (SDS) for more details available at
sds.harley-davidson.com Vent holes in front master cylinder cover face rear of
motorcycle.
(00240e)
NOTICE If master cylinder reservoir cover was removed. Tighten.

DOT 4 brake fluid will damage painted and body panel surfaces it a. Front:
comes in contact with. Always use caution and protect surfaces
from spills whenever brake work is performed. Failure to comply Torque: 9-18 in-lbs (1-2 N-m) Brake master
can result in cosmetic damage. (00239c) cylinder; front, reservoir cover screws
b. Rear:
NOTICE
Torque: 9-18 in-lbs (1-2 N-m) Brake master
Do not allow dirt or debris to enter the master cylinder reservoir.
cylinder; rear; reservoir cover screws
Dirt or debris in the reservoir can cause improper operation and
equipment damage. (00205c) 5. Verify front brake hand lever and rear brake foot pedal have a
firm feel when applied. If brakes are not firm, the brake
NOTE system must be bled. See BLEED BRAKES (Page 3-61).
• At every service, check moisture content of fluid using
DOT 4 BRAKE FLUID MOISTURE TESTER (PART
NUMBER: HD-48497-A). Follow the instructions included
with tool.

94000936 2-21
 DRAIN AND REPLACE FLUID

For this scheduled maintenance procedure, see BLEED

BRAKES (Page 3-61 ).

Figure 2-21. Front Master Cylinder Fill Level

2-22 94000936
CHECK AND ADJUST CLUTCH 2.12
CHECK AND ADJUST

FASTENER TORQUE VALUE

Clutch hub jamnut 72-120 in-lbs 8.1-13.6 N-m

Adjust
1. Stand motorcycle upright (not leaning on jiffy stand) on a
level surface. Front wheel straight ahead.

2. See Figure 2-23. Access two piece clutch cable.

a. Remove spring clip (1).

b. Slide cover (2) up.

4. NOTE
Inspect tabs on lock button (2). Replace if damaged.

See Figure 2-25. Unlock upper clutch cable (1).

a. Push tabs on lock button (2) slightly inboard and then

down to disengage.

5. Fully collapse cable (spring compressed) and push button in.

This releases cable tension.

3. See Figure 2-24. Identify upper clutch cable (1) and red lock Figure 2-25. Compressed Upper Clutch Cable
button (2).

6. NOTE
Perform clutch adjustment with motorcycle at room
temperature. Clearance at adjuster screw increases as
powertrain temperature increases. If adjustment is
made when hot, clearance at pushrod bearing could be
insufficient when cold. Clutch slippage could occur.

94000936 2-23
 Adjust clearance at hub. 9. NOTE
Inspect lock button (2). Replace if damaged.

a. Remove clutch inspection cover from primary

chaincase cover. See REPLACE PRIMARY
CHAINCASE LUBRICANT (Page 2-9).

b. See Figure 2-26. Loosen jamnut (1) on clutch adjuster

screw. Turn adjuster screw (2) inward (clockwise) until
lightly seated.

c. Squeeze clutch lever to maximum limit three times to

set release mechanism.

d. Back out adjuster screw one-half to one full turn. While

holding adjuster screw, tighten jamnut.
Torque: 72-120 in-lbs (8.1-13.6 N-m) Clutch hub
jamnut
e. Secure clutch inspection cover. Tighten in sequence.
See REPLACE PRIMARY CHAINCASE LUBRICANT

Figure 2-28. Secure Lock Button

10. See Figure 2-29. Spring force is sufficient to ensure correct

system freeplay.

a. Check free-play (4) at clutch lever.

b. If free-play is not to specification, check for proper

clutch cable routing.

11. Check clutch operation.

Figure 2-26. Clutch Adjuster Screw 12. See Figure 2-23. Slide cover down and reinstall spring clip
(Page 2-9). (1 ).

7. See Figure 2-27. Ensure clutch lever is in full open position

and that ferrule (1) is correctly seated in housing.
Clutch Cable Only Check
1. Rotate front wheel straight ahead.

2. See Figure 2-29. Check free play.

a. Pull clutch cable ferrule (2) away from clutch lever

bracket (3).

b. Check free play (4) dimension. Refer to Table 2-9.

c. Adjust clutch. See Adjustment in this section.

8. See Figure 2-25. Disengage lock button (2) allowing upper

clutch cable spring (1) to set free-play at clutch lever.

2-24 94000936
pd00059a
Table 2-9. Clutch Cable Free Play
ITEM DIMENSION
Free play dimension 1/16--% in (1.6--3.2 mm)

1. Clutch cable Cable

2. ferrule Clutch lever
3. bracket Free play
4. Figure 2-29. Clutch Cable Free Play

94000936 2-25
REBUILD FRONT FORK AND REPLACE OIL 2.13

REBUILD AND REPLACE FORK OIL

For this scheduled maintenance procedure, see FRONT FORK (Page 3-65).

2-26 94000936
ADJUST AND LUBRICATE STEERING HEAD BEARINGS 2.14

PREPARE

1. Support motorcycle upright with front wheel suspended and

vehicle level.

2. Remove all accessory weight from front of motorcycle. a.

Remove windshield if equipped.

3. Move forks from stop to stop to check for smooth operation.
Rough operation indicates damaged bearings. See
STEERING HEAD (Page 3-78).

4. Grasping both forks near the front axle, pull forks to front
then push to rear.

a. If a clunk is felt, perform Adjust in ADJUSTMENT

CHECK.

CHECK AND ADJUST

Table 2-10. Pull Force Specifications
MODEL MINIMUM MAXIMUM
FASTENER TORQUE VALUE
FXFBS 3 lb 7 lb
Fork stem pinch bolt - 16-20 ft-lbs 21.7-27.1 N-m FXBBS,FXST 4Ib 8Ib
Lower fork bracket pinch bolt 16-20 ft-lbs 21.7-27.1 N-m FXLRS,FXLRST 6 lb 9Ib
FLSB,FLFBS,FLHCS 7lb 11 lb
Measure FXBRS 10 lb 14Ib
1. Perform test. Adjust
a. Move handlebars from left to right steering stops three 1. FLHCS: Remove rear headlight nacelle panels. See
times, ending at full left steering stop. HEADLAMP NACELLE (Page 3-96)

b. Using a 0-25 lb pull force scale with a peak hold 2. FXBBS, FXBRS, FXST: Remove handlebars. See
feature, pull from the inside diameter of the front axle HANDLEBAR (Page 3-109)
until the front end is straight.
NOTE 3. See Figure 2-31. Loosen fork stem pinch bolt (2).
See Figure 2-30. While pulling, keep scale parallel
to front tire and perpendicular to fork leg. 4. Loosen upper fork bracket pinch bolts (3).

Be sure to pull slowly without tugging the scale. 5. Adjust fork stem bolt (1).
a. If pull force dimension is more than the maximum,
c. Repeat steps a and b until the peak force value loosen the fork stem bolt.
becomes consistent.
b. If pull force dimension is less than the minimum,
2. If peak force value is not within specification, adjust the tighten the fork stem bolt.
fork stem bolt. Refer to Table 2-10.
6. Tighten fork stem pinch bolt (2).
Torque: 16-20 ft-lbs (21.7-27.1 N-m) Fork stem pinch bolt

7. Tighten upper fork bracket pinch bolts (3).

Torque: 16-20 ft-lbs (21.7-27.1 N-m) Lower fork bracket
pinch bolt

8. FXBBS, FXBRS, FXST: Install handlebars. See

HANDLEBAR (Page 3-109)

9. FLHCS: Install rear headlight nacelle panels. See

HEADLAMP NACELLE (Page 3-96)

94000936 2-27
 10. Repeat measure and adjust as needed. LUBRICATE

Figure 2-31. Pull Force Adjustment Points (Typical)

1. Disassemble the steering head assembly and lubricate the

tapered roller bearings with SPECIAL PURPOSE GREASE.
See STEERING HEAD (Page 3-78)

COMPLETE ____________________________

1. Lower motorcycle.

2. Replace all items removed in prepare.

2-28 94000936
INSPECT FUEL LINES AND FITTINGS 2.15

INSPECT

For this scheduled maintenance procedure, see FUEL LINE

(Page 6-13).

94000936 2-29
INSPECT AND LUBRICATE JIFFY STAND 2.16

INSPECT AND LUBRICATE

For this scheduled maintenance procedure, see JIFFY STAND (Page 3-

140).

2-30 94000936
INSPECT AND ADJUST DRIVE BELT AND SPROCKETS 2.17
INSPECT

General
A WARNING
Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop. Over
bending can damage belt resulting in premature failure,
which could cause loss of control and death or serious
injury. (00339a)

In the case of stone damage to belt, inspect the sprockets for

damage and replace as required. If replacing belt, always replace
both transmission and rear sprockets.

Cleaning
Keep dirt, grease, oil, and debris off the drive belt and sprockets.
Clean the belt with a rag slightly dampened with a light cleaning
agent.

Sprockets Drive Belt

1. See Figure 2-32. Inspect each tooth (1) of rear sprocket for: See Figure 2-33 and Refer to Table 2-11. Inspect drive belt
for:
a. Major tooth damage
• Cuts or unusual wear patterns

b. Large chrome chips with sharp edges • Outside bevel wear (8). Some beveling is common, but it
indicates that sprockets are misaligned
c. Gouges caused by hard objects • Outside ribbed surface for signs of stone damage (7). If cracks
or other damage exists near edge of belt, replace belt
d. Excessive loss of chrome plating (see next step)
immediately. Damage to center of belt eventually requires belt
replacement. However, when cracks extend to edge of belt,
2. Check for worn chrome plating. Drag a sharp object across failure is imminent
the bottom of a groove (2) using medium pressure.
• Inside (toothed portion) of belt for exposed tensile cords
(normally covered by nylon layer and polyethylene layer).
a. If sharp object slides across groove without digging in Replace belt and transmission sprocket
or leaving a visible mark, chrome plating is still good.
• Signs of puncture or cracking at the base of the belt teeth.
b. If sharp object digs in and leaves a Visible mark, it is Replace belt if either condition exist:.
cutting the bare aluminum. The chrome plating is • Replace belt if conditions 2, 3, 6 or 7 (on edge of belt) exist
worn.
NOTE
Condition 1 may develop into 2 or 3 over time. Condition 1 is
3. Replace rear sprocket if major tooth damage or loss of
not grounds for replacing the belt, but it should be watched
chrome exists.
closely before condition 2 develops which will require belt
replacement.

94000936 2-31
 A WARNING
• With the vehicle unladen: no rider, no luggage and empty
saddlebags.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before
proceeding. (00251b)

1. Disarm security system. Remove main fuse. See TOWER

DISCONNECT (Page 7-7).

2. Shift transmission to neutral.

NOTE
When adjusting a new belt, rotate rear wheel a few
revolutions prior to setting the tension.

3. See Figure 2-34. Measure belt deflection using BELT

TENSI GAUGE (PART NUMBER: HD-35381-A):

a. Slide O-ring (4) to zero mark (3).

b. Models equipped with belt deflection window: Fit

belt cradle (2) against bottom of drive belt in line with belt
deflection window.
c. All other models: Fit belt cradle (2) against bottom of
drive belt hafvay between drive pulleys.
d. Press upward on knob (6) until O-ring slides down to 10
lb (4.54 kg) mark (5) and hold steady.

4. Measure belt deflection:

Table 2-11. a. Models equipped with belt deflection window: See

NO. CONDITION REQUIRED ACTION Figure 2-35. Measure belt deflection as viewed through
Internal tooth cracks OK to run, but monitor con- belt deflection viewing window while holding gauge
1
(hairline) dition. steady. Each deflection graduation is approxiately 1/16 in
2 External tooth cracks Replace belt. (1.6 mm).
3 Missing teeth Replace belt.
4 Chipping (not serious) b. All other models: See Figure 2-36. Measure amount of
OK to run, but monitor con-
deflection (4) while holding gauge steady.
dition.
5 Fuzzy edge cord OK to run, but monitor con- NOTE
dition.
Hook wear Replace belt and sprocket. Service belt tension specification is for belts with more than
6
7 Stone damage 1000 mi (1,600 km). Set belt to new belt tension specification
Replace belt if damage is
if the belt has less than 1000 mi (1,600 km).
on the edge.
Bevel wear (outboard OK to run, but monitor con- 5. Compare with specifications. Refer to Table 2-12. If not
8
edge only) dition. within specifications, see a Harley-Davidson dealer.
MEASURE DRIVE BELT DEFLECTION
PART NUMBER TOOL NAME 6. Install main fuse.

HD-35381-A BELT TENSION GAUGE

NOTE Table 2-12. Drive Belt Deflection

Always use BELT TENSION GAUGE (PART NUMBER: HD- MODEL
35381-A) to measure belt deflection. Failure to use tension DEFLECTION w
in mm
gauge may cause under-tensioned belts. Loose belts can fail
Service belt tension 1/2-9/16 12.7-14.2
due to "ratcheting"ljumping a tooth) which causes tensile
cord crimping and breakage. New belt tension 3/16-1/2 4.7-12.7
(1) Deflection measured at 10 lb (4.5 kg) tension.

Check deflection:
• With transmission in neutral.
• With motorcycle at ambient temperature.
• With motorcycle upright or on jiffy stand with rear wheel on
the ground.

2-32 94000936
 1. Transmission sprocket
2. Rear wheel sprocket
3. 10 lb (4.5 kg) of force
4. Amount of deflection
Figure 2-36. Checking Belt Deflection

ADJUSTBELT

PART NUMBER TOOL NAME

321326 HD-47925 AXLE NUT TORQUE ADAPTER

FASTENER TORQUE VALUE

Axle nut, rear 95-105 ft-lbs 128.8--142.4N-
m
Screw Style:
1. See Figure 2-37. Loosen rear axle nut (2).

2. Adjust drive belt deflection.

a. Screw style: Turn axle adjusters (3) an equal amount.

b. Keep wheel aligned until specification is achieved.

3. NOTE
See Figure 2-38. To tighten rear axle nut without
1. Drive belt
removing exhaust, use AXLE NUT TORQUE ADAPTER
2. Deflection graduations (Approx: 1.5 mm
(PART NUMBER: HD-47925).
(1/16-in) ____________________________
Figure 2-35. Belt Deflection Window
Tighten axle nut (2).
Torque: 98--105 ft-lbs (128.8-142.4 N-m) Axle nut, rear
4. Install E-clip (1).

5. Verify rear wheel alignment. See WHEEL ALIGNMENT

(Page 3-33).

6. Verify drive belt deflection.

A WARNING

Check wheel bearing end play after tightening axle nut to

specified torque. Excessive end play can adversely affect
stability and handling and can cause loss of control, which could
result in death or serious injury. (00285b)

7. Check wheel bearing end play. See SEALED WHEEL

BEARINGS (Page 3-25).

94000936 2-33
1. Torque wrench
2. Axle nut torque adapter (HD-4792
Figure 2-38. Install ToolPerpend icularto Torque Wrench

2-34 94000936
ADJUST SUSPENSION 2.18

ADJUST SHOCK ABSORBER b. Heritage Classic (FLHCS):

Refer to Table 2-14.

PART NUMBER TOOL NAME
14900102 SPANNER WRENCH KIT c. Sport Glide (FLSB):
Calculate Preload Setting Refer to Table 2-15.

A WARNING
d. Street Bob 114 (FXBBS), Softail Standard (FXST)
Do not exceed the motorcycle's Gross Vehicle Weight Rating
Refer to Table 2-16.
(G^WR) or Gross Axle Weight Rating (GAWR). Exceeding
these weight ratings can lead to component failure and
adversely affect stability, handling and performance, which e. Breakout 114 (FXBRS):
could result in death or serious injury. (00016f) Refer to Table 2-17.

Adjust suspension to suit load conditions, riding style and f. Fat Bob 114 (FXFBS):
personal comfort. Increase preload to accommodate the total
load. Reduce the preload if carrying less weight. Do not Refer to Table 2-18.
exceed maximum GVWR or GAWR when loading.
g. Low Rider S (FXLRS):
NOTE
To determine the motorcycle configuration check the Refer to Table 2-19.
model character stamped on the VIN. See Vehicle
Identification Number (VIN) (Page 3-10). h. Low Rider ST (FXLRST):

Refer to Table 2-20.

1. Add the weight of the rider to the total weight of the passenger
and/or cargo to Identify the proper preload setting.

a. Fat Boy 114 (FLFBS):

Refer to Table 2-13.

Table 2-13. Suspension Preload Table: Fat Boy 114 (FLFBS)
ADDITIONAL WEIGHT OF PASSENGER, CARGO AND ACCESSORIES
LB 0 20 40 60 80 100 120 140 160 180
KG 0 9 18 27 36 45 54 64 73 82
RIDER WEIGHT
LB KG Preload Setting
160 73 0 0.5 1 1.5 2 25 3 3.5 4 4
180 82 0.5 1 1.5 2 2.5 3 3 3.5 4 4,5
200 91 1 1.5 2 2 2.5 3 3.5 4 4.5 5
220 100 1 1,5 2 2.5 3 3.5 4 4.5 5 5
240 109 1.5 2 2.5 3 3.5 4 4 4.5 5 5
260 118 2 2.5 3 3 3.5 4 4.5 5 5 5
280 127 2 2,5 3 3.5 4 45 5 5 5 NA
300 136 2.5 3 35 4 4.5 5 NA NA NA NA

Table 2-14. Suspension Preload Table: Heritage Classic (FLHCS)

ADDITIONAL WEIGHT OF PASSENGER, CARGO AND ACCESSORIES O
Q
LB 0 20 40 60 80 100 120 140 160 o

KG 0 9 18 27 36 45 54 64 73 82
RIDER WEIGHT
LB KG Preload Setting
160 73 0.5 1 1.5 2 2,5 3 3,5 4 4,5 5
180 82 1 1.5 2 2.5 3 3 3.5 4 4.5 5
200 91 1 1.5 2 2.5 3 3.5 4 4.5 5 5
220 100 1.5 2 2.5 3 3.5 4 4.5 5 5 5
240 109 2 2,5 3 3,5 4 45 4,5 5 5 5
260 118 2 2.5 3 3.5 4 45 5 5 5 NA
280 127 2.5 3 3.5 4 NA NA NA NA NA NA
300 136 NA NA NA NA NA NA NA NA NA NA

94000936 2-35
 Table 2-15. Suspension Preload Table: Sport Glide (FLSB)
ADDITIONAL WEIGHT OF PASSENGER, CARGO AND ACCESSORIES
LB 0 20 40 60 80 100 120 140 160 180
KG 0 9 18 27 36 45 54 64 73 82
RIDER WEIGHT
LB KG Preload Setting
160 73 1 1.5 2 2.5 3 3.5 4 4.5 5 5
180 82 1 1.5 2 2.5 3 3.5 4 4.5 5 5
200 91 1.5 2 2.5 3 3.5 4 4.5 5 5 5
220 100 2 2.5 3 3.5 4 4.5 5 5 5 5
240 109 2.5 3 3.5 4 4.5 5 5 5 5 5
260 118 2.5 3 35 4 4.5 5 5 5 5 5
280 127 3 3.5 4 45 5 5 5 5 5 5
300 136 3.5 4 45 5 5 5 5 5 5 NA
Table 2-16. Suspension Preload Table: Street Bob 114 (FXBBS), Softail Standard (FXST)
ADDITIONAL WEIGHT OF PASSENGER, CARGO AND ACCESSORIES
LB 0 20 40 60 80 100 120 140 160 180
KG 0 9 18 27 36 45 54 64 73 82
RIDER WEIGHT
LB KG Preload Setting
160 73 1 1 2 3 4 5 6 7 7 7
180 82 1 2 3 4 5 6 6 7 7 7
200 91 2 3 4 4 5 6 7 7 7 7
220 100 2 3 4 5 6 7 7 7 7 7
240 109 3 4 5 6 7 7 7 7 7 7
260 118 4 5 5 6 7 7 7 7 7 7
280 127 4 5 6 7 7 7 7 7 7 7
300 136 5 6 7 7 7 7 7 7 7 7
Table 2-17. Suspension Preload Table: Breakout 114 (FXBRS)
ADDITIONAL WEIGHT OF PASSENGER, CARGO AND ACCESSORIES
LB 0 20 40 60 80 100 120 140 160 180
KG 0 9 18 27 36 45 54 64 73 82
RIDER WEIGHT
LB KG Preload Setting
160 73 0 0 0.5 1 1.5 2 2.5 3 35 4
180 82 0 0.5 1 1.5 2 2.5 3 3 3.5 4
200 91 0.5 1 1 1.5 2 2.5 3 3.5 4 4.5
220 100 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
240 109 1 1.5 2 2.5 3 35 4 4.5 4.5 5
260 118 1.5 2 2.5 3 3 3.5 4 4.5 5 5
280 127 1.5 2 2.5 3 3.5 4 4.5 5 5 5
300 136 2 2.5 3 3.5 4 4.5 5 5 5 5
Table 2-18. Suspension Preload Table: Fat Bob 114 (FXFBS)
ADDITIONAL WEIGHT OF PASSENGER, CARGO AND ACCESSORIES
LB 0 20 40 60 80 100 120 140 160 180
9 18
KG 0 27 36 45 54 64 73 82
RIDER WEIGHT
LB KG Preload Setting
160 73 0 0 0.5 1 15 2 2.5 3 3.5 4
180 82 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
200 91 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
220 100 0.5 1 15 2 2.5 3 3.5 4 4.5 NA
240 109 1 15 2 2.5 3 3.5 4 NA NA NA
260 118 1.5 2 2.5 3 NA NA NA NA NA NA
280 127 1.5 2 NA NA NA NA NA NA NA NA
300 136 NA NA NA NA NA NA NA NA NA NA
Table 2-19. Suspension Preload Table: Low Rider S (FXLRS)
ADDITIONAL WEIGHT OF PASSENGER, CARGO AND ACCESSORIES
LB 0 20 40 60 80 100 120 140 160 180
KG 0 9 18 27 36 45 54 64 73 82
RIDER WEIGHT
LB KG Preload Setting
160 73 0 0 0.5 1 1.5 2 2.5 3 3.5 4
180 82 0 0.5 1 1.5 2 2 2.5 3 3.5 4
200 91 0 0.5 1 1.5 2 25 3 3.5 4 4.5
220 100 0.5 1.5 2 25 3 3.5 4 4.5 5
240 109 1 1.5 2 2.5 3 3.5 3.5 4 4.5 5
260 118 1 1.5 2 2.5 3 3.5 4 4.5 5 NA
280 127 1.5 2 2.5 3 NA NA NA NA NA NA
300 136 NA NA NA NA NA NA NA NA NA NA

2-36 94000936
 Table 2-20. Suspension Preload Table: Low Rider ST (FLXRST)
ADDITIONAL WEIGHT OF PASSENGER, CARGO AND ACCESSORIES
LB 0 20 40 60 80 100 120 140 160 180
KG 0 9 18 27 36 45 54 64 73 82
RIDER WEIGHT
LB KG Preload Setting
160 73 05 1,5 2 2.5 3 3.5 4 4.5 5
180 82 1 1.5 2 25 3 3 3.5 4 4.5 5
200 91 1 1.5 2 2.5 3 3.5 4 4.5 5 5
220 100 1.5 2 25 3 3.5 4 4,5 5 5 5
240 109 2 2.5 3 3.5 4 45 4.5 5 5 5
260 118 2 2,5 3 35 4 4.5 5 5 5 NA
280 127 2.5 3 3,5 4 NA NA NA NA NA NA
300 136 NA NA NA NA NA NA NA NA NA NA

Adjustment
NOTE
Adjust the shock with the motorcycle resting on the jiffy
stand.

1. Cam style: See Figure 2-39.

a. Remove seat.
NOTE
The provided spanner wrench is to be assembled before
use.

b. Insert the tang of the SPANNER WRENCH KIT (PART

NUMBER: 14900102) in the slots in the rear shock, turn
the cam until the indicator (1) points to the appropriate
preload setting (2).

2. Hydraulic external: See Figure 2-40.

a. Rotate the adjustment knob clockwise to increase
preload setting, or counterclockwise to decrease preload
Figure 2-39. Preload Adjustment Cam
setting until the indicator knob shows the appropriate
preload setting on the scale.

3. Hydraulic under seat: See Figure 2-41.

a. Remove seat.
NOTE
The provided spanner wrench is to be assembled before
use.

b. Using the socket end of the SPANNER WRENCH KIT

(PART NUMBER: 14900102), rotate adjustment screw
clockwise to increase preload setting, or
counterclockwise to decrease preload setting until the
indicator shows the appropriate preload setting.

Figure 2-40. Preload Adjustment Knob

94000936 2-37
2-38 94000936
INSPECT EXHAUST SYSTEM 2.19
LEAK CHECK ___________________________

1. Check exhaust system for obvious signs of leakage such as

carbon tracks and marks at pipe joints.
a. Check for loose or missing fasteners.
b. Check for cracked pipe clamps or brackets.
c. Check for loose or cracked exhaust shields.

2. Check exhaust system for audible signs of leakage.

a. Start engine.
b. Cover end of muffler with clean, dry shop towel.
c. Listen for signs of exhaust leakage.
3. Correct any detected leaks.
a. See EXHAUST SYSTEM (Page 6-36). Disassemble
exhaust system.
b. Clean all mating surfaces.
c. Repair or replace damaged components.
d. Assemble exhaust system.

NOTE
If leak continues, disassemble and apply PERMATEX ULTRA
COPPER or LOCTITE 5920 FLANGE SEALANT or equivalent
oxygen sensor/catalyst-safe alternative to mating surfaces.

94000936 2-39
INSPECT AIR FILTER 2.20
REMOVE AND INSTALL:. ROUND

FASTENER TORQUE VALUE

Air filter cover screw, single 50-65 in-lbs 5.6-7.3 N-m
screw cover
Air filter cover screws, five- 48-72 in-lbs 5.4-8.1 N-m
screw cover
Air filter element screws, round 48-72 in-lbs 5.4-8.1 N-m
cover

REMOVE
1. See Figure 2-43 or Figure 2-44. Remove air filter cover.
a. Remove screws (1).
b. Remove cover (2).

2. Remove filter element.

a. Remove screws (3).

b. Remove filter element (4) while pulling breather tube (5)

from element.
Figure 2-43. Replace Air Filter Element, Single Screw Cover
1. Screw (5)
INSTALL 2. C
over
1. See Figure 2-43 or Figure 2-44. Install filter element. 3. S
crew (3)
a. Install breather tube (5) into filter element (4). 4. Fil
ter element
b. Install breather tube onto breather bolts. 5. Br
eather tube
c. Install filter element. assembly
6. S
d. Install screws (3). Tighten. eal
Torque: 48-72 in-lbs (5.^^.1 Nm)Airfilter element Figure 2-44. Replace Air Filter Element, Five-Screw Cover
screws, round cover
REMOVE AND INSTALL: OVAL ____________
2. Verify that rubber seal (6) is properly seated and not
damaged. REMOVE
1. Remove rain sock (6), if equipped.
3. Install air filter cover.
2. Remove air filter trim insert.
a. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to threads of
a. Remove trim insert screws (1).
screw (1).
FASTENER TORQUE VALUE
b. Install cover (2). 50-60 in-lbs 5.7-6.8 N-m
Air filter cover screws, oval
cover
c. Single screw cover: Install screw (1). Tighten.
Air filter trim insert screws 27-32 in-lbs 3-3.6 N-m
Torque: 50-65 in-lbs (5.6-7.3 N-m) Air filter cover
b. Remove trim insert (2).
screw, single screw cover
d. Five-screw cover: Install screws (1). Tighten in a star
pattern.
Torque: 48-72 in-lbs (5.4-8.1 N-m) Air filter cover
screws, five-screw cover

2-40
94000936
3. Remove cover and filter element. Install
a. Remove screws (3). FASTENER TORQUE VALUE
Air filter cover screw, cone 18-24 in-lbs 2-2.7 N-m
b. Remove cover (4).

1. Install air filter.

c. Clean and inspect the filter element. Replace if
necessary.
a. See Figure 2-46. Apply threadlocker to screws (1, 2).
INSTALL LOCTITE 243 MEDIUM STRENGTH
1. See Figure 2-45. Install cover and filter element. THREADLOCKER AND SEALANT (BLUE) (99642-97)
b. Install air filter element (3) and cover (4).
a. Install filter element (5).
c. Install screws (1, 2). Tighten.
b. Install cover (4).
Torque: 18-24 in-lbs (2-2.7 N-m) Air filter cover
screw, cone
c. Install screws (3). Tighten.
Torque: 50-60 in-lbs (5.7-6.8 N-m) Air filter cover
screws, oval cover

2. Install air filter trim insert.

a. Install trim insert (2).

b. Install trim insert screws (1). Tighten.

Torque: 27-32 in-lbs (3-3.6 N-m) Air filter trim insert
screws

3. Install rain sock (6), if equipped.

REMOVE AND INSTALL: CONE

CONSUMABLE PART NUMBER
LOCTITE 243 99642-97
MEDIUM
STRENGTH
THREADLOCKER
AND SEALANT
(BLUE)

Remove
1. Remove air filter.

a. See Figure 2-46. Remove screws (1, 2).

b. Remove cover (4).

c. Remove air filter element (3).

94000936 2-41
 1197191

Figure 2-46. Air Filter Element

1. Screw (2) 3. Air filter element (synthetic)

2. Long Screw 4. Cover

CLEAN AND INSPECT ____________________

3. Clean filter element.
1. Remove breather tube from breather bolts. a. Wash the filter element and breather tubes in lukewarm
water with a mild detergent.
2. Inspect the breather tube and fittings for damage.
b. Synthetic element: Rinse filter element with clean water.
NOTE
The filter element is sufficiently clean when water running
• Do not strike filter element on a hard surface to
from the filter element appears clear.
dislodge dirt. 3
c. Allow filter element to air dry or use low-pressure
compressed air from the inside.

d. Paper/wire mesh element: Hold the filter element up to a

strong light source. The element is sufficiently clean when
light is uniformly visible through the media.

e. Replace the filter element if damaged or if filter media

cannot be adequately cleaned.

3 Do not use air cleaner filter oil on the Harley-Davidson

paper/wire mesh or synthetic air filter element.

A WARNING

Do not use gasoline or solvents to clean filter element.

Flammable cleaning agents can cause an intake system
fire, which could result in death or serious injury. (00101a)

2-42 94000936
INSPECT BATTERY 2.21
PREPARE _ _

1. Remove seat. See SEAT (Page 3-142).

2. Remove right side cover. See RIGHT SIDE COVER (Page

3-64).

3. Disconnect negative battery cable. See POWER

DISCONNECT (Page 7-7).

REMOVE

1. See Figure 2-47. Remove close-out cover (3).

1. WSS connector
2. Open clip (1) and position wiring harnesses (2) out-of-way. 2. Retaining clip
3. WSS wiring
4. Battery strap fingers ________________________
Figure 2-48. WSS and Wiring

6. See See Figure 2-49.. Remove battery strap (3).

a. Disconnect back tab (2) from battery strap to battery

tray (4).

b. Disconnect front left tab (1) from battery strap to

battery tray.

c. Remove battery strap.

7. Disconnect positive battery cable.

8. If needed: Remove engine oil dipstick.

NOTE
Ifdipstick is removed, cover fill hole with tape or clean rag.
Figure 2-47. Close-Out Cover and Clip (Typical)
9. Remove battery.
3. See Figure 2-48. Disconnect WSS connector (1 ).
a. Slide battery out and remove.
4. Remove WSS wiring from battery strap.

a. Remove WSS wiring (3) from battery strap fingers (4).

b. Slide WSS connector forward and remove from

battery strap.

5. Unlock retaining clip (2).

94000936 2-43
 8. See Figure 2-47. Position wiring harnesses (2) into place
and close clip (1).

9. Install close-out cover (3).

NOTE
Verify all close-out tabs are fully set into battery strap.

CLEAN AND INSPECT ____________________

NOTE
Battery top must be clean and dry Dirt and electrolyte on top
of the battery causes self-discharge.

1. Clean battery top.

a. Mix a solution of five teaspoons of baking soda (sodium
bicarbonate) per liter or quart of water.
b. Apply to battery top.

2. When the solution stops bubbling, rinse off battery with clean
water.
Figure 2-49. Battery Strap and Tray: (Removed for clarity)
3. Clean cable connectors and battery terminals with a wire
INSTALL _______________________________ brush or sandpaper. Remove any oxidation.

FASTENER TORQUE VALUE 4. Inspect the battery terminal screws and cables for breakage,
Battery, positive cable, screw 60-70 in-lbs 16.78-7.91 N-m loose connections and corrosion.

1. See Figure 2-49. Install battery into battery. 5. Check the battery terminals for melting or damage.
6. Inspect the battery for discoloration, raised top or a warped
NOTE
or distorted case. Replace as necessary.
• Verify battery is under tab on Electronic Control Module
(ECM) caddy, upper left corner on back side. 7. Inspect the battery case for cracks or leaks.
VOLTAGE TEST _________________________
2. If removed: Install engine oil dipstick.
The voltage test provides a general indicator of battery condition.
3. Connect positive battery cable. Tighten. Check the voltage of the battery to verify that it is fully charged.
Torque 60-70 in-lbs (6.78-7.91 N-m) Battery positive Refer to Table 2-21.
cable, screw 1. If the open circuit (disconnected) voltage reading is below
4. Install battery strap (3). 12.6 V:
a. Charge the battery.
a. Position battery strap.
b. Check the voltage after the battery has set for at least
one hour.
b. Connect front left tab (2) on battery strap to battery
tray.
2. If the voltage reading is 12.7 Vor above:
NOTE
a. Perform a battery diagnostic test. See the electrical
Verify front tab (5) is align with battery tray when installing
diagnostic manual for the load test procedure.
battery strap.
Table 2-21. Voltage Test For Battery Charge Conditions
c. Connect back tab (1) on battery strap to battery tray. VOLTAGE (OCV) STATE OF CHARGE
12.7 V 100%
5. Lock retaining clip (9). 12.6 V 75%
12.3 V 50%
6. See Figure 2-48. Install WSS wiring (3) to battery strap. 12.0 V 25%
11.8 V 0%
a. Side WSS connector (1) rearward into battery strap. STORAGE
b. Install WSS wiring into battery strap fingers (4).
See Figure 2-50. A battery is affected by self-discharge whether
7. Connect WSS connector (1). stored in or out of the vehicle. A battery that is stored in the
vehicle is also affected by parasitic loads. A parasitic load is

2-44 94000936
caused by things like diode leakage or maintaining computer
om00036
memory with the vehicle turned off.

Batteries self-discharge at a faster rate at higher ambient

temperatures. Store battery in a cool, dry place to reduce the
self-discharge rate.
100 %
Charge the battery every two weeks if stored in the vehicle.
Charge the battery once per month if removed the vehicle.
75 %
NOTE
Use a Harley-Davidson constant monitoring battery
50 %
charger/tender to maintain battery charge for extended
I I
periods of time without risk of overcharging or boiling. 0 12 15

1. Capacity
2. Months of non-use
3. Measured at 40 °C (105 °F)
4. Measured at 25 °C (77 °F)
Figure 2-50. Effective Rate of Temperature on Battery Self-
discharging Rate
COMPLETE ____________________________

1. Install negative battery cable. See POWER DISCONNECT

(Page 7-7).

2. Install right side cover. See RIGHT SIDE COVER (Page 3-

64).

3. Install seat. See SEAT (Page 3-142).

94000936 2-45
CLEAN, INSPECT, REPLACE SPARK PLUGS 2.22

PREPARE
A WARNING Table 2-22. Spark Plug Deposit Analysis
DEPOSITS POSSIBLE CAUSE
Gasoline is extremely flammable and highly explosive. Keep
Light brown and glassy* Air-fuel mixture too lean
gasoline away from ignition sources which could result in death
(May be accompanied by Hot running engine
or serious injury. See the Safety chapter. (00635c)
cracks in the insulator or Valves not seating
by electrode erosion.) Improper ignition timing
1. Remove seat. See SEAT (Page 3-142). White, gray or tan and Balanced combustion
2. Purge fuel system. See PURGE FUEL LINE (Page 6-12). powdery Clean off deposits at regular inter-
vals.
3. Remove main fuse. See POWER DISCONNECT (Page 7-7). * The glassy deposit on a spark plug may cause high speed
A WARNING misfiring.
Spark Plug Cables
To prevent spray of fuel, purge system of high-pressure fuel
before supply line is disconnected. Gasoline is extremely 1. Inspect spark plug cables. Replace as necessary.
flammable and highly explosive, which could result in death or
a. Check for cracks or loose terminals.
serious injury. (00275a)
b. Check for loose fit on ignition coil and spark plugs.
4. Remove fuel tank. See FUEL TANK (Page 6-14).
2. Check cable boots/caps for cracks or tears. Replace as
REMOVE _______________________________ necessary.
INSTALL ____________________________
A WARNING FASTENER TORQUE VALUE
Disconnecting spark plug cable with engine running can result in Spark plug 86-108 in-lbs 9.7-12.2 N-m
electric shock and death or serious injury. (00464b)
NOTE
1. See Figure 2-51 . Remove spark plug cables from spark
The spark plug gap is within specification when there is a
plugs.
slight drag on the gauge.
2. Thoroughly clean around spark plug base.
3. Remove spark plugs. 1. Verify proper gap before installing new or cleaned spark
plugs.
CLEAN AND INSPECT ____________________
a. Use a wire-type feeler gauge within specification.
Spark Plugs Refer to Table 2-23.

NOTE b. Pass the wire gauge between the center and the outer
Discard plugs with eroded electrodes, heavy deposits or electrodes.
cracked insulators.
c. Adjust gap to within specification.
1. Inspect spark plugs. Compare plug deposits to Table 2-22.
2. Verify that spark plug threads are clean and dry.
Table 2-22. Spark Plug Deposit Analysis
3. Install spark plugs. Tighten.
Torque: 86-108 in-lbs (9.7-12.2 N-m) Spark plug

4. Install spark plug cables. See SPARK PLUG CABLES (Page

7-13).

DEPOSITS POSSIBLE CAUSE

Wet, black and shiny Worn pistons
Worn piston rings
Worn valves
Worn valve guides
Worn valve seals
Weak battery
Faulty ignition system
Dry, fluffy or sooty and Air-fuel mixture too rich
black

2-46 94000936
 Figure 2-51. Spark Plug Location

Table 2-23. Spark Plug Gap

MODEL MM IN
All Models 0.8-0.9 0.031-0.035
COMPLETE

94000936 2-47
1. Install fuel tank. See FUEL TANK (Page 6-14). 2. Install seat. See SEAT (Page 3-142).
3. Install main fuse. See POWER DISCONNECT (Page 7-7).

NOTE
Add at least 3.8 L (1 gal) of fuel to fuel tank before operating
fuel pump.

4. Set OFF/RUN switch to RUN and check for leaks.

2-48 94000936
STORAGE 2.23

PLACE IN STORAGE 7. Check tire inflation and inspect tires for wear and/or damage.
See INSPECT TIRES AND WHEELS (Page 2-13).
A WARNING
8. If the motorcycle will be stored for an extended period of
Do not store motorcycle with gasoline in tank within the home or time, securely support the motorcycle under the frame so
garage where open flames, pilot lights, sparks or electric motors that all weight is off the tires.
are present. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury. (00003a)
9. Inspect operation of all electrical equipment and switches.

1. Change engine oil and filter. See REPLACE ENGINE OIL

A WARNING
AND FILTER (Page 2-7).
Be sure that brake fluid or other lubricants do not contact brake
2. Check transmission lubricant level. See REPLACE pads or discs. Such contact can adversely affect braking ability,
TRANSMISSION LUBRICANT (Page 2-11). which could cause loss of control, resulting in death or serious
injury. (00290a)
A WARNING
1. Wash painted and chrome-plated surfaces. Apply a light film
Avoid spills. Slowly open fuel filler cap. Do not fill above bottom of oil to exposed unpainted surfaces.
of filler neck insert, leaving air space for fuel expansion. Secure
filler cap after refueling. Gasoline is extremely flammable and
A WARNING
highly explosive, which could result in death or serious injury.
(00028b) Unplug or turn OFF battery charger before connecting charger
cables to battery. Connecting cables with charger ON can cause
A WARNING
a spark and battery explosion, which could result in death or
Use care when refueling. Pressurized air in fuel tank can force serious injury. (00066a)
gasoline to escape through filler tube. Gasoline is extremely A WARNING
flammable and highly explosive, which could result in death or
serious injury. (00029a) Explosive hydrogen gas, which escapes during charging, could
cause death or serious injury. Charge battery in a well-ventilated
1. Prepare fuel tank. area. Keep open flames, electrical sparks and smoking materials
away from battery at all times. KEEP BATTERIES AWAY FROM
a. Fill fuel tank. CHILDREN. (00065a)

b. Add fuel stabilizer. 1. Battery maintenance.

2. Lubricate cylinders. a. Remove battery from vehicle. See INSPECT

BATTERY (Page 2-43).
a. Remove spark plugs. See CLEAN, INSPECT,
REPLACE SPARK PLUGS (Page 2-46). b. Charge battery until the correct voltage is obtained.

b. Inject a few squirts of engine oil into each cylinder. c. Charge the battery every other month if it is stored at
temperatures below specification.
c. Crank engine for 5-6 revolutions.
Temperature: 60 °F (16 °C)
d. Install spark plugs. See CLEAN, INSPECT, REPLACE
SPARK PLUGS (Page 2-46). 2. Charge battery once a month if it is stored at temperatures
above specification.
3. Inspect drive belt deflection. See INSPECT AND ADJUST Temperature: 60 °F (16 °C)
DRIVE BELT AND SPROCKETS (Page 2-31).
A WARNING
4. Inspect drive belt and sprockets. See INSPECT AND
ADJUST DRIVE BELT AND SPROCKETS (Page 2-31). Unplug or turn OFF battery charger before disconnecting charger
cables from battery. Disconnecting clamps with charger ON can
5. Inspect air cleaner filter. See INSPECT AIR FILTER (Page cause a spark and battery explosion, which could result in death
2-40). or serious injury. (00067a)

6. Lubricate controls. See LUBRICATE CABLES AND 1. Covering the motorcycle.

CHASSIS (Page 2-16).
a. If the motorcycle is to be covered, use a material that will
breathe, such as a Harley-Davidson storage cover or
light canvas.

94000936 2-49
 b. Plastic materials that do not breathe promote the
formation of condensation, which leads to corrosion.

REMOVE FROM STORAGE________ _______

A WARNING

The clutch failing to disengage can cause loss of control,

which could result in death or serious injury. Prior to
starting after extended periods of storage, place
transmission in gear and push vehicle back and forth
several times to assure proper clutch disengagement.
(00075a)

1. Charge battery.

2. Install battery. See INSPECT BATTERY (Page 2-43).

3. Inspect spark plugs. See CLEAN, INSPECT, REPLACE
SPARK PLUGS (Page 2-46).

4. Fill fuel tank, if empty.

5. Start engine. Run until it reaches normal operating

temperature.

6. Check engine oil level. See REPLACE ENGINE OIL AND

FILTER (Page 2-7).

7. Check transmission lubricant level. See REPLACE

TRANSMISSION LUBRICANT (Page 2-11).

8. Perform all of the checks in the PRE-RIDING CHECKLIST in

the owner's manual.

2-50 94000936
TROUBLESHOOTING 2.24

ENGINE ________________________________ 4. Damaged wire or loose wire connection at ignition coil,

battery or ECM connector.

Starter Motor Does Not Operate or Does Not 5. Water or dirt in fuel system.
Turn Engine Over 6. Intake air leak.
1. Engine run switch in OFF position. 7. Fuel tank vent hose, filler cap vent or vapor valve plugged, or
2. Discharged battery, loose or corroded connections (solenoid fuel line closed off, restricting fuel flow.
chatters). 8. Engine lubricant too heavy (winter operation).
3. Starter control circuit faulty. NOTE
4. Electric starter shaft pinion gear not engaging or overrunning For cold-weather starts, always disengage clutch.
clutch slipping.
5. Bank Angle Sensor tripped and ignition not cycled OFF then 9. Ignition not functioning properly (possible sensor failure).
back to RUN. 10. Faulty ignition coil.
6. Security system activated. 11. Valves sticking.
7. Motorcycle in gear and clutch not pulled in. 12. Partially plugged fuel injector(s).
8. Jiffy stand down and transmission in gear (HDI models only).
Starts But Runs Irregularly or Misses
9. Main fuse not in place.
1. Spark plugs in poor condition or partially fouled.
Engine Turns Over But Does Not Start 2. Spark plug cables in poor condition and shorting or leaking.
1. Less than 1 USgal (3.79 L) of fuel in fuel tank. 3. Spark plug gap too close or too wide.
2. Fouled spark plugs. 4. Follow any current DTC's in order of priority.
3. Discharged battery, loose or damaged battery terminal 5. Faulty ignition coil, ECM or sensor.
connections.
6. Battery nearly discharged.
4. Engine lubricant too heavy (winter operation).
7. Damaged wire or loose wire connection at ignition coil,
NOTE battery or ECM connector.
For cold-weather starts, always disengage clutch. 8. Intermittent short circuit due to damaged wire insulation.
9. Water or dirt in fuel system.
5. Spark plug cables in bad condition and shorting, cable
connections loose or cables connected to incorrect 10. Fuel tank vent system plugged.
cylinders. 11. Air leak at intake manifold or air cleaner.
6. Damaged wire or loose wire connection at ignition coil, 12. Loose or dirty ECM connector.
battery or ECM connector. 13. Follow any current DTC's in order of priority. Monitor typical
7. Follow any current DTC's in order of priority. scan values of sensors in the Digital Technician to verify
performance is in normal parameters.
8. Ignition timing incorrect due to faulty ignition coil, ECM or
sensors. 14. Faulty Sensor(s): Temperature Manifold Absolute Pressure
(TMAP), Crank Position (CKP) or Oxygen (02).
9. Bank Angle Sensor tripped and ignition not cycled OFF then
back to RUN. 15. Incorrect valve timing.

10. Manually check fuel pressure to verify it is in specification. 16. Weak or damaged valve springs.

11. Manually check compression and leak down to verify they 17. Manually check compression and leak down to verify they
are in specification. are in specification.

12. Fuel filter clogged. 18. Damaged intake or exhaust valve.

13. Sticking or damaged valve(s) or wrong length pushrod(s). 19. Partially plugged fuel injector(s).

14. Plugged fuel injectors.

A Spark Plug Fouls Repeatedly
Starts Hard 1. Fuel mixture too rich.

1. Spark plugs in bad condition or have improper gap or are 2. Incorrect spark plug for the kind of service.
partially fouled. 3. Piston rings badly worn or damaged.
2. Spark plug cables in poor condition. 4. Valve guides or seals badly worn.
3. Battery nearly discharged.

94000936 2-51
Pre-Ignition or Detonation (Knocks or Pings) 9. Rear fork pivot shaft fasteners loose.

1. Fuel octane rating too low. 10. Exhaust system binding and causing unnecessary side
loads.
2. Faulty spark plugs.
3. Incorrect spark plug for the kind of service. Check Engine Light Illuminates During
4. Excessive carbon deposit on piston head or in combustion Operation
chamber.
Fault detected. For diagnostic information see the electrical
5. Ignition timing advanced due to faulty sensor inputs (TMAP diagnostic manual.
and/or CKP). LUBRICATION SYSTEM __________________
6. Ignition timing advanced due to ECM or sensors (CKP, ET or
TMAP) defective.
Oil Does Not Return To Oil Reservoir
7. Intake manifold vacuum leak.
1. Oil reservoir empty.
Overheating 2. Oil pump not functioning.
1. Insufficient oil supply or oil not circulating. 3. Restricted oil lines or fittings.
2. Oil cooler dirty. 4. Restricted oil filter.
3. Insufficient air flow over engine. 5. O-ring damaged or missing from oil pump/crankcase junction
(also results in poor engine performance).
4. Heavy carbon deposits.
5. Ignition timing retarded due to defective ECM or faulty Engine Uses Too Much Oil Or Smokes
sensor(s) (TMAP and/or CKP). Excessively
6. Leaking valve(s).
1. Oil reservoir overfilled.

Valve Train Noise 2. Restricted oil return line to oil reservoir.

NOTE 3. Restricted breather operation.

Some valve train noise at start-up is normal until lifters fill 4. Restricted oil filter.
with
oil. 5. Oil pump misaligned or in poor condition.
6. Piston rings badly worn or broken.
1. Low oil pressure caused by oil feed pump not functioning
7. Valve guides or seals worn or damaged.
properly or oil passages obstructed.
8. O-ring damaged or missing from oil pump/crankcase junction
2. Faulty hydraulic lifter(s). (also results in poor engine performance).
3. Bent pushrod(s). 9. Plugged crankcase scavenge port.
4. Incorrect pushrod length. 10. Oil diluted with gasoline.
5. Rocker arm binding on shaft.
Engine Leaks Oil From Cases, Pushrods,
6. Valve sticking in guide. Hoses, Etc.
7. Chain tensioning shoe worn. 1. Loose parts.
8. Cam(s), cam gear(s) or cam bushing(s) worn. 2. Imperfect seal at gaskets, pushrod covers, washers, etc.
9. Cam timing incorrect. 3. Restricted breather passages or hose to air cleaner.
10. Valve seat loose in cylinder. 4. Restricted oil filter.
11. Cam bearing in crankcase or cam support plate clearance is
5. Oil reservoir overfilled.
excessive.
6. Lower rocker housing gasket installed incorrectly (upside
down).
Excessive Vibration
7. Restricted oil return line to oil reservoir.
1. Wheels bent or damaged and/or tires worn or damaged.
8. Porosity.
2. Engine/Transmission/Rear Wheel not aligned properly.
3. Primary chain badly worn or links tight as a result of Low Oil Pressure
insufficient lubrication or misalignment.
1. Oil reservoir underfilled.
4. Engine to transmission mounting bolts loose.
2. Faulty low oil pressure switch.
5. Upper engine mounting bracket loose/damaged or mounting
bracket pre-loaded. 3. Oil pump O-ring damaged or missing.

6. Ignition timing advanced due to faulty sensor inputs (TMAP 4. Bypass valve stuck in open position.
and/or CKP)/pooriy tuned engine. 5. Ball missing or leaking in cam support plate.
6. Worn oil pump gerotor(s).
7. Internal engine problem.
8. Damaged frame. 7. Oil diluted with gasoline.

2-52 94000936
High Oil Pressure Clutch Drags Or Does Not Release
1. Oil reservoir overfilled. 1. Lubricant level too high in primary chaincase.
2. Bypass valve stuck in closed position. 2. Primary chain badly misaligned or too tight.

ELECTRICAL SYSTEM ___________________ 3. Insufficient clutch spring tension.

4. Clutch discs warped.
NOTE
For diagnostic information see the electrical diagnostic Clutch Chatters
manual.
Friction discs or steel discs worn or warped.

Alternator Does Not Charge HANDLING _____________________________

1. Engine ground wire loose or damaged.
Irregularities
2. Faulty voltage regulator module.
1. Improperly loaded motorcycle. Non-standard equipment on
3. Loose or damaged wires in charging circuit.
the front end such as heavy radio receivers, extra lighting
4. Faulty stator and/or rotor. equipment or luggage tends to cause unstable handling.
2. Damaged tire(s) or improper front-rear tire combination.
Alternator Charge Rate Is Below Normal
3. Irregular or peaked front tire tread wear.
1. Weak or damaged battery.
4. Incorrect tire pressure. See SPECIFICATIONS (Page 3-8)
2. Loose connections.
5. Shock absorber not functioning normally.
3. Faulty voltage regulator module.
6. Loose wheel axle nuts. Tighten to recommended torque
4. Faulty stator and/or rotor. specification.

Speedometer Operates Erratically 7. Rear wheel out of alignment with frame and front wheel.
8. Steering head bearings improperly adjusted. Correct
1. Contaminated vehicle speed sensor (remove sensor and
adjustment and replace pitted or worn bearings and races.
clean off metal particles).
9. Loose spokes (laced wheel vehicles only).
2. Loose connections.
TRANSMISSION _________________________ 10. Tire and wheel unbalanced.
11. Rims and tires out-of-round or eccentric with hub.

Shifts Hard 12. Rims and tires out-of-true sideways.

1. Primary chaincase overfilled. 13. Rear fork pivot-improper torque.

14. Incorrect, non-specified tire(s) mounted on front or rear
2. Clutch not fully disengaging.
wheel.
3. Transmission lubricant too heavy (winter operation).
BRAKES _______________________________
4. Shifter return spring (inside transmission) bent or otherwise
damaged.
Brake Does Not Hold Normally
5. Bent shifter rod.
6. Shifter forks sprung. 1. Brake fluid reservoir low, system leaking or pads worn.
7. Corners worn off shifter clutch dog rings (inside 2. Brake system contains air bubbles.
transmission). 3. Master cylinder/caliper piston seals worn or parts damaged.

Jumps Out Of Gear 4. Brake pads contaminated with grease or oil.

1. Shifter rod improperly adjusted. 5. Brake pads badly worn.

2. Shifter drum damaged/worn. 6. Brake disc badly worn or warped.

7. Brake drags - insufficient brake pedal or hand lever free play,
3. Shifter engaging parts badly worn and rounded. caliper piston worn or damaged, or excessive brake fluid in
4. Bent shifter forks . reservoir.

5. Damaged gears. 8. Brake fades due to heat build up - brake pads dragging or
excessive braking.
Clutch Slips
1. Reservoir overfull.
2. Clutch lever not returning completely.
3. Insufficient clutch spring tension.
4. Worn friction discs.

94000936 2-53
 9. Brake fluid leak when under pressure.

2-54 94000936
NOTES
SUBJECT PAGE NO.
3.1 FASTENER TORQUE VALUES ................................................................................................. 3-1
3.2 SPECIFICATIONS ..................................................................................................................... 3-8
3.3 VEHICLE IDENTIFICATION NUMBER (VIN) .......................................................................... 3-10
3.4 FRONT WHEEL ..................................................................................................................... 3-12
3.5 REAR WHEEL ......................................................................................................................... 3-16
3.6 WHEEL LACING ..................................................................................................................... 3-19
3.7 CHECKING AND TRUING WHEELS ...................................................................................... 3-21
3.8 SEALED WHEEL BEARINGS ................................................................................................. 3-25
3.9 TIRES ...................................................................................................................................... 3-28
3.10 WHEEL ALIGNMENT ............................................................................................................ 3-33
3.11 FRONT BRAKE MASTER CYLINDER .................................................................................. 3-35
3.12 FRONT BRAKE CALIPER ..................................................................................................... 3-38
3.13 REAR BRAKE MASTER CYLINDER ..................................................................................... 3-42
3.14 REAR BRAKE CALIPER ....................................................................................................... 3-46
3.15 BRAKE LINES ....................................................................................................................... 3-51
3.16 ABS MODULE ....................................................................................................................... 3-59
3.17 BLEED BRAKES ................................................................................................................... 3-61
3.18 LEFT SIDE COVER ............................................................................................................... 3-63
3.19 RIGHT SIDE COVER ............................................................................................................ 3-64
3.20 FRONT FORK ....................................................................................................................... 3-65
3.21 STEERING HEAD/FORK STEM AND BRACKET ASSEMBLY ............................................. 3-78
3.22 FORK LOCK .......................................................................................................................... 3-80
3.23 REAR FORK ......................................................................................................................... 3-81
3.24 BELT GUARDS ..................................................................................................................... 3-85
3.25 REAR SHOCK ABSORBER .................................................................................................. 3-87

CHASSIS
3.26 CLUTCH CONTROL ............................................................................................................. 3-91
3.27 HEADLAMP NACELLE ......................................................................................................... 3-96
3.28 FAIRING ................................................................................................................................ 3-99
3.29 FAIRING: FRAME MOUNTED ............................................................................................ 3-102
3.30 WINDSHIELD ...................................................................................................................... 3-106
3.31 HAND GRIPS ...................................................................................................................... 3-108
3.32 HANDLEBAR ...................................................................................................................... 3-109
3.33 MIRRORS ........................................................................................................................... 3-112
3.34 FRONT FENDER ................................................................................................................ 3-113
3.35 REAR FENDER ................................................................................................................... 3-116
3.36 REAR FENDER WIRE CONDUIT ....................................................................................... 3-122
3.37 SAREE GUARD .................................................................................................................. 3-124
3.38 FRONT LICENSE PLATE BRACKET .................................................................................. 3-125
3.39 REAR LICENSE PLATE BRACKET .................................................................................... 3-126
3.40 LEFT FOOT CONTROLS .................................................................................................... 3-128
3.41 RIGHT FOOT CONTROLS.................................................................................................. 3-133
3.42 PASSENGER FOOTRESTS ............................................................................................... 3-138
3.43 JIFFY STAND...................................................................................................................... 3-140
3.44 SEAT ................................................................................................................................... 3-142
3.45 FRAME CROSSMEMBER................................................................................................... 3-144
3.46 SADDLEBAGS .................................................................................................................... 3-145
3.47 MEDALLIONS, BADGES, TANK EMBLEMS AND ADHESIVE STRIPS .............................. 3-156
NOTES
FASTENER TORQUE VALUES 3.1

FASTENER TORQUE VALUES IN THIS

CHAPTER _________________________
FASTENER TORQUE VALUE NOTES
ABS Module bracket screw 96-119 in-lbs 10.8-13.5 N-m 3.16 ABS MODULE, Install
ABS Module frame screw 96-119 in-lbs 10.8-13.5 N-m 3.16 ABS MODULE, Install
Banjo bolt 21-23 ft-lbs 29-31 N-m 3.17 BLEED BRAKES, Fill and Bleed
Banjo bolt to ABS module 17-19 ft-lbs 23.1-25.8 N-m 3.15 BRAKE LINES, Front ABS Lines
Banjo bolt to ABS module, rear 17-19 ft-lbs 23.1-25.8 N-m 3.15 BRAKE LINES, Brake Line: Rear Master Cyl-
inder to ABS Module
Banjo bolt to ABS module, rear 17-19 ft-lbs 23.1-25.8 N-m 3.15 BRAKE LINES, Brake Line: Rear Caliper to ABS
Module
Banjo bolt to brake caliper, rear 21-23 ft-lbs 29-31 N-m 3.15 BRAKE LINES, Brake Line: Rear Caliper to ABS
Module
Banjo bolt to master cylinder, rear 21-23 ft-lbs 29-31 N-m 3.15 BRAKE LINES, Brake Line: Rear Master Cyl-
inder to ABS Module
Belt guard, lower screw 70-80 in-lbs 7.9-9 N-m 3.24 BELT GUARDS, Remove and Install: Standard
Belt guard, upper screw 70-80 in-lbs 7.9-9 N-m 3.24 BELT GUARDS, Remove and Install: Standard
Belt guard, upper screw 70-80 in-lbs 7.9-9 N-m 3.24 BELT GUARDS, Remove and Install: Standard
Bleeder screw 35-61 in-lbs 3.9-6.9 N-m 3.17 BLEED BRAKES, Fill and Bleed
Brake caliper, front, bridge bolt 14-18 ft-lbs 19.6-24.5 N-m 3.12 FRONT BRAKE CALIPER, Assemble
Brake line, P-clamp, screw 36-48 in-lbs 4.1-5.4 N-m 3.15 BRAKE LINES, Brake Line: Front Master
Cylinder (ABS)
Brake line bracket, rear, screw 24-35 in-lbs 2.7-4 N-m 3.15 BRAKE LINES, Brake Line: Rear Master Cyl-
inder to ABS Module
Brake line bracket, rear, screw 24-35 in-lbs 2.7-4 N-m 3.15 BRAKE LINES, Brake Line: Rear Caliper to ABS
Module
Brake line to caliper, rear, P-clamp screw 24-35 in-lbs 2.7-4 N-m 3.15 BRAKE LINES, Brake Line: Rear Caliper to ABS
Module
Brake line to master cylinder, rear, P- 24-35 in-lbs 2.7-4 N-m 3.15 BRAKE LINES, Brake Line: Rear Master Cyl-
clamp screw inder to ABS Module
Brake line tube nuts, manifold 128-173 in-lbs 14.5-19.5 N-m 3.15 BRAKE LINES, Brake Line: Front Master
Cylinder (ABS)
Brake master cylinder, rear, mounting 18-22 ft-lbs 24.4-29.9 N-m 3.13 REAR BRAKE MASTER CYLINDER, Install
screws
Brake master cylinder, reservoir cover 9-18 in-lbs 1-2 N-m 3.17 BLEED BRAKES, Fill and Bleed
screw
Brake pedal linkage, mid control, front, 15-18 ft-lbs 20.3-24.4 N-m 3.41 RIGHT FOOT CONTROLS, Remove and Install:
screw Mid Foot Controls
Brake pedal linkage, mid control, rear, 15-18 ft-lbs 20.3-24.4 N-m 3.41 RIGHT FOOT CONTROLS, Remove and Install:
screw Mid Foot Controls
Brake pedal pivot, footboard control, 18-22 ft-lbs 24.5-30 N-m 3.41 RIGHT FOOT CONTROLS, Remove and Install:
screw. Footboards
Brake pedal pivot, forward control, screw 18-22 ft-lbs 24.4-29.8 N-m 3.41 RIGHT FOOT CONTROLS, Remove and Install:
Forward Foot Controls
Brake pedal pivot, mid control, screw 10-14 ft-lbs 13.6-19 N-m 3.41 RIGHT FOOT CONTROLS, Remove and Install:
Mid Foot Controls
Clutch cable lever screw 60-80 in-lbs 6.8-9 N-m 3.26 CLUTCH CONTROL, Install
ECM caddy small screw 55-60 in-lbs 6.2-6.8 N-m 3.45 FRAME CROSSMEMBER, Install
Fairing, frame mounted, air deflector 25-30 in-lbs 2.8-3.4 N-m 3.29 FAIRING: FRAME MOUNTED, Remove and
screws Install: Air Deflector

94000936
FASTENER TORQUE VALUE NOTES

Fairing, frame mounted, air deflector 25-30 in-lbs 2.8-3.4 N-m 3.29 FAIRING: FRAME MOUNTED, Remove and
screws Install: Outer Fairing Shell
Fairing, frame mounted, air duct screws 4.5-5.5 in-lbs 0.51-0.62 N-m
3.29 FAIRING: FRAME MOUNTED, Disassemble
and Assemble: Inner Fairing Shell
Fairing, frame mounted, bracket screws 48-60 in-lbs 5.4-6.8 N-m
3.29 FAIRING: FRAME MOUNTED, Disassemble
and Assemble: Inner Fairing Shell
20-27 ft-lbs 27-37 N-m
Fairing, frame mounted, fairing mount to 3.29 FAIRING: FRAME MOUNTED, Remove and
steering head locknut Install: Fairing Supports
Fairing, frame mounted, inner fairing 96-144 in-lbs 10.8-16.3 N-m 3.29 FAIRING: FRAME MOUNTED, Remove and
screws Install: Inner Fairing Shell
Fairing, frame mounted, inner fairing 96-144 in-lbs 10.8-16.3 N-m 3.29 FAIRING: FRAME MOUNTED, Remove and
screws Install: Fairing Supports
Fairing, frame mounted, lower mount 16-20 ft-lbs 21.7-27.1 N-m 3.29 FAIRING: FRAME MOUNTED, Remove and
screws Install: Inner Fairing Shell
Fairing, frame mounted, lower mount 16-20 ft-lbs 21.7-27.1 N-m 3.29 FAIRING: FRAME MOUNTED, Remove and
screws Install: Fairing Supports
Fairing, frame mounted, lower support 48-60 in-lbs 5.4-6.8 N-m 3.29 FAIRING: FRAME MOUNTED, Remove and
screws Install: Inner Fairing Shell
71-84 in-lbs 8-9.5 N-m
Fairing, frame mounted, mount screws 3.29 FAIRING: FRAME MOUNTED, Remove and
upper Install: Fairing Supports
Fairing, frame mounted, outer fairing 25-30 in-lbs 2.8-3.4 N-m 3.29 FAIRING: FRAME MOUNTED, Remove and
screws Install: Outer Fairing Shell
Fairing, inner screw 32-40 in-lbs 3.6-4.5 N-m 3.28 FAIRING, Disassemble and Assemble
Fairing, screw-on, inner fairing screws 35-62 in-lbs 4-7 N-m 3.28 FAIRING, Remove and Install: Screw-On
Fairing, screw-on, lower bracket screws 97-120 in-lbs 11-13.6 N-m 3.28 FAIRING, Remove and Install: Screw-On
Fairing, screw-on, screws 20-30 in-lbs 2.3-3.4 N-m 3.28 FAIRING, Remove and Install: Screw-On
Fairing, screw-on, upper bracket screws 35-62 in-lbs 4-7 N-m 3.28 FAIRING, Remove and Install: Screw-On
Fairing windshield screw 32-40 in-lbs 3.6-4.5 N-m 3.28 FAIRING, Disassemble and Assemble
Footboard assembly, left side, mounting 40-45 ft-lbs 54-61 N-m 3.40 LEFT FOOT CONTROLS, Remove and Install:
screw Footboards
Footboard assembly, right side, mounting 40-45 ft-lbs 54-61 N-m 3.41 RIGHT FOOT CONTROLS, Remove and Install:
screw Footboards
Foot support bracket, forward control, left 40-45 ft-lbs 54-61 N-m 3.40 LEFT FOOT CONTROLS, Remove and Install:
side, screw Forward Foot Controls
Foot support bracket, forward control, right 40-45 ft-lbs 54.2-61 N-m 3.41 RIGHT FOOT CONTROLS, Remove and Install:
side, screw Forward Foot Controls
Foot support bracket, left side, screw 40-45 ft-lbs 54.2-61 N-m 3.40 LEFT FOOT CONTROLS, Install
Foot support bracket, mid control, left side, 40-45 ft-lbs 54-61 N-m 3.40 LEFT FOOT CONTROLS, Remove and Install:
screw Mid Foot Controls
Foot support bracket, mid control, right 40-45 ft-lbs 54.2-61 N-m 3.41 RIGHT FOOT CONTROLS, Remove and Install:
side, screw Mid Foot Controls
Fork, left side, inverted, cartridge screw 13-17 ft-lbs 17.5-22.5 N-m 3.20 FRONT FORK, Disassemble and Assemble:
Inverted, Left Side
Fork, right side, inverted, inner fork nut 69-83 ft-lbs 93-113 N-m
3.20 FRONT FORK, Disassemble and Assemble:
Inverted, Right Side
Fork bracket, lower, pinch bolt 16-20 ft-lbs 21.7-27.1 N-m 3.20 FRONT FORK, Install
Models with two lower pinch bolts per side: Altern-
ately tighten until specification is met.
Fork bracket, upper, pinch bolt 16-20 ft-lbs 21.7-27.1 N-m 3.20 FRONT FORK, Install
Fork damper tube screw, front 30-37 ft-lbs 40-50 N-m 3.20 FRONT FORK, Disassemble and Assemble:
Standard

Fork stem pinch bolt 16-20 ft-lbs 21.7-27.1 N-m 3.21 STEERING HEAD/FORK STEM AND
BRACKET ASSEMBLY, Install
i

3-2
94000936
FASTENER TORQUE VALUE NOTES
Fork stem screw, 1st torque 160-168 in-lbs 18.1-19 N-m 3.21 STEERING HEAD/FORK STEM AND
BRACKET ASSEMBLY, Install
Fork stem screw, final torque - All except 62-68 in-lbs 7-7.7 N-m 3.21 STEERING HEAD/FORK STEM AND
FXLRS,FXLRST BRACKET ASSEMBLY, Install
Fork stem screw, final torque - FXLRS, 110-122 in-lbs 12.4-13.8 N-m 3.21 STEERING HEAD/FORK STEM AND
FXLRST BRACKET ASSEMBLY, Install
Fork tube plug, left side, inverted 22-28 ft-lbs 30-40 N-m 3.20 FRONT FORK, Disassemble and Assemble:
Inverted, Left Side
Fork tube plug, right side, inverted 22-30 ft-lbs 30-40 N-m 3.20 FRONT FORK, Disassemble and Assemble:
Inverted, Right Side
Fork tube plug, standard 22-59 ft-lbs 30-80 N-m 3.20 FRONT FORK, Disassemble and Assemble:
Standard
Fork tube plug to damper nut, left side, 13-16 ft-lbs 17.5-22.5 N-m 3.20 FRONT FORK, Disassemble and Assemble:
inverted Inverted, Left Side
Fork tube plug to damper nut , right side, 13-16 ft-lbs 17.5-22.5 N-m 3.20 FRONT FORK, Disassemble and Assemble:
inverted Inverted, Right Side
Frame crossmember mounting screws 17-20 ft-lbs 23.1-27.1 N-m 3.45 FRAME CROSSMEMBER, Install
Front ABS brake line P-clamp screw 36-48 in-lbs 4.1-5.4 N-m 3.15 BRAKE LINES, Front ABS Lines
Front ABS brake line to front brake line 128-173 in-lbs 14.5-19.5 N-m 3.15 BRAKE LINES, Front ABS Lines
Front brake caliper banjo bolt 14-18 ft-lbs 19-24.4 N-m 3.12 FRONT BRAKE CALIPER, Install
Front brake caliper bleeder screw 35-61 in-lbs 3.9-6.9 N-m 3.12 FRONT BRAKE CALIPER, Assemble
Front brake caliper bridge bolt 14-18 ft-lbs 19.6-24.5 N-m 3.12 FRONT BRAKE CALIPER, Install
Front brake caliper mounting bolts 28-38 ft-lbs 38-51.5 N-m 3.12 FRONT BRAKE CALIPER, Install
Front brake caliper mounting bolts 28-38 ft-lbs 38-51.5 N-m 3.12 FRONT BRAKE CALIPER, Install
Front brake caliper mounting bolts 28-38 ft-lbs 38-51.5 N-m 3.12 FRONT BRAKE CALIPER, Install
Front brake caliper pad hanger pin 11-14 ft-lbs 14.7-19.6 N-m 3.12 FRONT BRAKE CALIPER, Install
Front brake caliper pad hanger pin 11-14 ft-lbs 14.7-19.6 N-m 3.12 FRONT BRAKE CALIPER, Install
Front brake disc screw 16-24 ft-lbs 22-33 N-m 3.4 FRONT WHEEL, Assemble
Front brake line screw 36-48 in-lbs 4.1-5.4 N-m 3.15 BRAKE LINES, Front Brake Line: Non-ABS
Front brake line screw 36-48 in-lbs 4.1-5.4 N-m
3.15 BRAKE LINES, Brake Line: Front Caliper (ABS)
Front brake master cylinder banjo bolt - 24-25 ft-lbs 32-34 N-m 3.11 FRONT BRAKE MASTER CYLINDER, Install
Dual disk front brake
21-23 ft-lbs 29-31 N-m 3.11 FRONT BRAKE MASTER CYLINDER, Install
Front brake master cylinder banjo bolt -
Single disk front brake
Front fender mounting screw, 16-21 ft-lbs 22-28 N-m 3.34 FRONT FENDER, Install
FXBBS/FXST
Front fender mounting screw, FXFBS 72-96 in-lbs 8.1-10.8 N-m 3.34 FRONT FENDER, Install
Front fender mounting screw, 72-96 in-lbs 8.1-10.8 N-m 3.34 FRONT FENDER, Install
FXLRS/FXLRST
Front fender mounting screw (typical) 16-21 ft-lbs 22-28 N-m 3.34 FRONT FENDER, Install
Front fender side trim nut 10-15 in-lbs 1.1-1.7 N-m 3.34 FRONT FENDER, Assemble
Front fender to bracket screw, FXFBS 36-48 in-lbs 4.1-5.4 N-m 3.34 FRONT FENDER, Install
Front fork bottom mount pinch bolt 11-15 ft-lbs 15-20 N-m 3.4 FRONT WHEEL, Install
Front fork side mount pinch bolt 21-25 ft-lbs 28-34 N-m 3.4 FRONT WHEEL, Install
Front licence plate clamp bracket screws 1-1 ft-lbs 1.1-1.7 N-m 3.38 FRONT LICENSE PLATE BRACKET, Install
Front licence plate one hole bracket screw 25-30 ft-lbs 34-40.7 N-m 3.38 FRONT LICENSE PLATE BRACKET, Install

Front licence plate two hole bracket 16-20 ft-lbs 21.7-27 N-m 3.38 FRONT LICENSE PLATE BRACKET, Install
screws
Front wheel axle 70-75 ft-lbs 94.9-101.6 N-m 3.4 FRONT WHEEL, Install

94000936
FASTENER TORQUE VALUE NOTES
Handlebar clamp gap limiting fasteners 12-16 ft-lbs 16.3-21.7 N-m 3.32 HANDLEBAR, Disassemble and Assemble:
Standard
Handlebar clamp open gap fasteners 12-16 ft-lbs 16.3-21.7 N-m 3.32 HANDLEBAR, Disassemble and Assemble:
Standard
Handlebar switch clamp screw 60-80 in-lbs 6.8-9 N-m 3.11 FRONT BRAKE MASTER CYLINDER, Install
Headlamp, nacelle mounted, bezel screw 25-32 in-lbs 2.8-3.6 N-m 3.27 HEADLAMP NACELLE, Install
Headlamp, nacelle mounted, left side, 84-108 in-lbs 9.5--12.2 N-m 3.27 HEADLAMP NACELLE, Install
cover screw
Headlamp, nacelle mounted, right side, 84-108 in-lbs 9.5--12.2 N-m 3.27 HEADLAMP NACELLE, Install
cover screw
Headlamp nacelle, standard round, clamp 36-48 in-lbs 4.1-5.4 N-m 3.27 HEADLAMP NACELLE, Install
screw
Headlamp nacelle, standard round, trim 84-108 in-lbs 9.5--12.2 N-m 3.27 HEADLAMP NACELLE, Install
strip screw
Headlamp nacelle, standard round, trim 84-108 in-lbs 9.5--12.2 N-m 3.27 HEADLAMP NACELLE, Install
strip screw
Headlamp nacelle mounted, rear panel 85--104 in-lbs 9.6-11.7 N-m 3.27 HEADLAMP NACELLE, Install
bracket screw
Hub cap screw 16-24 ft-lbs 22-33 N-m 3.4 FRONT WHEEL, Assemble
Jiffy stand screws 40-45 ft-lbs 54.2--61 N-m 3.43 JIFFY STAND, Install
License plate bracket inner mounting 18-21 in-lbs 2.03-2.37 N-m 3.39 REAR LICENSE PLATE BRACKET, Center
screws Mount
License plate bracket outer mounting 63-77 in-lbs 7.11-8.69 N-m 3.39 REAR LICENSE PLATE BRACKET, Center
screws Mount
License plate holder screw 63-77 in-lbs 7.11-8.69 N-m
3.39 REAR LICENSE PLATE BRACKET, Center
Mount With Lighting
License plate standard assembly bolt 62-89 in-lbs 7-10 N-m 3.39 REAR LICENSE PLATE BRACKET, Standard
License plate standard mount screws 71-97 in-lbs 8-11 N-m 3.39 REAR LICENSE PLATE BRACKET, Standard
Lower shock screw 70-75 ft-lbs 94.9-101.7 N-m 3.25 REAR SHOCK ABSORBER, Install
Master brake cylinder yoke 11-14 ft-lbs 14.7-19.6 N-m
3.13 REAR BRAKE MASTER CYLINDER, Disas-
semble and Assemble: Master Cylinder
Master cylinder, rear, banjo bolt 14-18 ft-lbs 19-24.4 N-m 3.13 REAR BRAKE MASTER CYLINDER, Install
Master cylinder bracket to frame screw 30-40 ft-lbs 40.7-54.2 N-m 3.13 REAR BRAKE MASTER CYLINDER, Install
Mirror mounting nut 96-144 in-lbs 10.8-16.3 N-m 3.33 MIRRORS, Install
One piece seat grab strap screw 60-90 in-lbs 6.8-10.16 N-m 3.44 SEAT, Install
Passenger footpeg support screw 38-47 ft-lbs 51.5-63.7 N-m 3.42 PASSENGER FOOTRESTS, Install
Rear brake caliper banjo bolt 21-23 ft-lbs 29-31 N-m 3.14 REAR BRAKE CALIPER, Install
Rear brake caliper pad hanger pin 11-14 ft-lbs 14.7-19.6 N-m 3.14 REAR BRAKE CALIPER, Install
Rear brake caliper pad hanger pin 11-14 ft-lbs 14.7-19.6 N-m 3.14 REAR BRAKE CALIPER, Install
Rear brake disc screws 30-45 ft-lbs 40.7--61 N-m 3.5 REAR WHEEL, Assemble
.

Rear brake line bracket screws 24-36 in-lbs 2.7-4.1 N-m 3.15 BRAKE LINES, Rear Brake Line: Non-ABS
Rear brake line clamp screws 24-36 in-lbs 2.7-4.1 N-m 3.15 BRAKE LINES, Rear Brake Line: Non-ABS
Rear caliper sleeve screw 15—18 ft-lbs 20.3-24.4 N-m 3.14 REAR BRAKE CALIPER, Install
Rear caliper slider bolt 15—18 ft-lbs 20.3-24.4 N-m 3.14 REAR BRAKE CALIPER, Install
Rear fender inner mount screw 21-27 ft-lbs 28.4-37 N-m
3.35 REAR FENDER, Disassemble and Assemble:
Chopped Fender Without License Plate Bracket
Lighting
Rear fender mounting screw 42-46 ft-lbs 57--62.5 N-m 3.35 REAR FENDER, Remove and Install: Standard

Rear fender support screw 21-27 ft-lbs 28.4-37 N-m 3.35 REAR FENDER, Disassemble and Assemble:
Chopped Fender Without License Plate Bracket
Lighting

3-4
94000936
FASTENER TORQUE VALUE NOTES
Rear fender support screw 21-27 ft-lbs 28.4-37 N-m
3.35 REAR FENDER, Disassemble and Assemble:
Chopped Fender Without License Plate Bracket
Lighting
Rear fender support screw 21-27 ft-lbs 28.4-37 N-m 3.35 REAR FENDER, Disassemble and Assemble:
Chopped Fender With License Plate Bracket
Lighting
Rear fender support screws 21-27 ft-lbs 28.4-37 N-m 3.35 REAR FENDER, Disassemble and Assemble:
Chopped Fender Without License Plate Bracket
Lighting
Rear fender support screws 21-27 ft-lbs 28.4-37 N-m 3.35 REAR FENDER, Disassemble and Assemble:
Full Fender
Rear fork pivot shaft nut, final torque 154-170 ft-lbs 209-230 N-m 3.23 REAR FORK, Remove and Install
Rear fork pivot shaft nut, first torque 25-30 ft-lbs 34--41 N-m 3.23 REAR FORK, Remove and Install
Rear fork pivot shaft nut, second 1-48 in-lbs 0.1-5.4 N-m 3.23 REAR FORK, Remove and Install
torque
Rear fork pivot shaft nut, third torque 154-170 ft-lbs 209-230 N-m 3.23 REAR FORK, Remove and Install
Rear fork pivot shaft pinch bolt 18-20 ft-lbs 24-27 N-m 3.23 REAR FORK, Remove and Install
Rear shock adjuster knob screw 26.6--44.3 in-lbs 3-5 N-m
3.25 REAR SHOCK ABSORBER, Disassemble and
Assemble: Rear Shock Adjuster
Rear sprocket screws, final torque 77-83 ft-lbs 104.4-112.5 N-m 3.5 REAR WHEEL, Assemble
Rear sprocket screws, first torque 60 ft-lbs 81.3 N-m 3.5 REAR WHEEL, Assemble
Riser flange nuts 30--40 ft-lbs 40.7-54.3 N-m 3.32 HANDLEBAR, Remove and Install: Standard
Riser flange nuts 30--40 ft-lbs 40.7-54.3 N-m 3.32 HANDLEBAR, Disassemble and Assemble:
Standard
Saddle bag, docking bracket screw 38--47 ft-lbs 52-64 N-m 3.24 BELT GUARDS, Remove and Install:
Standard
96-120 in-lbs 10.9-13.6 N-m 3.46 SADDLEBAGS, Remove and Install:
Saddlebag, left side, mounting bracket
Standard
grommet screw
Saddlebag, left side, mounting bracket 38--47 ft-lbs 52-64 N-m 3.46 SADDLEBAGS, Remove and Install:
screw Standard

Saddlebag, left side, mounting bracket 38--47 ft-lbs 52-64 N-m 3.46 SADDLEBAGS, Remove and Install: Quick
screw Disconnect
Saddlebag, mounting bolt 21-27 ft-lbs 29-37 N-m 3.46 SADDLEBAGS, Remove and Install: Quick
Disconnect
Saddlebag, mounting screw 21-27 ft-lbs 29-37 N-m 3.46 SADDLEBAGS, Remove and Install:
Standard
Saddlebag, right side, mounting 97-124 in-lbs 11-14 N-m 3.46 SADDLEBAGS, Remove and Install: Quick
bracket grommet screw Disconnect
Saddlebag docking rod 13-15 ft-lbs 17-21 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Quick Disconnect
Saddlebag hinge screw 18-25 in-lbs 2-2.8 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Standard
Saddlebag hinge screw 20-30 in-lbs 2.3-3.4 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Quick Disconnect
Saddlebag hinge screw 20-30 in-lbs 2.3-3.4 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Quick Disconnect
Saddlebag indicator flag cover screw 24-36 in-lbs 2.7—4.1 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Quick Disconnect
Saddlebag latch assembly 10-15 in-lbs 1.1-1.7 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Quick Disconnect
Saddlebag latch lever screw 20-30 in-lbs 2.3-3.4 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Quick Disconnect
Saddlebag left side mounting bracket 97-124 in-lbs 11-14 N-m 3.46 SADDLEBAGS, Remove and Install: Quick
grommet screw Disconnect
Saddlebag locking knob cover screw 97-120 in-lbs 11-13.6 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Quick Disconnect

94000936
FASTENER TORQUE VALUE NOTES
Saddlebag locking knob screw 97-120 in-lbs 11-13.6 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Quick Disconnect
saddlebag lock screw 15-20 in-lbs 1.7-2.3 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Quick Disconnect
Saddlebag lockset nut 45--55 in-lbs 5.1-6.2 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Standard
Saddlebag right side mounting bracket 96-120 in-lbs 10.9-13.6 N-m 3.46 SADDLEBAGS, Remove and Install: Standard
grommet screw
Saddlebag strike screw 20-30 in-lbs 2.3-3.4 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Quick Disconnect
Saddlebag tether screw 45--55 in-lbs 5.1—6.2 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Quick Disconnect
Saddlebag tether stud 45--55 in-lbs 5.1-6.2 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Quick Disconnect
Saddlebag tether to lid screw 8-15 in-lbs 0.9-1.7 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Standard
Saddlebag tether to lid screw 8-15 in-lbs 0.9-1.7 N-m 3.46 SADDLEBAGS, Disassemble and Assemble:
Standard
Saree lower guard lower screw 10-13 ft-lbs 14-18 N-m 3.37 SAREE GUARD, Install
Saree lower guard top screw 71-80 in-lbs 8-9 N-m 3.37 SAREE GUARD, Install
Saree upper guard screw 21-27 ft-lbs 28-37 N-m 3.37 SAREE GUARD, Install
Seat mounting nut 9-15 in-lbs 1-1.7 N-m 3.44 SEAT, Install
Seat thumbscrew 15--30 in-lbs 1.7-3.4 N-m 3.44 SEAT, Install
Seat thumbscrew 15--30 in-lbs 1.7-3.4 N-m 3.44 SEAT, Install
Seat thumbscrew 15-30 in-lbs 1.7-3.4 N-m 3.44 SEAT, Install
Shift lever bracket screws 120-144 in-lbs 13.6-16.3 N-m 3.40 LEFT FOOT CONTROLS, Disassemble and
Assemble: Footboard
Shock adjuster mounting screw 90-114 in-lbs 10.2-12.9 N-m 3.45 FRAME CROSSMEMBER, Install
Shock pinch bolt 12-15 ft-lbs 16.3-20.3 N-m 3.25 REAR SHOCK ABSORBER, Install
Side cover, left side, bracket to frame 8-10 in-lbs 0.9-1.1 N-m 3.18 LEFT SIDE COVER, Install
screw
Side cover mounting stud 72-96 in-lbs 8.1-10.8 N-m 3.16 ABS MODULE, Install
Side cover screw, single screw 24-36 in-lbs 2.7-4.1 N-m 3.18 LEFT SIDE COVER, Install
Side cover screw, vertical screw 24-36 in-lbs 2.7-4.1 N-m 3.19 RIGHT SIDE COVER, Install
Side-mounted shock adjuster screw 90-114 in-lbs 10.2-12.9 N-m 3.25 REAR SHOCK ABSORBER, Install
Splash guard screw 35-45 in-lbs 3.9-5.1 N-m 3.23 REAR FORK, Remove and Install
Spoke nipple 55 in-lbs 6.2 N-m 3.7 CHECKING AND TRUING WHEELS, True Laced
Wheels
Under seat frame cover, front screw 20-30 in-lbs 2.3-3.4 N-m 3.15 BRAKE LINES, Front ABS Lines
Under seat frame cover, rear screw 96-120 in-lbs 10.8-13.6 N-m 3.15 BRAKE LINES, Front ABS Lines
Upper shock screw 80-90 ft-lbs 108.5--122 N-m 3.25 REAR SHOCK ABSORBER, Install
Valve stem nut 12-15 in-lbs 1.4-1.7 N-m 3.9 TIRES, Install
Wear peg 30-42 in-lbs 3.4-4.7 N-m 3.40 LEFT FOOT CONTROLS, Disassemble and
Assemble: Footboard
Wear peg 30-42 in-lbs 3.4-4.7 N-m 3.40 LEFT FOOT CONTROLS, Disassemble and
Assemble: Footpeg
Wear peg 30-42 in-lbs 3.4-4.7 N-m 3.41 RIGHT FOOT CONTROLS, Disassemble and
Assemble: Footboard
Wear peg 30-42 in-lbs 3.4-4.7 N-m 3.41 RIGHT FOOT CONTROLS, Disassemble and
Assemble: Footpeg
Windshield, frame mounted fairing, screws 5-7 in-lbs 0.6-0.8 N-m 3.29 FAIRING: FRAME MOUNTED, Remove and
Install: Windshield

3-6
94000936
FASTENER TORQUE VALUE NOTES
Windshield acorn nuts 23-27 in-lbs 2.6-3 N-m 3.30 WINDSHIELD, Assemble

94000936
SPECIFICATIONS 3.2

CHASSIS

Chassis Specifications
Table 3-1. Capacities
ITEM U.S. L
Sport Glide (FLSB), Fat Boy 114 (FLFBS), Heritage Classic (FLHCS), Low Rider
5.0 gal 18.9
S (FXLRS)
Fuel tank (total)
Breakout 114 (FXBRS), Street Bob 114 (FXBBS), Softail Standard (FXST),
Fat Bob 114 ( FXFBS) 3.5 gal 13.25
Low fuel warning light on'" 1.0 gal 3.8
Oil tank with filter'2' 5.0 qt 4.73
Transmission (approximate)'31 1.0 qt 0.95
Heritage Classic (FLHCS), Sport Glide (FLSB), Street Bob 114 (FXBBS), Fat Bob
Primary chaincase (approxim- 1.25 qt 1.18
114 (FXFBS), Low Rider S (FXLRS), Softail Standard (FXST)
21
ate)' Fat Boy 114 (FLFBS), Breakout 114 (FXBRS) 1.43 qt 1.35
(1) When refilling from empty, add at least 3.8 L (1.0 gal).
(2) When refilling, initially add 3.78 L (4.0 qt) and add as needed to bring level within specification.
(3) When refilling, initially add 0.83 L (28 oz) and add as needed to bring level within specification.
(4) When refilling, initially add 1.06 L (36 oz) and add as needed to bring level within specification.

Table 3-2. Dimensions: FL Models

Item
Fat Boy® 114 (FLFBS) Heritage Classic 114 (FLHCS) Sport Glide™ (FLSB)
Length 93.3 in (2,370 mm) 95.1 in (2,415 mm) 91.5 in (2,325 mm)
Overall width 38.8 in (985 mm) 36.6 in (930 mm) 37.8 in (960 mm)
Overall height 43.1 in (1,095 mm) 53.9 in (1,370 mm) 44.1 in (1,120 mm)
Wheelbase 65.6 in (1,665 mm) 64.2 in (1,630 mm) 64.0 in (1,625 mm)
Road clearance 4.5 in (115 mm) 4.7 in (120 mm) 4.7 in (120 mm)
Seat height"1 25.9 in (658 mm) 26.3 in (668 mm) 25.7 in (653 mm)
(1) With 180 lb (81.6 kg) rider on seat

Table 3-3. Dimensions: FX Models

TM
Item Breakout® 114 Low Rider®S Low Rider®ST
Street Bob® 114 Fat Bob 114 (FXFBS)
(FXBRS) (FXLRS) (FXLRST)
(FXBBS) Softail
Stand-
ard®(FXST)
Length 91.3 in (2,320 mm) 93.3 in (2,370 mm) 92.1 in (2,340 mm) 93.1 in (2,365 mm) 93.1 in (2,365 mm)
Overall width 34.1 in (865 mm) 37.4 in (950 mm) 37.8 in (960 mm) 34.3 in (870 mm) 34.3 in (870 mm)
Overall height 45.7 in (1,160 mm) 41.9 in (1,065 mm) 43.7 in (1,110 mm) 47.0 in (1,195 mm) 51.2 in (1,300 mm)
Wheelbase 64.2 in (1,630 mm) 66.7 in (1,695 mm) 63.6 in (1,615 mm) 63.6 in (1,615 mm) 63.6 in (1,615 mm)
Road clearance 4.9 in (125 mm) 4.5 in (115 mm) 4.7 in (120 mm) 5.7 in (145 mm) 5.9 in (150 mm)
Seat height"1 25.8 in (655 mm) 25.6 in (650 mm) 27.7 in (704 mm) 27.0 in (686 mm) 27.0 in (686 mm)
(1) With 180 lb (81.6 kg) rider on seat

Table 3-4. Weights: FL Models

Item Fat Boy® 114 (FLFBS) Heritage Classic 114 (FLHCS) Sport Glide ™ (FLSB)
1
Running weight" 699 lb (317 kg) 728 lb (330 kg) 699 lb (317 kg)
476 lb (216 kg) 432 lb (196 kg) 461 lb (209 kg)
Maximum added weight al-
lowed'21
GVWR 1,175 lb (533 kg) 1,160 lb (526 kg) 1,160 lb (526 kg)
GAWR front 450 lb (204 kg) 450 lb (204 kg) 450 lb (204 kg)
GAWR rear 760 lb (345 kg) 730 lb (331 kg) 730 lb (331 kg)
(1) The total weight of the motorcycle as delivered with all oil/fluids and approximately 90% of fuel.
(2) The total weight of accessories, cargo, riding gear, passenger and rider must not exceed this weight.

3-8
94000936
 Table 3-5. Weights: FX Models
TM
Item
Softail Stand- Breakout® 114 Street Bob® 114 Fat Bob 114 Low Rider®S Low Rider®ST
ard®(FXST) (FXBRS) (FXBBS) (FXFBS) (FXLRS) (FXLRST)
Running weight™ 655 lb (297 kg) 672 lb (305 kg) 655 lb (297 kg) 675 lb (306 kg) 679 lb (308 kg) 721 lb (327 kg)

Maximum added 505 lb (229 kg) 503 lb (228 kg) 505 lb (229 kg) 485 lb (220 kg) 481 lb (218 kg) 439 lb (199 kg)

weight allowed®
GVWR 1,160 lb (526 kg) 1,175 lb (533 kg) 1,160 lb (526 kg) 1,160 lb (526 kg) 1,160 lb (526 kg) 1,160 lb (526 kg)
GAWR front 450 lb (204 kg) 450 lb (204 kg) 450 lb (204 kg) 450 lb (204 kg) 450 lb (204 kg) 450 lb (204 kg)
GAWR rear 730 lb (331 kg) 760 lb (345 kg) 730 lb (331 kg) 730 lb (331 kg) 730 lb (331 kg) 730 lb (331 kg)
(1) The total weight of the motorcycle as delivered with all oil/fluids and approximately 90% of fuel.
(2) The total weight of accessories, cargo, riding gear, passenger and rider must not exceed this weight.

A WARNING
• For important information regarding tire data and tire
inflation, see INSPECT TIRES AND WHEELS (Page 2-13).
Do not exceed the motorcycle's Gross Vehicle Weight Rating
(GVWR) or Gross Axle Weight Rating (GAWR). Exceeding
these weight ratings can lead to component failure and Tire Specifications
adversely affect stability, handling and performance, which A WARNING
could result in death or serious injury. (00016f)
Match tires, tubes, rim strips or seals, air valves and caps to
• GVWR is the sum of the weight of the motorcycle, the correct wheel. Contact a Harley-Davidson dealer.
accessories, and the maximum weight of the rider, passenger Mismatching can lead to tire damage, allow tire slippage on
and cargo that can be safely carried. the wheel or cause tire failure, which could result in death or
serious injury. (00023c)
• GAWR is the maximum amount of weight that can be safely
carried on each axle. NOTE
ABS equipped motorcycles must always use tires and
• The GVWR and GAWR are shown on the information plate,
wheels that are the same as the original equipment. ABS
located on the frame down tube.
monitors rotational speed of the wheels through individual
NOTE wheel speed sensors to determine the application of ABS.
• The maximum additional weight allowed on the Changing to different diameter wheels or different size tires
motorcycle equals the Gross Vehicle Weight Rating can alter the rotational speed. This will upset the system
(GVWR) minus the running weight. For example, a calibration and have an adverse effect on its ability to detect
motorcycle with GVWR of 1,199.30 lb (544 kg) having a and prevent lockups. Operating with inflation pressure other
running weight of 800.27 lb (363 kg), would allow a than those specified can reduce ABS performance.
maximum of an additional 399.03 lb (181 kg) combined
weight of the rider, passenger, riding gear, cargo and
installed accessories.

94000936
 1038766
1. Stamped Vehicle Identification Number (VIN)
VEHICLE IDENTIFICATION NUMBER (VIN) _
Location
2. VIN label
See Figure 3-1. The full 17-digit VIN is stamped on the right side Figure 3-1. VIN Locations
VEHICLE IDENTIFICATION NUMBER (VIN) 3.3
General
of the frame near the steering head. In some destinations, a
printed VIN label is also attached on the front downtube.
See Figure 3-2. A unique 17-digit serial or Vehicle Identification
Number (VIN) is assigned to each motorcycle. Refer to Table 3-
Abbreviated VIN
6.
An abbreviated VIN showing the vehicle model, engine type,
model year, and sequential number is stamped on the left side of
the crankcase between the engine cylinders.
NOTE
Always give the full 17-digit Vehicle Identification Number
when ordering parts or making any inquiry about your
motorcycle.

1606058

1 HD 1 YC J 1 3 N B 111000
Figure 3-2. Typical Harley-Davidson VIN: 2022 Softail Models
Table 3-6. Harley-Davidson VIN Breakdown: 2022 Softall Models
POSITION DESCRIPTION POSSIBLE VALUES
1 World manufacturer identifier 1HD=Originally manufactured in the United States
5HD=Originally manufactured in the United States or Thailand for sale
outside of the United States
932=Originally manufactured in Brazil
MLY=Originally manufactured in Thailand
2 Motorcycle type
1=Heavyweight motorcycle (901 cm or larger)
3 Model See VIN model table
4 Engine type
J=Milwaukee Eight 107 (1753 cm ) air-cooled, fuel-injected, balanced
K=Milwaukee Eight™ 114 (1868 cm3) air-cooled, fuel-injected, balanced
Z=Milwaukee Eight 117 (1923 cm ) air-cooled, fuel-injected, balanced

94000936
3-10
Table 3-6. Harley-Davidson VIN Breakdown: 2022 Softail Models
POSITION DESCRIPTION POSSIBLE VALUES
5 Calibration/configuration, introduction 1=Domestic (DOM)
2=California (CAL)
3=Canada (CAN)
4=ENG, EN2, HDI, HD2, HD4
S=Japan (JPN)
6=Australia (AUS)
7=Brazil (BRZ)
8=Asia Pacific (APC)
9=India (IND/IN2)
0=ASEAN (AZN)
A=China (CHN)
G=HD3
6 VIN check digit Can be 0-9 or X
7 Model year N=2022
8 Assembly plant B=York, PA U.S.A.
D=H-D Brazil-Manaus, Brazil (CKD)
S=Tasit, Pluagdang, Rayong, Thailand
9 Sequential number Varies
Table 3-7. VIN Model Codes: Softail Models
CODE MODEL CODE MODEL
BV FXST Softail Standard YM FLSB Sport Glide®
YB FLHCS Heritage Classic 114 yy FXBBS Street Bob® 114
YG FLFBS Fat Boy® 114 YW FXLRS Low Rider® S
YH FXBRS Breakout® 114 YX FXLRST Low Rider® ST
YL FXFBS Fat Bob® 114

94000936
FRONT WHEEL 3.4

PREPARE c. See Figure 3-5. Install front axle through right fork,
right bearing spacer (2), front wheel, left bearing
spacer (10) or wheel speed sensor (7).
1. Raise front wheel. See Secure the Motorcycle for Service
(Page 2-2). NOTE
See Figure 3-4. Position wheel speed sensor (1)
2. Check wheel bearing end play. See SEALED WHEEL with index pin (2) contacting fork.
BEARINGS (Page 3-25).
NOTE
3. Remove front brake caliper(s). See FRONT BRAKE Models with a hub cap assembly (11) will not have
CALIPER (Page 3-38). a right bearing spacer (2), use hub cap assembly
in place of right bearing spacer.
NOTE
Do not operate front brake lever with the front brake d. Thread the front axle into the left fork. lighten.
caliper removed. Without the rotor, brake pressure
forces the pistons out of the piston bores. Seating Torque: 70-75 ft-lbs (94.9-101.6 N-m) Front wheel
pistons requires caliper disassembly axle

2. See Figure 3-3. Tighten pinch bolt.

REMOVE 1. See Figure 3-3. Remove front wheel.
a. Bottom mount pinch bolt:
NOTE
Torque: 11-15 ft-lbs (15--20 N-m) Front fort< bottom
• ABS models: Never pull wheel speed sensor cable taut or
mount pinch bolt
use to retain wheel, axle or other components.
b. Side mount pinch bolt:
• Keep wheel speed sensor and ABS encoder bearing away
from magnetic fields. Torque: 21-25 ft-lbs (28-34 N-m) Front fork side
mount pinch bolt
a. Loosen pinch bolt (2 or 3) depending on model.

b. See Figure 3-5 Remove front axle (1), left bearing

spacer (10) or wheel speed sensor (7) and right
bearing spacer (2).

c. Remove front wheel (5).

NOTE
If equipped with a hub cap, the hub cap will come off with the
wheel.

INSTALI ________________________________

FASTENER TORQUE VALUE

Front fork bottom mount pinch 11-15 ft-lbs 15-20 N-m
bolt
Front fork side mount pinch 21-25 ft-lbs 28-34 N-m
bolt
Front wheel axle 70-75 ft-lbs 94.9-101.6 N-m

CONSUMABLE PART NUMBER

LOCTITE SILVER 11100001
GRADE
ANTI-SEIZE
1. See Figure 3-5 . Install front wheel.

a. Apply a light coat of ANTI-SEIZE LUBRICANT to front

axle (1), wheel bearing bores and bore of the inner
wheel bearing spacer (4).

LOCTITE SILVER GRADE ANTI-SEIZE (11100001)

b. Position front wheel (5) between front forks.

3-12
94000936
 CLEAN AND INSPECT

1. Clean all parts thoroughly.

2. Inspect front wheel for damage. Replace or repair as

necessary.

3. Check wheel lateral and radial runout before installing a new

tire. See CHECKING AND TRUING WHEELS (Page 3-21).

ASSEMBLE _____________________________

FASTENER TORQUE VALUE

Front brake disc screw 16-24 ft-lbs 22-33 N-m
Hub cap screw 16-24 ft-lbs 22-33 N-m
1. Install new valve stem. See TIRES (Page 3-28).
2. Install tire. See TIRES (Page 3-28).
Figure 3-4. Front Wheel Speed Sensor Index Pin (ABS
equipped) 3. See Figure 3-5 or Figure 3-6. Install wheel bearing inner
DISASSEMBLE ___ spacer (4).

1. See Figure 3-6. Disassemble hub cap assembly if equipped. 4. Install new wheel bearings. See SEALED WHEEL
BEARINGS (Page 3-25).
a. Remove and discard retaining ring from hub cap
assembly (11 ). 5. See Figure 3-6. Install hub cap if equipped.

a. Align holes on hubcap (12) with holes on the right side

b. Remove hub spacer from hub cap.
of front wheel.
2. See Figure 3-5 or Figure 3-6. Remove front brake disc(s).
b. Install screws (13). Tighten.
a. Remove and discard screws (9). Torque: 16-24 ft-lbs (22-33 N-m) Hub cap screw
b. Remove front brake disc(s) (8).
NOTICE
3. Remove front tire. See TIRES (Page 3-28). Do not re-use brake disc/rotor screws. Re-using these
screws can result in torque loss and damage to brake
4. Remove valve stem. See TIRES (Page 3-28). components. (00319c)
5. Remove and discard sealed wheel bearings. See SEALED
WHEEL BEARINGS (Page 3-25). 6. See Figure 3-5 or Figure 3-6. Install front brake disc(s).

6. See Figure 3-5 or Figure 3-6. Remove wheel bearing inner a. Align front brake disc(s) (8) with mounting holes in
spacer (4). front wheel (5).

7. See Figure 3-6. Remove screws (13) and hub cap (12) if b. Install new screws (9). Tighten.
equipped. Torque: 16-24 ft-lbs (22-33 N-m) Front brake disc
screw

94000936
1627125

1. Front axle 6- Wheel bearing (ABS encoder)

2. Right bearin g spacer 7. Wheel speed sensor (ABS)
3. Wheel bearing (2) 8. Brake disc
4. Inner wheel bearing spacer 9. Brake disc screw (5)
5. Wheel 10. Left bearingspacer
Figure 3-5. Cast Front Wheel (Typical)

3-14
94000936
 1103740

1. Front axle 8. Brake disc

2. Right bearing spacer 9. Brake disc screw (5)
3. Wheel bearing (2) 10. Left bearing spacer
4. Inner wheel bearing spacer 11. Hub spacer, hub cap and retaining ring
5. Wheel 12. Hub cap (if equipped)
6. Wheel bearing (ABS encoder) 13. Screw (5)
7. Wheel speed sensor (ABS)
Figure 3-6. Laced Front Wheel
COMPLETE ___________ 2. Lower front wheel. See Secure the
Motorcycle for Service
(Page 2-2).
1. Install caliper(s). See FRONT BRAKE CALIPER (Page 3-
38)

94000936 3-15
REAR WHEEL 3.5

PREPARE e. Support brake caliper bracket (2).

f. Remove rear axle (9), right outer spacer (1 ), right

1. Remove main fuse. See POWER DISCONNECT (Page 7-7). inner spacer (3) or WSS (4) and left spacer (6).

2. Remove saddlebags, if equipped. See SADDLEBAGS (Page g. Remove drive belt from rear sprocket (8).
3-145).
h. Remove rear wheel assembly.
3. Measure wheel alignment. See WHEEL ALIGNMENT (Page
3-33).

4. Remove belt guards, if necessary. See BELT GUARDS CONSUMABLE PART NUMBER
(Page 3-85). LOCTITE SILVER 11100001
GRADE
5. Remove muffler, if necessary. See MUFFLERS (Page 6-34). ANTI-SEIZE
1. See Figure 3-7. Install rear wheel.
6. Raise rear wheel. See Secure the Motorcycle for Service INSTALL
(Page 2-2).
a. Apply a light coat of anti-seize lubricant to rear axle
7. Check wheel bearing end play. See SEALED WHEEL (9), wheel bearing bores, and bore of wheel bearing
BEARINGS (Page 3-25). spacer (16).

8. NOTE LOCTITE SILVER GRADE ANTI-SEIZE (11100001)

Do not operate rear brake pedal with the rear brake b. Position rear wheel between rear fork.
caliper removed. Without the rotor, brake pressure
forces the pistons out of the piston bores. Seating c. Install rear axle through left spacer (6), left leg of rear
pistons requires caliper disassembly fork, and rear sprocket (8).

Remove rear brake caliper. See REAR BRAKE CALIPER d. Install rear axle through rear wheel.
(Page 3-46).
e. Install rear axle through right inner spacer (3) or WSS
(4), caliper bracket (2), right outer spacer (1) and right
REMOVE
PART NUMBER TOOL NAME leg of rear fork.

HD-47925 AXLE NUT TORQUE ADAPTER

f. Install washer (11 ).
1. See Figure 3-7. Remove rear wheel.
g. Install axle nut (12). Hand-tighten.
a. Remove E-clip (13).
h. Slide rear axle forward. Install drive belt on front and
b. Loosen axle nut (12) using axle nut torque adapter. rear sprockets.
Special Tool: AXLE NUT TORQUE ADAPTER (HD-
2. See Figure 3-8. Rotate WSS to position shown, if equipped.
47925)
Verify wire harness is routed correctly.
c. Loosen axle adjuster screws (10) and slide rear wheel
forward. 3. Align rear wheel. See WHEEL ALIGNMENT (Page 3-33).

d. Remove axle nut and washer (11 ). 4. Adjust drive belt deflection. See INSPECT AND ADJUST
DRIVE BELT AND SPROCKETS (Page 2-31).

5. Verify drive belt tracking properly.

3-16 94000936
 1644977 9. Rear axle
1. Right outer spacer 10. Adjuster screw (2)
2. Brake caliper bracket 11. Washer
3. Right inner spacer, non ABS 12. Axle nut
4. WSS 13. E-clip
5. Brake disk (typical) 14. Wheel bearing (2)
6. Left spacer 15. Brake disk screw (5)
7. Sprocket screw (5) 16. Wheel bearing spacer
8. Rear sprocket
Figure 3-7. Rear Wheel (Typical)

94000936 3-17
 1. Install new valve stem. See TIRES (Page 3-28).

2. Install tire. See TIRES (Page 3-28).

3. Install wheel bearing spacer (16), if removed.

4. See Figure 3-7. Install new sealed wheel bearings (14), if
removed. See SEALED WHEEL BEARINGS (Page 3-25).

NOTICE

Do not re-use sprocket mounting screws. Re-using sprocket

mounting screws can result in torque loss and damage to
the sprocket and/or belt assembly. (00480b)

5. Install rear sprocket.

a. Align rear sprocket (8) with mounting holes in rear

wheel.

b. Install new sprocket screws (7). Tighten using the

following sequence.

c. Tighten screws to initial torque.

Torque: 60 ft-lbs (81.3 N-m) Rear sprocket screws,

first torque

d. Back off screws one-half turn (180 degrees).

e. Tighten screws to final torque.

Figure 3-8. Rear Wheel Speed Sensor Orientation
Torque: 77-83 ft-lbs (104.4-112.5 N-m) Rear sprocket
DISASSEMBLE _______ ______________ screws, final torque
1. See Figure 3-7. Remove rear brake disc.
NOTICE
a. Discard brake disk screws (15).
Do not re-use brake disc/rotor screws. Re-using these
b. Remove rear brake disc (5).
screws can result in torque loss and damage to brake
components. (00319c)
2. Remove rear sprocket.
a. Discard rear sprocket screws (7) 6. Install rear brake disc.
b. Remove rear sprocket (8).
a. Align rear brake disc (5) with mounting holes in rear
3. Remove rear tire. See TIRES (Page 3-28). wheel.
4. Remove valve stem. See TIRES (Page 3-28). b. Install new brake disk screws (15). Tighten
5. If necessary, remove and discard sealed wheel bearings. Torque: 30-45 ft-lbs (40.7-61 N-m) Rear brake disc
See SEALED WHEEL BEARINGS (Page 3-25). screws
CLEAN AND INSPECT __________
COMPLETE ___________ ____ ___________
1. Clean all parts thoroughly.
1. Lower rear wheel. See Secure the Motorcycle for Service
2. Inspect rear wheel for damage. Replace or repair as (Page 2-2).
necessary.
3. Check wheel runout. See CHECKING AND TRUING 2. Install muffler, if removed. See MUFFLERS (Page 6-34).
WHEELS (Page 3-21).

ASSEMBLE 3. Install belt guards, if removed. See BELT GUARDS (Page 3-

85).

4. Install saddlebags, if removed. See SADDLEBAGS (Page 3-

FASTENER TORQUE VALUE 145).
Rear brake disc screws 30-45 fl-lbs 40.7-81 N-m
77-83 ft-lbs 104.4-112.5 N- 5. Install main fuse. See POWER DISCONNECT (Page 7-7).
Rear sprocket screws, final
torque m
Rear sprocket screws, first 60 ft-lbs 81.3 N-m
torque

3-18 94000936
WHEEL LACING 3.6

WHEEL LACING: ANGLE FLANGE HUB 343809

NOTE
• See Figure 3-9. The following procedure is valid for wheels
that use an angle flange hub regardless of rim style or
diameter.
• Disc mounting surface for primary brake side of hub has
one or two grooves.

Figure 3-10. Spokes Gathered

1. Outer spoke
2. Inner spoke
7. Install lower flange outer spokes and loosely install spoke
nipples:
a. Rim with side valve hole: See Figure 3-11. Start at the
valve stem hole (1 ).
b. Rim with center valve hole: See Figure 3-12. Start at
the first hole counterclockwise (1) from valve stem hole.

8. Install remaining outer spokes in every fourth hole.

1. Place hub on workbench:
9. Install lower flange inner spokes and loosely install spoke
a. Front: primary brake side up. nipples:
b. Rear: brake side down. a. Starting at the second hole counterclockwise (2) from first
spoke installed, install inner spoke.
2. Install all spokes in the lower flange.
b. Install remaining inner spokes in every fourth hole.
3. See Figure 3-10. Flip hub over. Gather all outer spokes and
hold upright with a rubber band. Repeat with the inner 10. Carefully release upper flange inner spokes and fan out
spokes using a second rubber band. around rim, rotating them clockwise.
4. Install spokes in remaining flange. 11. Starting at the first hole counterclockwise (3) from first spoke
5. Rotate the lower flange spokes as far as they go: installed, install inner spoke. Install remaining inner spokes
in every fourth hole.
a. Outer spokes clockwise.
12. Carefully release upper flange outer spokes and fan out
b. Inner spokes counterclockwise. around rim, rotating them counterclockwise.

6. Center the rim over the hub and spokes assembly and 13. Install outer spokes in remaining holes (4).
support on wooden blocks approximately 1.5 in (38.1 mm) 14. Verify that spoke heads are seated. See CHECKING AND
thick. TRUING WHEELS (Page 3-21).
a. If valve is not located in the center of the rim, place valve a. Evenly hand-tighten spoke nipples until snug.
hole facing up.
b. Only tighten until slack is removed.
b. If the valve is located in the center of the rim, it can be
c. Proper torque is applied when the wheel is trued.
placed either side up.
d. Adjust offset and true the wheel.
NOTE
Install nipples until approximately % in (32 mm) of spoke
thread shows.

94000936 3-19
3-20 94000936
CHECKING AND TRUING WHEELS 3.7

GENERAL

Check wheels for lateral and radial runout before installing a new
tire, tube or rim seal. Checking cast or laced wheels is performed
using the same procedure.

Laced wheels having excess runout can be trued. However, cast

wheels must be replaced. Never attempt to straighten cast
wheels.

Always check condition of the wheel bearings before checking or

adjusting wheel runout. See SEALED WHEEL BEARINGS (Page
3-25).

CHECKING WHEEL RUNOUT _ _ _

PART NUMBER TOOL NAME

HD-99500-80 WHEEL TRUING STAND
Check wheels for both radial runout and lateral runout. If either
measurement is not within specification:

• Cast wheel: Replace the wheel.

• Laced wheel: Adjust spokes to true the wheel. See steps in
this section.

Checking Radial Runout

1. See Figure 3-13. Mount wheel in WHEEL TRUING STAND
(PART NUMBER: HD-99500-80).

2. Adjust gauge rod or dial indicator to the rim's tire bead safety
hump.

3. Rotate wheel and measure distance at several locations.

Runout must not exceed specification. Checking Lateral Runout
• Cast Wheels: 0.030 in (0.76 mm) 1. See Figure 3-14. Mount wheel in WHEEL TRUING STAND
• Laced Wheels: 0.050 in (1.27 mm) (PART NUMBER: HD-99500-80).
NOTE
Dial indicators are more accurate than gauge rods.

2. Place a gauge rod near, or dial indicator on the rim bead

flange.
3. Measure distance at several locations. Lateral runout must
not exceed specification.
• Cast Wheels: 0.030 in (0.76 mm)
• Laced Wheels: 0.050 in (1.27 mm)

3-21
94000936
 2. See Figure 3-16. Mount wheel in WHEEL TRUING STAND
(PART NUMBER: HD-99500-80) so hub turns freely on its
bearings.
NOTE
Disc mounting surface for primary brake side of hub has one
or two grooves.

3. Measure offset.
a. Lay a straightedge across the primary brake disc
mounting surface and one of the marked spoke groups.
b. See Figure 3-17. Measure the distance from the
straightedge to the location shown to determine distance
A. '
c. Compare to dimensions in Table 3-8.

NOTE
• Always loosen the appropriate spokes before tightening
the other two. Reversing this procedure causes the rim to
become out-of-round. For example: If the right side is
less than specification, loosen the two spokes on the
hub right side. Then tighten the two spokes attached to
the hub left side.
• Tighten or loosen spokes one flat at a time and recheck
LACED WHEEL RIM OFFSET measurement.
• Always work on groups that are opposite each other to
PART NUMBER TOOLNAME maintain radial runout.
HD-94681-80 SPOKE WRENCH
HD-99500-80 WHEEL TRUING STAND 4. If the dimension is not correct, adjust the four spokes using
SPOKE WRENCH (PART NUMBER: HD-94681-80). Turn
1. See Figure 3-15. Prepare rim.
all four spokes an equal number of turns until offset is at
a. Place a piece of tape to mark the center of each group of specification.
four spokes as shown.
5. Repeat the previous step for all groups on the wheel.
b. Mark groups directly opposite one another and 6. Check wheel runout. See True Laced Wheels (Page 3-23).
approximately 90 degrees apart.
c. Use different colors of tape or number each group.

Figure 3-16. Checking Wheel Hub Offset Dimension (Typical)

Figure 3-15. Marking Spoke Groups

3-22 94000936
 Table 3-8. Laced Wheel Offset Dimensions
MODEL SIZE WHEEL IN MM
FLHCS 16 X 3 Front 1.267-1.297 32.18-32.94
FXBBS, FXST 19 X 2.5 Front 1.258-1.288 31.95-32.72
FXBBS,FXST,FLHCS 16 X 3 Rear 1.387-1.417 35.23-35.99

Figure 3-17. Laced Wheel Hub Offset Dimensions

TRUE LACED WHEELS 4. Spin the rim slowly. Check radial runout (2). The rim must
be true within 0.030 in (0.76 mm).
FASTENER TORQUE VALUE
PARTnipple
Spoke NUMBER TOOL
55 NAME 6.2 N-m
in-lbs a. Use SPOKE WRENCH (PART NUMBER: HD-94681-80).
HD-48985 SPOKE TORQUE WRENCH b. If the rim contacts the gauge on or near a marked group
HD-94681-80 SPOKE WRENCH of spokes, loosen the spokes in the group on the
HD-99500-80 WHEEL TRUING STAND opposite side of the rim. Then tighten the spokes in the
group where the rim makes contact an equal number of
turns.
NOTE
c. If the rim contacts the gauge between two marked
• Dial indicators are more accurate than gauge rods. groups, loosen the spokes in both groups on the opposite
side of the rim. Then tighten the spoke groups on the
• Perform radial truing before lateral truing.
side of the rim that makes contact an equal number of
turns.
Adjust Radial Runout
5. When the wheel is true, start at the valve stem hole and
1. See Figure 3-18. Mount wheel in WHEEL TRUING STAND tighten any loose spoke nipples one turn at a time until they
(PART NUMBER: HD-99500-80). are snug.
2. Adjust the gauge rod (3) near to the tire bead safety hump 6. Working alternately across the wheel, use SPOKE TORQUE
(4). If using a dial indicator, place the tip on the safety bead WRENCH (PART NUMBER: HD-48985) evenly tighten all
hump. spokes to specification listed in Table 3-9.
3. Straight flange hub: Seat each spoke head in the hub flange 7. Straight flange hub: Verify that each spoke head is seated in
using a flat nose punch and mallet. the hub flange using a flat nose punch and mallet.
NOTE 8. Verify that radial runout is still within specification.
• Always loosen the appropriate spokes before tightening 9. Proceed to lateral runout.
the other two. Reversing this procedure causes the rim to
become out of round. A WARNING
• Tighten or loosen spoke. Then recheck measurement.
Spokes that are too tight can draw nipples through the rim or
Small changes in the spokes can make large changes in
distort hub flanges. Spokes that are too loose can continue to
the runout.
loosen when put in service. Either condition can adversely affect
• Always work on groups that are opposite each other to stability and handling, which could result in death or serious
maintain radial runout. injury. (00286a)

94000936 3-23
 2. Rotate the rim slowly to check lateral runout (2). If runout
exceeds 0.030 in (0.76 mm), adjust spokes:
NOTE
• Always loosen the appropriate spokes before tightening
the other two. Reversing this procedure causes the rim to
become out of round.
• Tighten or loosen spoke. Then recheck measurement.
Small changes in the spokes can make large changes in
the runout.
• Always work on groups that are opposite each other to
maintain radial runout.

3. Working in groups of four, loosen two spokes on the tight

side and tighten the two spokes on the loose side.
4. Repeat with each group until wheel is within specification.
5. Verify that all spoke nipples are tightened to the specification.
Refer to Table 3-9.
6. File or grind off ends of spokes that protrude through the
nipples to prevent puncturing tube or rim seal.

Table 3-9. Spoke Nipple Torque Specification

RIM TYPE MINIMUM TORQUE
All 55 in-lbs (6.2 N-m)
Adjust Lateral Runout
NOTE
Dial indicators are more accurate than gauge rods.

1. See Figure 3-19. Adjust the gauge rod (3) near to the rim
bead flange. If using a dial indicator, place the tip against
the bead flange.

3-24
94000936
SEALED WHEEL BEARINGS 3.8

PREPARE 2. See Figure 3-21. Assemble WHEEL BEARING

INSTALLER/REMOVER (PART NUMBER: HD-44060D).
1. Raise front or rear wheel. See Secure the Motorcycle for a. Lubricate draw down bolt or a suitable threaded rod with
Service (Page 2-2). two locking nuts.
INSPECT b. Install nut (2), washer (3) and bearing (4) on screw.
c. Insert assembly through hole in bridge (6).
1. Turn the wheel through several rotations.
d. Install ball bearing inside collet (5). Fasten collet and ball
NOTE
bearing to forcing screw (1).
• When checking end play. pull or push on the wheel not the
brake disc. Pulling or pushing brake disc can distort disc 3. Remove bearings.
causing a false end play reading.
a. See Figure 3-21. Hold end of forcing screw (1) and turn
collet (5) to expand edges of collet.
2. Check end play:
b. See Figure 3-22. Hold end of forcing screw (1) and turn
a. See Figure 3-20. Mount a magnetic base dial indicator to nut (2) to remove bearing from wheel.
the brake disc. Set the indicator contact point on the end
of the axle. c. Remove spacer from inside wheel hub.

b. Firmly push the wheel to one side. Zero the dial indicator d. Repeat on opposite side.
4. Discard all bearings.
gauge.

c. Firmly pull the wheel back. Note the reading of the dial
indicator.

d. Repeat the procedure to verify the reading.

e. Replace the bearings if end play exceeds Dimension:
0. 002 in (0.051 mm) or if there is drag, rough rotation or
abnormal noise.

Figure 3-20. Measuring Lateral End Play (Front Wheel)

(Typical)
REMOVE
PART NUMBER TOOL NAME
HD-44060D WHEEL BEARING
INSTALLER/REMOVER

1. Remove wheel. See FRONT WHEEL (Page 3-12) or REAR

WHEEL (Page 3-16).

NOTE
OE disc removal is not necessary. Place the scrap disc
directly over the OE disc mounting screws.

94000936 3-25
 NOTICE

Replace both bearing assemblies even if one assembly appears

to be good. Mismatched bearings can lead to excessive wear
and premature replacement. (00532c)

2. Install bearings.

a. Hold hex end of threaded rod (1) and turn nut (3).

b. Bearing is fully seated when nut can no longer be

turned.

c. Remove tool.

d. Install spacer sleeve inside wheel hub.

e. Reverse tool.

f. Install opposite side bearing.

3. Install wheel. See FRONT WHEEL (Page 3-12) or REAR
WHEEL (Page 3-16).

INSTALL
PARTNUMBER TOOLNAME
HD-44060D WHEEL BEARING
INSTALLER/REMOVER

NOTE
• Front wheel: Install bearing on the brake disc or left side
first.
• Rear wheel: Install bearing on the brake disc or right
side first.
• Install ABS bearing on the brake disc side of the wheel.

1. See Figure 3-23. Assemble wheel bearing installer/remover.

Special Tool: WHEEL BEARING INSTALLER/REMOVER
(HD-44060D)

a. Lubricate draw down bolt or a suitable threaded rod

with two locking nuts.

b. Insert threaded rod (1) through support plate (2).

c. Insert assembly through wheel.

d. Place new bearing on threaded rod (1).

NOTE
• Bearing orientation is important.
• Standard bearing: Lettered side against pilot (6).
• ABS bearing: Red side against wheel.

e. Install pilot (6), bearing (5), washer (4) and nut (3)
over rod.

3-26 94000936
 COMPLETE

1. Lower wheel.

1. Threaded rod
2. Support plate
3. Nut
4. Washer
5. Bearing
6. Pilot _____________________________
Figure 3-23. Installing Wheel Bearing

94000936 3-27
TIRES 3.9
GENERAL

A WARNING
Be sure tires are properly inflated, balanced, undamaged, and
have adequate tread. Inspect your tires regularly and see a
Harley-Davidson dealer for replacements. Riding with excessively
worn, unbalanced, improperly inflated, overloaded or damaged
tires can lead to tire failure and adversely affect stability and
handling, which could result in death or serious injury. (00014b)

Always maintain proper tire pressure. See INSPECT TIRES AND

WHEELS (Page 2-13). Do not load tires beyond GAWR. Refer to
tables in SPECIFICATIONS (Page 3-8). Underinflated, over-
inflated or overloaded tires can fail.

NOTE
• Check runout on wheel before installing a new tire. See
CHECKING AND TRUING WHEELS (Page 3-21).

• Store new tires on a horizontal tire rack. Storing in a

vertical stack compresses the tires and closes the beads.

• Inspect tires for punctures, cuts, breaks and wear at least

weekly

• See Figure 3-24. The tread wear indicators appear when %

in (0.8 mm) or less tread remains. Always replace tires
before tread is worn to the indicators.

Replace tire if:

• Tread is worn to the tire wear indicators.

• Tire cords or fabric are visible.
• Tire has a bump, bulge or split.
• Puncture that cannot be repaired. NOTE
Refer to INSPECT TIRES AND WHEELS (Page 2-13) for ABS models must use properly inflated tires and wheels that
recommended tires. are the same as the original equipment. The ABS monitors
rotational speed of the wheels through individual wheel
speed sensors to determine the application of ABS.
Different diameter wheels or tires can:
• Alter the rotational speed which can upset the calibration
of the ABS.
• Adversely affect its ability to detect and prevent lockups.
Operating with over- or under-inflated tires can reduce ABS
performance.
PREPARE

1. Remove wheel. See FRONT WHEEL (Page 3-12) or REAR

WHEEL (Page 3-16).

2. Check wheels for lateral and radial runout. See Checking

Wheel Runout (Page 3-21).
REMOVE _______________________________

NOTE
Take care when replacing tire to prevent cosmetic damage to
wheel.

1. Deflate tire.

3-28 94000936
2. Loosen both tire beads from rim flange. For tire pressures, refer to INSPECT TIRES AND WHEELS
(Page 2-13).
3. Remove tire.
CLEAN. INSPECT AND REPAIR_____________ NOTE
• Mount tires with arrows molded into the tire sidewall
1. Clean. pointing in the direction of forward rotation.
a. Clean the inside of tire and outer surface of tube. • If tire has a balance dot on the sidewall, align the balance
dot with the valve stem.
b. Clean rim bead area with a stiff wire brush.

2. Inspect. Tube-Type Tires

a. Verify that wheel is true. See CHECKING AND TRUING A WARNING
WHEELS (Page 3-21).
Match tires, tubes, rim strips or seals, air valves and caps to the
b. Check tire tread depth. correct wheel. Contact a Harley-Davidson dealer. Mismatching
can lead to tire damage, allow tire slippage on the wheel or cause
c. Inspect tire for punctures or tears. Small punctures can tire failure, which could result in death or serious injury. (00023c)
be repaired.
NOTE
A WARNING • For correct tire and tube types, see SPECIFICATIONS
Replace punctured or damaged tires. In some cases, small (Page 3-8).
punctures in the tread area may be repaired from within the
• When replacing a tube-type tire, replace the inner tube
removed tire by a Harley-Davidson dealer. Speed should NOT
and rim strip.
exceed 50 mph (80 km/h) for the first 24 hours after repair, and
the repaired tire should NEVER be used over 80 mph (129 km/h). • Always use a rim strip on tube-type laced wheels.
Failure to follow this warning could lead to tire failure and result in
death or serious injury. (00015b) 1. See Figure 3-25. Tube-type laced wheels:
a. Verify that no spokes protrude through nipples.
3. Repair.
b. Install a new rim strip.
a. Patch inner tubes only as an emergency measure. c. Align the valve stem hole in rim strip with valve stem hole
Replace a damaged or patched tube as soon as in rim.
possible.
d. Install new tube and tire.
b. Repair tread on tubeless tires if puncture is % in (6.4
mm) or smaller. 2. Balance wheel. See Balance (Page 3-31).

c. Make repairs from inside the tire. 3. Check tire lateral and radial runout. See Checking Wheel
Runout (Page 3-21).
d. Always combine a patch and plug when repairing tire.
4. Install wheel. See FRONT WHEEL (Page 3-12) or REAR
INSTALL WHEEL (Page 3-16).

Harley-Davidson recommends the use of its specified tires. sm02466a

FASTENER TORQUE VALUE

Valve stem nut 12-15 in-lbs 1.4—1.7 N-m Figure 3-25.
Installed Rim
A WARNING Strip
Harley-Davidson vehicles are not designed for operation with
non-specified tires, including snow, moped and other special-use
tires. Use of non-specified tires can adversely affect stability,
handling or braking and lead to loss of vehicle control, which
could result in death or serious injury. (00024d)

A WARNING
Harley-Davidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure, which
could result in death or serious injury. (00026a)

A WARNING
Do not exceed manufacturer's recommended pressure to seat
beads. Exceeding recommended bead seat pressure can cause
tire rim assembly to burst, which could result in death or serious
injury. (00282a)

94000936
3-29
Tubeless Tires: Cast Wheels
A WARNING

Only install original equipment tire valves and valve caps. A

valve, or valve and cap combination, that is too long or too
heavy can strike adjacent components and damage the
valve, causing rapid tire deflation. Rapid tire deflation can
cause loss of vehicle control, which could result in death or
serious injury. (00281a)

Replace damaged or leaking valve stems.

1. See Figure 3-26. Metal valve stem.

a. Install rubber grommet (5) on valve stem.

b. Insert valve stem into rim hole.

c. Install metal washer (4) and nut (3). Tighten. Torque:

12-15 in-lbs (1.4—1.7 N-m) Valve stem nut
2. See Figure 3-26. or Figure 3-27 Rubber valve stem.

a. Cut old valve stem to remove.

CHECK TIRE RUNOUT
NOTE
Install new 90 degree valve stem perpendicular to
wheel. Lateral Runout
NOTE
b. Install new valve stem.
• Measure runout with wheel installed on motorcycle or
c. Verify that valve stem is securely seated. using a wheel stand.
• Avoid measuring on raised letters or vents.
3. Install tire.
1. Check tire pressure.
4. Balance wheel. See Balance (Page 3-31).
2. See Figure 3-28. Spin the wheel and measure lateral runout
5. Check tire lateral and radial runout. See Checking Wheel from a fixed point to a smooth area on the tire sidewall.
Runout (Page 3-21).
3. If lateral runout exceeds 0.090 in (2.29 mm), remove tire from
rim and check rim lateral runout. See CHECKING AND
6. Install wheel. See FRONT WHEEL (Page 3-12) or REAR TRUING WHEELS (Page 3-21).
WHEEL (Page 3-16).
a. If rim runout is within specification, replace faulty tire.
b. If rim runout is not within specification, adjust spokes on
laced wheel or replace cast wheel. See CHECKING AND
TRUING WHEELS (Page 3-21).

Radial Runout
1. Check tire pressure.
2. See Figure 3-29. Spin the wheel on the axle and measure
radial runout at the tread centerline.

3-30 94000936
3. lftire runout exceeds 0.090 in (2.29 mm), remove tire from 2. Remove paper backing from the weight. Press firmly in place
rim and check rim radial runout. See CHECKING AND and hold for ten seconds.
TRUING WHEELS (Page 3-21).
a. If rim runout is within specification, replace faulty tire.
b. If rim runout is not within specification, adjust spokes on
laced wheel or replace cast wheel. See CHECKING AND
TRUING WHEELS (Page 3-21).

Figure 3-29. Checking Tire Radial Runout

BALANCE ____ __________________

Static vs Dynamic
Wheel balancing is recommended to improve handling. Balanced
wheels reduce vibration especially at high speeds.
Static balancing produces satisfactory results for normal highway
speeds. Dynamic balancing can produce better results for
deceleration.

Weights
NOTE
• If more than 3.5 oz (99.2 g) of weight is required to balance
wheel, rotate the tire 180 degrees on the rim and again
balance the assembly. Balance wheels to within 0.5 oz (14
g).
• All wheel weights currently supplied by Harley-Davidson
are made from zinc which is lighter than lead. The weight
of each zinc segment is 0.18 oz (5 g) as compared to
0. 25 oz (7 g) for lead. Weights are stamped for easy
identification.
• If adding more than 1.5 oz (43 g) of weight at one
location, divide the amount to apply half to each side of
rim.
• On cast wheels without a flat area near the bead, place
the weights cross-wise through the opening.

1. See Figure 3-31. Place weights on a smooth surface of the

wheel rim such that centrifugal force keeps them in place.
Make sure that the area of application is clean, dry and free
of oil and grease.
NOTE
See Figure 3-30. When installing wheel weights, consider
cosmetics. Snaking (1) is not to exceed 0.040 in (1.02 mm) (2)
of straight. The angle alignment of individual segments is
not to exceed three degrees (3).

94000936 3-31
Figure 3-31. Wheel Weight Placement
1. Laced steel 3. Cast (special with no flat bead area)
2. Cast (typical with flat bead area)
COMPLETE

1. Install wheel. See FRONT WHEEL (Page 3-12) or REAR

WHEEL (Page 3-16).

3-32 94000936
WHEEL ALIGNMENT 3.10
PREPARE d. Record measurement.

1. Remove mufflers as necessary. See MUFFLERS (Page 6- 3. Measure Right side: Measure distance between rear fork flat
34). and rear axle alignment tool center.

INSPECT ___________ _____ _ a. See Figure 3-34. Place end of alignment tool (1)
against rear fork flat (2).
PART NUMBER TOOL NAME
HD-48856-B AXLE ALIGNMENT PLUGS b. If necessary, slide rubber grommet (3) along tool shaft
until it aligns with hole in center of rear axle alignment
A WARNING
tool (4).
Only a Harley-Davidson dealer should perform vehicle alignment.
Improper alignment can adversely affect stability and handling,
which could result in death or serious injury. (00060a)

A WARNING

Check vehicle alignment according to following procedures.

Incorrect alignment can adversely affect stability and handling,
which could result in death or serious injury. (00287a)

1. Install rear axle alignment components to rear axle.

Special Tool: AXLE ALIGNMENT PLUGS (HD-48856-B)

a. See Figure 3-33. Insert alignment plug (2) into left end
of rear axle. Turn handle until plug is firmly held in
axle.

b. See Figure 3-34. Install rear axle alignment tool (4)

onto right end of rear axle over the e-clip.

Measure: Rear Fork Flat

NOTE
This method should be used prior to disassembly if
alignment and belt tension are good.
Figure 3-32. Wheel Alignment Tool
1. See Figure 3-32. Fabricate an alignment tool.

a. Cut a piece of 0.13 in (3.175 mm) diameter aluminum

welding rod approximately 6 in (153 mm) long.

b. Bend rod at a 90 degree angle, 3 in (76 mm) (3) from

the flat end.

c. Place a snug-fitting rubber grommet (2) on rod.

2. Measure left side: Measure distance between rear fork

flat and rear axle alignment plug center.

a. See Figure 3-33. Place end of alignment tool (1)

against rear fork flat (4).

b. Slide rubber grommet (3) along tool shaft until it aligns

with hole in center of rear axle alignment plug (2).

c. Without moving grommet, position alignment tool on

other side of rear fork.

94000936 3-33
 1. Loosen rear axle nut. See REAR WHEEL (Page 3-16).
2. See Figure 3-36. Adjust rear axle.
a. Turn axle adjuster screw counterclockwise to shorten
distance on the side with the longer distance.

b. If measured from rear fork flats: Adjust axle until left

and right side alignment measurements match any
difference from left or right side previously recorded.
c. If measured from rear fork pivot shaft: Adjust axle until
measurements on left and right side are equal.

NOTE
• Keep axle adjuster mechanisms firmly seated (under
tension) on each side of rear fork during wheel
alignment.
• Do not tighten rear axle nut until after checking drive belt
tracking and tension.
Figure 3-34. Rear Axle Alignment: Right Side
3. Verify drive belt deflection. See INSPECT AND ADJUST
Measure: Rear Fork Pivot Shaft DRIVE BELT AND SPROCKETS (Page 2-31).
NOTE 4. Verify drive belt tracking properly.
This method should be used if measurement not taken prior A WARNING
to disassembly.
Do not exceed specified torque when tightening axle nut.
Exceeding torque can cause wheel bearings to seize during
1. See Figure 3-35. Place a steel rod through rear fork pivot
vehicle operation, which could result in death or serious
shaft.
injury. (00408e)
5/16 in (8 mm)
5. Tighten rear axle nut. See Adjust Belt (Page 2-33).
2. Measure the distance between the center of the steel rod
6. Verify alignment. See Inspect (Page 3-33).
and the axle alignment tools.

a. Using this method, the left and right side

measurements should be equal.

3. Adjust if necessary.

Figure 3-35. Rear Fork Pivot Shaft Alignment Rod

ADJUST COMPLETE
1. If removed, install muffler. See MUFFLERS (Page 6-34).

NOTE
Do not remove E-clip when loosening rear axle nut.

3-34 94000936
FRONT BRAKE MASTER CYLINDER 3.11
PREPARE ______________________________ NOTICE Avoid leakage. Be sure
gaskets, banjo bolt(s),
brake line and master cylinder bore are clean and
1. Remove right mirror. See MIRRORS (Page 3-112).
undamaged before assembly. (00322a)

2. Drain brake fluid from front brake system. See BLEED

BRAKES (Page 3-61). 1. Remove brake line.

REMOVE a. Remove banjo bolt and two gasket washers.

b. Discard gasket washers.

NOTICE
DOT 4 brake fluid will damage painted and body panel
c. Remove brake line.
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is See Figure 3-37. Remove screws (17), washers (16),
performed. Failure to comply can result in cosmetic handlebar clamp (15) and master cylinder.
damage. (00239c)
NOTICE 3. Remove master cylinder.

Do not allow dirt or debris to enter the master cylinder

reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)

352749

[Z]

1. Screws (2) 10. Dust boot

2. Cover 11. Retaining ring
3. Gasket 12. Piston
4. Pivot pin 13. Secondary cup
5. Bushing 14. Spring
6. Brake hand lever 15. Handlebar clamp
7. Retaining ring 16. Washer (2)
8. Master cylinder reservoir 17. Screw (2)
9. Primary cup
Figure 3-37. Front Brake master Cylinder

94000936 3-35
INSTALL DISASSEMBLE
FASTENER TORQUE VALUE
Front brake master cylinder 24-25 ft-lbs 32-34 N-m 3. Remove dust boot (10) and discard.
banjo bolt - Dual disk front
brake 4. Remove retaining ring (11).
Front brake master cylinder 21-23 ft-lbs 29-31 N-m
banjo bolt - Single disk front 5. Remove and discard piston assembly (9, 12-14).
brake
Handlebar switch clamp screw 60-80 in-lbs 6.8-9 N-m 6. Remove screws (1), cover (2) and gasket (3).

1. See Figure 3-38. Position the brake lever/master cylinder CLEAN ANDJNSPECT
assembly inboard of the switch housing assembly, engaging
the tab (2) on the lower switch housing (1) in the groove (3) Use denatured alcohol to clean brake system components. Do
at the top of the brake lever bracket (4). not use mineral-based solvents (such as gasoline or paint
thinner), which will deteriorate rubber parts even after assembly.
2. Secure the handlebar clamp to master cylinder with two Deterioration of these components can cause brake failure, which
screws (with flat washers). Position hand lever and controls
for rider comfort. Beginning with the top screw, tighten.
CONSUMABLE PART NUMBER
Torque: 60-80 in-lbs (6.8-9 N-m) Handlebar switch clamp
DOT 4 BRAKE 41800219
screw
FLUID
NOTE
A WARNING
See RIGHT HAND CONTROL MODULE (RHCM) (Page 7-20)
could result in death or serious injury. (00291a)
For proper positioning of hand lever.
A WARNING
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and
NOTICE Compressed air can pierce the skin and flying debris from
caliper bore are clean and undamaged before assembly. compressed air could cause serious eye injury. Wear safety
(00321a) glasses when working with compressed air. Never use your hand
to check for air leaks or to determine air flow rates. (00061a)

3. Attach brake line to master cylinder with banjo bolt and new
1. Clean all parts with denatured alcohol or brake fluid.
gasket washers. Tighten.
Torque: 21-23 ft-lbs (29-31 N-m) Front brake master Consumable: DOT 4 BRAKE FLUID (41800219)
cylinder banjo bolt - Single disk front brake Torque: 24- a. Wipe parts dry with a clean, lint-free cloth.
25 ft-lbs (32-34 N-m) Front brake master cylinder banjo
bolt - Dual disk front brake b. Clear drilled passages and bore with clean
compressed air.

2. NOTE
Do not use a wire or similar instrument to clean drilled
passages in bottom of reservoir.

Inspect parts for wear or damage. Replace parts if

necessary.

3. Inspect the piston bore in the master cylinder housing for

scoring, pitting or corrosion. Replace as necessary.

4. Carefully inspect the outlet port that mates with the brake line
fitting. As a critical sealing surface, replace the master
cylinder assembly if any damage is noted.

5. Carefully inspect the cover gasket for damage. Replace as

necessary.

Figure 3-38. Attach Master Cylinder to Right Handlebar Switches

1. See Figure 3-37. Remove retaining ring (7) from pivot pin
groove at bottom of master cylinder bracket.

2. Remove pivot pin (4) and brake hand lever (6).

3-36 94000936
ASSEMBLE 4. Install new dust boot (10). Press large end against retaining
ring. Small end should fit into groove on shaft.
CONSUMABLE PART NUMBER
5. Install gasket (3), cover (2) and screws (1). Leave fasteners
CCI #20 BRAKE 42830-05
loose.
GREASE
1. NOTE 6. Coat front brake lever pin pivot hole and on the end of piston
• Always reassemble the master cylinder using new that contacts brake lever with grease (supplied in kit).
parts from the correct repair kit.
Consumable: CCI #20 BRAKE GREASE (42830-05)
• Use CCI #20 BRAKE GREASE (42830-05), included in
kit, to lubricate cylinder bore, cups and seals before 7. Assemble brake hand lever (6) with pivot pin (4) to master
assembly. cylinder reservoir (8).

See Figure 3-37. Coat piston bore of master cylinder A WARNING

reservoir (8), piston (12), primary cup (9) and secondary cup Wear safety glasses or goggles when removing or installing
(13) with grease (supplied in kit). retaining rings. Retaining rings can slip from the pliers and
Consumable: CCI #20 BRAKE GREASE (42830-05) could be propelled with enough force to cause serious eye
injury. (00312a)
2. Install piston assembly into piston bore of master cylinder
reservoir. 8. Install new retaining ring (7).

a. Press small end of spring (14) onto piston (12).

COMPLETE
b. Install piston/spring assembly into master cylinder
reservoir (8) bore. 1. Fill and bleed front brake system. See BLEED BRAKES
(Page 3-61).
3. Press in on piston (12). Install new retaining ring (11).

2. Install right mirror. See MIRRORS (Page 3-112).

94000936
3-37
 3.12
FRONT BRAKE CALIPER
PREPARE
b. Remove and discard gasket washers (5).

1. Caliper service only: Drain brake fluid from front brake system. 3. Loosen bridge bolts (7).
See BLEED BRAKES (Page 3-61).
4. Remove mounting bolts (2). Slide caliper rearward, and
REMOVE remove front brake caliper.

A WARNING
Contact with DOT 4 brake fluid can have serious health effects.
Failure to wear proper skin and eye protection could result in
death or serious injury.

• If inhaled: Keep calm, remove to fresh air, seek medical

attention.

• If on skin: Remove contaminated clothing. Rinse skin

immediately with plenty of water for 15-20 minutes. If irritation
develops, seek medical attention.

• If in eyes: Wash affected eyes for at least 15 minutes under

running water with eye lids held open. If irritation develops,
seek medical attention.
1. WSS harness retainer - ABS only
• If swallowed: Rinse mouth and then drink plenty of water. Do 2. Caliper mounting bolt (2)
not induce vomiting. Contact Poison Control. Immediate 3. Front brake line
medical attention required. 4. Banjo bolt
5. Gasket washer (2)
• See Safety Data Sheet (SDS) for more details available at 6. Brake pad hanger pin (2)
sds.harley-davidson.com 7. Bridge bolt (4)
Figure 3-39. Front Brake Caliper: (Typical)
(00240e)
INSTALL
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and Install Caliper After Service
caliper bore are clean and undamaged before assembly. (00321
a) FASTENER TORQUE VALUE

NOTICE Front brake caliper banjo bolt 14-18 ft-lbs 19-24.4 N-m
Front brake caliper bridge bolt 14-18 ft-lbs 19.6-24.5 N-m
DOT 4 brake fluid will damage painted and body panel surfaces it
Front brake caliper mounting 28-38 ft-lbs 38-51.5 N-m
comes in contact with. Always use caution and protect surfaces
from spills whenever brake work is performed. Failure to comply bolts
can result in cosmetic damage. (00239c) Front brake caliper pad hanger 11-14 ft-lbs 14.7-19.6 N-m
pin

Remove Caliper to Remove Front Wheel CONSUMABLE PART NUMBER

DOT 4 BRAKE 41800219
1. See Figure 3-39. Remove mounting bolts (2). Slide caliper
rearward, and position out-of-way. FLUID
1. NOTE
ABS Models: Install WSS harness retainer (1) when
Remove Caliper to Remove Front Brake Pads
installing caliper to front fork.
1. See Figure 3-39. Loosen brake pad hanger pins (6).
See Figure 3-39. Install caliper.
2. Remove mounting bolts (2). Slide caliper rearward, and
position out-of-way. a. Slide caliper forward, guiding the brake pads around
brake rotor.
Remove Caliper for Service
b. Align the caliper with the mounting bolt holes.
1. See Figure 3-39. Loosen brake pad hanger pins (6).
2. Install mounting bolts (2). Tighten.
2. Remove banjo bolt (4). Torque: 28-38 ft-lbs (38-51.5 N-m) Front brake caliper
mounting bolts
a. Remove banjo bolt.

3-38 94000936
3. Install banjo bolt (4). NOTE
Avoid making hard stops for the first 100 mi (160 km). This
a. Lubricate new gasket washers (3) with brake fluid. allows the new pads to become conditioned to the brake
discs.
DOT 4 BRAKE FLUID (41800219)
DISASSEMBLE
NOTICE

Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and 1. Remove one brake pad. See INSPECT BRAKES (Page 2-
master cylinder bore are clean and undamaged before 17).
assembly. (00322a)
2. Verify that remaining brake pad is installed with brake pad
b. Install banjo bolt, new gasket washers (1) and front pins.
brake line (3). Tighten.
Torque: 14-18 ft-lbs (19-24.4 N-m) Front brake 3. Verify that bleeder screw is installed.
caliper banjo bolt NOTE
Do not damage banjo bolt sealing surface or threads of
4. Tighten bridge bolts (7).
banjo bolt hole in brake caliper. Use an air nozzle with a
Torque: 14-18 ft-lbs (19.6-24.5 N-m) Front brake caliper rubber tip.
bridge bolt
A WARNING
5. Tighten brake pad hanger pin (6).
Compressed air can pierce the skin and flying debris from
Torque: 11-14 ft-lbs (14.7-19.6 N-m) Front brake caliper compressed air could cause serious eye injury. Wear safety
pad hanger pin glasses when working with compressed air. Never use your
hand to check for air leaks or to determine air flow rates.
Install Caliper After Installing Front Brake Pads (00061a)

1. NOTE A CAUTION
ABS Models: Install WSS harness retainer (1) when
When removing piston with compressed air, piston can
installing caliper to front fork.
develop considerable force and fly out of caliper bore. Keep
See Figure 3-39. Install caliper. hands away from piston to avoid possible injury. (00530b)

a. Slide caliper forward, guiding the brake pads around 4. Gently apply low pressure compressed air to banjo bolt hole
brake rotor. to force pistons from caliper bores.

b. Align the caliper with the mounting bolt holes. 5. Remove brake pad pins and brake pad.

2. Install mounting bolts (2). Tighten. 6. See Figure 3-40. Remove bridge bolts (11, 12) and separate
caliper housings.
Torque: 28-38 ft-lbs (38-51.5 N-m) Front brake caliper
mounting bolts
7. Remove pistons from each housing by hand. If necessary,
3. Tighten brake pad hanger pin (6). wiggle pistons gently to remove.

Torque: 11-14 ft-lbs (14.7-19.6 N-m) Front brake caliper NOTE

pad hanger pin Damaged piston bores leak when reassembled. Do not
use metal objects to remove or install objects from
Install Caliper After Installing Front Wheel piston bores. Prevent damage to pistons, seals and
bores by only using a wooden toothpick when servicing
1. NOTE calipers.
ABS Models: Install WSS harness retainer (1) when
installing caliper to front fork. 8. Using a wooden toothpick, remove dust seals (5, 9) and
piston seals (4,10) from each caliper bore. Discard seals.
See Figure 3-39. Install caliper.
9. If necessary, remove bleeder screw (1).
a. Slide caliper forward, guiding the brake pads around
brake rotor.

b. Align the caliper with the mounting bolt holes.

2. Install mounting bolts (2). Tighten.

Torque: 28-38 ft-lbs (38-51.5 N-m) Front brake caliper

mounting bolts

3. ABS models: Verify WSS wire harness clips are in place.

94000936
3-39
 352696

1. Bleeder screw Bleeder 7. Cross-over seal

2. screw cap Outer caliper 8. 32 mm piston (2)
3. housing 34 mm seal (2) 9. 32 mm dust seal (2)
4. 34 mm dust seal (2) 34 10. 32 mm seal (2)
5. mm piston (2) 11. Short bridge bolt (2)
6. 12. Long bridge bolt (2)
Figure 3^0. Front Caliper
CLEAN AND INSPECT 3. Carefully inspect all components. Replace as
necessary.

CONSUMABLE PART NUMBER a. Check pistons for pitting, scratches or corrosion

DOT4 BRAKE 41800219 on outside surfaces.
FLUID
b. Inspect piston bores. Do not hone bores. Replace
A WARNING
as necessary.
Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or NOTE
paint thinner), which will deteriorate rubber parts even after The pad pins are manufactured with a relief near
assembly. Deterioration of these components can cause the center of their length, where the pad spring
brake failure, which could result in death or serious injury. touches.
(00291a) Do not use this area as a measurement point to determine
pad pin wear.
1. Clean all rubber parts with brake fluid. Do not contaminate
with mineral oil or other solvents. Clean all metal parts c. Inspect pad pin for grooving and wear at the pad
with denatured alcohol. Wipe parts dry with a clean, lint- contact points. Measure the pad pin diameter in an
free cloth. unworn area and in an area of any grooving or
wear. If wear exceeds 0.011 in (0.28 mm), replace
Consumable: DOT 4 BRAKE FLUID (41800219) pad pin.

A WARNING d. Inspect pad spring for wear or cracks. Replace if

necessary.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear safety
e. Always replace all seals after disassembly.
glasses when working with compressed air. Never use your
hand to check for air leaks or to determine air flow rates. A WARNING
(00061a)
Always replace brake pads in complete sets for correct and
safe brake operation. Improper brake operation could result
in death or serious injury. (00111a)

2. Blow out drilled passages and piston bore with low 4. Inspect brake pads and brake disc. Replace if
pressure compressed air from a clean air supply. Do necessary.
not use a wire or similar instrument to clean drilled
passages. a. Specifications: content: See INSPECT BRAKES (Page

3-40 94000936
 See Figure 3-40. Install a new piston seal (4, 10) and a
new dust seal (5, 9) into each piston bore.

2-17).

94000936 3-41
 b. Brake Disc: See FRONT WHEEL (Page 3-12). 2.

ASSEMBLE
3. Carefully insert pistons (6, 8) by hand, nose radius first, into
FASTENER TORQUE VALUE caliper bores. If installation shows resistance, remove
Brake caliper, front, bridge bolt 14-18 ft-lbs 19.6-24.5 N-m pistons. Check that seals are properly installed and fully
seated in grooves. Press pistons completely into bores.
Front brake caliper bleeder 35-61 in-lbs 3.9-6.9 N-m
screw
4. Install new cross-over seal (7).
CONSUMABLE PART NUMBER
5. Install bridge bolts (11, 12).
G40M BRAKE 42820-04
GREASE
a. Apply a drop of threadlocker to the threads of the
LOCTITE 569 Loctite 569 bridge bolts.
BROWN THREAD
SEALANT LOCTITE 569 BROWN THREAD SEALANT (Loctite
1. Lubricate the following parts using a light coat of grease. 569)
All other surfaces must be dry. b. Assemble caliper housings.
Consumable: G40M BRAKE GREASE (42820-04)
c. Install bridge bolts. Tighten.
a. Nose radius of pistons.
Torque: 14-18 ft-lbs (19.6-24.5 N-m) Brake caliper,
NOTE front, bridge bolt
• Damaged piston bores leak when reassembled.
6. Install bleeder screw on caliper housing if removed. Tighten.
Do not use metal objects to remove or install
objects in piston bores. Prevent damage to Torque: 35-61 in-lbs (3.9-6.9 N-m) Front brake caliper
bores by only using a wooden toothpick when bleeder screw
servicing calipers.
• Pistons and bores differ slightly in diameter: one COMPLETE
large and one small in each housing.
1. If drained: Fill and bleed front brake system. See BLEED
b. All surfaces of piston seals and dust seals. BRAKES (Page 3-61).

3-42 94000936
REAR BRAKE MASTER CYLINDER 3.13
See Figure 3-40. Install a new piston seal (4, 10) and a
new dust seal (5, 9) into each piston bore.
PREPARE

1. Drain brake fluid from rear brake system. See BLEED

BRAKES (Page 3-61).

2. If needed: Remove right footboard/footpeg bracket. See

RIGHT FOOT CONTROLS (Page 3-133).

REMOVE

2. Remove clevis pin.

1. See Figure 3-41. Remove cotter circle (1 ).

Figure 3-42. Rear Master Cylinder - Front View: (exhaust

remove for clarity)

5. Remove rear master cylinder bracket.

a. See Figure 3-43. Remove screw (3).

b. Remove rear master cylinder bracket.

3. See Figure 3-42. Remove banjo bolt (2) and two gasket
Figure 3-41. Rear Master Cylinder - Rear View: (exhaust
remove for clarity)
washers (1) to disconnect fitting of hydraulic brake line from
master cylinder. Discard washers.

4. Remove screws (4).

INSTALL

FASTENER TORQUE VALUE

Brake master cylinder, rear, 18-22 ft-lbs 24.4-29.9 N-m

mounting screws
Master cylinder bracket to 30-40 ft-lbs 40.7-54.2 N-m
frame screw
Master cylinder, rear, banjo bolt 14-18 ft-lbs 19-24.4 N-m

1. NOTE
Verify that the brake pedal link is between the master
cylinder yoke when placing the master cylinder into
place.

94000936 3-43
 Install rear master cylinder onto rear master cylinder Disassemble
e. Remove retaining ring (14) and pushrod assembly
bracket. Hand tighten. (13, 12 and 11).

2. See Figure 3-41. Install clevis pin. f. Remove piston assembly (9 and 10).

g. Remove spring (7) and primary cup (8).

3. Install cotter circle.
3. Discard piston set.
4. Position rear master assembly into place on frame.

5. See Figure 3-43. Install screw. Tighten.

Torque: 30-40 ft-lbs (40.7-54.2 N-m) Master cylinder
bracket to frame screw

6. See Figure 3-42. Install screws (4). Tighten.

Torque: 18-22 ft-lbs (24.4-29.9 N-m) Brake master

cylinder, rear, mounting screws

NOTICE

Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and

caliper bore are clean and undamaged before assembly.
(00321a)

7. Attach brake line (3) to master cylinder with banjo bolt (2)
and new gasket washers (1). Tighten.
Torque: 14-18 ft-lbs (19-24.4 N-m) Master cylinder, rear,
banjo bolt

DISASSEMBLE AND ASSEMBLE: MASTER

CYLINDER _____________________________
FASTENER TORQUE VALUE
Master brake cylinder yoke 11-14 ft-lbs 14.7-19.6 N-m

CONSUMABLE PART NUMBER

G40M BRAKE 42820-04
GREASE
CCI #20 BRAKE 42830-05
GREASE
1. NOTE
Install a new rebuild kit when unit is reassembled.

See Figure 3-44. Remove cover.

a. Remove cover screws (3).

b. Remove cover (5).

c. Remove reservoir gasket (2).

2. Remove piston set (1).

a. Hold nut (18). Remove yoke (20).

b. Remove return spring boot (19).

A WARNING

Wear safety glasses or goggles when removing or installing

retaining rings. Retaining rings can slip from the pliers and could
be propelled with enough force to cause serious eye injury.
(00312a)

c. Remove nut (18), spring retainer (17) and return

spring (16).

d. Remove boot (15).

94000936 3-44
 1095057

1. Piston set 11. Push rod

2. Reservoir gasket 12. Stop plate
3. Cover screw (2) 13. Boot collar
4. Decal 14. Retaining ring
5. Cover 15. Boot
6. Screw (2) 16. External return spring
7. Spring 17. Spring retainer
8. Primary cup 18. Nut
9. Piston 19. Return spring boot
10. Secondary cup 20. Yoke

Figure 3-44. Rear Master Cylinder Assembly

Clean and Inspect 4. Inspect the reservoir cover gasket for cuts, tears or general
deterioration.
A WARNING
Use denatured alcohol to clean brake system components. Do Assemble
not use mineral-based solvents (such as gasoline or paint
thinner), which will deteriorate rubber parts even after assembly. 1. NOTE
Deterioration of these components can cause brake failure, When assembling rear brake master cylinder, always use
new parts from the service parts kit
which could result in death or serious injury. (00291a)

See Figure 3-44. Install new piston set (1).

1. NOTE
Do not use wire or similar tool to clean drilled passages.
a. Apply grease to cylinder bore, piston (9) and cups (8
and 10).
Clean all metal parts, except the cartridge body assembly,
and blow dry with compressed air. Clean all rubber parts CCI #20 BRAKE GREASE (42830-05)
using denatured alcohol.
b. Install primary cup (8) on small end of spring (7).
2. Inspect the cylinder bore for scratches. Replace the master c. Insert large end of spring first. Install spring and cup
cylinder assembly if scratches are present. into cylinder bore.

3. Inspect O-ring grooves on the cartridge body for dirt. d. Insert flat end of piston first. Install piston and cup into
Carefully clean O-ring grooves using a soft cotton cloth cylinder bore.
moistened with alcohol and allow to dry. Inspect O-ring
grooves for scratches. Replace cartridge body if grooves are e. Lightly apply grease to ball end of the pushrod
scratched. assembly.

3-45 94000936
 G40M BRAKE GREASE (42820-04) n. Hold nut and install yoke (20). Tighten.
f. Install ball end of pushrod into cupped end of piston. Torque: 11-14 ft-lbs (14.7-19.6 N-m) Master brake
cylinder yoke
g. Compress piston with pushrod.
sm07934

A WARNING COM
PLE
Wear safety glasses or goggles when removing or installing
retaining rings. Retaining rings can slip from the pliers and
TE
could be propelled with enough force to cause serious eye
injury. (00312a) 1. If
remov
h. Install retaining ring (14). Verify that retaining ring is ed:
completely seated in groove. Install
right
i. Install boot (15) over pushrod and into end of master Figure 3-45. 1.92 in (48.8 mm) footbo
cylinder bore. Press lip of inner boot down around ard/foo
groove in boot collar (13). tpeg bracket. See RIGHT FOOT CONTROLS (Page 3-133).

j. Install external return spring (16). 2. Fill and bleed rear brake system. See BLEED BRAKES
(Page 3-61).
k. Compress return spring and Install spring retainer
(17) and nut (18).

l. See Figure 3-45. Tighten nut to 1.9 in (48.8 mm) from

face of master cylinder to end of hex nut.

m. See Figure 3-44. Install return spring boot (19).

Position boot taps at 3 o'clock and 9 o'clock position
when master cylinder body is held upright.

94000936 3-46
REAR BRAKE CALIPER 3.14

PREPARE _________________ 2. Remove caliper.

1. If necessary: Remove muffler. See EXHAUST SYSTEM a. Slide caliper forward to clear rear brake rotor, and
(Page 6-36). position to remove rear brake pads.

2. Caliper service only: Drain brake fluid from rear brake Removing Caliper for Service
system. See BLEED BRAKES (Page 3-61).
1. Loosen the brake pad hanger pins (7).
REMOVE
2. Remove banjo bolt (2).

A WARNING
a. Remove banjo bolt.
Contact with DOT 4 brake fluid can have serious health b. Remove and discard gasket washers (1).
effects. Failure to wear proper skin and eye protection
could result in death or serious injury. 3. Remove caliper.
• If inhaled: Keep calm, remove to fresh air, seek medical
attention. a. Slide caliper forward to clear rear brake rotor, and remove
rear brake caliper.
• If on skin: Remove contaminated clothing. Rinse skin 1. Gasket washer (2)
immediately with plenty of water for 15-20 minutes. If irritation 2. Banjo bolt
develops, seek medical attention. 3. Rear brake line
• If in eyes: Wash affected eyes for at least 15 minutes under 4. WSS harness - ABS only
5. Slider bolt
running water with eye lids held open. If irritation develops,
6. Sleeve screw
seek medical attention.
7. Brake pad hanger pin (2)
• If swallowed: Rinse mouth and then drink plenty of water. Do Figure 3-46. Rear Caliper
not induce vomiting. Contact Poison Control. Immediate
medical attention required.
Remove Rear Caliper Mounting Bracket
• See Safety Data Sheet (SDS) for more details available at
sds.harley-davidson.com

(00240e)
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it 1. Remove rear wheel. See REAR WHEEL (Page 3-16).
comes in contact with. Always use caution and protect surfaces
from spills whenever brake work is performed. Failure to comply 2. Remove rear caliper mounting bracket. a.
can result in cosmetic damage. (00239c)

NOTE Inspect for damage or worn parts.

IfDOT4 brake fluid contacts painted surfaces, /MMEDIATELY INSTALL ____________________

flush area with clear water.

1. See Figure 3-46. Remove slider bolt (5) and sleeve screw (6).

a. Clean threads of sleeve screw.

Removing Caliper to Remove Rear Wheel

1. Remove caliper.

a. Slide caliper forward to clear rear brake rotor, and

position out-of-way.
PART NUMBER TOOL NAME
HD-52351 12MM TORQUE ADAPTER
Removing Caliper to Removing Rear Brake
Pads FASTENER TORQUE VALUE
1. Loosen the brake pad hanger pins (7). Rear brake caliper banjo bolt 21-23 ft-lbs 29-31 N-m
Rear brake caliper pad hanger 11-14 ft-lbs 14.7-19.6Nm
pin
Rear caliper sleeve screw 15-18 ft-lbs 20.5-24.4 Nm

94000936 3-47
 FASTENER TORQUE VALUE c. Align the caliper with the slider bolt hole and sleeve
Rear caliper slider bolt 15-18 ft-lbs 20.3-24.4 N-m screw hole.

CONSUMABLE PART NUMBER d. Install slider bolt (5) and sleeve screw (6). Hand
tighten.
LOCTITE 242 Loctite 242
MEDIUM
2. Tighten brake pad hanger pins (7).
STRENGTH
THREADLOCKER Torque: 11-14 ft-lbs (14.7-19.6 N-m) Rear brake caliper
ADHESIVE (BLUE) pad hanger pin

Install Rear Caliper Mounting Bracket Installing Caliper from Remove Rear Wheel
1. Position rear caliper mounting bracket on rear wheel. 1. See Figure 3-46. Install caliper

2. Install rear wheel. See REAR WHEEL (Page 3-16). a. Position caliper on mounting bracket in front of brake
rotor.
Installing Caliper from Service
b. Slide caliper rearward, guiding the brake pads around
1. See Figure 3-46. Install caliper brake rotor.
NOTE
a. Position caliper on mounting bracket in front of brake
rotor. Verify the WSS harness (4) is routed under the
caliper mounting bracket.
b. Slide caliper rearward, guiding the brake pads around
brake rotor. c. Align the caliper with the slider bolt hole and sleeve
screw hole.
NOTE
Verify the WSS harness (4) is routed under the caliper
d. Install slider bolt (5) and sleeve screw (6). Hand
mounting bracket.
tighten.

c. Align the caliper with the slider bolt hole and sleeve
screw hole. Install All
d. Apply threadlocker to sleeve screw. Install slider bolt 1. See Figure 3-47. Using torque adapter.
(5) and sleeve screw (6). Hand tighten. Special Tool: 12MM TORQUE ADAPTER (HD-52351)
LOCTITE 242 MEDIUM STRENGTH a. Tighten sleeve screw (4).
THREADLOCKER ADHESIVE (BLUE) (Loctite 242) Torque: 15-18 ft-lbs (20.3-24.4 N-m) Rear caliper
sleeve screw
2. Install banjo bolt (2).
b. Tighten slider bolt (3).
a. Install banjo bolt, new gasket washers (1) and rear Torque: 15-18 ft-lbs (20.3-24.4 N-m) Rear caliper
brake line (3). Tighten. slider bolt
Torque: 21-23 ft-lbs (29-31 N-m) Rear brake caliper
banjo bolt

3. Tighten brake pad hanger pins (7).

Torque: 11-14 ft-lbs (14.7-19.6 N-m) Rear brake caliper
pad hanger pin

Installing Caliper from Removing Rear Brake

Pads
1. See Figure 3-46. Install caliper

a. Position caliper on mounting bracket in front of brake

rotor.

b. Slide caliper rearward, guiding the brake pads around

brake rotor.

NOTE
Verify the WSS harness (4) is routed under the caliper
mounting bracket. Figure 3-47. 12mm Torque Adapter (HD-52351)

3-48 94000936
 PART NUMBER TOOLNAME
HD-48648 REAR BRAKE PISTION REMOVAL TOOL

DISASSEMBLE

Caliper
1. Remove rear brake pads. See INSPECT BRAKES (Page 2-
17).

A WARNING
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear safety
glasses when working with compressed air. Never use your
hand to check for air leaks or to determine air flow rates.
(00061a) 3. See Figure 3-49. Remove seals and discard.

2. See Figure 3-49. Removal pistons (1 ). a. Remove dust seal (2).

a. Place caliper on working bench. b. Remove piston seal (3).

b. Remove brake pad retaining spring (10). 4. Remove brake caliper sleeve (8).

c. See Figure 3-48. Using low pressure compressed air 5. Remove brake caliper sleeve boot (9).
and removal tool, remove pistons and discard.

Special Tool: REAR BRAKE PISTION REMOVAL 6. Remove bleeder screw cap (5).
TOOL (HD-48648)
7. Remove bleeder screw (4).

8. Remove medallion (7).

1. Piston (2) 6. Brake caliper body
2. Dust seal (2)
1098738 7. Medallion
3. Piston seal (2) 8. Brake caliper sleeve
4. Bleeder screw 9. Brake caliper sleeve boot
5. Bleeder screw cap 10. Brake pad retaining spring

Figure 3-49. Rear Brake Caliper Assembly

3-49 94000936
Rear Caliper Mounting Bracket 3. Carefully inspect all components. Replace as necessary.
3. Install bleeder screw cap (5). e. Install brake pad retaining spring (10).

1. See Figure 3-50. Remove slider pin (5). a. Check pistons for pitting, scratches or corrosion
on outside surfaces.
2. Remove slider pin dust cover (4).
3. Remove caliper damper (3). b. Inspect piston bores. Do not hone bores. Replace
as necessary.
NOTE
The pad pins are manufactured with a relief near the center
of their length, where the pad spring touches.
Do not use this area as a measurement point to determine
pad pin wear.

c. Inspect pad pin for grooving and wear at the pad

contact points. Measure the pad pin diameter in
an unworn area and in an area of any grooving or
wear. If wear exceeds 0.011 in (0.28 mm), replace
pad pin.

d. Inspect pad spring for wear or cracks. Replace if

necessary.

e. Always replace all seals after disassembly.

A WARNING

Figure 3-50. Rear Caliper Mounting Bracket Always replace brake pads in complete sets for correct and
CLEAN AND INSPECT safe brake operation. Improper brake operation could result
in death or serious injury. (00111a)
Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even after 4. Inspect brake pads and brake disc. Replace if
necessary.
CONSUMABLE PART NUMBER
DOT 4 BRAKE 41800219
a. Specifications: content: See INSPECT BRAKES
FLUID (Page 2-17).
A WARNING
assembly. Deterioration of these components can cause
brake failure, which could result in death or serious injury.
(00291a) CONSUMABLE PART NUMBER
DOT 4 BRAKE 41800219
1. Clean all rubber parts with brake fluid. Do not FLUID
contaminate with mineral oil or other solvents. Clean all G40M BRAKE 42820-04
metal parts with denatured alcohol. Wipe parts dry with GREASE
a clean, lint-free cloth. CCI #20 BRAKE 42830-05
GREASE
Consumable: DOT 4 BRAKE FLUID (41800219)
b. Brake Disc: See REAR WHEEL (Page 3-16).
A WARNING
ASSEMBLE ___________
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear safety Rear Caliper Mounting Bracket
glasses when working with compressed air. Never use your
hand to check for air leaks or to determine air flow rates. 1. See Figure 3-50. Install caliper damper (3).
(00061a)
2. Apply grease to the inside of slider pin dust cover (4).
2. Blow out drilled passages and piston bore with low Consumable: G40M BRAKE GREASE (42820-04)
pressure compressed air from a clean air supply. Do
not use a wire or similar instrument to clean drilled 3. Install slider pin dust cover.
passages.
4. Install slider pin (5).

Caliper
1. See Figure 3-49. Install new medallion (7). See
2. Install bleeder screw (4). Hand
tighten.

3-50 94000936
 MEDALLIONS, BADGES, TANK EMBLEMS AND
ADHESIVE STRIPS (Page 3-156).

94000936 3-51
3. Install bleeder screw cap (5). e. Install brake pad retaining spring (10).

4. Lightly apply silicone grease to brake caliper sleeve boot (9).

'
Consumable: CCI #20 BRAKE GREASE (42830-05)

5. Install brake caliper sleeve (8).

NOTICE

Avoid leakage. Prevent damage to piston or piston bore.

Use non-metallic tools when servicing components.
(00529d)

6. Install piston (1).

a. Apply a light coating of brake fluid over the pistons,

dust seal (2) and piston seal (3).

DOT 4 BRAKE FLUID (41800219)

b. See Figure 3-51. Install the piston seals (3) into the
brake caliper piston bore.

c. Install the dust seals (2) into the brake caliper piston
bore.

d. Insert pistons, by hand, into bores of caliper housing.

Press pistons squarely into place until they bottom in
the bores. If installation shows resistance, remove
piston. Check that seals are properly installed.

COMPLETE

1. If drained: Fill and bleed rear brake system. See BLEED

BRAKES (Page 3-61 ).

2. If removed: Install muffler. See EXHAUST SYSTEM (Page

6-36).

3-52 94000936
BRAKE LINES 3.15
FRONT BRAKE LINE: NON-ABS

FASTENER TORQUE VALUE

Front brake line screw 36-48 in-lbs 4.1-5.4 N-m

Prepare
1. Drain front brake line. See BLEED BRAKES (Page 3-61).

Remove
1. Remove brake line (1) from front brake master cylinder. See
FRONT BRAKE MASTER CYLINDER (Page 3-35).
NOTE
If equipped with dual front calipers, remove brake lines from 1. Brake line
both calipers.
2. Wire form

2. Remove brake line from front brake caliper. See FRONT 3. Clamp
BRAKE CALIPER (Page 3-38). 4. Screw
5. Front brake line manifold
3. See Figure 3-52. Remove brake line.
Figure 3-52. Front Brake Line: Single and Dual Front Cal-
a. Remove brake line from wireform (2). iper (Non ABS)
b. Remove cable strap, if equipped.
c. Remove screw (4).
FASTENER TORQUE VALUE
d. Remove brake line. Rear brake line bracket 24-36 in-lbs 2.7-4.1 N-m
screws
e. Single caliper: Remove clamp (3) from front brake line.
Rear brake line clamp screws 24-36 in-lbs 2.7-4.1 N-m

Install CONSUMABLE PART NUMBER

1. Install brake line (1) to front brake master cylinder. See LOCTITE 243 99642-97
FRONT BRAKE MASTER CYLINDER (Page 3-35). MEDIUM
STRENGTH
2. See Figure 3-52. Install brake line. THREADLOCKER
AND SEALANT
(BLUE)
a. Route brake line as shown.
REAR BRAKE LINE: NON-ABS _____________
b. Single caliper: Install clamp (3) onto front brake line.
Prepare
c. Dual caliper: Position front brake line manifold (5)
1. Remove seat. See SEAT (Page 3-142).
d. Install screw (4). Tighten. 2. Remove right side cover. See RIGHT SIDE COVER (Page 3-
Torque: 3^-48 in-lbs (4.1-5.4 N-m) Front brake line 64).
screw 3. Remove negative battery cable. See POWER DISCONNECT
(Page 7-7).
3. Install brake line to front brake caliper. See FRONT BRAKE
CALIPER (Page 3-38). 4. Remove battery strap. See INSPECT BATTERY (Page 2-
43).
NOTE
5. Remove battery. See INSPECT BATTERY (Page 2-43).
If equipped with dual front calipers, install brake lines to
both calipers. 6. Remove battery tray. See BATTERY TRAY (Page 7-97).
7. Drain rear brake line. See BLEED BRAKES (Page 3-61).
4. Install brake line into wireform (2).
8. Remove rear stoplamp switch. See REAR STOPLAMP
SWITCH (Page 7-63).
5. Install cable strap, if removed.
Remove
Complete 1. Remove brake line from rear brake master cylinder. See
1. Bleed brake system. See BLEED BRAKES (Page 3-61). REAR BRAKE MASTER CYLINDER (Page 3-42).

2. Remove brake line from rear brake caliper. See REAR

94000936 3-53
3. Install
BRAKE bleeder screw(Page
CALIPER cap (5).
3-46). e. Install brake pad retaining spring (10).

3-54 94000936
 6. Install right side cover. See RIGHT SIDE COVER
(Page 3-64).
3. See Figure 3-53. Remove rear brake line retaining bracket. 7. Install seat. See SEAT (Page 3-142).

a. Remove screws (1). 8. Bleed brake system. See BLEED BRAKES (Page 3-61).
1. Screw (2)
b. Remove rear brake line bracket (2). 2. Rear brake line bracket

4. Remove brake line.

a. Remove screws (5).

b. Remove brake line (4).

c. Remove clamps (6) from brake line.

d. Remove grommet (3) from brake line.

Install
1. See Figure 3-53. Install grommet (3) onto brake line (4).

2. Route brake line as shown.

3. Install brake line at rear brake master cylinder. See REAR 3. Grommet
BRAKE MASTER CYLINDER (Page 3-42). 4. Brake line
5. Screw (3)
4. Install brake line at rear brake caliper. See REAR BRAKE 6. Clamp (3)
Figure 3-53. Rear Brake Line: (Non ABS)
CALIPER (Page 3-46).
BRAKE LINE: FRONT MASTER CYLINDER
5. Install rear brake line retaining bracket. (ABS) __ __________
FASTENER TORQUE VALUE
a. Install rear brake line bracket (2). Brake line tube nuts, manifold 128-173 in-lbs 14.5-19.5 N-m
Brake line, P-clamp, screw 36-48 in-lbs 4.1-5.4 N-m
b. Install screws (1). Tighten.
PART NUMBER TOOL NAME
Torque: 24-36 in-lbs (2.7-4.1 N-m) Rear brake line HD-48650 1 DIGITAL TECHNICIAN II
bracket screws

6. Install brake line.

Prepare
1. Drain front brake lines. See BLEED BRAKES (Page 3-61).
a. Install clamps (6).
Remove
b. Apply threadlocker to screws (5).
LOCTITE 243 MEDIUM STRENGTH 1. See Figure 3-54. Remove brake line (5) from front brake
master cylinder. See FRONT BRAKE MASTER CYLINDER
THREADLOCKER AND SEALANT (BLUE) (99642-
(Page 3-35).
97)
c. Install screws. Tighten.
2. Remove tube nut (3) from manifold (4).
Torque: 24-36 in-lbs (2.7-4.1 N-m) Rear brake line
clamp screws 3. Remove brake line from wireform, if equipped.

Complete 4. Remove clamp, if equipped.

1. Install rear stoplamp switch. See REAR STOPLAMP

a. Remove screw (1).
SWITCH (Page 7-63).
b. Remove clamp (2).
2. Install battery tray. See BATTERY TRAY (Page 7-97).

3. Install battery. See INSPECT BATTERY (Page 2-43).

4. Install negative battery cable. See POWER DISCONNECT

(Page 7-7).

5. Install battery strap. See INSPECT BATTERY (Page 2-43).

3-55 94000936
Install
1. See Figure 3-54. Install brake line (5) at front master
cylinder. See FRONT BRAKE MASTER CYLINDER (Page
3-35).

2. Install tube nut (3) to manifold (4). Do not tighten.

3. See Figure 3-55 or Figure 3-56. Position brake line (1) in

orientation shown and snug tube nut (2).

4. Move handlebars to full left lock and full right lock, adjust
brake line as needed.

5. Tighten tube nut.

Torque: 128-173 in-lbs (14.5-19.5 N-m) Brake line tube
nuts, manifold

6. Move handlebars to full left lock and full right lock to verify
brake line routing and there is no binding of brake lines or
manifold. 1. Brake line
2. Tube nut
NOTE Figure 3-55. Single Disc Brake Line Orientation
Manifold assembly should face forward, primarily
stationary but free to rotate.

7. Install brake line into wireform, if equipped.

8. Install clamp, if equipped.

a. Install clamp (2).

b. Install screw (1). Tighten
Torque: 3^48 in-lbs (4.1-5.4 N-m) Brake line, P-
clamp, screw

Figure 3-56. Dual Disc Brake Line Orientation Complete

NOTE
DIGITAL TECHNICIAN II (PART NUMBER: HD-48650) is
required to properly bleed brake system.

1. Screw 1. Bleed brake system. See BLEED BRAKES (Page 3-61).

2. Clamp
3. Tube nut
BRAKE LINE: FRONT CALIPER (ABS) _____
4. Front brake line manifold
5. Brake line PART NUMBER TOOL NAME
Figure 3-54. Brake Line: Front Master Cylinder (ABS) HD-48650 DIGITAL TECHNICIAN II

FASTENER TORQUE VALUE

Front brake line screw 36-48 in-lbs 4.1-5.4 N-m

Prepare
1. Drain front brake lines. See BLEED BRAKES (Page 3-61).

3-56 94000936
Remove
NOTE
If equipped with dual front calipers, remove brake lines from
both calipers.

1. Remove brake line from front brake caliper. See FRONT

BRAKE CALIPER (Page 3-38).
2. See Figure 3-57. Disconnect ABS lines (4) from manifold (2).
See Front ABS Lines (Page 3-54).
3. Disconnect front master cylinder brake line (1) from
manifold. See Brake Line: Front Master Cylinder (ABS)
(Page 3-52).
4. Remove brake line.
a. Remove wire harness retainers (6).
b. Remove Screw (5).
c. Remove brake line (3).

Install
1. See Figure 3-57. Install brake line.
FRONT ABS LINES
a. Install brake line (3).

b. Install screw (5). Tighten. PART NUMBER TOOL NAME

Torque: 36-48 in-lbs (4.1-5.4 N-m) Front brake line HD-52351 12MM TORQUE ADAPTER
screw
FASTENER TORQUE VALUE
c. Install wire harness retainers (6).
Banjo bolt to ABS module 17-19 ft-lbs 23.1-25.8 N-m
2. Install front master cylinder brake line (1) at manifold (2). Front ABS brake line P-clamp 36-48 in-lbs 4.1-5.4 N-m
See Brake Line: Front Master Cylinder (ABS) (Page 3-52). screw
Front ABS brake line to front 128-173 in-lbs 14.fr-19.5 N-m
3. Install ABS lines (4) at manifold. See Front ABS Lines (Page brake line
3-54). Under seat frame cover, front 20-30 in-lbs 2.3-3.4 N-m
screw
4. NOTE Under seat frame cover, rear 96-120 in-lbs 10.8—13.6 N-m
If equipped with dual front calipers, Install brake lines to screw
both calipers.
Prepare
Install brake line (3) at front caliper. See FRONT BRAKE 1. Remove main fuse. See POWER DISCONNECT (Page 7-7).
CALIPER (Page 3-38).
2. Remove seat. See SEAT (Page 3-142).
Complete
3. Remove fuel tank. See FUEL TANK (Page 6-14).
NOTE
DIGITAL TECHNICIAN II (PART NUMBER: HD-48650) is 4. Drain front brake line. See BLEED BRAKES (Page 3-61).
required to properly bleed brake system.
5. Remove right side cover. See RIGHT SIDE COVER (Page
3-64).
1. Bleed brake system. See BLEED BRAKES (Page 3-61).

6. Remove rear lighting caddy. See REAR LIGHTING CADDY

(Page 7-96). ~

Remove
1. See Figure 3-59. Disconnect ABS lines (2, 4) from front
brake line (1).

2. Remove P-clamp screws (3).

94000936 3-57
3. See Figure 3-60. Remove under seat frame cover (5).
1104270

a. Remove front screw (4).

b. Remove rear screws (6).

4. See Figure 3-61. Remove banjo bolts (1) from ABS

module (5).

5. Remove brake lines from vehicle.

6. See Figure 3-59 and Figure 3-60. Remove P-clamps

and grommets from brake lines.

Install
1. NOTE
Under seat frame cover requires two grommets.
See Figure 3-59 and Figure 3-60. Install grommets and P- Figure 3-58. HD-52351 In Use
clamps.

2. See Figure 3-61. Install brake lines to ABS module. Special

Tool: 12MM TORQUE ADAPTER (HD-52351)

a. Install banjo bolt (1 ), new gaskets (4) and brake line

(3).

b. Install banjo bolt (1 ), new gaskets (4) and brake line

(2).

c. See Figure 3-58. Tighten banjo bolts.

Torque: 17-19 ft-lbs (23.1-25.8 N-m) Banjo bolt to
ABS module
NOTE
The torque wrench should be 90 degrees to special tool.

3. See Figure 3-60. Install under seat frame cover (5).

a. Install rear screws (6). Tighten.

Torque: 96-120 in-lbs (10.8-13.6 N-m) Under seat
frame cover, rear screw

b. Install front screw (4). Tighten.

Torque: 20-30 in-lbs (2.3-3.4 N-m) Under seat frame
cover, front screw

4. See Figure 3-59. Connect ABS lines (2, 4) to front brake line
(1). Tighten.
Torque: 128-173 in-lbs (14.5-19.5 N-m) Front ABS brake
line to front brake line
5. Install P-clamp screws (3). Tighten.
Torque: 36-48 in-lbs (4.1-5.4 N-m) Front ABS brake line P-
clamp screw 1. Grommet (4)
2. Front master cylinder to ABS module brake line
3. ABS Module to front brake line
4. Front screw
5. Under seat frame cover
6. Rear screw (2)
Figure 3-60. Rear Frame Cover For Front ABS Lines

3-58 94000936
 2. Remove right side cover. See RIGHT SIDE COVER (Page 3-
64).

3. Remove seat. See SEAT (Page 3-142).

4. Remove rear lighting caddy. See REAR LIGHTING CADDY

(Page 7-96).

5. Remove battery and battery tray. See INSPECT BATTERY

(Page 2-43). "

6. Remove rear stoplamp switch. See REAR STOPLAMP

SWITCH (Page 7-63).

Remove
1. See Figure 3-62. Remove clamps.

a. Remove screw (1).

b. Remove clamp (2).

2. See Figure 3-63. Remove screws (4).

3. Remove bracket (5).

Complete
1. Install rear lighting caddy. See REAR LIGHTING CADDY 4. Remove banjo bolt (1) and gaskets (2) from master cylinder.
(Page 7-96).
5. Remove banjo bolt (1) and gaskets (2) from ABS module.
2. Bleed brake system. See BLEED BRAKES (Page 3-61 ).
6. Discard gaskets (2)
3. Install right side cover. See RIGHT SIDE COVER (Page 3-
64). 7. Remove brake line from clip (6).

4. Install seat. See SEAT (Page 3-142). 8. Remove brake line (7).

5. Install fuel tank. See FUEL TANK (Page 6-14).

Install
6. Install main fuse. See POWER DISCONNECT (Page 7-7).
1. See Figure 3-63. Route brake line (7).

7. Install left side cover. See LEFT SIDE COVER (Page 3-63). 2. NOTE
The torque wrench should be at a 90 degree angle or
BRAKE LINE: REAR MASTER CYLINDER TO perpendicular to the special tool so the setting on the
ABS MODULE ___________________________ torque wrench will be applied.

Prepare Install banjo bolt (1), new gaskets (2) and brake line (7) to
ABS module. Tighten.
1. Drain fluid from rear brake. See BLEED BRAKES (Page 3-61).
Torque: 17-19 ft-lbs (23.1-25.8 N-m) Banjo bolt to ABS
FASTENER TORQUE VALUE module, rear
Banjo bolt to ABS module, rear 17-19 ft-lbs 23.1-25.8 N-m
3. Install banjo bolt (1), new gaskets (2) and brake line (7) to
21-23 ft-lbs 29-31 N-m master cylinder. Tighten.
Banjo bolt to master cylinder,
rear Torque: 21-23 ft-lbs (29-31 N-m) Banjo bolt to master
Brake line bracket, rear, screw 24-35 in-lbs 2.7-4 N-m cylinder, rear

Brake line to master cylinder, 24-35 in-lbs 2.7-4 N-m 4. Install bracket (5).
rear, P-clamp screw
5. Install screws (4). Tighten.

Torque: 24-35 in-lbs (2.7-4 N-m) Brake line bracket, rear,

screw

6. Attach brake line to clip (6).

94000936 3-59
7. See Figure 3-62. Install clamp.

a. Install clamp (2).

b. Install screw (1). Tighten.

Torque: 24-35 in-lbs (2.7-4 N-m) Brake line to
master cylinder, rear, P-clamp screw

Complete
1. Install rear stoplamp switch. See REAR STOPLAMP
SWITCH (Page 7-63).

2. Bleed brake system. See BLEED BRAKES (Page 3-61).

3. Install battery tray and battery. See INSPECT BATTERY

(Page 2-43).

4. Install rear lighting caddy. See REAR LIGHTING CADDY

(Page 7-96).

5. Install seat. See SEAT (Page 3-142).

6. After installing seat, pull up on the seat to verify it is secure.

7. Install right side cover. See RIGHT SIDE COVER (Page 3-

64). 1. Banjo bolt (2)
2. Gasket (4)
3. ABS Module
4. Screw (2)
5. Bracket
6. Clip
7. Brake Line
8. Master cylinder
Figure 3-63. Master Cylinder Brake Line
BRAKE LINE: REAR CALIPER TO ABS
MODULE

PART NUMBER TOOL NAME

HD-52351 12MM TORQUE ADAPTER

FASTENER TORQUE VALUE

1. Screw (2)
Banjo bolt to ABS module, rear 17-19 ft-lbs 23.1-25.8 N-m
2. Clamp (2) _____________________
Figure 3-62. Brake Line Clamp Banjo bolt to brake caliper, rear 21-23 ft-lbs 29—31 N-m

Brake line bracket, rear, screw 24-35 in-lbs 2.7-4 N-m

Brake line to caliper, rear, P- 24-35 in-lbs 2.7-4 N-m
clamp screw

Prepare
1. Remove right saddlebag, if equipped. See SADDLEBAGS
(Page 3-145).

2. Drain fluid from rear brake. See BLEED BRAKES (Page 3-

61).

3. Remove right side cover. See RIGHT SIDE COVER (Page

3-64).

4. Remove seat. See SEAT (Page 3-142).

3-60 94000936
5. Remove rear lighting caddy. See REAR LIGHTING CADDY Complete
(Page 7-96). 1. Bleed brake system. See BLEED BRAKES (Page 3-61).

6. Remove battery and battery tray. See INSPECT BATTERY 2. Install battery tray and battery. See INSPECT BATTERY
(Page 2-43). (Page 2-43).

Remove 3. Install rear lighting caddy. See REAR LIGHTING CADDY

(Page 7-96).
1. See Figure 3-64. Remove brake line from clip (1).
4. Install seat. See SEAT (Page 3-142).
2. Remove clamp (2).
5. After installing seat, pull up on the seat to verify it is secure.
a. Remove screw from clamp.
b. Remove WSS wire from clamp. 6. Install right side cover. See RIGHT SIDE COVER (Page 3-
64).
3. See Figure 3-65. Remove screws (5).
7. Install right saddlebag, if equipped. See SADDLEBAGS
4. Remove bracket (6). (Page 3-145).

5. Remove banjo bolt (3) and gaskets (2) from brake caliper.

6. Remove banjo bolt (3) and gaskets (2) from ABS module.

7. Discard gaskets (2)

8. Remove brake line (7).

Install
1. See Figure 3-65. Route brake line (7).
1. Clip
2. NOTE 2. Clamp
Figure 3-64. Rear Brake Line
The torque wrench should be at a 90 degree angle or 1104242
perpendicular to the special tool so the setting on the
torque wrench will be applied.

Install banjo bolt (3), new gaskets (2) and brake line (7) to
ABS module. Tighten.
Torque: 17-19 ft-lbs (23.1-25.8 N-m) Banjo bolt to ABS
module, rear
Special Tool: 12MM TORQUE ADAPTER (HD-52351)

3. Install banjo bolt (3), new gaskets (2) and brake line (7) to
brake caliper. Tighten.
Torque: 21-23 ft-lbs (29-31 N-m) Banjo bolt to brake
caliper, rear

4. Install bracket (6).

5. Install screws (5). Tighten.

1. Rear caliper
Torque: 24-35 in-lbs (2.7-4 N-m) Brake line bracket, rear, 2. Gasket (4)
screw 3. Banjo bolt (2)
4. ABS Module
6. See Figure 3-64. Install clamp (2). 5. Screw (2)
6. Bracket
a. Install WSS wire into clamp. 7. Brake line
Figure 3-65. Brake Line Routing
b. Install screw. Tighten.

Torque: 24-35 in-lbs (2.7-4 N-m) Brake line to

caliper, rear, P-c/amp screw

7. Attach brake line to clip (1).

94000936 3-61
ABS MODULE 3.16

GENERAL ______________________________ NOTICE

This device is sensitive to electrostatic discharge (ESD). To
NOTE prevent damage to the device, always touch the motorcycle
The ABS module consists of the Hydraulic Control Unit frame or a grounded surface before handling. (00588c)
(HCU) and the Electronic Control Unit (ECU). The two are not
serviced separately. 1. Install ABS module.

PREPARE a. See Figure 3-67. Install bracket (1).

1. Remove seat. See SEAT (Page 3-142). b. Install screws (2). Tighten.
Torque: 96-119 in-lbs (10.8-13.5 N-m) ABS Module
2. Disconnect negative battery cable. See POWER
bracket screw
DISCONNECT (Page 7-7).
c. Install ABS module (3) with bracket.
3. Remove right side cover. See RIGHT SIDE COVER (Page
3-64). d. See Figure 3-66. Install screw (1). Tighten.
Torque: 9^—119 in-lbs (10.S-13.5 N-m)ABS Module
4. Drain fluid from system. See BLEED BRAKES (Page 3-61). frame screw
e. Install side cover mounting stud (2).
5. Disconnect brake lines from ABS module. See BRAKE
LINES (Page 3-51). Torque: 72-96 in-lbs (8.1-10.8 N-m) Side cover
mounting stud
REMOVE ____________________ ____ f. Install cable straps (3).

NOTICE g. Connect ABS connector (4).

This device is sensitive to electrostatic discharge (ESD). To
2. If installing a new ABS module, use DTII for set-up
prevent damage to the device, always touch the motorcycle
procedure:
frame or a grounded surface before handling. (00588c)
Special Tool: DIGITAL TECHNICIAN II (HD-48650)
1. Remove ABS module.
a. Choose the REFLASH icon.
a. See Figure 3-66. Disconnect ABS connector (4). b. Follow the on-screen prompts.

b. Remove cable straps (3).

c. Remove side cover mounting stud (2).

d. Remove screw (1).

e. See Figure 3-67. Remove ABS module (3) with
bracket.

f. Remove screws (2).

g. Remove bracket (1).

INSTALL ________ _______________ „ ____

PART NUMBER TOOL NAME

HD-48650 DIGITAL TECHNICIAN II

FASTENER TORQUE VALUE

ABS Module bracket screw 96-119 in-lbs 10.8—13.5 N-m
ABS Module frame screw 96-119 in-lbs 10.8—13.5 N-m
Side cover mounting stud 72-96 in-lbs 8.1-10.8 N-m

3-62 94000936
 1. Connect brake lines from ABS module. See BRAKE LINES
(Page 3-51).

2. Bleed brake system. See BLEED BRAKES (Page 3-61).

3. Connect negative battery cable. See POWER

DISCONNECT (Page 7-7).

4. Install seat. See SEAT (Page 3-142).

5. Install right side cover. See RIGHT SIDE COVER (Page 3-

64).

1. Bracket A WARNING
2. Screw (2)
3. ABS Module After repairing the brake system, test brakes at low speed. If
4. ABS module to rear brake line brakes are not operating properly, testing at high speeds can
5. Rear master cylinder to ABS module line cause loss of control, which could result in death or serious
6. ABS module to front brake line injury. (00289a)
7. Front master cylinder to ABS module line
Figure 3-67. ABS Module Bracket 6. Operate motorcycle at low speeds to verify that braking
COMPLETE ________________________ . systems operate properly.

A WARNING

When any hydraulic brake component, line or connection is

loosened or replaced on an ABS motorcycle, Digital Technician
II must be used during the brake bleeding procedure to verify all
air is removed from the system. Failure to properly bleed the
brake system could adversely affect braking, which could result
in death or serious injury. (00585c)

94000936 3-63
BLEED BRAKES 3.17

DRAIN

PART NUMBER TOOL NAME

BB200A BASIC VACUUM BRAKE BLEEDER
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it
comes in contact with. Always use caution and protect surfaces
from spills whenever brake work is performed. Failure to comply
can result in cosmetic damage. (00239c)

NOTE
• Procedure for draining brake fluid is the same for both
the front and the rear brake systems.

• For best results, use BASIC VACUUM BRAKE BLEEDER

(PART NUMBER: BB200A) to drain the brake systems.

• Both front and rear brake systems are affected when

removing ABS module.

1. Remove master cylinder reservoir cap of the affected system. FILL AND BLEED

2. See Figure 3-68. Remove cap (1) from bleeder screw (2). PART NUMBER TOOL NAME
BB200A BASIC VACUUM BRAKE BLEEDER
3. Using vacuum brake bleeder to drain system.
HD-48650 DIGITAL TECHNICIAN II
Special Tool: BASIC VACUUM BRAKE BLEEDER
(BB200A) FASTENER TORQUE VALUE
Banjo bolt 21-23 ft-lbs 29-31 N-m
a. Attach vacuum brake bleeder to a caliper bleeder Bleeder screw 35-61 in-lbs 3.9-6.9 N-m
screw. Loosen screw 3/4 turn.
Brake master cylinder, reservoir 9-18 in-lbs 1-2 N-m
b. Operate vacuum bleeder to evacuate all fluid from cover screw
master cylinder and line. A WARNING

c. If needed: Repeat with remaining calipers. When any hydraulic brake component, line or connection is
loosened or replaced on an ABS motorcycle, Digital Technician II
4. Using brake lever or pedal to drain system. must be used during the brake bleeding procedure to verify all air
is removed from the system. Failure to properly bleed the brake
a. Install end of a length of 0.31 in (7.9 mm) of the Inside system could adversely affect braking, which could result in
Diameter (ID) clear plastic tubing over bleeder screw. death or serious injury. (00585c)

b. Place free end of tubing in a suitable container. A WARNING

Use denatured alcohol to clean brake system components. Do

c. Open bleeder screw one-half turn.
not use mineral-based solvents (such as gasoline or paint
d. Pump brake lever or pedal repeatedly to drain brake thinner), which will deteriorate rubber parts even after assembly.
fluid. Deterioration of these components can cause brake failure,
which could result in death or serious injury. (00291 a)

5. Close bleeder screw. Tighten. Refer to Table 3-10.

6. Wipe out any remaining fluid inside master cylinder reservoir

with a clean, lint-free cloth.

3-64 94000936
 A WARNING A WARNING
Contact with DOT 4 brake fluid can have serious health A plugged or covered relief port can cause brake drag or lock-up,
effects. Failure to wear proper skin and eye protection which could lead to loss of control, resulting in death or serious
could result in death or serious injury. injury. (00288a)
• If inhaled: Keep calm, remove to fresh air, seek medical
attention. 5. Top off the reservoir. Verify proper operation of the master
cylinder relief port by actuating the brake pedal or lever. A
• If on skin: Remove contaminated clothing. Rinse skin slight spurt of fluid breaks the fluid surface in the reservoir
immediately with plenty of water for 15-20 minutes. If irritation with internal components are working properly. See CHECK
develops, seek medical attention. AND REPLACE BRAKE FLUID (Page 2-21).
• If in eyes: Wash affected eyes for at least 15 minutes under NOTE
running water with eye lids held open. If irritation develops,
Pay careful attention to fluid level in the master cylinder
seek medical attention.
reservoir. Add fluid before it empties to avoid drawing
• If swallowed: Rinse mouth and then drink plenty of water. Do air into the brake lines.
not induce vomiting. Contact Poison Control. Immediate
medical attention required. 6. Operate the brake lever or pedal to build hydraulic pressure.
• See Safety Data Sheet (SDS) for more details available at
sds.harley-davidson.com 7. While holding pressure with the brake lever or pedal:

(00240e)
a. Open bleeder screw about three-quarter turn.
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it b. Close bleeder screw as soon as the lever or pedal has
comes in contact with. Always use caution and protect surfaces moved full range of travel.
from spills whenever brake work is performed. Failure to comply
can result in cosmetic damage. (00239c) c. Allow brake lever or pedal to return slowly to its
released position.
■ If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY
flush area with clear water. 8. Repeat steps until all air bubbles are purged and a solid
NOTICE column of fluid is observed in the bleeder tube.

Do not allow dirt or debris to enter the master cylinder reservoir.

9. Install bleeder screw cap. Tighten. Refer to Table 3-10.
Dirt or debris in the reservoir can cause improper operation and
equipment damage. (00205c)
10. Check and fill reservoir to specified level. See CHECK AND
REPLACE BRAKE FLUID (Page 2-21).
Verify front brake hand lever and rear brake foot pedal have a
firm feel when applied. If not, bleed system as described.
11. ABS Models: Connect Digital Technician II (DT 11) and
1. Check for moisture content in brake fluid. See CHECK AND perform "ABS Service” procedure.
REPLACE BRAKE FLUID (Page 2-21).
NOTE 12. Check operation of rear lamps.
• For best results, use BASIC VACUUM BRAKE
BLEEDER (PART NUMBER: BB200A), particularly if A WARNING
the brake system was drained completely. If a After repairing the brake system, test brakes at low speed. If
vacuum brake bleeder is not available, use the brakes are not operating properly, testing at high speeds can
following procedure. cause loss of control, which could result in death or serious
• ABS Models: Use DIGITAL TECHNICIAN II (PART injury. (00289a)
NUMBER: HD-48650) to verify that system is bled.
13. Test ride motorcycle. Repeat the bleeding procedure if
2. Remove bleeder screw cap. Install end of clear plastic tubing brakes feel spongy.
over bleeder screw and place free end in a clean container. Table 3-10. Torque Specifications
COMPONENT'’^ TORQUE
3. Position vehicle or handlebar so master cylinder reservoir is Bleeder screws 35-61 in-lbs (3.9-6.9 N-m)
level. Banjo bolts 21-23 ft-lbs (29-31 N-m)
Reservoir cover 9-18 in-lbs (1-2 N-m)
4. Remove cover from master cylinder reservoir. screws
(1) Applies to both front and rear brake systems.

94000936 3-65
LEFT SIDE COVER 3.18

REMOVE _____ ________________________ c. Install screw (1). Tighten.

Torque: 24-36 in-lbs (2.7—4.1 N-m) Side cover
1. See See Figure 3-69.. Remove side cover. screw, single screw

a. Remove screw (1).

b. Pull side cover (2) away to release grommet from

mounting stud (3).

2. Remove bracket (4) if needed.

INSTALI _______________________________

FASTENER TORQUE VALUE

Side cover screw, single screw 24-36 in-lbs 2.7-4.1 N-m
Side cover, left side, bracket 8-10 in-lbs 0.9-1.1 N-m
to frame screw
1. See Figure 3-69. Install bracket, if removed.

a. Install bracket (4).

b. Install screw securing bracket to frame. Tighten.

Torque: 8-10 in-lbs (0.9-1.1 N-m) Side cover, left

side, bracket to frame screw 1. Screw
2. Left side cover
2. Install side cover.
3. Mounting stud (2)
4. Bracket
a. Align side cover (2) with mounting studs (3).
Figure 3-69. Left Side Cover
b. Press side cover until fully seated.

3-66 94000936
RIGHT SIDE COVER 3.19

REMOVE

1. See Figure 3-70. Remove side cover.

a. Remove screws (1).

b. Pull side cover (2) away to release grommet from

mounting stud (3).

INSTALL

FASTENER TORQUE VALUE

Side cover screw, vertical 24-36 in-lbs 2.7—-4.1 N-m
screw

1. See Figure 3-70. Install side cover.

1. Screw and washer (2)
a. Align side cover (2) with mounting stud (3). 2. Right side cover
3. Mounting stud
b. Press side cover until fully seated. Figure 3-70. Right Side Cover

c. Install screws (3). Tighten.

Torque: 24-36 in-lbs (2.7--4.1 N-m) Side cover
screw, vertical screw

94000936 3-67
FRONT FORK 3.20

CHECK FOR_OIL LEAK Check Oil Leak

Fork Oil Seals 1. Observe oil ring.
The fork oil seal allows a fine film of oil to lubricate the fork 2. Wipe fork clean.
sliding surface. 3. Ride motorcycle over bumpy road or complete six braking
• The oil film is more visible after continuous high-speed events.
compression and rebound movement. 4. See Figure 3-71. Check fork slider tube for oil.
• Due to greater lubrication needs, larger forks have a greater a. If a normal oil/dust film (1,2) is present, there is no leak.
amount of oil film than smaller forks.
b. If an oil run or drip (3) is present, perform procedure two
or three more times to confirm oil leak.

Figure 3-71. Front Forks

PREPARE c. Remove fork tube assemblies (5) from fork brackets
(2, 3).
1. Remove front wheel. See FRONT WHEEL (Page 3-12).

2. Remove front fender. See FRONT FENDER (Page 3-113).

3. Remove windshield, if equipped (except FXLRST). See

WINDSHIELD (Page 3-106).

4. Remove front brake caliper(s). See FRONT BRAKE

CALIPER (Page 3-38).

5. FLFBS, FLHC, FLHCS Remove rear headlamp nacelle

panels. See HEADLAMP NACELLE (Page 3-96).

REMOVE ____
Remove Upper fork bracket pinch bolt (2) Figure 3-72.
Upper fork bracket Four Pinch Bolt
1. See Figure 3-72 or Figure 3-73. Remove front fork tube Lower fork bracket Fork Brackets
assemblies. Lower fork bracket pinch bolt (2)
Fork tube assembly (2) __________
a. Loosen the upper fork bracket pinch screws (1).

b. Loosen the lower fork bracket pinch screws (4).

3-68 94000936
 1095545 1098814

1. Upper fork bracket pinch bolt (2) 1. Fork tube installed height Figure 3-74. Fork
2. Upper fork bracket Height Dimension Location
3. Lower fork bracket
4. Lower fork bracket pinch bolt (4) Table 3-11. Front Fork Assembly Dimension
5. Fork tube assembly (2) MODEL DIMENSION
Figure 3-73. Six Pinch Bolt Fork Brackets FLHCS 8.82-8.94 in (224.0-227.1 mm)
INSTALL __________________ FLFBS 8.94-9.06 in (227.1-230.1 mm)
FLSB 7.73-7.85 in (196.3-199.4 mm)
FXBBS,FXST 7.90-8.02 in (200.7-203.7 mm)
FASTENER TORQUE VALUE FXBRS Distance: 7.84-7.96 in (199.1-202.2 mm)
Fork bracket, lower, pinch bolt 16-20 ft-lbs 21.7-27.1 N-m FXFBS Distance: 9.15-9.27 in (232.4-235.5 mm)
Fork bracket, upper, pinch bolt 16-20 ft-lbs 21.7-27.1 N-m FXLRS Distance: 8.88-9 in (225.6-228.6 mm)
FXLRST Distance: 8.51-8.63 in (216.2-219.2 mm)
Install
1. Install front fork tube assemblies.

a. See Figure 3-74. Install fork tube assemblies through

lower and upper fork brackets.
PART NUMBER TOOL NAME
b. Set installed height (1) at dimension given and match HD-41177 FORK TUBE HOLDER
left and right sides. Refer to Table 3-11. HD-45305 FORK SEAL DRIVER
HD-59000B FORK OIL LEVEL GAUGE
c. See Figure 3-72 or Figure 3-73. Tighten lower fork
bracket pinch bolt (4 ). FASTENER TORQUE VALUE
Torque: 16-20 ft-lbs (21.7-27.1 N-m) Fork bracket, Fork damper tube screw, front 30-37 ft-lbs 40-50 N-m
lower, pinch bolt NOTE Fork tube plug, standard 22-59 ft-lbs 30-80 N-m
For models equipped with two lower pinch A WARNING
bolts per side: Tighten alternately until torque
specification is maintained. DISASSEMBLE AND ASSEMBLE: STANDARD
______________________________
d. Tighten upper fork bracket pinch bolt (1).
Torque: 16-20 ft-lbs (21.7-27.1 N-m) Fork bracket, Wear safety glasses or goggles when servicing fork
upper, pinch bolt assembly. Do not remove slider tube caps without relieving
spring preload or caps and springs can fly out, which could
e. FXBBS, FXST: See See Figure 3-76.. Slide upper end
result in death or serious injury. (00297a)
of protector (5) up until it contacts underside of lower
fork bracket.
Disassemble Initial
Disassembly
1. See Figure 3-75. Clamp fork tube in fork tube holder. Mount
in vise with fork vertical.
Special Tool: FORK TUBE HOLDER (HD-41177)

2. See Figure 3-76. Remove fork tube plug (1) and O-ring (21).
'

3. NOTE
Have a suitable container ready to place spring assembly
into after removal from tube.

94000936 3-69
 1096076
Pull spring collar (20), washer (19), and spring (18) out
of fork tube (2).

4. Remove fork assembly from tool.

1. Fork tube holder

2. Fork tube
Figure 3-75. Fork Tube Holder

94000936
3-70
1. Fork tube plug 12. Slider
2. Fork tube 13. Washer
3. Lower slider bushing 14. Screw
4. Case cover (FXBRS) 15. Damper tube spring
5. Protector (FXBBS, FXST) 16. Damper tube
6. Dust seal 17. Damper tube ring
7. Retaining ring 18. Spring
8. Slider oil seal 19. Washer
9. Seal spacer 20. Spring collar
10. Upper slider bushing 21. O-ring
11. Lower stop

Figure 3-76. Standard Fork Components

Fork Drain Turn fork assembly upside down to drain fork oil.

1. NOTE a. If only performing a fork oil change, see FORK FILL

Drain fork oil into a suitable container. later in this procedure. If overhauling the fork
assembly, continue with procedure.

94000936 3-71
 1096522
Complete Disassembly 6. See Figure 3-77. Check runout with a dial indicator.

1. Separate slider from fork tube. a. Set fork tube on V-blocks.

NOTE b. Replace fork if runout exceeds dimension.

Since there is little resistance to rotation when removing 0.008 in (0.2 mm)
socket screw (14), the job is done more easily with an air
impact wrench.

a. Remove screw (14) with washer (13) from the bottom

end of slider (12).

b. FXBRS: Remove case cover (4).

c. FXBBS, FXST: Remove protector (5).

d. Remove dust seal (6).

e. Compress retaining ring (7) and remove from slider
(12).
Assemble
2. NOTE
The upper slider bushing (10) is a slight interference fit Initial Assembly
in slider (12). The upper bushing, seal spacer (9) and NOTE
slider oil seal (8) are removed together. Lubricate all seal lips, quad rings and O-rings with HARLEY
DAVIDSON SEAL GREASE during assembly.
Use the fork tube and lower slider bushing (3) as a slide
hammer. Pull the fork tube in a quick continuous stroke.
1. Install damper tube ring (17). Place damper tube spring (15)
Continue this slide hammer action until the components are
on damper tube (16). Insert damper tube into fork tube (2).
freed.

2. Insert spring (18) into fork tube (2), tapered side toward
3. Push damper tube (16) and damper tube spring (15) free of
damper tube (15), and push bottom of damper tube through
fork tube (2) by inserting a small diameter rod through the
the opening at the bottom end of the fork tube. Place lower
opening in the bottom of tube.
stop (11) over end of damper tube (16).

4. Remove lower stop (11) from the lower end of damper tube 3. Apply LOCTITE 565 THREAD SEALANT to screw (14).
(16).
4. Position fork tube (2) and damper tube (16) in slider (12).
5. Damper tube ring (17) can now be removed from the Hold the assembly in place by exerting pressure on the
grooves at the top end of damper tube (16). Do not remove spring. Install socket screw (14) with washer (13).
lower slider bushing (3) unless it requires replacement.
5. Tighten screw (14).
Clean and Inspect Torque: 30-37 ft-lbs (40-50 N-m) Fork damper tube screw,
front
1. Clean all parts.
a. Remove spring (18).

2. Inspect parts for wear or damage. Replace parts if 6. Place upper slider bushing (10), seal spacer (9) and a new
necessary. slider oil seal (8) (in that order) over fork slider (2). Verify
that the lettered side of the seal is facing upward.
3. Inspect OD of slider bushing and ID of fork tube bushing.
7. Place fork oil seal installer over fork slider (2). Seat upper
a. If coating is worn through (metallic substrate showing), slider bushing (10), seal spacer (9), and slider oil seal (8)
replace bushing. into the slider bore by lightly tapping the components into
place with the installation tool.
b. Inspect for distortion. Special Tool: FORK SEAL DRIVER (HD-45305)

c. If deep scratches or scoring are found, replace 8. Install retaining ring (7).
bushing. Also inspect mating components for similar
wear. Replace or repair as necessary.

4. Check fork tube and slider for scoring, scratches and

abnormal wear.
5. Inspect fork tube for nicks from stones and road debris,
especially in area where seal contacts it. Replace if
necessary.

3-72 94000936
9. Install dust seal (6). b. Install washer (19) and spring collar (20).
a. FXBBS, FXST: Install protector (5). 2. Install fork tube plug.

b. FXBRS: Install case cover (4). a. Install new O-ring (2).

Fork Fill b. Install fork tube plug (1). Tighten.

Torque: 22-59 ft-lbs (30-80 N-m) Fork tube plug,
A WARNING
standard
Incorrect amount of fork oil can adversely affect handling and
lead to loss of vehicle control, which could result in death or DISASSEMBLE AND ASSEMBLE: INVERTED.
serious injury. (00298a) LEFT SIDE _____________________________

1. Fill fork tube.

PART NUMBER TOOL NAME
a. Fully compress fork. B-42571 FORK SEAL DRIVER AND DUST BOOT
INSTALLER (43MM)
b. See Figure 3-78. Fill with TYPE "E” HYDRAULIC HD-41177 FORK TUBE HOLDER
FORK OIL until oil level matches specification from top HD-45966 FRONT FORK COMPRESSOR
of fork tube with spring removed. Adjust oil level to HD-59000B FORK OIL LEVEL GAUGE
specification using fork oil level gauge. Refer to Table
3-12. FASTENER TORQUE VALUE
Special Tool: FORK OIL LEVEL GAUGE (HD-59000B) Fork tube plug to damper nut, 13-16 ft-lbs 17.5-22.5 N-m
left side, inverted
Fork tube plug, left side, inver- 22-28 ft-lbs 30-40 N-m
ted
Table 3-12. Oil Level, Front Fork
MODEL FLUID FILL DIMENSION Fork, left side, inverted, cart- 13-17 ft-lbs 17.5--22.5 N-m
FLHCS, FXBBS, FXST 4.65 in (118 mm) ridge screw
FLFBS 4.17 in (106 mm)
FXBRS 3.90 in (99 mm) Disassemble
Initial Disassembly
NOTICE
Exercise caution to avoid scratching or nicking fork tube.
Damaging tube can result in fork oil leaks after assembly.
(00421b)

1. See Figure 3-75.Clamp fork tube in fork tube holder. Mount

in vise with fork vertical.

Special Tool: FORK TUBE HOLDER (HD-41177)

2. See Figure 3-79 .

a. Remove fork tube plug (1).

b. Compress fork assembly to expose cartridge damper

Figure 3-78. Oil Level Gauge (15) rod.

Complete Assembly c. Hold nut (10). Remove fork tube plug (1) from end of
damper rod.
1. See Figure 3-76. Install fork spring.
d. Discard O-ring (2).
a. Fully extend fork. Install spring (18) with tightly wound
end at bottom. 3. NOTE
Have a suitable container ready to place spring into after
removal from assembly.

Remove spring from fork tube.

a. Clamp front fork compressor vertically in vise with

length adjuster screw topside.
Special Tool: FRONT FORK COMPRESSOR (HD-
45966)

3-73 94000936
 b. Compress fork spring. e. See Figure 3-79. Remove spring seat stopper (11),
spring collar (12) and spring joint (13).
c. See Figure 3-80. Remove nut (1).
f. Remove fork assembly from tool. Remove spring (14).
d. Release fork spring.

1129836

Hi,

\
\
\
\

1. Fork tube plug 11. Spring seat stopper

2. O-ring 12. Spring collar
3. Rubber stopper 13. Spring joint
4. Fork tube 14. Spring
5. Fork tube bushing 15. Cartridge damper
6. Seal Spacer 16. Centering plate
7. Oil seal 17. Slider bushing
8. Retaining ring 18. Fork slider
9. Dust seal 19. Screw
10. Nut 20. Dust cover(FLSB)
Figure 3-79. Cartridge Fork (Left Side)

3-74 94000936
 b. Separate dust seal (9) from fork tube.

c. Remove retaining ring (8).

d. Expand fork slider (18) and tube (4) against each other
repeatedly (in a slide-hammer effect) to remove fork
tube.

e. Gently pry at split line to remove slider bushing (17).

f. Remove fork tube bushing (5), seal spacer (6), oil seal
(7), retaining ring (8), and dust seal (9). Discard oil
seal.

g. If equipped, remove dust cover (20).

3. Remove centering plate (16).

Fork Drain
1. NOTE Clean and Inspect
Drain fork oil into a suitable container. 1. Clean all parts.

Drain fork oil. 2. Inspect parts for wear or damage. Replace parts if
necessary.
a. Thread rod extension tool (part of front fork
compressor) onto end of damper rod. 3. Inspect OD of slider bushing and ID of fork tube bushing.
Special Tool: FRONT FORK COMPRESSOR (HD-
45966) a. If coating is worn through (metallic substrate showing),
replace bushing.
b. Turn fork assembly upside down over drain pan and
slowly pump damper rod at least 20 times until rod b. Inspect for distortion.
moves freely.
c. If deep scratches or scoring are found, replace
c. If only performing a fork oil change, see FORK FILL bushing. Also inspect mating components for similar
later in this procedure. If overhauling the fork wear. Replace or repair as necessary.
assembly, continue with procedure.
4. Check fork tube and slider for scoring, scratches and
d. Remove extension tool from damper rod. abnormal wear.

Complete Disassembly 5. Inspect fork tube for nicks from stones and road debris,
especially in area where seal contacts it. Replace if
1. See Figure 3-79. Remove cartridge damper (15). necessary.

a. Place fork spring into fork tube. 6. See Figure 3-77. Check runout with a dial indicator.

b. Place fork assembly upside down on a clean shop rag a. Set fork tube on V-blocks.
on the floor.
b. Replace fork if runout exceeds dimension.
c. While compressing spring (14) to prevent rotation of
damper, remove screw (19). Use an air impact wrench 0. 008 in (0.2 mm)
for best results.
Assemble
d. Discard screw.
Initial Assembly
e. Remove spring (14) and cartridge damper (15) from NOTICE |
45
fork tube.

2. NOTE
Do not bend or stretch oil seal retaining ring during
removal.
Exercise caution to avoid scratching or nicking fork tube.
Damaging tube can result in fork oil leaks after assembly.
Remove fork tube.
(00421b)
a. If equipped, separate dust cover (20) from fork tube (4). NOTE
- Lubricate all seal lips, quad rings and O-rings with
HARLEY-DAVIDSON SEAL GREASE during assembly.
5 Use FORK TUBE HOLDER (PART NUMBER: HD-41177) as
necessary.

94000936 3-75
• Place dust seal with larger diameter end toward top of b. Fill with TYPE "E" HYDRAULIC FORK OIL until it is
fork assembly. approximately 2.0 in (50.8 mm) from top of fork tube.
• Place oil seal with lettering toward top of fork assembly.
c. Pump fork slider ten times to remove air from system.

1. See Figure 3-79. Assemble fork slider. d. See Figure 3-78. Fully compress fork. Measure oil
level from top of fork tube with spring removed. Adjust
a. If equipped, install dust cover (20) onto fork slider (18). oil level to specification using fork oil level gauge.
Refer to Table 3-13.
b. Install dust seal (9), retaining ring (8), oil seal (7), seal
spacer (6) and fork tube bushing (5) onto fork slider. Special Tool: FORK OIL LEVEL GAUGE (HD-59000B)

c. Lightly coat fork slider (18) and slider bushing (17) Table 3-13. Oil Level, Left Fork
with fork oil. MODEL FLUID FILL DIMENSION
FLSB 5.20 in (132 mm)
d. Install slider bushing (17). Expand bushing only FXFBS,FXLRS 5.39 in (137 mm)
enough to fit onto fork slider (18). FXLRST 4.49 in (114 mm)

e. Install centering plate (16). Complete Assembly

1. Clamp fork slider vertically in fork tube holder.
f. Install fork slider (18) into fork tube (4).
Special Tool: FORK TUBE HOLDER (HD-41177)
g. Slide cartridge damper (15) into fork slider (18).
h. Apply LOCTITE 243 MEDIUM STRENGTH 2. See Figure 3-79. Install fork spring.
THREADLOCKER AND SEALANT (blue) to new
screw (19). a. Fully extendfork. Install spring (14) with tightly wound
end at bottom.
i. Install screw (19). Tighten.
Torque: 13-17 ft-lbs (17.5-22.5 N-m) Fork, left side, b. Install spring joint (13) and spring collar (12).
inverted, cartridge screw
c. Compress fork using front fork compressor.
2. Clamp fork slider horizontally in fork tube holder. Special Tool: FRONT FORK COMPRESSOR (HD-
45966)
Special Tool: FORK TUBE HOLDER (HD-41177)
d. Install spring seat stopper (11).
3. Install fork oil seal.
e. Install nut (10) so that there is/ in (14 mm) between
a. Install fork tube bushing (5) and seal spacer (6). top of nut and top of damper shaft.

b. Assemble fork seal driver and dust boot installer

3. Install fork tube plug.
(43mm) in front of oil seal (7). Long end of tool faces
oil seal.
a. Install new O-ring (2).
Special Tool: FORK SEAL DRIVER AND DUST
BOOT INSTALLER (43MM) (B-42571) b. Install rubber stopper (3).

c. Drive oil seal into fork tube until seated. c. Install fork tube plug (1) onto damper (15). Tighten.
d. Install retaining ring (8). Torque: 13-16 ft-lbs (17.5-22.5 N-m) Fork tube plug
to damper nut, left side, inverted
e. Tap dust seal (9) into place. d. Install fork tube plug onto fork tube (4). Tighten.
f. If equipped rotate dust cover (20) to match any
Torque: 22-28 ft-lbs (30-40 N-m) Fork tube plug, left
removal burrs in slider. Tap dust cover into place.
side, inverted

Fork Fill DISASSEMBLE AND ASSEMBLE: INVERTED.

RIGHT SIDE

PART NUMBER TOOL NAME

A WARNING
B-42571 FORK SEAL DRIVER AND DUST BOOT
Incorrect amount of fork oil can adversely affect handling and
INSTALLER (43MM)
lead to loss of vehicle control, which could result in death or HD-41177 FORK TUBE HOLDER
serious injury. (00298a)
HD-47852 INNER FORK NUT
REMOVER/INSTALLER
1. Fill fork tube.
HD-59000B FORK OIL LEVEL GAUGE

a. Install damper rod extension tool.

3-76 94000936
 FASTENER TORQUE VALUE b. Compress fork assembly to expose joint rod (7).

Fork tube plug to damper nut , 13-16 ft-lbs 17.5-22.5 N-m

c. Hold nut (5). Remove fork tube plug (1) from end of
right side, inverted
joint rod.
Fork tube plug, right side, in- 22-30 ft-lbs 30-40 N-m
verted
d. Discard O-ring (2).
Fork, right side, inverted, inner 69-83 ft-lbs 93-113 N-m
fork nut
3. NOTE
Disassemble Have a suitable container ready to place spring assembly
into after removal from tube.
Initial Disassembly
NOTICE Remove spring assembly from fork tube.

Exercise caution to avoid scratching or nicking fork tube. a. Using inner fork nut remover/installer remove inner
Damaging tube can result in fork oil leaks after assembly. fork nut (6).
(00421b)
Special Tool: INNER FORK NUT
REMOVER/INSTALLER (HD-47852)
1. See Figure 3-75. Clamp fork tube in fork tube holder. Mount
b. Remove nut (5) and joint rod (7).
in vise with fork vertical.

Special Tool: FORK TUBE HOLDER (HD-41177) c. Remove spring collar (8), washer (9) and spring (10).

2. See Figure 3-81. d. Remove fork assembly from tool.

a. Remove fork tube plug (1 ).

94000936 3-77
1. Fork tube plug 11. Slider bushing
2. O-ring 12. Fork tube bushing
3. Rubber stopper 13. Seal spacer
4. Fork tube 14. Oil seal
5. Nut 15. Retaining ring
6. Inner fork nut 16. Dust seal
7. Joint rod 17. Dust cover(FLSB)
8. Spring collar 18. Fork slider
9. Washer 19. Screw
10. Spring

Figure 3-81. Front Fork (Right Side)

Fork Drain 2. Remove fork tube.

NOTE
1. NOTE
Do not bend or stretch oil seal retaining ring during removal.
Drain fork oil into a suitable container.

Turn fork assembly upside down to drain fork oil. a. If equipped, separate dust cover (17) from fork tube
(4) .
a. If only performing a fork oil change, see FORK FILL b. Separate dust seal (16) from fork tube.
later in this procedure. If overhauling the fork
assembly, continue with procedure. c. Remove retaining ring (15).

Complete Disassembly d. Expand fork slider (18) and fork tube (4) against each
other repeatedly (in a slide-hammer effect) to remove
1. See Figure 3-75. Clamp fork tube in fork tube holder. Mount fork tube.
in vise with fork vertical.

Special Tool: FORK TUBE HOLDER (HD-41177)

3-78 94000936
 e. Gently pry at split line to remove fork tube bushing b. Place dust seal (16), retaining ring (15), oil seal (14),
(12). seal spacer (13) and slider bushing (11) onto fork
slider.
f. Remove slider bushing (11), seal spacer (13), oil seal
(14), retaining ring (15), and dust seal (16) from fork c. Install fork tube bushing (12). Expand bushing only
slider. Discard oil seal. enough to fit onto fork slider (18).

g. If equipped, remove dust cover (17). d. Lightly coat fork slider (18) and fork tube bushing (12)
with fork oil.
Clean and Inspect
e. Install fork slider (18) into fork tube (4).
1. Clean all parts.
2. Clamp fork slider horizontally in fork tube holder.
2. Inspect parts for wear or damage. Replace parts if Special Tool: FORK TUBE HOLDER (HD-41177)
necessary.
3. Install fork oil seal.
3. Inspect OD of slider bushing and ID of fork tube bushing. a. Install slider bushing (11) and seal spacer (13).

a. If coating is worn through (metallic substrate b. Assemble fork seal driver and dust boot installer (43mm)
showing), replace bushing. in front of oil seal (14). Long end oftool faces oil seal.
Special Tool: FORK SEAL DRIVER AND DUST BOOT
b. Inspect for distortion. INSTALLER (43MM) (B-42571)
c. Drive oil seal into fork tube until seated.
c. If deep scratches or scoring are found, replace
bushing. Also inspect mating components for similar
d. Install retaining ring (15).
wear. Replace or repair as necessary.
e. Install dust seal (16).
4. Check fork tube and slider for scoring, scratches and
abnormal wear. f. Tap dust seal into place.

5. Inspect fork tube for nicks from stones and road debris, g. If equipped, install dust cover (17).
especially in area where seal contacts it. Replace if h. Rotate dust cover to match any removal burrs in slider.
necessary. Tap dust cover into place.

6. See Figure 3-77. Check run-out with a dial indicator.

a. Set fork tube on V-blocks. Fork Fill
b. Replace fork if runout exceeds dimension. A WARNING

0. 008 in (0.2 mm) Incorrect amount of fork oil can adversely affect handling and
lead to loss of vehicle control, which could result in death or
Assemble serious injury. (00298a)

Initial Assembly 1. Fill fork tube.

NOTICE
Exercise caution to avoid scratching or nicking fork tube. a. Fully compress fork.
Damaging tube can result in fork oil leaks after assembly.
(00421b) b. See Figure 3-78. Fill with TYPE "E" HYDRAULIC FORK
OIL until oil level matches specification from top of fork
NOTE tube with spring removed. Adjust oil level to specification
- Lubricate all seal lips, quad rings and O-rings with using fork oil level gauge. Refer to Table 3-14.
HARLEY-DAVIDSON SEAL GREASE during assembly.
• Use FORK TUBE HOLDER (PART NUMBER: HD-41177) Table 3-14. Oil Level, Right Fork
as necessary. MODEL FLUID FILL DIMENSION
FLSB 5.5 in (140 mm)
• Place dust seal with larger diameter end toward top of
fork assembly. FXFBS,FXLRS 5.6 in (141 mm)
FXLRST 4.8 in (123 mm)
• Place oil seal with lettering toward top of fork assembly.
Special Tool: FORK OIL LEVEL GAUGE (HD-
1. See Figure 3-81. Assemble fork slider.
59000B)

a. If equipped, place dust cover (17) onto fork slider (18).

94000936 3-79
Complete Assembly 2. Install fork tube plug.
A WARNING
b. Install rubber stopper (3).
Wear safety glasses or goggles when servicing fork
assembly. Do not remove slider tube caps without relieving c. Install fork tube plug (1) onto joint rod (7). Tighten.
spring preload or caps and springs can fly out, which could Torque: 13-16 ft-lbs (17.5-22.5 N-m) Fork tube plug
result in death or serious injury. (00297a) to damper nut , right side, inverted
d. Install fork tube plug onto fork tube (4). Tighten.
1. See Figure 3-81. Install fork spring.
Torque: 22-30 ft-lbs (30-40 N-m) Fork tube plug,
right side, inverted
a. Fully extend fork. Install spring (10) with tightly
wound end at bottom. COMPLETE ____________________________
b. Install washer (9) and spring collar (8).
1. FLFBS, FLHC, FLHCS: Install rear headlamp nacelle
c. Install nut (5) and joint rod (7). panels. See HEADLAMP NACELLE (Page 3-96).

d. Using inner fork nut remover/installer install inner fork 2. Install front brake caliper(s). See FRONT BRAKE CALIPER
nut (6). (Page 3-38).
Special Tool: INNER FORK NUT
REMOVER/INSTALLER (HD-47852) 3. Install windshield, if equipped. See WINDSHIELD (Page 3-
106)
e. Tighten inner fork nut.
Torque: 69-83 ft-lbs (93-113 N-m) Fork, right side, 4. Install front fender. See FRONT FENDER (Page 3-113).
inverted, inner fork nut
a. Install new O-ring (2).

5. Install front wheel. See FRONT WHEEL (Page 3-12).

94000936 3-80
STEERING HEAD/FORK STEM AND BRACKET ASSEMBLY 3.21
PREPARE ______________________________ from steering head.

1. All but FXLRST:. Remove front light bar, if equipped. See CLEAN AND INSPECT ___________________
FRONT LIGHT BAR (Page 7-43)

2. All but FXLRST:. Remove headlamp. See HEADLAMP

(Page 7-31)

3. Remove handlebar. See HANDLEBAR (Page 3-109).

4. Support front of motorcycle enough to take weight off of front

tire without lifting. See Secure the Motorcycle for Service
(Page 2-2).

REMOVE _______________________________

Upper Fork Bracket

NOTE FASTENER TORQUE VALUE
Fork stem pinch bolt 16-20 ft-lbs 21.7-27.1 N-m
If only removing upper fork bracket, use following Fork stem screw, 1st torque 160-168in-lbs 18.1-19 N-m
Fork stem screw, final torque - 62-68 in-lbs 7-7.7 N-m
procedure.
All except FXLRS, FXLRST
Fork stem screw, final torque - 110-122 in-lbs 12.4-13.8 N-m
1. See Figure 3-82. Remove upper fork bracket assembly. FXLRS, FXLRST
a. Loosen fork stem pinch bolt (4).
CONSUMABLE PART NUMBER
b. Remove fork stem screw (1) and washer (2). SPECIAL 99857-97A
PURPOSE
GREASE
c. Remove upper fork bracket (3).
A WARNING
Lower Fork Bracket
1. Remove front fork. See FRONT FORK (Page 3-65).

2. Remove front brake line manifold screw from lower fork

bracket. See BRAKE LINES (Page 3-51).

3. Remove upper fork bracket.

4. Secure lower fork bracket to frame.

5. Remove fork stem and lower fork bracket assembly (10)

PART NUMBER TOOL NAME

HD-33416 UNIVERSAL DRIVER HANDLE
HD-39301-A STEERING HEAD BEARING RACE
REMOVER
1. Clean all parts.

2. Inspect fork stem and upper and lower brackets. Replace as

necessary.

____________________ NOTICE _____________________

Replace both bearing assemblies even if one assembly appears

to be good. Mismatched bearings can lead to excessive wear
and premature replacement. (00532c)

94000936 3-81
3. Inspect bearings for the following conditions:

• Pitting

• Wear
• Scoring
Replace as necessary.

4. Inspect bearing cups. Replace as necessary

a. Remove bearing cups from steering head using

STEERING HEAD BEARING RACE REMOVER (PART
NUMBER: HD-39301-A) and UNIVERSAL DRIVER
HANDLE (PART NUMBER: HD-33416).

b. Install new steering head bearing cups.

INSTALL _______________________________
Properly seat bearing cups in steering head bore. Improper
seating can loosen fork stem bearings adversely affecting
stability and handling, which could result in death or serious
injury. (00302a)

A WARNING

Properly adjust fork stem bearings. Improper adjustments can

adversely affect stability and handling, which could result in
death or serious injury. (00301 c)

3-82 94000936
Lower Fork Bracket 1099123

1. See Figure 3-82. Install front fork stem and lower fork
bracket assembly.

a. Install new dust seal (6) over fork stem and lower fork
bracket assembly (10).
b. Apply SPECIAL PURPOSE GREASE (99857-97A) to
lower steering head bearing (7).
c. Install lower steering head bearing.
d. Install fork stem through steering head.
e. Apply SPECIAL PURPOSE GREASE (99857-97A) to
upper steering head bearing.

f. Install upper steering head bearing and new dust seal

(6).

g. Install front brake line manifold screw to lower fork

bracket. See BRAKE LINES (Page 3-51).

2. Install upper fork bracket (3).

Upper Fork Bracket

1. See Figure 3-82. Install upper fork bracket (3) assembly.

a. Place front fork tube assemblies in fork bracket 1. Fork stem screw
assemblies (3,10). 2. Washer
3. Upper fork bracket
4. Fork Stem Pinch Bolt
b. Install washer (2) and fork stem screw (1). Tighten.
5. Upper fork clamp pinch bolt (2)
Torque: 160-168 in-lbs (18.1-19 N-m) Fork stem 6. Dust seal (2)
screw, 1st torque 7. Steering head bearing (2)
8. Bearing cup (2)
c. Loosen fork stem screw.
9. Lower fork bracket pinch bolt (2) (if equipped)
Angle: 45° 10. Fork stem and lower fork bracket assembly
d. Final tighten fork stem screw. Tighten. 11. Fork stem retaining ring
Figure 3-82. Fork Clamp Components (Typical)
Torque: 62-68 in-lbs (7-7.7 N-m) Fork stem screw, COMPLETE _________________
final torque - All except FXLRS, FXLRST Torque:
110-122 in-lbs (12.4-13.8 N-m) Fork stem screw,
final torque - FXLRS, FXLRST 1. Adjust and tighten front fork. See FRONT FORK (Page 3-
65).
e. Tighten fork stem pinch bolt (4). Tighten.
Torque: 16-20 ft-lbs (21.7-27.1 N-m) Fork stem pinch
bolt
2. Install handlebar. See HANDLEBAR (Page 3-109).

3. Install headlamp if removed (except FXLRST). See 3. HEADLAMP (Page 7-31)

4. Install front light bar, if equipped (except FXLRST). See

FRONT LIGHT BAR (Page 7-43)

5. Adjust steering head bearings. See ADJUST AND

LUBRICATE STEERING HEAD BEARINGS (Page 2-27).

94000936 3-83
FORK LOCK 3.22
PREPARE

1. Remove left side cover. See LEFT SIDE COVER (Page 3-

63).

2. Remove main fuse. See POWER DISCONNECT (Page 7-7).

3. Remove seat. See SEAT (Page 3-142).

4. Remove fuel tank. See FUEL TANK (Page 6-14).

5. Remove frame plug and front electrical caddy. See FRONT

ELECTRICAL CADDY (Page 7-87).

REMOVE

1. Turn forks to full right position.

2. NOTE
Fork lock mounting screw has left handed threads.

Remove fork lock mounting screw through hole in lower fork

clamp.

3. See Figure 3-83. Remove fork lock (1) and gasket (2).

INSTALL_______________________________
COMPLETE
1. Turn handlebars to full right position, aligning hole in lower
fork clamp with mounting hole for fork lock fastener. 1. Verify proper operation of fork lock.

2. NOTE 2. Install electrical caddy and frame plug. See FRONT

Fork lock needs to be in the retracted/unlocked position ELECTRICAL CADDY (Page 7-87).
for installation.
3. Install fuel tank. See FUEL TANK (Page 6-14).
See Figure 3-83. Place fork lock and gasket in position.
4. Install seat. See SEAT (Page 3-142).
3. Install fork lock mounting screw. Tighten.
Torque: 54-79 in-lbs (6.1-8.9 N-m) 5. Install main fuse. See POWER DISCONNECT (Page 7-7).

6. Install left side cover. See LEFT SIDE COVER (Page 3-63).

3-84 94000936
REAR FORK 3.23

PREPARE Install
1. Remove negative battery cable. See POWER 1. See Figure 3-84. Install splash guard.
DISCONNECT (Page 7-7).
a. Place the bottom tabs on splash guard (2) into the
2. Remove saddlebags, if equipped. See SADDLEBAGS (Page slots on rear fork (3).
3-145).
b. Slightly bend the splash guard top mounting tabs and
3. Remove mufflers and exhaust bracket. See EXHAUST push the top onto the stubs (13) protruding from the
SYSTEM (Page 6-36). fork.

c. Install screw (1). Tighten.

4. Remove brake line P-clip from rear fork. See BRAKE LINES
(Page 3-51). Torque: 3^45 in-lbs (3.9-5.1 N-m) Splash guard
screw
5. Remove belt guards. See BELT GUARDS (Page 3-85).
2. Install rear fork.

6. Remove rear wheel. See REAR WHEEL (Page 3-16). a. Align rear fork (3) with frame.

7. Remove drive belt. See DRIVE BELT (Page 5-7). b. Lift top of drive belt (9). Install pivot shaft through right
side of frame, rear fork (3), transmission fork mount,
8. Remove lower shock screw. See REAR SHOCK drive belt, spacer (6) and left side of frame.
ABSORBER (Page 3-87).
c. Install pivot shaft nut (7). Tighten.
REMOVE AND INSTALL Torque: 25-30 ft-lbs (34-41 N-m) Rear fork pivot
shaft nut, first torque
FASTENER TORQUE VALUE d. Back off pivot shaft nut.
Rear fork pivot shaft nut, final 154-170 ft-lbs 209-230 N-m Angle: 90°
torque
e. Tighten pivot shaft nut.
Rear fork pivot shaft nut, first 25-30 ft-lbs 34-41 N-m
torque Torque: 1-48 in-lbs (0.1-5.4 N-m) Rear fork pivot
1-48 in-lbs 0.1-5.4 N-m shaft nut, second torque
Rear fork pivot shaft nut,
second torque f. Install lower shock bolt. See REAR SHOCK
Rear fork pivot shaft nut, third 154-170 ft-lbs 209-230 N-m ABSORBER (Page 3-87).
torque NOTE
Rear fork pivot shaft pinch bolt 18-20 ft-lbs 24-27 N-m
Verify spacer (6) does not have lateral play.
Splash guard screw 35-45 in-lbs 3.9-5.1 N-m

Remove g. Install belt slot spacer. See DRIVE BELT (Page 5-7).

1. See Figure 3-84. Remove splash guard. h. Install rear wheel. See REAR WHEEL (Page 3-16).

a. Remove screw (1). NOTE

Adjust the belt tension after the drive belt slot
b. Pull bottom of splash guard (2) out and down to spacer screws have been torqued to final
remove. specifications and before the pivot shaft nut has
been torqued to final specifications.
2. Remove rear fork.
i. Tighten pivot shaft nut (7).
a. Support rear of transmission and frame. Torque: 154-170 ft-lbs (209-230 N-m) Rear fork pivot
shaft nut, third torque
b. Support rear fork (3).
j. Back off pivot shaft nut.
c. Remove nut (7). Angle: 90°

d. Loosen pinch bolt (8). k. Tighten pivot shaft nut.

Torque: 154-170 ft-lbs (209-230 N-m) Rear fork pivot
e. Remove pivot shaft (9) and spacer (6). shaft nut, final torque

f. Remove rear fork.

94000936 3-85
 NOTE I. Tighten pivot shaft pinch bolt (8).
After final torque of pivot shaft nut there will still Torque: 18-20 ft-lbs (24-27 N-m) Rear fork pivot
be a slight gap between the right side bearing and shaft pinch bolt
rear fork. NOTE
Verify spacer (6) does not have lateral play.

1. Splash guard screw 8. Pivot shaft pinch bolt

2. Splash guard 9. Pivot shaft
3. Rear fork 10. Retaining ring (2)
4. Belt slot spacer 11. Bearing (2)
5. Belt slot spacer screw (2) 12. Adjusting screw (2)
6. Spacer 13. Splash guard stubs (2)
7. Pivot shaft nut
Figure 3-84. Rear Fork Assembly
DISASSEMBLE AND ASSEMBLE: STANDARD Clean and Inspect
______________________________
PART NUMBER TOOL NAME 1. See Figure 3-86. Clean all components in solvent.

HD-46281 BEARING REMOVER/INSTALLER TOOL

2. Dry parts with low-pressure, compressed air.

3. Carefully inspect bearings (2) for wear and/or corrosion.

Disassemble Replace or repair as necessary.
1. See Figure 3-85. Remove bearings from rear fork using.
4. Verify that the bearing retaining rings (3) are not bent or
Special Tool: BEARING REMOVER/INSTALLER TOOL
damaged. Replace or repair as necessary.
(HD-46281)
NOTE
Remove bearings only if replacement is required. 5. If the bearings were removed, clean the bearing bores (4)
with a clean shop towel, removing any dirt or grit adhering
2. See Figure 3-86. Remove adjusting screws (1). to the bearing surface.

6. Rough check rear fork (5) for correct alignment or damage.

Replace if bent or damaged.

3-86 94000936
7. Clean threads on adjustment screws (1) and adjusting
screw holes.

Assemble
1. See Figure 3-86. Install adjusting screw.

a. Inspect condition of adjusting screws (1) and replace

if necessary.

b. Install adjusting screws.

2. Install bearings.

a. Install new retaining rings (3) onto grooves on new

bearings (2) if removed.

b. See Figure 3-87. Position left bearing squarely on left

bearing bore.

c. Press left bearing into fork bearing bore until retaining

ring bottoms out.

d. Position right bearing on right bearing bore.

e. See Figure 3-88. Press right bearing into fork bearing
bore leaving a gap.

0.06-0.13 in (1.47-3.2 mm)

94000936 3-87
 145)

8. Install negative battery cable. See POWER DISCONNECT

(Page 7-7)

COMPLETE

1. Install lower shock screw. See REAR SHOCK ABSORBER

(Page 3-87)

2. Install drive belt. See DRIVE BELT (Page 5-7)

3. Install rear wheel. See REAR WHEEL (Page 3-16)

4. Install belt guards. See BELT GUARDS (Page 3-85)

5. Install brake line P-clip into rear fork. See BRAKE LINES
(Page 3-51)

6. Install mufflers and exhaust bracket. See EXHAUST

SYSTEM (Page 6-36)

7. Install saddlebags, if equipped. See SADDLEBAGS (Page 3-

3-88 94000936
BELT GUARDS 3.24

PREPARE ______________________________ b. Place lower guard in position.

c. Apply threadlock to screw (3).

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).
LOCTITE 243 MEDIUM STRENGTH
2. Remove saddlebag, if equipped. See SADDLEBAGS (Page THREADLOCKER AND SEALANT (BLUE) (99642-97)
3-145).
d. Install screws. Tighten.
REMOVE AND INSTALL: STANDARD Torque: 70-80 in-lbs (7.9--9 N-m) Belt guard, lower
screw

FASTENER TORQUE VALUE 2. Install upper guard.

Belt guard, lower screw 70-80 in-lbs 7.9-9 N-m
a. Place upper guard (6) in position.
Belt guard, upper screw 70-80 in-lbs 7.9-9 N-m
Saddle bag, docking bracket 38-47 ft-lbs 52-64 N-m b. Apply threadlock to screw (4).
screw
LOCTITE 243 MEDIUM STRENGTH
CONSUMABLE PART NUMBER THREADLOCKER AND SEALANT (BLUE) (99642-97)
LOCTITE 243 99642-97
c. Install screw. Tighten.
MEDIUM
STRENGTH Torque: 70-80 in-lbs (7.9-9 N-m) Belt guard, upper
THREADLOCKER screw
AND SEALANT
(BLUE) d. Apply threadlock to screw (5).

REMOVE LOCTITE 243 MEDIUM STRENGTH

THREADLOCKER AND SEALANT (BLUE) (99642-97)
1. See Figure 3-89. Remove upper guard.
e. Install screw and nut. Tighten.
a. Remove screw (5) andnut.
Torque: 70-80 in-lbs (7.9-9 N-m) Belt guard, upper
b. Remove screw (4). screw

3. Install docking bracket, if equipped.

c. Remove upper guard (6).
2. Remove lower guard.
a. Apply threadlock to screw (1).

a. Remove screw (1) and docking bracket (2) if LOCTITE 243 MEDIUM STRENGTH
equipped. THREADLOCKER AND SEALANT (BLUE) (99642-97)

b. Remove screws (3). b. Position docking bracket (2) on frame and install
screw. Tighten.
c. Remove lower belt guard (7) through opening in rear
Torque: 38-47 ft-lbs (52-84 N-m) Saddle bag,
fork.
docking bracket screw

INSTALL
1. See Figure 3-89. Install lower belt guard. a. Guide

lower guard (7) through rear fork.

94000936 3-89
1. Screw 5. Screw
2. Docking bracket 6. Upper guard
3. Screw (2) 7. Lower guard
4. Screw

Figure 3-89. Belt Guards

COMPLETE 2. Install main fuse. See POWER DISCONNECT
(Page 7-7).
1. Install saddlebag, if equipped. See SADDLEBAGS (Page 3-
145).

3-90 94000936
REAR SHOCK ABSORBER 3.25

PREPARE CONSUMABLE PART NUMBER

LOCTITE 243 99642-97
1. Disconnect negative battery cable. See POWER MEDIUM
DISCONNECT (Page 7-7). STRENGTH
THREADLOCKER
AND SEALANT
2. Remove seat. See SEAT (Page 3-142).
(BLUE)

3. Remove fender, if necessary. See REAR FENDER (Page NOTE

3-116). • Lower shock mount bushing and bearing are not
serviceable.
4. Remove frame crossmember. See FRAME
CROSSMEMBER (Page 3-144). 1. See Figure 3-93. Install rear shock.

5. Models with side mounted shock adjuster. a. Place rear shock (1, 2 or 3) in position.

a. Remove right side cover. See RIGHT SIDE COVER b. Install screw (5). Tighten.
(Page 3-64). Torque: 70-75 ft-lbs (94.9-101.7 N-m) Lower shock
screw
b. Remove battery strap. See INSPECT BATTERY
(Page 2-43). c. Apply threadlocker to screw (6).
LOCTITE 243 MEDIUM STRENGTH
6. Using a suitable lift, support frame and raise slightly to THREADLOCKER AND SEALANT (BLUE) (99642-
relieve pressure on the shock.
97)

REMOVE _ _______ _________ d. Raise or lower rear fork to align upper shock
mount.
1. Models with top-mounted shock adjuster: See Figure 3-
90. Remove cable strap (2). e. Install screw (6). Tighten.
Torque: 80-90 ft-lbs (108.5-122 N-m) Upper shock
2. Models with side-mounted shock adjuster: See Figure 3- screw
91. Remove shock adjuster from bracket.
f. See Figure 3-92. Apply thread locker to pinch
screws.
a. Remove clip from ABS bracket (4).
LOCTITE 243 MEDIUM STRENGTH
b. Remove screw (2) and washer (1). THREADLOCKER AND SEALANT (BLUE) (99642-
97)
c. Set side mounted shock adjuster (3) to the side,
being careful not to damage oil line. g. See Figure 3-92. Install pinch bolt (1). Tighten.
Torque: 12-15 ft-lbs (16.3-20.3 N-m) Shock pinch
3. Remove rear shock.
bolt

a. See See Figure 3-92.. Remove pinch bolt (1). 2. Models with side-mounted shock adjuster: See Figure 3-
91. Install shock adjuster on bracket.
b. See See Figure 3-93.. Remove screw (6).
a. Route side mounted shock adjuster (3) in front of
c. Remove screw (5). the battery tray.

d. Remove rear shock (1, 2 or 3).

b. Position side mounted shock adjuster on
INSTALL mounting bracket.

c. Install washer (1) and screw (2). Tighten.

FASTENER TORQUE VALUE
Torque: 90-114 in-lbs (10.2-12.9 N-m)
Lower shock screw 70-75 ft-lbs 94.9-101.7 N-m Side-mounted shock adjuster screw
Shock pinch bolt 12-15 ft-lbs 16.3-20.3 N-m
d. Insert shock adjuster hose clip onto ABS bracket
Side-mounted shock adjuster 90-114 in-lbs 10.2-12.9 N-m (4).
screw
Upper shock screw 80-90 ft-lbs 108.5-122 N-m 3. Models with top-mounted shock adjuster See Figure 3-

94000936 3-91
 90. Install cable strap (2).

3-92 94000936
Figure 3-90. Top Mounted Shock Adjuster

94000936 3-93
 1096314

1. Shock, side mounted adjuster 5. Lower shock screw

2. Shock, top mounted adjuster 6. Upper shock screw
3. Shock, cam adjustable 7. Rear fork
4. Pinch bolt 8. Frame

Figure 3-93. Rear Shocks

DISASSEMBLE AND ASSEMBLE: REAR Remove shock adjuster knob.
SHOCK ADJUSTER 1. See Figure 3-94. Remove shock adjuster knob (1).

FASTENER TORQUE VALUE

a. Remove screw (3) and washer (2).
Rear shock adjuster knob screw 26.^6--44.3 in- 3--5 N-m
lbs b. Hold a rag wrapped around the adjuster housing and
knob to prevent loss of the detent ball (4) and spring
CONSUMABLE PART NUMBER (5) . Carefully remove the knob.
ANTI-SEIZE 98960-97
LUBRICANT c. Remove detent ball and spring.
LOCTITE 243 99642-97
MEDIUM Install shock adjuster knob.
STRENGTH
THREADLOCKER 1. Lubricate adjuster shaft.
AND SEALANT
(BLUE) a. Apply a light coat of ANTI-SEIZE LUBRICANT to the
knob adjuster shaft.
The rear shock absorbers contain no serviceable parts except an
adjustment knob and hardware kit. ANTI-SEIZE LUBRICANT (98960-97)

3-94 94000936
 COMPLETE
b. Rotate adjuster shaft, using a wrench, completely in
both directions to distribute lubricant.

2. See Figure 3-94. Install shock adjuster knob.

a. Apply threadlocker to screw (3).

LOCTITE 243 MEDIUM STRENGTH

THREADLOCKER AND SEALANT (BLUE) (99642-
97)

b. Install spring (5) and detent ball (4).

c. Install adjuster knob (1).

d. Install washer (2) and screw (3). Tighten.

Torque: 26.6-44.3 in-lbs (3-5 N-m) Rear shock
adjuster knob screw
e. Rotate knob to verify that the detent is properly
assembled. Clicks are heard every half rotation.

1. Adjust shock absorber. See ADJUST SUSPENSION (Page

2-35).

2. Connect negative battery cable. See POWER

DISCONNECT (Page 7-7).

3. Models with side-mounted shock adjuster.

a. Install battery strap. See INSPECT BATTERY (Page

2-43).

b. Install right side cover. See RIGHT SIDE COVER

(Page 3-64).

4. Install frame crossmember. See FRAME CROSSMEMBER

(Page 3-144).

5. Install fender, if removed. See REAR FENDER (Page 3-

116).

6. Install seat. See SEAT (Page 3-142).

3-95 94000936
CLUTCH CONTROL 3.26

PREPARE

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

REMOVE

Clutch Cable Disconnect

NOTE
The two cable halves should only be taken apart if replacing
the upper clutch cable or housing. Otherwise disconnect at
clutch lever and leave two halves assembled.

1. See Figure 3-95. Access two piece clutch cable.

a. Remove spring clips (1).

b. Slide cover (2) up.

2. See Figure 3-96. Identify upper clutch cable (1) and red lock
button (2).

3. NOTE
Inspect lock button (2). Replace if damaged.

See Figure 3-97. Unlock upper clutch cable (1).

a. Push lock button tabs (2) slightly inboard and then down
to disengage.

4. Fully collapse cable (spring compressed) and push button in.

5. See Figure 3-98. Lift locking tab (1) from swaged ball end
(2).

6. See Figure 3-99. Push swaged ball end (2) out from coupler
from opposite side and slightly pull clutch lever in until
locking tab is at top of window. Remove swaged ball end
from coupler (1).

7. See Figure 3-100. Pry flex fingers (3) open and slide lower
clutch cable (2) from housing (1).

Figure 3-96. Lock Button

3-96 94000936
Figure 3-97. Compressed Upper Clutch Cable

1. Remove clutch cable.

a. Disconnect clutch cable at release cover. See

CLUTCH RELEASE COVER (Page 5-12).

b. Disconnect clutch cable. See Clutch Cable

Disconnect in this section.

Clutch Cable: Upper End

1. Locking tab (2) 1. See Figure 3-101. Remove clutch cable.
2. Swaged ball end
a. Remove retaining ring (7).

b. Remove pivot pin (3).

c. Remove clutch hand lever (6).

d. Remove pin (5).

e. Remove clutch cable (8).

f. Disconnect clutch cable. See Clutch Cable
Disconnect in this section.

Clutch Hand Control

1. See Figure 3-101. Remove clutch hand control assembly.

a. Remove screws (1) and washers (2).

b. Remove lever bracket clamp (9).

c. Remove hand lever bracket (4).

Figure 3-99. Coupler Disengagement

Clutch Cable: Lower End

94000936 3-97
 b. Install pin (5).

c. Install clutch hand lever (6).

d. Install pivot pin (3)

e. Install retaining ring (7).

f. Connect clutch cable. See Clutch Cable Disconnect in
this section.

Clutch Cable Connect

1. See Figure 3-100. Install lower clutch cable (2) into housing
(1).

2. See Figure 3-99. Pull clutch cable swaged ball end (2) out
slightly from window and then manipulate clutch lever to
align coupler (1) with swagged ball end and then release.

3. See Figure 3-98. Secure locking tab (1) swaged ball end (2).
NOTE
Replace upper clutch cable if locking tab is damaged or
missing.

4. See Figure 3-101. Ensure clutch lever (6) is in full open

position and that ferrule is correctly seated in housing.

5. NOTE
CLEAN AND INSPECT Inspect lock button (2). Replace if damaged.

1. Inspect clutch lever and cable for wear or damage. Replace See Figure 3-97. Disengage lock button (2) allowing upper
or repair as necessary. clutch cable spring to set free-play at clutch lever.

6. See Figure 3-96. Push in lock button (2).

2. Inspect clutch cable. Replace as necessary.

7. Check clutch operation.

NOTICE

The clutch control cable must be oiled and adjusted periodically to 8. See Figure 3-95. Slide cover (2) down and install spring clips
compensate for lining wear. Failure to oil and adjust the clutch (1).
control cable can result in equipment damage. (00203c)
Clutch Hand Control
3. Lubricate clutch cable and hand lever pivot pin hole with
HARLEY LUBE. 1. See Figure 3-101. Install clutch hand control assembly.

a. Install hand lever bracket (4).

INSTALL
FASTENER TORQUE VALUE
b. Install lever bracket clamp (9).
Clutch cable lever screw 60-80 in-lbs 6.8-9 N-m
c. Install washers (2) and screws (1). Tighten.
Clutch Cable: Lower End Torque: 60-80 in-lbs (6.8-9 N-m) Clutch cable lever
screw
1. Install clutch cable.

a. Connect clutch cable at release cover. See CLUTCH

RELEASE COVER (Page 5-12).

b. Connect clutch cable. See Clutch Cable Disconnect in

this section.
Clutch Cable: Upper End
1. See Figure 3-101. Install clutch cable.

a. Install clutch cable (8).

3-98 94000936
 DISASSEMBLE ______________________

Lock Button
1. See Figure 3-102. Access two piece clutch cable.

a. Remove spring clips (1).

b. Slide cover (2) up.

2. NOTE
Upper clutch cable (1) spring must be uncompressed.

See Figure 3-103. Unlock upper clutch cable (1).

a. Push lock button tabs (2) slightly inboard and then down
to disengage.

3. Remove lock button.

Housing
1. Disconnect clutch cable. See Clutch Cable Disconnect in the
this section.

2. See Figure 3-103. Remove housing (4) from upper housing

(3).

ASSEMBLE

Lock Button
1. NOTE
Upper clutch cable (1) spring must be uncompressed.

See Figure 3-103. Install lock button (2).

2. See Figure 3-102. Slide cover (2) down and install spring
clips (1).

Housing
1. See Figure 3-104. Align coupler guide (2) with the guide in
housing.

2. See Figure 3-103. Install housing (4) to upper housing (3).

3. Connect clutch cable. See Clutch Cable Connect in this

section.

94000936 3-99
 COMPLETE

1. Install main fuse. See POWER DISCONNECT (Page 7-7).

3-100 94000936
HEADLAMP NACELLE 3.27

PREPARE FASTENER TORQUE VALUE

Headlamp, nacelle mounted, 84-108 in-lbs 9.5-12.2 N-m
left side, cover screw
PREPARE
Headlamp, nacelle mounted, 84-108 in-lbs 9.5-12.2 N-m
1. Remove main fuse. See POWER DISCONNECT (Page 7-7). right side, cover screw
CONSUMABLE PART NUMBER
2. FLHC/S: Remove headlamp. See HEADLAMP (Page 7-31).
LOCTITE 243 99642-97
MEDIUM
REMOVE _______________________________ STRENGTH
THREADLOCKER
AND SEALANT
HORIZONTAL
(BLUE)
1. See HEADLAMP (Page 7-31).
HORIZONTAL
STANDARD ROUND
1. See HEADLAMP (Page 7-31).
1. See Figure 3-105 and Figure 3-106. Remove screws (1) and
clamps (2). STANDARD ROUND
2. See Figure 3-105. Remove screws (3). 1. Inspect upper and lower pads. Replace as needed.

3. Remove trim cover (4). 2. See Figure 3-105. Install nacelle (7), right cover (6) and trim
strip (2).
4. Remove left and right cover (5 and 6).
3. Apply threadlocker and install screws (3). Tighten.
5. Remove nacelle (7).
Torque: 84-108 in-lbs (9.5-12.2 N-m) Headlamp nacelle,
standard round, trim strip screw Consumable: LOCTITE
NACELLE MOUNTED 243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (BLUE) (99642-97)
1. See Figure 3-107. Remove screw (6).
4. Install left cover (5) and trim strip (4).
2. NOTE
Bezel is under pressure from isolators (7), disassemble 5. Install screws (3). Tighten.
slowly. Torque: 84-108 in-lbs (9.5-12.2 N-m) Headlamp nacelle,
standard round, trim strip screw
Remove bezel (5).
6. See Figure 3-105 and Figure 3-106. Install clamps (2) and
screws (1). Tighten.
3. Remove screws (8) and washers (9).
Torque: 36-48 in-lbs (4.1-5.4 N-m) Headlamp nacelle,
4. Remove screws (3). standard round, clamp screw

5. Remove left and right cover (2 and 1).

6. Remove nacelle (4).

INSTALL
FASTENER TORQUE VALUE
Headlamp nacelle mounted, 85-104 in-lbs 9.6-11.7 N-m
rear panel bracket screw
Headlamp nacelle, standard 36-48 in-lbs 4.1-5.4 N-m
round, clamp screw
Headlamp nacelle, standard 84-108 in-lbs 9.5-12.2 N-m
round, trim strip screw
Headlamp, nacelle mounted, 25-32 in-lbs 2.8-3.6 N-m
bezel screw

3-101 94000936
COMPLETE 1.
3. FLHC/S:
Apply Install and
threadlocker headlamp. See HEADLAMP
install screws (Page 7-31).
(3). Tighten.
Torque: 84-108 in-lbs (9.5-12.2 N-m) Headlamp, nacelle
mounted, right side, cover screw Consumable: LOCTITE
243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (BLUE) (99642-97)

4. Install left cover (2).

5. Install screws (3). Tighten.

Torque: 84-108 in-lbs (9.5-12.2 N-m) Headlamp, nacelle
mounted, left side, cover screw

6. Install washers (9) and screws (8). Tighten.

Torque: 85--104 in-lbs (9.6-11.7 N-m) Headlamp nacelle
mounted, rear panel bracket screw

7. Install bezel (5). Insert gasket behind lip of bezel.

8. Install screw (6). Tighten.

Torque: 25-32 in-lbs (2.8-3.6 N-m) Headlamp, nacelle
mounted, bezel screw

NACELLE MOUNTED

1. See Figure 3-107. Inspect trim strip (10). Replace if

necessary. See MEDALLIONS, BADGES, TANK EMBLEMS
AND ADHESIVE STRIPS (Page 3-156).

2. Install nacelle (4) and right cover (1).

3-102 94000936
COMPLETE 2. Install main fuse. See POWER DISCONNECT (Page 7-7).

94000936 3-103
 FAIRING 3.28

REMOVE AND INSTALL: SCREW-ON b. Remove lower bracket (5).

APPLICABILITY
^ • 2022 LOW RIDERS (FXLRS) Install
1. Install lower bracket.
FASTENER TORQUE VALUE
Fairing, screw-on, innerfairing 35-62 in-lbs 4-7 N-m a. Install lower bracket (5).
screws
b. Install screws (4). Tighten.
Fairing, screw-on, lower bracket 97-120 in-lbs 11-13.6 N-m
screws Torque: 97-120 in-lbs (11-13.6 N-m) Fairing, screw-
Fairing, screw-on, screws 20-30 in-lbs 2.3-3.4 N-m on, lower bracket screws
Fairing, screw-on, upper 35-62 in-lbs 4-7 N-m
2. Install upper bracket.
bracket screws
a. Install upper bracket (7).
Fairing
b. Install screws (6). Tighten.
Remove Torque: 35-62 in-lbs (4-7 N-m) Fairing, screw-on,
1. See Figure 3-108. Remove fairing. upper bracket screws

3. Install inner fairing.

a. Remove screws and washers (8).
a. Install inner fairing (2).
b. Pull fairing (3) away from upper bracket (7).

c. Pull speed screen away from lower bracket (5) to b. Install screws (1). Tighten.
remove posts from grommets. Torque: 35-62 in-lbs (4-7 N-m) Fairing, screw-on,
inner fairing screws
Install
1. Install fairing.

a. Align studs on fairing (3) to grommets in lower bracket

(5).

b. Press fairing firmly until seated.

c. Align fairing (3) with inner fairing (2).

d. Install screws and washers (8). Tighten.

Torque: 20-30 in-lbs (2.3-3.4 N-m) Fairing, screw-on,
screws

Brackets

Remove
1. See Figure 3-108. Remove inner fairing.

a. Remove screws (1).

b. Remove inner fairing (2).

2. Remove upper bracket.

a. Remove screws (6).

b. Remove upper bracket (7).

3. Remove lower bracket.

a. Remove screws (4).

94000936 3-104
REMOVE AND INSTALL: CLAMP-ON DISASSEMBLE AND ASSEMBLE
APPLICABILITY
• 2022 SPORT GLIDE (FLSB)
0
Removal
1. See Figure 3-109. Remove fairing.

a. Open clamps (4).

b. Lift fairing (3) up over headlamp.

Installation
1. See Figure 3-110. Install fairing.

a. Open clamps (4).

b. Place fairing over headlamp and onto front forks (5).

c. Verify there are no cables or wires pinched.

d. See Figure 3-109. Position upper bumper (2) on upper
fork bracket (1).

APPLICABILITY
e. Verify lower bumper (5) is seated on lower fork bracket
(6). • 2022 SPORT GLIDE (FLSB)
0
f. Lock clamps.
FASTENER TORQUE VALUE
g. Verify the upper bumpers and lower bumpers are Fairing windshield screw 32-40 in-lbs 3.6-4.5 N-m
properly seated and fairing is secure. Fairing, inner screw 32-40 in-lbs 3.6-4.5 N-m
a. Remove fairing.

b. Remove screws (7).

c. Separate inner fairing (1) from outer fairing (3).

d. Remove clips (2) if needed.

2. Remove clamps.

a. Remove pins (4).

b. Remove clamps (6).

3. See Figure 3-111. Remove windshield.

a. Loosen screws (3).

NOTE
Do not remove screws.

b. Lift windshield (2) from inner fairing (1).

Disassemble
1. See Figure 3-112. Remove inner fairing.

94000936
3-105
Assemble
1. See Figure 3-111. Install windshield.

a. Slide windshield (2) onto screws (3).

b. Verify the windshield is properly seated. Tighten.

Torque: 32-40 in-lbs (3.6-4.5 N-m) Fairing
windshield screw
2. See Figure 3-112. Install clamps.

a. Place clamps (6) in position on inner fairing (1 ).

b. Install pins (4) through holes on inner fairing and

through clamps until flush.

c. Verify operation of clamps.

3. Install inner fairing.

a. Place inner fairing (1) and outer fairing (3) together.

b. Install screws (7).

c. See Figure 3-113. Tighten screws in sequence

shown.

Torque: 32-40 in-lbs (3.^-45 N-m) Fairing, inner

screw

Figure 3-111. Quick Disconnect Fairing Windshield

3-106 94000936
FAIRING: FRAME MOUNTED 3.29

REMOVE AND INSTALL: WINDSHIELD mounted fairing, screws

FASTENER TORQUE VALUE 1. Windshield
2. Fairing
Windshield, frame mounted 5-7 in-lbs 0.6-0.8 N-m
3. Windshield seal
fairing, screws 4. Bushing (6)
5. Screw (6)
Remove Figure 3-114. Windshield

1. See Figure 3-114. Remove screws (5). REMOVE AND INSTALL: AIR DEFLECTOR
2. Remove windshield (1).

Re
mo
ve
1. S
ee
Figur
e 3-
115.
Rem
ove
scre
ws
(3).

2. R
emov
e
defle
1. Left air deflector
2. Right air deflector
3. Screw (2) ________________________________
Figure 3-115. Air Deflector
REMOVE AND INSTALL: OUTER FAIRING
SHELL ___________________________ __
ctors
(1,2).
FASTENER TORQUE VALUE
Fairing, frame mounted, air 25-30 in-lbs 2.8-3.4 N-m
deflector screws
Fairing, frame mounted, outer 25-30 in-lbs 2.8-3.4 N-m
fairing screws

Install
1. See Figure 3-114. Verify windshield seal (3) is in place on
fairing (2) and not damaged. Replace if damaged.
2. Verify bushings (4) are not damaged. Replace if damaged.

3. Install bushings in windshield (1).

FASTENER TORQUE VALUE

Fairing, frame mounted, air 25-30 in-lbs 2.8-3.4 N-m
deflector screws

4. Position windshield on fairing.

5. Install screws (5). Tighten.

Torque: 5-7 in-lbs (0.6-0.8 N-m) Windshield, frame

94000936
3-107
Install
1. See Figure 3-115. Position air deflectors (1, 2) at side of
inner fairing.

2. Install screws (3). Tighten.

Torque: 25-30 in-lbs (2.8-3.4 N-m) Fairing, frame
mounted, air deflector screws

Prepare
1. Remove windshield. See Remove and Install: Windshield
(Page 3-102).

2. Remove air deflectors. See Remove and Install: Air Deflector

(Page 3-102).

Remove
1. See Figure 3-116. Remove outer fairing.

a. Support outer fairing (3) from front.

b. Remove screws (2).

c. Disconnect head lamp connector.

d. Remove outer fairing.

3-108 94000936
Install Remove
1. Install outer fairing. 1. See Figure 3-117. Release connector retainer (3).

a. Connect headlamp connector. 2. Disconnect fairing harness connector (1).

b. See Figure 3-116. Position outer fairing (3) on inner

3. Disconnect turn signal connectors (4).
fairing (1).

c. Install screws (2). Do not tighten. 4. Remove screws (7) and washers (6).

d. Install air deflectors and screws (3). Do not tighten. 5. Remove screws (2).
See Remove and Install: Air Deflector (Page 3-102).
6. Remove inner fairing (8).
e. See Figure 3-116. Tighten outer fairing screws (2).
Torque: 25-30 in-lbs (2.8-3.4 N-m) Fairing, frame Install
mounted, outer fairing screws
1. See Figure 3-117. Loosen lower fairing mounting bracket
f. See Remove and Install: Air Deflector (Page 3-102).
screws (5).
Tighten air deflector screws.
Torque: 25-30 in-lbs (2.8-3.4 N-m) Fairing, frame NOTE
mounted, air deflector screws Loosening these screws will aid in lining up and starting
other screws.
Complete
2. Position inner fairing (8), install screws (2). Tighten.
1. Install windshield. See Refer to Remove and Install:
Windshield (Page 3-102). Torque: 96-144 in-lbs (10.8-16.3 N-m) Fairing, frame
mounted, inner fairing screws
2. Verify headlamp operation.
3. Install screws (7) and washers (6). Tighten.
Torque: 48-60 in-lbs (5.4-6.8 N-m) Fairing, frame
mounted, lower support screws

4. Connect fairing harness connector (1) to main harness.

5. Install retainer (3).

6. Connect turn signals (4).

7. Tighten lower fairing mounting bracket screws (5).

Torque: 16-20 ft-lbs (21.7-27.1 N-m) Fairing, frame
mounted, lower mount screws

Complete
Figure 3-116. Outer Fairing: Fixed Fairing
REMOVE AND INSTALL: INNER FAIRING 1. Install outer fairing. See Refer to Remove and Install: Outer
SHELL _______ Fairing Shell (Page 3-102)..
1. Inner fairing
2. Screws (4)
3. Outer fairing

FASTENER TORQUE VALUE

Fairing, frame mounted, inner 96-144 in-lbs 10.8-16.3 N-m

fairing screws
Fairing, frame mounted, lower 16-20 ft-lbs 21.7-27.1 N-m
mount screws
Fairing, frame mounted, lower 48-60 in-lbs 5.4-6.8 N-m
support screws

Prepare
1. Remove outer fairing. Remove and Install: Outer Fairing Shell
(Page 3-102).

94000936
3-109
 3. Position air ducts (4), install screws (3). Tighten.
Torque: 4.5-5.5 in-lbs (0.51-0.62 N-m) Fairing, frame
mounted, air duct screws
4. Position fairing harness (5). Install harness retainers (7).

5. Verify upper air deflector clips (9) are installed on upper

fairing tabs. Replace as needed.

6. Install upper air deflector. Verify clips are fully seated.

1. Air deflector upper

1. Fairing harness connector

2. Screw (4)
3. Retainer
4. Turn signal connector (2)
5. Screw (2)
6. Washer (2)
7. Screw (2) 2. Clips (6)
8. Inner fairing 3. Screws (6)
Figure 3-117. Inner Fairing 4. Air duct (2)
5. Fairing harness
6. Screws (4)
7. Harness retainers (6)
8. Inner fairing
FASTENER TORQUE VALUE 9. Clips (4)
Fairing, frame mounted, air duct 4.5-5.5 in-lbs 0.51-0.62 N-m 10. Fairing bracket
screws Figure 3-118. Air Ducts
Fairing, frame mounted, bracket 48-60 in-lbs 5.4-6.8 N-m
REMOVE AND INSTALL: FAIRING SUPPORTS
screws
DISASSEMBLE AND ASSEMBLE: INNER Prepare
FAIRING SHELL _______________________
FASTENER TORQUE VALUE
Disassemble Fairing, frame mounted, inner 96-144 in-lbs 10.8-16.3 N-m
fairing screws
1. Remove upper air deflector.
Fairing, frame mounted, fairing 20-27 ft-lbs 27-37 N-m
a. See Figure 3-118. Release two outer clips (9). mount to steering head locknut
Fairing, frame mounted, lower 16-20 ft-lbs 21.7-27.1 N-m
b. Pull air deflector (1) straight back to release inner mount screws
clips. Fairing, frame mounted, mount 71-84 in-lbs 8-9.5 N-m
screws upper
c. Remove upper air deflector. 1. Remove outer fairing. See Remove and Install: Outer Fairing
Shell (Page 3-102)
2. Release harness retainers (7) from inner fairing (8). Remove
harness.
2. If removing upper mounting bracket, remove inner fairing
assembly. See Remove and Install: Inner Fairing Shell
3. Remove screws (3) and air ducts (4).
(Page 3-103).

4. Remove screws (6) and fairing bracket (10).

Remove
Assemble 1. Remove fairing mounting bracket, upper.

1. Position fairing bracket (10), Install screws (6). Tighten. a. See Figure 3-119. Remove locknut (2) and screw (1).
Torque: 48-60 in-lbs (5.4-6.8 N-m) Fairing, frame b. Remove screws (4).
mounted, bracket screws

2. See Figure 3-118. Inspect and verify fairing clips (2) are
installed on inner fairing (8). Replace as needed.

3-110 94000936
 c. Remove fairing mounting bracket (3).

2. Remove fairing mounting bracket, lower.

a. See Figure 3-120. Disconnect front turn signal

connectors (3).

b. Remove screws (1) and washers (2).

c. Remove screws (4).

d. Remove fairing mounting bracket (5).

Install
1. Install fairing mounting bracket, lower.
1. Screw
2. Flange locknut
a. See Figure 3-120. Position fairing mounting bracket
3. Fairing mounting bracket
(5). 4. Screw (2)
b. Install screws (1) and washers (2). Do not tighten. Figure 3-119. Fairing Mounting Bracket Upper

c. Connect front turn signal connectors (3).

d. Install screws (4). Tighten.

Torque: 16-20 ft-lbs (21.7-27.1 N-m) Fairing, frame
mounted, lower mount screws
e. Tighten screws (1).
Torque: 96-144 in-lbs (10.8-16.3 N-m) Fairing, frame
mounted, inner fairing screws

2. See Figure 3-119. Install fairing mounting bracket, upper.

a. Install fairing mounting bracket (3).

1. Screw (2)
b. Install screw (1) and locknut (2). Do not tighten.
2. Washer (2)
3. Turn signal connector (2)
c. Install screws (4). Tighten.
4. Screw (2)
Torque: 71-84 in-lbs (8-9.5 N-m) Fairing, frame 5. Fairing mounting bracket lower
mounted, mount screws upper Figure 3-120. Fairing Mounting Bracket Lower
d. Tighten screw (1).
Complete
Torque: 20-27 ft-lbs (27-37 N-m) Fairing, frame
mounted, fairing mount to steering head locknut 1. Install inner fairing assembly. See Remove and Install: Inner
Fairing Shell (Page 3-103).

94000936
3-111
WINDSHIELD 3.30
APPLICABILITY

• 2022 HERITAGE CLASSIC 114 (FLHCS)

REMOVE. ____ _

1. See Figure 3-121. Remove windshield.

NOTE
For fairing mounted windshield, see FAIRING: FRAME
MOUNTED (Page 3-102).

a. Grab windshield at either side of horizontal bracket

(2).

b. Pull windshield so that upper notches (1) separate

from grommets.

c. Raise windshield until lower notches (5) separate from

grommets.

d. Remove windshield.

INSTALL

1. See Figure 3-121. Install windshield. Figure 3-121. Windshield DISASSEMBLE

NOTE
For fairing mounted windshield, see FAIRING: FRAME 1. See Figure 3-122. Disassemble windshield brackets.
MOUNTED (Page 3-102)
a. Place windshield on a clean padded surface.
a. Place upper and lower notches (1,5) on upper and lower b. Remove acorn nuts (2) and discard screws (6, 7) from
grommets. each vertical bracket (8).

b. Push evenly on horizontal bracket (2) until notches are fully c. Remove and discard remaining screws from horizontal
seated on grommets. bracket (5).

ASSEMBLE

FASTENER TORQUE VALUE

Windshield acorn nuts 23-27 In-lbs 2.6-3 N-m

1. See Figure 3-122. Install horizontal bracket.

a. Position inner horizontal bracket (3) and outer

horizontal bracket (5) on windshield (4).

b. Loosely install three new short screws (6) and acorn

nuts (2).

2. Install vertical bracket.

a. Position mounting brackets (1) and vertical brackets

(8) on windshield.

b. Loosely install new long screws (7) and new short

screws (6) through vertical brackets, windshield and
mounting brackets.

c. loosely install acorn nuts.

3-112 94000936
 d. Tighten all nuts.
Torque: 23-27 in-lbs (2.6-3 N-m) Windshield acorn nuts

1. M
o
u
n
t
i
n
g

b
r
a
c
k
e
t
(2)
2. Acorn nut (9)
3. Inner horizontal bracket
4. Windshield
5. Outer horizontal bracket
6. Short Screw (7)
7. Long screw (2)
8. Vertical bracket
Figure 3-122. Windshield Assembly

94000936 3-113
HAND GRIPS 3.31

REMOVE NOTE
Adhesive sets in 4 minutes and cures in 24 hours.

Left a. Prepare the left grip end of the handlebar with emery
1. Remove LHCM. See LEFT HAND CONTROL MODULE cloth.
(LHCM) (Page 7-16).
b. Clean the left grip end of the handlebar with acetone.
2. Remove left hand grip. c. Apply primer to the inside of the new hand grip.

a. Cut hand grip open with a sharp knife. LOCTITE 770 PRISM PRIMER (Loctite 770)
d. Remove excess primer. Wait 2 minutes for the primer
b. Peel hand grip open. to set.

c. Remove from handlebar. e. Apply adhesive to the inside of the new hand grip.

HARLEY-DAVIDSON ADHESIVE (GRIPLOCK)

Right
(99839-95)
1. Remove RHCM. See RIGHT HAND CONTROL MODULE
(RHCM) (Page 7-20). f. Install the new hand grip with a twisting motion,
ending with cosmetic features properly positioned.
2. Remove right hand grip.
2. Install LHCM. See LEFT HAND CONTROL MODULE (LHCM)
(Page 7-16).
INSTALL
Right
CONSUMABLE PART NUMBER
HARLEY- 99839-95 1. Install hand grip with cosmetic features properly positioned.
DAVIDSON
ADHESIVE
a. Rotate to verify that internal splines are engaged with
(GRIPLOCK) Loctite 770
LOCTITE 770 the twist grip sensor.
PRISM PRIMER
Install RHCM. See RIGHT HAND CONTROL MODULE
Left 2
. (RHCM) (Page 7-20)

1. Install left hand grip.

3-114 94000936
 HANDLEBAR 3.32

PREPARE

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

2. All but FXLRST: Remove windshield, if equipped. See

WINDSHIELD (Page 3-106).

3. All but FXLRST: Remove fairing, if equipped. See FAIRING

(Page 3-99).

4. Remove front brake master cylinder. See FRONT BRAKE

MASTER CYLINDER (Page 3-35).

5. Disconnect RHCM, TGS, and LHCM from front electrical

caddy. See RIGHT HAND CONTROL MODULE (RHCM)
(Page 7-20).

6. Remove clutch hand control from handlebar. See CLUTCH

CONTROL (Page 3-91).

REMOVE AND INSTALL: STANDARD

FASTENER TORQUE VALUE

Riser flange nuts 30-40 ft-lbs 40.7-54.3 N-m

Remove
1. See Figure 3-123 or Figure 3-124. Remove handlebar
assembly.

a. Remove flange nuts (11) and lower cup washers (10).

b. FXBBS, FXST, FXBRS, FXLRS, FXLRST 1. Handlebar

Disconnect IM. See INSTRUMENT MODULE (IM) 2. Handlebar clamp
(Page 7-24). 3. Handlebar clamp fastener (4)
4. Riser (2)
c. Remove handlebar (1) and attached components as 5. Stud (2)
an assembly. 6. Upper cup washer (2)
7. Bushing (4)
8. Spacer (2)
Install 9. Upper fork bracket (typical)
10. Lower cup washer (2)
1. See Figure 3-123 or Figure 3-124. Install handlebar assembly.
11. Flange nut (2)
Figure 3-123. Handlebar Mounting (Typical)

a. Place upper cup washers (6) on top of bushings (7).

b. Install studs (5) through upper cup washers (6),

bushings (7), spacers (8), and upper fork bracket (9).

c. Install lower cup washers (10) and flange nuts (11).

Tighten flange nuts.
Torque: 30-40 ft-lbs (40.7-54.3 N-m) Riser flange
nuts
d. FXBBS, FXST, FXBRS, FXLRS, FXLRST Connect IM.
See INSTRUMENT MODULE (IM) (Page 7-24).

94000936 3-115
 b. Remove studs (5) from riser, if necessary.

c. Remove spacers (8) and bushings (7), if necessary.

Assemble
1. See Figure 3-123 or Figure 3-124. Assemble handlebar
assembly.

a. Install bushings (7) and spacers (8), if removed.

b. Thread short end of studs (5) into risers (4) until

bottomed, if removed.

c. Install upper cup washer (6) on top of left and right

bushings (7).

d. Insert studs in bushings and install lower cup washer

(10) and flange nut (11) loosely.

e. Center handlebar (1) in risers.

1. Handlebar
2. Handlebar clamp f. Place handlebars in normal riding position and hold.
3. Handlebar clamp fastener (4)
4. Riser (2) g. Attach handlebar clamp (2) with handlebar clamp
5. Stud (2) fasteners (4).
6. Upper cup washer (2)
NOTE
7. Bushing (4)
8. Spacer (2) Tighten handlebar clamp fasteners just enough to maintain
9. Upper fork bracket handlebar position.
10. Lower cup washer (2)
11. Flange nut (2) h. Tighten gap limiting fasteners.
Figure 3-124. Handlebar, Speedometer Mount
Torque: 12-16 ft-lbs (16.3-21.7 N-m) Handlebar
DISASSEMBLE AND ASSEMBLE: STANDARD clamp gap limiting fasteners NOTE
___________________________________ Handlebar clamps are manufactured with pads on
one half of top clamp that should be touching the
riser when assembled. Fasteners (gap limiting
FASTENER TORQUE VALUE fasteners) closest to the pads need to be tightened
Handlebar clamp gap limiting 12-16 ft-lbs 16.3-21.7 N-m first.
fasteners
Handlebar clamp open gap 12-16 ft-lbs 16.3-21.7 N-m i. Tighten open gap fasteners. Verify that there is a gap
fasteners between upper and lower clamps at opposite gap
limiting fasteners.
Riser flange nuts 30-40 ft-lbs 40.7-54.3 N-m
Torque: 12-16 ft-lbs (16.3-21.7 N-m) Handlebar
Disassemble clamp open gap fasteners
1. Remove RHCM. See RIGHT HAND CONTROL MODULE j. Tighten flange nuts (11).
(RHCM) (Page 7-20).
Torque: 30-40 ft-lbs (40.7-54.3 N-m) Riser flange
nuts
2. Remove TGS. See TWIST GRIP SENSOR (TGS) (Page 6-
24).
2. FXBBS, FXST, FXBRS, FXLRS, FXLRST Connect IM. See
INSTRUMENT MODULE (IM) (Page 7-24).
3. Remove LHCM. See LEFT HAND CONTROL MODULE
(LHCM) (Page 7-16).
3. FXBRS, FXFBS, FLFBS, FLSB, FXLRS, FXLRST Install
weight inside left handlebar, if necessary.
4. Remove left hand grip, if necessary.
4. Install left hand grip, if necessary. See HAND GRIPS (Page
5. FXBRS, FXFBS, FLFBS, FLSB, FXLRS, FXLRST 3-108).
Remove weight inside left handlebar, if necessary.
5. Install LHCM. See LEFT HAND CONTROL MODULE
6. See Figure 3-123 or Figure 3-124. Disassemble handlebar (LHCM) (Page 7-16).
assembly.
6. Install clutch control. See CLUTCH CONTROL (Page 3-91).
a. Remove handlebar clamp fasteners (3) to separate
handlebar (1), handlebar clamp (2), and risers (4).

3-116 94000936
 7. Install TGS. See TWIST GRIP SENSOR (TGS) (Page 6-24).

8. Install RHCM. See RIGHT HAND CONTROL MODULE

(RHCM) (Page 7-20).

COMPLETE _____________________________

1. Connect clutch hand control to handlebar. See CLUTCH

CONTROL (Page 3-91).

2. Connect RHCM, TGS, and LHCM tofront electrical caddy.

See RIGHT HAND CONTROL MODULE (RHCM) (Page 7-
20).
3. Install front brake master cylinder. See FRONT BRAKE
MASTER CYLINDER (Page 3-35).

4. All but FXLRST: Install fairing, if equipped. See FAIRING

(Page 3-99).

5. All but FXLRST: Install windshield, if equipped. See

WINDSHIELD (Page 3-106).

6. Install main fuse. See POWER DISCONNECT (Page 7-7).

94000936 3-117
MIRRORS 3.33

1059283

Remove
1. See Figure 3-125. Support turn signal assembly (2), if
equipped.

2. Remove nut (4) and washer (3).

3. Remove mirror (1).

INSTALL _______________________________

FASTENER TORQUE VALUE

Mirror mounting nut 96-144 in-lbs 10.8-16.3 N-m

REMOVE
Install Torqu
e: 96-
1. See Figure 3-125. Insert threaded stem of mirror into hole in 144
clutch or brake lever bracket. in-lbs
(10.8-
2. Install turn signal (2), if equipped. 16.3
N-m)
3. Install washer (3) and nut (4). Mirror
moun
ting
4. Adjust mirror as necessary and tighten nut.
nut

M
i
r
r
o
r
T
urn signal assembly, if equipped
Lock washer
Nut
Figure 3-125. Mirror Mount (Typical)

3-118 94000936
 FRONT FENDER 3.34
REMOVE f. Install screws. Tighten.
Torque: 72-96 in-lbs (8.1-10.8 N-m) Front fender
1. See Figure 3-126. Remove front fender. mounting screw; FXFBS

a. Remove screws (3,5,7, 12) and nuts (8), depending on FXBBS, FXST
model. 1. See Figure 3-126. Install front fender.
NOTE
b. Remove fender (2,4,6,11), depending on model.
Verify that the mounting brackets are resting against the
c. Inverted fork: Fender (2) assembly, remove screws machined bosses of the forks before tightening.
(1) and nuts (9). Separate from bracket (10).
a. Align fender (6) mounting brackets to the machined
bosses on the front forks.

FASTENER TORQUE VALUE

b. Apply threadlock to screws (7).
Front fender mounting screw 16-21 ft-lbs 22-28 N-m
LOCTITE 243 MEDIUM STRENGTH
(typical)
THREADLOCKER AND SEALANT (BLUE) (99642-97)
Front fender mounting screw, 16-21 ft-lbs 22-28 N-m
FXBBS/FXST
c. Install Screws and nuts (8). Tighten.
Front fender mounting screw, 72-96 in-lbs 8.1-10.8 N-m
FXFBS Torque: 16-21 ft-lbs (22-28 N-m) Front fender
mounting screw; FXBBS/FXST
Front fender mounting screw, 72-96 in-lbs 8.1-10.8 N-m
FXLRS/FXLRST
FXLRS,FXLRST
Front fender to bracket screw, 36--48 in-lbs 4.1-5.4 N-m
FXFBS 1. See Figure 3-126. Install front fender.
NOTE
CONSUMABLE PART NUMBER
Verify that the mounting brackets are resting against the
LOCTITE 243 99642-97
machined bosses of the forks before tightening.
MEDIUM
STRENGTH
THREADLOCKER a. Align fender (11) mounting brackets to the machined
AND SEALANT bosses on the front forks.
(BLUE)
b. Apply threadlock to screws (12).
INSTALL
LOCTITE 243 MEDIUM STRENGTH
Inverted Fork THREADLOCKER AND SEALANT (BLUE) (99642-97)

1. See Figure 3-126. Install front fender. c. Install screws. Tighten.

Torque: 72-96 in-lbs (8.1-10.8 N-m) Front fender
a. Align fender (2) with bracket (10). mounting screw; FXLRS/FXLRST

b. Apply threadlock to screws (1). Standard Fork (Typical)

LOCTITE 243 MEDIUM STRENGTH
1. See Figure 3-126. Install front fender.
THREADLOCKER AND SEALANT (BLUE) (99642-97)

c. Install screws and nuts (9), if equipped. Tighten. a. Align fender (4) to the mounting holes on fork.

Torque: 36-48 in-lbs (4.1-5.4 N-m) Front fender to b. Apply threadlock to screws (5).
bracket screw, FXFBS
LOCTITE 243 MEDIUM STRENGTH
d. Align fender assembly with mounting holes on front THREADLOCKER AND SEALANT (BLUE) (99642-97)
fork.
c. Install Screws. Tighten.
e. Apply threadlock to screws (3). Torque: 16-21 ft-lbs (22-28 N-m) Front fender
LOCTITE 243 MEDIUM STRENGTH mounting screw (typical)
THREADLOCKER AND SEALANT (BLUE) (99642-97)

94000936 3-119
 1631694

1. Screw (4) 7. Screw (4)

2. Fender, FXFBS 8. Nut (4)
3. Screw (4) 9. Nut (4)
4. Fender (typical) 10. Bracket
5. Screw (4) 11. Fender, FXLRS, FXLRST
6. Fender, FXBBS, FXST 12. Screw (4)

Figure 3-126. Front Fenders

DISASSEMBLE _________________________ ______ b, Remove trim (1 ),

Full Fender ASSEMBLE

1. See Figure 3-127. Remove side trim. FASTENER TORQUE VALUE
Front fender side trim nut 10-15 in-lbs 1.1-1.7 N-m
a. Remove nuts (5).
1. See Figure 3-127. Install skirt trim.
b. Remove trim (6).
a. Position skirt trim (1) on fender (2).
c. Remove tee bolts (7) from trim.
2. Remove fender tip. b. Install nuts (8).

a. Remove nuts (4). 2. Install medallions.

b. Remove tip (3).

a. Clean mounting surface. See MEDALLIONS,
BADGES, TANK EMBLEMS AND ADHESIVE STRIPS
3. Remove medallions (9). See MEDALLIONS, BADGES,
(Page 3-156).
TANK EMBLEMS AND ADHESIVE STRIPS (Page 3-156).
b. Remove adhesive backing from medallion (9).
4. See Figure 3-127. Remove skirt trim.
c. Install medallion pressing firmly to make sure there is
good adhesion.

a. Remove nuts (8).

3-120 94000936
 3. Install fender tip.
a. Position fender tip (3) on fender (2).

b. Install nuts (4).

Install side trim.

4.
a. Loosely install tee bolt (7) and nut (5) on fender.
b. Slide side trim (6) on tee bolts.

c. Hold side trim tight to fender tip (3) and tighten nuts.
Torque: 10-15 in-lbs (1.1-1.7 N-m) Front fender side
trim nut

94000936 3-121
REAR FENDER 3.35
PREPARE ______________________________

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

2. Remove saddle bags, if equipped. See SADDLEBAGS (Page

3-145).

3. Remove seat. See SEAT (Page 3-142).

REMOVE AND INSTALL: STANDARD

FASTENER TORQUE VALUE
Rear fender mounting screw 42-46 ft-lbs ! 57-62.5 N-m

Remove
1. See Figure 3-128. Disconnect connectors (2, 3).

2. Discard cable strap(s) (1).

3. Remove fender.

a. Support rear fender. DISASSEMBLE AND ASSEMBLE: FULL

FENDER ____________________________
b. Remove fender screws (4) and washers from both FASTENER TORQUE VALUE
sides. Rear fender support screws 21-27 ft-lbs 28.4-37 N-m
CONSUMABLE PART NUMBER
c. Remove fender.
LOCTITE 243 99642-97
MEDIUM
Install STRENGTH
THREADLOCKER
1. See Figure 3-128. Install rear fender.
AND SEALANT
(BLUE)
a. Place fender into position.

b. Install screws (4) and washers. Tighten. Disassemble

Torque: 42-46 ft-lbs (57-62.5 N-m) Rear fender 1. Remove rear fender lighting. See REAR TURN SIGNAL
mounting screw LAMPS (Page 7-52) and TAIL LAMP (Page 7-57).
2. Connect connectors (2, 3).
2. NOTE
3. Install new cable strap(s) (1) into hole(s) on frame and attach Rear fender wire conduit is not reusable.
cable.
Remove rear fender wire conduit, if necessary. See REAR
FENDER WIRE CONDUIT (Page 3-122).

3. Remove license plate bracket mount. See REAR LICENSE

PLATE BRACKET (Page 3-126).

4. See Figure 3-129. Remove fender support.

a. Remove screws (13).

b. Remove fender mounts (9,10).

c. Remove fender supports (11,12).

5. Remove fender tip.

a. Remove nuts (8).

b. Remove fender tip (1).

3-122 94000936
 6. Remove seat retention nut.

a. Hold nut (7).

b. Remove clip (2).

c. Remove nut.

d. If equipped, remove plugs (3).

7. Remove stud plate.

a. Remove washers (4).

b. Remove stud plate (6).

Assemble 1. Fender tip

2. Clip
1. See Figure 3-129. Install stud plate. 3. Plug (2)
4. Washer (2)
a. Position stud plate (6) on fender. 5. Reflector (2)
6. Stud plate
b. Install washers (4). 7. Nut
8. Nut (3)
2. Install seat retention nut. 9. Fender mount rear (2)
10. Fender mount front (2)
a. Position nut (7) through fender. 11. Left fender support
b. Install clip (2). 12. Right fender support
13. Fender support screw (8)
Figure 3-129. Full Fender
c. If equipped, install plugs (3).
DISASSEMBLE AND ASSEMBLE: CHOPPED
3. Install fender tip. FENDER WITHOUT LICENSE PLATE BRACKET
LIGHTING ______________________________
a. Position fender tip (1) on fender.
b. Install nuts (8). Disassemble

4. Install fender supports. 1. Remove taillight, if equipped. See TAIL LAMP (Page 7-57).

a. Align holes on fender supports (11,12) with holes in FASTENER TORQUE VALUE
fender. Rear fender inner mount 21-27 ft-lbs 28.4-37 N-m
screw
b. Place fender mounts (10) in the holes near rear of Rear fender support screw 21-27 ft-lbs 28.4-37 N-m
fender.
Rear fender support screws 21-27 ft-lbs 28.4-37 N-m

c. Place fender mounts (9) in the holes near front of CONSUMABLE PART NUMBER
fender.
LOCTITE 243 99642-97
MEDIUM
d. Apply threadlock and Install screws (13). Tighten. STRENGTH
Torque: 21-27 ft-lbs (28.4-37 N-m) Rear fender support THREADLOCKER
screws AND SEALANT
LOCTITE 243 MEDIUM STRENGTH (BLUE)

THREADLOCKER AND SEALANT (BLUE) (99642-97) 2. Remove license plate bracket. See REAR LICENSE PLATE
BRACKET (Page 3-126).
5. Install license plate bracket mount. See REAR LICENSE
PLATE BRACKET (Page 3-126). 3. See Figure 3-130, Figure 3-131 , Figure 3-132 or Figure 3-
133. Remove rear fender support.
6. Install rear fender wire conduit. See REAR FENDER WIRE
CONDUIT (Page 3-122). a. Models equipped with inner fender mount screws:
Remove screws (13).
7. Install fender lighting. See REAR TURN SIGNAL LAMPS
(Page 7-52) and TAIL LAMP (Page 7-57). b. Models without saddlebags: Remove screws (11).

94000936 3-123
 c. Models with saddlebags: Remove screws (18), Before installing fender supports, route and secure turn
bracket (17) and spacer (16). signal wire harnesses through fender supports. See REAR
TURN SIGNAL LAMPS (Page 7-52)
d. Remove fender mounts (9).
a. Align holes on fender supports (7, 10) with holes in
e. Remove fender supports (7,10). fender.

f. Remove license plate support bracket (12), if b. Place fender mounts (9) in holes on fender.
equipped.
c. Models without saddlebags: Apply threadlock and
4. Remove turn signals. See REAR TURN SIGNAL LAMPS install screws (11). Tighten.
(Page 7-52). Torque: 21-27 ft-lbs (28.4-37 N-m) Rear fender
support screws
5. Remove reflector bracket (2) and reflectors (1, 6), if LOCTITE 243 MEDIUM STRENGTH
equipped.
THREADLOCKER AND SEALANT (BLUE) (99642-97)
a. Saw behind reflectors with mono-filament fishing line d. Models with saddlebags: Apply threadlock to
or waxed dental floss. screws (18), Install spacers (16), brackets (17).
Tighten.
6. NOTE Torque: 21-27 ft-lbs (28.4-37 N-m) Rear fender
Some fenders will have two seat retention nuts. support screw
LOCTITE 243 MEDIUM STRENGTH
Remove seat retention nut.
THREADLOCKER AND SEALANT (BLUE) (99642-97)
a. Hold nut (3). 6. See Figure 3-131, Figure 3-132 or Figure 3-133. Models
with license plate support brackets: Install rear fender
b. Remove clip (4). supports.

7. See Figure 3-132. Remove stud plate, if equipped. a. Align holes on bracket (12) with holes on fender and
insert fender mounts (9).
a. Remove washers (15).
b. Remove stud plate (14). b. Align fender supports (7,10).

c. Models equipped with license plate bracket and

Assemble inner fender screws: Apply threadlock and install
1. See Figure 3-132. Install stud plate, if equipped. screw (13) through license plate bracket. Tighten.
Torque: 21-27 ft-lbs (28.4-37 N-m) Rear fender inner
a. Position stud plate (14) on fender. mount screw
LOCTITE 243 MEDIUM STRENGTH
b. Install washers (15).
THREADLOCKER AND SEALANT (BLUE) (99642-97)
2. See Figure 3-130, Figure 3-131, Figure 3-132 or Figure 3-
d. Apply threadlock and install screws (11). Tighten.
133. Install seat retention nut.
Torque: 21-27 ft-lbs (28.4-37 N-m) Rear fender
support screw
a. Position nut (3).
LOCTITE 243 MEDIUM STRENGTH
b. Install clip (4). THREADLOCKER AND SEALANT (BLUE) (99642-97)

3. Install reflector bracket (2) and reflectors (1, 6) if equipped. 7. Install license plate bracket. See REAR LICENSE PLATE
BRACKET (Page 3-126).
a. Clean mounting surface. See MEDALLIONS,
BADGES, TANK EMBLEMS AND ADHESIVE 8. Install taillight if equipped. See TAIL LAMP (Page 7-57).
STRIPS (Page 3-156).

b. Test fit reflector (1, 6).

c. Remove adhesive backing.

d. Install and press firmly to adhere.

4. Install turn signals. See REAR TURN SIGNAL LAMPS (Page

7-52).
5. See Figure 3-130. Models without license plate support
brackets: Install rear fender supports.
NOTE

3-124 94000936
 1. Rear reflector
2. Reflector bracket 1. Rear reflector
3. Seat retention nut (2) 2. Reflector bracket
4. Clip (2) 3. Seat retention nut
5. Plug 4. Clip
6. Side reflector (2) 6. Side reflector (2)
7. Left fender support 7. Left fender support
8. Inner fender screw (2) 9. Fender mount (2)
9. Fender mount (2) 10. Right fender support
10. Right fender support 11. Fender support screw (4)
11. Fender support screw (4) 12. License plate support bracket
Figure 3-130. Chopped Fender: W/O License Plate Bracket
13. Inner fender mount screw (2)
14. Stud plate
15. Washer (2)
Figure 3-132. Chopped Fender: With license Plate Bracket
and Inner Fender Mount Screws

1. Rear reflector
2. Reflector bracket
3. Seat retention nut
4. Clip
5. Plug
6. Side reflector (2)
7. Left fender support
8. Inner fender screw (2)
9. Fender mount (2)
10. Right fender support
11. Fender support screw (4)
12. License plate support bracket _______________
Figure 3-131. Chopped Fender: With Licence Plate Bracket,
W/O Inner Fender Mounting Screws

94000936 3-125
 3. Remove seat retention nuts.

a. Hold nut (2).

b. Remove clip (1 ).

4. Disassemble inner bracket assembly (13).

a. Remove turn signals. See REAR TURN SIGNAL

LAMPS (Page 7-52).

b. Remove taillight. See TAIL LAMP (Page 7-57).

c. Disassemble license plate bracket. See REAR

LICENSE PLATE BRACKET (Page 3-126).

5. Remove reflectors (11 ).

3. Seat retention nut a. Saw behind reflectors with mono-filament fishing line or
4. Clip waxed dental floss.
5. Plug (3)
6. Side reflectors (2) Assemble
7. Left fender support
8. Inner fender screw (2) 1. See Figure 3-134. Install reflectors (11 ).
9. Fender mount (2)
10. Right fender support a. Clean mounting surface. See MEDALLIONS,
11. Fender support screw (4) BADGES, TANK EMBLEMS AND ADHESIVE STRIPS
16. Saddlebag mounting spacer (4) (Page 3-156).
17. Saddlebag mounting bracket (4)
18. Screw (4) b. Test fit reflector.
Figure 3-133. Chopped Fender: License Plate Bracket With
Tail Lamp Mounted Below c. Remove adhesive backing.
DISASSEMBLE AND ASSEMBLE: CHOPPED
FENDER WITH LICENSE PLATE BRACKET d. Install and press firmly to adhere.
LIGHTING
CONSUMABLE PART NUMBER 2. Assemble inner bracket assembly (13).
LOCTITE 243 99642-97
MEDIUM FASTENER TORQUE VALUE a. Assemble license plate bracket. See REAR LICENSE
STRENGTH PLATE BRACKET (Page 3-126).
Rear fender support screw 21-27 ft-lbs 28.4-37 N-m
THREADLOCKER
AND SEALANT b. Install taillight. See TAIL LAMP (Page 7-57).
(BLUE)
c. Install turn signals. See REAR TURN SIGNAL LAMPS
Disassemble (Page 7-52).

1. See Figure 3-134. Remove rear fender support. 3. Install seat retention nuts.

a. Remove screws (10). a. Position nut (2).

b. Remove saddlebag mounting bracket (9) and spacer b. Install clip (1 ).

8
( ).

4. Insert new cable strap (12) into fender.

c. Remove fender mount bracket (6).
5. Install rear fender support.
d. Remove fender supports (4, 7).
a. Route harnesses through access hole in right side of
e. Remove inner bracket assembly (13). fender.
2. Discard cable strap (12).
b. Install inner bracket assembly (13).

c. Route and secure harnesses with cable strap (12).

d. Install fender mount brackets (6).

e. Install fender supports (4, 7).

3-126 94000936
 NOTE
Route harnesses under right fender support (7).

f. Install saddlebag mounting spacers (8) and brackets

(9) .

g. Apply threadlocker and install screws (10). Tighten.

Torque: 21-27 ft-lbs (28.4-37 N-m) Rear fender

support screw
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-97)

1. C
l
i
p

(
2
)
2. Seat retention nut (2)
3. Plug
4. Left fender support
5. Fender seat nut screw (2)
6. Fender mount bracket (2)
7. Right fender support
8. Saddlebag mounting spacer (4)
9. Saddlebag mounting bracket (4)
10. Screw (4)
11. Reflector (2)
12. Anchored cable strap
13. Inner bracket assembly
Figure 3-134. Chopped Fender: License Plate Bracket With
Lights
COMPLETE

COMPLETE
1. Install seat. See SEAT (Page 3-142).

2. Install saddle bags if removed. See SADDLEBAGS (Page 3-

145).

3. Install main fuse. See FUSES (Page 7-6).

94000936 3-127
REAR FENDER WIRE CONDUIT 3.36
PREPARE

1. Remove rear fender. See REAR FENDER (Page 3-116).

2. Remove rear fender wire harness. See the electrical

diagnostic manual.

a. Remove wire terminals from harness connectors.

b. Remove wire harness from conduit.

REMOVE ________________________

1. Remove conduit.

a. Pull conduit from fender.

b. Thoroughly clean inside surface of fender with soap

and water until it is free of dirt, oil or other debris.

INSTALL

1. See Figure 3-135, Figure 3-136, Figure 3-137. Install wiring

conduit.

a. Clean mounting surface. See MEDALLIONS,

BADGES, TANK EMBLEMS AND ADHESIVE STRIPS
(Page 3-156).

b. With the adhesive backing still in place, test fit the

conduit.

c. See Figure 3-136 and Figure 3-137. Remove the

adhesive backing (2).

d. Lightly position the conduit (1) in place.

e. Using Iii wallpaper roller (4), roll along conduit (3) to

purge the air from between adhesive and fender.

Figure 3-136. Removing Protective Strip From Conduit

Figure 3-137. Purging Air Between Adhesive and Fender

3-128 94000936
94000936 3-129
COMPLETE b. Install wire terminals into connector housings. See the
electrical diagnostic manual.

1. Install wiring harness.

Install connectors to proper component and install rear
fender. See REAR FENDER (Page 3-116).
a. Slide wiring harness through new conduit.

3-130 94000936
 SAREE GUARD 3.37

REMOVE 2. Install lower saree belt guard.

1. See Figure 3-138 Remove upper saree guard. a. Place lower saree belt guard (4) in position with the
lower tab behind P-clamp (6).
a. Remove screws (1) and washers.
b. Install threadlocker to screws (3,5).

b. Remove guard (2). LOCTITE 243 MEDIUM STRENGTH

THREADLOCKER AND SEALANT (BLUE) (99642-97)
2. Remove lower saree belt guard.
c. Install screws.
a. Remove screws (3, 5).
d. Tighten screw (3).

b. Remove guard (4). Torque: 71-80 in-lbs (8-9 N-m) Saree lower guard
top screw
INSTALL ___________________ e. Tighten screw (5).
FASTENER TORQUE VALUE
Torque: 10-13 ft-lbs (14-18 N-m) Saree lower guard
Saree lower guard top screw 71-80 in-lbs 8-9 N-m
lower screw
Saree lower guard lower screw 10-13 ft-lbs 14-18 N-m

Saree upper guard screw 21-27 ft-lbs 28-37 N-m

CONSUMABLE PART NUMBER
LOCTITE 243 99642-97
MEDIUM
STRENGTH
THREADLOCKER
AND SEALANT
(BLUE)
1. See Figure 3-138. Install upper saree guard.

a. Place upper saree guard (2) in position.

b. Install threadlocker to screws (1).

LOCTITE 243 MEDIUM STRENGTH

THREADLOCKER AND SEALANT (BLUE) (99642-97)

c. Install screws and washers. Tighten.

Torque: 21-27 ft-lbs (28-37 N-m) Saree upper guard

screw

94000936 3-131
 FRONT LICENSE PLATE BRACKET 3.38

REMOVE b. Install headlamp. See HEADLAMP (Page 7-31).

c. Install screws (4). Tighten.

1. See Figure 3-139. Remove front license plate bracket.
Torque: 16-20 ft-lbs (21.7-27 N-m) Front licence plate
a. If equipped with two hole bracket (1) remove two hole bracket screws
headlamp, screws and bracket. See HEADLAMP
(Page 7-31). One hole bracket
1. Install license plate bracket (2).
b. If equipped with one hole bracket (2) or clamp bracket
(3), remove nuts (6), screws (4 or 8), washers (5), a. See Figure 3-139. Position spacer (7) between lower
spacer (7), depending on the bracket. triple clamp and bracket (2).

c. Remove license plate bracket (2 or 3). b. Install washer (5) and screw (8). Tighten.
Torque: 25-30 ft-lbs (34-40.7 N-m) Front licence plate
one hole bracket screw
FASTENER TORQUE VALUE
1-1 ft-lbs 1.1—1.7 N-m
Clamp brackets
Front licence plate clamp
bracket screws 1. Install license plate brackets (3).
Front licence plate one hole 25-30 ft-lbs 34-40.7 N-m
bracket screw a. See Figure 3-139. Position brackets (3) on either side
16-20 ft-lbs 21.7-27 N-m of risers on handle bar with tab facing front of bike.
Front licence plate two hole
bracket screws
b. Install screws (4), washers (5) and nuts (6). Tighten.
INSTALL _____________
Torque: 1-1 ft-lbs (1.1-1.7 N-m) Front licence plate
clamp bracket screws
Two hole bracket
1. Install license plate bracket (1).

a. See Figure 3-139. Position bracket (1) on upper triple clamp.

1. Two hole bracket 5.

2. One hole bracket 6.
3. Clamp bracket 7.
4. Button head screw (2) 8.

3-132 94000936
 Washer(s) Spacer
Nut (2) Screw
Figure 3-139. License Plate Bracket

94000936 3-133
REAR LICENSE PLATE BRACKET 3.39
GENERAL

Remove side mounted bracket: See REAR TURN SIGNAL

LAMPS (Page 7-52)

Remove rear mounted bracket: See LICENSE PLATE LAMP

(Page 7-64)

STANDARD

FASTENER TORQUE VALUE

License plate standard as- 62-89 in-lbs 7-10 N-m
sembly bolt
License plate standard mount 71-97 in-lbs 8-11 N-m
screws

Remove
1. Reflector
1. See Figure 3-140. Remove license plate bracket. 2. Bolt
3. Bracket
a. Reach up under the rear fender and remove nuts (9). 4. Clamp
5. Washer
b. Remove license plate bracket assembly.
6. Nut
7. Support
Install 8. Screw (3)
9. Nut (3) _______________________________
1. Install license plate bracket on fender.
Figure 3-140. Standard License Plate Bracket

a. Position license plate assembly on fender. CENTER MOUNT _____________________

b. Install screws (8) and nuts (9). Tighten.

FASTENER TORQUE VALUE
Torque: 71-97 in-lbs (8-11 N-m) License plate
standard mount screws License plate bracket inner 18-21 in-lbs 2.03-2.37 N-m
mounting screws
Disassemble License plate bracket outer 63-77 in-lbs 7.11-8.69 N-m
mounting screws
1. Disassemble license plate bracket.
Disassemble
a. Remove nut (6), washer (5) and bolt (2). 1. See Figure 3-141. Remove center mounted license plate
bracket.
b. Separate the bracket (3), clamp (4) and support (7).
a. Remove license plate lamp housing. See LICENSE
2. Remove reflector if needed. See MEDALLIONS, BADGES, PLATE LAMP (Page 7-64).
TANK EMBLEMS AND ADHESIVE STRIPS (Page 3-156)
b. Remove screws (3,5) from rear fender support (4).
Assemble
c. Separate license plate bracket (2) from rear fender
1. Assemble the license plate bracket. support.

a. Position clamp (4) between the bracket (3) and the Assemble
support (7).
1. Install center mounted license plate bracket.
b. Install bolt (2), washer (5) and nut (6). Tighten.
Torque: 62-89 in-lbs (7-10 N-m) License plate a. Align holes on center mounted licence plate bracket
standard assembly bolt (2) with rear fender support (4).

c. Install reflector (1) if removed. See MEDALLIONS,

b. Install screws (5). Tighten.
BADGES, TANK EMBLEMS AND ADHESIVE STRIPS
(Page 3-156) Torque: 18-21 in-lbs (2.03-2.37 N-m) License plate
bracket inner mounting screws

3-134 94000936
 c. Install screws (3). Tighten.

Torque: 63-77 in-lbs (7.11-8.69 N-m) License plate

bracket outer mounting screws

2. Install center mount lamp housing. See LICENSE PLATE

LAMP (Page 7-64)

Figure 3-141. Center Mount License Plate Bracket

CENTER MOUNT WITH LIGHTING
FASTENER TORQUE VALUE
Assemble
License plate holder screw 63-77 in-lbs 7.11-8.69 N-m
1. See Figure 3-142. Install center mount licence plate holder.

Disassemble a. Assemble license plate holder (3), support bracket

assembly (1) and support bracket reinforcement (2).
1. Remove license plate lamp. See LICENSE PLATE LAMP
(Page 7-64).
b. Install screws (4). Tighten.

2. Remove turn signal lamps. See REAR TURN SIGNAL Torque: 63-77 in-lbs (7.11-8.69 N-m) License plate
LAMPS (Page 7-52). holder screw

3. See Figure 3-142. Remove center mount licence plate 2. Install license plate lamp. See LICENSE PLATE LAMP
holder. (Page 7-64).

3. Install turn signal lamps. See REAR TURN SIGNAL LAMPS

a. Remove screws (4).
(Page 7-52).
b. Disassemble license plate holder (3), support bracket
assembly (1) and support bracket reinforcement (2).

94000936 3-135
LEFT FOOT CONTROLS 3.40
PREPARE

1. Set motorcycle upright. See Secure the Motorcycle for

Service (Page 2-2).

2. Remove shifter linkage. See SHIFTER LINKAGE (Page 5-9).

REMOVE

1. See Figure 3-143. Remove foot support bracket.

a. Remove screws (2).

b. Remove foot support bracket (1).

INSTALL ___________________
Figure 3-143. Left Foot Support Bracket (Typical)
REMOVE AND INSTALL: FORWARD FOOT
FASTENER TORQUE VALUE CONTROLS ____________________________
Foot support bracket, left side, 40-45 ft-lbs 54.2-61 N-m
screw FASTENER TORQUE VALUE
Foot support bracket, forward 40-45 ft-lbs 54-61 N-m
CONSUMABLE PART NUMBER
control, left side, screw
LOCTITE 243 99642-97
MEDIUM CONSUMABLE PART NUMBER
STRENGTH
LOCTITE 243 99642-97
THREADLOCKER
MEDIUM
AND SEALANT
STRENGTH
(BLUE)
THREADLOCKER
1. See Figure 3-143. Install foot support bracket. AND SEALANT
(BLUE)

a. Apply threadlocker to screws (2).

Prepare
LOCTITE 243 MEDIUM STRENGTH
1. Set motorcycle upright. See GENERAL (Page 2-2).
THREADLOCKER AND SEALANT (BLUE) (99642-
97) 2. Remove shifter linkage. See SHIFTER LINKAGE (Page 5-9).

b. Install foot support bracket (1).

Remove
c. Install screws. Tighten.
1. See Figure 3-144. Remove screws (2).
Torque: 40-45 ft-lbs (54.2-61 N-m) Foot support
bracket, left side, screw
2. Remove foot support bracket (1 ).

Install
1. See Figure 3-144. Install foot support bracket (1).

2. Apply threadlocker to screws (2).

Consumable: LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-97)

3. Install screws (2). Tighten.

Torque: 40-45 ft-lbs (54-61 N-m) Foot support bracket,
forward control, left side, screw

3-136 94000936
 Complete
1. Install shifter linkage. See SHIFTER LINKAGE (Page 5-9).

REMOVE AND INSTALL: FOOTBOARDS

REMOVE AND INSTALL: MID FOOT
CONTROLS FASTENER TORQUE VALUE
FASTENER TORQUE VALUE Footboard assembly, left side, 40-45
CONSUMABLE PARTft-lbs
NUMBER54-61 N-m
Foot support bracket, mid 40-45 ft-lbs 54-61 N-m mounting screw
LOCTITE 243 99642-97
control, left side, screw MEDIUM
STRENGTH
CONSUMABLE PART NUMBER THREADLOCKER
LOCTITE 243 99642-97 AND SEALANT
MEDIUM (BLUE)
STRENGTH
THREADLOCKER Prepare
AND SEALANT
(BLUE) 1. Set motorcycle upright. See GENERAL (Page 2-2).

Prepare 2. Remove shifter linkage. See SHIFTER LINKAGE (Page 5-9).

1. Set motorcycle upright. See GENERAL (Page 2-2).

Remove
Remove 1. See Figure 3-146. Remove screws (1).

1. See Figure 3-145. Remove screws (2).

2. Remove footboard assembly (2).

2. Remove foot support bracket (1).

Install
Install 1. Apply threadlocker to screws (1).

1. See Figure 3-145. Install foot support bracket (1). Consumable: LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-97)
2. Apply threadlocker to screws (2).
2. See Figure 3-146. Install footboard assembly (2).
Consumable: LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-97) 3. Install screws (1). Tighten.
3. Install screws (2). Tighten. Torque: 40-45 ft-lbs (54-61 N-m) Footboard assembly, left
Torque: 4^45 ft-lbs (54-61 N-m) Foot support bracket, mid side, mounting screw
control, left side, screw
Complete
1. Install shifter linkage. See SHIFTER LINKAGE (Page 5-9).

94000936 3-137
 Assemble
1. See Figure 3-148. Install footboard.

a. Insert short leg of torsion spring (4) in hole in

footboard (3).

b. Position footboard and torsion spring on foot support

bracket (1).

c. Install clevis pin (2).

NOTE
Be careful when installing E-c/ip, use E-c/ip tool to
help prevent damage to painted surfaces.

d. Install E-clip (5).

Special Tool: E-CLIP TOOL (HD-52369)
e. Push the long leg of the torsion spring into the slot in
the foot support bracket.

2. Install wear peg, if equipped.

DISASSEMBLE AND ASSEMBLE:
FOOTBOARD __________________ a. Apply threadlocker to wear peg.
PART NUMBER TOOL NAME
LOCTITE 243 MEDIUM STRENGTH
HD-52369 E-CLIP TOOL
THREADLOCKER AND SEALANT (BLUE) (99642-
FASTENER TORQUE VALUE
97)
Shift lever bracket screws 120-144 in-lbs 13.6-16.3 N-m
Wear peg 30-42 in-lbs 3.4-4.7 N-m b. Install wear peg (6). Tighten.

CONSUMABLE PART NUMBER Torque: 30-42 in-lbs (3.4-4.7 N-m) Wear peg
LOCTITE 243 99642-97 3. See Figure 3-147. Install shift lever bracket.
MEDIUM
STRENGTH a. Install shift lever bracket (2).
THREADLOCKER
AND SEALANT b. Apply threadlocker to screws.
(BLUE)
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-
Disassemble
97)
1. See Figure 3-147. Remove shift lever bracket. c. Install screws (3). Tighten.

a. Remove screws (3). Torque: 120-144 in-lbs (13.6-16.3 N-m) Shift/ever

bracket screws
b. Remove shift lever bracket (2). d. If removed, install O-rings (1).

c. Inspect O-rings (1) for damage, replace if necessary.

2. See Figure 3-148. Remove wear peg (6), if equipped.

3. Remove footboard.

NOTE
Be careful when removing E-c/ip, use E-c/ip tool to help
prevent damage to painted surfaces.

a. Remove E-clip (5).

Special Tool: E-CLIP TOOL (HD-52369)
b. Remove clevis pin (2).

c. Remove torsion spring (4).

d. Remove footboard (3).

3-138 94000936
 NOTE
When removing E-clip, use E-clip tool to prevent
damage to painted surfaces.

a. Remove E-clip (2).

Special Tool: E-CLIP TOOL (HD-52369)
b. Remove clevis pin (5).

c. Remove footpeg (3).

d. Remove torsion spring (4).

3. Inspect O-rings (1) for damage, replace if necessary.

Assemble
1. See Figure 3-149. Install footpeg (3).

a. Insert short leg of torsion spring (4) into hole in

footpeg.

b. Insert long leg of torsion spring into hole in foot

support (6).

c. Rotate footpeg into position and install clevis pin (5).

NOTE
When installing E-clip, use E-clip tool to prevent
damage to painted surfaces.

d. Install E-clip (2).

Special Tool: E-CLIP TOOL (HD-52369)

2. If removed, install O-rings (1).

3. Install wear peg, if equipped.

a. Apply threadlocker to wear peg.

LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-
97)
DISASSEMBLE AND ASSEMBLE: FOOTPEG
b. Install wear peg (7). Tighten.
PART NUMBER TOOL NAME Torque: 30-42 in-lbs (3.4-4.7 N-m) Wear peg
HD-52369 E-CLIP TOOL

FASTENER TORQUE VALUE

Wear peg 30-42 in-lbs 3.4-4.7 N-m

CONSUMABLE PART NUMBER

LOCTITE 243 99642-97
MEDIUM
STRENGTH
THREADLOCKER
AND SEALANT
(BLUE)

Disassemble
1. See Figure 3-149. Remove wear peg (7), if equipped.

2. Remove footpeg.

94000936 3-139
 1.COMPLETE
1095100
Install shifter linkage. See SHIFTER LINKAGE (Page 5-9).

2. Remove vehicle from upright. See Secure the Motorcycle for

Service (Page 2-2).

1. O-ring (2)
2. E-clip
3. Footpeg
4. Torsion spring
5. Clevis pin
6. Foot support bracket
7. Wear peg
Figure 3-149. Left Side Footpeg (Typical)

3-140 94000936
 RIGHT FOOT CONTROLS 3.41

REMOVE AND INSTALL: FORWARD FOOT 2. See Figure 3-150. Install foot support bracket.
CONTROLS
a. Apply threadlocker to screws (2).
FASTENER TORQUE VALUE LOCTITE 243 MEDIUM STRENGTH
Brake pedal pivot, forward 18-22 ft-lbs 24.4-29.8 N-m THREADLOCKER AND SEALANT (BLUE)
control, screw
(99642-97)
Foot support bracket, forward 40-45 ft-lbs 54.2-61 N-m
control, right side, screw b. Install foot support bracket (1).
CONSUMABLE PART NUMBER c. Install screws. Tighten.

LOCTITE 243 99642-97 Torque: 40-45 ft-lbs (54.2-61 N-m) Foot support
MEDIUM bracket, forward control, right side, screw
STRENGTH
THREADLOCKER
AND SEALANT
(BLUE)
Remove
1. See Figure 3-150. Remove foot support bracket

a. Remove screws (2).

b. Remove foot support bracket (1).

2. See Figure 3-151. Remove brake pedal.

a. Remove rear master cylinder bracket (5). See REAR 1. Foot support bracket
BRAKE MASTER CYLINDER (Page 3-42). 2. Screw (2)
Figure 3-150. Right Foot Support Bracket
b. Remove rear brake master cylinder clevis pin (8). (Typical)
See REAR BRAKE MASTER CYLINDER (Page 3- Figure 3-151. Brake Pedal
42). 1095445 _ _ REMOVE AND INSTALL:
c. Remove flange nut (7) and washer (6).
MID FOOT CONTROLS _____________

d. Remove screw (1) and large washer (2).

e. Remove brake pedal (3).

f. Inspect O-rings (4) for damage, replace if necessary

Install
1. See Figure 3-151. Install brake pedal.
1. Screw
a. If removed, install O-rings (4).
2. Large washer
3. Brake pedal
b. Install brake pedal (3).
4. O-ring (2)
c. Install screw (1) and large washer (2). 5. Bracket
6. Washer
d. Install washer (6) and flange nut (7). Tighten. 7. Flange nut
8. Clevis pin
Torque: 18-22 ft-lbs (24.4-29.8 N-m) Brake pedal
pivot, forward control, screw

e. Install rear brake master cylinder clevis pin (8). See

REAR BRAKE MASTER CYLINDER (Page 3-42).

f. Install rear master cylinder bracket (5). See REAR FASTENER TORQUE VALUE
BRAKE MASTER CYLINDER (Page 3-42). Brake pedal linkage, mid con- 15-18 ft-lbs 20.3-24.4 N-m
trol, front, screw
Brake pedal linkage, mid con- 15-18 ft-lbs 20.3-24.4 N-m
trol, rear, screw

94000936 3-141
 FASTENER TORQUE VALUE LOCTITE 243 MEDIUM STRENGTH THREADLOCKER
Brake pedal pivot, mid control, 10-14 ft-lbs 13.6-19 N-m AND SEALANT (BLUE) (99642-97)
screw
Foot support bracket, mid 40-45 ft-lbs 54.2-61 N-m e. Install pivot screw and washer (6). Tighten.
control, right side, screw Torque: 10-14 ft-lbs (13.6-19 N-m) Brake pedal pivot,
CONSUMABLE PART NUMBER mid control, screw
LOCTITE 243 99642-97 f. Apply threadlocker to front brake pedal linkage screw
MEDIUM (2) .
STRENGTH
LOCTITE 243 MEDIUM STRENGTH THREADLOCKER
THREADLOCKER
AND SEALANT AND SEALANT (BLUE) (99642-97)
(BLUE)

Remove g. Install front brake pedal linkage screw. Tighten.

Torque: 15-18 ft-lbs (20.3-24.4 N-m) Brake pedal
1. See Figure 3-152. Remove brake pedal.
linkage, mid control, front, screw

a. Remove front brake pedal linkage screw (2).

b. Remove pivot screw (1) and washer (6).

c. Remove brake pedal.

d. Remove rear brake pedal linkage screw (5).

2. Remove foot support bracket

a. Remove screws (3).

b. Remove foot support bracket (4).

1. Pivot screw
2. Front linkage screw
Install 3. Screw (2)
4. Foot support bracket
1. See Figure 3-152. Install foot support bracket. 5. Rear linkage screw
6. Washer
a. Apply threadlocker to screws (3). Figure 3-152. Right Side Mid Controls
LOCTITE 243 MEDIUM STRENGTH
REMOVE AND INSTALL: FOOTBOARDS
THREADLOCKER AND SEALANT (BLUE) (99642-97)

b. Install foot support bracket (4).

FASTENER TORQUE VALUE
c. Install screws (3). Tighten. Brake pedal pivot, footboard 18-22 ft-lbs 24.5-30 N-m
Torque: 40-45 ft-lbs (54.2-61 N-m) Foot support control, screw.
bracket, mid control, right side, screw Footboard assembly, right side, 40-45 ft-lbs 54-61 N-m
mounting screw
2. Install brake pedal.
CONSUMABLE PART NUMBER
a. Apply threadlocker to rear brake pedal linkage screw
LOCTITE 243 99642-97
(5). MEDIUM
LOCTITE 243 MEDIUM STRENGTH STRENGTH
THREADLOCKER
THREADLOCKER AND SEALANT (BLUE) (99642-97) AND SEALANT
(BLUE)
b. Install rear brake pedal linkage screw. Tighten.
Torque: 15--18 ft-lbs (20.3-24.4 N-m) Brake pedal
linkage, mid control, rear, screw Prepare
c. Install brake pedal. 1. Set motorcycle upright. See GENERAL (Page 2-2).

d. Apply threadlocker to pivot screw (1). Remove

1. See Figure 3-153. Remove footboard assembly.

a. Remove screws (1 ).

3-142 94000936
 b. Remove footboard assembly (2).

2. See Figure 3-151. Remove brake pedal.

a. Remove rear master cylinder bracket (5). See REAR

BRAKE MASTER CYLINDER (Page 3-42).

b. Remove rear brake master cylinder clevis pin (8). See

REAR BRAKE MASTER CYLINDER (Page 3-42).

c. Remove flange nut (7) and washer (6).

d. Remove screw (1) and large washer (2).

e. Remove brake pedal (3).

f. Inspect O-rings (4) for damage, replace if necessary.

Install
1. See Figure 3-151. Install brake pedal.

a. If removed, install O-rings (4).

b. Install brake pedal (3). DISASSEMBLE AND ASSEMBLE: FOOTBOARD

______________________________
c. Install screw (1) and large washer (2).

d. Install washer (6) and flange nut (7). Tighten. PART NUMBER TOOLNAME
Torque: 18-22 ft-lbs (24.5-30 N-m) Brake pedal pivot, HD-52369 E-CLIP TOOL
footboard control, screw.
FASTENER TORQUE VALUE
e. Install rear brake master cylinder clevis pin (8). See
Wear peg 30-42 in-lbs 3.4-4.7 N-m
REAR BRAKE MASTER CYLINDER (Page 3-42).
CONSUMABLE PART NUMBER
f. Install rear master cylinder bracket (5). See REAR
BRAKE MASTER CYLINDER (Page 3-42). LOCTITE 243 99642-97
MEDIUM
STRENGTH
2. See Figure 3-153. Install footboard assembly.
THREADLOCKER
AND SEALANT
a. Apply threadlocker to screws (1).
(BLUE)
LOCTITE 243 MEDIUM STRENGTH Disassemble
THREADLOCKER AND SEALANT (BLUE) (99642-97)
1. See Figure 3-154. Remove wear peg (5), if equipped.
b. Install footboard assembly (2).
2. Remove footboard.
c. Install screws (1). Tighten.
NOTE
Torque: 40-45 ft-lbs (5^^1 N-m) Footboard assembly, When removing E-clip, use E-c/ip tool to help prevent
right side, mounting screw damage to painted surfaces.

a. Remove E-clip (3).

Special Tool: E-CLIP TOOL (HD-52369)
b. Remove clevis pin (6).

c. Remove torsion spring (2).

d. Remove footboard (4).

Assemble
1. See Figure 3-154. Install footboard.

a. Insert short leg of torsion spring (2) in hole in footboard

(4).

94000936 3-143
 b. Position footboard and torsion spring on foot support Disassemble
bracket (1 ).
1. See Figure 3-155. Remove wear peg (4), if equipped.
c. Install clevis pin (6).
2. Remove footpeg.
NOTE
When installing E-clip, use E-clip tool to help prevent NOTE
damage to painted surfaces. When removing E-clip, use E-clip tool to help prevent damage to
painted surfaces.
d. Install E-clip (3).
a. Remove E-clip (5).
Special Tool: E-CLIP TOOL (HD-52369)
Special Tool: E-CLIP TOOL (HD-52369)
e. Push the long leg of the torsion spring into the slot in b. Remove clevis pin (1).
the foot support bracket.
c. Remove footpeg (3).
2. Install wear peg, if equipped.
d. Remove torsion spring (2).
a. Apply threadlocker to wear peg.

LOCTITE 243 MEDIUM STRENGTH Assemble

THREADLOCKER AND SEALANT (BLUE) (99642- 1. See Figure 3-155. Install footpeg.
97)
a. Insert short leg of torsion spring (2) into hole in
b. Install wear peg (5). Tighten.
footpeg (3).
Torque: 30-42 in-lbs (3.4-4.7 N-m) Wear peg
b. Insert long leg of torsion spring into hole in foot
support bracket (6).

c. Rotate footpeg into position and install clevis pin (1).

NOTE
When installing E-c/ip, use E-clip tool to help prevent damage to
painted surfaces.

d. Install E-clip (5).

Special Tool: E-CLIP TOOL (HD-52369)
2. Install wear peg, if equipped.

a. Apply threadlocker to wear peg.

LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-
97)
b. Install wear peg (4). Tighten.
Torque: 30-42 in-lbs (3.4-4.7 N-m) Wear peg

Figure 3-154. Right Side Footboard (Typical)

DISASSEMBLE AND ASSEMBLE: FOOTPEG
PART NUMBER TOOL NAME
HD-52369 E-CLIP TOOL
FASTENER TORQUE VALUE
Wear peg 30-42 in-lbs 3.4-4.7 N-m
CONSUMABLE PART NUMBER
LOCTITE 243 99642-97
MEDIUM
STRENGTH
THREADLOCKER
AND SEALANT
(BLUE)

3-144 94000936
 1. Clevis pin
2. Torsion spring
3. Footpeg
4. Wear peg
5. E-clip
6. Foot support bracket
Figure 3-155. Right Side Footpeg (Typical)

94000936 3-145
PASSENGER FOOTRESTS 3.42

REMOVE NOTE
FLHC and FLHCS do not have alignment tabs for the
PART NUMBER TOOL NAME passenger footpeg supports. Align footpeg supports at
HD-52369 E-CLIP TOOL a 5-15 ° rearward angle.

1. See Figure 3-156. Remove footpeg. b. Left side: Align notch in footpeg support with rear fork
pivot shaft.
NOTE
When removing e-clip, use e-clip tool to help prevent damage to
c. Apply threadlocker to screw (2).
painted surfaces.
LOCTITE 243 MEDIUM STRENGTH
a. Remove e-clip (8). THREADLOCKER AND SEALANT (BLUE) (99642-
Special Tool: E-CLIP TOOL (HD-52369) 97)

b. Remove clevis pin (3). d. Install screw. Tighten.

NOTE Torque: 3^47 ft-lbs (51.5-63.7 N-m) Passenger
Remove footpeg and detent plate as an assembly to keep detent footpeg support screw
ball and detent spring in place.
2. Install detent spring (6) and detent ball (7) into footpeg (5).

c. Remove footpeg (5) with detent plate (4). 3. Install detent plate (4) onto footpeg.
NOTE
2. NOTE
Detent ball is under spring pressure, place finger over • Hold detent ball in place while installing detent plate to
detent ball when removing detent plate to keep detent ball prevent detent ball from falling out.
from falling out. • Detent plate should be oriented with the detent holes on the
bottom.
Remove detent plate from footpeg.
• Make sure detent ball is aligned with the innermost hole in
the detent plate when installed.
3. Remove detent ball (7) and detent spring (6) from footpeg.

4. NOTE
4. Remove footpeg support (1).
Install footpeg and detent plate as an assembly.
a. Remove screw (2). a. Install footpeg into footpeg support.

b. Remove footpeg support. b. Install clevis pin (3).

NOTE
INSTALL ______________
PART NUMBER TOOL NAME When Installing e-clip, use e-clip tool to help prevent
damage to painted surfaces.
HD-52369 E-CLIP TOOL
FASTENER TORQUE VALUE c. Install e-clip (8).
Passenger footpeg support 38-47 ft-lbs 51.5--63.7 N-m
Special Tool: E-CLIP TOOL (HD-52369)
screw
Install footpeg.

CONSUMABLE PART NUMBER

LOCTITE 243 99642-97
MEDIUM
STRENGTH
THREADLOCKER
AND SEALANT
(BLUE)

1. See Figure 3-156. Install footpeg support (1).

a. Right side: Align notch in footpeg support with

alignment tab on exhaust bracket.

3-146 94000936
 1. Footpeg support
2. Screw
3. Clevis pin
4. Detent plate
5. Footpeg
6. Detent spring
7. Detent ball
8. E-clip ________________________
Figure 3-156. Passenger Footpeg

94000936 3-147
JIFFY STAND 3.43

PREPARE ASSEMBLE ____________

1. Set motorcycle upright. See Secure the Motorcycle for 2. Install bushings (5).
Service (Page 2-2).
CONSUMABLE PART NUMBER
REMOVE _______________________________ LOCTITE SILVER 11100001
GRADE
ANTI-SEIZE
1. See Figure 3-157. Lower jiffy stand (1).
1. See Figure 3-158. Install jiffy stand bumper (7).
2. Remove screws (2).
3. Install jiffy stand (6).
3. Remove jiffy stand.
4. Apply anti-sieze lubricant to pivot pin (8).
INSTALL _______________________________
Consumable: LOCTITE SILVER GRADE ANTI-SEIZE
(11100001)
FASTENER TORQUE VALUE 5. Install pivot pin (8).
Jiffy stand screws 40-45 ft-lbs 54.2-61 N-m
1. See Figure 3-157. Install Jiffy stand (1). 6. Install screw (4). Tighten.
Torque: 20-25 in-lbs (2.3-2.8 N-m)
2. Install screws (2). Tighten.
7. Apply anti-sieze lubricant to spring hook groove on jiffy stand
Torque: 40--45 ft-lbs (54.2-61 N-m) Jiffy stand screws bracket (2).

Consumable: LOCTITE SILVER GRADE ANTI-SEIZE

(11100001)
NOTE
Spring hooks must point towards rear when jiffy stand is
down.

8. Install spring (3).

9. Install JSS (1), if equipped. See JIFFY STAND SENSOR

(JSS) (Page 7-86).

8. Remove jiffy stand bumper (7).

DISASSEMBLE

1. See Figure 3-158. Remove Jiffy Stand Sensor (JSS) (1), if

equipped. See JIFFY STAND SENSOR (JSS) (Page 7-86).

2. Remove spring (3).

3. Remove screw (4).

4. Remove pivot pin (8).

5. Remove jiffy stand (6).

6. Remove bushings (5).

7. Inspect bushings for wear or damage, replace if necessary.

3-148 94000936
 COMPLETE

1. Remove vehicle from upright. See Secure the Motorcycle for

Service (Page 2-2).

3-149
94000936
SEAT 3.44

REMOVE _______________________________ d. See Figure 3-163. Install thumbscrew (1). Tighten.

Torque: 15-30 in-lbs (1.7-3.4 Nm) Seat thumbscrew

Two-Up One-Piece Seat
2. After installing seat, pull up on the seat to verify it is secure.
1. See Figure 3-163. Remove seat.
Two-up Two-piece Seat
a. Remove thumbscrew (1).
1. See Figure 3-163 or Figure 3-161. Install Seat.
b. Slide seat tongue out of the frame.
a. Install grab strap (4) if removed.
c. Slide seat forward to remove from grab strap (4).
d. Remove Screw (10), washer (9) and grab strap (4), if b. See Figure 3-159. Engage seat tongue in frame
necessary. bracket.

c. See Figure 3-163 or Figure 3-161. Install mounting

Two-Up Two-Piece Seat
nuts (2) or screw with washers (1-3).
1. See Figure 3-163 or Figure 3-161. Remove seat.
d. Install passenger pillion (3).
a. Remove the thumbscrew (1) or screw (1 ).
e. Install thumbscrew (1) or screw with washer (1, 2).
Tighten.
b. Remove the passenger pillion (3).
Torque: 15-30 in-lbs (1.7-3.4 Nm) Seat
c. Remove mounting nuts (2) or screw with washers (1- thumbscrew
3).
2. After installing seat, pull up on the seat to verify it is secure.
d. Remove seat and grab strap (4), if necessary.
Solo Seat
Solo Seat
1. See Figure 3-163. Install Seat.
1. Figure 3-163

a. Remove thumbscrew (1) or mounting nuts (2). a. See Figure 3-159 and . Engage seat tongue in frame
bracket.
b. Remove seat.
b. See Figure 3-163. Install thumbscrew (1), if equipped.
Tighten.
INSTALL _______________________________
Torque: 15-30 in-lbs (1.7-3.4 Nm) Seat
thumbscrew
FASTENER TORQUE VALUE c. Install mounting nuts (2), if equipped. Tighten. Torque:
One piece seat grab strap 60-90 in-lbs 6.8-10.16 Nm
9-15 in-lbs (1-1.7 N m) Seat mounting nut
screw
Seat mounting nut 9-15 in-lbs 1-1.7Nm 2. After installing seat, pull up on the seat to verify it is secure.
Seat thumbscrew 15-30 in-lbs 1.7-3.4 Nm

Two-up One-piece Seat

1. See Figure 3-163. Install Seat.
NOTE
See for FXBRS, FLFBS, FXFBS grab strap installation.

a. Install washer (9), screw (10) and grab strap (4) if

removed. Tighten.

Torque: 60-90 in-lbs (6.8-10.16 Nm) One piece seat

grab strap screw

b. Install seat (5) rearward through the grab strap.

c. See Figure 3-159. Engage seat tongue in frame

bracket.

3-150 94000936
 Figure 3-161. Two-up Two-piece Seat (Two fastener)

Figure 3-163. Seat: Softail Models

94000936 3-151
FRAME CROSSMEMBER 3.45

PREPARE ______________________________ 5. Install wire harness anchor (7).

6. If equipped with hydraulic under seat adjust shock absorber:

1. Remove seat. See SEAT (Page 3-142).
a. Install preload adjuster (4).
REMOVE _______________________________
b. Install screw (6) and washer (5). Tighten.
1. See Figure 3-164. Ifequipped with hydraulic under seat adjust Torque: 90-114 in-lbs (10.2-12.9 N-m) Shock adjuster
shock: mounting screw

a. Remove screw (6) and washer (5).

b. Move preload adjuster (4) forward.

2. Remove wire harness anchor (7).

3. Remove small screw (2).

4. Remove mounting screws (1).

5. Remove frame crossmember (3).

INSTALL _______________________________

FASTENER TORQUE VALUE

ECM caddy small screw 55-60 in-lbs 6.2-6.8 N-m
Frame crossmember mounting 17-20 ft-lbs 23.1-27.1 N-m 1. Mounting screw (2)
screws 2. Small screw
Shock adjuster mounting screw 90-114 in-lbs 10.2-12.9 N-m 3. Frame crossmember
4. Preload adjuster
5. Washer
1. See Figure 3-164. Install frame crossmember (3).
6. Screw
7. Wire harness anchor
2. Install small screw (2) hand tight.
Figure 3-164. Frame Crossmember
3. Install mounting screws (1). Tighten.
Torque: 17-20 ft-lbs (23.1-27.1 N-m) Frame crossmember COMPLETE
mounting screws COMPLETE
4. Tighten small screw.
1. Install seat. See SEAT (Page 3-142).
Torque: 55-60 in-lbs (6.2-6.8 N-m) ECM caddy small screw

3-152 94000936
 SADDLEBAGS 3.46

REMOVE AND INSTALL: STANDARD 1. See Figure 3-165. Install right side mounting bracket
APPLICABILITY grommet.
^ • 2022 HERITAGE CLASSIC 114 (FLHCS)
a. Seat the mounting bracket grommet (1) nubs with the
holes on frame.
FASTENER TORQUE VALUE
Saddlebag right side mounting 96-120 in-lbs 10.9-13.6 N-m b. Apply threadlock to screw (2).
bracket grommet screw
LOCTITE 243 MEDIUM STRENGTH
Saddlebag, left side, mounting 96-120 in-lbs 10.9-13.6 N-m
bracket grommet screw THREADLOCKER AND SEALANT (BLUE) (99642-97)

Saddlebag, left side, mounting 38-47 ft-lbs 52-64 N-m c. Install screw. Tighten.
bracket screw
Saddlebag, mounting screw 21-27 ft-lbs 29-37 N-m Torque: 96-120 in-lbs (10.9-13.6 N-m) Saddlebag right
side mounting bracket grommet screw

2. See Figure 3-166. Install left side mounting bracket

CONSUMABLE PART NUMBER grommet.
LOCTITE 243 99642-97
MEDIUM
a. Position mounting bracket (9) on frame.
STRENGTH
THREADLOCKER b. Apply threadlock to screw (8).
AND SEALANT
(BLUE) LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-97)
Remove c. Install screw. lighten.
1. See Figure 3-166. Remove saddlebag.
a. Open saddlebag lid. Torque: 38-47 ft-lbs (52-64 N-m) Saddlebag, left side,
mounting bracket screw
b. Remove screws (6).
d. Seat the mounting bracket grommet (1) nubs with the
c. Pull saddlebag (7) out and remove. holes on mounting bracket.

d. Remove spacers (5) and O-rings (4), if necessary. e. Apply threadlock to screw (2).

LOCTITE 243 MEDIUM STRENGTH

2. See Figure 3-165. Remove right side mounting bracket
grommet. THREADLOCKER AND SEALANT (BLUE) (99642-97)

f. Install screw. lighten.

a. Remove screw (2).
Torque: 96-120 in-lbs (10.9-13.6 N-m) Saddlebag, left
b. Remove mounting bracket grommet (1). side, mounting bracket grommet screw

3. See Figure 3-166. Remove left side mounting bracket 3. Install saddlebag.
grommet.
a. Position docking rod (3) on mounting bracket grommet
a. Remove screw (2). (1).

b. Remove mounting bracket grommet (1). b. Slide screws (6) through holes in saddlebag. Install
spacers (5) and O-rings (4), if removed.
c. Remove screw (8).
c. Apply threadlock to screws (6).
d. Remove mounting bracket (9). LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-97)
Install
d. Align screws on saddlebag with holes on fender
NOTICE
support. Tighten.

Check that saddlebag frame(s) are fully seated and tightly Torque: 21-27 ft-lbs (29-37 N-m) Saddlebag, mounting
secured with mounting hardware. Failure to do so could result in screw
the saddlebags becoming detached and/or damaged. (00171b)

94000936 3-153
 FASTENER TORQUE VALUE
Saddlebag, mounting bolt 21-27 ft-lbs 29-37 N-m
Saddlebag, right side, mounting 97-124 in-lbs 11-14 N-m
bracket grommet screw

CONSUMABLE PART NUMBER

LOCTITE 243 99642-97
MEDIUM
STRENGTH
THREADLOCKER
AND SEALANT
(BLUE)

Remove
1. See Figure 3-167. Remove saddlebag.

a. Open saddlebag outer clamshell (3).

b. Pull out and turn lock knob (4) to the unlocked position
(5).
Figure 3-165. Right Side Saddlebag Docking Rod

c. Close saddlebag outer clamshell and lower latch lever

(2).

d. See Figure 3-168. Slide saddlebag rearward to

disengage the saddlebag docking rod (4) from the
mounting bracket grommet (5).

e. Lift saddlebag away from motorcycle.

2. See Figure 3-169 and Figure 3-170. Remove docking mount.

a. Remove mounting bolt (5), docking mount (4) and

spacer (3).

3. See Figure 3-169. Remove right side mounting bracket

grommet.

a. Remove screw (9).

b. Remove mounting bracket grommet (7).

4. See Figure 3-170. Remove left side mounting bracket

grommet.

a. Remove screw (9).

b. Remove mounting bracket grommet (7).

c. Remove screw (11).

d. Remove mounting bracket (10).

DISCONNECT Install
APPLICABILITY
NOTICE
• 2022 SPORT GLIDE (FLSB)
0 • 2022 LOW RIDER ST (FXLRST) Check that saddlebag frame(s) are fully seated and tightly
secured with mounting hardware. Failure to do so could result in
FASTENER TORQUE VALUE the saddlebags becoming detached and/or damaged. (00171b)
Saddlebag left side mounting 97-124 in-lbs 11-14 N-m
bracket grommet screw
Saddlebag, left side, mounting 38--47 ft-lbs 52--64 N-m
bracket screw

3-154 94000936
 1. See Figure 3-169 and Figure 3-170. Install docking mount. c. See Figure 3-168. Place saddlebag mounting bracket
(2) on mounting studs (3) while aligning the saddlebag
a. Slide docking mount (4) on mounting bolt (5). docking rod (4) with the mounting bracket grommet
(5). Slide saddlebag completely forward.
b. Slide spacer (3) on mounting bolt.
d. See Figure 3-167. Rotate lock knob to the locked
c. Apply threadlock to mounting bolt. position (6) until a click is heard. Without pulling out on
LOCTITE 243 MEDIUM STRENGTH the knob, verify that knob cannot rotate back to the
unlocked position.
THREADLOCKER AND SEALANT (BLUE) (99642-97)
NOTE
d. Install mounting bolt through fender supports into Indicator flag (1) is for showing when lock knob is
fender mount. Tighten. unlocked only. Do not use indicator flag to lock or
Torque: 21-27 ft-lbs (29--37 N-m) Saddlebag, unlock saddlebag from motorcycle.
mounting bolt
e. See Figure 3-168. Verify the indicator flag is not
2. See Figure 3-169. Install right side mounting bracket showing and saddlebag is securely fastened.
grommet.
f. Pull saddlebag rearward to verify it is secure.
a. Seat the mounting bracket grommet (7) nubs with the
holes on bracket (8). g. Close saddlebag.

b. Apply threadlock to screw (9).

LOCTITE 243 MEDIUM STRENGTH

THREADLOCKER AND SEALANT (BLUE) (99642-97)

c. Install screw. Tighten.

Torque: 97-124 in-lbs (11-14 N-m) Saddlebag, right
side, mounting bracket grommet screw

3. See Figure 3-170. Install left side mounting bracket

grommet.

a. Position mounting bracket (10) on frame (8).

b. Apply threadlock to screw (11).

LOCTITE 243 MEDIUM STRENGTH

THREADLOCKER AND SEALANT (BLUE) (99642-97)

c. Install screw. Tighten. 1. Lock

2. Latch lever
Torque: 38-47 ft-lbs (52-64 N-m) Saddlebag, left side,
3. Outer clamshell
mounting bracket screw
4. Lock knob
d. Seat the mounting bracket grommet (7) nubs with the 5. Unlocked position
holes on mounting bracket. 6. Locked position
Figure 3-167. Saddlebag Lock Knob
e. Apply threadlock to screw (9).

LOCTITE 243 MEDIUM STRENGTH

THREADLOCKER AND SEALANT (BLUE) (99642-
97)

f. Install screw. Tighten.

Torque: 97-124 in-lbs (11-14 N-m) Saddlebag left
side mounting bracket grommet screw

4. See Figure 3-167. Install saddlebag.

a. Open saddlebag outer clamshell (3).

b. Pull out and turn lock knob (4) to the unlocked

position (5).

94000936 3-155
Figure 3-168. Saddlebag Mounting Bracket

1. Indicator flag (unlocked position)

2. Mounting bracket
3. Mounting stud (2)
4. Docking rod
5. Mounting bracket grommet
1.
ender mount
2.
ender support
3.
pacer
4.
ocking mount
5.
ounting bolt
6.
ocking rod
7.
ounting bracket grommet
8.
rame
9.
crew
10.
ounting bracket
11.
crew
Figure 3-170. Left Side Quick Disconnect Saddlebag
DISASSEMBLE AND ASSEMBLE: STANDARD__________
APPLICABILITY
• 2022 HERITAGE CLASSIC 114 (FLHCS)
0
FASTENER TORQUE VALUE
Saddlebag hinge screw 18-25 in-lbs 2-2.8 N-m
Saddlebag lockset nut 45-55 in-lbs 5.1-6.2 N-m
Saddlebag tether to lid 8-15 in-lbs 0.9-1.7 N-m
screw

Disassemble
1. See Figure 3-171. Remove saddlebag lid.

a. Open saddlebag lid (4).

b. Remove screws (7) and tether bracket (14).

c. Remove screws (8) and medallion (15).

d. Remove saddlebag lid.

2. Remove reflector.

a. Remove retainer clips (11).

3-156 94000936
 b. Remove reflector bracket (9) and reflector (10).

3. Remove lock assembly.

a. Remove nut (6) and lockwasher (5).

94000936 3-157
 b. Remove lock (1), gasket (2) and bezel (3). able to be pressed in.

4. See Figure 3-173. Remove lockset. 3. See Figure 3-171. Install lock assembly.

a. Place key in lock. a. Place bezel (3) through opening on saddlebag lid (4).
b. Turn key half way between locked and open so the
tumbler (3) shows in the access hole (2). b. Place gasket (2) on lock (1).

c. Place a pin in the access hole. Press down the c. Place lock through bezel.
tumbler and slide out the lockset (4).
d. Place lockwasher (5) on bottom of bezel and install nut
(6).
5. See Figure 3-171. Remove saddlebag gasket.
e. Tighten nut.
a. Open saddlebag lid (4).
Torque: 45-55 in-lbs (5.1-6.2 N-m) Saddlebag lockset
b. Remove screws (7) from the tether bracket (14) and nut
saddlebag lid.
4. Install reflector.
c. Completely remove gasket (13).
a. Place reflector (10) and bracket (9) on saddlebag as
NOTE shown.
Do not remove stitching.
b. Install retainer clips (11).

Assemble 5. Install saddlebag lid.

1. See Figure 3-172. Install saddlebag gasket.

a. Place medallion (15) on saddlebag lid (4).
b. Align the holes on hinge with holes on lid.
a. Align the new gasket (1) with the center of the tether
(2) on the saddlebag lip.
c. Install screws (8) through hinge and into medallion.
Tighten.
b. Press the gasket firmly onto saddlebag lip.
Torque: 18-25 in-lbs (2-2.8 N-m) Saddlebag hinge
c. Continue pressing gasket around saddlebag lip until screw
gasket ends meet. d. Place tether bracket (14) beneath tether (12) and
install screws (7) into bracket on the lid. Tighten.
d. Trim gasket to length and press onto lip.
Torque: 8-15 in-lbs (0.9-1.7 N-m) Saddlebag tether to
e. See Figure 3-171. Place tether bracket (14) beneath lid screw
tether (12) and install screws (7) into bracket on the lid
(4). Tighten.
Torque: 8-15 in-lbs (0.9-1.7 N-m) Saddlebag tether
to lid screw

2. See Figure 3-174. Install lockset.

a. Place key in lockset (2).

b. Align notches (1) on lockset as shown. Pull key out.

c. Align cam (6) and housing notches (5) in the open

position as shown.

d. Verify the cam is in the open position by pressing

down on the spring loaded lockset housing.

NOTE
If you can not press down on the spring loaded
lockset housing the cam is in the locked position.

e. Align the lockset notches with the housing notches

and slide together.

f. Verify the operation of the lock.

NOTE
In the locked position the lockset should not be

3-158 94000936
 1. Housing
2. Access hole
3. Tumbler
4. Lockset ________________________
Figure 3-173. Lockset Removal

1. Lock
2. Gasket
3. Bezel
4. Saddlebag lid
5. Lockwasher
6. Nut
7. Screw (2)
8. Screw (4)
9. Reflector bracket
10. Reflector
11. Retainer clip (2) 1. Lockset notch (3)
12. Tether 2. Lockset
13. Gasket 3. Tumbler
14. Tether bracket 4. Housing
15. Medallion 5. Housing notch (3)
16. Lockset 6. Cam
Figure 3-174. Lockset in Unlocked Position
Figure 3-171. Saddlebag Assembly DISASSEMBLE AND ASSEMBLE: QUICK
DISCONNECT ______________ _______

APPLICABILITY
ryf ■ 2022 SPORT GLIDE (FLSB)
^ ■ 2022 LOW RIDER ST (FXLRST)

FASTENER TORQUE VALUE

Saddlebag docking rod 13-15 ft-lbs 17-21 N-m
Saddlebag hinge screw 20-30 in-lbs 2.3-3.4 N-m
Saddlebag indicator flag 24-36 in-lbs 2.7-4.1 N-m
cover screw
Saddlebag latch assembly 10-15 in-lbs 1.1-1.7 N-m
Saddlebag latch lever screw 20-30 in-lbs 2.3-3.4 N-m
Saddlebag locking knob 97-120 in-lbs 11-13.6 N-m
cover screw
Saddlebag locking knob 97-120 in-lbs 11-13.6 N-m
screw

94000936 3-159
 FASTENER TORQUE VALUE 6. See Figure 3-177. Remove hinges.
Saddlebag strike screw 20-30 in-lbs 2.3-3.4 N-m
a. Remove screws (6).
Saddlebag tether screw 45-55 in-lbs 5.1-6.2 N-m
Saddlebag tether stud 45-55 in-lbs 5.1-6.2 N-m
b. Remove hinges (7).
saddlebag lock screw 15-20 in-lbs 1.7-2.3 N-m
7. Remove docking rod.
CONSUMABLE PART NUMBER
LOCTITE 243 99642-97 a. Remove docking rod screws (8).
MEDIUM b. Remove docking rod (5).
STRENGTH
THREADLOCKER
8. Remove latch assembly.
AND SEALANT
(BLUE)
a. Remove screw (11).
Disassemble b. Remove latch lever (4) and O-ring (3) from inner
clamshell (2).
1. See Figure 3-175. Remove outer clamshell.

a. Open saddlebag. c. Remove screws (12) on front of latch.

b. Pry out slightly on damper clip (9) on lower damper (1) d. Remove latch assembly (1).
while pulling damper from stud (7).
9. Remove lock.
NOTE
Do not remove clip from damper. a. Place lock (10) in the unlocked position.
b. Remove screws (9).
c. Remove two screws (4) attached to the outer
clamshell (6). c. Remove lock.

d. See Figure 3-176. If necessary remove gasket (2) 10. See Figure 3-178. Remove lock knob assembly.
from outer clamshell (1).
a. Remove screws (8) and indicator flag cover (9).
e. Remove hinge screws (4) from outer clamshell. b. Remove cap (17).

f. Remove outer clamshell. c. Remove nut (16) and screw (7).

2. See Figure 3-175. Remove damper. d. Remove lock knob (15).

a. Pry out slightly on damper clip (9) on upper damper e. Remove screws (1) and cover (13).
(1) while pulling damper from stud (7). f. Remove latching arm cover (10), spacer (4) and
NOTE spring (5).

Do not remove clip from damper.

g. Remove indicator flag (12) and latching arm (11) from
latching arm cover.
b. Remove damper (1).

h. Remove grommets (6).

3. Remove tether.
a. Remove remaining screw (4) from inner clamshell i. Remove seals (14).
(3) .
11. Remove Retaining clip.
b. Remove studs (7).

c. Remove tether (5). a. Pry center of clip (2) out.

b. Remove clip.
4. See Figure 3-176. Remove strikes.
Assemble
a. Remove screws (9).
b. Remove strikes (8). 1. See Figure 3-176. Install strikes.

5. Remove medallions. See MEDALLIONS, BADGES, TANK a. Place strikes (8) on outer clamshell (1).
EMBLEMS AND ADHESIVE STRIPS (Page 3-156).
b. Apply threadlocker to screws (9).

3-160 94000936
 LOCTITE 243 MEDIUM STRENGTH locking knob cover screw
THREADLOCKER AND SEALANT (BLUE) (99642-97) h. Place pins on locking knob (15) into holes on latching
arm.
c. Install screws. Tighten.
Torque: 20-30 in-lbs (2.3-3.4 N-m) Saddlebag strike i. Install screw (7) through assembly and install new lock
screw nut (16). Tighten.

2. Install medallions and reflectors. Torque: 97-120 in-lbs (11-13.6 N-m) Saddlebag
locking knob screw
a. Clean mounting surface. See MEDALLIONS,
j. Install cap (17).
BADGES, TANK EMBLEMS AND ADHESIVE STRIPS
(Page 3-156)
k. Place indicator flag cover (9) on latching arm cover.

b. With the adhesive backing still in place, test fit the l. Apply threadlocker to screws (8).
medallions (10) and reflectors.
m. Install screws. Tighten.
c. Remove the adhesive backing. Torque: 24-36 in-lbs (2.7--4.1 N-m) Saddlebag
indicator flag cover screw
d. Install medallions and reflectors.
n. Verify operation.
e. Press firmly to make sure that there is good adhesion.
6. Install retaining clips.
3. Install hinges.
a. Place new clips (2) in position and press in place.
a. Position hinges (6) on outer clamshell (1).
7. See Figure 3-177. Install lock.
b. Apply threadlocker to screws (4).
a. Place lock (10) in the unlocked position.
c. Install screws. Tighten.
b. Place lock onto latch assembly (1).
Torque: 20-30 in-lbs (2.0-3.4 N-m) Saddlebag hinge
screw NOTE
Lock pin should be toward inner clamshell.
4. Install gasket.
c. Install screws (9). Tighten.
a. Clean gasket surface (3). See MEDALLIONS,
BADGES, TANK EMBLEMS AND ADHESIVE STRIPS Torque: 10-20 in-lbs (1.7-2.3 N-m) saddlebag lock
(Page 3-156). screw
d. Verify lock installation.
b. Trim gasket (2) to length.
NOTE 8. Install latch assembly.
Do not stretch gasket. Gasket split (5) should be
located on the bottom of clamshell. a. Place latch (1) in position on inner clamshell (2).
b. Install screws (12). Tighten.
c. Install gasket at midpoint (7) of hinge area. Press Torque: 10-15 in-lbs (1.1-1.7 N-m) Saddlebag latch
gasket firmly in place. assembly

c. Place O-ring (3) on latch lever (4) and position on

5. See Figure 3-178. Install lock knob assembly.
inner clamshell.
a. Install bushings (6) to latching arm cover (10).
d. Install screw (11). Tighten.
NOTE
Torque: 20-30 in-lbs (2.3-3.4 N-m) Saddlebag latch
Grommet tabs must be fully seated.
lever screw
b. Replace seals (14) on locking knob cover (13). 9. Install docking rod.

c. Place indicator flag (12) on latching arm (11) and slide a. Place docking rod (5) on inner clamshell (2).
through opening on latching arm cover.
b. Apply threadlocker to screws (8).
d. Place spring (5) and spacer (4) on latching arm.

e. Place locking knob cover on inner clamshell (3)

aligning the holes.
f. Place locking knob cover (13) on inner clamshell.

g. Install screws (1). Tighten.

Torque: 97-120 in-lbs (11-13.6 N-m) Saddlebag

94000936 3-161
 c. Install screws. Tighten.

Torque: 13-15ft-lbs (17-21 N-m) Saddlebag docking

rod

10. Install outer clamshell.

a. Align outer clamshell with inner clamshell.

b. Position outer clamshell hinges (7) in inner clamshell

hinge slot.

c. Apply threadlocker to screws (6).

d. Install screws. Tighten.

Torque: 20-30 in-lbs (2.3-3.4 N-m) Saddlebag hinge

screw

e. See Figure 3-175. Place tether (5) in position.

f. Apply threadlocker to screws (4).

g. Install screws.
Torque: 45-55 in-lbs (5.1-6.2 N-m) Saddlebag tether
screw

h. Install studs (7).

Torque: 45-55 in-lbs (5.1-6.2 N-m) Saddlebag tether 1.

stud 2.
3.
i. Slide damper (1) through tether loop (2). 4.
5.
NOTE
Rod end of damper oriented toward outer clamshell. 6.
7.
j. Press damper on studs to secure. 8.
9.
k. Verify damper is secure.
Figure 3-175. Saddlebag Tether

1. Outer clamshell
2. Gasket
3. Gasket surface
4. Hinge screw (4)
5. Gasket split
6. Hinge (2)
7. Gasket gap location
8. Strike (2)
9. Screw (4)
10. Medallions and reflectors (2)
Figure 3-176. Outer Clamshell Assembly

3-162 94000936
 1128749

Latch assembly 7. Hinge (2)

Inner clamshell 8. Screw (2)
O-ring 9. Screw (2)
Latch lever 10. Lock
Docking rod 11. Screw (1)
Hinge screw (4) 12. Screw (5)
1.
2.
3.
4.
5.
6.
Figure 3-177. Latch Assembly

3-163 94000936
 1. Screw (5) 10. Latching arm cover
2. Clip (5) 11. Latching arm
3. Inner clamshell 12. Indicator flag
4. Spacer 13. Locking knob cover
5. Spring 14. Seal (2)
6. Bushing (2) 15. Locking knob
7. Screw 16. Lock nut
8. Screw (2) 17. Cap
9. Indicator flag cover
Figure 3-178. Inner lock knob Assembly

3-164 94000936
 MEDALLIONS, BADGES, TANK EMBLEMS AND ADHESIVE
STRIPS 3.47

REMOVE Parts cannot be repositioned after initial installation. Do

not remove protective film from adhesive until ready to
CONSUMABLE PART NUMBER apply.

3M GENERAL Do not bend emblem to fit contour of mounting surface.

PURPOSE Allow at least 24 hours after application before exposing
ADHESIVE the area to vigorous washing, strong water spray or
REMOVER extreme weather.
1. Mark location of emblem with masking tape.
The adhesive bond will increase to maximum strength after
about 72 hours at normal room temperature.

2. Remove emblem using fishing line or waxed dental floss. 1. Test fit medallion.
NOTE
a. Check medallion against curve of mounting surface.
Wear protective gloves.

b. Match left and right sides of fuel tank or top cover, as

3. Remove remaining foam backing tape and adhesive from
applicable.
mounting surface.
Consumable: 3M GENERAL PURPOSE ADHESIVE 2. Remove protective film from back of medallion.
REMOVERQ
NOTE
NOTE
• Do not clean with denatured alcohol, mineral spirits or • Protect adhesive from grease, oil, dust, dirt and
other solvents. Damage to components may occur. fingerprints.
• Once applied, do not shift medallion.
• For maximum bond, surface must be clean and dry.

3. Apply even pressure across entire surface. Hold in place for

4. Clean with a mixture of 50 percent isopropyl alcohol and 50 15 seconds.
percent distilled water.

4. Wait 20 minutes before touching medallion.

INSTALL _______________________________

NOTE
• Apply in ambient temperatures between 70-100 °F (21-38

94000936 3-165
 °C).

3-166 94000936
SUBJECT PAGE NO.
4.1 FASTENER TORQUE VALUES .................................................................................................4-1
4.2 SPECIFICATIONS .....................................................................................................................4-4
4.3 ENGINE OIL FLOW ...................................................................................................................4-7
4.4 OIL PUMP OPERATION ..........................................................................................................4-10
4.5 BREATHER OPERATION ....................................................................................................... .4-11
4.6 OIL PRESSURE .......................................................................................................................4-12
4.7 TROUBLESHOOTING .............................................................................................................4-14
4.8 CRIMP CLAMPS ..................................................................................................................... .4-18
4.9 OIL COOLER ...........................................................................................................................4-19
4.10 OIL CHECK VALVE .............................................................................................................. .4-21
4.11 OIL COOLANT LINES ........................................................................................................... .4-22
4.12 FRONT ENGINE MOUNT ..................................................................................................... .4-24
4.13 LEFT SIDE ENGINE MOUNT ................................................................................................4-26
4.14 UPPER ROCKER COVERS ...................................................................................................4-27
4.15 BREATHERS .........................................................................................................................4-29
4.16 LOWER ROCKER COVERS ..................................................................................................4-30
4.17 ROCKER ARMS ................................................................................................................... .4-32
4.18 PUSHRODS, LIFTERS AND COVERS ..................................................................................4-34
4.19 CYLINDER HEADS ............................................................................................................... .4-38
4.20 CYLINDERS.......................................................................................................................... .4-44
4.21 PISTONS .............................................................................................................................. .4-47
4.22 CAM COMPARTMENT AND COMPONENTS .......................................................................4-53
4.23 OIL PUMP ............................................................................................................................. .4-59
4.24 REPLACE ENGINE ............................................................................................................... .4-62
4.25 CRANKCASE ........................................................................................................................ .4-65

ENGINE
4.26 FLYWHEEL AND CONNECTING RODS ...............................................................................4-75
4.27 OIL PAN .................................................................................................................................4-77
NOTES
FASTENER TORQUE VALUES 4.1

FASTENER TORQUE VALUES IN THIS

CHAPTER _________________________
FASTENER TORQUE VALUE NOTES
Balancer bearing screw 80-110 in-lbs 9-12.4 N-m 4.25 CRANKCASE, Repair Right Crankcase Half
Balancer bearing screw 80-110 in-lbs 9-12.4 N-m 4.25 CRANKCASE, Repair Left Crankcase Half H
Breather screw 90-120 in-lbs 10.2-13.6 N-m 4.15 BREATHERS, Install
Cam chain tensioner fasteners 90-120 in-lbs 10.2-13.6 N-m 4.22 CAM COMPARTMENT AND COMPONENTS,
Install
Cam needle bearing installation maximum 25 ft-lbs 33.9 N-m 4.22 CAM COMPARTMENT AND COMPONENTS,
torque Camshaft Needle Bearings
Camshaft cover screws 90-120 in-lbs 10.2-13.6 N-m 4.22 CAM COMPARTMENT AND COMPONENTS,
Remove and Install: Camshaft Cover
Camshaft sprocket screw, 1st torque 15.0 ft-lbs 20.3 N-m
4.22 CAM COMPARTMENT AND COMPONENTS,
Install
See procedure to verify alignment specification
before tightening. Apply LOCTITE 262 HIGH
STRENGTH THREADLOCKER AND SEALANT
(red).
Camshaft sprocket screw, alignment 15.0 ft-lbs 20.3 N-m 4.22 CAM COMPARTMENT AND COMPONENTS,
check torque Install
See procedure to verify alignment specification
before tightening.
Camshaft sprocket screw, final torque 34 ft-lbs 46.1 N-m 4.22 CAM COMPARTMENT AND COMPONENTS,
Install
Camshaft timer cover screws 25-35 in-lbs 2.8-4 N-m 4.22 CAM COMPARTMENT AND COMPONENTS,
Remove and Install: Camshaft Cover
Cam support plate screws 90-120 in-lbs 10.2-13.6 N-m 4.22 CAM COMPARTMENT AND COMPONENTS,
Install
18-22 ft-lbs 24.4-29.8 N-m 4.10 OIL CHECK VALVE, Install
Crankcase oil check valve or plug with O-
ring
Crankcase oil check valve or plug with O- 18-22 ft-lbs 24.4-29.8 N-m 4.25 CRANKCASE, Plugs and Oil Fittings
ring
Crankcase screws, first torque 120 in-lbs 13.6 N-m 4.25 CRANKCASE, Assemble
Crankcase screws, last torque 15-19 ft-lbs 20.3-25.8 N-m 4.25 CRANKCASE, Assemble
Crankcase tapered plugs 120-144 in-lbs 13.6-16.3 N-m 4.25 CRANKCASE, Plugs and Oil Fittings
Crankshaft sprocket screw, 1st torque 15.0 ft-lbs 20.3 N-m
4.22 CAM COMPARTMENT AND COMPONENTS,
Install
Apply LOCTITE 262 HIGH STRENGTH THREAD-
LOCKER AND SEALANT (red)
Crankshaft sprocket screw, alignment 15.0 ft-lbs 20.3 N-m
4.22 CAM COMPARTMENT AND COMPONENTS,
check torque
Install
See procedure to verify alignment specification
before tightening.
Crankshaft sprocket screw, final torque 24 ft-lbs 32.5 N-m 4.22 CAM COMPARTMENT AND COMPONENTS,
Install
Cylinder head nut torque step 1. 20-30 ft-lbs 27.1--40.7 N-m
4.19 CYLINDER HEADS, Install
Apply ENGINE OIL to new cylinder head bolt
washers and threaded portion of the cylinder head
bolts. See procedure for torque sequence.
Cylinder head nut torque step 2. Loosen -360° -360° 4.19 CYLINDER HEADS, Install
one turn.
Cylinder head nut torque step 3. 9-11 ft-lbs 12.2-14.9 N-m 4.19 CYLINDER HEADS, Install
Cylinder head nut torque step 4. 25-27 ft-lbs 33.9-36.6 N-m 4.19 CYLINDER HEADS, Install

4-1
94000936
FASTENER TORQUE VALUE NOTES
90° 90° 4.19 CYLINDER HEADS, Install
Cylinder head nut torque step 5. Tighten
additional degree value.
Cylinder stud 120-240 in-lbs 13.6-27.1 N-m 4.25 CRANKCASE, Cylinder Studs
Cylinder temperature sensor 120-180 in-lbs 13.6-20.3 N-m 4.19 CYLINDER HEADS, Assemble
Engine mount bolt, front, lower 50-55 ft-lbs 67.8-74.5 N-m
4.12 FRONT ENGINE MOUNT, Remove and Install:
Lower Front Engine Mount
Engine mount pinch bolt, front, lower 8-9 ft-lbs 10.2-12.2 N-m
4.12 FRONT ENGINE MOUNT, Remove and Install:
Lower Front Engine Mount
Engine mount screw, front, upper engine 45-50 ft-lbs 61-67.8 N-m 4.12 FRONT ENGINE MOUNT, Remove and Install:
bracket Upper Front Engine Mount
Engine mount screw, front, upper frame 45-50 ft-lbs 61-67.8 N-m 4.12 FRONT ENGINE MOUNT, Remove and Install:
bracket Upper Front Engine Mount
45-50 ft-lbs 61-67.8 N-m
Engine mount screw, front, upper frame 4.12 FRONT ENGINE MOUNT, Remove and Install:
bracket-to-engine bracket Upper Front Engine Mount
Engine mount screw, left side, bracket- to- 45-50 ft-lbs 61-67.8 N-m 4.13 LEFT SIDE ENGINE MOUNT, Install
frame
Engine mount screw, left side, bracket- to- 28-33 ft-lbs 38-44.7 N-m 4.13 LEFT SIDE ENGINE MOUNT, Install
head
Engine oil drain plug 14-21 ft-lbs 19-28.5 N-m 4.27 OIL PAN, Install
Knock sensor screw 13-17 ft-lbs 17.6-23 N-m 4.19 CYLINDER HEADS, Assemble
Lifter anti-rotation device screw 90-120 in-lbs 10.2-13.6 N-m 4.18 PUSHRODS, LIFTERS AND COVERS, Install
Lifter cover screws 132-156 in-lbs 14.9-17.6 N-m 4.18 PUSHRODS, LIFTERS AND COVERS, Install
Lower rocker cover screws 90-120 in-lbs 10.2-13.6 N-m 4.16 LOWER ROCKER COVERS, Install
Lower rocker cover stud 90-120 in-lbs 10.2-13.6 N-m 4.14 UPPER ROCKER COVERS, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to screws.

Oil cooler cover screw 32-42 in-lbs 3.6-4.7 N-m 4.9 OIL COOLER, Install
Oil cooler screw 84-102 in-lbs 9.5-11.5 N-m 4.9 OIL COOLER, Install
Oil line manifold screws 90-120 in-lbs 10.2-13.6 N-m
4.11 OIL COOLANT LINES, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
Oil pan fasteners 132-156 in-lbs 14.9-17.6 N-m
4.27 OIL PAN, Install
Torque sequence; LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT
(blue) with used fasteners
Oil pump screws, 1st torque 12-60 in-lbs 1.4-6.8 N-m 4.22 CAM COMPARTMENT AND COMPONENTS,
Install
sm0854B (5J
Oil pump screws, final torque 90-120 in-lbs 10.2-13.6 N-m

©*©5®>
dV ©A

e-®-®
Figure 4-54. Cam Support Plate Tightening Se-
quence

Piston jet screws 25-35 in-lbs 2.8-3.9 N-m 4.25 CRANKCASE, Repair Right Crankcase Half
Rocker shaft screw 23-27 ft-lbs 31.2-36.6 N-m 4.17 ROCKER ARMS, Install

4-2 94000936
FASTENER TORQUE VALUE NOTES
Spark plug 86-108 in-lbs 9.7-12.2 N-m 4.7 TROUBLESHOOTING, Compression Test
Transmission drain plug 14-21 ft-lbs 19-28.5 N-m 4.27 OIL PAN, Install
Upper rocker cover screws 120-140 in-lbs 13.6-15.8 N-m 4.14 UPPER ROCKER COVERS, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to screws.

94000936 4-3
SPECIFICATIONS 4.2
ENGINE Table 4-5. Oiling System
ITEM SPECIFICATION
Table 4-1. Engine: Milwaukee-Eight™ 107 Engine Recommended oil Genuine Harley-Davidson H-D 360 or
ITEM SPECIFICATION SCREAMIN' EAGLE SYN3 FULL SYN-
Number of cylinders 2 THETIC MOTORCYCLE LUBRICANT
Type 4-cycle, 45 degree 20W50
V-Type, oil-cooled Motorcycle Oil
Single camshaft Pump Twin gerotor, dual scavenge, crank
Dual balance shafts mounted and driven, internal oil pump, dry
Compression ratio 10.0:1 sump
Bore 3.937 in 100 mm Pressure 35-45 psi (242-310 kPa) at 2000 RPM and
Stroke 4.375 in 111.1 mm normal operating temperature of 230 °F
Displacement 107 in3 1753 cm3 (110 °C)
Fuel requirement Premium unleaded Filtration 5 micron media, filtered between pump
Lubrication system Pressurized, dry sump with oil cooler and engine
Cooling Oil cooler

Table 4-6. Oiling System: Air-Cooled Milwaukee-Eight 117 ™

Table 4-2. Engine: Milwaukee-Eight™ 114 Engine
ITEM SPECIFICATION
ITEM SPECIFICATION
Number of cylinders Oil capacity with filter Air-Cooled (new system): 5.2 qt (4.9 L)
2
Type (service oil change) Service oil change: 4.5 qt (4.3 L)
4-cycle, 45 degree V-
Type, oil-cooled
Recommended oil Genuine Harley-Davidson H-D 360 Mo-
Single camshaft
torcycle Oil or SCREAMIN' EAGLE SYN3
Dual balance shafts
Compression ratio 10.5:1 FULL SYNTHETIC MOTORCYCLE
Bore 4.016 in 102 mm LUBRICANT 20W50
Pump Twin gerotor, dual scavenge, crank
Stroke 4.500 in 114.3 mm
mounted and driven, internal oil pump, dry
Displacement 114 in3 1868 cm3
sump
Fuel requirement Premium unleaded
Pressure 35-45 psi (241-310 kPa) at 2000 rpm and
Lubrication system Pressurized, dry sump with oil
normal operating temperature of
cooler
230 °F (110 °C)
Filtration 5 micron media, filtered between pump
Table 4-3. Engine: Air-Cooled Milwaukee-Eight 117 ™ and engine
ITEM SPECIFICATION
Number of cylinders 2
Type Table 4-7. Rocker Arms Specifications
4-cycle, 45 degree V-type ROCKER ARMS IN MM
Single camshaft Shaft fit in bushing (loose) 0.0005-0.0022 0.013-0.056
Single balance shaft End clearance 0.004-0.015 0.10-0.38
Compression ratio 10.2:1
Bore 4.075 in 103.5 mm
Table 4-8. Rocker Arm Shaft Specifications
Stroke 4.500 in 114.3 mm
ROCKER ARM SHAFTS IN MM
Displacement 117 in3 1923 cm3
Diameter 0.5538-0.5543 14.067-14.079 |
Fuel requirement Premium unleaded
Lubrication system Pressurized, dry sump Table 4-9. Hydraulic Lifter Specifications
Cooling system Oil-cooled cylinder heads with HYDRAULIC LIFT IN MM
oil cooler ERS
Fit in crankcase 0.0009-0.0026 0.023-0.066
Table 4-4. Engine Idle Characteristics (loose)
CONDITION DOM* ALL OTHERS *
Cold start 1450 rpm 1700 rpm Table 4-10. Cylinder Head Specifications
Hot idle 850 rpm 850 rpm CYLINDER HEAD IN MM
Hot idle; EITMS en- 950 rpm 950 rpm Head gasket surface (flatness) 0-0.003 0-0.08
gaged
Low voltage 200 rpm increase from normal Table 4-11. Valve Specifications
* All values are approximate VALVES IN MM
Exhaust: fit in guide 0.001-0.003 0.0254-0.0762
Table 4-5. Oiling System Intake: fit in guide 0.001-0.003 0.0254-0.0762
ITEM SPECIFICATION Seat width 0.040-0.080 1.02-2.03
Capacity with filter Air-Cooled (new system): 5 qt (4.7 L) Stem protrusion from cylinder 1.714-1.721 43.54-43.71
Service oil change (initial fill): 4 qt (3.8 L) head boss

4-4 94000936
Table 4-11. Valve Specifications Table 4-18. Hydraulic Lifter
VALVES IN MM HYDRAULIC LIFTER REPLACE IF WEAR EXCEEDS
Valve lash * 0.000-0.003 0.00-0.08 IN MM
* Variation between valve pairs operated by a common rocker Fit in crankcase 0.006 0.152
arm. Roller fit 0.0015 0.038
Roller end clearance 0.022 0.559
Table 4-12. Valve Spring Specifications
VALVE IN MM Table 4-19. Cam Support Plate
SPRINGS ITEM REPLACE IF WEAR EXCEEDS
IN MM
Closed 63 lbs @ 1.535 in. 280 N @ 39.0 mm
Cam chain tensioner shoe 0.060 min. 1.52 min.
Open 165 lbs @ 1.154 in. 735 N @ 29.3 mm
Free length 1.838 in. 46.69 mm thickness
Crankshaft bore maximum 0.8545 21.704
Table 4-13. Piston ID
PISTON IN MM Camshaft bore 1.1023 27.998
Fit in cylinder 0.0025-0.0036 0.064-0.091 Flatness 0.010 0.25
Piston pin fit (loose) 0.0002-0.0005 0.005-0.013
Ring end Top compression 0.010-0.016 0.25-0.40 Table 4-20. Oil Pump
gap 2nd compression 0.016-0.024 0.40-0.60 OIL PUMP REPLACE IF WEAR
Oil control ring 0.008-0.028 0.20-0.70 EXCEEDS
Ring side Top compression 0.0012-0.0027 0.030-0.068 IN MM
clearance 2nd compression 0.0012-0.0027 0.030-0.068 Rotor tip clearance 0.004 0.10
Oil control rails 0.001-0.007 0.025-0.178 Rotor thickness variation 0.001 0.025

Table 4-21. Cylinder Head

Table 4-14. Connecting Rod Specifications
CONNECTING ROD IN MM CYLINDER HEAD REPLACE IF
Piston pin fit (loose) 0.0007-0.0012 0.018-0.030 IN MM
Side play between fly- greater than greater than 0.13 Valve seat width (max) 0.080 2.03
wheels 0.005 Valve margin (min) 0.031 0.80
Valve stem protrusion (max) 1.752 44.50
Table 4-15. Flywheel Specifications Cylinder head warpage (max) 0.006 0.152
FLYWHEELS IN MM Valve lash (max)* 0.008 0.20
Runout (shaft measured in 0.000-0.010 0.0-0.254 • Variation between valve pairs operated by a common rocker
case) arm.
Runout (measured in truing 0.000-0.004 0.0-0.102
stand) Table 4-22. Valve Stem to Guide
End play 0.003-0.013 0.076-0.330 VALVE STEM TO GUIDE REPLACE IF WEAR EXCEEDS
IN MM
Intake 0.0038 0.0965
Table 4-16. Crankshaft/Sprocket Shaft Bearing Specifica-
tions Exhaust 0.0038 0.0965
CRANKSHAFT/SPROCK- IN MM
ET SHAFT BEARINGS Table 4-23. Valve Springs
Roller bearing fit (loose) 0.0002-0.0015 0.005-0.038 VALVE IN MM
0.0038-0.0054 0.097-0.137 SPRINGS
Bearing fit in crankcase
(tight) Closed 56.8-66.1 lbs @ 1.154 253-294 N @ 29.3 mm
Bearing inner race on 0.0004-0.0014 0.010-0.036 in
crankshaft (tight) Open 150.0-172.7 lbs @ 667-768 N @ 27.70
1.091 in mm
SERVICE WEAR LIMITS Free length 1.838 in 46.70 mm

Wear limits are given here as a guideline for measuring used Table 4-24. Cylinder
engine components. Replace components when they exceed CYLINDER REPLACE IF WEAR EXCEEDS
these values. IN MM
Warpage of gasket sur 0.006 0.152
Table 4-17. Rocker Arm/Rocker Arm Shaft face: top
ROCKER ARM/ROCKER REPLACE IF WEAR EXCEEDS Warpage of gasket sur- 0.004 0.102
ARM SHAFT IN MM face: base
Shaft fit in bushing 0.006 0.152
End clearance 0.025 0.635 Table 4-25. Piston
PISTON REPLACE IF WEAR EX-
CEEDS
IN MM
Fit in cylinder (loose) 0.0041 0.104
Piston pin fit (loose) 0.0008 0.020

4-5
94000936
Table 4-25. Piston Table 4-27. Flywheel
PISTON REPLACE IF WEAR EX- FLYWHEEL REPLACE IF WEAR EXCEEDS
CEEDS IN MM
IN MM Runout (shaft measured in 0.012 0.305
Ring end Top compression 0.020 0.508 case)
gap Second compres- 0.030 0.762 Runout (measured in truing 0.005 0.127
sion stand)
Oil control rails 0.050 1.27 End play 0.013 0.330
Ring side Top compression 0.004 0.102
clearance Second compres- 0.004 0.102 Table 4-28. Crankshaft Roller Bearing
sion CRANKSHAFT ROLLER REPLACE IF
Oil control rails 0.010 0.254 BEARING IN MM
Roller bearing fit (loose) More than 0.0015 More than 0.038
Table 4-26. Connecting Rod
CONNECTING ROD REPLACE IF WEAR Bearing fit in crankcase Less than 0.0038 Less than 0.097
EXCEEDS (tight)
IN MM Inner race on crankshaft Less than 0.0004 Less than 0.010
Piston pin fit (loose) 0.002 0.051 (tight)

4-6 94000936
ENGINE OIL FLOW 4.3

OPERATION ____ _____________ oil cooler and circulate oil between the exhaust ports for
additional heat control.
Milwaukee-Eight engines are dry sump engines meaning that
they have external oil reservoirs. Air cooled engines have an

sm08728
1. Oil in from oil pan 8. Cam plain bearing
2. Oil pump feed rotors 9. Oil to camshaft, lifters and piston jets
3. Oil pump scavenge rotors 10. Piston jets
4. Scavenge oil in from cam chest Oil through crankshaft to crankpin and rod
11.
bearings
5. Oil pressure switch 12. Oil through pushrods to rocker arms
6. Oil out to oil cooler (oil cooled only) 13. Oil spillover to lubricate valve stems
7. Oil filter 14. Hydraulic chain tensioner
Figure 4-1. Internal Engine Oil Flow

94000936 4-7
Internal Oil Distribution: All
1. See Figure 4-1.

a. Oil from the oil pan (1) is pulled through ports in the
oil pan (not shown), the transmission housing and
crankcase

b. Oil enters the oil pump feed gerotors.

c. Oil exits the pump and passes oil pressure switch

(5) and oil cooler port (6) headed to oil filter (7). Oil
cooler port is plugged on Twin-Cooled engines.

d. Oil exits filter and is directed back into cam support

plate where its split between crankshaft, hydraulic
chain tensioner (14), and lifters (9).

e. Crankshaft oil travels through crankshaft to the

crankpin and rod bearings (11 ).
f. Flow toward lifters splits to cam plain bearing (8), lifters
and on to piston jets (10).

g. Oil flows from lifters up through pushrods to rocker arms

(12).

h. Oil exits rocker arms to lubricate valve stems via

spillover (13).

i. Oil drains through passages in the heads and cylinders

back to the camchest cavity. Residual oil in the
camchest cavity and the crankcase cavity is picked up
by the scavenge port (4) in the pump. Return oil is fed
through the scavenge gerotors and case passages back
to the oil pan.

j. Main bearings, balancer bearing and left cam bearing

are lubricated by oil splash.

4-8 94000936
 1019069
4

1. Oil out check valve 7. Passages around exhaust ports

2. Hose, engine to oil cooler 8. Return oil line
3. Oil cooler 9. Oil return line to transmission
4. Manifold 10. Connection to engine oil passage in transmission
5. Return oil to oil pan
Hose, oil cooler to supply line 11.
6. Supply oil line
Figure 4-2. External Engine Oil Flow: Air Cooled
External Oil Distribution: Air Cooled Only c. Oil flow splits at oil supply line (6) and flows to manifolds
(4).
1. See Figure 4-2.
d. Oil flows through passages between the exhaust ports
a. Pressurized oil exits crankcase and flows through (7) in cylinder heads and back to manifolds.
check valve (1 ), hose (2) to oil cooler (3).
e. Oil flows through return line (8) to return oil line to
b. Oil flows through oil cooler, hose (5) to oil supply transmission (9).
line
f. Return fitting (10) connects to a passage in transmission
(6) .
where it returns to the oil pan (11).

94000936 4-9
OIL PUMP OPERATION 4.4

GENERAL

See Figure 4-3. The oil pump has two crankshaft driven gerotor
gear sets.

• The feed gerotor set distributes engine oil.

• The scavenge gerotor set draws oil from the cam and flywheel
compartments and returns it to the oil pan.

Each gerotor gear set has an inner and outer gerotor. The inner
and outer gerotors have fixed centers that are slightly offset to
one another. The inner gerotor has one less tooth.

OPERATION

The oil pump is crankshaft driven. Pump inlet and outlet sides are
sealed by tips and lobes of inner and outer gerotors, preventing
outlet side (high pressure) oil from being transferred to the inlet
side.

See Figure 4-4. As gerotors rotate, cavity volume increases

between inner and outer gerotors on pump inlet side. A vacuum
is created causing oil to be drawn in. The cavity increases until
the volume is equivalent to that of missing tooth on inner gerotor.

See Figure 4-5. As oil moves to pump outlet side, the cavity
decreases in volume. Pressurized oil is forced out the discharge
port. In operation, gerotors provide continuous oil flow.

4-10 94000936
BREATHER OPERATION 4.5

GENERAL

A breather assembly is mounted to each cylinder head to prevent

a buildup of pressure caused by the downward force of the
pistons. Burning crankcase vapor eliminates the pollutants
normally discharged from the crankcase.

See Figure 4-6. As pistons push downward, displaced air in the

crankcase is vented through the crankshaft roller bearing into the
cam compartment. The air flows up the pushrod covers (1) into
the rocker housing. The moving air absorbs a small amount of oil
vapor as it travels through the engine.

The oil/air vapor passes through an opening in the breather

assembly (3).

In the breather assembly, the flow of air passes downward

through a labyrinth where most of the oil is separated from the
air. It then moves upward through the breather element (4) where
the remaining oil is removed. Two small holes in the bottom of
the breather housing allow the separated oil to drain back into the
crankcase.

Passing through the breather element, the vapor passes through

the umbrella valve (2). Vapor passes down into the cylinder head
passageway and through the breather bolt (5). It passes through
a breather tube (6) into the air filter element where it combines
with the intake air stream and is burned during normal
combustion.

94000936 4-11
OIL PRESSURE 4.6

OPERATION 2. Run motorcycle until engine oil reaches specification.

Temperature: 230 °F (110 °C)
See Figure 4-7. The red OIL PRESSURE indicator lamp
illuminates to indicate improper pressure of the engine oil. The 3. Stop Engine.
lamp illuminates when the ignition is initially turned on (before the
engine is started), but should extinguish once the engine is 4. Remove oil pressure switch from crankcase. See OIL
running. PRESSURE SWITCH (Page 7-28).

NOTICE
5. See Figure 4-8. Install test kit.
If the oil pressure indicator lamp remains lit, always check Special Tool: OIL PRESSURE TEST GAUGE KIT (HD-
the oil supply first. If the oil supply is normal and the lamp is 96921-52D)
still lit, stop the engine at once and do not ride further until
the trouble is located and the necessary repairs are made.
a. Hand-tighten adapter HD-96921-106 (2) in oil
Failure to do so may result in engine damage. (00157a)
pressure switch mounting hole.

If the indicator lamp does not extinguish, it may be caused by low b. Assemble banjo bolt (3), washer (4), oil pressure
oil level or diluted oil supply. In freezing weather, the oil feed and gauge (1), banjo fitting and second washer onto
return lines can clog with ice or sludge. Other conditions that may adapter. Hand-tighten.
cause the lamp to remain lit are:

• Faulty lamp wiring 6. Check oil pressure.

• Faulty oil pressure sending unit a. Operate engine at various speeds.

• Damaged oil pump
b. Record results.
• Plugged oil filter element
• Incorrect oil viscosity for the operating temperature c. Stop engine.

• Fractured or weak spring in the oil pressure relief valve

7. Verify that oil pressure is within specifications. Refer to Table
• Incorrectly installed O-rings in the engine 4-29.
To troubleshoot the problem, always check the engine oil level
first. If the oil level is OK, determine if oil returns to the oil pan. If 8. Remove oil pressure gauge assembly.
oil does not return, shut off the engine until the problem is located
and corrected. 9. Install oil pressure switch. See OIL PRESSURE SWITCH
(Page 7-28).
Table 4-29. Oil Pressure
SPECIFICATION*
CHECK
SAE METRIC
Oil pressure - min at idle 5 psi 34.5 kPa
Oil pressure - normal at 35-45 psi 242-310 kPa
2000 rpm
Oil pressure - max 50 psi 345 kPa
* With oil at normal operating temperature of 230 °F (110 °C)

Figure 4-7. Oil Pressure Indicator Lamp (Typical)

OIL PRESSURE CHECK ________________

PART NUMBER TOOL NAME

HD-96921-52D OIL PRESSURE TEST GAUGE KIT

1. Verify that engine oil is at the proper level. See REPLACE

ENGINE OIL AND FILTER (Page 2-7).

4-12 94000936
 1. Gauge
2. Adapter
3. Banjo bolt
Washer ( 2 ) ______________ ______
Figure 4-8. Oil Pressure Gauge Set

94000936 4-13
TROUBLESHOOTING 4.7

TYPICAL SYMPTOMS b. Crank engine continuously through 5-7 full

compression strokes.

Typical Symptoms c. Note gauge readings at the end of the first and last
compression strokes. Record test results.
Symptoms indicating a need for engine repair are often
misleading. If more than one symptom is present, possible
d. Disconnect ACR and repeat test.
causes can be narrowed to make at least a partial diagnosis.
e. Connect ACR.
For example, an above normal consumption of oil could be
caused by several mechanical faults. However when
f. Repeat steps (a-e) on rear cylinder.
accompanied by blue-gray smoke from the exhaust and low
compression, it indicates the rings need replacing. Low
compression by itself is more likely to be caused by improperly 5. Compare with specifications. Refer to Table 4-30
seated or burned valves, not worn rings.
a. If compression is within specifications and the variance
Certain knocking noises may occur because of loose bearings, between cylinders is less than 10%, compression is
others by piston slap. Piston slap is a condition where piston or normal.
cylinder or both are out of tolerance. This excessive clearance
allows the piston to slap the cylinder as it moves up and down. b. If readings do not meet specifications, inject 0.5 fl oz
(15 ml) engine oil into each cylinder and repeat the
Most frequently, valves, rings, pins, bushings and bearings need compression tests on both cylinders. Readings that
attention at about the same time. If the symptoms indicate that are considerably higher during the second test indicate
any one of the above components is worn, service all related worn piston rings.
parts.
c. Refer to Table 4-31 for possible causes of low
COMPRESSION TEST
compression.
Check for cylinder leakage with a compression test. Use
d. Inspect cylinder using borescope. Refer to Clean and
PART NUMBER TOOL NAME
Inspect (Page 4-45) for more detail.
HD-33223-1 CYLINDER COMPRESSION GAUGE
Special Tool: BORESCOPE (HD-50549)
HD-50549 BORESCOPE
6. Remove dowel from induction module.
FASTENER TORQUE VALUE
00
CO
T

00
c
n

Spark plug 9.7-12.2 N-m 7. Connect TCA connector.

</)
■
o

CYLINDER COMPRESSION GAUGE (PART NUMBER: HD-

33223-1) with a screw-in type adapter. 8. Assemble the air cleaner. See INSPECT AIR FILTER
(Page 2-40).
1. Remove all spark plug cables.
9. Install the spark plugs. Connect spark plug wires.
2. Remove one spark plug from each cylinder. Torque: 86-108 in-lbs (9.7-12.2 N-m) Spark plug
NOTE
Never use a metal object to hold the throttle plate open. Table 4-30. Compression Specifications
ACR STATUS PSI kPa
3. Open throttle plate. ACR connected 90 (min) 621 (min)
ACR disconnected 175 (min) 1207 (min)
a. Remove air cleaner cover and filter. See INSPECT
AIR FILTER (Page 2-40). Table 4-31. Compression Test Results
TEST RESULTS DIAGNOSIS
b. Disconnect TCA connector [211] from the induction ■ Compression low on first stroke. - Ring trouble
module.
. Compression builds on the following
c. Insert a 0.75 in (19 mm) diameter by 12 in (30.5 cm) strokes, but does not reach normal.
long wooden or nylon dowel to hold the throttle valve
■ Improves considerably when oil is
open.
added to cylinder.

4. Test compression. ■ Compression low on first stroke. - Head gasket leak

- Incorrect valve lash
. Compression does not build much on
- Valve trouble
a. Connect compression tester to front cylinder following following strokes.
manufacturer's instructions.
■ Does not improve considerably with the
addition of oil.

4-14 94000936
CYLINDER LEAKDOWN_TEST d. Air sound from the oil fill spout indicates leaking past
piston rings.
PART NUMBER TOOL NAME
e. Inspect cylinder using borescope. Refer to Clean and
HD-35667-A CYLINDER LEAKDOWN TESTER Inspect (Page 4-45) for more detail.
HD-50549 BORESCOPE
Special Tool: BORESCOPE (HD-50549)
HD-52252 CRANKSHAFT LOCKING TOOL
1. Verify that the leakdown tester is free from leakage. 8. Remove crankshaft locking tool.
Special Tool: CYLINDER LEAKDOWN TESTER (HD-35667-
A) MEASURECRANKSHAFT RUNOUT

a. Apply a soap/water solution around all tester fittings.

Crankshaft Installed
b. Connect cylinder leakdown tester to compressed air NOTE
source.
• Perform the following checks during engine disassembly
c. Bubbles indicate leakage. as a method to determine condition of crankshaft and
whether crankshaft is suitable for reuse. The checks can
be done with the engine either installed in the frame or
2. NOTE
removed.
Perform the test with the ignition switch turned OFF
• Dial indicators must be set up and zeroed perpendicular
to the shaft in both directions. The indicator must be 90
Remove one spark plug per cylinder.
degrees when viewed from the end and from the side.

3. Set piston in the cylinder being tested at top dead center • For a reliable reading, only measure on the cam support
(TDC) of compression stroke (both valves closed). plate bushing machined surface of the crankshaft, never
on a shaft adapter or the bolt holes.
4. NOTE • Never secure the dial indicator base to the vehicle frame.
Never use CRANKSHAFT LOCKING TOOL (PART Movement within the engine mounts will result in a false
NUMBER: HD-52252) for procedures such as servicing reading.
the compensator, servicing the clutch or servicing the
• While rotating the crankshaft, the indicator needle may
camshaft. Crankcase damage will result.
move to both the minus and plus sides of zero. The total
indicator reading is the value to record.
Lock the crankshaft.

1. Right Side
a. Remove CKP. See CRANKSHAFT POSITION
SENSOR (CKP) (Page 7-78). a. Remove spark plugs.
b. Remove the cam support plate. See CAM
b. Install crankshaft locking tool.
COMPARTMENT AND COMPONENTS (Page 4-53).
Special Tool: CRANKSHAFT LOCKING TOOL (HD-
52252) c. Secure a dial indicator base to a stable location
(crankcase, engine stand, etc.).
5. Follow the manufacturer's instructions to perform the NOTE
leakdown test.
To obtain an accurate measurement, the dial indicator
must be set up perpendicular in both directions to the shaft
a. Record the percent of leakage. being measured.

b. Listen for air leaks at throttle body, exhaust pipe, oil fill
spout and head gasket. d. Attach a dial indicator and set it up to measure runout at
the cam plate bearing contact area of the crankshaft.
Adjust the indicator to zero.
6. Verify that the piston is still at TDC. Repeat the test if it
moved. e. Slowly rotate the crankshaft one complete revolution and
record the total needle movement.
7. Results: f. Compare results of measurements. If the total indicator
reading exceeds service wear limit, the
a. Leakage greater than 25 percent indicates that further crankshaft/flywheel assembly should be removed and
diagnosis is warranted. checked on a truing stand. Refer to Table 4-32.

b. Air escaping through the throttle body indicates

leaking past intake valves.

c. Air escaping through the exhaust pipe indicates

leaking past exhaust valves.

94000936 4-15
2. Left Side 6. Compare results of measurements. If the total indicator
reading exceeds service wear limit, replace the
a. Remove spark plugs. crankshaft/flywheel assembly. Refer to Table 4-32.
b. Remove the primary cover and compensating sprocket.
See DRIVE COMPONENTS (Page 5-18).
c. Secure a dial indicator base to a stable location
(crankcase, engine stand, etc.).
NOTE
To obtain an accurate measurement, the dial indicator
must be set up perpendicular in both directions to the
shaft being measured.

d. Attach a dial indicator set up to measure runout near the

end of the splined area of the crankshaft. Adjust the
indicator to zero on the "high" part of one spline.
e. Mark the crankshaft and crankcase to use as reference
for the amount of rotation.
NOTE
Pay attention to only the values from the "high"part of
the splines.

f. Slowly rotate the crankshaft one complete revolution and

record the total needle movement.
g. Compare results to Table 4-32. If the total indicator
reading exceeds service wear limit, remove the
crankshaft/flywheel assembly and check on a truing
stand.
Table 4-32. Flywheel
FLYWHEEL REPLACE IF WEAR EXCEEDS
Crankshaft Removed
IN MM
NOTE Runout (shaft measured in 0.305
0.012
■ The following procedure should be performed if the case)
crankshaft/flywheel assembly is suspected of being out- Runout (measured in truing 0.005 0.127
of-true. stand)
End play 0.013 0.330
• The crankshaft must be supported by the bearing races
during inspection. Never use centers as the holes may DIAGNOSE VALVE TRAIN NOISE
not be perfectly centered.
• Verify that the bearing races are in good condition and 1. NOTE
suitable for performing this inspection. Some valve train noise at start-up is normal until lifters fill
with oil. Continuous noise requires diagnosis.
1. See Figure 4-9. Mount crankshaft in truing stand so it is
supported on the bearing races (1) by the roller supports (2). With engine and oil at normal operating temperature, check
oil pressure at 2000 rpm.
2. Secure a dial indicator mount near each end of the
crankshaft. 2. Check oil pressure. See Oil Pressure Check (Page 4-12).
NOTE
3. If oil pressure is outside of range, inspect following:
Dial indicators must be perpendicular to the shaft in both
directions.
a. Oil pump wear
3. Set up each indicator (3) to measure the machined surface b. Crankcase passages for blockages
(4) on one end and splines (5) on the other.
c. Oil hoses for blockages
4. Adjust both indicators to zero.
5. Slowly rotate the crankshaft assembly while observing the 4. If oil-starved hydraulic lifters are suspected, remove lifters
total indicator reading. and inspect. See Inspect Lifters (Page 4-35).
NOTE
Twin Cam crankshaft/flywheel assemblies are not a. Clean lifter bore of all foreign material.
serviceable. Replace parts not within specifications.
5. Inspect pushrod, lifter and lifter bore for improper fit and
unusual wear.

4-16 94000936
6. Visually inspect camshaft lobes for abnormal wear.

7. Check top end components.

a. Check for excess rocker arm end play or binding.

b. Inspect valve stems for scuffing. Check stem to guide
clearance.

c. Check for loose valve seats or signs of shifting.

8. Grind valves and valve seats. See Valve and Seat Repair
(Page 4-41).

DIAGNOSE SMOKING ENGINE OR HIGH OIL

CONSUMPTION

Perform both a compression test and a cylinder leakage test. See

Compression Test (Page 4-14) and Cylinder Leakdown Test
(Page 4-15). If further testing is needed, inspect for the following:

Check Before Cylinder Head Removal:

1. Oil level too high
2. Oil carryover
3. Restricted breather hose
4. Restricted oil filter

Check After Cylinder Head Removal:

1. Clogged oil return passages
2. Valve guide seals
3. Valve guide to valve stem clearance
4. Gasket surfaces of head and cylinder
5. Cylinder head casting porosity allowing oil to drain into
combustion chamber

6. O-ring damaged or missing from oil pump/crankcase junction

7. If the above checks do not reveal the cause:
a. Remove the cylinder.
b. Verify that the piston ring gaps are properly staggered.
c. Inspect for excess piston ring wear.

94000936 4-17
CRIMP CLAMPS 4.8
REMOVE

Removal
NOTE
Pry overlap to release crimp clamps. If clamps must be cut,
use a sharp high-quality wire cutter. To prevent breaking
plastic fittings, do not twist clamp while cutting.

1. See Figure 4-10. Push the tip of a small screwdriver under

end of tang (2).

2. NOTE
Plastic fittings are fragile. Use care when removing clamp.

Pry until tang is free of tab (1). INSTALL

3. Remove clamp. PART NUMBER TOOL NAME

HD-41137 HOSE CLAMP PLIERS

Installation
1. Install new clamp.

2. Tighten clamp using:

Special Tool: HOSE CLAMP PLIERS (HD-41137)

4-18 94000936
OIL COOLER 4.9
PREPARE ____________ CONSUMABLE PART NUMBER
AND SEALANT
1. Remove main fuse. See POWER DISCONNECT (Page 7-7). (BLUE)
b. Install washer (3) and screw (4). Apply thread locker
REMOVE _____ ________________________ and tighten.
Torque: 84-102 in-lbs (9.5-11.5 N-m) Oil cooler
Oil Cooler Cover screw

1. See Figure 4-11. Remove oil cooler cover. 3. Install new clamps (2, 8) onto hose (9, 10) ends.

a. Remove screw (6). 4. NOTE

Clamps should be tightened close to the end of the hose,
b. Remove oil cooler cover (5). NOT right behind the barb bead.

Oil Cooler Connect hoses (9, 10) to the oil cooler (1).
1. See Figure 4-11. Disconnect hoses (9, 10) from the oil cooler
(1). a. Tighten clamps (2, 8). See CRIMP CLAMPS (Page 4-
18).
a. Remove clamps (2, 8). See CRIMP CLAMPS (Page 4-
18). Oil Cooler Cover
1. See Figure 4-11. Install oil cooler cover.
b. Remove hoses.
NOTE a. Install oil cooler cover (5).
If any damage is caused to the hoses during
removal of the crimp clamps, replace the hoses. b. Install screw (6). Tighten.
Torque: 32-42 in-lbs (3.^4.7 N-m) Oil cooler cover
2. Remove screw (4) and washer (3). screw

3. Slide oil cooler assembly up to disengage from isolators

(7) . Remove oil cooler assembly.

INSTALL ________ _____________________

FASTENER TORQUE VALUE
Oil cooler cover screw 32-42 in-lbs 3.6-4.7 N-m
Oil cooler screw 84-102 in-lbs 9.5-11.5 N-m

CONSUMABLE PART NUMBER

LOCTITE 243 99642-97
MEDIUM
STRENGTH
THREADLOCKER

Oil Cooler
NOTE
• See Figure 4-11. If removed, install hose (9) with paint stripe
facing out and at check valve end.

1. See Figure 4-11. Inspect condition of isolators (7).

2. Install oil cooler assembly.

Consumable: LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-97)

a. Engage pins on bottom of oil cooler into isolators (7).

NOTE
Lubricate pins with 50/50 mix of isopropyl alcohol and water.

94000936 4-19
 1019081

1. Oil cooler 6. Screw

2. Hose clamp (upper hose) 7. Isolator (2)
3. Washer 8. Hose clamp (lower hose)
4. Screw 9. Lower hose
5. Oil cooler cover 10. Upper hose
Figure 4-11.
COMPLETE 2. Install main fuse. See POWER (Page 7-7). DISCONNECT

1. Check engine oil level. See REPLACE ENGINE OIL AND

FILTER (Page 2-7).

4-20 94000936
OIL CHECK VALVE 4.10
PREPARE b. Connect hose to check valve (2).

c. Install clamp. See CRIMP CLAMPS (Page 4-18).

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

REMOVE

1. See Figure 4-12. Disconnect hose from oil check valve (2).
See CRIMP CLAMPS (Page 4-18).

2. Remove oil check valve.

3. Discard O-ring (3).

INSTALL________________________________

FASTENER TORQUE VALUE

Crankcase oil check valve or 18-22 ft-lbs 24.4-29.8 N-m
plug with O-ring
1. See Figure 4-12. Lubricate new O-ring (3) with fresh oil.
2. Install oil check valve (2) with O-ring. Tighten.
Torque: 18-22 ft-lbs (24.4-29.8 N-m) Crankcase oil check COMPLETE
valve or plug with O-ring
1. Check engine oil level. See REPLACE ENGINE OIL AND
3. Install lower hose. FILTER (Page 2-7).

a. Place new clamp on lower hose.

2. Install main fuse. See POWER DISCONNECT (Page 7-7).

94000936 4-21
OIL COOLANT LINES 4.11
PREPARE b. Clean all debris from mating surfaces and threaded
holes.
1. Remove left and right side covers. See LEFT SIDE COVER
(Page 3-63) and RIGHT SIDE COVER (Page 3-64). c. Clean all debris from coolant ports in heads and
manifolds.
2. Remove main fuse. See POWER DISCONNECT (Page 7-7).
d. Thoroughly clean interior of all lines, especially if an
engine failure occurred.
3. Remove seat. See SEAT (Page 3-142).

2. See Figure 4-13. If removed, install hose (2) to line

4. Remove fuel tank. See FUEL TANK (Page 6-14).
assembly. Secure clamp. See CRIMP CLAMPS (Page 4-
18).
5. Remove upper engine mount. See FRONT ENGINE MOUNT
(Page 4-24).
3. NOTE
Make sure o-rings are not rolled after assembly.
6. Remove oil cooler cover and upper screw. See OIL
COOLER (Page 4-19). Install new O-rings (5) on the ports of each manifold (4).

REMOVE ______________________________ 4. Install line assembly with screws (1).

1. Disconnect right side spark plug cables. a. Apply threadlocker to threads of screws.
2. See Figure 4-13. Disconnect upper hose (3) from oil cooler. LOCTITE 243 MEDIUM STRENGTH
3. Use low-pressure compressed air to clear residual oil out of THREADLOCKER AND SEALANT (BLUE) (99642-
line assembly.
97)
a. Remove engine oil filler cap. b. Tighten to 90-120 in-lbs (10.2-13.6 N-m).
b. Blow into the hose (3) where disconnected from oil
5. Install hose (2) to transmission fitting with spring clamp.
cooler. 6. Connect right spark plug cables.

4. Disconnect hose (2) from transmission fitting.

a. Remove hose clamp from hose.

5. Remove screws (1) from each manifold (4).

6. Remove line assembly from the right side.
7. If necessary, remove rear oil hose (2) from line assembly.
INSTALL

NOTE

FASTENER TORQUE VALUE

Oil line manifold screws 90-120 in-lbs 10.2-13.6 N-m

CONSUMABLE PART NUMBER

LOCTITE 243 99642-97
MEDIUM
STRENGTH
THREADLOCKER
AND SEALANT
(BLUE)

Verify that all components and mating surfaces are free of all COMPLETE
debris before assembling.
1. Install upper front engine mount. See FRONT ENGINE
1. Clean components. MOUNT (Page 4-24).

a. Remove all residual thread locking material from screws 2. Install oil cooler upper screw and cover. See OIL COOLER
and manifolds. (Page 4-19).

4-22 94000936
3. Install fuel tank. See FUEL TANK (Page 6-14).

4. Install seat. See SEAT (Page 3-142).

5. Install main fuse. See POWER DISCONNECT (Page 7-7).

6. Install side covers. See LEFT SIDE COVER (Page 3-63)
and RIGHT SIDE COVER (Page 3-64).

7. Check engine oil level. See REPLACE ENGINE OIL AND

FILTER (Page 2-7).

94000936 4-23
FRONT ENGINE MOUNT 4.12

PREPARE
PART NUMBER TOOL NAME
HD-45968 FAT JACK

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

2. Lower Front Engine Mount:

a. Support engine using the following jack or equivalent.

Special Tool: FAT JACK (HD-45968)
b. Detach right foot control bracket. See RIGHT FOOT
CONTROLS (Page 3-133).

c. Detach rear brake master cylinder bracket. See REAR

BRAKE MASTER CYLINDER (Page 3-42).
1. Mounting bolt
2. Spacer
REMOVE AND INSTALL: LOWER FRONT 3. Pinch bolt
ENGINE MOUNT ________ _______________ 4. Locknut

Remove
FASTENER TORQUE VALUE
Engine mount bolt, front, lower 50-55 ft-lbs 67.8-74.5 N-m
Engine mount pinch bolt, front, 8-9 ft-lbs 10.2-12.2 N-m
lower
1. See Figure 4-14. Loosen pinch bolt (3).

2. Remove and discard locknut (4).

3. Remove mounting bolt (1).

4. Remove spacer (2).

Install
Figure 4-15. Spacer Installed Properly
1. See Figure 4-14. Install mounting bolt (1) through spacer (2).
REMOVE AND INSTALL: UPPER FRONT
ENGINE MOUNT
2. Install new locknut (4). Tighten.
Torque: 50-55 ft-lbs (67.8-74.5 N-m) Engine mount bolt,
FASTENER TORQUE VALUE
front, lower
Engine mount screw, front, 45-50 ft-lbs 61-67.8 N-m
3. See Figure 4-15.Verify spacer is installed properly. upper engine bracket
Engine mount screw, front, 45-50 ft-lbs 61-67.8 N-m
4. See Figure 4-14.Tighten pinch bolt (3). upper frame bracket
Engine mount screw, front, 45-50 ft-lbs 61-67.8 N-m
Torque: 8-9 ft-lbs (10.2-12.2 N-m) Engine mount pinch
upper frame bracket-to-engine
bolt, front, lower
bracket

1. See Figure 4-16. Remove frame-to-engine bracket screws

(4).

2. Remove frame bracket (2).

a. Remove frame bracket screws (3).

b. Remove frame bracket (2).

4-24 94000936
Remove

94000936 4-25
3. Remove engine bracket (1 ).

a. Loosen engme bracket screws (5).

b. Remove engine bracket (1) by lifting left side up then

pulling to the left.

Install
1. See Figure 4-16. Install engine bracket.

a. Install engine bracket (1).

b. Hand tighten engme bracket screws (5).

2. Install frame bracket.

a. Install frame bracket (2).

b. Install frame bracket screws (3). Hand tighten.

3. Install frame bracket-to-engine bracket screws (4). Hand

tighten.

4. Tighten fasteners in the following order.

a. Tighten engine bracket screws (5).

Torque: 45-50 ft-lbs (61-67.8 N-m) Engine mount
screw, front, upper engine bracket
b. If left side engine mount removed: Tighten bracket-to-
head screws. See LEFT SIDE ENGINE MOUNT
(Page 4-26).
COMPLETE
c. Tighten frame bracket screws (3).
Torque: 45-50 ft-lbs (61-67.8 N-m) Engine mount 1. Lower Front Engine Mount:
screw, front, upper frame bracket
a. Attach rear brake master cylinder bracket. See REAR
d. If left side engine mount removed: Tighten bracket-to- BRAKE MASTER CYLINDER (Page 3-42).
frame screws. See LEFT SIDE ENGINE MOUNT
(Page 4-26).
b. Attach right foot control bracket. See RIGHT FOOT
CONTROLS (Page 3-133).
e. Tighten frame bracket-to-engine bracket screws (4).
Torque: 45-50 ft-lbs (61-67.8 N-m) Engine mount c. Remove jack.
screw, front, upper frame bracket-to-engine
bracket 2. Install main fuse. See POWER DISCONNECT (Page 7-7).

94000936 4-26
LEFT SIDE ENGINE MOUNT 4.13
UPPER ROCKER COVERS 4.14
PREPARE Tighten fasteners in the following order.

a. Tighten screws and washers (2).

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).
Torque: 28-33 ft-lbs (38-44.7 N-m) Engine mount
screw, left side, bracket-to-head
2. Remove ignition coil. See IGNITION COIL (Page 7-14).
b. Tighten screws (3).
3. Lift rear of fuel tank. See Lift Rear Of Fuel Tank (Page 6-12). Torque: 45-50 ft-lbs (61-67.8 N-m) Engine mount
screw, left side, bracket-to-frame
REMOVE

1. See Figure 4-17. Remove bracket (1).

a. Remove screws (3).

b. Remove screws and washers (2).

c. Remove bracket (1).

INSTALL

a. Install bracket (1).

FASTENER TORQUE VALUE

Engine mount screw, left side, 45-50 ft-lbs 61-67.8 N-m
bracket-to-frame
Engine mount screw, left side, 28-33 ft-lbs 38-44.7 N-m
bracket-to-head
1. See Figure 4-17. Install bracket (1).

b. Install screws and washers (2). Hand tighten.

c. Install screws (3). Hand tighten.

2. NOTE COMPLETE
If upper front engine mount was also removed, see the
combined tightening sequence in Remove and Install: 1. Install main fuse. See POWER DISCONNECT (Page 7-7).
Upper Front Engine Mount (Page 4-24).
2. Install ignition coil. See IGNITION COIL (Page 7-14).

3. Secure fuel tank. See Secure Fuel Tank (Page 6-12).

94000936 4-27
PREPARE 3. Clean threadlocker from all screws and threaded holes. See
Cleaning Threads and Threaded Holes in Cleaning (Page
II).
NOTE
Abrasive particles can damage machined surfaces or plug oil
passageways. Clean parts before disassembly to prevent a. Cover exposed internal engine area to prevent
component damage. contamination from loosened threadlocker.

b. Verify that no foreign material in the threaded hole.

1. Use low-pressure compressed air to clean exterior surfaces
of engine.
INSTALL ___________________
2. Disconnect negative battery cable. See POWER
FASTENER TORQUE VALUE
DISCONNECT (Page 7-7).
Lower rocker cover stud 90-120 in-lbs 10.2-13.6 N-m

3. Remove seat. See SEAT (Page 3-142). Upper rocker cover screws 120-140 in-lbs 13.6-15.8 N-m
1. Verify that all threaded holes are free from oil and
4. Remove fuel tank. See FUEL TANK (Page 6-14). threadlocking residue.

5. Remove spark plug cables. See SPARK PLUG CABLES 2. Install rocker cover and new gasket.
(Page 7-13).
a. Verify torque of stud (4).
6. Remove upper front engine mount. See FRONT ENGINE Torque: 90-120 in-lbs (10.2-13.6 N-m) Lower rocker
MOUNT (Page 4-24). cover stud
b. Apply LOCTITE 243 MEDIUM STRENGTH
7. Remove upper cooling lines. See OIL COOLANT LINES THREADLOCKER AND SEALANT (blue) to 5-7 screw
(Page 4-22). threads.

8. See Figure 7-163. Reposition engine harness caddy. c. Start all screws.
a. Disconnect rear knock sensor (8).
b. d. Hold hex on stud (4) when tightening center screw
Separate rear knock sensor connector from electrical (3) .
caddy.
e. See Figure 4-19. Tighten in sequence shown.
c. Disconnect rear ACR (9).
Torque: 120-140 in-lbs (13.0-15.8 N-m) Upper rocker
cover screws
d. Disconnect front ACR (10).
COMPLETE
Remove push/lock pin securing electrical caddy to
e.
right side of backbone. 1. See Figure 7-163. Attach engine harness and caddy.
f.
Gently bend tabs outward at rear of electrical caddy a. Gently bend tabs outward at rear of electrical caddy to
to separate from backbone. allow rear mounting pins to engage holes in backbone.

g. Move rear electrical caddy and engine wire harness b. Install push/lock pin through electrical caddy mounting
to gain access as needed. hole on right side of backbone.
REMOVE
c. Connect front ACR (10).

d. Connect rear ACR (9).

1. See Figure 4-18. Remove the rocker cover screws.
a. Hold hex on stud (4). e. Attach rear knock sensor (8) to electrical caddy.

b. Remove center screw (3). f. Connect rear knock sensor.

c. Remove remaining screws. 2. Install upper cooling lines. See OIL COOLANT LINES
(Page 4-22).
2. Remove the rocker cover (2) and gasket (1) from right side of
vehicle. Discard gasket. 3. Install upper front engine mount. See FRONT ENGINE
MOUNT (Page 4-24).

4-28 94000936
 4. Install spark plug cables. See SPARK PLUG CABLES (Page
UPPER ROCKER COVERS 7-13). 4.14

5. Install fuel tank. See FUEL TANK (Page 6-14).

6. Install seat. See SEAT (Page 3-142).

7. Connect negative battery cable. See POWER

DISCONNECT (Page 7-7).

Figure 4-

94000936 4-29
BREATHERS
LOWER ROCKER COVERS 4.15
4.16

PREPARE 1. See Figure 4-20. Lubricate O-ring (3).

NOTE 2. Install breather with screw (1). Tighten to 90-120 in-lbs (10.2-
Abrasive particles can damage machined surfaces or plug 13.6 N-m).
oil passageways. Clean parts before disassembly to prevent
component damage.

1. Use low-pressure compressed air to clean exterior surfaces

of engine.

2. Disconnect negative battery cable. See POWER

DISCONNECT (Page 7-7).

3. Remove seat. See SEAT (Page 3-142).

4. Remove fuel tank. See FUEL TANK (Page 6-14).

5. Remove spark plug cables. See SPARK PLUG CABLES

(Page 7-13).

6. Remove upper front engine mount. See FRONT ENGINE

MOUNT (Page 4-24).

7. Remove oil cooler upper screw. See OIL COOLER (Page 4-

19).
COMPLETE

8. Remove upper cooling lines. See OIL COOLANT LINES 1. Install upper rocker covers. See UPPER ROCKER COVERS
(Page 4-22). (Page 4-27).

9. Disconnect electrical connectors. 2. Install spark plugs. See CLEAN, INSPECT, REPLACE
SPARK PLUGS (Page 2-46).
a. Rear cylinder: Knock sensor and ACR.
3. Connect electrical connectors.
b. Front cylinder: ACR.
a. Rear cylinder: Knock sensor and ACR.
10. Remove left side spark plugs. See CLEAN, INSPECT,
REPLACE SPARK PLUGS (Page 2-46). b. Front cylinder: ACR.

11. Remove upper rocker covers. See UPPER ROCKER 4. Install upper cooling lines. See OIL COOLANT LINES (Page
COVERS (Page 4-27). 4-22).

REMOVE 5. Install oil cooler upper screw. See OIL COOLER (Page 4-
19).
1. See Figure 4-20 . Remove screw (1).
2. Remove breather assembly (2). 6. Install upper front engine mount. See FRONT ENGINE
MOUNT (Page 4-24).
NOTE
Breather assembly contains no service parts. Replace as an
7. Install spark plug cables. SPARK PLUG CABLES (Page 7-
assembly
13).

INSTALL
8. Install fuel tank. See FUEL TANK (Page 6-14).

9. Install seat. See SEAT (Page 3-142).

FASTENER TORQUE VALUE
Breather screw 90-120 in-lbs 10.2-13.6 N-m 10. Connect negative battery cable. See POWER
DISCONNECT (Page 7-7).

4-30 94000936
PREPARE 3. Clean threadlocker from all screws and threaded holes. See
Cleaning Fastener Threads in Cleaning (Page II).
NOTE a. Cover exposed internal engine area to prevent
Abrasive particles can damage machined surfaces or plug contamination from loosened threadlocker.
oil passageways. Clean parts before disassembly to prevent
component damage. INSTALL __________________________________________

1. Use low-pressure compressed air to clean exterior surfaces FASTENER TORQUE VALUE
of engine.
Lower rocker cover screws 90-120 in-lbs 10.2-13.6 N-m
1. Install new gasket.
2. Disconnect negative battery cable. See POWER
2. See Figure 4-21. Install lower rocker cover.
DISCONNECT (Page 7-7).
a. Engine in chassis: Install from left side.
3. Remove seat. See SEAT (Page 3-142).
b. Apply LOCTITE 243 MEDIUM STRENGTH
4. Remove fuel tank. See FUEL TANK (Page 6-14). THREADLOCKER AND SEALANT (blue) to 5-7 screw
threads.
5. Remove spark plug cables. See SPARK PLUG CABLES
(Page 7-13). c. Start four screws and the stud.

6. Remove air cleaner. See INSPECT AIR FILTER (Page 2- d. lighten in sequence shown to 90-120 in-lbs (10.2-13.6
40). N-m).

7. Remove air cleaner backplate assembly. See AIR CLEANER

BACKPLATE ASSEMBLY (Page 6-4).

8. Remove upper front engine mount. See FRONT ENGINE

MOUNT (Page 4-24).

9. Remove oil cooler upper screw. See OIL COOLER (Page 4-

19).

10. Remove upper cooling lines. See OIL COOLANT LINES

(Page 4-22).

11. Disconnect electrical connectors.

a. Rear cylinder: Knock sensor and ACR.

b. Front cylinder: ACR.

12. Remove spark plugs. See CLEAN, INSPECT, REPLACE COMPLETE

SPARK PLUGS (Page 2-46).
1. Install breathers. See BREATHERS (Page 4-29).
13. Remove upper rocker covers. See UPPER ROCKER
COVERS (Page 4-27). 2. Install upper rocker covers. See UPPER ROCKER COVERS
(Page 4-27).
14. Remove breathers. See BREATHERS (Page 4-29).
3. Install spark plugs. See CLEAN, INSPECT, REPLACE
REMOVE SPARK PLUGS (Page 2-46).

1. See Figure 4-21 . Remove lower rocker cover. 4. Connect electrical connectors.

a. Remove five screws. a. Rear cylinder: Knock sensor and ACR.

b. Lift off from cylinder head.
b. Front cylinder: ACR.
c. Engine in chassis: Remove from left side.

2. Discard gasket.

94000936 4-31
5. Install upper cooling lines. See OIL COOLANT LINES (Page
LOWER
4-22).
ROCKER COVERS 4.16

6. Install oil cooler upper screw. See OIL COOLER (Page 4-

19).

7. Install upper front engine mount. See FRONT ENGINE

MOUNT (Page 4-24).

8. Install air cleaner backplate assembly. See AIR CLEANER

BACKPLATE ASSEMBLY (Page 6-4).
9. Install air cleaner. See INSPECT AIR FILTER (Page 2-40).

10. Install spark plug cables. See SPARK PLUG CABLES

(Page 7-13).

11. Install fuel tank. See FUEL TANK (Page 6-14).

12. Install seat. See SEAT (Page 3-142).

13. Connect negative battery cable. See POWER

DISCONNECT (Page 7-7).

4-32 94000936
ROCKER ARMS 4.17

PREPARE

NOTE
Abrasive particles can damage machined surfaces or plug
oil passageways. Clean parts before disassembly to prevent
component damage.

1. Use low-pressure compressed air to clean exterior surfaces

of engine.

2. Disconnect negative battery cable. See POWER

DISCONNECT (Page 7-7).

3. Remove seat. See SEAT (Page 3-142).

4. Remove fuel tank. See FUEL TANK (Page 6-14).

5. Remove spark plug cables. See SPARK PLUG CABLES

(Page 7-13).

6. Remove upper front engine mount. See FRONT ENGINE CLEAN AND INSPECT
MOUNT (Page 4-24).
1. Clean all parts.
7. Remove oil cooler upper screw. See OIL COOLER (Page 4-
19). 2. Inspect for wear. Replace or repair as necessary.
a. Measure rocker arm bore.
8. Remove upper cooling lines. See OIL COOLANT LINES
b. Measure rocker arm shaft for excessive wear.
(Page 4-22).
c. Inspect valve contact areas for excessive wear.
9. Disconnect electrical connectors. d. Inspect pushrod pocket for excessive wear.

a. Rear cylinder: Knock sensor and ACR. e. Verify that oil holes in rocker arms are clean and open.

b. Front cylinder: ACR.

10. Remove left side spark plugs. See CLEAN, INSPECT, FASTENER TORQUE VALUE
REPLACE SPARK PLUGS (Page 2-46).
Rocker shaft screw 23-27 ft-lbs 31.2-36.6 N-m
1. Set piston at approximate BDC on the power stroke.
11. Remove upper rocker covers. See UPPER ROCKER
COVERS (Page 4-27). INSTALL

REMOVE_______________________________ 2. Install rocker arms.

a. Verify that lifters are on the base circle of the camshaft

1 . Remove rocker arms.
lobe.
a. Set piston at TDC on the compression stroke.
b. See Figure 4-22 . Install rocker arm (4) and rocker
b. See Figure 4-22. Alternately loosen screws (3) until shaft (1).
screws can be turned by hand.
c. Verify that rocker shaft is seated in both towers.
c. Remove screws.
d. Install screws (3).
d. Remove rocker shaft (1) and rocker arm (4).
e. Alternately tighten screws to pull rocker shaft down
e. Repeat with remaining rocker arm. evenly.

f. Tighten to 23-27 ft-lbs (31.2-36.6 N-m).

g. Repeat with remaining rocker arms.

3. Allow lifters to bleed down. When lifters have bled down,

4-33 94000936
PUSHRODS, LIFTERS AND COVERS 4.18

pushrods can be rotated by hand.

4-34 94000936
 NOTE
Do not rotate crankshaft until lifters have bled down.
Rotating crankshaft sooner could result in valve-to-piston
contact resulting in damage.

4. Check valve lash after lifters have bled down.

a. Position crankshaft at TDC of compression stroke. All

valves will be closed.

b. While holding rocker arm against valves, attempt to

slide a feeler gauge between each valve stem tip and
the rocker arm.

c. The maximum allowable lash on a common rocker

arm is 0.008 in (0.2 mm). A measurement in excess
requires disassembly and repair of cylinder head
assembly.

COMPLETE _________________

1. Install upper rocker covers. See UPPER ROCKER COVERS

(Page 4-27).

2. Install spark plugs. See CLEAN, INSPECT, REPLACE

SPARK PLUGS (Page 2-46).
3. Connect electrical connectors.

a. Rear cylinder: Knock sensor and ACR.

b. Front cylinder: ACR.

4. Install upper cooling lines. See OIL COOLANT LINES (Page

4-22).

5. Install oil cooler upper screw. See OIL COOLER (Page 4-

19).

6. Install upper front engine mount. See FRONT ENGINE

MOUNT (Page 4-24).

7. Install spark plug cables. SPARK PLUG CABLES (Page 7-

13).

8. Install fuel tank. See FUEL TANK (Page 6-14).

9. Install seat. See SEAT (Page 3-142).

10. Connect negative battery cable. See POWER

DISCONNECT (Page 7-7).

94000936 4-35
PUSHRODS, LIFTERS AND COVERS 4.18
PREPARE 2. Remove pushrod covers using 94086-09 (PUSHROD
COVER RETAINER INSTALLATION AND REMOVAL
TOOL).
NOTE
Abrasive particles can damage machined surfaces or plug oil a. See Figure 4-23. Alternately, insert the blade of a
passageways. Clean parts before disassembly to prevent screwdriver in tab (1) of spring cap retainer.
component damage.
b. While pushing down on spring cap (2), rotate bottom of
retainer outboard.
1. Use low-pressure compressed air to clean exterior surfaces
of engine.
3. Remove pushrod covers.

2. Disconnect negative battery cable. See POWER a. Collapse upper and lower pushrod covers.
DISCONNECT (Page 7-7).
4. Disassemble pushrod cover assemblies.
3. Remove seat. See SEAT (Page 3-142). a. Discard three O-rings.

4. Remove fuel tank. See FUEL TANK (Page 6-14). 5. See Figure 4-24. Remove lifter covers.
a. Remove four screws (1).
5. Remove spark plug cables. See SPARK PLUG CABLES
(Page 7-13). b. Remove the lifter cover (2) and gasket (3). Discard
gasket.
6. Remove air cleaner. See INSPECT AIR FILTER (Page 2-40).
NOTE
7. Remove air cleaner backplate assembly. See AIR CLEANER Heat lifter anti-rotation device screw (4) to soften the thread
BACKPLATE ASSEMBLY (Page 6-4). sealant with ROB/NAIR HEAT GUN (PART NUMBER: HD-
25070). Do not use an open flame.
8. Remove upper front engine mount. See FRONT ENGINE
MOUNT (Page 4-24). 6. Remove lifters.
a. Remove screw (4) securing anti-rotation device (5).
9. Remove oil cooler cover and upper screw. See OIL COOLER
(Page 4-19). b. Remove anti-rotation device.
c. Remove the lifters (6) and place in clean plastic bags to
10. Remove upper cooling lines. See OIL COOLANT LINES prevent contamination.
(Page 4-22).

11. Disconnect electrical connectors.

a. Rear cylinder: Knock sensor and ACR.

b. Front cylinder: ACR

12. Remove spark plugs. See CLEAN, INSPECT, REPLACE

SPARK PLUGS (Page 2-46).

13. Remove upper rocker covers. See UPPER ROCKER

COVERS (Page 4-27).

14. Remove rocker arms. See ROCKER ARMS (Page 4-32).

REMOVE

PART NUMBER TOOL NAME

HD-25070 ROBINAIR HEAT GUN

NOTE

Mark parts for location and orientation during

removal. 1. Remove pushrods.

4-36 94000936
 3. Check lifter roller end clearance.
b. Install new lifters and/or replace crankcases if
clearance exceeds service wear limit of 0.006 in
a.
(0.152Allowable
mm) end clearance is within. 0.008-0.022 in
(0.203-0.559 mm)

b. Replace lifters if end clearance exceeds service wear

limit of. 0.022 in (0.559 mm)

4. Soak lifters in clean engine oil. Keep covered until assembly.

5. Examine lifter rollers. If damaged, examine the associated

cam lobe.

a. Verify that the hydraulic lifter rollers turn freely.

b. Check for flat spots, scuff marks and pitting.

c. See Figure 4-25. A dull lifter roller surface is called

frosting (2). Frosting is a cosmetic condition and does
not affect function.

6. Inspect the lifter for signs of wear.

a. Verify that the plunger is fully extended against the C-clip.

CLEAN AND INSPECT

1. Except for the hydraulic lifters, clean all parts in a non-

volatile cleaning solution or solvent.
A WARNING
Compressed air can pierce the skin and flying debris from b. Pump plunger to verify operation.
compressed air could cause serious eye injury. Wear safety
glasses when working with compressed air. Never use your
hand to check for air leaks or to determine air flow rates.
(00061a)

2. Dry parts with low-pressure, compressed air.

3. Verify that the O-ring seats and contact surfaces of the

pushrod covers are completely clean.

4. Verify that all oil holes are clean and open.

5. Examine the pushrods. Replace any pushrods that are bent,

dented, damaged, discolored or if the ball ends show signs
of excessive wear or damage.
1. Normal roller
2. Frosted roller
6. Cover all parts to protect them from dust and dirt. Figure 4-25. Roller Inspection

INSPECT LIFTERS ____ ASSEMBLEPUSHROD COVER _

1. See Figure 4-26. Apply a film of clean engine oil to new O-

1. Measure the lifter outer diameter. Record the measurement.
rings (1,6 and 8).

2. Measure lifter bore. Subtract this measurement from the lifter 2. Install upper O-ring (1) on the upper pushrod cover (2).
measurement to determine clearance. 3. Slide the spring cap (4) and spring (5) onto the body of the
upper pushrod cover. Move parts up until spring cap
a. Clearance when new is 0.0009-0.0026 in (0.023-0.066 contacts upper O-ring seat.
mm) 4. Install middle O-ring (6) into groove on top of lower pushrod
cover (7).

94000936 4-37
5. Apply a light film of clean engine oil on the upper pushrod b. Rotate crankshaft until both cam lobes are visible in
cover. lifter bores.

6. Slide the straight end of the upper pushrod cover into the c. Carefully install lifters in lifter bores. Do not drop lifters
end of the lower pushrod cover. onto cam lobes.

7. Wipe pushrod covers clean. d. See Figure 4-24 . Install anti-rotation device.
8. Install lower O-ring (8) on lower pushrod cover.
e. Install screw (4). Tighten.
Torque: 90-120 in-lbs (10.2-13.6 N-m) Lifter anti-
rotation device screw

2. Install lifter cover (2), new gasket (3) and screws (1). Tighten
in a cross-wise pattern.
Torque: 132-156 in-lbs (14.9-17.6 N-m) Lifter cover
screws

3. Install pushrod covers.

a. Assemble pushrod covers with new O-rings.

b. Install new O-rings on each end of the pushrod cover.

c. Compress pushrod cover assembly and fit into lifter

cover bore.

d. Extend assembly into cylinder head bore.

e. Verify that the ends of the pushrod cover fit snugly

into cylinder head and lifter cover bores.

4. Install spring cap retainers using 94086-09 (PUSHROD

COVER RETAINER INSTALLATION AND REMOVAL
TOOL).

a. Insert upper edge of spring cap retainer into cylinder

head bore.

b. See Figure 4-27. Alternately, insert blade of small

screwdriver between bottom edge of spring cap
retainer and top of spring cap.

c. Press spring cap down and slide bottom edge of

retainer toward tip of screwdriver.

d. Verify that spring cap retainer seats tightly against

upper pushrod cover.

Apply a small amount of SCREAMIN' EAGLE ASSEMBLY

5
INSTALL . LUBE to ends of each pushrod.
FASTENER TORQUE VALUE 6. NOTE
Lifter anti-rotation device 90-120 in-lbs 10.2—13.6 N- If installing original parts, install them in their original
screw m location and orientation. Use 10.301 inch long (light blue
Lifter cover screws 132-156in-lbs 1-4.9—17.6 N- stripes) as intake and 10.531 inch long (yellow stripes) as
m exhaust.
NOTE
Anti-rotation devices are marked "F" (front) and "R" (rear).
Install pushrods.

1. Install lifters.

a. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to outer

surface of each lifter. Pour a small amount onto each
cam lobe.

4-38 94000936
COMPLETE

1. Install rocker arms. See ROCKER ARMS (Page 4-32).

2. Install upper rocker covers. See UPPER ROCKER COVERS

(Page 4-27).

3. Install spark plugs. See CLEAN, INSPECT, REPLACE

SPARK PLUGS (Page 2-46).
4. Connect electrical connectors.

a. Rear cylinder: Knock sensor and ACR.

b. Front cylinder: ACR

5. Install upper cooling lines. See OIL COOLANT LINES (Page

4-22).

6. Install oil cooler upper screw and cover. See OIL COOLER
(Page 4-19).

7. Install upper front engine mount. See FRONT ENGINE

MOUNT (Page 4-24).

8. Install air cleaner backplate assembly. See AIR CLEANER

BACKPLATE ASSEMBLY (Page 6-4).

9. Install air cleaner. See INSPECT AIR FILTER (Page 2-40).

10. Install spark plug cables. See SPARK PLUG CABLES

(Page 7-13).

11. Install fuel tank. See FUEL TANK (Page 6-14).

12. Install seat. See SEAT (Page 3-142).

13. Connect negative battery cable. See POWER

DISCONNECT (Page 7-7).

94000936 4-39
CYLINDER HEADS 4.19

PREPARE 19. Remove rocker arms. See ROCKER ARMS (Page 4-32).

NOTE 20. Remove pushrods, lifters and covers. See PUSHRODS,

Abrasive particles can damage machined surfaces or plug LIFTERS AND COVERS (Page 4-34).
oil passageways. Clean parts before disassembly to prevent
component damage. REMOVE ________
1. Use low-pressure compressed air to clean exterior surfaces 1. Disconnect knock sensor connector.
of engine. 2. See Figure 4-28. Discard cylinder head bolts.
a. Loosen each cylinder head bolt in sequence shown.
2. Disconnect negative battery cable. See POWER
DISCONNECT (Page 7-7). b. Discard head bolts.

3. Remove seat. See SEAT (Page 3-142). 3. Remove cylinder head.

a. Lift cylinder head from dowel pins.
4. Remove fuel tank. See FUEL TANK (Page 6-14).
b. Discard gasket.
5. Remove spark plug cables. See SPARK PLUG CABLES
(Page 7-13).

6. Remove coil. See IGNITION COIL (Page 7-14).

7. Remove left side engine mount. See LEFT SIDE ENGINE

MOUNT (Page 4-26).

8. Remove air cleaner. See INSPECT AIR FILTER (Page 2-

40).

9. Remove air cleaner backplate assembly. See AIR CLEANER

BACKPLATE ASSEMBLY (Page 6-4).

10. Remove upper front engine mount. See FRONT ENGINE Figure 4-28. Head Bolt Tightening Sequence
MOUNT (Page 4-24).
CLEAN
11. Remove oil cooler cover and upper screw. See OIL
COOLER (Page 4-19). NOTE
Avoid getting debris in coolant and oil passages during
gasket removal and cleaning.
12. Remove upper cooling lines. See OIL COOLANT LINES
(Page 4-22).
1. Remove old gasket material from cylinder head. Do not cause
13. Remove induction module. See INDUCTION MODULE scratches or nicks.
(Page 6-27).
NOTE

14. Disconnect electrical connectors. Bead blasting materials could enter threaded holes.
This would adversely affect fastener engagement and
a. Rear cylinder: Engine temperature sensor, knock torque indication. Cover all threaded holes before bead
sensor, and ACR. blasting.

b. Front cylinder: Knock sensor and ACR. NOTICE

Do not use glass or sand to bead blast surfaces exposed to
15. Remove spark plugs. See CLEAN, INSPECT, REPLACE engine oil. Blasting materials can lodge in pores of the
SPARK PLUGS (Page 2-46). casting. Heat expansion releases this material which can
contaminate oil resulting in engine damage. (00534b)
16. Remove upper rocker covers. See UPPER ROCKER
COVERS (Page 4-27).
2. Remove all carbon deposits from combustion chamber and
machined surfaces of cylinder head. Do not remove any
17. Remove breathers. See BREATHERS (Page 4-29). metal material.

18. Remove lower rocker covers. See LOWER ROCKER

COVERS (Page 4-30).

4-40 94000936
3. To soften stubborn deposits, soak the cylinder head in a 5. See Figure 4-28 .Tighten new head nuts in five stages
chemical solution, such as GUNK HYDRO-SEAL or other following sequence shown.
carbon and gum dissolving agent. Repeat previous step as
necessary. a. Tighten.
NOTE Torque: 20-30 ft-lbs (27.1-40.7 N-m) Cylinder head
Keep all parts grouped by location so they can be installed nut torque step 1.
in the original location.
b. Loosen one full turn.

4. Thoroughly clean the cylinder head, spring retainers, tapered Torque: -360° (-360°) Cylinder head nut torque step
keepers, valves and valve springs in a non-volatile cleaning 2. Loosen one turn.
solution or solvent. Follow up with a thorough wash in hot c. Tighten.
soapy water.
Torque: 9-11 ft-lbs (12.2-14.9 N-m) Cylinder head nut
torque step 3.
5. Thoroughly flush all coolant and oil passages to remove
loose debris. d. Tighten.
Torque: 25-27 ft-lbs (33.9-36.6 N-m) Cylinder head
A WARNING nut torque step 4.
Compressed air can pierce the skin and flying debris from e. Tighten to final torque.
compressed air could cause serious eye injury. Wear safety
glasses when working with compressed air. Never use your Torque: 90° (90°) Cylinder head nut torque step 5.
hand to check for air leaks or to determine air flow rates. Tighten additional degree value.
(00061a) 6. Connect knock sensor, engine temperature sensor, and
ACR.
6. Dry parts with low-pressure, compressed air.

7. Clean threadlocker from all screws and threaded holes. See

Cleaning Fastener Threads in Cleaning (Page 11).

a. Cover exposed internal engine area to prevent

contamination from loosened threadlocker.

INSTALL _______________________________

FASTENER TORQUE VALUE

Cylinder head nut torque step 1. 20-30 ft-lbs 27.1--40.7 N-m

Cylinder head nut torque step 2. -360° -360°

Loosen one turn.
Cylinder head nut torque step 3. 9-11 ft-lbs 12.2-14.9 N-m

Cylinder head nut torque step 4. 25-27 ft-lbs 33.9-36.6 N-m

Cylinder head nut torque step 5. go° go°

Tighten additional degree value.

1. Clean all gasket surfaces.

2. Thoroughly flush all coolant and oil passages to remove
loose debris.

3. See Figure 4-29. Install cylinder head.

a. Install new gasket with the part number facing up. DISASSEMBLE

b. Install cylinder head on dowel pins.

PART NUMBER TOOLNAME
4. Install new cylinder head flange nuts. B-49312 CYLINDER HEAD HOLDING FIXTURE
HD-34736-B VALVE SPRING COMPRESSOR

a. Apply new engine oil to flanges of cylinder head nuts.

b. Install cylinder head nuts.

94000936 4-41
1. Secure cylinder head for service.
a. Remove spark plugs.
b. Turn 12 mm end of CYLINDER HEAD HOLDING
FIXTURE (PART NUMBER: B-49312) (1) into cylinder
head (2) spark plug hole.
c. Clamp tool in vise at a comfortable working position.

2. Remove ACR. See AUTOMATIC COMPRESSION

RELEASE (ACR) (Page 7-81).
3. See Figure 4-30. Remove screw (2) and knock sensor (1).
4. Remove cylinder head temperature sensor (3).
5. See Figure 4-32. Remove valves.
a. See Figure 4-31. Use VALVE SPRING COMPRESSOR
(PART NUMBER: HD-34736-B) to compress valve
spring.
b. Remove tapered keepers (1).
c. Slowly release valve spring compression.
d. Remove the spring retainer (2) and valve spring (3).
e. Remove the valve (11).

6. Remove and discard valve stem seal assembly (4).

7. Identify components.
a. Mark the valve head for identification.
Figure 4-31. Valve Spring Compressor
b. Place tapered keepers, valve spring and spring retainer
in a plastic bag with identification.
8. Remove the remaining valves and components.

Figure 4-32. Valve Components

4-42 94000936
CLEAN AND INSPECT 2. Inspect the valve for burning, cracking, carbon tracking, or
other indications of combustion gas leakage.
PART NUMBER TOOLNAME
3. Inspect the end of the valve stem for pitting or uneven wear.
B-45525 VALVE GUIDE HONE
HD-34751 CLEANING BRUSH
4. Remove burrs around the valve stem keeper groove with a
See SPECIFICATIONS (Page 4-4) for specifications not shown fine tooth file.
here.
5. To determine if the valve stem is excessively worn, see valve
Cylinder Head guide inspection.

1. Check all gasket sealing surfaces for scratches and nicks.

Valve Springs
2. Check head flatness with feeler gauge. 1. Inspect springs for cracked or discolored coils.
2. Check for squareness.
a. Using a straightedge, check gasket surface for
warpage. 3. Check free length.
4. Load test using a commercially available valve spring tester.
b. Replace the head if warpage is beyond specification.
Length/Dimension/Distance: 0.006 in (0.152 mm) Tapered Keepers
3. Verify that all oil holes are clean and open. Install new keepers any time valves are installed.

Valve Guides Valve Seats

1. Inspect external surfaces for cracks. 1. Inspect seats for cracking, chipping or burning, carbon
tracking, or other indications of combustion gas leakage.
2. Prepare valve guides for inspection. 2. Check seat wear by measuring valve stem protrusion. See
Valve and Seat Repair (Page 4-41).
a. Lightly hone bore.
3. Replace cylinder head if seats are damaged or worn
Special Tool: VALVE GUIDE HONE (B-45525)
excessively.
b. Scrub bore.
VALVE AND SEAT REPAIR 6 7
Special Tool: CLEANING BRUSH (HD-34751)

c. Polish valve stem with fine emery cloth or steel wool to

remove carbon buildup.

3. Check valve stem to guide clearance.

a. Measure the inside diameter of the valve guide.

b. Measure the outside diameter of the valve stem.

c. If stem to guide clearance exceeds service limits,

repeat measurements with a new valve to determine
worn components.

d. If stem to guide clearance exceeds service limits with

a new valve, replace cylinder head.
NOTE
• Verify correct valve stem to valve guide clearance before
Valves and Valve Seats
refacing. Refer to Table 4-33.
1. With valves removed, inspect the sealing surface of the • The correct finished angles are 45 degree valve face and
valve face and valve seat. 46 degree valve seat eliminating the need to lap.
• Finish valve seat to an even width of 0.040-0.062 in (1.016-
1.575 mm).
a. The sealing surfaces must be smooth and even • See Figure 4-33. Replace the valve if margin (5) is less
around entire contact area. than
0. 0313 in (0.795mm).
b. If the sealing contact area is uneven or shows 7 Refurbish valves and seats in pairs. Valve stem
evidence of pitting, carbon tracking, or other protrusion of a pair operated by the same rocker arm
indications of combustion gas leakage, recondition the must be equal. Verify that valve lash is within
valve and seat, or replace cylinder head assembly. specification. See Install (Page 4-32).
See Valve and Seat Repair (Page 4-41)
• If valve stem protrusion exceeds 1.752 in (44.5 mm),
replace the valve or cylinder head as necessary.

94000936 4-43
 3. e. Remove
Install valvethe valve
stem and apply a second coat of
seal.
SCREAMIN' EAGLE ASSEMBLY LUBE to the valve
stem. Install the valve.
a. Slide special tool over valve stem tip.
Special Tool: VALVE GUIDE SEAL INSTALLER (HD-
45322)
b. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to
installer.

c. See Figure 4-34. Slide new valve stem seal assembly

over installer and down valve stem until seated
against cylinder head casting.
d. Remove installer from valve stem tip.

Figure 4-33. Valve and Seat Dimensions

Table 4-33. Valve Stem to Guide Clearance

VALVE IN MM
Intake 0.001-0.003 0.0254-0.0762
Exhaust 0.001-0.003 0.0254-0.0762

PART NUMBER TOOLNAME

B-49312 CYLINDER HEAD HOLDING FIXTURE
HD-34736-B VALVE SPRING COMPRESSOR
HD-34751 CLEANING BRUSH
HD-45322 VALVE GUIDE SEAL INSTALLER

FASTENER TORQUE VALUE

Cylinder temperature sensor 120-180 in-lbs 13.6-20.3 N-m
Knock sensor screw 13-17 ft-lbs 17.6-23 N-m
1. Secure cylinder head for service.

ASSEMBLE
a. Turn 10 mm end of special tool into spark plug hole. 4. See Figure 4-32. Install valve spring.
Special Tool: CYLINDER HEAD HOLDING FIXTURE
(B-49312) a. Apply a liberal amount of SCREAMIN' EAGLE
ASSEMBLY LUBE to valve stem tip and keeper
b. Clamp tool in vise at a comfortable working position. groove.
NOTE
b. Install the valve spring (3) with the smaller diameter
Install all parts in their original location and position.
coils topside.

2. Install valve.
c. Place the spring retainer (2) on top of the valve spring.

a. Clean valve guide with special too. 5. Install new keepers.

Special Tool: CLEANING BRUSH (HD-34751)
b. Apply a liberal amount of SCREAMIN' EAGLE a. Compress valve spring with special tool.
ASSEMBLY LUBE to valve stem. Special Tool: VALVE SPRING COMPRESSOR (HD-
34736-B)
c. Install the valve into the cylinder head.
b. Install the keepers.
d. Spin the valve as it is installed to distribute the
lubricant evenly. c. Slowly release valve spring compression.

4-44 94000936
 d. Tap the end of the valve stem once or twice with a
soft mallet to make sure that tapered keepers are
tightly seated.

6. Install remaining valves.

7. Install ACR. See AUTOMATIC COMPRESSION RELEASE

(ACR) (Page 7-81).

8. See Figure 4-30. Install knock sensor with screw (2).

a. Rotate sensor housing up against head casting.

94000936 4-45
 b. Tighten. 18. Install seat. See SEAT (Page 3-142).
Torque: 13-17 ft-lbs (17.6-23 N-m) Knock sensor
19. Connect negative battery cable. See POWER
screw
DISCONNECT (Page 7-7).
9. Install temperature sensor (3). Tighten.
Torque: 120-180 in-lbs (13.6-20.3 N-m) Cylinder
temperature sensor

COMPLETE _____________________________

1. Install pushrods, lifters and covers. See PUSHRODS,

LIFTERS AND COVERS (Page 4-34).

2. Install rocker arms. See ROCKER ARMS (Page 4-32).

3. Install lower rocker covers. See LOWER ROCKER COVERS

(Page 4-30).

4. Install breathers. See BREATHERS (Page 4-29).

5. Install upper rocker covers. See UPPER ROCKER COVERS

(Page 4-27).

6. Install spark plugs. See CLEAN, INSPECT, REPLACE

SPARK PLUGS (Page 2-46).

7. Connect electrical connectors.

a. Rear cylinder: Engine temperature sensor, knock

sensor and ACR.

b. Front cylinder: Knock sensor and ACR.

8. Install induction module. See INDUCTION MODULE (Page

6-27).
9. Install upper cooling lines. See OIL COOLANT LINES (Page
4-22).

10. Install oil cooler upper screw and cover. See OIL COOLER
(Page 4-19).

11. NOTE
See Remove and Install: Upper Front Engine Mount (Page 4-
24) for proper tightening sequence.

Install left side engine mount. See LEFT SIDE ENGINE

MOUNT (Page 4-26).

12. Install upper front engine mount. See FRONT ENGINE

MOUNT (Page 4-24).

13. Install air cleaner backplate assembly. See AIR CLEANER

BACKPLATE ASSEMBLY (Page 6-4).

14. Install air cleaner. See INSPECT AIR FILTER (Page 2-40).

15. Install coil. See IGNITION COIL (Page 7-14).

16. Install spark plug cables. See SPARK PLUG CABLES (Page
7-13).

17. Install fuel tank. See FUEL TANK (Page 6-14).

4-46 94000936
CYLINDERS 4.20

PREPARE 19. Remove rocker arms. See ROCKER ARMS (Page 4-32).

20. Remove pushrods, lifters and covers. See PUSHRODS,

NOTE LIFTERS AND COVERS (Page 4-34).
Abrasive particles can damage machined surfaces or plug oil
passageways. Clean parts before disassembly to prevent
21. Remove cylinder heads. See CYLINDER HEADS (Page 4-
component damage.
38).

1. Use low-pressure compressed air to clean exterior surfaces

of engine.
REMOVE ___________ _____________

NOTE
2. Disconnect negative battery cable. See POWER
DISCONNECT (Page 7-7). Do not bend the cylinder studs.

1. Remove the cylinder.

3. Remove seat. See SEAT (Page 3-142).
a. Raise the cylinder and place clean shop towels under the
4. Remove fuel tank. See FUEL TANK (Page 6-14). piston.
b. Hold the piston to prevent touching the studs as it exits
5. Remove spark plug cables. See SPARK PLUG CABLES the cylinder.
(Page 7-13).
c. Lift cylinder clear of piston.
6. Remove coil. See IGNITION COIL (Page 7-14).
2. Slide plastic tubing, rubber hose or conduit over each
cylinder stud to protect cylinder studs and piston from
7. Remove left side engine mount. See LEFT SIDE ENGINE
damage.
MOUNT (Page 4-26).
3. See Figure 4-35. Discard gasket (4).

8. Remove air cleaner. See INSPECT AIR FILTER (Page 2-

40).

9. Remove air cleaner backplate assembly. See AIR CLEANER

BACKPLATE ASSEMBLY (Page 6-4).

10. Remove upper front engine mount. See FRONT ENGINE

MOUNT (Page 4-24).

11. Remove oil cooler cover and upper screw. See OIL
COOLER (Page 4-19).

12. Remove upper cooling lines. See OIL COOLANT LINES

(Page 4-22).

13. Remove induction module. See INDUCTION MODULE

(Page 6-27).

14. Disconnect electrical connectors.

INSTALL
a. Rear cylinder: Engine temperature sensor, knock
sensor and ACR.

b. Front cylinder: Knock sensor and ACR. PART NUMBER TOOL NAME
HD-96333-51F PISTON RING COMPRESSOR
15. Remove spark plugs. See CLEAN, INSPECT, REPLACE NOTE
SPARK PLUGS (Page 2-46).
Front and rear cylinders are unique. Install them in the
correct locations.
16. Remove upper rocker covers. See UPPER ROCKER
COVERS (Page 4-27).

17. Remove breathers. See BREATHERS (Page 4-29).

18. Remove lower rocker covers. See LOWER ROCKER

COVERS (Page 4-30).

94000936 4-47
1. Prepare for cylinder installation.
a. Install new base gasket to the crankcase.
b. See Figure 4-48 . Verify piston ring alignment.
c. Apply clean engine oil to piston, piston rings and
cylinder bore.

d. Rotate crankshaft until piston is at top dead center.

2. Remove protective covers from cylinder studs.

3. See Figure 4-36. Install the HD-52185 (PISTON SUPPORT
PLATE) under piston.
4. Rotate crankshaft until piston skirt is centered and
firmly seated on top of support plate.

1. Pliers
2. Compressor band
Figure 4-37. Piston Ring Compressor

Figure 4-38. Install Threaded Cylinders to Studs

5. See Figure 4-37. Install cylinder using PISTON RING
COMPRESSOR (PART NUMBER: HD-96333-51F). CLEAN AND INSPECT
DOWN NUTS) onto cylinder studs.
a. Align tool with the top of the band positioned
between the top compression ring and the piston
crown.
b. Compress piston rings.
c. Align the indent in the cooling fins to the right side
of the engine. Slide cylinder over the cylinder studs
and piston until it rests on the top of the ring
compressor.
d. Push down on the cylinder with a sharp, quick
motion using the palms of both hands.

e. Remove pliers and piston support plate.

f. Remove shop towels from around the crankcase
bore.
g. Push down on the cylinder until it is fully seated in
the crankcase bore.
h. See Figure 4-38. Install HD-52020 (CYLINDER HOLD-

4-48 94000936
1. Clean all gasket material from the cylinder.
2. Clean parts in a non-volatile cleaning solution. Dry parts
with low-pressure, compressed air.
3. Inspect the cylinder bore for defects or damage in the
ring travel area.
a. Light scratches that are not the length of the piston
travel are considered normal. Hone pattern should
travel through the scratches. This cylinder is fit for
operation.
b. Run a fingernail across the scratches. If a scratch
catches a fingernail, the cylinder must be replaced.
c. Scoring or broad bands that are the length of piston
travel, or evidence that material transferred between
the piston and cylinder, replace the cylinder.

4. Deglaze cylinders. See Deglaze Cylinder (Page 4-46).

94000936 4-49
5. Verify that all oil holes are clean and open. 5. Install breathers. See BREATHERS (Page 4-29).
6. Carefully remove any nicks or burrs from the machined
gasket surfaces. 6. Install upper rocker covers. See UPPER ROCKER COVERS
(Page 4-27).
7. Check the gasket surfaces for flatness. Measure with a
straightedge and feeler gauge. 7. Install spark plugs. See CLEAN, INSPECT, REPLACE
a. Check head gasket surface of the cylinder. Record SPARK PLUGS (Page 2-46).
measurements.
8. Connect electrical connectors.
b. Check lower gasket surface of the cylinder. Record
measurements.
a. Rear cylinder: Engine temperature sensor, knock
c. Discard cylinder if either gasket surface flatness is not sensor and ACR.
within wear limits. See SPECIFICATIONS (Page 4-4)
b. Front cylinder: Knock sensor and ACR
DEGLAZE CYLINDER
9. Install induction module. See INDUCTION MODULE (Page
6-27).
1. Lightly swab the cylinder bore with a cloth dipped in clean
engine oil.
10. Install upper cooling lines. See OIL COOLANT LINES (Page
NOTE 4-22).
A precise 60 degree crosshatch pattern in the piston travel
area is important. 11. Install oil cooler upper screw and cover. See OIL COOLER
(Page 4-19).

NOTICE __________ |
12. NOTE
The angular crosshatch pattern ensures an even flow of oil onto See Remove and Install: Upper Front Engine Mount (Page 4-
the cylinder walls and promotes longer cylinder, piston and ring 24) for proper tightening sequence.
life. An incorrect cross hatch pattern will result in insufficient oil
retention and possible piston seizure and/or high oil consumption. Install left side engine mount. See LEFT SIDE ENGINE
(00536c) MOUNT (Page 4-26).

2. Deglaze cylinder with a 240 grit flexible ball-type deglazing 13. Install upper front engine mount. See FRONT ENGINE
tool. Create a 60 degree crosshatch. MOUNT (Page 4-24).

NOTICE 14. Install air cleaner backplate assembly. See AIR CLEANER
BACKPLATE ASSEMBLY (Page 6-4).
Failure to remove all abrasive particles may result in premature
cylinder, piston and ring wear and engine failure. (00537c) 15. Install air cleaner. See INSPECT AIR FILTER (Page 2-40).

3. Thoroughly wash the cylinder bore with liquid dishwashing 16. Install coil. See IGNITION COIL (Page 7-14).
soap and hot water. Continue cleaning until a clean cloth
shows no evidence of dirt or debris. 17. Install spark plug cables. See SPARK PLUG CABLES (Page
7-13).
a. Hot rinse the cylinder and dry with moisture free
compressed air. 18. Install fuel tank. See FUEL TANK (Page 6-14).

19. Install seat. See SEAT (Page 3-142).

b. Immediately apply a thin film of clean engine oil to a
clean white paper towel and thoroughly wipe the inside
20. Connect negative battery cable. See POWER
of the cylinder.
DISCONNECT (Page 7-7).
c. Repeat wiping process until a new towel remains
white.

COMPLETE

1. Install cylinder heads. See CYLINDER HEADS (Page 4-38).

2. Install pushrods, lifters and covers. See PUSHRODS,
LIFTERS AND COVERS (Page 4-34).

3. Install rocker arms. See ROCKER ARMS (Page 4-32).

4. Install lower rocker covers. See LOWER ROCKER COVERS

(Page 4-30).

4-50 94000936
PISTONS 4.21
PREPARE 19. Remove rocker arms. See ROCKER ARMS (Page 4-32).

NOTE 20. Remove pushrods, lifters and covers. See PUSHRODS,

Abrasive particles can damage machined surfaces or plug LIFTERS AND COVERS (Page 4-34).
oil passageways. Clean parts before disassembly to prevent
component damage. 21. Remove cylinder heads. See CYLINDER HEADS (Page 4-
38).
1. Use low-pressure compressed air to clean exterior surfaces
of engine. 22. Remove cylinders. See CYLINDERS (Page 4-44).

2. Disconnect negative battery cable. See POWER REMOVE _______________________________

DISCONNECT (Page 7-7).
NOTE
3. Remove seat. See SEAT (Page 3-142). It is not necessary to remove both piston pin retaining rings
for piston removal.
4. Remove fuel tank. See FUEL TANK (Page 6-14).
1. Place clean shop towels over crankcase bore to prevent the
5. Remove spark plug cables. See SPARK PLUG CABLES
piston pin retaining ring from falling into the crankcase.
(Page 7-13).
2. See Figure 4-39. Using HD-51069-2 (PISTON PIN
6. Remove coil. See IGNITION COIL (Page 7-14). RETAINING RING INSTALLER) with HD-51069-17 (NOSE
ADAPTER), remove and discard one piston pin retaining
7. Remove left side engine mount. See LEFT SIDE ENGINE ring.
MOUNT (Page 4-26).
a. Insert tool (1) into piston pin bore with claw on tool in slot
of piston (2) (directly under retaining ring).
8. Remove air cleaner. See INSPECT AIR FILTER (Page 2-
40). b. Squeeze handles of tool together.
c. Pull retaining ring from bore. Discard retaining ring.
9. Remove air cleaner backplate assembly. See AIR CLEANER
BACKPLATE ASSEMBLY (Page 6-4).

10. Remove upper front engine mount. See FRONT ENGINE

MOUNT (Page 4-24).

11. Remove oil cooler cover and upper screw. See OIL
COOLER (Page 4-19).

12. Remove upper cooling lines. See OIL COOLANT LINES

(Page 4-22).

13. Remove induction module. See INDUCTION MODULE

(Page 6-27).

14. Disconnect electrical connectors.

a. Rear cylinder: Engine temperature sensor, knock

sensor and ACR.

b. Front cylinder: Knock sensor and ACR. Figure 4-39. Piston Pin Retaining Ring Removal
3. See Figure 4-40. Remove piston.
15. Remove spark plugs. See CLEAN, INSPECT, REPLACE
SPARK PLUGS (Page 2-46). a. Remove the piston pin using HD-42320-8 (PISTON PIN
EXTRACTOR) with HD-42320-D (PISTON PIN
16. Remove upper rocker covers. See UPPER ROCKER REMOVER).
COVERS (Page 4-27). b. Hold the connecting rod to prevent it from striking the
crankcase. Remove the piston.
17. Remove breathers. See BREATHERS (Page 4-29).
c. Place a piece of foam-type water pipe insulation around
connecting rod to prevent damage.
18. Remove lower rocker covers. See LOWER ROCKER
COVERS (Page 4-30).

94000936 4-51
4. Identify piston location by marking piston pin boss 2. Install piston.
underneath. a. Verify that one retaining ring is installed in piston pin
bore.
b. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to piston
pin, piston pin bores and upper connecting rod bore.
c. Remove water pipe insulation from connecting rod shank.
d. See Figure 4-43. Place piston over rod end with the arrow
(1) pointing toward the front of the engine.
e. Insert piston pin through pin bore and upper connecting
rod until it contacts retaining ring installed in opposite pin
boss.
f. Place clean shop towels over the cylinder and lifter bores.

3. See Figure 4-41. Install new retaining ring using PISTON

PIN RETAINING RING INSTALLER (PART NUMBER:
INSTALL HD-51069-2) with NOSE ADAPTER (PART NUMBER:
HD-51069-17).
PART NUMBER TOOL NAME a. See Figure 4-42. Verify that retaining ring end gap (3) is
HD-51069-17 NOSE ADAPTER opposite from opening (2).
HD-51069-2 PISTON PIN RETAINING RING b. Inspect the retaining ring to verify that it is fully seated in
INSTALLER the groove.
A WARNING
Failure to properly install and inspect piston pin retaining
rings will result in engine failure and possible rear wheel
lockup, which could result in death or serious injury.
(03406a)

NOTE
Do not reuse piston pin retaining rings.

1. Install one new piston pin retaining ring using PISTON

PIN RETAINING RING INSTALLER (PART NUMBER:
HD-51069-2) with NOSE ADAPTER (PART NUMBER:
HD-51069-17).
a. See Figure 4-41. Slide retaining ring down nose of tool
until it contacts claw.
b. Center retaining ring at top of tool. Lightly squeeze
handles of tool to capture retaining ring in claw.
c. Tilt the retaining ring forward until the end gap contacts
nose of tool.
d. See Figure 4-43. Insert the tool (2) into the piston pin bore
until claw is aligned with slot (3) in piston.
e. Firmly push the tool into the piston pin bore until it
bottoms.
f. Release handles, Remove tool.
g. See Figure 4-42. Verify that retaining ring end gap (3) is
opposite from opening (2).
h. Inspect the retaining ring to verify that it is fully seated in
the groove.

Figure 4-42. Pre-Installed Retaining Ring

4-52 94000936
 Inspect
1. Check piston running clearance.

a. Insert a lightly oiled good piston pin into piston pin

bore to feel for proper fit. The pin should slide in and
out without binding, pivoting or rocking.

b. Measure pin and pin bore diameters to determine

running clearance. Replace piston and/or pin if
clearance exceeds specified dimension.
0. 0008 in (0.02 mm)

2. NOTE
Pistons with superficial wear marks, minor scratching or
mild scoring are acceptable for use.

Carefully inspect pistons for damage or excessive wear.

Discard if any following conditions are found:

a. Using dye penetrant, inspect pistons for surface

DISASSEMBLE cracks. Particularly examine area around pin bores,
ring lands and oil drain holes beneath piston crown.
1. Remove piston rings.
NOTE
CLEAN_AND INSPECT Thoroughly wash usable pistons to remove traces of
dye.
Clean
b. Cracked, worn or bent ring lands.
A WARNING
Compressed air can pierce the skin and flying debris from c. Cracks, gouges, deep scratches or heavy scoring.
compressed air could cause serious eye injury. Wear safety
glasses when working with compressed air. Never use your hand d. Evidence of burning, etching or melting.
to check for air leaks or to determine air flow rates. (00061a)
e. Marks or imprints caused by contact with valves.

1. NOTE 3. Lightly file to remove any dings, nicks or burrs around edge
- Do not sandblast or glass bead blast pistons. Bead blasting of piston crown.
rounds off ring lands.
4. See Figure 4-44. Measure piston ring side clearance.
• Do not damage or enlarge holes.
• Do not use a wire brush to clean oil holes. a. Insert edge of a new ring into piston ring groove.
• Avoid scratching sides of the piston ring grooves.
b. Insert a feeler gauge between upper surface of ring
Remove all combustion deposits. and ring land.

a. Soak pistons in hot water with dishwashing liquid or a c. Repeat this check at several locations around piston.
cleaner designed to remove carbon and does not
corrode aluminum. d. Discard piston if side clearance of either compression
ring exceeds specified dimension.
b. Thoroughly rinse pistons. 0. 004 in (0.102 mm)

c. Clean oil drain holes in oil control ring groove with a e. Discard piston if oil control ring side clearance
small bristle brush. exceeds specified dimension.

0. 010 in (0.25 mm)

d. Dry parts with low-pressure, compressed air.
5. NOTE
2. Verify that all oil holes are clean and open. • Check piston clearance in the cylinder in which that
piston will run. Cylinder must be deglazed. See
3. NOTE Deglaze Cylinder in CYLINDERS (Page 4-44).
A portion of a compression ring properly ground to a sharp
chisel-like edge works well to clean piston ring grooves.

Thoroughly clean the three piston ring grooves of all carbon

deposits.

94000936 4-53
• This inspection is very heat-sensitive.
• Both piston and cylinder must be at room temperature
before proceeding.
• Do not check piston running clearance immediately
after honing or deglazing cylinder.
• Even holding the piston for too long can cause
measurements to vary by as much as Dimension:
0. 0002 in (0.0051 mm).

• See upper frame of Figure 4-45. The coating has an

oval-shaped opening (1) on each side of the piston

Figure 4-45. Measure Piston Running Clearance

CHECK PISTON. RING GAP

clearance exceeds service wear limit. See

SPECIFICATIONS (Page 4-4).

for proper micrometer placement. ASSEMBLE 8

• See lower frame of Figure 4-45. Use a blade or ball
anvil style micrometer to measure piston.

See Figure 4-45. Measure running clearance of pistons:

a. Measure piston skirt at bare aluminum openings

(1).
8 The top ring has chamfered corners on the ring face. The
b. Transfer measurement to dial bore gauge. second ring has a sharp upper corner and a groove cut
around the lower edge.
c. Measure at top and middle of piston ring travel
2. Install second compression ring (4).
zone.
Measure parallel and perpendicular to crankshaft. 3. Install top compression ring (5).
4. Verify that all piston rings rotate freely.
d. Replace piston and/or cylinder if running
5. See Figure 4-48. Arrange gaps as shown.

4-54 94000936
 1. Expander ring
2. Bottom oil rail
3. Top oil rail
4. Second compression ring
5. Top compression ring
Figure 4-47. Piston Rings

1. Expander ring
2. Bottom oil rail
3. Top oil rail
4. Second compression ring
5. Top compression ring
Figure 4-48. Piston Ring Order of Assembly and Gap
Alignment
COMPLETE ________________

1. Install cylinders. See CYLINDERS (Page 4-44).

2. Install cylinder heads. See CYLINDER HEADS (Page 4-38).

3. Install pushrods, lifters and covers. See PUSHRODS,

LIFTERS AND COVERS (Page 4-34).

4. Install rocker arms. See ROCKER ARMS (Page 4-32).

5. Install lower rocker covers. See LOWER ROCKER COVERS

(Page 4-30).

94000936 4-55
6. Install breathers. See BREATHERS (Page 4-29).

7. Install upper rocker covers. See UPPER ROCKER COVERS

(Page 4-27).

8. Install spark plugs. See CLEAN, INSPECT, REPLACE

SPARK PLUGS (Page 2-46).

9. Connect electrical connectors.

a. Rear cylinder: Engine temperature sensor, knock

sensor and ACR.

b. Front cylinder: Knock sensor and ACR.

10. Install induction module. See INDUCTION MODULE (Page

6-27).

11. Install upper cooling lines. See OIL COOLANT LINES (Page
4-22).

12. Install oil cooler upper screw and cover. See OIL COOLER
(Page 4-19).
13. NOTE
See Remove and Install: Upper Front Engine Mount (Page 4-
24) for proper tightening sequence.

Install left side engine mount. See LEFT SIDE ENGINE

MOUNT (Page 4-26).

14. Install upper front engine mount. See FRONT ENGINE

MOUNT (Page 4-24).

15. Install air cleaner backplate assembly. See AIR CLEANER

BACKPLATE ASSEMBLY (Page 6-4).

16. Install air cleaner. See INSPECT AIR FILTER (Page 2-40).

17. Install coil. See IGNITION COIL (Page 7-14).

18. Install spark plug cables. See SPARK PLUG CABLES (Page
7-13).

19. Install fuel tank. See FUEL TANK (Page 6-14).

20. Install seat. See SEAT (Page 3-142).

21. Connect negative battery cable. See POWER

DISCONNECT (Page 7-7).

4-56 94000936
 4.22
CAM COMPARTMENT AND COMPONENTS
PREPARE

FASTENER TORQUE VALUE

Camshaft cover screws 90-120 in-lbs 10.2-13.6 N-m
Camshaft timer cover screws 25-35 in-lbs 2.8-4 N-m

REMOVE AND INSTALL: CAMSHAFT COVER

NOTE COVERS (Page 4-27).
Abrasive particles can damage machined surfaces or plug oil
passageways. Clean parts before disassembly to prevent 15. Loosen rocker arm screws to relieve tension on pushrods.
component damage. See PUSHRODS, LIFTERS AND COVERS (Page 4-34).

1. Use low-pressure compressed air to clean exterior surfaces

of engine.

2. Disconnect negative battery cable. See POWER

DISCONNECT (Page 7-7).

3. NOTE
Detach rider foot control bracket only if needed to remove
exhaust system.

Detach right side rider foot control bracket. See RIGHT

FOOT CONTROLS (Page 3-133).

4. Remove exhaust system. See EXHAUST SYSTEM (Page 6-

36).

5. Remove seat. See SEAT (Page 3-142).

6. Remove fuel tank. See FUEL TANK (Page 6-14).

7. Remove air cleaner. See INSPECT AIR FILTER (Page 2-

40).

8. Remove air cleaner backplate assembly. See AIR CLEANER

BACKPLATE ASSEMBLY (Page 6-4).

9. Remove spark plug cables. SPARK PLUG CABLES (Page 7-

13).

10. Remove upper front engine mount. See FRONT ENGINE

MOUNT (Page 4-24).

11. Remove oil cooler cover upper screw. See OIL COOLER
(Page 4-19).

12. Remove upper cooling lines. See OIL COOLANT LINES

(Page 4-22).

13. Disconnect electrical connectors.

a. Rear cylinder: Engine temperature sensor, knock

sensor and ACR.

b. Front cylinder: Knock sensor and ACR

14. Remove upper rocker covers. See UPPER ROCKER

94000936 4-57
Remove
1. See Figure 4-49. Remove camshaft cover.

a. Remove screws (3).

b. Remove camshaft cover (4).

c. Discard gasket (5).

Install
1. See Figure 4-49. Install camshaft cover.

a. Install new gasket (5).

b. Install camshaft cover (4).

c. Install screws (3). Hand tighten.

d. See Figure 4-50. Tighten screws in the sequence
shown.

Torque: 90-120 in-lbs (10.2-13.6 N-m) Camshaft

cover screws

2. See Figure 4-49. Install timer cover, if removed.

a. Install timer cover (2).

b. Install screws (1). Tighten.

Torque: 25-35 in-lbs (2.8-4 N-m) Camshaft timer
cover screws

4-58 94000936
Figure 4-50. Cam Cover Tightening Sequence
REMOVE
PART NUMBER TOOLNAME
93979-10 MAGNETIC LIFTER HOLDERS
HD-47941 CRANKSHAFT/CAMSHAFT SPROCKET
LOCKING TOOL

1. See Figure 4-51. Remove chain and sprockets.

a. Mark one of the chain links with a colored marker.
b. Remove cam chain tensioner fasteners (2). Remove cam
chain tensioner (1).
a. See Figure 4-52. Support lifters using MAGNETIC
c. Install CRANKSHAFT/CAMSHAFT SPROCKET
LIFTER HOLDERS (PART NUMBER: 93979-10).
LOCKING TOOL (PART NUMBER: HD-47941) between
cam sprocket (9) and crank sprocket (8). b. See Figure 4-53. Remove four screws (5).

d. Remove cam sprocket screw (4) and washer (3). c. Remove screws (1).

e. Remove crank sprocket screw (5) and washer (6). d. Remove cam support plate (2).

f. Remove sprocket locking tool. e. Remove camshaft (3).

g. Remove both sprockets and chain. f. Remove O-ring (4).

h. Remove spacer (10).

Figure 4-52. SCREAMIN' EAGLE Magnetic Lifter Holder

94000936 4-59
 sm08545
FASTENER TORQUE VALUE
Camshaft sprocket screw, 15.0 ft-lbs 20.3 N-m
alignment check torque
Camshaft sprocket screw, final 34 ft-lbs 46.1 N-m
torque
Crankshaft sprocket screw, 1st 15.0 ft-lbs 20.3 N-m
torque
Crankshaft sprocket screw, 15.0 ft-lbs 20.3 N-m
alignment check torque
Crankshaft sprocket screw, final 24 ft-lbs 32.5 N-m
torque
Oil pump screws, 1st torque 12-60 in-lbs 1.4-6.8 N-m
Oil pump screws, final torque 90-120 in-lbs 10.2-13.6 N-m
1. Support plate screw (6)
2. Cam support plate CONSUMABLE PART NUMBER
3. Camshaft SCREAMIN' 11300002
4. O-ring EAGLE
5. Oil pump screws (4) ASSEMBLY LUBE
Figure 4-53. Cam Support Plate LOCTITE 262 HIGH 94759-99
INSPECT CAM_COMPONENT ______________ STRENGTH
THREADLOCKER
AND SEALANT
NOTE
(RED)
See SPECIFICATIONS (Page 4-4) for specifications.
1. Apply assembly lube to all bearing surfaces and bearings.

Consumable: SCREAMIN' EAGLE ASSEMBLY LUBE

Camshaft
(11300002)
1. Inspect lobes for abnormal wear or discoloration.
2. See Figure 4-53. Install cam and cam support plate.
2. Inspect bearing surfaces for scoring or discoloration.
3. Measure bearing journals. a. Install camshaft in crankcase.

4. If desired, remove and inspect lifters. b. Install new O-ring (4) into crankcase feed oil port.

a. Mark lifters so they can be installed in the same location c. Apply assembly lube to cam support plate feed oil
and orientation as original. port.
b. Remove lifters through camshaft cavity. SCREAMIN' EAGLE ASSEMBLY LUBE (11300002)
c. Measure lifters.
d. Slide cam support plate over shafts and mate to
crankcase.
Cam Support Plate
e. Verify cam support plate is fully seated.
1. Measure the diameters of the camshaft and crankshaft
bores. f. Start all screws.
2. Measure flatness of support plate.
3. See Figure 4-54. Tighten screws in sequence.
3. Inspect gerotor area for excessive wear or deep grooves.
4. Verify that all oil passages are clean and open. a. Tighten screws (1,2).
Torque: 12-60 in-lbs (1.4-6.8 N-m) Oil pump screws,
Cam Drive Components 1st torque
1. Inspect sprockets and chain for wear.
b. Rotate crankshaft one full revolution (360 degrees).
INSTALL
c. Tighten screws (3-8) in sequence shown.

PART NUMBER TOOL NAME Torque: 90-120 in-lbs (10.2-13.6 N-m) Cam support
plate screws
HD-47941 CRANKSHAFT/CAMSHAFT SPROCKET
LOCKING TOOL d. Final tighten four oil pump screws (1-2,9-10) in same
sequence.
FASTENER TORQUE VALUE
Cam chain tensioner fasteners 90-120 in-lbs 10.2-13.6 N-m Torque: 90-120 in-lbs (10.2-13.6 N-m) Oil pump
screws, final torque
Cam support plate screws 90-120 in-lbs 10.2-13.6 N-m
Camshaft sprocket screw, 1st 15.0 ft-lbs 20.3 N-m
torque

4-60 94000936
 Table 4-34. Cam Sprocket Spacers
PART NO. IN MM
25729-06 0.100 2.54
25731-06 0.110 2.79
25734-06 0.120 3.05
25736-06 0.130 3.30
25737-06 0.140 3.56
25738-06 0.150 3.81
5. Install camshaft drive.

a. Apply assembly lube to camshaft and crankshaft.

SCREAMIN' EAGLE ASSEMBLY LUBE (11300002)

b. Install cam sprocket spacer (10).

c. See Figure 4-55. Assemble sprockets and chain with
Figure 4-54. Cam Support Plate Tightening Sequence timing marks aligned. Verify marked chain link is on
the same side as the timing marks.
4. NOTE
Check sprocket alignment if any following parts are new: d. Rotate camshaft until keyed spline is up.
• Cam sprocket
e. Rotate crankshaft until flat is up.
• Cam support plate
f. Install sprockets and chain.
• Camshaft
• Crankshaft sprocket g. Verify that timing marks on sprockets are aligned.
h. If reusing screws, clean old threadlockerfrom screws
• Flywheel assembly
and mating components.

Check sprocket alignment.

i. Apply threadlocker (red) to both screws.

a. See Figure 4-51. Install original cam sprocket spacer LOCTITE 262 HIGH STRENGTH THREADLOCKER
(10) . ‘
AND SEALANT (RED) (94759-99)
b. Install cam sprocket without chain using screw (4) and j. Apply a film of oil to bottom of both sprocket screw
washer (3). heads and washers.
k. Loosely install screws and washers.
c. Install crankshaft sprocket without chain using screw
(5) and a smaller diameter flat washer from bulk
inventory.

d. Install sprocket locking tool between sprockets.

Special Tool: CRANKSHAFT/CAMSHAFT
SPROCKET LOCKING TOOL (HD-47941)

e. Tighten camshaft sprocket screw.

Torque: 15.0 ft-lbs (20.3 N-m) Camshaft sprocket
screw, alignment check torque

f. Tighten crankshaft sprocket screw.

Torque: 15.0 ft-lbs (20.3 N-m) Crankshaft sprocket
screw, alignment check torque

g. Remove sprocket locking tool.

h. Push on crankshaft and camshaft to eliminate end

play. a. Position sprocket locking tool between sprockets.
i. Place a straightedge across sprocket faces. Alignment Special Tool: CRANKSHAFT/CAMSHAFT
offset maximum. SPROCKET LOCKING TOOL (HD-47941)

Length/Dimension/Distance: 0.009 in (0.23 mm)

j. Remove cam sprocket.

k. Install appropriate spacer (10) using Table 4-34 as a

guide.

l. Check alignment with new spacer installed.

m. Remove both sprockets.

94000936 4-61
 b. Tighten camshaft sprocket screw. 13. Attach right side foot control bracket, if removed. See
Torque: 15.0 ft-lbs (20.3 N-m) Camshaft sprocket RIGHT FOOT CONTROLS (Page 3-133).
screw, 1st torque
14. Connect negative battery cable. See POWER
c. Tighten crankshaft sprocket screw. DISCONNECT (Page 7-7).
Torque: 15.0 ft-lbs (20.3 N-m) Crankshaft sprocket
screw, 1st torque CAMSHAFT NEEDLE BEARINGS __________
d. Loosen both screws one revolution (360 degrees).
PART NUMBER TOOL NAME
e. Final tighten camshaft sprocket screw. HD-42325-C CAMSHAFT NEEDLE BEARING
REMOVER/INSTALLER
Torque: 34 ft-lbs (46.1 N-m) Camshaft sprocket
screw, final torque
FASTENER TORQUE VALUE
f. Final tighten crankshaft sprocket screw. Cam needle bearing installation 25 ft-lbs 33.9 N-m
Torque: 24 ft-lbs (32.5 N-m) Crankshaft sprocket maximum torque
screw, final torque Remove
g. Remove sprocket locking tool. 1. See Figure 4-56. Remove camshaft bearing using
components of CAMSHAFT NEEDLE BEARI
7. Install primary cam chain tensioner. Tighten. VER/INSTALLER (PART NUMBER: HD-42325-C).
Torque: 90-120 in-lbs (10.2-13.6 N-m) Cam chain 2. Hold the flat on the HD-42325-12A (COLLET). Turn hex at
tensioner fasteners end to expand collet.
8. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to chain and
sprockets. 3. Turn hex nut to remove bearing.

COMPLETE _____________________________

1. Install rocker arms. See ROCKER ARMS (Page 4-32).

2. Install upper rocker covers. See UPPER ROCKER COVERS

(Page 4-27).

3. Connect electrical connectors.

a. Rear cylinder: Engine temperature sensor, knock

sensor and ACR.

b. Front cylinder: Knock sensor and ACR.

4. Install upper cooling lines. See OIL COOLANT LINES (Page

4-22).

5. Install oil cooler cover and upper screw. See OIL COOLER Figure 4-56. Remove Camshaft Needle Bearing
(Page 4-19). Install
6. Install upper front engine mount. See FRONT ENGINE 1. Calculate bearing installed depth.
MOUNT (Page 4-24).
a. Measure thickness of HD-42325-4 (SUPPORT PI^R).

7. Install spark plug cables. SPARK PLUG CABLES (Page 7-

b. Add support plate thickness to 3.737 in (94.92 mm).
13).
Record this value.

8. Install fuel tank. See FUEL TANK (Page 6-14).

2. See Figure 4-56. Install bearing using HD-42325-7A
(CAMSAFT NEEDLE BEARING INSTALLER).
9. Install air cleaner backplate assembly. See AIR CLEANER
BACKPLATE ASSEMBLY (Page 6-4). a. Place new needle bearing on installer with letters
facing installer (visible from cam chest when installed).
10. Install air cleaner. See INSPECT AIR FILTER (Page 2-40).
b. Install support plate.
11. Install seat. See SEAT (Page 3-142).

12. Install exhaust system. See EXHAUST SYSTEM (Page 6-

36).

4-62 94000936
3. See Figure 4-57. Turn forcing screw to press needle bearing
to depth calculated earlier± 0.020 in (0.54 mm).

a. Do not exceed torque specification during needle

bearing installation or damage to crankcase will
occur..
Torque: 25 ft-lbs (33.9 N-m) Cam needle bearing
installation maximum torque

Figure 4-57. Measure from Top of Support Plate to Edge of

Needle Bearing

94000936 4-63
OIL PUMP 4.23

PREPARE REMOVE
NOTE 1. See Figure 4-58. Remove oil pump assembly from camshaft
Abrasive particles can damage machined surfaces or plug compartment.
oil passageways. Clean parts before disassembly to prevent
component damage. 2. Discard oil seal (6).
3. Discard O-ring (5).
1. Use low-pressure compressed air to clean exterior surfaces
of engine.

2. Disconnect negative battery cable. See POWER

DISCONNECT (Page 7-7).

3. NOTE
Detach rider foot control bracket only if needed to remove
exhaust system.

Detach right side rider foot control bracket. See RIGHT

FOOT CONTROLS (Page 3-133).

4. Remove exhaust system. See EXHAUST SYSTEM (Page 6-

36).

5. Remove seat. See SEAT (Page 3-142).

1. Feed gerotor set
2. Oil pump housing
6. Remove fuel tank. See FUEL TANK (Page 6-14).
3. Scavenge gerotor set
4. Back housing
7. Remove air cleaner. See INSPECT AIR FILTER (Page 2-
5. Scavenge port O-ring
40).
6. Oil seal
Figure 4-58. Oil Pump
8. Remove air cleaner backplate assembly. See AIR
CLEANER BACKPLATE ASSEMBLY (Page 6-4). DISASSEMBLE AND INSPECT

9. Remove spark plug cables. SPARK PLUG CABLES (Page

1. See Figure 4-58 . Remove gerotors (1, 3).
7-13).
2. See Figure 4-59. Remove pressure relief valve.
10. Remove upper front engine mount. See FRONT ENGINE
MOUNT (Page 4-24).
a. Hold spring (1) compressed.
b. Drive out roll pin (3).
11. Remove oil cooler cover and upper screw. See OIL
COOLER (Page 4-19).
c. Carefully release spring pressure.

12. Remove upper cooling lines. See OIL COOLANT LINES d. Remove spring and piston (2).
(Page 4-22). 3. Clean parts in a non-volatile cleaning solution.

13. Disconnect electrical connectors. 4. Dry parts using low-pressure compressed air.

a. Rear cylinder: Engine temperature sensor, knock

5. Inspect housing.
sensor and ACR.

a. Verify oil holes are clean and open.

b. Front cylinder: Knock sensor and ACR.
b. Inspect relief valve piston and seat for damage.
14. Remove upper rocker covers. See UPPER ROCKER
c. Inspect oil pump housing bores for scoring, gouging or
COVERS (Page 4-27).
cracking.

15. Loosen rocker arm screws to relieve tension on pushrods.

See PUSHRODS, LIFTERS AND COVERS (Page 4-34).

16. Remove camshaft cover and cam support plate. See CAM
COMPARTMENT AND COMPONENTS (Page 4-53).

4-64 94000936
 d. See Figure 4-58 . Inspect for grooves or scratches on
cam support plate and back housing (4).

6. See Figure 4-60. Check gerotor wear.

a. Check lobes of gerotors for damage.

b. Mesh gerotor sets together.

c. Measure distance between tips of lobes on inner and

outer feed gerotor set.

d. Measure distance between tips of lobes on inner and

outer scavenge gerotor set.

e. Refer to Table 4-35. Compare measurements to

maximum specification.

f. Measure and compare thickness of each rotor in feed

gerotor set.

g. Measure and compare thickness of each rotor in

scavenge gerotor set. Figure 4-60. Measure Gerotor Sets for Wear

h. Refer to Table 4-35. Compare measurements to Table 4-35. Oil Pump Feed and Scavenge Gerotor Toler-
maximum specification. ances
MAXIMUM LOBE CLEAR- MAXIMUMTHICKNESS DIF-
ANCE FERENCE
0.004 in (0.1 mm) 0.001 in (0.025 mm)

CONSUMABLE PART NUMBER

SCREAMIN' 11300002
EAGLE
ASSEMBLY LUBE
1. Install pressure relief valve.

ASSEMBLE

a. See Figure 4-59 . Apply assembly lube to piston (2)

and bore. CONSUMABLE PART NUMBER
SCREAMIN' EAGLE ASSEMBLY LUBE (11300002) SCREAM IN' 11300002
EAGLE
b. Install piston and spring (1 ). ASSEMBLY LUBE

c. Hold spring compressed and install roll pin (3). 1. Lubricate all parts with assembly lube during assembly.

INSTALL _______________________________ Consumable: SCREAMIN' EAGLE ASSEMBLY LUBE

(11300002)

2. See Figure 4-58 . Install new oil seal (6) on back housing
(4) .

3. Install back housing (4) and scavenge gerotor set (3) onto
crankshaft.

4. Install new O-ring (5) in crankcase scavenge port.

94000936 4-65
5. Apply assembly lube to scavenge port spigot.
Consumable: SCREAMIN' EAGLE ASSEMBLY LUBE
(11300002)

6. Slide oil pump housing (4) onto crankshaft while fitting

scavenge port into O-ring.

a. Firmly push on oil pump housing to fully seat.

7. Install feed gerotor set (1).

COMPLETE _____________________________
1. Install cam support plate and camshaft cover. See CAM
COMPARTMENT AND COMPONENTS (Page 4-53).

2. Install rocker arms. See ROCKER ARMS (Page 4-32).

3. Install upper rocker covers. See UPPER ROCKER COVERS

(Page 4-27).

4. Connect electrical connectors.

a. Rear cylinder: Engine temperature sender, knock

sensor and ACR.

b. Front cylinder: Knock sensor and ACR.

5. Install upper cooling lines. See OIL COOLANT LINES (Page
4-22).

6. Install oil cooler upper screw and cover. See OIL COOLER
(Page 4-19).

7. Install upper front engine mount. See FRONT ENGINE

MOUNT (Page 4-24).

8. Install spark plug cables. SPARK PLUG CABLES (Page 7-

13).

9. Install fuel tank. See FUEL TANK (Page 6-14).

10. Install air cleaner backplate assembly. See AIR CLEANER

BACKPLATE ASSEMBLY (Page 6-4).

11. Install air cleaner. See INSPECT AIR FILTER (Page 2-40).

12. Install seat. See SEAT (Page 3-142).

13. Install exhaust system. See EXHAUST SYSTEM (Page 6-

36).

14. Attach right side foot control bracket, if removed. See

RIGHT FOOT CONTROLS (Page 3-133).

15. Connect negative battery cable. See POWER

DISCONNECT (Page 7-7).

4-66 94000936
REPLACE ENGINE 4.24

PREPARE 21. Remove rear splash guard. See REAR FORK (Page 3-81).

22. Disconnect line from oil check valve. See OIL COOLER
Prepare
(Page 4-19).
1. Secure motorcycle on lift. See GENERAL (Page 2-2).
23. Release main harness and brake line from lower frame rail.
2. Disconnect negative battery cable. See POWER
DISCONNECT (Page 7-7). a. Allow to hang below frame.

3. Remove saddlebags, if equipped. See SADDLEBAGS (Page 24. Remove right foot support bracket. See RIGHT FOOT
3-145). CONTROLS (Page 3-133).

4. Remove seat. See SEAT (Page 3-142). 25. Remove brake pedal master cylinder assembly. See REAR
BRAKE MASTER CYLINDER (Page 3-42).
5. Remove fuel tank. See FUEL TANK (Page 6-14).
a. Place on work surface. Wrap rear master cylinder with
6. Remove battery. See INSPECT BATTERY (Page 2-43). protective padding.

7. Remove battery tray. See BATTERY TRAY (Page 7-97) 26. Disconnect VSS. See VEHICLE SPEED SENSOR (VSS)
8. Remove exhaust system. See EXHAUST SYSTEM (Page 6- (Page 7-83).
36).
27. Disconnect ACRs. See AUTOMATIC COMPRESSION
9. Remove air cleaner. See INSPECT AIR FILTER (Page 2- RELEASE (ACR) (Page 7-81).
40).
28. Disconnect ground cable from transmission case. Do this
10. Remove air cleaner backplate assembly. See AIR only if removing as one assembly or transmission case
CLEANER BACKPLATE ASSEMBLY (Page 6-4). separately.

11. Disconnect front oil hose from oil cooler. See OIL 29. Disconnect knock sensors. See KNOCK SENSOR (KS)
COOLANT LINES (Page 4-22). (Page 7-80).

12. Drain engine oil and discard filter. See REPLACE ENGINE 30. Disconnect cylinder temperature sensor. See ENGINE
OIL AND FILTER (Page 2-7). TEMPERATURE (ET) SENSOR (Page 7-79).

13. Remove voltage regulator. See VOLTAGE REGULATOR 31. Remove USB caddy. See USB CADDY (Page 7-90).
(Page 7-12).
32. Disconnect spark plug cables. See SPARK PLUG CABLES
(Page 7-13).
a. Release stator harness anchor.

14. Disconnect CKP sensor. See CRANKSHAFT POSITION 33. Remove ignition coil. See IGNITION COIL (Page 7-14).
SENSOR (CKP) (Page 7-78).
34. Remove left side engine mount (coil bracket). See LEFT
SIDE ENGINE MOUNT (Page 4-26).
15. Disconnect jiffy stand sensor, if equipped. See JIFFY
STAND SENSOR (JSS) (Page 7-86).
REMOVE ______________________________
16. Disconnect oil pressure sender. See OIL PRESSURE
SWITCH (Page 7-28). Remove
1. Wrap rocker covers and frame rails with protective padding
17. Disconnect clutch cable. See CLUTCH CONTROL (Page 3- or tape.
91).
2. Support powertrain.
18. Remove starter. See STARTER (Page 7-9).
a. Support engine using FAT JACK (PART NUMBER:
19. Remove primary chaincase. See PRIMARY CHAINCASE HD-45968) or similar.
HOUSING (Page 5-27).
b. Place support under crankcase.
20. Remove drive belt from transmission pulley. See DRIVE
BELT (Page 5-7).

94000936 4-67
 c. Support transmission using FAT JACK (PART 5. Connect cylinder temperature sensor. See ENGINE
NUMBER: HD-45968) or similar. TEMPERATURE (ET) SENSOR (Page 7-79).

d. Place support under frame.

6. Connect knock sensors. See KNOCK SENSOR (KS) (Page
7-80).
3. Remove pivot shaft. See REAR FORK (Page 3-81)
7. Connect ground cable to transmission case.
4. Remove front engine mount. See FRONT ENGINE MOUNT
(Page 4-24)
8. Connect ACRs. See AUTOMATIC COMPRESSION
RELEASE (ACR) (Page 7-81).
5. Remove lower front engine mount bolt. See FRONT
ENGINE MOUNT (Page 4-24) 9. Connect VSS. See VEHICLE SPEED SENSOR (VSS) (Page
7-83).
6. Remove powertrain from chassis.
10. Install brake pedal master cylinder assembly. See REAR
a. Slide transmission case as far back as possible. BRAKE MASTER CYLINDER (Page 3-42).

b. Remove engine from right side. 11. Install right foot support bracket. See RIGHT FOOT
CONTROLS (Page 3-133).
7. Remove induction module assembly. See INDUCTION
MODULE (Page 6-27) a. Secure main harness and brake line to lower frame rail.

INSTALL __ __ , 12. Connect line to oil check valve. See OIL COOLER (Page 4-
19)
Install
13. Install rear splash guard. See REAR FORK (Page 3-81)
1. Make sure motorcycle is secure on lift.
14. Install drive belt. See DRIVE BELT (Page 5-7).
2. Install induction module assembly. See INDUCTION
MODULE (Page 6-27) 15. Install primary chaincase. See PRIMARY CHAINCASE
HOUSING (Page 5-27).
3. Install powertrain into chassis.
16. Install starter. See STARTER (Page 7-9).
a. Install engine from right side.
17. Install and adjust clutch cable. See CLUTCH CONTROL
b. Position in chassis. (Page 3-91).

4. Install lower front engine mount. See FRONT ENGINE 18. Connect oil pressure sender. See OIL PRESSURE SWITCH
MOUNT (Page 4-24) (Page 7-28).

5. Install front stabilizer link and bracket. See FRONT ENGINE 19. Connect jiffy stand sensor, if equipped. See JIFFY STAND
MOUNT (Page 4-24) SENSOR (JSS) (Page 7-86).

6. Install pivot shaft. See REAR FORK (Page 3-81) 20. Connect CKP sensor. See CRANKSHAFT POSITION
SENSOR (CKP) (Page 7-78).
7. Remove powertrain supports.
21. Install voltage regulator. See VOLTAGE REGULATOR
8. Remove protective padding/tape from rear master cylinder, (Page 7-12).
rocker covers and frame rails.
22. Fill engine oil and install new filter. See REPLACE ENGINE
OIL AND FILTER (Page 2-7).
COMPLETE
23. Connect upper cooling lines. See OIL COOLANT LINES
Complete (Page 4-22).
1. Install left side engine mount (coil bracket). See LEFT SIDE
ENGINE MOUNT (Page 4-26). 24. Install air cleaner backplate assembly. AIR CLEANER
BACKPLATE ASSEMBLY (Page 6-4).

2. Install ignition coil. See IGNITION COIL (Page 7-14).

25. Install air cleaner. See INSPECT AIR FILTER (Page 2-40).
3. Connect spark plug cables. See SPARK PLUG CABLES
26. Install exhaust system. See EXHAUST SYSTEM (Page 6-
(Page 7-13).
36).
27. Install battery tray. See BATTERY TRAY (Page 7-97).
4. Install USB caddy. See USB CADDY (Page 7-90).

4-68 94000936
28. Install battery. See INSPECT BATTERY (Page 2-43).

29. Install fuel tank. See FUEL TANK (Page 6-14).

30. Install seat. See SEAT (Page 3-142).

31. Install saddlebags, if equipped. See SADDLEBAGS (Page
3-145).
32. Connect negative battery cable. See POWER
DISCONNECT (Page 7-7).

33. Run motorcycle until engine is at normal operating

temperature.

a. Check clutch operation. Adjust if needed.

b. Check instrument lamps.

c. Check for leaks.

d. Check engine oil level (hot).

94000936 4-69
 CRANKCASE 4.25

PREPARE the crankshaft gear, allowing the balancer scissor gear

to unload. Rotating the scissor gear back into position
is difficult.
1. Remove engine. See REPLACE ENGINE (Page 4-62).

Separate crankcase halves.

2. NOTE
Abrasive particles can damage machined surfaces or
plug oil passageways. Clean parts before disassembly a. See Figure 4-61. Remove 14 crankcase screws in the
to prevent component damage. sequence shown.

b. Separate case halves.

Use low-pressure compressed air to clean exterior surfaces
of engine.
c. See Figure 4-62. Lift left crankcase half (2) off end of
crankshaft.
3. Remove spark plugs. See CLEAN, INSPECT, REPLACE
SPARK PLUGS (Page 2-46).
4. Remove two dowel pins in split line face of right case half.

4. Remove upper rocker covers. See UPPER ROCKER NOTE

COVERS (Page 4-27). HD-52065 (Balancer Gear Alignment Tool) must be installed
before removing balancer.
5. Remove breathers. See BREATHERS (Page 4-29).
5. Remove balancers (4).
6. Remove lower rocker covers. See LOWER ROCKER
a. Rotate gear teeth slightly with a screwdriver to allow
COVERS (Page 4-30).
tool installation.

7. Remove rocker arms. See ROCKER ARMS (Page 4-32).

b. Install HD-52065 (Balancer Gear Alignment Tool).

8. Remove pushrods, lifters and covers. See PUSHRODS, c. Lift balancer from crankcase.
LIFTERS AND COVERS (Page 4-34). 6. Remove flywheel assembly (3).

9. Remove cylinder heads. See CYLINDER HEADS (Page 4-

38).

10. Remove cylinders. See CYLINDERS (Page 4-44).

11. Remove pistons. See PISTONS (Page 4-47).

12. Remove cam cover and cam compartment components.

See CAM COMPARTMENT AND COMPONENTS (Page 4-
53).

13. Remove oil pump. See OIL PUMP (Page 4-59).

DISASSEMBLE ____

1. Remove oil pump from crankshaft.

A CAUTION

Do not rotate crankcase half in engine stand when flywheel

is installed. The flywheel assembly can fall out, resulting in
parts damage or moderate injury. (00552c)

2. Position crankcase with cam compartment facing down.

NOTE
Never move or lift the crankcase by grasping the
cylinder studs.

3. NOTE
Use care to not allow the balancer gears to raise when
lifting off left crankcase. The balancer gears can
disengage

4-70 94000936
 9. Spray all machined surfaces with clean engine oil.

10.Inspect crankshaft/flywheel assembly. See FLYWHEEL AND

CONNECTING RODS (Page 4-75).

ASSEMBLE
PART NUMBER TOOL NAME
HD-42326-B CRANKSHAFT GUIDE
HD-52064 LEFT MAIN BEARING OIL SEAL
INSTALLATION TOOL
HD-97225-55C SPROCKET SHAFT BEARING
INSTALLER
FASTENER TORQUE VALUE
Crankcase screws, first torque 120 in-lbs 13.6 N-m
Crankcase screws, last torque 15-19 ft-lbs 20.3-25.8 N-m
CONSUMABLE PART NUMBER
SCREAMIN' 11300002
EAGLE
ASSEMBLY LUBE
HARLEY- 99650-02
DAVIDSON
HIGH
PERFORMANCE
SEALANT -GRAY
1. Position right crankcase with cam compartment facing down.

2. Install flywheel assembly.

a. Work a liberal amount of SCREAMIN' EAGLE

ASSEMBLY LUBE into both main bearings and balancer
bearings.

Figure 4-62. Separate Crankcase Halves b. Slide crankshaft guide onto flywheel sprocket shaft.
CLEAN AND INSPECT Special Tool: CRANKSHAFT GUIDE (HD-42326-B)

c. Slide flywheel assembly into right crankcase half.

1. Remove all gasket material from the crankcase flanges.
d. Remove crankshaft guide tool.
2. Clean all parts in a non-volatile cleaning solution or solvent.
3. NOTE
A WARNING • See Figure 4-63. When aligning timing marks match dash
to dash and circle to circle.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear safety • Timing marks may not align exactly. Align to the closest
glasses when working with compressed air. Never use your hand tooth.
to check for air leaks or to determine air flow rates. (00061a)
3. Dry parts with moisture-free compressed air. See Figure 4-63, Install balancers.

4. Verify that all oil holes are clean and open. a. Rotate flywheel so crankpin is at BDC.

5. Check ring dowels for looseness, wear or damage. b. Install balancer while aligning timing marks (2).
Replace if necessary.
c. Repeat with remaining balancer.
4. Remove alignment tool.
6. Use a file to carefully remove any nicks or burrs from
machined surfaces.

7. Clean out tapped holes and clean up damaged threads. a, Rotate gear teeth slightly with a screwdriver to unload
pressure on tool.
8. Check the top of the crankcase for flatness with a
straightedge and feeler gauge. Replace if warped. b. Remove tool.

94000936 4-71
5. NOTE Special Tool: LEFT MAIN BEARING OIL SEAL
The balancer shafts may splay away from the INSTALLATION TOOL (HD-52064)
crankshaft. Wiggle crankcase during installation to a. Verify that lip garter spring is in place on both sides of oil
help fully seat balancer shaft in bearing. seal.
10. Rotate crankcase so that cam compartment is facing up.
Mate crankcase halves.
11. Apply a liberal amount of lube to main bearing. Rotate
a. Verify that both dowel pins are installed in split line flywheel assembly to distribute lube.
face of right case half.
Consumable: SCREAMIN' EAGLE ASSEMBLY LUBE
(11300002)
b. See Figure 4-64. Apply a bead of sealant to
specification to the split line face of right crankcase
half.
Length/Dimension/Distance: 0.06 in (1.52 mm)
HARLEY-DAVIDSON HIGH PERFORMANCE
SEALANT - GRAY (99650-02)

c. Place crankshaft guide over end of crankshaft until it

contacts shoulder on shaft.
Special Tool: CRANKSHAFT GUIDE (HD-42326-B)
d. Mate case halves. Keep crankcase splitline parallel
as left crankcase is lowered into place.

e. Wiggle crankcase during installation to help fully seat

balancer shafts in bearing.

f. Remove crankshaft guide.

6. See Figure 4-61. Install 14 crankcase screws.

a. Finger-tighten each screw.

b. Tighten screws in sequence shown
Torque: 120 in-lbs (13.6 N-m) Crankcase screws,
first torque
c. Loosen, then following the same sequence, final
tighten.
Torque: 15-19 ft-lbs (20.3-25.8 N-m) Crankcase
screws, last torque

7. Rotate crankcase assembly so sprocket shaft is pointing

straight up.

8. Install thrust washer on sprocket shaft with "THIS SIDE

OUT" facing out (and the chamfer inboard). If using original
part without markings, position to preserve existing wear
pattern.

9. See Figure 4-65. Install new sprocket shaft oil seal using
components from the following tools.
Special Tool: SPROCKET SHAFT BEARING INSTALLER
(HD-97225-55C)

b. Install sprocket shaft spacer.

c. Install oil seal with rounded feature of metal casing

facing in and sharp edge facing out.

4-72 94000936
 355319

1. Main bearing arbor

2. Bearing support
Figure 4-66. Remove Right Main Bearing

Install Main Bearing

1. See Figure 4-67. Install bearing.

Special Tool: MAIN BEARING REMOVER AND

INSTALLER (HD-52071)

a. Place crankcase with flywheel side facing up on

Figure 4-65. Sprocket Shaft Oil Seal Installer main bearing support (3).

REPAIR RIGHT CRANKCASE HALF b. Spread clean engine oil on OD of new bearing (5).

PART NUMBER TOOL NAME c. Place bearing on bearing bore with lettering facing
HD-52071 MAIN BEARING REMOVER AND up.
INSTALLER
d. Place main bearing installer (2) with side marked
RIGHT against bearing.
FASTENER TORQUE VALUE
Balancer bearing screw 80-110 in-lbs 9-12.4 N-m e. Place main bearing arbor (1) through main bearing
Piston jet screws 25-35 in-lbs 2.8-3.9 N-m installer and bearing into bearing support.

CONSUMABLE PART NUMBER f. Press until main bearing installer contacts

machined surface.
LOCTITE 222 LOW 99811-97
STRENGTH
2. Check installed depth. Refer to Table 4-36.
THREADLOCKER
(PURPLE)

Remove Main Bearing

1. NOTE
Never move or lift crankcase by grasping cylinder studs.

See Figure 4-66. Remove bearing.

Special Tool: MAIN BEARING REMOVER AND
INSTALLER (HD-52071)

a. Press bearing from cam side into flywheel side of

crankcase.

2. Discard bearing.

94000936 4-73
 Install Balancer Bearing
1. Apply engine oil to OD of new bearing.

2. NOTE Install
bearings with lettering facing up.
1. Main bearing arbor
2. Main bearing installer Properly support area of crankcase where bearing is being
3. Bearing support installed.
4. Press ram
5. Main bearing Do not use screw to draw bearing in.
Figure 4-67. Right Main Bearing Installation
Using a press, install new bearing until fully seated in bore.

Table 4-36. Right Crankcase Bearing Installed Depth 3. Install retaining screw. Tighten.
BEARING LOCATION DEPTH from SPLIT LINE
Torque: 80-110 in-lbs (9-12.4 N-m) Balancer bearing
Right side main 2.160-2.180 in (54.86-55.37 mm)
screw
Right side balancer 2.070-2.090 in (52.58-53.09 mm)
Remove Balancer Bearing Remove Piston Jets
1. See Figure 4-68. Remove retaining screw (2). 1. See Figure 4-69. Remove screws (3) to free piston jet (2)
from crankcase.
2. NOTE
Non-open flame heat may be applied to vicinity of
2. Discard gasket (1).
bearing to assist in removal.

Use appropriate puller to remove bearing (1) from bore.

3. Discard bearing.

4-74 94000936
 3. Remove bearing.
Special Tool: MAIN BEARING REMOVER AND INSTALLER
(HD-52071)

a. See Figure 4-70. Remove bearing retaining ring.

b. See Figure 4-71. Press bearing from stator side into

flywheel side of crankcase.
4. Discard bearing.

1. NOTE
If piston jet screws are being reused, apply threadlocker
to screws. LOCTITE 222 LOW STRENGTH
THREADLOCKER (PURPLE) (99811-97)

See Figure 4-69. Install piston jets. 1. Main bearing arbor

2. Bearing support
a. Install new gasket (1 ).
Figure 4-71.
b. With jet pointed up, secure piston jet (2) and gasket
with screws (3). Remove Left

c. Tighten. 25-35 in-lbs (2.8-3.9 N-m). Main Bearing

REPAIR LEFT CRANKCASE HALF _ ______ Install

Main
PART NUMBER TOOLNAME
HD-52071 MAIN BEARING REMOVER AND Bearing
INSTALLER 1. N
OTE
Alternator
FASTENER TORQUE VALUE
stator may
Balancer bearing screw 80-110 in-lbs 9-12.4 N-m be left
Remove Main Bearing installed
when main bearing press adapter is used.
A CAUTION
See Figure 4-72. Install bearing.
Do not rotate crankcase half in engine stand when flywheel is
installed. The flywheel assembly can fall out, resulting in parts Special Tool: MAIN BEARING REMOVER AND INSTALLER
damage or moderate injury. (00552c) (HD-52071)

a. Place main bearing press adapter (3) on bearing

1. NOTE support (4).
• Never move or lift crankcase by grasping cylinder studs.
b. Place crankcase on main bearing press adapter (3)
• Always replace sprocket shaft bearing inner race with flywheel side facing up.
whenever left main bearing is replaced. See Sprocket
Shaft Bearing Inner Race (Page 4-71).

Remove thrust washer from outboard side of crankcase half

by pulling it past oil seal. Set thrust washer aside for
inspection or reuse.

2. Remove oil seal.

94000936 4-75
 c. Spread clean engine oil on OD of new bearing. Install Balancer Bearing
d. Place bearing on bearing bore with lettering facing up. 1. Apply engine oil to OD of new bearing.

e. Place main bearing installer (2) with side marked LEFT 2. NOTE Install bearings with lettering
against bearing.
facing up.
f. Place main bearing arbor (1) through main bearing Properly support area of crankcase where bearing is being
installer (2) and bearing into main bearing press installed.
adapter (3) and bearing support (4).
Using a press, install new bearing until fully seated in bore.
g. Press until main bearing installer contacts machined
surface.
3. Install retaining screw. Tighten.
2. Install new retaining ring. Make sure retaining ring is fully Torque: 80-110 in-lbs (9-12.4 N-m) Balancer bearing
seated in groove. screw

SPROCKET SHAFT BEARING INNER RACE

Remove Balancer Bearing Remove

1. See Figure 4-73. Remove retaining screw (2).
PART NUMBER TOOLNAME
2. NOTE HD-25070 ROBINAIR HEAT GUN
Non-open flame heat may be applied to vicinity of HD-34902-B BIG-TWIN MAINSHAFT PRIMARY
bearing to assist in removal. BEARING RACE REMOVER AND
INSTALLER
Use appropriate puller to remove bearing (1) from bore. HD-44358 FLYWHEEL SUPPORT FIXTURE
HD-95637-46B WEDGE ATTACHMENT
3. Discard bearing.
HD-97225-55C SPROCKET SHAFT BEARING
INSTALLER

NOTE
For proper clamping force, hold-down clamp must not be
tilted. Rotate hex on outboard stud until clamp is level.

4-76 94000936
1. See Figure 4-74. Secure flywheel assembly in FLYWHEEL A WARNING
SUPPORT FIXTURE (PART NUMBER: HD-44358).
Do not use heating devices with penetrating oil. Penetrating
a. Secure fixture in soft-jawed vise with the round hole oil is flammable which could result in death or serious injury.
topside. (00375a)
b. Insert crankshaft end through hole, resting flywheel
assembly on fixture. 4. See Figure 4-75. Remove bearing race.
c. Engage knurled locating pin in crank pin hole.
a. Turn forcing screw until thrust washer and bearing
d. Hand-tighten locating pin.
inner race move approximately 0.125 in (3.2 mm).
e. Secure flywheel with hold-down clamps (2).
b. Reposition WEDGE ATTACHMENT (PART NUMBER:
HD-95637-46B) to pull on bearing inner race only.

c. Verify that the tool assembly is square.

d. Heat the bearing inner race for about 30 seconds.

e. Turn forcing screw until bearing inner race is free of

sprocket shaft.

f. Remove thrust washer from sprocket shaft.

NOTICE

Install wedge attachment only so far as necessary to ensure

positive contact with bearing inner race. Installing tool with
more contact than necessary will result in damage to the
flywheel (00500b)

2. See Figure 4-75. Install pulling tool.

a. Position WEDGE ATTACHMENT (PART NUMBER:

HD-95637-46B) (5) on inboard side of thrust washer.

b. Draw wedge halves together evenly.

c. Secure the bridge and forcing screw from BIG-TWIN

MAINSHAFT PRIMARY BEARING RACE REMOVER
AND INSTALLER (PART NUMBER: HD-34902-B) to
the wedge attachment with flat washers and two 3/8-
16 x 7-1/2 in bolts.

d. Place hardened washer between end of sprocket shaft

and the end of the forcing screw.

3. Uniformly heat the bearing inner race for about 30 seconds

using the ROBINAIR HEAT GUN (PART NUMBER: HD- Figure 4-75. Remove Inner Race from Sprocket Shaft
25070). Install
NOTE 1. Place new thrust washer over sprocket shaft.
To assist removal without heat, apply a light penetrating
oil to shaft and leading edge of bearing inner race. 2. Uniformly heat new bearing for about 60 seconds using the
ROBINAIR HEAT GUN (PART NUMBER: HD-25070).

3. Drop heated bearing inner race over sprocket shaft.

94000936 4-77
 NOTE Remove
To assist installation without heat, apply a light
penetrating oil to shaft and leading edge ofbearing inner See Figure 4-77. Turn pipe plug or oil check valve
race. counterclockwise to remove.

Install
A WARNING
1. See Figure 4-77. Install tapered plug (1).
Do not use heating devices with penetrating oil. Penetrating oil is
flammable which could result in death or serious Injury. (00375a)
a. Apply LOCTITE 565 THREAD SEALANT to threads.
Torque: 120-144 in-lbs (13.6-16.3 N-m) Crankcase
4. See Figure 4-76. Seat the bearing race using SPROCKET tapered plugs
SHAFT BEARING INSTALLER (PART NUMBER: HD-
97225-55C). Follow instructions supplied with tool. 2. Install oil check valve (2) or plug with O-ring (3).
5. Verify that thrust washer cannot be rotated by hand.
a. Install new O-ring.

b. Tighten.
Torque: 18-22 ft-lbs (24.4-29.8 N-m) Crankcase oil
check valve or plug with O-ring

Figure 4-76. Press Inner Race onto Sprocket Shaft: Operation

CYLINDER STUDS
Remove
1. Tighten two nuts together on threads of stud.

FASTENER TORQUE VALUE COMPLETE

Cylinder stud 120-240in-lbs 13.6-27.1 N-m
1. Install oil pump. See OIL PUMP (Page 4-59).
2. Place wrench on lower nut. Turn to remove stud.

Install 2. Install cam compartment components and cam cover. See

CAM COMPARTMENT AND COMPONENTS (Page 4-53).
1. Place a steel ball inside a cylinder head screw.
3. Install pistons. See PISTONS (Page 4-47).
2. Put the head screw on the long end of the cylinder stud.
4. Install cylinders. See CYLINDERS (Page 4-44).
3. Install stud using air gun until collar reaches crankcase.
5. Install cylinder heads. See CYLINDER HEADS (Page 4-38).

4. Tighten to 120-240 in-lbs (13.6-27.1 N-m).

6. Install pushrods, lifters and covers. See PUSHRODS,
LIFTERS AND COVERS (Page 4-34).
PLUGS AND OIL FITTINGS _______________
7. Install rocker arms. See ROCKER ARMS (Page 4-32).

8. Install lower rocker covers. See LOWER ROCKER COVERS

(Page 4-30).
FASTENER TORQUE VALUE
Crankcase oil check valve or 18-22 ft-lbs
24.4-29.8 N-m 9. Install breathers. See BREATHERS (Page 4-29).
plug with O-ring
Crankcase tapered plugs 120-144 in-lbs 13.6-16.3 N-m

4-78 94000936
 11.10. Install
Install upper
spark rocker
plugs. Seecovers.
CLEAN, See UPPER REPLACE
INSPECT, ROCKER
SPARKCOVERS
PLUGS (Page
(Page2-46).
4-27).

12. Insta

4-79 94000936
 FLYWHEEL AND CONNECTING RODS 4.26

SYMPTOMS 9. Remove cylinder heads. See CYLINDER HEADS (Page 4-

38).

Overview 10. Remove cylinders. See CYLINDERS (Page 4-44).

Flywheels that shift out of true at the crank pin generally exhibit
one of two symptoms: no oil pressure or vibration. This condition 11. Remove pistons. See PISTONS (Page 4-47).
is also known as scissored flywheels.
12. Remove cam cover and cam compartment components,
No Oil Pressure See CAM COMPARTMENT AND COMPONENTS (Page 4-
53).
When the crankshaft shifts more than 0.015 in (0.381 mm), it can
break the oil pump gerotors. This causes a loss of oil pressure.
13. Remove oil pump. See OIL PUMP (Page 4-59).
If a low or no oil pressure condition is confirmed, inspect the oil
pump and cam support plate. If the oil pump gerotors are bound 14. Separate crankcase and remove flywheel and connecting
or damaged, the cause is likely from a contaminant running rods. See CRANKCASE (Page 4-65).
through the pump or a shifted crankshaft. If this type of damage is
found, always replace the oil lines and clean all debris from the NOTE
entire lubrication system. See TROUBLESHOOTING (Page 2-50) For measure crankshaft runout procedure, see
for general diagnostics of low oil pressure. TROUBLESHOOTING (Page 4-14).

Vibration INSPECT _

Generally, left crankshaft runout must exceed 0.020 in (0.508 NOTE

mm) to be noticeable to the rider. It is much more likely that • Do not attempt to straighten connecting rods. Damage to
vibration issues are resolved by following the checklist in upper bushing and lower bearing will occur.
TROUBLESHOOTING (Page 2-50). • Zones of resistance when connecting rods are rotated
If correct chassis set-up has been verified and other items in through their range of motion alone is not an indication
TROUBLESHOOTING (Page 2-50) have been eliminated, of a performance or durability concern. Connecting rod
checking left crankshaft runout is appropriate. bearing failures generally exhibit noise, visible clearance,
piston to valve contact, and/or secondary damage in the
PREPARE ______________________________ form of a high level of steel debris circulating throughout
the engine. Verify that one or more of these symptoms is
1. Remove engine. See REPLACE ENGINE (Page 4-62). present before attempting to qualify the rod bearing
condition.
2. NOTE • Connecting rods when placed in limit conditions, defined
as positions outside the normal rod operating position
Abrasive particles can damage machined surfaces or (pinched together or spread to the extent of separation),
plug oil passageways. Clean parts before disassembly may exhibit areas of resistance.
to prevent component damage. • The induction heat treat operation on Milwaukee-Eight®
connecting rods will "blue" the lower end of the rod.
Use low-pressure compressed air to clean exterior surfaces "Blueing" on the lower rod end only is normal.
of engine.
1. Inspect flywheel/connecting rod assembly if any of the
3. Remove spark plugs. See CLEAN, INSPECT, REPLACE following are evident.
SPARK PLUGS (Page 2-46). NOTE
Replace assembly if any of the following conditions are
4. Remove upper rocker covers. See UPPER ROCKER noted.
COVERS (Page 4-27).
a. Rod knock noise
5. Remove breathers. See BREATHERS (Page 4-29).
b. Steel debris in oil filter
6. Remove lower rocker covers. See LOWER ROCKER
COVERS (Page 4-30). c. Piston skirt scoring/scuffing with material transfer

d. Worn oil pump scavenge rotor and housing

7. Remove rocker arms. See ROCKER ARMS (Page 4-32).
e. Piston to valve contact
8. Remove pushrods, lifters and covers. See PUSHRODS,
f. Damage to flywheel left or right main bearing inner
LIFTERS AND COVERS (Page 4-34).
races

4-80 94000936
 g. Bent or twisted connecting rods 2. Install oil pump. See OIL PUMP (Page 4-59).

h. Sprocket teeth are worn in an irregular pattern or 3. Install cam compartment components and cam cover. See
chipped CAM COMPARTMENT AND COMPONENTS (Page 4-53).

i. Main bearing inner races are burnt, scored, blued or 4. Install pistons. See PISTONS (Page 4-47).
damaged
5. Install cylinders. See CYLINDERS (Page 4-44).
j. Flywheel, connecting rods or right side bearing inner
race require replacement 6. Install cylinder heads. See CYLINDER HEADS (Page 4-38).

2. Measure crankshaft runout if crankshaft is suspected of

7. Install pushrods, lifters and covers. See PUSHRODS,
being out-of-true. See TROUBLESHOOTING (Page 4-14).
LIFTERS AND COVERS (Page 4-34).
3. Measure connecting rod side play.
8. Install rocker arms. See ROCKER ARMS (Page 4-32).
a. See Figure 4-78. Position connecting rod (3) as
shown. 9. Install lower rocker covers. See LOWER ROCKER COVERS
(Page 4-30).
b. Measure connecting rod side play using a feeler
gauge (1) at location (4) shown. 10. Install breathers. See BREATHERS (Page 4-29).

c. Side play should be at or greater than. 0.005 in (0.13 11. Install upper rocker covers. See UPPER ROCKER COVERS
(Page 4-27).
mm)

12. Install spark plugs. See CLEAN, INSPECT, REPLACE

SPARK PLUGS (Page 2-46).

13. Install engine. See REPLACE ENGINE (Page 4-62).

COMPLETE _____________________ ___

1. Install flywheel and connecting rods and assemble

crankcase. See CRANKCASE (Page 4-65).

94000936 4-81
OIL PAN 4.27

PREPARE ______________________________
1. Clean and examine all flange surfaces.
1. Position motorcycle on a lift.
2. Clean engine oil and transmission lubricant drain plugs. a.
2. Drain engine oil. See REPLACE ENGINE OIL AND FILTER
(Page 2-7).
Replace O-rings as required.
3. Drain transmission lubricant. See REPLACE
TRANSMISSION LUBRICANT (Page 2-11). 3. Install transmission drain plug and O-ring. Tighten.
REMOVE _______________________________ Torque: 14-21 ft-lbs (19-28.5 N-m) Transmission drain
plug
1. Remove the engine oil fill plug/dipstick.
4. Install engine oil drain plug and O-ring. Tighten.
2. See Figure 4-79. Remove oil pan.
a. Remove 10 screws (3). Torque: 14-21 ft-lbs (19-28.5 N-m) Engine oil drain plug

b. Remove oil pan (2). 5. Install oil pan.

c. Discard oil pan gasket (1).

a. Apply a thin coat of HYLOMAR GASKET AND
THREAD SEALANT to oil pan flange.
NOTE
Debris that remains in the pan can cause a repeat failure. b. Apply threadlocker to used oil pan screws.
Install a new oil pan if necessary.
3. Thoroughly inspect and clean the oil pan. LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-
97)

c. Place new gasket (1) on oil pan flange. Allow sealer to

dry until tacky.

d. Position oil pan with gasket on bottom of transmission.

e. Loosely install fasteners (3).

f. Verify that the gasket is properly positioned. Tighten

following sequence shown.
Torque: 132-156 in-lbs (14.9-17.6 N-m) Oil pan
fasteners

INSTALL

FASTENER TORQUE VALUE

Engine oil drain plug 14-21 ft-lbs 19-28.5 N-m
Oil pan fasteners 132-156 in-lbs 14.9-17.6 N-m
Transmission drain plug 14-21 ft-lbs 19-28.5 N-m
CONSUMABLE PART NUMBER COMPLETE
LOCTITE 243 99642-97
MEDIUM 1. Add fluids.
STRENGTH
THREADLOCKER
a. Add transmission lubricant. See REPLACE
AND SEALANT
TRANSMISSION LUBRICANT (Page 2-11).
(BLUE)
b. Install new engine oil filter.

4-82 94000936
 c. Fill engine oil. See REPLACE ENGINE Olt AND
FILTER (Page 2-7).

94000936 4-83
SUBJECT PAGE NO.
5.1 FASTENER TORQUE VALUES ................................................................................................. 5-1
5.2 SPECIFICATIONS ..................................................................................................................... 5-3
5.3 TRANSMISSION OPERATION .................................................................................................. 5-5
5.4 DRIVE BELT .............................................................................................................................. 5-7
5.5 SHIFTER LINKAGE ................................................................................................................... 5-9
5.6 CLUTCH RELEASE COVER .................................................................................................... 5-12
5.7 CLUTCH RELEASE PUSH ROD COMPONENTS ................................................................... 5-15
5.8 PRIMARY CHAINCASE COVER ............................................................................................. 5-17
5.9 DRIVE COMPONENTS............................................................................................................ 5-18
5.10 CLUTCH ................................................................................................................................ 5-22
5.11 PRIMARY CHAINCASE HOUSING ....................................................................................... 5-27
5.12 ENGINE OIL FILL SPOUT ..................................................................................................... 5-31
5.13 TRANSMISSION SPROCKET ............................................................................................... 5-32
5.14 TRANSMISSION .................................................................................................................... 5-35
5.15 MAIN DRIVE GEAR AND BEARING...................................................................................... 5-45
5.16 TRANSMISSION CASE ......................................................................................................... 5-50

DRIVE AND TRANSMISSION

NOTES
 FASTENER TORQUE VALUES 5.1

FASTENER TORQUE VALUES IN THIS

CHAPTER _______
FASTENER TORQUE VALUE NOTES
Battery ground cable to transmission 66-114 in-lbs 7.5--12.9 N-m 5.16 TRANSMISSION CASE, Install
Clutch cable fitting 90-120 in-lbs 10.2-13.6 N-m 5.6 CLUTCH RELEASE COVER, Install
Clutch hub mainshaft nut 70-80 ft-lbs 94.9-108.5 N-m 5.9 DRIVE COMPONENTS, Install
Clutch release cover screws 132-156 in-lbs 14.9-17.6 N-m 5.6 CLUTCH RELEASE COVER, Install
Compensating sprocket bolt, 1st torque 100 ft-lbs 135.6 N-m
5.9 DRIVE COMPONENTS, Install
Loosen then final tighten
Compensating sprocket bolt, final torque 175 ft-lbs 237.3 N-m 5.9 DRIVE COMPONENTS, Install
Drive belt slot spacer screw, 1st torque 50-55 ft-lbs 68-75 N-m 5.4 DRIVE BELT, Install
Drive belt slot spacer screw, final torque 65-70 ft-lbs 88-95 N-m 5.4 DRIVE BELT, Install
Engine oil fill spout screw. 100-120 in-lbs 11.3-13.6 N-m 5.12 ENGINE OIL FILL SPOUT, Install
Forward Foot Control shifter rod to front 120-168 in-lbs 13.6-19 N-m 5.5 SHIFTER LINKAGE, Shifter Rod
shifter rod lever
Forward Foot Control shifter rod to rear 120-168 in-lbs 13.6-19 N-m 5.5 SHIFTER LINKAGE, Shifter Rod
shifter rod lever
Forward Foot Control shifter rod to shifter 120-168 in-lbs 13.6-19 N-m 5.5 SHIFTER LINKAGE, Shifter Rod Lever, Front
rod lever
Forward Foot Control shift lever pinch 9-12 ft-lbs 12.2-16.3 N-m 5.5 SHIFTER LINKAGE, Shifter Rod Lever, Front
screw
Forward foot control with footboards shift 108-144 in-lbs 12.2-16.3 N-m 5.5 SHIFTER LINKAGE, Foot Shift Lever
lever pinch screw
Forward foot control with footpegs shift 18-22 ft-lbs 24.4-29.8 N-m 5.5 SHIFTER LINKAGE, Foot Shift Lever
lever pinch screw
Forward or Mid Foot Control shifter peg 96-144 in-lbs 10.9-16.3 N-m 5.5 SHIFTER LINKAGE, Foot Shift Lever
screw
Forward or Mid Foot Control shifter rod 84-132 in-lbs 9.5-14.9 N-m 5.5 SHIFTER LINKAGE, Shifter Rod
jamnut
Forward or Mid Foot Control shifter rod to 120-168 in-lbs 13.6-19 N-m 5.5 SHIFTER LINKAGE, Shifter Rod
shifter rod lever
Mid Foot Control shifter rod lever pinch 18-22 ft-lbs 24.4-29.8 N-m 5.5 SHIFTER LINKAGE, Shifter Rod Lever, Front
screw
Mid Foot Control shifter rod to shifter rod 120-168 in-lbs 13.6-19 N-m 5.5 SHIFTER LINKAGE, Shifter Rod
lever
Mid Foot Control shifter rod to shifter rod 120-168 in-lbs 13.6-19 N-m 5.5 SHIFTER LINKAGE, Shifter Rod Lever, Front
lever
Mid foot control shift lever pinch screw 24-28 ft-lbs 32.5-38 N-m 5.5 SHIFTER LINKAGE, Foot Shift Lever
Oil return tube screw 100-120 in-lbs 11.3-13.6 N-m 5.16 TRANSMISSION CASE, Assemble
Primary chaincase sealing screws 26-28 ft-lbs 35.3-38 N-m 5.11 PRIMARY CHAINCASE HOUSING, Install
Primary chain tensioner fasteners 21-24 ft-lbs 28.5-32.6 N-m 5.9 DRIVE COMPONENTS, Install
Primary cover screws 144-156 in-lbs 16.3-17.6 N-m 5.8 PRIMARY CHAINCASE COVER, Install
See sequence in the procedure

Rear fork pivot shaft nut, 1st torque 25-30 ft-lbs 34-41 N-m 5.4 DRIVE BELT, Install
Rear fork pivot shaft nut, 2nd torque 1-48 in-lbs 0.1-5.4 N-m 5.4 DRIVE BELT, Install
Rear fork pivot shaft nut, 3rd torque 154-170 ft-lbs 209-230 N-m 5.4 DRIVE BELT, Install
Rear fork pivot shaft nut, final torque 154-170 ft-lbs 209-230 N-m 5.4 DRIVE BELT, Install
Rear fork pivot shaft pinch bolt 18-20 ft-lbs 24-27 N-m 5.4 DRIVE BELT, Install
Shift drum detent screw 120-150 in-lbs 13.6-17 N-m 5.14 TRANSMISSION, Assemble

94000936 5-1
FASTENER TORQUE VALUE NOTES
Shift drum detent screw 120-150 in-lbs 13.6-17 N-m 5.14 TRANSMISSION, Assemble
Shift drum lock plate screws 57-63 in-lbs 6.4-7.1 N-m 5.14 TRANSMISSION, Assemble
Shift drum lock plate screws 57-63 in-lbs 6.4-7.1 N-m 5.14 TRANSMISSION, Assemble
Shifter pawl centering screw 18-23 ft-lbs 24.4-31.2 N-m 5.16 TRANSMISSION CASE, Assemble
Shifter rod lever pinch screw, transmission 18-22 ft-lbs 24.4-29.8 N-m 5.16 TRANSMISSION CASE, Assemble
lever
Transmission bearing housing screws 22-25 ft-lbs 29.8-33.9 N-m 5.14 TRANSMISSION, Install
Transmission mainshaft/countershaft 85-95 ft-lbs 115.3—128.8 N- 5.14 TRANSMISSION, Assemble
locknuts m
Transmission mounting bolts, 1st torque 15 ft-lbs 20.3 N-m 5.16 TRANSMISSION CASE, Install
Transmission mounting bolts, final torque 34-39 ft-lbs 46.1-52.9 N-m 5.16 TRANSMISSION CASE, Install
Transmission sprocket lockplate screws 90-120 in-lbs 10.2-13.6 N-m 5.13 TRANSMISSION SPROCKET, Install
Lock patch, use 3-5 times

Transmission sprocket nut, 1st torque 100 ft-lbs 135.6 N-m

5.13 TRANSMISSION SPROCKET, Install
Apply LOCTITE 271 HIGH STRENGTH THREAD-
LOCKER (red) to last few threads. Loosen one full
turn after first torque.
Transmission sprocket nut, 2nd torque 35 ft-lbs 47.5 N-m 5.13 TRANSMISSION SPROCKET, Install
Transmission sprocket nut, final torque 35-40° 35-40°
5.13 TRANSMISSION SPROCKET, Install
Do not loosen to align lockplate screws.
Transmission top cover 132-156 in-lbs 14.9-17.6 N-m 5.14 TRANSMISSION, Install

5-2 94000936
SPECIFICATIONS 5.2

DRIVE SPECIFICATIONS NOTE

Final gear ratios indicate the number of mainshaft
revolutions required to drive the output sprocket one
FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE
revolution.
LUBRICANT and SCREAMIN' EAGLE SYN3 FULL SYNTHETIC
MOTORCYCLE LUBRICANT 20W50 are both acceptable SERVICE WEAR LIMITS __________________
lubricants.
5-7. Main
Table 5-6. Mainshaft
DriveTolerance Specifications
Gear Specifications
Table 5-1. Primary Chaincase Lubricant MAINSHAFT
MAIN TOLERANCE
DRIVE GEAR (sixth) IN MM
Table
AMOUNT*5-2. Sprocket DRY
Teeth
FILL** WET FILL*** Mainshaft runout 0.000-0.003 0.00-0.08
Bearing fit in transmission case 0.0003-0.0017 0.0076-0.043
DRIVE Oz ITEM
L Oz NUMBER LOF Mainshaft end play none none
(loose)
Primary 40 1.27 36 TEETH 1.06 Fifth
Fit in gear end(press-fit)
bearing play (axial) 0.001-0.003
0.002-0.026 0.05-0.66
0.025-0.076
Primary Engine
* Amount is approximate. Fill to bottom of pressure 34plate OD Fifth play:
End gear Two
clearance (radial)
row bearing 0.0004-0.0020
none 0.009-0.052
none
with vehicle upright. Clutch 46 Mainplay:
End driveSingle
gear (sixth) fit
row bearing 0.0009-0.0022
0.000-0.012 0.023-0.056
0.000-0.305
Final Transmission 32
** Cover was removed and installed.
Rearthrough
*** Lubricant was drained wheel the drain plug only.66
Table 5-8. Countershaft Tolerance Specifications
COUNTERSHAFT IN MM
Table 5-3. Overall Drive Ratios TOLERANCE
GEAR RATIO Countershaft runout 0.000-0.003 0.00-0.08
First 9.311 Countershaft end play 0.001-0.003 0.025-0.08
Second 6.454 First gear end play (axial) 0.001-0.023 0.03-0.58
Third 4.793 First gear clearance (radi- 0.0004-0.0020 0.010-0.052
Fourth 3.882 al)
Fifth 3.307 Second gear end play 0.001-0.40 0.03-1.02
Sixth 2.790 (axial)
Second gear clearance 0.0004-0.0020 0.010-0.052
NOTE (radial)
Overall gear ratios indicate number of engine revolutions Third gear end play (axial) 0.001-0.042 0.03-1.07
required to drive rear wheel one revolution. Third gear clearance (radi- 0.0004-0.0020 0.010-0.052
al)
TRANSMISSION SPECIFICATIONS__________ Fourth gear end play (axi- 0.001-0.028 0.03-0.71
al)
Fourth gear clearance 0.0004-0.0020 0.010-0.052
Table 5-4. Transmission Specifications
TRANSMISSION DATA (radial)
Type 6-speed forward constant mesh
Table 5-9. Shifter Dog Clearance Specifications
FORMULA+ TRANSMISSION Part No. 99851-05 (qt) SHIFTER DOG IN MM
AND PRIMARY CHAINCASE First 0.013-0.121 0.33-3.07
LUBRICANT Second 0.016-0.138 0.41-3.51
SYN3 20W50 Oil Part No. 99824-03/00QT (qt) Third 0.010-0.125 0.25-3.17
Capacity * ( approximate) 28 fl oz (0.83 L) Fourth 0.018-0.129 0.46-3.28
* Add additional fluid as necessary to bring level within spe- Fifth 0.007-0.117 0.18-2.97
cification. Sixth 0.022-0.131 0.56-3.33

Table 5-5. Transmission Gear Ratios

Tab
GEAR GEARSpecifications
le 5-10. Bearing Housing Bearing RATIO
First (low) BEARING HOUSING BEAR- 3.34IN MM
Second ING 2.31
Third Fit in bearing housing (tight) 1.72
0.0001-0.0014 0.0025-0.0356
Fourth Fit on countershaft (tight) 1.39
-0.0004 -0.010
Fifth Fit on countershaft (loose) 1.19
+0.0012 +0.030
Sixth (high) Fit on mainshaft (tight) 1.00
-0.0004 -0.010
Fit on mainshaft (loose) +0.0012 +0.030

94000936 5-3
5-4 94000936
 Table 5-11. Shifter Fork Specifications
SHIFTER FORKS IN MM
SHIFTER FORKS IN MM
Shifter fork to cam groove end 0.004-0.012 0.102-0.305
0.198 5.03
Third and fourth gear shift fork
play
pad thickness wear limit
Shifter fork to dog ring end play 0.004-0.016 0.102-0.4060
Fifth and sixth gear shift fork 0.258 6.55
pad thickness wear limit
First and second gear shift fork 0.258 6.55
pad thickness wear limit

Table 5-11. Shifter Fork Specifications

94000936 5-5
TRANSMISSION OPERATION 5.3

POWER FLOW sixth to turn. Countershaft sixth transmits the power to the main
drive gear and the sprocket as shown (1).
See Figure 5-1. The 6-speed transmission consists of two
parallel shafts supporting six gears each. The longer, or Second Gear
mainshaft (7), also supports the clutch and serves as the input
Second gear is engaged when the dog ring between countershaft
shaft. The shorter shaft is called the countershaft (8).
first and second is shifted out of countershaft first and engages
Each gear on the mainshaft is in constant mesh with a countershaft second. This locks countershaft second to the
corresponding gear on the countershaft. Each of these six pairs countershaft to complete the power flow as shown (2).
of gears makes up a different speed in the transmission.
Third Gear
The transmission gears are divided into two types, gears that
rotate with the shaft, and gears that spin freely on the shaft. A Two shifter forks are used to make the shift from second to third.
gear that rotates with the shaft always meshes with a One fork moves the dog ring between countershaft first and
freewheeling gear. Also, three dog rings are able to slide second to its neutral position. At the same time another fork
sideways on the shaft. These dog rings are used to change engages the dog ring between countershaft third and fourth with
transmission speeds. The dogs on the sides of dog rings engage countershaft third. This locks countershaft third to the
dogs on adjacent freewheeling gears, transmitting power through countershaft to complete the power flow as shown (3).
the transmission.
Fourth Gear
Gear shifting is accomplished by three forks which fit into
grooves machined into the dog rings that slide on the guide hubs. Fourth gear is engaged when the dog ring between countershaft
The position of the shifter forks is controlled by a drum-shaped third and fourth is shifted out of countershaft third and engages
shifter cam located in the transmission bearing housing. countershaft fourth. This locks countershaft fourth to the
countershaft to complete the power flow as shown (4).
Neutral
Fifth Gear
Power is introduced to the transmission through the clutch. In
neutral, with the clutch engaged, the mainshaft first, second, third Two shifter forks are used to make the shift from fourth to fifth.
and fourth gears are rotating. No power is transferred to the One fork moves the dog ring between countershaft third and
countershaft since countershaft first, second, third and fourth fourth to its neutral position. At the same time another fork
gears are freewheeling gears. engages the dog ring between mainshaft fifth and sixth with
mainshaft fifth. This locks mainshaft fifth to the mainshaft to
complete the power flow as shown (5).
First Gear
When the transmission is shifted into first gear, the dog ring Sixth Gear
between countershaft first and second, which rotates with the
The shift from fifth to sixth gear occurs when the dog ring
countershaft, engages countershaft first, which has been
between mainshaft fifth and sixth is shifted out of mainshaft fifth.
spinning freely on the countershaft driven by mainshaft first.
It is shifted directly into the main drive gear (sixth gear). The
Now countershaft first is no longer freewheeling, but locked to main drive gear is locked to the mainshaft. this results in a direct
the countershaft causing the countershaft and countershaft one-to-one drive ratio from the clutch to the sprocket as shown
(6).

5-6 94000936
 sm00068a

1. First gear 5. Fifth gear

2. Second gear 6. Sixth gear
3. Third gear 7. Mainshaft
4. Fourth gear 8. Countershaft
Figure 5-1. Transmission Power Flow

5-7 94000936
DRIVE BELT 5.4

PREPARE FASTENER TORQUE VALUE

Drive belt slot spacer screw, 65-70 ft-lbs 88-95 N-m
A WARNING final torque
Rear fork pivot shaft nut, 1st 25-30 ft-lbs 34-41 N-m
To prevent accidental vehicle start-up, which could cause
torque
death or serious injury, disconnect negative (-) battery
Rear fork pivot shaft nut, 2nd 1-48 in-lbs 0.1-5.4 N-m
cable before proceeding. (00048a)
torque
Rear fork pivot shaft nut, 3rd 154-170 ft-lbs 209-230 N-m
1. Disconnect negative battery cable. See POWER torque
DISCONNECT (Page 7-7).
Rear fork pivot shaft nut, final 154-170 ft-lbs 209-230 N-m
2. Remove saddlebags if equipped. See SADDLEBAGS (Page torque
3-145) Rear fork pivot shaft pinch bolt 18-20 ft-lbs 24-27 N-m
3. Remove mufflers and exhaust bracket. See EXHAUST A WARNING
SYSTEM (Page 6-36) Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop. Over
4. Remove rear wheel. See REAR WHEEL (Page 3-16).
bending can damage belt resulting in premature failure, which
5. Remove rider footboard and bracket, if needed. See LEFT could cause loss of control and death or serious injury. (00339a)
FOOT CONTROLS (Page 3-128).
6. Mid-mount controls: Remove foot shift lever. See SHIFTER 1. See Figure 5-2. Install drive belt (3) on final drive sprocket.
LINKAGE (Page 5-9).
2. Install pivot shaft.
7. Drain primary chaincase oil. See REPLACE PRIMARY
CHAINCASE LUBRICANT (Page 2-9).
a. Position round spacer (2) between drive belt (3), frame
8. Remove primary chaincase cover. See PRIMARY and rear fork.
CHAINCASE COVER (Page 5-17).
b. Slide pivot shaft through round spacer and left side of
9. Remove starter. See STARTER (Page 7-9).
frame.
10. Remove primary chain, clutch and compensating sprocket.
See DRIVE COMPONENTS (Page 5-18). c. Install pivot shaft nut (1). Tighten.
11. Remove primary chaincase housing. See PRIMARY Torque: 25-30 ft-lbs (34-41 N-m) Rear fork pivot
CHAINCASE HOUSING (Page 5-27). shaft nut, 1st torque

REMOVE d. Back off pivot shaft nut.

Angle: 90°
1. See Figure 5-2. Loosen pivot shaft.
e. Tighten pivot shaft nut.

a. Remove nut (1). Torque: 1-48 in-lbs (0.1-5.4 N-m) Rear fork pivot
shaft nut, 2nd torque
NOTE
Hold pivot shaft while loosening nut. 3. NOTE
Verify round spacer (2) does not have lateral play.
b. See See Figure 3-84.. Loosen pivot shaft pinch bolt.
Install slot spacer.
c. See Figure 5-2. Slide pivot shaft out enough to
remove round spacer (2).
a. Place slot spacer (4) in the center of the drive belt and
between frame and rear fork.
2. Remove slot spacer.
b. Install slot spacer screws (5). Tighten.
a. Remove screws (5).
Torque: 50-55 ft-lbs (68-75 N-m) Drive belt slot
spacer screw, 1st torque
b. Remove slot spacer (4).
c. Loosen slot spacer screws.
3. Remove belt (3).
Angle: 90°

INSTALL d. Tighten slot spacer screws.

Torque: 65-70 ft-lbs (88-95 N-m) Drive belt slot
FASTENER TORQUE VALUE spacer screw, final torque

Drive belt slot spacer screw, 50-55 ft-lbs 68-75 N-m

1st torque

5-8
94000936
4. Place drive belt on sprocket and install rear wheel. See 4. Install primary chaincase cover and new gasket. See
REAR WHEEL (Page 3-16). PRIMARY CHAINCASE COVER (Page 5-17).
NOTE 5. Fill primary chaincase oil. See REPLACE PRIMARY
Adjust the belt tension after the drive belt slot spacer CHAINCASE LUBRICANT (Page 2-9).
screws have been torqued to final specifications and 6. Mid-mount controls: Install foot shift lever. See SHIFTER
before the pivot shaft nut has been torqued to final LINKAGE (Page 5-9).
specifications.
7. Install rider left footboard and bracket, if removed. See LEFT
FOOT CONTROLS (Page 3-128).
5. Tighten pivot shaft nut (1).
8. Install mufflers and exhaust bracket. See EXHAUST
SYSTEM (Page 6-36).
a. Tighten pivot shaft nut.
Torque: 154-170 ft-lbs (209-230 N-m) Rear fork pivot 9. Install saddlebags if equipped. See SADDLEBAGS (Page 3-
shaft nut, 3rd torque 145).

b. Loosen pivot shaft nut. 10. Connect negative battery cable. See POWER
DISCONNECT (Page 7-7).
Angle: 90°
c. Tighten pivot shaft nut.
Torque: 154-170 ft-lbs (209-230 N-m) Rear fork pivot
shaft nut, final torque NOTE
After final torque of pivot shaft nut there will be a
slight gap between the right side bearing and rear
fork.

6. NOTE
Verify round spacer (2) does not have lateral play.

See See Figure 3-84.. Tighten pivot shaft pinch bolt.

Torque: 18-20 ft-lbs (24-27 N-m) Rear fork pivot shaft
pinch bolt

COMPLETE

1. Install primary chaincase housing. See PRIMARY

CHAINCASE HOUSING (Page 5-27).
2. Install the primary chain, clutch, compensating sprocket and
chain tensioner. See DRIVE COMPONENTS (Page 5-18).
3. Install starter. See STARTER (Page 7-9).

5-9
94000936
SHIFTER LINKAGE 5.5
SHIFTER ROD 1. See Figure 5-3 or Figure 5-4. Disconnect forward end of
shifter rod from forward shifter rod lever.
FASTENER TORQUE VALUE
2. Loosen jamnuts. Adjust rod (3) as necessary.
Forward Foot Control shifter 120-168in-lbs 13.6-19 N-m
rod to front shifter rod lever
3. Secure shifter rod to front shifter rod lever. Tighten.
Forward Foot Control shifter 120-168in-lbs 13.6-19 N-m
rod to rear shifter rod lever Torque: 120-168 in-lbs (13.6-19 N-m) Forward or Mid Foot
Forward or Mid Foot Control 84-132 in-lbs 9.5-14.9 N-m Control shifter rod to shifter rod lever
shifter rod jamnut 4. Tighten jamnuts.
Forward or Mid Foot Control 120-168 in-lbs 13.0-19 N-m
Torque: 84-132 in-lbs (9.5-14.9 N-m) Forward or Mid Foot
shifter rod to shifter rod lever
Control shifter rod jamnut
Mid Foot Control shifter rod to 120-168in-lbs 13.6-19 N-m
shifter rod lever

Replace

Forward Foot Control Models

1. See Figure 5-3. Discard nut (2) and remove screw (6) from
front shifter rod lever (1).

2. Remove screw (5) from rear shifter rod lever (4).

3. Remove shifter rod (3)

4. Install shifter rod.

a. Install shifter rod to each shifter rod lever.

b. Install screw (5). Tighten.
Torque: 120-168 in-lbs (13.0-19 N-m) Forward Foot
Control shifter rod to rear shifter rod lever
c. Install screw (6) and new nut. Tighten.
Torque: 120-168 in-lbs (13.6-19 N-m) Forward Foot
Control shifter rod to front shifter rod lever
Figure 5-3. Shift Linkage: Forward Foot Control Models

Mid Foot Control Models

1. See Figure 5-4. Remove screws (4).

2. Remove shifter rod (3).

3. Install shifter rod.

a. Install shifter rod to each shifter rod lever.

b. Install screws. Tighten.
Torque: 120-168 in-lbs (13.6-19 N-m) Mid Foot
Control shifter rod to shifter rod lever

Adjust
NOTE
• The shifter rod should not require adjustment under
normal circumstances. However, if full gear engagement
or full lever travel is not achieved, adjust the shifter rod.

• Do not allow shift lever to contact footboard or support

bracket when shifting. This prevents proper gear
engagement. Contact may also damage the transmission.

5-10 94000936
 Installation
1. Mid Foot Control Models: Install spacer (8).
NOTE
Foot shift lever peg height is a customer preference.
During installation, check operation of shift lever. To
achieve proper gear engagement and to avoid damage
to transmission, the peg must not contact the footboard
or supports when shifting.

2. Install foot shift lever.

a. Align to marks made during removal.

b. Press foot shift lever onto shaft.

c. Install pinch screw and nut.

1. Shifter rod lever, front
2. Shifter rod lever, rear d. Tighten.
3. Shifter rod Torque: 24-28 ft-lbs (32.5-38 N-m) Mid foot control
4. Screw (2) shift lever pinch screw
5. Pinch screw Torque: 108-144 in-lbs (12.2-16.3 N-m) Forward foot
6. Washer control with footboards shift lever pinch screw
7. Foot shift lever Torque: 18-22 ft-lbs (24.4-29.8 N-m) Forward foot
8. Spacer control with footpegs shift lever pinch screw
9. Nut
3. Verify shift lever operation.
10. Shaft
11. Pinch screw
Figure 5-4. Shift Linkage: Mid Foot Control Models SHIFTER ROD _LEVER,. FRONT ___________
FOOT SHIFT LEVER
FASTENER TORQUE VALUE
FASTENER TORQUE VALUE Forward Foot Control shift lever 9-12 ft-lbs 12.2-16.3 N-m
10^144 in-lbs 12.2-16.3 N-m pinch screw
Forward foot control with foot-
boards shift lever pinch screw Forward Foot Control shifter rod 120-168 in-lbs 13.6-19 N-m
18-22 ft-lbs 24.4-29.8 N-m to shifter rod lever
Forward foot control with foot-
Mid Foot Control shifter rod 18-22 ft-lbs 24.4-29.8 N-m
pegs shift lever pinch screw
96-144 in-lbs 10.9-16.3 N-m lever pinch screw
Forward or Mid Foot Control
Mid Foot Control shifter rod to 120-168 in-lbs 13.6-19 N-m
shifter peg screw
shifter rod lever
Mid foot control shift lever pinch 24-28 ft-lbs 32.5-38 N-m
screw
Removal
Removal 1. See Figure 5-3 or Figure 5-4. Remove screw to free linkage
from front shifter rod lever (1 ).
1. See Figure 5-3 or Figure 5-4. Mark position of lever in
relation to shaft. 2. Mark position of foot shift lever in relation to shaft.
3. Forward Foot Control Models:
2. Mid Foot Control Models: Remove nut (9). Forward Foot
Control Models: Remove nut (8). a. See Figure 5-3. Remove pinch screw (7) and nut (8).
b. Remove foot shift lever assembly.
3. Remove pinch screw securing foot shift lever.
c. Remove shifter rod lever and shaft.

4. Remove lever from shaft.

4. Mid Foot Control Models:

5. Mid Foot Control Models: Remove spacer (8). a. See Figure 5-4. Remove pinch screw from front shifter
rod lever (1).
Repair
b. Pull foot shifter rod lever (1) and shaft outward until
1. Remove screw securing rubber peg to lever. Separate screw shifter rod lever is free.
from peg.
c. Remove shifter rod lever (7).

2. Assemble peg to lever with screw. Tighten.

Torque: 96-144 in-lbs (10.9-16.3 N-m) Forward or Mid
Foot Control shifter peg screw

94000936 5-11
Installation
1. Forward Foot Control Models:

a. See Figure 5-3. Install shifter rod lever (1) and shaft.

b. Install foot shift lever, aligning to marks made during

removal.

c. Install pinch screw (7). Tighten.

Torque: 9-12 ft-lbs (12.2-16.3 N-m) Forward Foot
Control shift lever pinch screw
d. Connect shifter rod. Tighten.
Torque: 120-168 in-lbs (13.6-19 N-m) Forward Foot
Control shifter rod to shifter rod lever
2. Mid Foot Control Models:

a. See Figure 5-4. Hold shifter rod lever (1) in place.

b. Push foot shift lever and rod into shifter rod lever
aligning splines as they mate.

c. Install pinch screw. Tighten.

Torque: 18-22 ft-lbs (24.4-29.8 N-m) Mid Foot
Control shifter rod lever pinch screw

3. Secure linkage to shifter rod lever (1). Tighten.

Torque: 128-168 in-lbs (13.8-19 N-m) Mid Foot Control
shifter rod to shifter rod lever

4. Verify shifter rod operation.

5-12 94000936
CLUTCH RELEASE COVER 5.6

PREPARE Install screws. Tighten in sequence shown.

Torque: 132-156 in-lbs (14.9-17.6 N-m) Clutch release
1. Remove main fuse. See POWER DISCONNECT (Page 7- cover screws
7)
5. Tighten clutch cable fitting, if removed.
2. Remove exhaust system if needed. See EXHAUST
Torque: 90-120 in-lbs (10.2-13.6 N-m) Clutch cable fitting
SYSTEM (Page 6-36).
3. Drain transmission. See REPLACE TRANSMISSION DISASSEMBLE __________________________
LUBRICANT (Page 2-11).
REMOVE 1. NOTE
Do not separate clutch cable halves.
1. NOTE
Actuating the clutch hand lever after removing the six Add free play to clutch cable. See CHECK AND ADJUST
screws will help break the cover free. CLUTCH (Page 2-23).

See Figure 5-5. Remove screws. A WARNING

Wear safety glasses or goggles when removing or installing
2. Remove clutch release cover. retaining rings. Retaining rings can slip from the pliers and
could be propelled with enough force to cause serious eye
3. Discard gasket.
injury. (00312a)

2. See Figure 5-6. Disconnect clutch cable.

a. Remove retaining ring (4).

b. Lift inner ramp (5) and ramp coupling (3) out of

clutch release cover.

c. Disconnect clutch cable end (2) from the ramp

coupling (3).

3. Remove coupling (3) from inner ramp.

4. See Figure 5-7. Remove balls (4) and outer ramp (2).
5. Remove clutch cable fitting from clutch release cover.

Figure 5-5. Clutch Release Cover Torque Sequence (Short

Screws at Locations 1 and 6)
INSTALL _ ____________
1. Verify that two dowel pins are in place on transmission

FASTENER TORQUE VALUE

Clutch cable fitting 90-120 in-lbs 10.2-13.6 N-m
Clutch release cover screws 132-156in-lbs 14.9-17.6 N-m
bearing housing flange.

2. Install new gasket.

3. Install clutch release cover.

4. NOTE
See Figure 5-5 . Clutch release cover screws in
positions (1) and (6) are shorter than the others.

5-13 94000936
 Adjust clutch. See CHECK AND ADJUST CLUTCH
(Page 2-23).

ASSEMBLE
NOTE
Replace cable fitting O-ring if damaged.
CLEAN AND INSPECT
1. See Figure 5-6 . Apply a drop of LOCTITE 243 MEDIUM
1. See Figure 5-8. Wash the ball and ramp mechanism
STRENGTH THREADLOCKER AND SEALANT (blue) to
components in cleaning solvent.
the clutch cable fitting (1).
2. Inspect the three balls (2) and ball socket surfaces on ramps
(1,3) for wear, pitting, surface breakdown and other 2. Install clutch cable fitting in clutch release cover. Leave
damage. Replace as necessary. fasteners loose.
3. Check fit of the ramp coupling (4) on inner ramp (1). Replace
both parts if there is excessive wear. 3. See Figure 5-8 . Place outer ramp (3) with ball socket side
up in clutch release cover. Confirm tab (8) is in clutch
4. Inspect the retaining ring (6) for damage or distortion. release cover slot.
5. Check clutch cable end for frayed or worn ends. Replace
cable if damaged or worn. Check cable fitting 0-ring for 4. Apply a multi-purpose grease to the balls and outer ramp
damage. sockets. Place a ball in each of the outer ramp sockets.
6. Check the bore in the clutch release cover (5) where the
ramps (1, 3) are retained. There should be no wear that 5. See Figure 5-6 . Connect clutch cable.
would cause the ramps to tilt, causing improper clutch
adjustment. a. Connect cable end to ramp coupling (3).

b. Install coupling on inner ramp (5).

c. Place inner ramp and coupling in position in clutch

release cover.

A WARNING

Wear safety glasses or goggles when removing or installing

retaining rings. Retaining rings can slip from the pliers and
could be propelled with enough force to cause serious eye
injury. (00312a)

6. Install retaining ring.

a. Center opening of retaining ring above break in

ribbing at bottom of clutch release cover.

5-14 94000936
 b. Install retaining ring (4). 2.

COMPLETE
3 Install exhaust system. See EXHAUST SYSTEM (Page 6-
. 36).
1. Fill transmission. See REPLACE TRANSMISSION LUBRICANT
(Page 2-11).
Install main fuse. See POWER DISCONNECT (Page 7-7)
4
.

94000936 5-15
 Adjust clutch. See CHECK AND ADJUST CLUTCH
CLUTCH RELEASE PUSH ROD COMPONENTS
(Page 2-23). 5.7

PREPARE Right Side

1. See Figure 5-10. Verify push rod (5) is installed.
1. Remove clutch inspection cover. See REPLACE PRIMARY
CHAINCASE LUBRICANT (Page 2-9).
2. Assemble bearing on oil slinger.
2. If necessary:
a. Install one thrust washer (2) on oil slinger (4).
a. Drain transmission lubricant. See REPLACE b. Install throw out bearing (3) on oil slinger.
TRANSMISSION LUBRICANT (Page 2-11).
c. Install second thrust washer on oil slinger.
b. Remove mufflers. See MUFFLERS (Page 6-34).
d. Install retaing ring (1) in groove.
c. Remove exhaust system if needed. See EXHAUST 3. Install assembly in transmission input shaft.
SYSTEM (Page 6-36).

d. Remove clutch release cover. See CLUTCH

RELEASE COVER (Page 5-12).

REMOVE

Right Side
1. See Figure 5-10. Remove oil slinger (4).

2. Disassemble oil slinger.

a. Remove retaining ring (1).

b. Remove throw out bearing (3) with thrust washers (2).

3. If necessary, remove push rod (5).

Left Side
1. See Figure 5-9. Loosen jamnut (4). 1. Push rod
2. Release plate
2. Loosen adjuster screw (5). 3. Retaining ring
4. Jamnut
3. Remove retaining ring (3). 5. Adjuster screw
Figure 5-9. Left Side Clutch Push Rod
4. Remove release plate (2).

5. If necessary, remove push rod (1 ).

INSTALL

Left Side
1. See Figure 5-9. Verify push rod (1) is installed.

2. Install release plate (2).

3. Install retaining ring (3).

4. Install adjuter screw (5).

5. Install jam nut (4).

5-16 94000936
 COMPLETE
1. If necessary:

a. Install clutch release cover. See CLUTCH RELEASE

COVER (Page 5-12).

b. Fill transmission. See REPLACE TRANSMISSION

LUBRICANT (Page 2-11).

c. Install exhaust system if removed. See EXHAUST

SYSTEM (Page 6-36).

d. Install mufflers. See MUFFLERS (Page 6-34).

2. Adjust clutch. See CHECK AND ADJUST CLUTCH (Page 2-

23).
1. Retaining ring
2. Thrust washer (2) 3. Install clutch inspection cover. See REPLACE PRIMARY
3. Throw out bearing CHAINCASE LUBRICANT (Page 2-9).
4. Oil slinger
5. Push rod
Figure 5-10. Right Side Clutch Push Rod

5-17 94000936
 PRIMARY CHAINCASE COVER
PREPARE c. See Figure 5-12. Tighten in sequence shown.
Torque: 144-156 in-lbs (16.3-17.6 N-m) Primary cover
A WARNING screws
To prevent accidental vehicle start-up, which could cause death
or serious injury, disconnect negative (-) battery cable before
proceeding. (00048a)

1. Disconnect negative battery cable. See POWER

DISCONNECT (Page 7-7).
2. Remove rider left footboard and bracket, if necessary. See
LEFT FOOT CONTROLS (Page 3-128).
3. Mid-mount controls: Remove foot shift lever. See SHIFTER
LINKAGE (Page 5-9).
4. Drain primary chaincase oil. See REPLACE PRIMARY
CHAINCASE LUBRICANT (Page 2-9).
REMOVE 1. See Figure 5-11. Remove primary chaincase
cover.

a. Remove cover screws (4, 5).

b. Remove cover.

INSTALL ____________________

FASTENER TORQUE VALUE

Primary cover screws 144-156 in-lbs 16.3-17.6 N-m

CONSUMABLE PART NUMBER

LOCTITE 243 99642-97
MEDIUM
STRENGTH
THREADLOCKER
AND SEALANT
(BLUE)

1. See Figure 5-11. Verify that all debris is washed from the
inside ribs of the cover.
2. Verify hollow dowels (2) are installed properly. Figure 5-12. Primary Chaincase Cover Torque Sequence
COMPLETE
3. Install new cover gasket (1).
1. Fill primary chaincase with oil. See REPLACE PRIMARY
4. Install cover. CHAINCASE LUBRICANT (Page 2-9).
a. Apply a drop of threadlocker to the threads of each
screw. 2. Mid-mount controls: Install foot shift lever. See SHIFTER
LOCTITE 243 MEDIUM STRENGTH LINKAGE (Page 5-9).
THREADLOCKER AND SEALANT (BLUE) (99642-
3. Install rider footboard and bracket, if removed. See LEFT
97) FOOT CONTROLS (Page 3-128).
b. Install cover with screws (4, 5) in positions shown.
4. Install negative battery cable. See POWER DISCONNECT
(Page 7-7).

5-18 94000936
DRIVE COMPONENTS 5.9

PREPARE 5. See Figure 5-16. Remove compensating sprocket bolt.

a. Place the primary drive locking tool between the
A WARNING sprockets as shown.

To prevent accidental vehicle start-up, which could cause death b. Rotate compensating sprocket bolt (1) counterclockwise
or serious injury, disconnect negative (-) battery cable before to loosen.
proceeding. (00048a)
c. See Figure 5-17. Remove bolt (9), retainer (8) and thrust
washer (7).
1. Disconnect negative battery cable. See POWER
DISCONNECT (Page 7-7). 6. Inspect thrust washers (7) for damage.
2. Remove rider left footboard and bracket, if necessary. See 7. Clean sprocket retainer (8). Verify that oil holes are clear.
LEFT FOOT CONTROLS (Page 3-128).
INSTALL________________________________
3. Mid-mount controls: Remove foot shift lever. See SHIFTER
LINKAGE (Page 5-9).
PART NUMBER TOOL NAME
4. Drain primary chaincase oil. See REPLACE PRIMARY HD-47977 PRIMARY DRIVE LOCKING TOOL
CHAINCASE LUBRICANT (Page 2-9).
FASTENER TORQUE VALUE
5. Remove primary chaincase cover. See PRIMARY
CHAINCASE COVER (Page 5-17). Clutch hub mainshaft nut 70-80 ft-lbs 94.9--108.5N-m
Compensating sprocket bolt, 100 ft-lbs 135.6 N-m
REMOVE _______________________________
PART NUMBER TOOL NAME 1st torque
Compensating sprocket bolt, 175 ft-lbs 237.3 N-m
HD-47977 PRIMARY DRIVE LOCKING TOOL
final torque
1. See Figure 5-13. Remove chain tensioner. Primary chain tensioner 21-24 ft-lbs 28.5-32.6 N-m
fasteners
a. Install cable strap (2) as shown. Exposed portion of cable
strap below cover indicates need for removal before NOTE
cover installation. The O-ring inside the shaft extension is for manufacturing
b. See Figure 5-14. Remove chain tensioner fasteners (2). assembly only and has no replacement part number.

c. Remove chain tensioner (1).

1. See Figure 5-17 and Figure 5-18. Install spring washers.

NOTE
a. Apply a thin layer of primary chaincase oil to the inner
Clutch hub does not need to be removed when removing diameter of the compensating sprocket (6) and the
compensating sprocket.
splines of shaft extension (1).

2. Mark one of the links of the primary chain for reference

b. Install shaft extension.
during installation.
3. Remove retaining ring and release plate from center of c. Install large spring washers (2) and medium spring
clutch assembly. washers (3). Outer diameter of spring washers must
NOTE contact each other.

The mainshaft nut has left-hand threads.

d. Install small spring washer (4) so outer diameter
contacts sliding cam (5).
4. See Figure 5-15. Remove mainshaft nut.
a. Place special tool between the sprockets as 2. Install primary chain, compensating sprocket and clutch.
shown.PRIMARY DRIVE LOCKING TOOL (PART
NUMBER: HD-47977) 3. Lightly lubricate thrust washer (7). Install components (7,
b. Wide frame only: See Figure 5-17. Discard oil spinner 8) and new bolt (9). Hand tighten.
(10). NOTE

c. Figure 5-15. Rotate clutch hub mainshaft nut (4) Clutch hub mainshaft nut has left-hand threads.
clockwise to remove.
4. See Figure 5-19. Install mainshaft nut.
a. Clean and prime threads of clutch hub mainshaft nut
(2).

b. Apply two drops of LOCTITE 262 HIGH STRENGTH

THREADLOCKER AND SEALANT (red) to the
threads.

94000936 5-19
c. Install nut onto mainshaft. Hand-tighten. b. Remove cable strap.

5. See Figure 5-20. Tighten compensating sprocket bolt. reminder to remove before installing primary cover.

a. Place special tool between the sprockets as shown. 10. See Figure 5-14. Install primary chain tensioner.
Special Tool: PRIMARY DRIVE LOCKING TOOL (HD- 11. Set preliminary chain tension.
47977)
a. Check tension at the top span while pulling down on
b. Tighten compensating sprocket bolt (1).
chain midway between sprockets. Correct tension is
Torque: 100 ft-lbs (135.6 N-m) Compensating
sprocket bolt, 1st torque 0. 500-0.625 in (12.7-15.88 mm)

c. Loosen one-half turn. b. If chain is loose, move chain adjuster one notch.
Check tension.
d. Final torque.
c. Repeat steps until tension is within specification.
Torque: 175 ft-lbs (237.3 N-m) Compensating
NOTE
sprocket bolt, final torque
Primary chain tensioner will not complete chain adjustment
6. Wide frame only: See Figure 5-17. Install new oil spinner until vehicle is ridden.
(10).
12. Test ride vehicle after tensioner removal/installation to
7. See Figure 5-19. Tighten clutch hub mainshaft nut. provide proper adjustment.

a. Place special tool between the sprockets as shown.

Special Tool: PRIMARY DRIVE LOCKING TOOL (HD-
47977)
b. Tighten clutch hub mainshaft nut (2).
Torque: 70--80 ft-lbs (94.9-108.5 N-m) Clutch hub
mainshaft nut

8. Install release plate and retaining ring into center of clutch

assembly.

9. If primary chain tensioner becomes disassembled, assemble

in order shown.
NOTE
• Primary chain tensioner is non-repairable. If tensioner is
worn or damaged, replace assembly

• Chain tensioner is not interchangable with previous

model year parts. Shoe color is black.

a. See Figure 5-21. Locate end of spring rod (2) on roll

pin (3).

b. See Figure 5-22. Slide wedge (2) of primary chain

tensioner in direction of arrow until all travel is
removed.

c. See Figure 5-13. Push shoe (1) down until it contacts

1. Chain tensioner
wedge. Keep tension on shoe so wedge stays in
2. Chain tensioner fasteners
place.
3. Cable strap _____________
Figure 5-14. Chain Tensioner
d. Insert cable strap (2) as shown to hold wedge in
place. Verify that end of cable strap hangs below
primary chain tensioner. Cable strap serves as a

a. Install primary chain tensioner (1) with fasteners (2).

Tighten.
Torque: 21-24 ft-lbs (28.5-32.6 N-m) Primary chain
tensioner fasteners

5-20 94000936
 sm05990b
Figure
Figure
5-15.5-16.
Removing
Removing
Clutch
Clutch
Hub Hub
Mainshaft
Mainshaft
Nut Nut 1. 5-19.
Figure
Figure Large
5-18. spring
Spring washer
Washer
Installing Clutch (2)Mainshaft Nut
Orientation
Hub
2. Medium spring washer (2)

1. Engine compensating sprocket

2. Primary drive locking tool 1. Bolt
3. Clutch sprocket 2. Primary drive locking tool
2. Nut
4. Clutch hub mainshaft nut

Figure 5-20. Installing Engine Compensating Sprocket Bolt

1. Shaft extension
2. Large spring washer (2)
3. Medium spring washer (2)
4. Small spring washer
5. Sliding cam
6. Compensating sprocket
7. Thrust washer
8. Sprocket retainer
9. Bolt
10. Oil spinner (wide frame only)
Figure 5-17. Engine Compensating Sprocket Assembly

94000936 5-21
 C
OMPLETE

1. I
nstall primary chaincase cover. See PRIMARY CHAINCASE
COVER (Page 5-17).

2. F
ill primary chaincase with oil. See REPLACE PRIMARY
CHAINCASE LUBRICANT (Page 2-9).

3. M
id-mount controls: Install foot shift lever. See SHIFTER
LINKAGE (Page 5-9).

4. I
nstall rider footboard and bracket, if removed. See LEFT FOOT
CONTROLS (Page 3-128).

5. Install negative battery cable. See POWER DISCONNECT

(Page 7-7).

5-22 94000936
CLUTCH 5.10

PREPARE NOTE
Friction and steel plates are only sold as a set.
A WARNING
1. NOTE
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (■) battery cable Do not wash friction plates or hub bearing with cleaning
before proceeding. (00048a) solvent.

Wash parts in cleaning solvent. Dry with low-pressure

1. Disconnect negative battery cable. See POWER
DISCONNECT (Page 7-7). compressed air.

2. Remove rider left footboard and bracket, if necessary. See 2. Check friction plates.
LEFT FOOT CONTROLS (Page 3-128).
NOTE
3. Mid-mount controls: Remove foot shift lever. See Do not use a rag to clean friction plates.
SHIFTER LINKAGE (Page 5-9).

4. Drain primary chaincase oil. See REPLACE PRIMARY a. Remove lubricant using compressed air.
CHAINCASE LUBRICANT (Page 2-9).
b. Measure thickness of each plate.
5. Remove primary chaincase cover. See PRIMARY
CHAINCASE COVER (Page 5-17).
c. If the thickness of any plate is less than specification,
DISASSEMBLE AND ASSEMBLE: CLUTCH replace entire clutch disc set. Refer to Table 5-12.
PACK
d. Look for worn or damaged fiber surface material (both
To replace the entire clutch assembly, see DRIVE sides).
COMPONENTS (Page 5-18).
3. Check steel plates for distortion.
Disassemble
a. Replace entire clutch disc set if any steel plates are
1. See Figure 5-23. Remove pressure plate (6). grooved.

a. Remove bolts (1). b. Lay plate on a precision flat surface.

b. Remove spring stopper plate (2). c. Using a feeler gauge, check for distortion in several
places.
c. Remove springs (4).
d. If any steel plate is warped beyond specification,
d. Remove spring seats (5).
replace entire clutch disc set.
Length/Dimension/Distance: 0.006 in (0.15 mm)
2. Remove friction and steel plates.
4. Check clutch hub bearing for smooth operation. Replace if
a. Remove narrow friction plates (7) and narrow steel necessary. See Disassemble and Assemble: Hub (Page 5-
plate (8). 25).

b. Remove wide steel plates (9) and wide friction plates 5. Check clutch shell chain sprocket and starter ring gear.
(10). Replace if worn or damaged.

c. Remove narrow friction plate (7).

6. Check clutch hub and shell steel plate slots for wear or
damage. Replace if necessary.
3. Remove damper spring.

7. Check coil springs for wear or damage. Replace if

a. Remove damper spring (11).
necessary.
b. Remove damper spring seat (12).

Table 5-12. FRICTION PLATE MINIMUM THICKNESS

Clean and Inspect FRICTION PLATE MM IN
Wide Plate 2.82 0.111
A WARNING
Narrow Plate 3.62 0.143
Compressed air can pierce the skin and flying debris from
Assemble
compressed air could cause serious eye injury. Wear safety
glasses when working with compressed air. Never use your 1. Submerge and soak all friction plates in primary chaincase
hand to check for air leaks or to determine air flow rates. lubricant for at least five minutes.
(00061a)

94000936 5-23
2. See Figure 5-23. Install Damper spring. d. Install narrow friction plate (7), narrow steel plate (8)
and remaining friction plate (7).
a. Install damper spring seat (12) into clutch hub (13).
4. Install pressure plate (6).
b. Install damper spring (11) onto damper spring seat
with concave side facing outside of motorcycle.
a. Install spring seats (5).
3. Install friction and steel plates. b. Align and install pressure plate (6) onto clutch hub
(13).
a. Install one narrow friction plate (7) into clutch hub.
c. Install springs (4).
b. Install one wide steel plate (9) onto narrow friction
plate and damper spring (11). d. Install spring stopper plate (2).

c. e.
Beginning with a wide friction plate (10), alternate Install bolts (1).
remaining wide friction plates with wide steel plates
Torque: 71-106 in-lbs (8-12 N-m)
(9).

5-24 94000936
 1. Bolt (3) 8. Narrow steel plate (1)
2. Stopper plate 9. Wide steel plate (8)
3. Mainshaft nut 10. Wide fri cti on plate (7)
4. Coil spring (3) 11. Damper spring
5. Seat (3) 12. Damper spring seat
6. Pressure plate 13. Clutch hub
7. Narrow fri cti on plate (3) 14. Clutch shell
Figure 5-23. Clutch Shell Assembly

94000936 5-25
DISASSEMBLE AND ASSEMBLE: HUB

Disassemble

A WARNING

Wear safety glasses or goggles when removing or installing

retaining rings. Retaining rings can slip from the pliers and
could be propelled with enough force to cause serious eye
injury. (00312a)

NOTE
Do not disassemble the clutch shell and hub assembly
unless the bearing, hub or shell require replacement.
Replace the bearing if disassembled.

1. Press out clutch hub.

Figure 5-25. Pressing Clutch Hub From Bearing
a. See Figure 5-24. Remove clutch hub retaining ring (2).

b. See Figure 5-25. Support clutch shell in press with

ring gear side up.

c. Press hub from bearing in clutch shell.

2. Remove bearing.

a. See Figure 5-24. Remove bearing retaining ring (1)

from groove in clutch shell bore.

b. See Figure 5-25. Support clutch shell in press with

ring gear side is down.

c. Use a suitable press plug to remove bearing.

3. Clean and inspect components. See Disassemble and

Assemble: Clutch Pack (Page 5-22).

Figure 5-26. Pressing Bearing From Clutch Shell

Assemble

1. Install new bearing.

a. Place clutch shell in press with ring gear side up.

b. Support clutch shell bore on sprocket side to avoid

damage to ears on clutch basket.

c. Using a suitable press plug, press against outer race

until bearing contacts shoulder in clutch shell bore.

A WARNING

Wear safety glasses or goggles when removing or installing

retaining rings. Retaining rings can slip from the pliers and
could be propelled with enough force to cause serious eye
injury. (00312a)

d. See Figure 5-24. Install bearing retaining ring (1) with

flat side toward bearing.

2. Install clutch hub.

a. Place clutch shell in press with sprocket side up.

5-26 94000936
 b. Center the hub in bearing.

c. Support bearing inner race with a sleeve on

transmission side.

d. Press hub into bearing until shoulder contacts bearing

inner race.

e. See Figure 5-24. Install clutch hub retaining ring (2) in

groove of clutch hub.

COMPLETE ________________________________________

1. Install primary chaincase cover. See PRIMARY

CHAINCASE COVER (Page 5-17).
2. Fill primary chaincase with oil. See REPLACE PRIMARY
CHAINCASE LUBRICANT (Page 2-9).

3. Mid-mount controls: Install foot shift lever. See SHIFTER

LINKAGE (Page 5-9).

4. Install rider footboard and bracket, if removed. See LEFT

FOOT CONTROLS (Page 3-128).

5. Install negative battery cable. See POWER DISCONNECT

(Page 7-7).

94000936 5-27
PRIMARY CHAINCASE HOUSING 5.11

PREPARE rotate freely. See Mainshaft Bearing and Seal (Page 5-28).
3. Replace the oil seal. See Mainshaft Bearing and Seal (Page
A WARNING 5-28).
4. Inspect shifter shaft bushing. Replace if necessary. See
To prevent accidental vehicle start-up, which could cause death
Shifter Shaft Bushing (Page 5-29).
or serious injury, disconnect negative (-) battery cable before
proceeding. (00048a) INSTALL

1. Disconnect negative battery cable. See POWER

DISCONNECT (Page 7-7). FASTENER TORQUE VALUE
2. Remove rider footboard and bracket, if needed. See LEFT Primary chaincase sealing 26-28 ft-lbs 35.3-38 N-m
FOOT CONTROLS (Page 3-128). screws

3. Mid-mount controls: Remove foot shift lever. See SHIFTER NOTE

LINKAGE (Page 5-9). Cover mainshaft clutch hub splines with tape to prevent the
splines from damaging the primary housing inner oil seal.
4. Drain primary chaincase oil. See REPLACE PRIMARY
CHAINCASE LUBRICANT (Page 2-9).
1. See Figure 5-29. Install gasket on surface (2). Verify dowels
5. Remove primary chaincase cover. See PRIMARY in gasket engage dowel holes (3).
CHAINCASE COVER (Page 5-17).
6. Remove starter. See STARTER (Page 7-9). 2. Spread a film of oil on mainshaft oil seal lip and rubber
portion of crankcase gasket.
7. Remove primary chain, clutch and compensating sprocket.
See DRIVE COMPONENTS (Page 5-18).
3. Install primary chaincase housing.
REMOVE
a. See Figure 5-30. Install new sealing screws.
1. See Figure 5-27. Remove five sealing screws (5).
2. Remove primary chaincase housing (6). b. See Figure 5-31. Tighten in sequence shown.
3. Discard the crankcase gasket (7) and sealing screws.
Torque: 26-28 ft-lbs (35.3-38 N-m) Primary
chaincase sealing screws

2. Check the mainshaft bearing. Replace if bearing does not

INSPECT

1. Inspect primary chaincase for cracks or damaged gasket

surface.

5-28 94000936
 A WARNING
Wear safety glasses or goggles when removing or installing
retaining rings. Retaining rings can slip from the pliers and
could be propelled with enough force to cause serious eye
injury. (00312a)

2. See Figure 5-32. Remove retaining ring (1).

NOTE
Support the bearing support area on the transmission
side of the primary chaincase while pressing out
bearing.

3. Place inner primary chaincase in a press with clutch side up.

4. Press out bearing from clutch side.

1. Crankcase Install
2. Gasket surface
1. Verify that the bearing bore is clean and smooth.
3. Dowel holes
Figure 5-29. Crankcase NOTE
Support the bearing support area on the clutch side of the
primary chaincase while pressing bearing.

2. Place primary chaincase in a press with the transmission

side up.
3. Install new bearing with letter side up.
a. Apply a thin film of oil to outer diameter of bearing.
b. Press outer race until it makes solid contact with the
bearing support area.

4. See Figure 5-32. Install retaining ring.

a. Retaining ring (1) must not block oil passage (2).
b. Verify that the ring is fully seated in the groove.
Figure 5-30. Primary Chaincase Sealing Screw
5. Install mainshaft oil seal.
a. Lubricate the OD of the new seal with SCREAMIN'
EAGLE ASSEMBLY LUBE.

b. Place over bore with the lip garter spring side (stamped
"OIL SIDE") facing toward the bearing.
c. Press against the outer rim of oil seal the seal until seal
is flush with machined surface of inner primary housing.

6. Lubricate the bearing and seal lip with multi-purpose grease

or SCREAMIN' EAGLE ASSEMBLY LUBE.
MAINSHAFT_BEARING_AND SEAL

Figure 5-31. Sealing Screw Tightening Sequence

Remove
1. Remove seal with a seal remover or rolling head pry bar for
best results.

94000936 5-29
 sm03455

MAINSHAFT BEARING INNER RACE

PART NUMBER TOOL NAME
HD-34902-C BEARING RACE REMOVER AND
INSTALLER KIT

Remove
NOTE
Use only BEARING RACE REMOVER AND INSTALLER KIT
(PART NUMBER: HD-34902-C).
1. Bearing inner race
1. See Figure 5-33. Remove bearing inner race using BEARING 2. Extension shaft
RACE REMOVER AND INSTALLER KIT (PART NUMBER: 3. Wrench flat
HD-34902-C). 4. Installer sleeve
5. Washer (2)
6. Nut _____________________________
Figure 5-34. Installing Bearing Race
SHIFTER SHAFT BUSHING _________

1. See Figure 5-35. Press out old bushing (1) from front to
back.
2. Inspect the bushing bore to verify that it is clean and
smooth.
3. Press new bushing from back of chaincase until it is flush to
0.020 in (0.51 mm) below edge of bore.

Figure 5-33. Pulling Mainshaft Inner Bearing Race

Install
1. See Figure 5-34. Install bearing inner race (1) onto
mainshaft until edge of race contacts step on shaft using
BEARING RACE REMOVER AND INSTALLER KIT (PART
NUMBER: HD-34902-C).
2. Lubricate race with SCREAMIN' EAGLE ASSEMBLY LUBE.

5-30 94000936
 COMPLETE

1. Install the primary chain, clutch, compensating sprocket and

chain tensioner. See DRIVE COMPONENTS (Page 5-18).
2. Install starter. See STARTER (Page 7-9).
3. Install primary chaincase cover and new gasket. See
PRIMARY CHAINCASE COVER (Page 5-17).
4. Fill primary chaincase oil. See REPLACE PRIMARY
CHAINCASE LUBRICANT (Page 2-9).
5. Mid-mount controls: Install foot shift lever. See SHIFTER
LINKAGE (Page 5-9).
6. Install rider left footboard and bracket, if removed. See LEFT
FOOT CONTROLS (Page 3-128).
7. Connect negative battery cable. See POWER
DISCONNECT (Page 7-7).

5-31 94000936
ENGINE OIL FILL SPOUT 5.12

PREPARE __________________

1. Drain engine oil. See REPLACE ENGINE OIL AND FILTER

(Page 2-7).

REMOVE

1. See Figure 5-36. Remove screws (4).

2. Remove fill spout (3).

3. Discard O-ring (1).

INSTALL _______________________________

FASTENER TORQUE VALUE

Engine oil fill spout screw. 100---120in-lbs 11.3-13.6 N-m
1. See Figure 5-36. Install new O-ring (1).
2. Install fill spout.

a. Install fill spout (3).

b. Install screws (4). Tighten.

Torque: 100---120 in-lbs (11.3-13.6 N-m) Engine oil
fill spout screw.

5-32 94000936
 COMPLETE

1. Fill engine oil. See REPLACE ENGINE OIL AND FILTER

(Page 2-7).

94000936 5-33
TRANSMISSION SPROCKET 5.13

PREPARE

A WARNING

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

1. Disconnect negative battery cable. See POWER

DISCONNECT (Page 7-7).
2. Remove rider footboard and bracket, if needed. See LEFT
FOOT CONTROLS (Page 3-128).
3. Mid-mount controls: Remove foot shift lever. See
SHIFTER LINKAGE (Page 5-9).
4. Drain primary chaincase oil. See REPLACE PRIMARY
CHAINCASE LUBRICANT (Page 2-9).
5. Remove primary chaincase cover. See PRIMARY
CHAINCASE COVER (Page 5-17). 1. Screw (2)
2. Lockplate
6. Remove starter. See STARTER (Page 7-9). 3. Sprocket nut
7. Remove primary chain, clutch and compensating sprocket. 4. Sprocket
See DRIVE COMPONENTS (Page 5-18). 5. Main drive gear
Figure 5-37. Transmission Sprocket
8. Remove primary chaincase housing. See PRIMARY
CHAINCASE HOUSING (Page 5-27).
9. Loosen drive belt. See INSPECT AND ADJUST DRIVE
BELT AND SPROCKETS (Page 2-31).
REMOVE

PART NUMBER TOOLNAME

HD-46282A FINAL DRIVE SPROCKET LOCKING
TOOL
HD-47910 MAINSHAFT LOCKNUT WRENCH
HD-94660-2 PILOT

NOTE
• Loosen sprocket nut only while transmission is installed
in frame. Otherwise damage to transmission or 1. Rear fork pivot
transmission stand results. 2. Final drive sprocket locking tool
• Sprocket nut has a right-hand thread. 3. Sprocket nut
Figure 5-38. Sprocket Nut Removal
1. See Figure 5-37. Remove sprocket nut. CLEAN AND INSPECT
a. Remove two screws (1) and lockplate (2).
b. See Figure 5-38. Install FINAL DRIVE SPROCKET 1. Using a non-volatile cleaning solvent, clean sprocket of all
LOCKING TOOL (PART NUMBER: HD-46282A) (2) with grease and dirt.
arm of tool against bottom of rear fork pivot (1).
2. Inspect belt and sprocket. See INSPECT AND ADJUST
c. Install PILOT (PART NUMBER: HD-94660-2) on DRIVE BELT AND SPROCKETS (Page 2-31).
mainshaft.
3. Inspect main drive gear and mainshaft seals. Replace if
d. Remove the sprocket nut (3) using MAINSHAFT damaged.
LOCKNUT WRENCH (PART NUMBER: HD-47910) (1).
INSTALL

2. Remove sprocket, allowing belt to slip from sprocket as PART NUMBER TOOL NAME
sprocket is removed. HD-46282A FINAL DRIVE SPROCKET LOCKING
TOOL
HD-47910 MAINSHAFT LOCKNUT WRENCH
HD-94660-2 PILOT

5-34 94000936
94000936 5-35
 PART NUMBER TOOL NAME 5. See Figure 5-40. Scribe lines (3) or use special tool for final
TA360 TORQUE ANGLE GAUGE torque.
Special Tool: TORQUE ANGLE GAUGE (TA360)
FASTENER TORQUE VALUE
Transmission sprocket lock- 90-120 in-lbs 10.2-13.6 N-m 6. Turn sprocket nut to specification.
plate screws Torque: 35-40° (35-40°) Transmission sprocket nut, final
Transmission sprocket nut, 1st 100 ft-lbs 135.6 N-m torque
torque NOTE
Transmission sprocket nut, 2nd 35 ft-lbs 47.5 N-m • The lockplate can be installed either side out.
torque
• Never LOOSEN nut to align screw holes.
Transmission sprocket nut, final 35-40° 35-40°
torque • If necessary, tighten the nut slightly to align lockplate.

CONSUMABLE PART NUMBER • Do not exceed a final torque of 45 degrees.

LOCTITE 271 HIGH Loctite 271

STRENGTH 7. Install lockplate.
THREADLOCKER
AND SEALANT a. Align lockplate holes with tapped holes in sprocket.
(RED)
b. See Figure 5-37 . Install two new screws (1 ). Tighten.
NOTE
Torque: 90--120 in-lbs (10.2-13.6 N-m) Transmission
• Tighten sprocket nut only while transmission is installed sprocket lockplate screws
in frame. Otherwise damage to transmission or
transmission stand results.
• Never get oil on the threads of the sprocket nut.
• The transmission sprocket nut has right-hand threads.

1. Place transmission sprocket in position. Install the belt as the

sprocket is installed.

2. Install sprocket nut.

a. See Figure 5-37 . Apply a film of clean engine oil to the

mating surfaces of the sprocket nut (3) and the
sprocket (4).

b. Apply threadlocker to the threads of the sprocket nut.

LOCTITE 271 HIGH STRENGTH THREADLOCKER

AND SEALANT (RED) (Loctite 271)

c. Install the sprocket nut finger-tight.

d. See Figure 5-39. Install special tool (2) resting against

the rear fork pivot (3).
Special Tool: FINAL DRIVE SPROCKET LOCKING
TOOL (HD-46282A)
e. Install special tool on mainshaft.
Special Tool: PILOT (HD-94660-2)
f. Using special tool, tighten sprocket nut to initial torque.
Torque: 100 ft-lbs (135.6 N-m) Transmission
sprocket nut, 1st torque
Special Tool: MAINSHAFT LOCKNUT WRENCH (HD-
47910)

3. Loosen sprocket nut one full turn.

4. Tighten to second torque.

Figure 5-40. Transmission Sprocket Nut Final Tightening
Torque: 35 ft-lbs (47.5 N-m) Transmission sprocket nut,
2nd torque
NOTE

5-36 94000936
COMPLETE

1. Install primary chaincase housing. See PRIMARY

CHAINCASE HOUSING (Page 5-27).
2. Install the primary chain, clutch, compensating sprocket and
chain tensioner. See DRIVE COMPONENTS (Page 5-18).
3. Install starter. See STARTER (Page 7-9).
4. Install primary chaincase cover and new gasket. See
PRIMARY CHAINCASE COVER (Page 5-17).
5. Fill primary chaincase oil. See REPLACE PRIMARY
CHAINCASE LUBRICANT (Page 2-9).
6. Mid-mount controls: Install foot shift lever. See SHIFTER
LINKAGE (Page 5-9).
7. Install rider left footboard and bracket, if removed. See LEFT
FOOT CONTROLS (Page 3-128).
8. Adjust drive belt deflection. See INSPECT AND ADJUST
DRIVE BELT AND SPROCKETS (Page 2-31).
9. Verify rear fork pivot shaft torque. See REAR FORK (Page 3-
81).
10. Connect negative battery cable. See POWER DISCONNECT
(Page 7-7).

94000936 5-37
TRANSMISSION 5.14

PREPARE NOTE
See Figure 5-43. Always pry bearing housing loose. Never
A WARNING tap on shafts to remove transmission assembly The bearing
housing bearings will be damaged.
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a) 6. See Figure 5-44. Remove the transmission and bearing
housing assembly:
1. Disconnect negative battery cable. See POWER a. Remove the transmission bearing housing screws (1).
DISCONNECT (Page 7-7). b. See Figure 5-43. Pry the bearing housing loose.
2. Drain transmission oil. See REPLACE TRANSMISSION c. Remove bearing housing and transmission components
LUBRICANT (Page 2-11). from transmission case as an assembly.
3. Drain engine oil. See REPLACE ENGINE OIL AND FILTER
(Page 2-7).
4. Remove exhaust system. See EXHAUST SYSTEM (Page 6-
36).
5. Remove engine oil fill spout. See ENGINE OIL FILL SPOUT
(Page 5-31).
6. Remove clutch release cover. See CLUTCH RELEASE
COVER (Page 5-12).
7. Remove rider footboard and bracket, if needed. See LEFT
FOOT CONTROLS (Page 3-128).
8. Mid-mount controls: Remove foot shift lever. See SHIFTER
LINKAGE (Page 5-9).
9. Drain primary chaincase oil. See REPLACE PRIMARY
CHAINCASE LUBRICANT (Page 2-9).
10. Remove primary chaincase cover. See PRIMARY
CHAINCASE COVER (Page 5-17).
11. Remove starter. See STARTER (Page 7-9).
12. Remove primary chain, clutch and compensating sprocket.
See DRIVE COMPONENTS (Page 5-18).
13. Remove primary chaincase housing. See PRIMARY
CHAINCASE HOUSING (Page 5-27).
14. Loosen drive belt. See INSPECT AND ADJUST DRIVE
BELT AND SPROCKETS (Page 2-31).
15. Remove transmission mainshaft bearing inner race. See
Mainshaft Bearing Inner Race (Page 5-29).
REMOVE

NOTE
Do not remove the transmission case unless the case
requires replacement. See TRANSMISSION CASE (Page 5-
50).

1. See Figure 5-41. Remove oil slinger assembly and pushrod

from main shaft.
2. Remove transmission top cover.
3. See Figure 5-42. Set a rag over the transmission case.
4. Set shifter cam pawl on rag.
5. Cover mainshaft clutch hub splines with tape to prevent
damaging the main drive gear bearings and oil seal.

5-38 94000936
 Figure 5-45. Transmission Bearing Housing Tightening Sequence
6. Install top cover.

a. Set shifter cam pawl on shift cam.

b. Inspect transmission top cover gasket. Replace as

necessary.

c. Install transmission top cover and screws. Tighten.

Torque: 132-156 in-lbs (14.9-17.6 N-m)
Transmission top cover
7. Install vent hose to top cover fitting, if removed.

8. See Figure 5-41. Install pushrod assembly (2-5) in mainshaft

hole.

a. Install new retaining ring (1) if removed.

INSTALL DISASSEMBLE

FASTENER TORQUE VALUE Remove Shift Cam and Shifter Forks

Transmission bearing housing 22-25 ft-lbs 29.8-33.9 N-m
1. See Figure 5-46. Remove shift fork shafts:
screws
Transmission top cover 132-156 in-lbs 14.9-17.6 N-m a. Set bearing housing on bench with shafts pointing up.

1. Cover mainshaft clutch hub splines with tape to prevent NOTE

damaging the main drive gear bearings and oil seal.
Shafts have slight interference fit.
2. Install a new gasket on the ring dowels.
b. Remove shift fork shafts using spiral-flute screw
extractor (14) or vise grips.
3. Apply clean transmission lubricant to the main drive gear
bearings. c. Mark end of shaft to aid assembly.

NOTE
2. Remove shift forks from dog rings.
Verify that transmission filler plug/dipstick is removed.
3. See Figure 5-47. Remove lock plate (2). Discard screws (3).

4. Install the transmission assembly in the transmission case. 4. Hold detent arm back and remove shift cam (4).
5. See Figure 5-48. If needed, remove detent assembly.
5. See Figure 5-44 . Install transmission bearing housing. a. Remove detent screw (1), detent arm (2), sleeve (3) and
detent spring (4).
a. Install screws (1).
b. Discard detent screw.
b. See Figure 5-45. Tighten in sequence to 22-25 ft-lbs
(29.8-33.9 N-m). '

94000936 5-39
 NOTE
Mark parts so they can be installed in same direction as
removed.

6. See Figure 5-49. Remove mainshaft and countershaft

locknuts.
a. Lock two gears in place using dog rings.
b. Temporarily put transmission assembly into transmission
case.
c. Remove locknuts.
d. Remove transmission assembly from transmission case.
1. Mainshaft
1019459

1. B
2. L
3. L
4. S

Figure 5-4

2. Countershaft
3. Mainshaft first gear
4. Mainshaft second gear
5. Mainshaft third gear
6. Mainshaft fourth gear
7. Mainshaft fifth gear
8. Countershaft first gear
9. Countershaft second gear
10.Countershaft third gear
11.Countershaft fourth gear
12.Countershaft fifth gear
13.Countershaft sixth gear
14.Screw extractor
Figure 5-46. Gear Set

94000936
5-40
Remove Mainshaft
NOTE
■ The mainshaft fourth gear, third gear, second gear and first
gear are integral parts of the shaft. Damage to any gear
requires mainshaft replacement.
• Always replace bearing housing bearings.

1. See Figure 5-50. Using 714 (OTC HORSESHOE LOCK Remove Countershaft
RING PLIERS,), remove retaining ring.
NOTE
2. Remove dog ring (3), guiding hub (2), mainshaft fifth gear (4)
Do not press directly on the end of the countershaft. Place a
and bearing.
spacer between the end of the countershaft and the press
NOTE ram.
Do not press directly on the end of the mainshaft. Use a
spacer between the end of the mainshaft and the press ram. 1. If mainshaft is not removed, hold countershaft third and
fourth gear shift dog up while removing countershaft.
3. Press mainshaft out of bearing housing bearing. 2. Press countershaft out of bearing housing bearing.
4. Replace bearing housing bearing. See procedure later in this
3. See Figure 5-51. Remove washer (1), countershaft first gear
section.
(2) and bearing.
4. Remove countershaft second, third and forth gears.
a. See Figure 5-52. Remove dog ring (5).
b. Remove lock ring (1 ).
c. Remove securing segments (2).
d. Remove guiding hub (3), countershaft second gear (4)
and bearing.
e. See Figure 5-53 and Figure 5-54. Repeat steps with third
and fourth gears.
NOTE
The countershaft fifth gear and sixth gear are integral parts
of the shaft. Damage to either gear requires countershaft
replacement.

5. Replace bearing housing bearing. See procedure later in this

section.

94000936 5-41
 1. Lock ring
2. Securing segment (2)
3. Internal spline washer
4. Countershaft third gear
Figure 5-53. Countershaft Third Gear

1. Lock ring
2. Securing segment (2) (not visible)
3. Guiding hub
1. Lock ring 4. Countershaft fourth gear
2. Securing segment (2) 5. Dog ring _________________________________
3. Guiding hub Figure 5-54. Countershaft Fourth Gear
4. Countershaft second gear
5. Dog ring __________________________ Remove Bearing Housing Bearings
Figure 5-52. Countershaft Second Gear NOTE
Always replace bearing housing bearing if the shaft is
pressed out.

1. See Figure 5-55. Remove the retaining rings (2). Discard

retaining rings.
2. Press the bearings out of the bearing housing.

5-42 94000936
CLEAN AND INSPECT

A WARNING
ASSEMBLE
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear safety FASTENER TORQUE VALUE
glasses when working with compressed air. Never use your hand Shift drum detent screw 120-150 in-lbs 13.6-17 N-m
to check for air leaks or to determine air flow rates. (00061a) Shift drum lock plate screws 57-63 in-lbs 6.4-7.1 N-m
Transmission mainshaft/coun- 85-95 ft-lbs 115.3-128.8Nm
1. Clean parts in a non-volatile cleaning solution. Dry parts with
tershaft locknuts
low-pressure, compressed air.
Install Bearing Housing Bearings
2. Replace gears that are worn or damaged.
NOTE
3. Replace the dog rings if dogs and/or pockets are rounded,
battered or chipped. • Always replace bearing housing bearing if the shaft was
removed.
4. Replace guiding hubs if splines are rounded, battered or
chipped. • Always support the bearing housing with a plate when
pressing bearings.
5. Replace shift fork shafts if bent or damaged.
• Press on the bearing outer race.
6. Replace a shift fork if it is excessively worn or shows signs of
overheating.
1. Install bearings.
7. See Figure 5-56. Using a small square, verify that the shift
forks are square. Replace shift fork if not square. a. Support the bearing housing at the bearing bores with
a flat plate.
8. Replace shift drum assembly if drum or bearing are
damaged.
b. Position new bearing over bore with number side up.
9. Clean shift cam lock plate mounting holes in transmission
bearing housing. c. Press the bearing until seated in the bore.

A WARNING

Wear safety glasses or goggles when removing or installing

retaining rings. Retaining rings can slip from the pliers and could
be propelled with enough force to cause serious eye injury.
(00312a)

2. See Figure 5-55 . Install new beveled retaining ring (1) with
the flat side against the bearing.

94000936 5-43
Install Countershaft
1. Install fourth, third and second gears on countershaft.

a. See Figure 5-54 . Install countershaft fourth gear (4).

b. Lubricate needle bearings and races with SCREAMIN'
EAGLE ASSEMBLY LUBE.
c. Install new needle bearing.
d. Install guiding hub (3).
e. Install dog ring (5).
f. Install securing segments (2) with the rounded edge
facing up. Verify that segments fully engage grooves in
countershaft.
g. Install lock ring (1) with waved, stepped face toward the
securing segments.
h. See Figure 5-53 . Install countershaft third gear (4).
NOTE
Install the second gear guiding hub with the deeper
counterbore facing countershaft second gear.

i. See Figure 5-52 . Install countershaft second gear (4).

2. See Figure 5-57. Preload scissor first gear.

Install Mainshaft
a. While holding thick gear, rotate thin gear until holes align.
NOTE
b. Install HD-52235 (SCISSOR FIRST GEAR TOOL). Failure to press on bearing inner race damages the bearing.

3. See Figure 5-51 . Install new needle bearing, countershaft

first gear (2) and washer (1). 1. Support mainshaft fourth gear in press.

NOTE 2. See Figure 5-59. Raise and hold dog ring engaged with
• If installing countershaft with mainshaft installed, raise countershaft third gear during the press procedure.
and hold countershaft third and fourth gear shift dog up
while pressing bearing housing bearing on to 3. Using a suitable sleeve, press on bearing inner race until
countershaft. bearing contacts mainshaft first gear.
• Failure to press on bearing inner race damages the
bearing. 4. See Figure 5-50 . With bearing housing on end (shafts
pointing up), install new bearing and mainshaft fifth gear (4).
4. See Figure 5-59. If mainshaft is not removed, raise and hold
countershaft third and fourth gear shift dog while installing 5. With guiding hub counterbore facing mainshaft fifth gear,
countershaft. install guiding hub (2) and dog ring (3).
5. See Figure 5-58. Install countershaft to bearing housing.
6. Install new retaining ring using 714 (OTC HORSESHOE
a. Support countershaft sixth gear in press.
LOCK RING PLIERS,) (1).
b. Using a suitable sleeve, press on bearing inner race until
bearing contacts countershaft first gear washer. 7. Remove holding tool from scissor first gear.

8. Install new mainshaft and countershaft locknuts.

a. Using dog rings, lock two gears in place.

b. Temporarily install transmission assembly in
transmission case.

c. Install locknuts. lighten to 85-95 ft-lbs

(115.3-128.8 N-m).

d. Remove transmission assembly from transmission

case.

5-44 94000936
 7. Install short shift shaft (4): a. Insert shifter fork (6) into the
dog ring between countershaft third and fourth gear.

b. Insert shifter fork (9) into the dog ring between countershaft
first and second gear.

c. Slide shift shaft through shifter forks.

d. Install shaft in bearing housing.

Figure 5-59. Raise and Hold Dog Ring

Install Shifter Cam/Shifter Forks
1. Set bearing housing on bench with shafts pointing up.

2. Install detent arm assembly, if removed.

a. See Figure 5-60. Clean detent screw mounting hole in

transmission bearing housing. 1. Detent screw
2. Detent arm
b. Assemble new detent screw (1), detent arm (2),
3. Sleeve
sleeve (3) and detent spring (4).
4. Detent spring
c. Align spring and detent arm as shown.

d. Install detent assembly in bearing housing with screw

(1).

e. Tighten.

Torque: 120-150 in-lbs (13.6-17 N-m) Shift drum

detent screw
Torque: 120-150 in-lbs (13.6-17 N-m) Shift drum
detent screw

3. See Figure 5-61. Hold detent arm back and install shift cam
assembly (4).

4. Install lock plate (2) and new lock plate screws (3). Tighten..
Torque: 57-63 in-lbs (6.4-7.1 N-m) Shift drum lock plate
screws
Torque: 57-63 in-lbs (6.4-7.1 N-m) Shift drum lock plate
screws

5. Remove any burrs created on shift shafts (1, 3) during

removal.

NOTE
See Figure 5-62. The shifter forks are unique and identified
Figure 5-61. Shift Drum
as shown.

6. See Figure 5-63. Install long shift shaft (1 ):

a. Insert shifter fork (2) into the dog ring between

mainshaft fifth and sixth gear.

b. Slide shift shaft through shifter fork.

c. Install shaft in hole in bearing housing.

94000936 5-45
 1021279

SB 1. Long shift shaft

1. Long shift shaft 2. Fifth and sixth gear shifter fork
2. Fifth and sixth gear shifter fork 3. Mainshaft fifth gear
3. Short shift shaft 4. Short shift shaft
4. Third and fourth gear shifter fork 5. Countershaft fifth gear
5. First and second gear shifter fork 6. Third and fourth gear shifter fork
Figure 5-62. Shifter Forks and Shafts 7. Third gear
8. Second gear
9. First and second gear shifter fork
10. First gear
Figure 5-63. Transmission Gears and Shifter Forks
COMPLETE

1. Install transmission mainshaft bearing inner race. See

Mainshaft Bearing Inner Race (Page 5-29).

2. Install clutch release cover. See CLUTCH RELEASE

COVER (Page 5-12).

3. Fill transmission oil. See REPLACE TRANSMISSION

LUBRICANT (Page 2-11).
4. Install engine oil fill spout. See ENGINE OIL FILL SPOUT
(Page 5-31).
5. Fill engine oil. See REPLACE ENGINE OIL AND FILTER
(Page 2-7).

6. Install exhaust system. See EXHAUST SYSTEM (Page 6-

36).
7. Install primary chaincase housing. See PRIMARY
CHAINCASE HOUSING (Page 5-27).
8. Install the primary chain, clutch, compensating sprocket and
chain tensioner. See DRIVE COMPONENTS (Page 5-18).
9. Install starter. See STARTER (Page 7-9).
10. Install primary chaincase cover. See PRIMARY
CHAINCASE COVER (Page 5-17).
11. Fill primary chaincase oil. See REPLACE PRIMARY
CHAINCASE LUBRICANT (Page 2-9).

5-46 94000936
12. Mid-mount controls: Install foot shift lever. See SHIFTER
LINKAGE (Page 5-9).
13. Install rider left footboard and bracket, if removed. See LEFT
FOOT CONTROLS (Page 3-128).
14. Adjust drive belt deflection. See INSPECT AND ADJUST
DRIVE BELT AND SPROCKETS (Page 2-31).
15. Verify rear fork pivot shaft torque. See REAR FORK (Page
3-81).
16. Connect negative battery cable. See POWER
DISCONNECT (Page 7-7).

94000936 5-47
MAIN DRIVE GEAR AND BEARING 5.15

PREPARE

A WARNING
To prevent accidental vehicle start-up, which could cause death
or serious injury, disconnect negative (-) battery cable before
proceeding. (00048a)

1. Disconnect negative battery cable. See POWER

DISCONNECT (Page 7-7).
2. Remove rider footboard and bracket, if needed. See LEFT
FOOT CONTROLS (Page 3-128).
3. Mid-mount controls: Remove foot shift lever. See SHIFTER
LINKAGE (Page 5-9).

4. Drain primary chaincase oil. See REPLACE PRIMARY

CHAINCASE LUBRICANT (Page 2-9).
5. Remove primary chaincase cover. See PRIMARY
CHAINCASE COVER (Page 5-17).
6. Remove starter. See STARTER (Page 7-9).
7. Remove primary chain, clutch and compensating sprocket.
See DRIVE COMPONENTS (Page 5-18).
8. Remove primary chaincase housing. See PRIMARY
CHAINCASE HOUSING (Page 5-27).
2. Screw (2)
9. Remove bearing inner race from transmission mainshaft. 3. 12-in bolt
See Mainshaft Bearing Inner Race (Page 5-29). 4. Main drive gear
5. Washer
10. Remove transmission sprocket. See TRANSMISSION
6. Bearing
SPROCKET (Page 5-32).
7. Nut
11. Remove transmission bearing housing and gear assembly. Figure 5-64. Removing Main Drive Gear
See TRANSMISSION (Page 5-35).

REMOVE

PART NUMBER TOOLNAME

HD-35316-D MAIN DRIVE GEAR REMOVER AND
INSTALLER SET
NOTICE

Failure to use Main Drive Gear Remover and Installer can cause
premature failure of bearing and related parts. (00540b)

NOTE
Main drive gear and bearing can be removed with the
transmission case in the frame after removing bearing
housing.

1. See Figure 5-64. Remove gear using MAIN DRIVE GEAR

REMOVER AND INSTALLER SET (PART NUMBER: HD-
35316-D).
2. Remove tool.
3. Remove large main drive gear oil seal.
4. Remove retaining ring from bearing bore.
5. See Figure 5-65. Remove main drive gear bearing from
transmission case using MAIN DRIVE GEAR REMOVER
AND INSTALLER SET (PART NUMBER: HD-35316-D).
6. Discard main drive gear bearing.

5-48 94000936
 1. 12-in bolt
2. Cross plate
3. Screw (2)
4. Main drive gear bearing
5. Bearing driver
6. Bearing
7. Nut _ ____________________ __
CLEAN AND INSPECT Figure 5-66. Installing Main Drive Gear Bearing (Typical)
2. See Figure 5-67. Install new O-ring (4) onto main drive gear
NOTE (3). Lubricate O-ring with clean engine oil.
Never wash the transmission case and needle bearings with 3. Install main drive gear using MAIN DRIVE GEAR
solvent unless replacing the needle bearings. Normal REMOVER AND INSTALLER SET (PART NUMBER: HD-
cleaning methods wash dirt or other contaminants into the 35316-D).
bearing case (behind the needles) and leads to bearing
failure. NOTE
See Figure 5-68. Install retaining ring with the flat side facing
1. Clean all parts in solvent except the transmission case and the bearing and the opening within the range shown.
needle bearings. Dry parts with low-pressure, compressed
air. 4. Install new retaining ring.

2. Inspect the main drive gear for pitting and wear.

3. Inspect the needle bearings inside the main drive gear.
4. Inspect mainshaft race. Replace the needle bearings if the
mainshaft race is damaged.

INSTALL

PART NUMBER TOOLNAME

HD-35316-D MAIN DRIVE GEAR REMOVER AND
INSTALLER SET
HD-47856 MAIN DRIVE GEAR SEAL INSTALLER
KIT
NOTICE

Improper tightening of sprocket nut can cause drive

component damage. (00541b)

1. See Figure 5-66. Install main drive gear bearing using MAIN
DRIVE GEAR REMOVER AND INSTALLER SET (PART
NUMBER: HD-35316-D).

94000936 5-49
 Figure
1. 5-69. Press
Crow's Seal
foot into Crankcase
wrench
2. Breaker bar
3. Adjustable wrench

1. 8-in bolt
2. Washer REPLACE NEEDLE BEARINGS
3. Main drive
gear PART NUMBER TOOL NAME
4. O-ring HD-47932 MAIN DRIVE GEAR BEARING AND SEAL
5. Installer cup INSTALLATION TOOL
6. Bearing
7. Nut
Figure 5-67. Installing Main Drive Gear (Typical) NOTE
See Figure 5-71. When replacing needle bearings, replace
retaining rings (1) with new retaining rings (2).

1. See Figure 5-70. Remove mainshaft seal (7).

2. Remove retaining rings (1 ), needle bearings (2, 6) and
spacer (5) from main drive gear (3). Discard retaining rings.
3. Discard O-ring (4).

Figure 5-68. Retaining Ring Opening

5. See Figure 5-69. Install new main drive gear large seal using
MAIN DRIVE GEAR SEAL INSTALLER KIT (PART
NUMBER: HD-47856).

1. Retaining ring (2)

2. Inner needle bearing
3. Main drive gear
4. O-ring
5. Spacer
6. Outer needle bearing
7. Mainshaft seal
Figure 5-70. Main Drive Gear Assembly

5-50 94000936
 sm03044

Figure 5-71. Main Drive Gear Retaining Rings

Figure 5-73. Pressing in Seal

Figure 5-74. Installing Inner Needle Bearing in Main Drive

Gear

REPLACE MAINSHAFT SEAL

Figure 5-72. Installing Outer Needle Bearing in Main Drive
Gear
PART NUMBER TOOL NAME
NOTE
HD-47933 MAIN DRIVE GEAR SEAL INSTALLER
4. See Figure 5-72. Use MAIN DRIVE GEAR BEARING AND
SEAL INSTALLATION TOOL (PART NUMBER: HD-47932) See Figure 5-75. Use the MAIN DRIVE GEAR SEAL INSTALLER
to install outer needle bearing. Press until tool contacts (PART NUMBER: HD-47933) to replace the mainshaft seal while
gear. the main drive gear is installed.
The mainshaft seal can also be installed after the main drive
gear is installed. See Replace Mainshaft Seal (Page 5-48).

5. See Figure 5-73. Install mainshaft seal with garter spring

side down.
a. Use the 0.090-in step of MAIN DRIVE GEAR BEARING
AND SEAL INSTALLATION TOOL (PART NUMBER:
HD-47932).
b. Press until tool contacts gear.

6. See Figure 5-70. Turn over the main drive gear. Install
spacer (5).
7. See Figure 5-74. Use MAIN DRIVE GEAR BEARING AND
SEAL INSTALLATION TOOL (PART NUMBER: HD-47932) 1. Remove the seal using a seal remover or rolling head pry bar.
to press inner needle bearing until tool contacts gear.
8. See Figure 5-70. Install new retaining rings (1).
2. Verify that bore is clean and smooth.
9. Install new O-ring (4).

94000936 5-51
3. See Figure 5-76. Place the seal protector sleeve (1) of MAIN 8. Fill primary chaincase oil. See REPLACE PRIMARY
DRIVE GEAR SEAL INSTALLER (PART NUMBER: HD- CHAINCASE LUBRICANT (Page 2-9).
47933) over the end of the mainshaft.
9. Mid-mount controls: Install foot shift lever. See SHIFTER
4. Lightly lubricate the protector sleeve and seal ID with clean LINKAGE (Page 5-9).
transmission oil.
10. Install rider left footboard and bracket, if removed. See LEFT
5. Slide the seal (2) on the seal protector sleeve with the garter FOOT CONTROLS (Page 3-128).
spring facing the bearing.
11. Adjust drive belt deflection. See INSPECT AND ADJUST
6. See Figure 5-77. Hand press seal onto place until seal driver DRIVE BELT AND SPROCKETS (Page 2-31).
contacts end of main drive gear using MAIN DRIVE GEAR 12. Verify rear fork pivot shaft torque. See REAR FORK (Page
SEAL INSTALLER (PART NUMBER: HD-47933). Lightly tap 3-81).
with a rubber mallet if necessary.
13. Connect negative battery cable. See POWER
DISCONNECT (Page 7-7).

Figure 5-77. Seal Driver

COMPLETE

1. Install bearing housing and gear assembly. See

TRANSMISSION (Page 5-35).
2. Install transmission sprocket. See TRANSMISSION
SPROCKET (Page 5-32).
3. Install bearing inner race to transmission malnshaft. See
Mainshaft Bearing Inner Race (Page 5-29).
4. Install primary chaincase housing. See PRIMARY
CHAINCASE HOUSING (Page 5-27).
5. Install the primary chain, clutch, compensating sprocket and
chain tensioner. See DRIVE COMPONENTS (Page 5-18).
6. Install starter. See STARTER (Page 7-9).
7. Install primary chaincase cover and new gasket. See
PRIMARY CHAINCASE COVER (Page 5-17).

5-52 94000936
TRANSMISSION CASE 5.16

PREPARE NOTICE
When lifting a motorcycle using a jack, be sure jack contacts
A WARNING both lower frame tubes where down tubes and lower frame
tubes converge. Never lift by jacking on cross-members, oil
Disconnect negative (-) battery cable first. If positive (+) pan, mounting brackets, components or housings. Failure to
cable should contact ground with negative (-) cable comply can cause serious damage resulting in the need to
connected, the resulting sparks can cause a battery perform major repair work. (00586d)
explosion, which could result in death or serious injury.
(00049a)
19. Position jack across lower frame to support rear of
motorcycle. Slide wooden blocks beneath the crankcase to
1. Remove battery. See INSPECT BATTERY (Page 2-43). support the weight of the engine and transmission
assembly.
2. Remove battery tray. See BATTERY TRAY (Page 7-97).
20. Remove rear fork. See REAR FORK (Page 3-81).
3. Drain engine oil. See REPLACE ENGINE OIL AND FILTER
(Page 2-7). 21. Disconnect vehicle speed sensor (VSS). See VEHICLE
SPEED SENSOR (VSS) (Page 7-83).
4. Drain transmission oil. See REPLACE TRANSMISSION
LUBRICANT (Page 2-11). 22. Disconnect neutral switch. See NEUTRAL INDICATOR
SWITCH (Page 7-29).
5. Drain primary chaincase oil. See REPLACE PRIMARY
CHAINCASE LUBRICANT (Page 2-9). REMOVE _______________________________
6. See Figure 5-78. Disconnect oil return line (1).
1. Remove battery negative cable from ground post at top of
transmission case.
7. Remove exhaust system. See EXHAUST SYSTEM (Page 6-
36). 2. Move aside the harness that terminates at the 02 sensor,
starter solenoid, neutral switch and VSS.
8. Remove clutch release cover. See CLUTCH RELEASE 3. Remove transmission shift lever.
COVER (Page 5-12).
a. Mark splines on transmission shift lever and shift shaft to
help with assembly.
9. Remove screw securing jiffy stand sensor, if equipped. See
JIFFY STAND SENSOR (JSS) (Page 7-86). b. Remove pinch screw.
c. Pull lever from shaft.
10. Remove rider footboard and bracket, if needed. See LEFT
FOOT CONTROLS (Page 3-128). 4. In a cross-wise pattern, remove four bolts securing
transmission to engine.
11. Mid-mount controls: Remove foot shift lever. See
SHIFTER LINKAGE (Page 5-9). NOTE
See Figure 5-79. Do not use a hammer to remove
12. Remove primary chaincase cover. See PRIMARY transmission. If the transmission sticks or binds on the ring
CHAINCASE COVER (Page 5-17). dowels, gently pry away from crankcase using the pry point.

13. Remove starter. See STARTER (Page 7-9). 5. Move transmission rearward until two ring dowels in lower
flange are free of crankcase.
14. Remove primary chain, clutch and compensating sprocket. 6. Remove transmission case from rear of the motorcycle.
See DRIVE COMPONENTS (Page 5-18).

15. Remove primary chaincase housing. See PRIMARY

CHAINCASE HOUSING (Page 5-27).

16. Loosen drive belt. See INSPECT AND ADJUST DRIVE

BELT AND SPROCKETS (Page 2-31).

17. Remove transmission assembly. See TRANSMISSION

(Page 5-35).

18. Remove oil pan. See OIL PAN (Page 4-77).

94000936 5-53
 5. Secure transmission.

a. Install shorter bolts at the top, longer bolts at the

bottom. Hand-tighten bolts.

b. See Figure 5-80. Tighten bolts in the sequence shown

to.
Torque: 15 ft-lbs (20.3 N-m) Transmission mounting
bolts, 1st torque
c. Tighten to the final torque in the same sequence.
Torque: 34-39 ft-lbs (46.1-52.9 N-m) Transmission
mounting bolts, final torque
6. Secure battery ground cable to ground post at top of
transmission case. Tighten to.
Torque: 66-114 in-lbs (7.5-12.9 N-m) Battery ground cable
to transmission

1. Oil return line

2. Clamp
3. Oil return tube
Figure 5-78. Oil Return Line

Figure 5-80. Transmission Housing to Crankcase Tightening

Sequence
DISASSEMBLE ______________

INSTALL
FASTENER TORQUE VALUE
Remove Shifter Pawl Lever
Battery ground cable to trans- 66-114 in-lbs 7.5-12.9 N-m
mission 1. See Figure 5-82 . Remove shifter rod lever.

Transmission mounting bolts, 15 ft-lbs 20.3 N-m a. Remove pinch screw (8).
1st torque b. Remove shifter rod lever (9) from the shifter pawl lever
Transmission mounting bolts, 34-39 ft-lbs 46.1-52.9 N-m assembly (1 ).
final torque
2. Remove shifter pawl assembly.
1. Install new ground post at top of transmission case. Tighten
ground post until snug. a. Remove retaining ring (7), washer (6) and seal (5).

NOTE b. Discard retaining ring and seal.

A new transmission case has the shifter shaft sleeve c. Remove shifter pawl lever assembly.
and seal, centering screw, countershaft needle bearing
and main drive gear bearing and seal installed. 3. Inspect sleeve (2) in transmission case.

2. Wipe all engine oil from pockets in crankcase flange. Remove Oil Return Tube
1. If transmission case is installed in vehicle:
3. Install new engine-to-transmission gasket.
a. Disconnect battery.
b. See Figure 5-78. Disconnect oil return hose (1) from
4. Verify that transmission dowels are seated. Place
return tube (3).
transmission case into position.

2. See Figure 5-81.. Remove screws (2, 4).

5-54 94000936
3. Remove oil return tube (1).

ASSEMBLE

PART NUMBER TOOLNAME

HD-51337 SHIFTER SHAFT SEAL INSTALLATION
CLEAN AND INSPECT TOOL

FASTENER TORQUE VALUE

A WARNING
Oil return tube screw 100-120 in-lbs 11.3-13.6 N-m
Compressed air can pierce the skin and flying debris from Shifter pawl centering screw 18-23 ft-lbs 24.4-31.2 N-m
compressed air could cause serious eye injury. Wear safety
Shifter rod lever pinch screw, 18-22 ft-lbs 24.4-29.8 N-m
glasses when working with compressed air. Never use your hand
to check for air leaks or to determine air flow rates. (00061 a) transmission lever

NOTE
Install Oil Return Tube
Never wash the transmission case and needle bearings with 1. See Figure 5-81. Install new O-ring on lower oil tube
solvent. Normal cleaning methods wash dirt or other adapter.
contaminants into the bearing case (behind the needles)
leading to bearing failure. 2. Install oil return tube (1).

1. Clean all parts in solvent except the case and main drive a. Locate oil return tube between shift lever (3) and
gear needle bearings. Dry parts with low-pressure, transmission housing.
compressed air.
3. Install screws (2, 4). a. Tighten.
2. See Figure 5-82. Inspect the shifter pawl lever assembly (1)
for wear. Replace assembly if pawl ends are damaged. Torque: 100-120 in-lbs (11.3-13.6 N-m) Oil return
Replace centering spring (3) if elongated. tube screw

3. Inspect the shifter shaft lever spring (4). Replace if the 4. If transmission case is installed in vehicle:
spring fails to hold the pawl on the cam pins.
a. See Figure 5-78. Connect oil return hose (1) to return
4. Thoroughly clean the oil pan. tube (3). Secure with clamp (2).
5. Inspect transmission top cover vent hose for damage. Verify
that hose and fitting are unobstructed. b. Connect battery.

94000936 5-55
 5. Check engine oil level after running engine.
sm03067a

Replace Countershaft Needle Bearing

1. Press or drive out bearing using a bearing driver 1.25 in
(31.75 mm) in diameter.

2. Install new bearing.

a. From the outside of the transmission case, place the
bearing on the bearing bore.
b. Install the bearing flush or to a maximum depth of 0.030
in (0.76 mm) with the outside surface of the case.

3. Lubricate the bearing with SCREAMIN' EAGLE ASSEMBLY

LUBE.
1.
Install Shifter Pawl Lever 2.
3.
1. See Figure 5-82 . Verify that sleeve (2) is in transmission
4.
case bore.

2. Install screw (10) into side of transmission case. Tighten.

Torque: 18-23 ft-lbs (24.4-31.2 N-m) Shifter pawl centering
screw
3. See Figure 5-83. Assemble shifter arm.

a. Slide shifter lever centering spring (2) over shaft of

shifter pawl lever assembly (3).

b. Align opening on spring with tab on lever.

c. Place shifter shaft lever spring (4) on shifter pawl lever

assembly. Flex spring only enough to assemble.

4. See Figure 5-84. Insert the shifter arm assembly into the
transmission case.

5. See Figure 5-85. Verify that pin of screw sits inside shifter
shaft lever spring.

6. Install new seal with garter spring facing the transmission. Figure 5-8

a. Drive the seal until the tool bottoms on the transmission

case.
Special Tool: SHIFTER SHAFT SEAL
INSTALLATION TOOL (HD-51337)
7. See Figure 5-84. Install washer (1) and new retaining ring
(2).

NOTE
Install shifter rod lever one spline from vertical toward front
of vehicle.

8. See Figure 5-82 . Install shifter rod lever (9).

a. Install pinch screw (8).

b. Tighten to 18-22 ft-lbs (24.4-29.8 N-m).

5-56 94000936
 COMPLETE ____________________________

1. Install neutral switch. See NEUTRAL INDICATOR SWITCH

(Page 7-29).

2. Install VSS. See VEHICLE SPEED SENSOR (VSS) (Page

7-83).

3. Install rear fork. See REAR FORK (Page 3-81).

4. Install oil pan. See OIL PAN (Page 4-77).

5. Install transmission. See TRANSMISSION (Page 5-35).

6. Install primary chaincase housing. See PRIMARY
CHAINCASE HOUSING (Page 5-27).

7. Install primary chain, clutch and compensating sprocket.

See DRIVE COMPONENTS (Page 5-18).

8. See Figure 5-78. Connect oil return line (1).

9. Install starter. See STARTER (Page 7-9).

10. Install primary chaincase cover and new gasket. See

PRIMARY CHAINCASE COVER (Page 5-17).

11. Mid-mount controls: Install foot shift lever. See SHIFTER

LINKAGE (Page 5-9).
12. Install rider footboard and bracket, if removed. See LEFT
FOOT CONTROLS (Page 3-128).

13. Install transmission shift linkage. See SHIFTER LINKAGE

(Page 5-9).

14. Install jiffy stand sensor, if removed. See JIFFY STAND

SENSOR (JSS) (Page 7-86).

15. Install clutch release cover. See CLUTCH RELEASE

COVER (Page 5-12).

16. Install exhaust system. See EXHAUST SYSTEM (Page 6-

36).

17. Fill primary chaincase. See REPLACE PRIMARY

CHAINCASE LUBRICANT (Page 2-9).

18. Fill transmission. See REPLACE TRANSMISSION

LUBRICANT (Page 2-11).

19. Fill engine oil. See REPLACE ENGINE OIL AND FILTER
(Page 2-7).

20. Adjust drive belt deflection. See INSPECT AND ADJUST

DRIVE BELT AND SPROCKETS (Page 2-31).

21. Install battery tray. See BATTERY TRAY (Page 7-97).

22. Install battery. See INSPECT BATTERY (Page 2-43).

94000936 5-57
SUBJECT PAGE NO.
6.1 FASTENER TORQUE VALUES ................................................................................................. 6-1
6.2 SPECIFICATIONS ..................................................................................................................... 6-3
6.3 AIR CLEANER BACKPLATE ASSEMBLY ................................................................................. 6-4
6.4 CONSOLE ................................................................................................................................. 6-8
6.5 FUEL PRESSURE TEST ......................................................................................................... 6-11
6.6 PURGE FUEL LINE ................................................................................................................. 6-12
6.7 FUEL LINE .............................................................................................................................. 6-13
6.8 FUEL TANK ............................................................................................................................ 6-14
6.9 FUEL PUMP ............................................................................................................................ 6-16
6.10 VENT TUBE .......................................................................................................................... 6-20
6.11 VAPOR VALVE ..................................................................................................................... 6-22
6.12 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE (TMAP) SENSOR ........................... 6-23
6.13 TWIST GRIP SENSOR (TGS) ............................................................................................... 6-24
6.14 FUEL INJECTORS ................................................................................................................ 6-26
6.15 INDUCTION MODULE .......................................................................................................... 6-27
6.16 INTAKE LEAK TEST ............................................................................................................. 6-31
6.17 HEATED OXYGEN SENSORS (HO2S) ................................................................................ 6-32
6.18 MUFFLERS ........................................................................................................................... 6-34
6.19 EXHAUST SYSTEM .............................................................................................................. 6-36
6.20 PURGE SOLENOID: EVAPORATIVE EMISSIONS ............................................................... 6-43
6.21 CHARCOAL CANISTER: EVAPORATIVE EMISSIONS ........................................................ 6-44
6.22 PURGE LINES: EVAPORATIVE EMISSIONS ....................................................................... 6-45

FUEL AND EXHAUST

NOTES
FASTENER TORQUE VALUES 6.1

FASTENER TORQUE VALUES IN THIS

CHAPTER _________________________
FASTENER TORQUE VALUE NOTES
Air filter element screws, round 48-72 in-lbs 5.4--8.1 N-m 6.3 AIR CLEANER BACKPLATE ASSEMBLY,
Remove and Install: Round
Backplate breather screw, cone 22-24 ft-lbs 30-32.5 N-m 6.3 AIR CLEANER BACKPLATE ASSEMBLY,
Remove and Install: Cone
Backplate cover screw, cone 43-53 in-lbs 4.9--6 N-m 6.3 AIR CLEANER BACKPLATE ASSEMBLY,
Remove and Install: Cone
Backplate screws, oval 50-60 in-lbs 5.6--6.8 N-m 6.3 AIR CLEANER BACKPLATE ASSEMBLY,
Remove and Install: Oval
Backplate to throttle body screw, cone 55--60 in-lbs 6.2-6.8 N-m 6.3 AIR CLEANER BACKPLATE ASSEMBLY,
Remove and Install: Cone
Breather bolts, oval 22-24 ft-lbs 29.8-32.5 N-m 6.3 AIR CLEANER BACKPLATE ASSEMBLY,
Remove and Install: Oval
metric
Breather bolts, round 22-24 ft-lbs 29.8-32.5 N-m 6.3 AIR CLEANER BACKPLATE ASSEMBLY,
Remove and Install: Round
Charcoal canister bracket to engine case 72-96 in-lbs 8.1-10.8 N-m 6.21 CHARCOAL CANISTER: EVAPORATIVE
screws EMISSIONS, Install
Charcoal canister to bracket screws 30-36 in-lbs 3.4-4.1 N-m 6.21 CHARCOAL CANISTER: EVAPORATIVE
EMISSIONS, Install
Console screw, , rear, no instrument 25-30 in-lbs 2.8-3.4 N-m 6.4 CONSOLE, Remove and Install: No Instrument
Console screw, front, no instrument 30-50 in-lbs 3.4-5.6 N-m 6.4 CONSOLE, Remove and Install: No Instrument
Console screw (Front) 30-50 in-lbs 3.4-5.6 N-m 6.4 CONSOLE, Remove and Install: Single Instru-
ment with Panel
Console screw (Rear) 25--30 in-lbs 2.8-3.4 N-m 6.4 CONSOLE, Remove and Install: Single Instru-
ment with Panel
Console screws 40-50 in-lbs 4.5--5.6 N-m 6.4 CONSOLE, Remove and Install: Single lnstru-
ment without Panel
Exhaust bracket screws 40-50 ft-lbs 54.2-67.8 N-m 6.19 EXHAUST SYSTEM, Install
Exhaust shield clamps 20-40 in-lbs 2.3-4.5 N-m 6.19 EXHAUST SYSTEM, Disassemble and As-
semble: Standard
Exhaust shield clamps 20-40 in-lbs 2.3-4.5 N-m 6.19 EXHAUST SYSTEM, Disassemble and As-
semble: Upswept
Exhaust shield clamps 20-40 in-lbs 2.3-4.5 N-m 6.19 EXHAUST SYSTEM, Disassemble and As-
semble: Two Into One
Exhaust shield screws 108-132 in-lbs 12.2-14.9 N-m 6.19 EXHAUST SYSTEM, Disassemble and As-
semble: Upswept
Exhaust support clamp screw 40-50 ft-lbs 54.2--67.8 N-m 6.19 EXHAUST SYSTEM, Install
Exhaust to engine flange nuts 100-120 in-lbs 11.3-13.6 N-m 6.19 EXHAUST SYSTEM, Install
Fuel line to fuel rail screw 22-40 in-lbs 2.5-4.5 N-m 6.7 FUEL LINE, Install
Fuel line to fuel rail screw 22-40 in-lbs 2.5-4.5 N-m 6.15 INDUCTION MODULE, Install
Fuel pump assembly screws 40-45 in-lbs 4.5-5 N-m 6.9 FUEL PUMP, Install
Fuel rail screws 31-49 in-lbs 3.5-5.5 N-m 6.14 FUEL INJECTORS, Install
Fuel tank, vent screws 11-13 ft-lbs 15-18 N-m 6.8 FUEL TANK, Install
Fuel tank mounting screw 28-32 ft-lbs 38-43.4 N-m 6.6 PURGE FUEL LINE, Secure Fuel Tank
Fuel tank mounting screw 28-32 ft-lbs 38-43.4 N-m 6.6 PURGE FUEL LINE, Secure Fuel Tank
HO2S (Heated oxygen sensor) 12-14 ft-lbs 16.3-19 N-m 6.17 HEATED OXYGEN SENSORS (HO2S), Install
HO2S (Heated oxygen sensor) 12-14 ft-lbs 16.3-19 N-m 6.17 HEATED OXYGEN SENSORS (HO2S), Install

94000936 6-1
FASTENER TORQUE VALUE NOTES
Induction module bracket 66-84 in-lbs 7.5-9.5 N-m 6.15 INDUCTION MODULE, Assemble
Induction module flange adapter screws 96-156 in-lbs 10.9-17.6 N-m 6.15 INDUCTION MODULE, Install metric

Induction module flange adapter screws 96-156 in-lbs 10.9-17.6 N-m 6.15 INDUCTION MODULE, Install metric

Intake tube screw, cone 66-72 in-lbs 7.5-8.1 N-m 6.3 AIR CLEANER BACKPLATE ASSEMBLY,
Remove and Install: Cone
Muffler clamp 38-43 ft-lbs 51.5-58.3 N-m 6.18 MUFFLERS, Install
Muffler end cap screws 96-120 in-lbs 10.8-13.6 N-m 6.18 MUFFLERS, Install
Muffler intermediate exhaust shield 108-132 in-lbs 12.2-14.9 N-m 6.19 EXHAUST SYSTEM, Disassemble and As-
screw semble: Two Into One
Muffler screws 120-144 in-lbs 13.6-16.3 N-m 6.18 MUFFLERS, Install
Muffler screws 120-144 in-lbs 13.6-16.3 N-m 6.19 EXHAUST SYSTEM, Install
Muffler shield clamps 20-40 in-lbs 2.3-4.5 N-m 6.19 EXHAUST SYSTEM, Disassemble and As-
semble: Standard
Temperature manifold absolute pressure 23-39 in-lbs 2.5-4.5 N-m 6.12 TEMPERATURE MANIFOLD ABSOLUTE
sensor (TMAP) screw PRESSURE (TMAP) SENSOR, Install
Throttle body to manifold screws 35-53 in-lbs 4-6 N-m 6.15 INDUCTION MODULE, Assemble

6-2 94000936
SPECIFICATIONS 6.2

SPECIFICATIONS
Table 6-1. Capacities
ITEM U.S. L
Sport Glide (FLSB), Fat Boy 114 (FLFBS), Heritage Classic (FLHCS), Low Rider
5.0 gal 18.9
S (FXLRS), Low Rider ST (FXLRST)
Fuel tank (total)
Breakout 114 (FXBRS), Street Bob 114 (FXBBS), Softail Standard (FXST), Fat
3.5 gal 13.25
Bob 114 ( FXFBS)
Low fuel warning light on™ 1.0 gal 3.8
Oil tank with filter™ 5.0 qt 4.73
Transmission (approximate)™ 1.0 qt 0.95
Heritage Classic (FLHCS), Sport Glide (FLSB), Street Bob 114 (FXBBS), Fat Bob
Primary chaincase (approxim- 114 (FXFBS), Low Rider S (FXLRS), Low Rider ST (FXLRST), Softail Standard 1.25 qt 1.18
ate)™ (FXST)
Fat Boy 114 (FLFBS), Breakout 114 (FXBRS) 1.43 qt 1.35
(1) When refilling from empty, add at least 3.8 L (1.0 gal).
(2) When refilling, initially add 3.78 L (4.0 qt) and add as needed to bring level within specification.
(3) When refilling, initially add 0.83 L (28 oz) and add as needed to bring level within specification.
(4) When refilling, initially add 1.06 L (36 oz) and add as needed to bring level within specification.

Table 6-2. Fuel Pump Specifications

MEASUREMENT VALUE
Pressure 54-62 psi (375-425 kPa)
Current draw 7.5A or less

94000936 6-3
AIR CLEANER BACKPLATE ASSEMBLY 6.3

PREPARE CONSUMABLE PART NUMBER

LOCTITE 565 99818-97
1. Remove air cleaner cover and filter. See INSPECT AIR THREAD SEALANT
FILTER (Page 2-40).
Remove
REMOVE AND INSTALL: ROUND 1. See Figure 6-1. Remove breather tube assembly (5) from
breather bolts (6).
FASTENER TORQUE VALUE 2. Remove breather bolts.
Air filter element screws, round 48-72 in-lbs 5.4-8.1 N-m
3. Remove backplate (7).

Breather bolts, round 22-24 ft-lbs 29.8-32.5 N-m 4. Discard seal ring (8).
5. Verify that passages in breather bolts (6) are clear.

1020965

1. Cover screw (1 or 5) 6. Breather bolt (2)

2. Air cleaner cover 7. Backplate
3. Filter screw (3) 8. Seal ring
4. Filter element 9. Rubber seal
5. Breather tube assembly
Figure 6-1. Air Cleaner Assembly

Install 5. Install breather tube assembly (5) to filter element (4).

1. See Figure 6-1. Install new seal ring (8) on backplate (7). 6. Install filter element.
2. Apply thread sealant to threads of breather bolts (6). 7. Install filter element screws (3). Tighten.
Consumable: LOCTITE 565 THREAD SEALANT (99818-97) Torque: 48-72 in-lbs (5.4-8.1 N-m) Air filter element
screws, round
3. Install backplate.
8. Tighten breather bolts.
4. Install breather bolts. Hand tighten.
Torque: 22-24 ft-lbs (29.8-32.5 N-m) Breather bolts, round

6-4 94000936
 CONSUMABLE PART NUMBER
9. Attach breather tube assembly (5) to breather bolts.
LOCTITE 565 99818-97
NOTE
THREAD SEALANT
Failure to connect the breather tubes allows crankcase
vapors to be vented into the atmosphere in violation of Remove
legal emissions standards.
1. See Figure 6-2. Remove breather tubes (1) from breather
bolts (2).
REMOVE AND INSTALL: OVAL 2. Remove breather bolts.
FASTENER TORQUE VALUE 3. Remove backplate screws (5).
Backplate screws, oval 50-60 in-lbs 5.6-6.8 N-m 4. Remove backplate (4).
Breather bolts, oval 22-24 ft-lbs 29.8-32.5 N-m
5. Discard gasket (3).
6. V
erify that passages in breather bolts are clear.
1050318 Breather tube (2)
Breather bolt (2)
Gasket

4. Backplate
5. Backplate screw (3)

Figure 6-2. Air Cleaner Assembly

Install 5. Install backplate screws (5). Tighten.

Torque: 50-60 in-lbs (5.6-6.8 N-m) Backplate screws, oval
1. See Figure 6-2. Install new gasket (3) on backplate (4).
6. Tighten breather bolts.
2. Apply thread sealant to threads of breather bolts (2).
Torque: 22-24 ft-lbs (29.8-32.5 N-m) Breather bolts, oval
Consumable: LOCTITE 565 THREAD SEALANT (99818-97)
7. Install breather tubes (1) onto breather bolts.
3. Install backplate.
NOTE
Failure to connect the breather tubes allows crankcase
4. Install breather bolts. Hand tighten. vapors to be vented into the atmosphere in violation of
legal emissions standards.

94000936 6-5
REMOVE AND INSTALL: CONE c. Install square ring adhesive (5) to backplate (4).

d. Install gasket (8) and backplate (4) to throttle body.

FASTENER TORQUE VALUE
Backplate breather screw, cone 22-24 ft-lbs 30-32.5 N-m e. Install screws (1). Tighten.
Torque: 56-60 in-lbs (6.2-6.8 N-m) Backplate to
Backplate cover screw, cone 43-53 in-lbs 4.9-6 N-m throttle body screw, cone
Backplate to throttle body 55--60 in-lbs 6.2-6.8 N-m
f. Install new O-rings (3).
screw, cone
Intake tube screw, cone 66-72 in-lbs 7.6-8.1 N-m g. Apply threadlocker to breather screws (2). Install and
Remove tighten.

1. Remove intake tube. Torque: 22-24 ft-lbs (30-32.5 N-m) Backplate

breather screw, cone

a. See Figure 6-3. Remove screws (3). 2. Install intake tube.

b. Remove intake tube (2) and gasket (1). Discard a. See Figure 6-3. Install new gasket (1) and intake tube
gasket. (2).

2. Remove backplate. b. Install screws (3). Tighten.

Torque: 66-72 in-lbs (7.5-8.1 N-m) Intake tube screw,
a. See Figure 6-4. Remove breather screws (2) and O- cone
rings (3). Discard O-rings.

b. Remove screws (1), backplate (4) and gasket (8).

c. Remove square ring adhesive (5) from backplate and

discard.

d. Remove short screws (7).

e. Remove cover (6).

Install
1. Install backplate.

a. See Figure 6-4. Position cover (6) on backplate (4).

b. Install short screws (7). Tighten.

Torque: 43-53 in-lbs (4.9-6 N-m) Backplate cover Figure 6-3. Intake Tube
1. Gasket
screw, cone 2. Intake tube
NOTE
3. Screw (3)
Peel adhesive off square ring.

6-6 94000936
 1518397

1. Screw (3) 5. Square ring adhesive (2)

2. Breather screw (2) 6. Cover
3. O-ring (2) 7. Short screw (3)
4. Backplate 8. Gasket

Figure 6-4. Air Cleaner Backplate

COMPLETE

1. Install filter and air cleaner cover. See INSPECT AIR FILTER
(Page 2-40)

94000936 6-7
CONSOLE 6.4

PREPARE

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

2. All but FXFBS: Remove seat. See SEAT (Page 3-142).
REMOVE AND INSTALL: NO INSTRUMENT

FASTENER TORQUE VALUE

Console screw, , rear, no in- 25-30 in-lbs 2.8-3.4 N-m
strument
Console screw, front, no instru- 30-50 in-lbs 3.4-5.6 N-m
ment

Remove
1. Remove console.
a. See Figure 6-5. Remove front screw (2). 1. Medallion
2. Front screw
b. Remove rear screw (4) 3. Console
4. Rear screw
c. Remove console (3).
5. Bracket
6. Hole (2) _______________________
2. Remove medallion. Figure 6-5. Console
REMOVE AND INSTALL: SINGLE INSTRUMENT
a. If removing medallion (1) use holes (6) to aid in WITH PANEL
removal. See MEDALLIONS, BADGES, TANK
EMBLEMS AND ADHESIVE STRIPS (Page 3-156).
FASTENER TORQUE VALUE
Console screw (Front) 30-50 in-lbs 3.4-5.6 N-m
Install
Console screw (Rear) 25-30 in-lbs 2.8-3.4 N-m
1. Install medallion if removed. See MEDALLIONS, BADGES,
TANK EMBLEMS AND ADHESIVE STRIPS (Page 3-156). Remove
1. See Figure 6-6. Detach console.
2. Install console.
a. Remove front screw (1).

a. See Figure 6-5. Align console (3) with bracket (5). b. Remove rear screw (4)
c. Move console (2) rearward.
b. Install front screw (2).
2. See Figure 6-7. Disconnect connector.
c. Install rear screw (4).
a. Remove grommet (4) from backbone (1).
d. Tighten front screw. b. Pull harness (2) from backbone.
Torque: 30-50 in-lbs (3.4-5.6 N-m) Console screw,
front, no instrument NOTE
See the electrical diagnostic manual for the appropriate
e. Tighten rear screw. disassembly procedure for the connector,
Torque: 25-30 in-lbs (2.8-3.4 N-m) Console screw, ,
rear, no instrument c. Disconnect connector (3).

3. Remove console.

Install
1. See Figure 6-7. Connect connector.

a. Connect connector (3).

b. Feed harness (2) into backbone (1).

c. Position grommet (4) into backbone.

6-8 94000936
2. See Figure 6-6. Install console. Remove
1. See Figure 6-8. Detach console.
a. Align console (2) with bracket (3).
a. Remove screws (1 ).
b. Install front screw (1).
b. Move console (2) rearward.
c. Install rear screw (4).
2. See Figure 6-9. Disconnect connector.
d. Tighten front screw. a. Remove grommet (4) from backbone (1 ).
Torque: 30-50 in-lbs (3.4-5.6 N-m) Console screw
(Front) b. Pull harness (2) from backbone.

e. Tighten rear screw. NOTE

See the electrical diagnostic manual for the appropriate
Torque: 25-30 in-lbs (2.8-3.4 N-m) Console screw disassembly procedure for the connector.
(Rear)
c. Disconnect connector (3).

Install
1. See Figure 6-9. Connect connector.

a. Connect connector (3).

b. Feed harness (2) into backbone (1 ).

c. Seat grommet (4) into backbone.

2. See Figure 6-8. Install console.

a. Align console (2) with bracket (3).

b. Install screws (1). Tighten.

Torque: 40-50 in-lbs (4.5-5.6 N-m) Console screws

REMOVE AND INSTALL: SINGLE

INSTRUMENT WITHOUT PANEL

FASTENER TORQUE VALUE

Console screws 40-50 in-lbs 4.5-5.6 N-m

94000936 6-9
 1638092 COMPLETE

1. Backbone
2. Harness
3. Connector
4. Grommet
Figure 6-9. Console Harness

1. All but FXFBS Install Seat. See SEAT (Page 3-142).

2. Install main fuse. See POWER DISCONNECT (Page 7-7).

6-10 94000936
FUEL PRESSURE TEST 6.5
PREPARE 7. Close clear tube bleeder valve.
8. Operate engine at various speeds. Note pressure gauge
A WARNING reading. Compare readings to specifications. Refer to Table
6-2..
Gasoline is extremely flammable and highly explosive. Keep
9. Turn off engine.
gasoline away from ignition sources which could result in death or
serious injury. See the Safety chapter. (00635c) 10. Open clear tube bleeder to remove pressure from fuel
pressure gauge.
11. Remove fuel pressure tester.
1. Remove seat. See SEAT (Page 3-142).

A WARNING

To prevent spray of fuel, purge system of high-pressure fuel

before supply line is disconnected. Gasoline is extremely
flammable and highly explosive, which could result in death or
serious injury. (00275a)

2. Purge fuel system. See PURGE FUEL LINE (Page 6-12).

TEST

PART NUMBER TOOL NAME

HD-41182 FUEL PRESSURE GAUGE
1. See Figure 6-10. Attach valve union (2) on FUEL
PRESSURE GAUGE (PART NUMBER: HD-41182) to
schrader valve (4) on fuel line (3).

2. Close fuel valve (1).

3. Insert clear tube of fuel pressure gauge into a suitable

container. COMPLETE
4. Start engine.
1. Secure fuel tank. See PURGE FUEL LINE (Page 6-12).
5. Open fuel valve. 2. Install seat. See SEAT (Page 3-142).

6. Open clear tube bleeder valve to remove air from fuel

pressure tester.

6-11
94000936
PURGE FUEL LINE 6.6
PREPARE ______________________________ 3. Tighten front fuel tank mounting screw (5) and acorn nut.
Torque: 28-32 ft-lbs (38-43.4 N-m) Fuel tank mounting
1. Remove seat. See SEAT (Page 3-142). screw
LIFT REAR OF FUEL TANK ________________

1. See Figure 6-11. Lift rear of fuel tank.

a. Loosen front fuel tank mounting screw (5).

b. Remove rear fuel tank mounting screw (1), washers (2),

and acorn nut (3).

NOTE
Verify fuel tank or fuel tank console do not contact any
components when lifting.

c. Lift rear of fuel tank.

PURGE _ ___ ________ _ _

1. See Figure 6-12. Disconnect fuel pump connector.

a. Disconnect fuel pump connector. 1. Rear fuel tank mounting screw
2. Washer (4)
2. Purge fuel line. 3. Acorn nut (2)
a. Start engine. 4. Bushing and grommet (4)
5. Front fuel tank mounting screw
b. Allow vehicle to stall. 6. Filler neck ring _____________
c. Operate starter for 3 seconds to remove any remaining
Figure 6-11. Fuel Tank
fuel.

A WARNING

Gasoline is extremely flammable and highly explosive. Keep

gasoline away from ignition sources which could result in death
or serious injury. See the Safety chapter. (00635c)

A WARNING

To prevent spray of fuel, purge system of high-pressure fuel

before supply line is disconnected. Gasoline is extremely
flammable and highly explosive, which could result in death or
serious injury. (00275a)

SECURE FUEL TANK ____________________

FASTENER TORQUE VALUE Figure 6-12. Fuel Pump Connector
Fuel tank mounting screw 28-32 ft-lbs 38-43.4 N-m COMPLETE _ _ _________ _______
1. See Figure 6-12. Connect fuel pump connector.

1. Install seat. See SEAT (Page 3-142).

2. See Figure 6-11. Install rear fuel tank mounting screw (1) ,
washers (2), and acorn nut (3). Tighten.
Torque: 28-32 ft-lbs (38--43.4 N-m) Fuel tank mounting
screw

6-12 94000936
FUEL LINE 6.7
PREPARE b. Connect fuel line (2) to quick disconnect fitting.

A WARNING c. Release sleeve of quick disconnect fitting to secure

fuel line.
Gasoline is extremely flammable and highly explosive. Keep
gasoline away from ignition sources which could result in death
or serious injury. See the Safety chapter. (00635c)

1. Remove seat. See SEAT (Page 3-142).

A WARNING

To prevent spray of fuel, purge system of high-pressure fuel

before supply line is disconnected. Gasoline is extremely
flammable and highly explosive, which could result in death or
serious injury. (00275a)

2. Purge fuel system. See PURGE FUEL LINE (Page 6-12).

3. Remove main fuse. See POWER DISCONNECT (Page 7-7).

4. Remove air cleaner. See INSPECT AIR FILTER (Page 2-

40).

5. Remove air cleaner backplate assembly. See AIR

CLEANER BACKPLATE ASSEMBLY (Page 6-4).

REMOVE ______________________

Remove
1. See Figure 6-14 Disconnect fuel line from fuel tank.
a. Push up on sleeve of quick disconnect fitting (1).
b. Remove fuel line (2) from quick disconnect fitting.

2. See Figure 6-13 Disconnect fuel line from fuel rail.

a. Remove screw (2).

b. Pull fuel line (1) away from fuel rail (3).
c. Inspect O-ring (4) for damage. replace as necessary.

FASTENER TORQUE VALUE

Fuel line to fuel rail screw 22-40 in-lbs 2.5-4.5 N-m
COMPLETE
1. Secure fuel tank. See PURGE FUEL LINE (Page 6-12).
1. See Figure 6-13. Install fuel line to fuel rail.
2. Install seat. See SEAT (Page 3-142).
INSTALL ______________________________
3. Install air cleaner backplate assembly. See AIR CLEANER
BACKPLATE ASSEMBLY (Page 6-4).
a. Install new O-ring (4) to fuel line (1), if removed.
4. Install air cleaner. See INSPECT AIR FILTER (Page 2-40).
b. Connect fuel line to fuel rail (3).
5. Install main fuse. See POWER DISCONNECT (Page 7-7).
c. Install screw (2). Tighten. 6. Set OFF/RUN switch to RUN and check for leaks.
Torque: 22-40 in-lbs (2.5-4.5 N-m) Fuel line to fuel
rail screw

2. See Figure 6-14 Install fuel line to fuel tank.

a. Press up on sleeve of quick disconnect fitting (1).

94000936
6-13
 FUEL TANK 6.8
PREPARE 2. NOTE
Vent screws on bottom of tank are not meant to be
removed. If removed for any reason, replace with new
A WARNING screws.
Gasoline is extremely flammable and highly explosive. Keep
gasoline away from ignition sources which could result in death See Figure 6-16. Install new screws. Tighten.
or serious injury. See the Safety chapter. (00635c) Torque: 11-13 ft-lbs (15-18 N-m) Fuel tank, vent screws
Figure 6-15. Fuel Tank
1. Remove seat. See SEAT (Page 3-142).
2. Purge fuel system. See PURGE FUEL LINE (Page 6-12).
3. Remove main fuse. See POWER DISCONNECT (Page 7-7).

A WARNING
To prevent spray of fuel, purge system of high-pressure fuel
before supply line is disconnected. Gasoline is extremely
flammable and highly explosive, which could result in death or
serious injury. (00275a)

4. Disconnect fuel line at quick disconnect fitting. See FUEL

LINE (Page 6-13).

5. Disconnect vent line. See VENT TUBE (Page 6-20).

6. Drain fuel tank.
7. If equipped with fuel tank console:
a. disconnect fuel tank console connector. See CONSOLE
(Page 6-8). 1. Rear fuel tank mounting screw
2. Washer (4)
b. If necessary remove console. See CONSOLE (Page 6-
3. Acorn nut (2)
8).
4. Bushing and grommet (4)
5. Front fuel tank mounting screw
REMOVE _______________________________

1. Remove fuel tank. COMPLETE

a. See Figure 6-15. Remove front fuel tank mounting

screw (5), washers (2), and acorn nut (3).

b. Remove fuel tank.

c. Remove bushings and grommets (4) if necessary.

2. See Figure 6-16. Vent screws in fuel tank are for

manufacturing purposes and not intended to be removed.

INSTALL
a. Install bushings and grommets (4) if removed. 1. Secure fuel tank. See PURGE FUEL LINE (Page 6-12).
2. If equipped with fuel tank console:
b. Place fuel tank onto frame backbone.
a. If necessary install console. See CONSOLE (Page 6-
8).
FASTENER TORQUE VALUE
Fuel tank, vent screws 11-13 ft-lbs 15-18 N-m b. Connect console connector. See CONSOLE (Page 6-
8).
1. See Figure 6-15. Install fuel tank.
c. Loosely install front fuel tank mounting screw (5), 3. Connect vent line. See VENT TUBE (Page 6-20).
washers (2), and acorn nut (3).

94000936
6-14
4. Connect fuel line at quick disconnect fitting. See FUEL LINE
(Page 6-13).
5. Install seat. See SEAT (Page 3-142).
6. Install main fuse. See POWER DISCONNECT (Page 7-7).
7. Set OFF/RUN switch to RUN and check for leaks.

94000936 6-15
FUEL PUMP 6.9

PREPARE

A WARNING
Gasoline is extremely flammable and highly explosive. Keep
gasoline away from ignition sources which could result in
death or serious injury. See the Safety chapter. (00635c)

1. Remove seat. See SEAT (Page 3-142).

2. Purge fuel system. See PURGE FUEL LINE (Page 6-12).
3. Remove main fuse. See POWER DISCONNECT (Page 7-7).

A WARNING
To prevent spray of fuel, purge system of high-pressure fuel
before supply line is disconnected. Gasoline is extremely
flammable and highly explosive, which could result in death
or serious injury. (00275a)

4. Remove fuel tank. See FUEL TANK (Page 6-14).

REMOVE Figure 6-17. Vent Tube O-ring Location
INSTALL
NOTE
Fuel pumps used in 5 gallon fuel tanks are equipped with a
FASTENER TORQUE VALUE
flexible siphon tube (6).
Fuel pump assembly screws 40-45 in-lbs 1 4.5-5 N-m
1. See Figure 6-18. Remove fuel pump assembly.
a. Remove screws (1).
b. Using a wooden tool, pull inlet strainer (3) from fuel tank.

c. Remove fuel pump assembly (5).

2. Discard seal (4).

CLEAN AND INSPECT _________

A WARNING
Do not use solvents or other products that contain chlorine
on plastic fuel system components. Chlorine can degrade
plastic fuel system components, which can cause a loss of
fuel system pressure or engine stalling and could result in
death or serious injury. (00621 b)

1. See Figure 6-18. Clean and inspect fuel pump assembly.

a. Inspect fuel pickup screen (3) for damage. Replace if

necessary.

b. Clean fuel pump assembly (5).

2. NOTE
Placing o-ring in wrong groove will hinder fuel system
venting.

3.5 gal tank pump: See Figure 6-17. Inspect o-ring (2) on
vent tube (1) and verify proper location.

6-16 94000936
 2. See Figure 6-22. Remove filter housing.
a. Remove retaining clip (3).
b. Remove filter housing (2) from filter base (5).

3. Remove and discard fuel filter (4).

4. Remove and discard O-ring (6).

Pump
1. Remove level sender.
2. See Figure 6-23. Remove pump retainer.
a. Press tabs (3) to release pump retainer (2).
b. Remove pump retainer.

3. Disconnect electrical connectors (1).

4. See Figure 6-24. Remove pump (4).
5. Remove lower isolator (1).
6. If necessary remove and discard inlet strainer (5).
7. Inspect parts for damage. Replace if necessary.
• pump
• spacer(3)
• O-ring (2)

Inlet Strainer
1. See Figure 6-24. Remove pump (4).
2. Remove and discard inlet strainer (5).
ASSEMBLE _____________________________

Level Sender
1. See Figure 6-20 Install level sender.
a. Align level sender bracket (2) with tab (1).
b. Install level sender (3).
c. Connect electrical connector (4).
DISASSEMBLE
Pressure Regulator
Level Sender 1. See Figure 6-21 Install new pressure regulator (2) and
1. See Figure 6-20. Remove level sender. adapter with O-ring (3).

a. Disconnect electrical connector (4). 2. Install regulator cover.

a. Install regulator cover (1).
b. Press tab (1) to release level sender bracket (2).
b. Install regulator cover retaining clip (4).
c. Remove level sender (3).

Pressure Regulator Filter

1. See Figure 6-21. Remove regulator cover. 1. See Figure 6-22 Install new filter (4).

a. Remove regulator cover retaining clip (4). 2. Install new O-ring (6).

b. Remove regulator cover (1). 3. Install filter housing.

2. Discard pressure regulator (2) and adapter with O-ring (3). a. Install filter housing (2) onto filter base (5) and bracket
(1).
NOTE b. Install filter housing retaining clip (3).
Plastic portion of pressure regulator may separate from
assembly during removal, if this occurs plastic portion must
be removed before installing new pressure regulator.
Filter
1. Remove regulator cover.
94000936 6-17
4. Install regulator cover.

Pump
1. See Figure 6-24 If necessary install new inlet strainer (5).
2. Install fuel pump spacer (3) and, O-ring (2).
3. Install lower isolator (1).
4. Install pump (4).
5. See Figure 6-23 Connect electrical connectors (1).
6. Install pump retainer (2).
7. Install level sender.

Inlet Strainer
1. See Figure 6-24 Install new inlet strainer (5) in proper
orientation.

2. Install pump (4).

Tab
Level sender bracket
Level sender
Electrical connector

6-18 94000936
 COMPLETE
Figure 6-20. Level Sender

94000936 6-19
1. Install fuel tank. See FUEL TANK (Page 6-14).
2. Install seat. See SEAT (Page 3-142).
3. Install main fuse. See POWER DISCONNECT (Page 7-7).
NOTE
Add at least 3.8 L (1 gal) of fuel to fuel tank before operating
fuel pump.

4. Set OFF/RUN switch to RUN and check for leaks.

1. Lower isolator
2. O-ring
3. Spacer
4. Pump
5. Inlet strainer
Figure 6-24. Fuel Pump and Inlet Strainer

6-20 94000936
 COMPLETE
VENT TUBE 6.10

PREPARE
1637130

1. Remove seat. See SEAT (Page 3-142).

2. Remove left side cover. See LEFT SIDE COVER (Page 3-
63).
3. Remove main fuse. See POWER DISCONNECT (Page 7-7).
NOTE
Right side cover, battery and tray removal are only
necessary if replacing lower vent line.

4. Remove right side cover. See RIGHT SIDE COVER (Page

3-64).
5. Remove battery. See INSPECT BATTERY (Page 2-43).
6. Remove battery tray. See BATTERY TRAY (Page 7-97).
REMOVE -------
* . tW .Vr j
1. Cable strap
1. Remove upper vent line. 2. Upper vent line
3. Vapor valve
a. See Figure 6-25. Remove and discard cable strap (1). 4. Lower vent line

b. Disconnect upper vent line (2) from vapor valve (3). Figure 6-25. Fuel Tank Vent Line

c. See Figure 6-26. Disconnect upper vent line (1) from 1637147

fuel tank (2).

d. Remove upper vent line (3).

2. Remove lower vent line.

a. See Figure 6-25. Disconnect lower vent line (4) from

vapor valve (3).

b. See Figure 6-27. Remove lower vent line from clips

(3).

c. Remove lower vent line. 1. Hose

2. Fuel tank
INSTALL 3. Upper vent line
Figure 6-26. Upper Vent Line Routing

1. Install upper vent line.

a. See Figure 6-26. Route upper vent line (3) as shown.

b. Connect hose (1) to fuel tank (2).

c. See Figure 6-25. Connect upper vent line to vapor

valve (3).

d. Install new cable strap (1 ).

2. Install lower vent line.

a. See Figure 6-27. Route lower vent line (2) as shown.

b. Connect lower vent line to vapor valve (1).

c. Install vent lines in clips (3).

94000936 6-21
1637401
1. Install battery tray, if removed. See BATTERY TRAY (Page
7-97).
2. Install battery, if removed. See INSPECT BATTERY (Page
2-43).
3. Install right side cover, if removed. See RIGHT SIDE
COVER (Page 3-64).
4. Install seat. See SEAT (Page 3-142).
5. Install main fuse. See POWER DISCONNECT (Page 7-7).
6. Install left side cover. See LEFT SIDE COVER (Page 3-63).

3. Clips (2) __________________________________

Figure 6-27. Lower Vent Line Routing (some parts removed
for clarity)

1. Vapor valve
2. Lower vent line

6-22 94000936
 COMPLETE
VAPOR VALVE 6.11
PREPARE

1. Remove left side cover. See LEFT SIDE COVER (Page 3-

63).

REMOVE _______________________________

1. See Figure 6-28 . Remove vapor valve.

a. Remove vent lines (1) from vapor valve (3).
b. Pull vapor valve from clip (2).

INSTALL _______________________________

A WARNING
Excessive pressure can build in the fuel tank if vapor valve
is not mounted vertically with long fitting to top. Leaks due
to excessive pressure can cause a fire or explosion, which
could result in death or serious injury. (00265a)

1. See Figure 6-28. Install vapor valve. 1. Vent lines

a. Press vapor valve (3) into clip (2). 2. Clip
b. Install vent lines (1). 3. Vapor valve
Figure 6-28. Vapor Valve
COMPLETE _________________
1. Install left side cover. See LEFT SIDE COVER 3-63).
(Page

94000936 6-23
TEMPERATURE MANIFOLD ABSOLUTE PRESSURE (TMAP) 6.12
SENSOR

PREPARE b. Install screw (2). Tighten to 23-39 in-lbs

(
2
2. Connect. TMAP sensor connector.
5
-
-
4
.
5

N
-
m
)
.
A WARNING

Gasoline is extremely flammable and highly explosive. Keep

gasoline away from ignition sources which could result in death
or serious injury. See the Safety chapter. (00635c)

A WARNING

To prevent spray of fuel, purge system of high-pressure fuel

before supply line is disconnected. Gasoline is extremely
flammable and highly explosive, which could result in death or
serious injury. (00275a)

1. Remove seat. See SEAT (Page 3-142).

2. Remove fuel tank. See FUEL TANK (Page 6-14).

3. Remove main fuse. See POWER DISCONNECT (Page 7-7). COMPLETE

REMOVE a. Remove screw (2).
b. Remove TMAP sensor (1).
1. Disconnect TMAP sensor connector.

2. See Figure 6-29 . Remove TMAP sensor. INSTALL _____________________

FASTENER TORQUE VALUE 1. Install fuel tank. See FUEL TANK (Page 6-14).
Temperature manifold absolute 23-39 in-lbs 2.5--4.5 N-m 2. Install seat. See SEAT (Page 3-142).
pressure sensor (TMAP) screw
3. Install main fuse. See POWER DISCONNECT (Page 7-7).
1. See Figure 6-29. Install TMAP sensor.

94000936 6-24
TWIST GRIP SENSOR (TGS)
a. Install TMAP sensor (1).
6.13

6-25 94000936
TWIST GRIP SENSOR (TGS) 6.13

PREPARE c. See Figure 6-32 Verify TGS is engaged into alignment

slots in handlebar.
A WARNING
3. See Figure 6-30 Connect TGS connector (2).
Gasoline is extremely flammable and highly explosive. Keep
gasoline away from ignition sources which could result in death
or serious injury. See the Safety chapter. (00635c) 4. Install new cable straps.

1. Remove seat. See SEAT (Page 3-142).

2. Purge fuel system. See PURGE FUEL LINE (Page 6-12).
3. Remove main fuse. See POWER DISCONNECT (Page 7-
7).
4. Remove fuel tank. See FUEL TANK (Page 6-14).
5. Remove frame plug and slide front electrical caddy away
from backbone. See FRONT ELECTRICAL CADDY (Page
7-87).
6. Remove right handlebar switch housing from handlebar. See
RIGHT HAND CONTROL MODULE (RHCM) (Page 7-20)
7. Remove right hand grip.
REMOVE ____________ _________________
Figure
1. 6-31. Install
Frame plug Seal Cap (Models without heated grips)
1. See Figure 6-30. Disconnect Twist Grip Sensor (TGS) 2. TGS connector
connector (2) 3. Heated hand grip connector
Figure 6-30. TGS Connector
2. Remove cable straps and note location for installation.
3. Remove TGS.
a. Attach a chaser wire to the TGS connector
b. Remove TGS.
c. Pull TGS harness out of handlebar.

INSTALL ____________ _________________

1. NOTE
Never use any kind of lubricant or spray cleaner on the
twist grip, handlebar or TGS. All parts are designed to
operate dry.
See Figure 6-31 The seal cap protects the TGS
terminals from dirt and moisture. It also serves as a
retention device for the throttle grip.

Install seal cap at end of TGS.

a. Check condition of O-ring on seal cap, replace if

necessary.

b. See Figure 6-31 Install seal cap engaging legs in

slots at end of TGS.

2. Install TGS.

a. Attach chaser wire used during removal to newTGS

connector.

b. Draw harness into handlebar while guiding TGS into

end into end of handlebar.

6-26 94000936
 COMPLETE

1. Install right handgrip.

2. Install right handlebar switch housing. See RIGHT HAND
CONTROL MODULE (RHCM) (Page 7-20).

3. Install front electrical caddy and frame plug. See FRONT

ELECTRICAL CADDY (Page 7-87).
4. Install fuel tank. See FUEL TANK (Page 6-14).
5. Install seat. See SEAT (Page 3-142).
6. Install main fuse. See POWER DISCONNECT (Page 7-7).

94000936 6-27
FUEL INJECTORS 6.14

PREPARE 2. Install fuel rail.

a. Install fuel rail (3).

A WARNING
Gasoline is extremely flammable and highly explosive. Keep b. Install screws (1). Tighten.
gasoline away from ignition sources which could result in death or Torque: 31-49 in-lbs (3.5-5.5 N-m) Fuel rail screws
serious injury. See the Safety chapter. (00635c)
3. Connect fuel injector connectors.
A WARNING
To prevent spray of fuel, purge system of high-pressure fuel a. Grey connector to front injector.
before supply line is disconnected. Gasoline is extremely
flammable and highly explosive, which could result in death or b. Black connector to rear injector.
serious injury. (00275a)

1. Remove seat. See SEAT (Page 3-142).

2. Purge fuel system. See PURGE FUEL LINE (Page 6-12).
3. Remove main fuse. See POWER DISCONNECT (Page 7-7).

4. Remove fuel tank. See FUEL TANK (Page 6-14).

5. Remove air cleaner. See INSPECT AIR FILTER (Page 2-
40).

6. Remove air cleaner backplate assembly. See AIR CLEANER

BACKPLATE ASSEMBLY (Page 6-4).

REMOVE _______________________________

1. Disconnect fuel injector connectors.

2. See Figure 6-33 . Remove fuel rail and fuel injectors.
a. Remove screws (1).
b. Remove fuel rail (3).
c. Remove fuel injectors (2, 4).

3. Discard O-rings from intake manifold.

INSTALL

COMPLETE
FASTENER TORQUE VALUE 1. Install air cleaner backplate assembly. See AIR CLEANER
Fuel rail screws 31-49 in-lbs 3.5-5.5 N-m BACKPLATE ASSEMBLY (Page 6-4).

1. See Figure 6-33. Install fuel injectors to intake manifold. 2. Install air cleaner. See INSPECT AIR FILTER (Page 2-40).
a. Install new O-rings into intake manifold. 3. Install fuel tank. See FUEL TANK (Page 6-14).

b. Install fuel injectors (2,4) to intake manifold. 4. Install seat. See SEAT (Page 3-142).
5. Install main fuse. See POWER DISCONNECT (Page 7-7).

6-28 94000936
INDUCTION MODULE 6.15

PREPARE 2. Disconnect connectors:

a. Remove TMAP sensor connector (10).
A WARNING b. Remove front fuel injector connector (8).
Gasoline is extremely flammable and highly explosive. Keep c. Remove rear fuel injector connector (5).
gasoline away from ignition sources which could result in death
or serious injury. See the Safety chapter. (00635c) d. Remove TCA connector (11).
e. Release harness from anchor point (12).
1. Remove seat. See SEAT (Page 3-142).
NOTE
2. Purge fuel system. See PURGE FUEL LINE (Page 6-12).
See Figure 6-35. For best results, use the INTAKE
3. Remove main fuse. See POWER DISCONNECT (Page 7-7). MANIFOLD WRENCH (PART NUMBER: HD-47250).

4. Remove fuel tank. See FUEL TANK (Page 6-14).

3. See Figure 6-34. Remove right side screws (3).
5. Remove air cleaner. See INSPECT AIR FILTER (Page 2-
4. Loosen left side screws (4).
40).
5. Remove induction module from right side.
6. Remove air cleaner backplate assembly. See AIR
CLEANER BACKPLATE ASSEMBLY (Page 6-4). 6. Discard seals (1).
7. Remove flange adapters (2, 9).
REMOVE ____ _________
8. Disconnect fuel line from induction module.
1. California models: See Figure 6-34. Pull purge tube from
a. Remove screw (6).
PART NUMBER TOOL NAME b. Pull fuel line from fuel rail inlet.
HD-47250 INTAKE MANIFOLD WRENCH
c. Discard O-ring (7).
fitting (13).

94000936 6-29
1. Seal (2) 8. Front fuel injector connector
2. Rear flange adapter 9. Front flange adapter
3. Right side screw (2) 10. TMAP sensor connector
4. Left side screw (2) 11. TCA connector
5. Rear fuel injector connector 12. TCA harness anchor point
6. Screw 13. Purge tube fitting/cap
7. O-ring

FASTENER TORQUE VALUE

Induction module flange ad- 96-156 ln-lbs 10.9-17.6 N-m
apter screws
1. Connect fuel line to induction module.
Figure 6-34. Induction Module Assembly
a. See Figure 6-34. Install new O-ring (7).

b. Push fuel line firmly onto fuel rail inlet.

c. Install screw (6). Tighten.

Torque: 22-40 in-lbs (2.5-4.5 N-m) Fuel line to fuel
rail screw

Figure 6-35. Intake Manifold Wrench 2. With the counterbore facing outward, install flange adapters
(2, 9) onto the induction module.
INSTALL _______________________
3. Place new seal (1) in each flange adapter with the beveled
PART NUMBER TOOL NAME side against the counterbore.
HD-47250 INTAKE MANIFOLD WRENCH NOTE
For best results, use the INTAKE MANIFOLD WRENCH
FASTENER TORQUE VALUE (PART NUMBER: HD-47250).
Fuel line to fuel rail screw 22-40 in-lbs 2.5-4.5 N-m

6-30 94000936
4. Install induction module. 3. Remove throttle body (4).
a. Remove screws (3).
a. Slide induction module into position until slots engage
left side screws (4). b. Remove throttle body.
c. California models: Disconnect vent hose.
b. Start right side screws (3).
d. Discard gasket (6).
c. Temporarily fasten mounting bracket to cylinder heads
with breather bolts. Induction Manifold
5. Tighten right side screws (3) until snug. 1. See Figure 6-36 . Remove TMAP sensor (7). See
TEMPERATURE MANIFOLD ABSOLUTE PRESSURE
6. Tighten left side screws (4). (TMAP) SENSOR (Page 6-23).

Torque: 96-156 in-lbs (10.9-17.6 N-m) Induction module 2. Remove fuel rail (9) and fuel injectors (8, 10). See FUEL
flange adapter screws INJECTORS (Page 6-26).

ASSEMBLE __________________________
7. Tighten right side screws (3).
Torque: 96-156 in-lbs (10.9-17.6 N-m) Induction module FASTENER TORQUE VALUE
flange adapter screws
Induction module bracket 66-84 in-lbs 7.5--9.5 N-m
Throttle body to manifold 35-53 in-lbs 4-6 N-m
8. Install connectors:
screws

a. Install rear fuel injector connector (5) (black). Induction Manifold

b. Install front fuel injector connector (8) (grey). 1. See Figure 6-36. Install TMAP sensor (7). See
TEMPERATURE MANIFOLD ABSOLUTE PRESSURE
c. Install TMAP sensor connector (10). (TMAP) SENSOR (Page 6-23).

d. Install TCA connector (11). 2. Install fuel injectors (8, 10) and fuel rail (9). See FUEL
INJECTORS (Page 6-26).
9. Capture TCA harness to anchor point (12) with new
anchored cable strap. Throttle Body

10. California models: Connect purge tube to fitting (13). 1. See Figure 6-36. Install throttle body (4).

11. Non-California models: Inspect rubber cap for damage. a. Install new gasket (6).
Replace as necessary.
b. Installthrottle body.
DISASSEMBLE _____ ___ ______ c. Install screws (3).
Torque: 35--53 in-lbs (4-6 N-m) Throttle body to
Throttle Body manifold screws
NOTE d. If removed, install new rubber cap (5) or connect vent
The throttle body can be removed without removing the hose.
entire induction module.
2. Install bracket (1) with screws (2).
1. Induction module still installed: Disconnect TCM Torque: 66-84 in-lbs (7.5-9.5 N-m) Induction module
connector. bracket
2. See Figure 6-36 Remove bracket (1).
3. Induction module still installed: Connect TCM connector.
a. Remove screws (2).
b. Remove bracket.

94000936 6-31
 1021047

1. Bracket Screw 7. TMAP sensor

2. (2) Screw (3) 8. Rear fuel injector
3. Throttle body 9. Fuel rail
4. Rubber cap 10. Front fuel injector
5. Gasket 11. Intake manifold
6.
Figure 6-36. Induction Module Assembly
COMPLETE 3. Install fuel tank. See FUEL TANK (Page 6-14).
4. Install seat. See SEAT (Page 3-142).
1. Install air cleaner backplate assembly. See AIR CLEANER
BACKPLATE ASSEMBLY (Page 6-4). 5. Install main fuse. See POWER DISCONNECT (Page 7-7).

2. Install air cleaner. See INSPECT AIR FILTER (Page 2-40).

6-32 94000936
INTAKE LEAK TEST 6.16

LEAK TESTER 3. Press and release trigger button to dispense propane.

4. Repeat as necessary to detect leak.
PART NUMBER TOOL NAME 5. When test is finished, close valve.
HD-41417 PROPANE ENRICHMENT KIT
A WARNING
Do not allow open flame or sparks near propane. Propane is
extremely flammable, which could cause death or serious injury.
(00521 b)

A WARNING

Read and follow warnings and directions on propane bottle.

Failure to follow warnings and directions can result in death or
serious injury. (00471 b)

Parts List
• Small propane cylinder.

• PROPANE ENRICHMENT KIT (PART NUMBER: HD-41417).

Tester Assembly
1. See Figure 6-37 . Make sure valve knob (6) is closed (fully
clockwise).

2. Install valve assembly (5) onto propane bottle (1).

Tester Adjustment
1. See Figure 6-37 . Press and hold trigger button (8).

2. Slowly open valve knob (6) until pellet in flow gauge (7) rises
5-10 SCFH on gauge.

3. Release trigger button.

PROCEDURE

NOTE
Propane injected into air cleaner causes false readings.
Keep air cleaner cover installed.

1. Run motorcycle until engine is at normal operating

temperature.

2. Aim nozzle toward possible sources of leak.

NOTE
The tone of the engine changes when propane enters source
of leak.

94000936 6-33
HEATED OXYGEN SENSORS (HO2S) 6.17
PREPARE 3. See Figure 6-40. Install third HO2S (if equipped). Tighten.

Torque: 12-14 ft-lbs (16.3-19 N-m) HO2S (Heated oxygen

1. Remove main fuse. See POWER DISCONNECT (Page 7-7). sensor)
Special Tool: 17MM OXYGEN SENSOR SOCKET (HD-
NOTE
52977)
Right side cover removal only necessary if replacing rear
Heated Oxygen Sensor (HO2S).

2. Remove right side cover. See RIGHT SIDE COVER (Page

3-64).
REMOVE _____

PART NUMBER TOOL NAME

HD-52977 17MM OXYGEN SENSOR SOCKET
1. See Figure 6-38 or Figure 6-39. Disconnect HO2S connector
(1).

2. Remove HO2S (2) with oxygen sensor wrench.

Special Tool: 17MM OXYGEN SENSOR SOCKET (HD-
52977) 1. HO2S connector
3. See Figure 6-40. Remove third HO2S (if equipped) with 2. HO2S _______________________________
oxygen sensor socket. Figure 6-38. Front HO2S (Heated Oxygen Sensor)

Special Tool: 17MM OXYGEN SENSOR SOCKET (HD-

52977)

INSTALL __________
PART NUMBER TOOL NAME
HD-52977 17MM OXYGEN SENSOR SOCKET

FASTENER TORQUE VALUE

HO2S (Heated oxygen sensor) 12-14 ft-lbs 116.3-19 N-m 9 10

Figure 6-39. Rear HO2S (Heated Oxygen Sensor)

NOTE
• Do not install sensors that have dropped or have been
impacted by other components. Damage to the sensing
element can occur.
• Replacement sensor assemblies have threads coated with
ANTI-SEIZE LUBRICANT and new gaskets.
10 If reusing HO2S. replace the gasket. Use a high-quality
professional grade side cutter for gasket removal. Make
sure larger side of new gasket faces exhaust.
• If reusing HO2S, apply a thin coat of ANTI-SEIZE
LUBRICANT to each oxygen sensor.

6-34 94000936
 COMPLETE

1. See Figure 6-38 or Figure 6-39. Install HO2S (2). Tighten

using special tool.

Torque: 12-14 ft-lbs (16.3-19 N-m) HO2S (Heated oxygen

sensor)
Special Tool: 17MM OXYGEN SENSOR SOCKET (HD-
52977)

2. Connect HO2S connector (1).

94000936 6-35
1443889

1. Install right side cover. See RIGHT SIDE COVER (Page 3-

64).
2. Install main fuse. See POWER DISCONNECT (Page 7-7).

1. HO2S connector
2. HO2S
Figure 6-40. Third HO2S (Heated Oxygen Sensor) typical
(If equipped)

6-36 94000936
MUFFLERS COMPLETE 6.18

PREPARE d. Tighten screws.

Torque: 120-144 in-lbs (13.6-16.3 N-m) Muffler
1. Remove exhaust shields as necessary. See EXHAUST screws
SYSTEM (Page 6-36).
e. Tighten clamp.
2. Remove rear HO2S connector. See HEATED OXYGEN Torque: 38-43 ft-lbs (51.5-58.3 N-m) Muffler clamp
SENSORS (HO2S) (Page 6-32).
REMOVE ______________________________ End Cap
1. See Figure 6-43. Install end cap.
Muffler
a. Apply anti-seize lubricant to screws (1 ).
1. See Figure 6-41, Figure 6-42. Remove muffler.
ANTI-SEIZE LUBRICANT (98960-97)
a. Discard clamp (4). b. Install end cap (2).

b. Remove screws (1). c. Install screws. Tighten.

c. Remove muffler (2). Torque: 96-120 in-lbs (10.8-13.6 N-m) Muffler end
cap screws
d. Discard muffler gasket (3), if equipped.

End Cap
1. See Figure 6-43. Remove end cap.

a. Remove screws (1).

b. Remove end cap (2).

c. Remove end cap gasket (3), if equipped.

INSTALL ______________________________

FASTENER TORQUE VALUE

Muffler clamp 38-43 ft-lbs 51.5-58.3 N-m
Muffler end cap screws 96-120 in-lbs 10.8--13.6 N-m
Muffler screws 120---144 in-lbs 13.6-16.3 N-m

CONSUMABLE PART NUMBER

ANTI-SEIZE 98960-97
LUBRICANT

Muffler
1. NOTE
Use a pipe expander (such as Snap-on Part No. PH300)
on mufflers (2) to aid installation of gaskets (3), if
necessary.

Flange on gasket should not be inside muffler inlet.

See Figure 6-41 or Figure 6-42. Install new gasket into

muffler.if equipped.

2. See Figure 6-41 or Figure 6-42 Install muffler.

a. Loosely install new clamp (4).

b. All others: Align muffler with bracket. Slide muffler on.

c. Install screws (1 ). Hand-tighten.

94000936 6-37
COMPLETE.

1. Install exhaust shields as necessary. See EXHAUST

SYSTEM (Page 6-36).
2. Install HO2S connector. See HEATED OXYGEN SENSORS
(HO2S) (Page 6-32).

94000936 6-38
EXHAUST SYSTEM 6.19
1053796

PREPARE 1. See Figure 6-44 or Figure 6-45. If removed install exhaust

bracket.
1. Remove main fuse. See POWER DISCONNECT (Page 7-7).
a. Install exhaust bracket (2).
2. If necessary remove right foot support bracket. See RIGHT
b. Apply thread-locker to exhaust bracket screws (3).
FOOT CONTROLS (Page 3-133).
LOCTITE 243 MEDIUM STRENGTH
3. Disconnect front and rear HO2S connectors. See HEATED THREADLOCKER AND SEALANT (BLUE) (99642-97)
OXYGEN SENSORS (HO2S) (Page 6-32).
c. Install exhaust bracket screws (3). Tighten.
REMOVE _______________________________ Torque: 40-50 ft-lbs (54.2--67.8 N-m) Exhaust
bracket screws
1. See Figure 6-44 or Figure 6-45. Remove exhaust system.
2. Install new gaskets (6).
a. Remove flange nuts (5).
3. Install exhaust system.
b. Remove support clamp screw (4), if equipped.
a. Align and install exhaust system.
c. Remove muffler screws (1). b. Apply thread-locker to muffler screws (1).

d. Remove exhaust system. LOCTITE 243 MEDIUM STRENGTH

2. Remove and discard gaskets (6).
THREADLOCKER AND SEALANT (BLUE) (99642-97)

3. If necessary remove exhaust bracket. c. Install muffler screws. Hand tighten.

a. Remove exhaust bracket screws (3). d. Install support clamp screw (4), if equipped. Hand
b. Remove exhaust bracket (2). tighten.

e. Install flange nuts (5). Hand tighten.

INSTALL _______________________________
f. Tighten flange nuts.
Torque: 100-120 in-lbs (11.3-13.6 N-m) Exhaust to
engine flange nuts
g. Tighten muffler screws.
FASTENER TORQUE VALUE
Exhaust bracket screws 40-50 ft-lbs 54.2--67.8 N-m Torque: 120-144 in-lbs (13.6-16.3 N-m) Muffler
screws
Exhaust support clamp screw 40-50 ft-lbs 54.2--67.8 N-m
Exhaust to engine flange nuts 100-120 in-lbs 11.3-13.6 N-m h. Tighten support clamp screw, if equipped.
Muffler screws 120--144 in-lbs 13.6-16.3 N-m Torque: 40-50 ft-lbs (54.2-67.8 N-m) Exhaust
support clamp screw
CONSUMABLE PART NUMBER
99642-97
LOCTITE 243
MEDIUM
STRENGTH
THREADLOCKER
AND SEALANT
(BLUE)

94000936 6-39
 1. Muffler screw (4) 4. Support clamp screw
2. Exhaust bracket 5. Flange nut (4)
3. Exhaust bracket screw (2) 6. Gasket (2)
Figure 6-44. Exhaust System (Typical)

160714

1. Muffler screw (2) 5. Flange nut (4)

2. Exhaust bracket 6. Gasket (2)
3. Exhaust bracket screw (2)
Figure 6-45. Exhaust System (Two Into One)
DISASSEMBLE AND ASSEMBLE: STANDARD _ 4. Remove exhaust flange.
a. Remove retaining ring (4).
b. Remove exhaust flange (5).
FASTENER TORQUE VALUE
Exhaust shield clamps 20--40 in-lbs 2.3--4.5 N-m
Muffler shield clamps 20--40 in-lbs 2.3--4.5 N-m
Assemble

Disassemble 1. NOTE
Recess in exhaust flange should face engine.
1. See Figure 6-46. Remove HO2S (6). See HEATED
OXYGEN SENSORS (HO2S) (Page 6-32). See Figure 6-46. Install exhaust flange.
2. Remove exhaust and muffler shields.
a. Install exhaust flange (5).
a. Remove exhaust and muffler shield clamps (1, 8).
b. Remove exhaust and muffler shields (3, 7, 9, 10). b. Install Retaining ring (4).

3. Remove muffler (2). See MUFFLERS (Page 6-34). 2. Install muffler (2). See MUFFLERS (Page 6-34).

6-40 94000936
3. Install exhaust and muffler shields. c. Install muffler shield clamps (1). Tighten.
a. Install and position exhaust and muffler shields (3, Torque: 20-40 in-lbs (2.3-4.5 N-m) Muffler shield
7,9,10). clamps

b. Install exhaust shield clamps (8). Tighten. 4. Install HO2S (6). See HEATED OXYGEN SENSORS
(HO2S) (Page 6-32).
Torque: 20-40 in-lbs (2.3-4.5 N-m) Exhaust shield
clamps

1055700

1. Muffler shield clamp (4) 6. HO2S (Heated oxygen sensor) (2)

2. Muffler (2) 7. Front exhaust shield
3. Rear exhaust shield 8. Exhaust shield clamp (6)
4. Retaining ring (2) 9. Intermediate exhaust shield (FXBBS, FXST)
5. Exhaust flange (2) 10. Muffler shield (2)
Figure 6-46. Exhaust System (Typical)
DISASSEMBLE AND ASSEMBLE: UPSWEPT Disassemble
1. See Figure 6-47. Remove HO2S (4). See HEATED
FASTENER TORQUE VALUE
OXYGEN SENSORS (HO2S) (Page 6-32).
Exhaust shield clamps 20-40 in-lbs 2.3-4.5 N-m
2. Remove intermediate exhaust shield.
Exhaust shield screws 108-132 in-lbs 12.2-14.9 N-m
a. Remove screws (7).
CONSUMABLE PART NUMBER
b. Remove intermediate exhaust shield (8).
ANTI-SEIZE 98960-97
LUBRICANT Remove front exhaust shield, rear exhaust shield, and
muffler shields.
a. Remove exhaust and muffler shield clamps (6, 11).
b. Remove exhaust shields (5, 9, 10).

6-41 94000936
4. Remove muffler (1). See MUFFLERS (Page 6-34).

5. Remove exhaust flange.

a. Remove retaining ring (2).
b. Remove exhaust flange (3).

Assemble

1. See Figure 6-47. Install exhaust flange.

NOTE
Recess in exhaust flange should face engine.

a. Install exhaust flange (3).

b. Install Retaining ring (2).

2. Install muffler (1). See MUFFLERS (Page 6-34).

3. Install front exhaust shield, rear exhaust shield, and muffler

shields.

a. Install and position muffler and exhaust shields (5, 9, 10).

4. Install intermediate exhaust shield.

a. Apply anti-seize lubricant to screws (7). ANTI-SEIZE

LUBRICANT (98960-97)

b. Install intermediate exhaust shield (8).

c. Install screws (7). Tighten.

Torque: 108-132 in-lbs (12.2-14.9 N-m) Exhaust

shield screws

5. Tighten muffler and exhaust shield clamps.

Torque: 20-40 in-lbs (2.3-4.5 N-m) Exhaust shield clamps

6. Install HO2S (4). See HEATED OXYGEN SENSORS

(HO2S) (Page 6-32).

6-42 94000936
 1054170 b. Install muffler and exhaust shield clamps (6, 11).
Hand tighten.

1. Muffler (2) 7. Screw (6)

2. Retaining ring (2) 8. Intermediate exhaust shield
3. Exhaust flange (2) 9. Muffler shield (2)
4. H02S (Heated oxygen sensor) (2) 10. Rear exhaust shield
5. Front exhaust shield 11. Muffler shield clamp (2)
6. Exhaust shield clamp (4)

Figure 6-47. Exhaust System: FXFBS

DISASSEMBLE AND ASSEMBLE: TWO INTO b. Remove
front clamps (10) or clamp (16).
FASTENER TORQUE VALUE ONE ______________________________________________
c. Remove intermediate exhaust shield (9 or 17).
Exhaust shield clamps 20--40 in-lbs 2.3-4.5 N-m
Muffler intermediate exhaust 108--132 in-lbs 12.2-14.9 N-m 3. Remove front exhaust shield and rear exhaust
shield screw
shield.

a. Remove clamps (3).

CONSUMABLE PART NUMBER

b. Remove shields (2, 8).
ANTI-SEIZE 98960-97
LUBRICANT
4. Remove muffler shield, if equipped.

Disassemble
a. Remove clamps (12).
1. See Figure 6-48. Remove HO2S (Heated oxygen sensor) b. Remove muffler shield (13).
(6) . See HEATED OXYGEN SENSORS (HO2S) (Page 6-
32). 5. Remove muffler (1). See MUFFLERS (Page 6-34)
6. Remove exhaust flanges.
2. Remove intermediate exhaust
shield.

94000936 6-43
 a. Remove rear clamp (11) or screws (15). a. Remove retaining rings (5).

b. Remove exhaust flanges (4).

6-44 94000936
Assemble b. Install clamps (3). Hand tighten.
1. NOTE 5. Install intermediate exhaust shield.
Recess in exhaust flange should face engine.
a. Apply anti-seize lubricant to screws (14). ANTI-SEIZE
See Figure 6-48. Install exhaust flanges.
LUBRICANT (98960-97)
a. Install exhaust flanges (4). b. Place intermediate exhaust shield (9 or 17) in position.

b. Install Retaining rings (5). c. Install exhaust shield rear clamp (11) or screws (14).
Hand tighten clamp or tighten screws.
2. Install muffler (1). See MUFFLERS (Page 6-34). Torque: 108-132 in-lbs (12.2-14.9 N-m) Muffler
intermediate exhaust shield screw
3. Install muffler shield, if equipped.
d. Install exhaust shield front clamps (10) or clamps (16).

a. Place muffler shield in position. 6. Tighten muffler and exhaust shield clamps.
b. Install clamps (12). Hand tighten.
Torque: 20-40 in-lbs (2.3-4.5 N-m) Exhaust shield clamps

4. Install front exhaust shield, rear exhaust shield. 7. Install HO2S (6). See HEATED OXYGEN SENSORS
(HO2S) (Page 6-32).
a. Place muffler and exhaust shields (2, 8) in position.

1. FLSB: Muffler 8. Front exhaust shield

2. Rear exhaust Shield 9. FLSB: Intermediate exhaust shield
3. Exhaust shield clamp (4) 10. Intermediate exhaust shield front clamp (2)
4. Exhaust flange (2) 11. Intermediate exhaust shield rear clamp
5. Retaining ring (2) 12. Muffler shield clamp (2)
6. H02S (Heated oxygen sensor) (2) 13. Muffler shield
7. Header assembly
Figure 6-48. Exhaust System (Two Into One)

94000936 6-45
COMPLETE

1. Connect front and rear HO2S connectors. See HEATED

OXYGEN SENSORS (HO2S) (Page 6-32).
2. If removed install right foot support bracket. See RIGHT
FOOT CONTROLS (Page 3-133).

3. Install main fuse. See POWER DISCONNECT (Page 7-7).

6-46 94000936
PURGE SOLENOID: EVAPORATIVE EMISSIONS 6.20
PREPARE ____________________________

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

2. Remove right side cover. See RIGHT SIDE COVER (Page

3-64).
3. Remove battery. See INSPECT BATTERY (Page 2-43).
4. Remove battery tray. See BATTERY TRAY (Page 7-97).
REMOVE

1. See Figure 6-49 . Remove purge solenoid.

a. Disconnect purge solenoid connector (2).
b. Remove solenoid-to-induction module and canister-to-
solenoid lines (3, 4) from purge solenoid (1).
c. Remove purge solenoid.

INSTALL

1. See Figure 6-49. Install purge solenoid.

a. Install purge solenoid (1).
b. Install solenoid-to-induction module and canister-to-
solenoid lines (3, 4).
c. Connect purge solenoid connector (2).

1. Purge solenoid
2. Purge solenoid connector
3. Solenoid-to-induction module line
4. Canister-to-solenoid line
5. BCM caddy _______________________________
Figure 6-49. Purge Solenoid
COMPLETE

1. Install battery tray. See BATTERY TRAY (Page 7-97).

2. Install battery. See INSPECT BATTERY (Page 2-43).
3. Install right side cover. See RIGHT SIDE COVER (Page 3-
64).
4. Install main fuse. See POWER DISCONNECT (Page 7-7).

94000936 6-47
 CHARCOAL CANISTER: EVAPORATIVE EMISSIONS 6.21
REMOVE FASTENER TORQUE VALUE
Charcoal canister to bracket 30-36 in-lbs 3.4-4.1 N-m
1. See Figure 6-50. Remove charcoal canister and bracket screws
assembly. 1. See Figure 6-50. If removed, install charcoal canister to
a. Remove lines (4, 5) from charcoal canister. bracket.

b. Remove screws (3). a. Install new charcoal canister (1) onto bracket (2).
c. Remove charcoal canister (1) and bracket (2).
b. Install new screws (6). Tighten.
NOTE Torque: 30-36 in-lbs (3.4-4.1 N-m) Charcoal canister
If charcoal canister is removed from bracket, a new charcoal to bracket screws
canister and screws are required for installation.
2. Install charcoal canister and bracket assembly.
2. If necessary, remove charcoal canister from bracket.
a. Remove and discard screws (6). b. Install screws (3). Tighten.
b. Discard charcoal canister. Torque: 72-96 in-lbs (8.1-10.8 N-m) Charcoal canister
bracket to engine case screws
INSTALL c. Install lines (4,5).
FASTENER TORQUE VALUE
Charcoal canister bracket to 72-96 in-lbs 8.1-10.8 N-m
engine case screws
a. Install charcoal canister and bracket assembly

Figure 6-50. Charcoal Canister

6-48 94000936
PURGE LINES: EVAPORATIVE EMISSIONS 6.22
1. Charcoal canister 4. Canister-to-solenoid line
2. Bracket 5. Vapor valve-to-canister line
3. Screw (2) 6. screw (2)

94000936 6-49
PREPARE INSTALL
1. Remove right side cover. See RIGHT SIDE COVER (Page 1. Install vapor valve-to-canister line.
3-64). a. See Figure 6-51. Install vapor valve-to-canister line (4) to
2. Remove main fuse. See POWER DISCONNECT (Page 7-7). charcoal canister (3).

3. Remove battery. See INSPECT BATTERY (Page 2-43). b. See Figure 6-52. Install valve-to-canister line to vapor
valve (5).
4. Remove battery tray. See BATTERY TRAY (Page 7-97).
NOTE 2. Install canister to solenoid line.
Air cleaner removal and lifting rear of fuel tank is only a. See Figure 6-51. Install canister-to-solenoid line (1) to
necessary for replacing purge solenoid to induction module charcoal canister (3).
line.
b. See Figure 6-52. Install canister-to-solenoid line to purge
solenoid (2).
5. Remove air cleaner. See INSPECT AIR FILTER (Page 2-
40). 3. Install solenoid-to-induction module line.
6. Remove air cleaner backplate assembly. See AIR a. Install solenoid-to-induction module line (3) to induction
CLEANER BACKPLATE ASSEMBLY (Page 6-4). module.
7. Lift rearof fuel tank. See PURGE FUEL LINE (Page 6-12). b. Install solenoid-to-induction module line to purge
REMOVE solenoid (2).

1. Remove vapor valve-to-canister line.

a. See Figure 6-52. Disconnect vapor valve-to-canister line
(4) from vapor valve (5).
b. See Figure 6-51. Disconnect vapor valve-to-canister line
(2) from charcoal canister (3).

c. Remove vapor valve-to-canister line.

2. Remove canister-to-solenoid line.

a. Disconnect canister-to-solenoid line (1) from charcoal
canister (3).
b. See Figure 6-52. Disconnect canister-to-solenoid line (1)
from purge solenoid (2).

3. Remove solenoid-to-induction module line.

a. Remove solenoid-to-induction module line (3) from
purge solenoid (2).
b. Remove solenoid-to-induction module line from
induction module.

6-50 94000936
PURGE LINES: EVAPORATIVE EMISSIONS 6.22
4. Vapor valve-to-canister line
5. Vapor valve

Figure 6-52. Purge Lines

1. Canister-to-solenoid line
2. Purge solenoid
3. Solenoid-to-induction module line
COMPLETE 4. Install battery tray. See BATTERY TRAY (Page 7-97).

1. Secure fuel tank. See PURGE FUEL LINE (Page 6-12). 5. Install battery. See INSPECT BATTERY (Page 2-43).
2. Install air cleaner backplate assembly. See AIR CLEANER 6. Install right side cover. See RIGHT SIDE COVER (Page 3-
BACKPLATE ASSEMBLY (Page 6-4). 64).

3. Install air cleaner. See INSPECT AIR FILTER (Page 2-40). 7. Install main fuse. See POWER DISCONNECT (Page 7-7).

94000936 6-51
SUBJECT PAGE NO.
7.1 FASTENER TORQUE VALUES ............................. ............7-1
7.2 SPECIFICATIONS ................................................. ............ 7-5
7.3 FUSES................................................................... ........... .7-6
7.4 POWER DISCONNECT......................................... ............ 7-7
7.5 STARTER .............................................................. ............ 7-9
7.6 ALTERNATOR....................................................... .......... 7-10
7.7 VOLTAGE REGULATOR....................................... ......... 7-12
7.8 SPARK PLUG CABLES ......................................... ..........7-13
7.9 IGNITION COIL ..................................................... ......... .7-14
7.10 HANDLEBAR CONTROL MODULES .................. .......... 7-15
7.11 LEFT HAND CONTROL MODULE (LHCM) ......... .......... 7-16
7.12 RIGHT HAND CONTROL MODULE (RHCM) ...... .......... 7-20
7.13 INSTRUMENT MODULE (IM) .............................. ..........7-24
7.14 INDICATOR LAMPS ............................................ .......... 7-27
7.15 OIL PRESSURE SWITCH ................................... .......... 7-28
7.16 NEUTRAL INDICATOR SWITCH ........................ .......... 7-29
7.17 HORN .................................................................. .......... 7-30
7.18 HEADLAMP ......................................................... .......... 7-31
7.19 FRONT LIGHT BAR ............................................ .......... 7-43
7.20 AUXILIARY LAMPS ............................................. .......... 7-45
7.21 FRONT TURN SIGNAL LAMPS .......................... .......... 7-48
7.22 REAR TURN SIGNAL LAMPS ............................. .......... 7-52
7.23 TAIL LAMP .......................................................... ......... 7-57
7.24 REAR STOPLAMP SWITCH ............................... .......... 7-63

ELECTRICAL
7.25 LICENSE PLATE LAMP ...................................... .......... 7-64
7.26 TERMINATING RESISTOR................................. .......... 7-69
7.27 ELECTRONIC CONTROL MODULE (ECM)........ .......... 7-70
7.28 BODY CONTROL MODULE (BCM) .................... ..........7-71
7.29 SECURITY SYSTEM ACTIVATION .................... .......... 7-72
7.30 PERSONAL IDENTIFICATION NUMBER (PIN). . ..........7-73
7.31 SECURITY SYSTEM MAINTENANCE ................ .......... 7-74
7.32 SECURITY SIREN .............................................. .......... 7-76
7.33 SECURITY SYSTEM ANTENNA ......................... .......... 7-77
7.34 CRANKSHAFT POSITION SENSOR (CKP)........ ..........7-78
7.35 ENGINE TEMPERATURE (ET) SENSOR ........... ..........7-79
7.36 KNOCK SENSOR (KS) ....................................... .......... 7-80
7.37 AUTOMATIC COMPRESSION RELEASE (ACR) ......... 7-81
7.38 VEHICLE SPEED SENSOR (VSS) ..................... ..........7-83
7.39 FRONT WHEEL SPEED SENSOR (WSS) .......... ..........7-84
7.40 REAR WHEEL SPEED SENSOR (WSS) ............ ..........7-85
7.41 JIFFY STAND SENSOR (JSS) ............................ ..........7-86
7.42 FRONT ELECTRICAL CADDY ............................ ..........7-87
7.43 USB CADDY ....................................................... ..........7-90
7.44 ECM CADDY ....................................................... ..........7-93
7.45 BCM CADDY ....................................................... ......... .7-95
7.46 REAR LIGHTING CADDY ................................... ..........7-96
7.47 BATTERY TRAY ................................................. .......... 7-97
7.48 ENGINE GROUND CABLE ................................. ..........7-98
7.49 ENGINE WIRE HARNESS .................................. ..........7-99
7.50 BACKBONE WIRE HARNESS ............................ ....... 7-102
7.51 FAIRING WIRE HARNESS ................................. ....... 7-104
7.52 MAIN WIRE HARNESS ....................................... ....... 7-105
NOTES
FASTENER TORQUE VALUES 7.1

FASTENER TORQUE VALUES IN THIS

CHAPTER

FASTENER TORQUE VALUE NOTES

ACR 17-19 ft-lbs 23-26.4 N-m
7.37 AUTOMATIC COMPRESSION RELEASE
(ACR), Install
Auxiliary lamp bezel nut 9-12 in-lbs 1.07-1.36 N-m 7.20 AUXILIARY LAMPS, Bulb Replacement
Auxiliary lamp nut 19-23 ft-lbs 25.76-31.18 N-m 7.20 AUXILIARY LAMPS, Remove and Install:
Standard Lighting
Auxiliary lamp nut 19-23 ft-lbs 25.7-31.1 N-m 7.20 AUXILIARY LAMPS, Adjust
Battery, negative cable, screw 60-70 in-lbs 6.8-7.9 N-m 7.4 POWER DISCONNECT, Negative Battery Cable

Battery tray screw 6-9 ft-lbs 8.1-12.2 N-m 7.47 BATTERY TRAY, Install
Brake line clamp screw 36-48 in-lbs 4.1-5.4 N-m 7.11 LEFT HAND CONTROL MODULE (LHCM),
Install
Brake line clamp screw 36-48 in-lbs 4.1-5.4 N-m 7.12 RIGHT HAND CONTROL MODULE (RHCM),
Install
Brake line clamp screw 36-48 in-lbs 4.1-5.4 N-m 7.42 FRONT ELECTRICAL CADDY, Install
Brake line clamp screw 36-48 in-lbs 4.1-5.4 N-m 7.50 BACKBONE WIRE HARNESS, Install
ECM caddy large screw 36-60 in-lbs 4.1-6.8 N-m 7.44 ECM CADDY, Install
ECM caddy small screw 5^5-60 in-lbs 6.2-6.8 N-m 7.44 ECM CADDY, Install
ET sensor 11-15 ft-lbs 14.9-21 N-m 7.35 ENGINE TEMPERATURE (ET) SENSOR,
Install
Fender Support, Screw 42-46 ft-lbs 57-62 N-m 7.22 REAR TURN SIGNAL LAMPS, Remove and
Install: Fender Mount
Fender Support, Screw 42-46 ft-lbs 57-62.3 N-m 7.25 LICENSE PLATE LAMP, Remove and Install:
Side Mount
Fender Support, Screw 21-27 ft-lbs 28-37 N-m 7.25 LICENSE PLATE LAMP, Remove and Install:
Side Mount
Frame ground stud nut 50-90 in-lbs 5.7-10.2 N-m 7.44 ECM CADDY, Install
Frame ground stud nut 50-90 in-lbs 5.6-10.2 N-m 7.48 ENGINE GROUND CABLE, Install
Frame ground stud nut 50-90 in-lbs 5.6-10.2 N-m 7.52 MAIN WIRE HARNESS, Install
Front light bar, bracket screw 16-20 ft-lbs 21.7-27.1 N-m 7.19 FRONT LIGHT BAR, Remove and Install:
Standard Lighting
Front light bar, clamp screw 6-10 in-lbs 0.67-1.1 N-m 7.19 FRONT LIGHT BAR, Remove and Install:
Standard Lighting
Front light bar mounting screw 20-25 ft-lbs 27.1-33.9 N-m 7.19 FRONT LIGHT BAR, Remove and Install:
Standard Lighting
Handlebar-mounted turn signal, ball stud 96-144 in-lbs 10.8-16.3 N-m 7.21 FRONT TURN SIGNAL LAMPS, Remove and
clamp Install: Handlebar Mount
Handlebar-mounted turn signal, ball stud 50-70 in-lbs 5.6-7.9 N-m 7.21 FRONT TURN SIGNAL LAMPS, Remove and
jam nut Install: Handlebar Mount
Handlebar-mounted turn signal, ball stud 50-70 in-lbs 5.6-7.9 N-m 7.21 FRONT TURN SIGNAL LAMPS, Remove and
locknut Install: Handlebar Mount
Handlebar-mounted turn signal, ball stud 3-5 ft-lbs 4-6.7 N-m 7.21 FRONT TURN SIGNAL LAMPS, Remove and
set screw Install: Handlebar Mount
Handlebar switch assembly retainer 8-10 in-lbs 0.9-1.1 N-m 7.11 LEFT HAND CONTROL MODULE (LHCM),
screws Install
Handlebar switch assembly retainer 8-10 in-lbs 0.9-1.1 N-m 7.11 LEFT HAND CONTROL MODULE (LHCM),
screws Clutch Switch Replacement
Handlebar switch assembly retainer 8-10 in-lbs 0.9-1.1 N-m 7.12 RIGHT HAND CONTROL MODULE (RHCM),
screws Install

94000936 7-1
FASTENER TORQUE VALUE NOTES
Handlebar switch assembly retainer 8-10 in-lbs 0.59-1.1 N-m 7.12 RIGHT HAND CONTROL MODULE (RHCM),
screws Front Brake Switch Replacement
Handlebar switch housing screws 35--4 in-lbs 4-5.1 N-m 7.11 LEFT HAND CONTROL MODULE (LHCM),
Install
Handlebar switch housing screws 35-45 in-lbs 4-5.1 N-m 7.12 RIGHT HAND CONTROL MODULE (RHCM),
Install
Headlamp, fixed fairing, Bracket-to-lamp in-lbs 9.459-12.2 N-m 7.18 HEADLAMP, Remove and Install: Fixed Fairing
screws
Headlamp, fixed fairing, retainer screws 22-32 in-lbs 2.59-3.6 N-m
7.18 HEADLAMP1, Remove and Install: Fixed Fairing
Headlamp, nacelle mounted, bezel screw 25-32 in-lbs 2.8-3.6 N-m 7.18 HEADLAMP Bulb Replacement: Nacelle
Mounted
Headlamp, nacelle mounted, retainer 17-25 in-lbs 1.9-2.8 N-m 7.18 HEADLAMP Bulb Replacement: Nacelle
screw Mounted
Headlamp, oblong, bracket-to-fork clamp 1(^20 ft-lbs 21.6-27.1 N-m 7.18 HEADLAMP Remove and Install: Oblong
screws
Headlamp, oblong, isolator screws 33-4 in-lbs 3.7--49 N-m 7.18 HEADLAMP Remove and Install: Oblong
Headlamp, oblong, mounting screw 10-13ft-lbs 13.6-17.6 N-m 7.18 HEADLAMP Remove and Install: Oblong
Headlamp, round, locknut 27-32 ft-lbs 36.6-4.3 N-m 7.18 HEADLAMP Remove and Install: Standard
Round
Headlamp, upper triple clamp mounted, 11-14 ft-lbs 15-19 N-m 7.18 HEADLAMP Remove and Install: Horizontal
screw
Headlamp (Oblong) mounting screw 1<0-13ft-lbs 13.5-17.6 N-m 7.18 HEADLAMP Bulb Replacement: Oblong
Headlamp bezel screw 9-14 in-lbs 1-1.6N-m 7.18 HEADLAMP Bulb Replacement: Standard
Round
Headlamp bracket to headlamp mounting 27-32 ft-lbs 36.6-43 N-m 7.1 (3 HEADLAMP Remove and Install: LED Round
bracket bolt
27-32 ft-lbs 36.6-4.3 N-m 7.18 HEADLAMP, Adjust
Headlamp FXBBS, FXST, FXLRS, FLSB
vertical adjustment screw
Headlamp FXBBS, FXST horizontal ad- 20-25 ft-lbs 27.1-33.9 N-m 7.18 HEADLAMP Adjust
justment screw
Headlamp FXBRS, vertical adjustment 1<0-13ft-lbs 13.5-17.6 N-m 7.18 HEADLAMP Adjust
screw
Headlamp FXFBS vertical adjustment 11-14 ft-lbs 14.9-19 N-m 7 .18 HEADLAMP Adjust
screw
Headlamp isolator bracket screw 6.5-8.0 ft-lbs 8.8-10.8 N-m 7.18 HEADLAMP Bulb Replacement: Standard
Round
Headlamp mounting bracket to lower fork 2(0-25 ft-lbs 27.1-33.9 N-m 7.18 HEADLAMP Remove and Install: LED Round
bracket
Headlamp mounting ring screw 16-20ft-lbs 21.6-27.1 N-m 7.18 HEADLAMP Remove and Install: Nacelle
Mounted
Headlamp nacelle, screw 16-20 ft-lbs 21.6-27.1 N-m 7.18 HEADLAMP Remove and Install: Horizontal
Headlamp retainer screw 18-22 in-lbs 2-2.5 N-m 7.18 HEADLAMP Bulb Replacement: Standard
Round
Headlamp to headlamp bracket screw 96-120 in-lbs 10.8-13.6 N-m 7.18 HEADLAMP Bulb Replacement: LED Round
Horn, Bracket Screw 62-71 in-lbs 7-8 N-m 7.17 HORN, Assemble
Horn, Narrow Mounting Screw 27-33 in-lbs 59-3.7 N-m 7.17 HORN, Install
Horn, Wide Mounting Screw in-lbs 9.5-12.2 N-m 7.17 HORN, Install
Housing to IM screw 2(0-25 in-lbs 2.3-2.8 N-m 7.13INSTRUMENT MODULE (IM), Remove and
Install: Console Without Panel
Ignition coil, screw 11-14ft-lbs 159-19 N-m 7.59 IGNITION COIL, Install
IM, rectangular, handlebar clamp screws 12-17 in-lbs 1.4-1.9 N-m 7.13 INSTRUMENT MODULE (IM), Remove and
Install: Handlebar Mount

7-2 94000936
FASTENER TORQUE VALUE NOTES
IM, round.cover screws 12-17 in-lbs 1.4-1.9 N-m 7.13 INSTRUMENT MODULE (IM), Remove and
Install: Handlebar Mount
Indicator lamp, screw 20-30 in-lbs 2.26-3.39 N-m 7.14 INDICATOR LAMPS, Install
JSS screw 20-25 in-lbs 2.3-2.8 N-m 7.41 JIFFY STAND SENSOR (JSS), Install
Knock sensor screw 13-17 ft-lbs 17.6-23 N-m 7.36 KNOCK SENSOR (KS), Install
License plate, center mount, lamp housing 10-20 in-lbs 1.1-2.25 N-m 7.25 LICENSE PLATE LAMP, Bulb Replacement
screw
License plate, center mount, lamp housing 10-20 in-lbs 1.1-2.25 N-m 7.25 LICENSE PLATE LAMP, Remove and Install:
screw Center Mount
License plate, center mount, tail lamp 10-20 in-lbs 1.1-2.25 N-m 7.23 TAIL LAMP, Remove and Install: Center Mount
screw
License plate, LED housing, screw 10-20 in-lbs 1.1-2.3 N-m 7.25 LICENSE PLATE LAMP, Remove and Install:
License Plate Bracket Mount
License plate, tail lamp, screw 10-20 in-lbs 1.1-2.3 N-m 7.23 TAIL LAMP, Remove and Install: License Plate
Bracket Mount
License plate holder, screw 60-80 in-lbs 6.8-9 N-m 7.23 TAIL LAMP, Remove and Install: License Plate
Bracket Mount
License plate holder, screw 60-80 in-lbs 6.8-9 N-m 7.25 LICENSE PLATE LAMP, Remove and Install:
License Plate Bracket Mount
License Plate Lamp Cover, Screw 8-16 in-lbs 0.9-1.8 N-m 7.25 LICENSE PLATE LAMP, Remove and Install:
Side Mount
Lower fairing bracket screw 96-120 in-lbs 10.8-13.6 N-m 7.18 HEADLAMP, Remove and Install: LED Round
Rear fork clamp screw 24-36 in-lbs 2.7-4.1 N-m 7.40 REAR WHEEL SPEED SENSOR (WSS),
Remove and Install: Standard Fork
Rear stoplamp switch 12-15 ft-lbs 16.3-20.3 N-m 7.24 REAR STOPLAMP SWITCH, Install
Rear Turn Signal, Center Mount, Screw 15-18 ft-lbs 20-24 N-m 7.22 REAR TURN SIGNAL LAMPS, Remove and
Install: Center Mount
Rear Turn Signal, Fender Mount, Screw 15-18 ft-lbs 20-24 N-m 7.22 REAR TURN SIGNAL LAMPS, Remove and
Install: Fender Mount
Rear Turn Signal, Fender Mount, Screw 15-18 ft-lbs 20-24 N-m 7.22 REAR TURN SIGNAL LAMPS, Remove and
Install: Fender Mount
Rear Turn Signal, Fender Mount, Screw 15-18 ft-lbs 20-24 N-m 7.25 LICENSE PLATE LAMP, Remove and Install:
Side Mount
Rear Turn Signal, Fender Support, Screw 21-27 ft-lbs 28-37 N-m 7.22 REAR TURN SIGNAL LAMPS, Remove and
Install: Fender Mount
Rear Turn Signal, Light Bar Mount, Screw 16-20 ft-lbs 22-27 N-m 7.22 REAR TURN SIGNAL LAMPS, Remove and
Install: Light Bar Mount
Rear turn signal, rear lighting assembly, 10-13 ft-lbs 14.12-17.74 N-m 7.22 REAR TURN SIGNAL LAMPS, Remove and
screw Install: Rear Lighting Assembly
Sensor, CKP, screw 90-120 in-lbs 10.2-13.6 N-m 7.34 CRANKSHAFT POSITION SENSOR (CKP),
Install
Sensor, vehicle speed, screw 100-120 in-lbs 11.3-13.6 N-m 7.38 VEHICLE SPEED SENSOR (VSS), Install
Solenoid nut 80-90 in-lbs 9-10.2 N-m 7.5 STARTER, Install
Starter, mounting screw 22-24 ft-lbs 29.8-32.5 N-m 7.5 STARTER, Install
Stator mounting screws 55-75 in-lbs 6.2-8.5 N-m
7.6 ALTERNATOR, Install
Always use new screws
Sub caddy screw 36-60 in-lbs 4.1-6.8 N-m 7.27 ELECTRONIC CONTROL MODULE (ECM),
Install
Switch, Neutral Indicator 120-180 in-lbs 13.6-20.3 N-m 7.16 NEUTRAL INDICATOR SWITCH, Install
Switch, Oil Pressure 13-17 ft-lbs 17-23 N-m 7.15 OIL PRESSURE SWITCH, Install
Tail lamp, circuit board screw 40-48 in-lbs 4.5-5.4 N-m 7.23 TAIL LAMP, Remove and Install: Standard
Tail lamp bracket, screw 40-48 in-lbs 4.5-5.4 N-m 7.23 TAIL LAMP, Remove and Install: Rear Lighting
Assembly

94000936 7-3
FASTENER TORQUE VALUE NOTES
Tail lamp lens screw 20-24 in-lbs 2.3-2.7 N-m 7.23 TAIL LAMP, Remove and Install: Standard
Tail Lamp Lens Screw 20-24 in-lbs 2.3-2.7 N-m 7.23 TAIL LAMP, Bulb Replacement
Transmission ground stud nut 72-96 in-lbs 8.1-10.9 N-m 7.48 ENGINE GROUND CABLE, Install
Turn signal, frame mounted fairing, screw 15-18 ft-lbs 20.34-24.4 N-m 7.21 FRONT TURN SIGNAL LAMPS, Remove and
Install: Fixed Fairing Mount
Under seat frame, rear screws 96-120 in-lbs 10.9-13.6 N-m 7.50 BACKBONE WIRE HARNESS, Install
Under seat frame cover, front screw 20-30 in-lbs 2.3-3.4 N-m 7.50 BACKBONE WIRE HARNESS, Install
USB caddy screw 14-17 in-lbs 1.6—1.9 N-m 7.43 USB CADDY, Assemble
Voltage regulator, screw 106-124 in-lbs 12-14 N-m 7.7 VOLTAGE REGULATOR, Install
Voltage regulator bracket, screw 100-120 in-lbs 11.3-13.6 N-m 7.7 VOLTAGE REGULATOR, Install
Wide mounting screw 84-108 in-lbs 9.5-12.2 N-m 7.43 USB CADDY, Install
Wireform screw, headlamp, oblong, 10-12 ft-lbs 13.5-16.2 N-m 7.18 HEADLAMP, Remove and Install: Oblong

7-4 94000936
SPECIFICATIONS 7.2

SPECIFICATIONS Table 7-5. Regulator Specifications

REGULATOR VALUE
Amperes @ 3,600 rpm 40--44A
Table 7-1. Battery Specifications
Voltage @ 3,600 rpm 14.1-14.5 V@ 75.2 °F (24 °C)
BATTERY SPECIFICATIONS
Size 12 V/17.5 Ah/315 CCA
Type Table 7-6. Fuse Specifications
Sealed, Absorbed Glass Mat
ITEM RATING
(AGM) battery
Main 40A
Battery 5A
Table 7-2. Starter Specifications Battery tender 7.5A
STARTER SPECIFICATIONS System 7.5A
Cranking current 250 A maximum
Free current 90A maximum Table 7-7. Ignition Coil Specifications
WINDING RESISTANCE
Table 7-3. Alternator Specifications
Primary resistance 0.2-0.5 0
ALTERNATOR VALUE
Secondary resistance 5,500-8,000 0
Three phase 42 A system
AC voltage output 16-28 VAC per 1,000 rpm
Stator coil resistance 0.1-0.3 0 Table 7-8. Spark Plug Cables
LOCATION LENGTH RESISTANCE
Left front and 7.36--7.64 In (187-194 mm) 1,840-5,085 0
Table 7-4. Spark Plug Cables
rear
LOCATION LENGTH RESISTANCE
Right front 15.00-15.24 in (381-387 3,750-10,070 0
Left front and 7.36-7.64 in (187-194 mm) 1,840-5,085 0
and rear mm)
rear
Right front 15.00-15.24 in (381-387 3,750-10,070 0
and rear mm)

94000936 7-5
 FUSES 7.3
PREPARE

1. Remove left side cover. See LEFT SIDE COVER (Page 3-

63).

REMOVE ______________________________

Primary Fuses
1. See Figure 7-1. Remove fuse block (3) from ECM sub
caddy.

2. Remove fuse cover (1).

3. See Figure 7-2. Remove required fuse.

INSTALL

See Figure 7-2 for proper amperage rating.

Primary Fuses
1. Fuse, main Fuse,
1. See Figure 7-2. Install required fuse. 2. system Fuse, battery
3. tender Fuse, battery
2. See Figure 7-1. Install primary fuse cover (1). 4. Fuse(s), spare
5.
3. Install fuse block (3) onto ECM sub caddy. Figure 7-2. Fuses
COMPLETE
1. Install left side cover. See LEFT SIDE COVER (Page 3-63).

A WARNING

Be sure that all lights and switches operate properly before

operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

2. Test affected circuit for proper operation.

Figure 7-1. Fuse Block

7-6 94000936
 POWER DISCONNECT 7.4
MAIN FUSE

Remove main fuse when there is a possibility of injury caused by

accidental vehicle start-up or electrical equipment damage.

Remove Main Fuse

1. Remove left side cover. See LEFT SIDE COVER (Page 3-63).

2. Models with security:

a. Verify that fob is present.

b. Turn OFF/RUN switch to RUN.

A WARNING
To prevent accidental vehicle start-up, which could cause death or
serious injury, remove main fuse before proceeding. (00251b)

3. See Figure 7-3. Remove fuse cover (1).

NEGATIVE BATTERY CABLE
a. Remove fuse block from ECM (Electronic control
module) sub caddy. FASTENER TORQUE VALUE
Battery, negative cable, screw 60-70 in-lbs ! 6.8-7.9 N-m
b. Remove fuse cover.
A WARNING
To prevent accidental vehicle start-up, which could cause death or
4. Remove main fuse (2).
serious injury, disconnect negative (-) battery cable before
proceeding. (00048a)
5. Models with security: Turn ignition switch OFF.
Install Main Fuse Disconnect negative battery cable when there is a possibility of
injury caused by starter engagement (engine rotation).
1. See Figure 7-3. Install main fuse (2).

2. Install fuse cover (1). Disconnect Negative Battery Cable

1. Remove right side cover. See RIGHT SIDE COVER (Page 3-
3. Install fuse block onto ECM sub caddy. 64).
4. Install left side cover. See LEFT SIDE COVER (Page 3-63).
2. Models with security:
A WARNING
Be sure that all lights and switches operate properly before a. Verify that fob is present.
operating motorcycle. Low visibility of rider can result in death or
serious injury. (00316a) b. Turn OFF/RUN switch to RUN.

5. Test affected circuits for proper operation. 3. See Figure 7-4. Remove screw (1).

4. Disconnect negative battery cable (2).

5. Models with security: Turn ignition switch OFF.

Connect Negative Battery Cable
1. See Figure 7-4. Connect negative battery cable (2).

2. Install screw (1). Tighten

Torque: 60-70 in-lbs (6.8-7.9 N-m) Battery, negative cable,

screw

3. Install right side cover. See RIGHT SIDE COVER (Page 3-

64).

94000936 7-7
 A WARNING

Be sure that all lights and switches operate properly before

operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

4. Test affected circuits for proper operation.

Figure 7-4. Negative Battery Cable Disconnect

7-8 94000936
STARTER 7.5
PREPARE 2. Install starter.

a. Apply thread-locker to screws (1).

A WARNING

To prevent accidental vehicle start-up, which could cause death LOCTITE 243 MEDIUM STRENGTH
or serious injury, disconnect negative (-) battery cable before THREADLOCKER AND SEALANT (BLUE) (99642-
proceeding. (00048a) 97)

1. Remove right side cover. See RIGHT SIDE COVER (Page b. Install screws. Tighten.
3-64). Torque: 22-24 ft-lbs (29.8-32.5 N-m) Starter,
mounting screw
2. Remove battery. See INSPECT BATTERY (Page 2-43). c. Connect connector (2) to solenoid.

3. Models with side mounted shock adjuster: Remove screw d. Install positive battery cable (3) to solenoid. Tighten.
securing shock adjustment knob to ABS bracket. See REAR
SHOCK ABSORBER (Page 3-87). Torque: 80-90 in-lbs (9-10.2 N-m) Solenoid nut
NOTE
REMOVE _______________________________ Install battery cable at 3 o'clock position.

1. See Figure 7-5. Remove positive cable (3).

2. Remove starter.

a. Disconnect connector (2) from solenoid.

b. Remove screws (1).

3. Discard O-ring (4).

INSTALL _______________________

FASTENER TORQUE VALUE

Solenoid nut 80-90 in-lbs 9-10.2 N-m
Starter, mounting screw 22-24 ft-lbs 29.8-32.5 N-m

CONSUMABLE PART NUMBER

LOCTITE 243 99642-97
MEDIUM
STRENGTH
THREADLOCKER COMPLETE
AND SEALANT
(BLUE) 1. Models with side mounted shock adjuster: Install screw
1. See Figure 7-5. Install new O-ring (4). securing shock adjustment knob to ABS bracket. See REAR
SHOCK ABSORBER (Page 3-87).
a. Lubricate new O-ring with clean engine oil.
2. Install battery. See INSPECT BATTERY (Page 2-43).
b. Install new O-ring (4).
3. Install right side cover. See RIGHT SIDE COVER (Page 3-
64).

94000936 7-9
ALTERNATOR 7.6
PREPARE 6. Remove stator assembly.

1. Remove left side cover. See LEFT SIDE COVER (Page 3- INSTALL___________
63).
PART NUMBER TOOLNAME
2. Remove main fuse. See POWER DISCONNECT (Page 7-7). HD-52073 ALTERNATOR ROTOR REMOVER AND
INSTALLER
3. Remove left side rider foot control assembly, if necessary.
See LEFT FOOT CONTROLS (Page 3-128). FASTENER TORQUE VALUE
Stator mounting screws 55-75 in-lbs 6.2-8.5 N-m
4. Drain primary chaincase. See REPLACE PRIMARY 1. Install grommet.
CHAINCASE LUBRICANT (Page 2-9).
a. Lubricate parts with glass cleaner or isopropyl alcohol.
5. Remove primary cover. See PRIMARY CHAINCASE Ribs of grommet must be clean and free of dirt and
HOUSING (Page 5-27). oily residue.

b. Feed connector and harness through hole from inside

6. Remove compensator assembly. See DRIVE
COMPONENTS (Page 5-18). crankcase.

c. Push grommet into crankcase bore while carefully

REMOVE _______________________________ pulling on outside cable.
PART NUMBER TOOL NAME
HD-52073 ALTERNATOR ROTOR REMOVER AND d. Installation is complete when cable stop contacts
INSTALLER casting and capped rib of grommet exits crankcase
bore.
1. See Figure 7-6. Disconnect connector (5) from voltage NOTE
regulator.
Do not reuse stator mounting screws.

A CAUTION
2. See Figure 7-6. Secure stator to crankcase using new
The high-output rotor contains powerful magnets. Exercise screws (2). Tighten to:
caution to prevent possible hand injury during removal and
installation. (00558b) Torque: 55-75 in-lbs (6.2-8.5 N-m) Stator mounting
screws

2. Remove rotor (4). 3. See Figure 7-7. Secure stator wiring (2) to frame with new
Special Tool: ALTERNATOR ROTOR REMOVER AND cable strap (1). Verify that stator wire does not contact the
INSTALLER (HD-52073) engine or frame.

3. See Figure 7-7. Discard cable strap. 4. Apply silicone based dielectric grease to connector.
NOTE
The rubber molded stator connector (5) is not serviceable. 5. Install connector to voltage regulator. Engage locking latch.
NOTE
4. See Figure 7-6. Discard screws (2). Install rotor slowly to prevent damaging rotor magnets.
Damaged magnet fragments can damage the stator.
5. See Figure 7-8. Remove grommet (2).

a. Use the end of an awl (1) or small screwdriver to A CAUTION

move grommet (2) away from crankcase.
The high-output rotor contains powerful magnets. Exercise
caution to prevent possible hand injury during removal and
b. Spray isopropyl alcohol or glass cleaner into opening.
installation. (00558b)

c. Repeat this step at one or two other locations around

grommet. 6. Install rotor.
Special Tool: ALTERNATOR ROTOR REMOVER AND
d. Push grommet from outside of crankcase while pulling INSTALLER (HD-52073)
through the bore with needle nose pliers.

NOTE
Do not pull stator wiring unless the stator is being
replaced.

7-10 94000936
 1. Stator
2. Screw (3)
3. Grommet
4. Rotor
5. Connector [47B]
Figure 7-6. Rotor and Stator
Figure 7-8. Remove Grommet From Crankcase (Typical)
COMPLETE

1. Install compensator assembly. See DRIVE COMPONENTS

(Page 5-18).

2. Install primary cover. See PRIMARY CHAINCASE

HOUSING (Page 5-27).

3. Fill primary chaincase. See REPLACE PRIMARY

CHAINCASE LUBRICANT (Page 2-9).

4. Install left side rider foot control assembly. See LEFT FOOT
CONTROLS (Page 3-128).

5. Install main fuse. See POWER DISCONNECT (Page 7-7).

6. Install left side cover. See LEFT SIDE COVER (Page 3-63).

94000936 7-11
VOLTAGE REGULATOR 7.7
PREPARE _____________ COMPLETE

1. Remove left side cover. See LEFT SIDE COVER (Page 3- 1. Install main fuse. See Refer to POWER DISCONNECT
63). (Page 7-7)..

2. Remove main fuse. See Refer to POWER DISCONNECT 2. Install left side cover. See LEFT SIDE COVER (Page 3-63).
(Page 7-7)..

REMOVE

1. See Figure 7-9 Remove screws (1).

2. Remove voltage regulator (2).

3. Disconnect voltage regulator connectors (3).

INSTALL
FASTENER TORQUE VALUE
Voltage regulator bracket, 100-120 in-lbs 11.3-13.6 N-m
screw
Voltage regulator, screw 106-124in-lbs 12-14 N-m

1. Install voltage regulator bracket, if removed.

a. Install bracket.

b. Install screws. Tighten.

Torque: 100-120 in-lbs (11.3-13.6 N-m) Voltage

regulator bracket, screw

2. See Figure 7-9. Connect voltage regulator connectors (3).

3. Align voltage regulator (2) to mounting bracket.

4. Install screws (1). Tighten.
Torque: 106-124 in-lbs (12-14 N-m) Voltage regulator.
screw

7-12 94000936
SPARK PLUG CABLES 7.8
REMOVE 4. NOTE
Make sure spark plug cables do not make contact with
rocker cover screw heads.
A WARNING

Disconnecting spark plug cable with engine running can result See Figure 7-11. Install cables retainers (5).
in electric shock and death or serious injury. (00464b)
5. Verify spark plug cable routing.
NOTE
• Remove cable end by pulling on rubber boot only. Do not
pull on cable or damage can result.
• Pull and twist simultaneously to remove rubber boot.

1. See Figure 7-10. Remove cables retainers (5).

2. Remove cables (1--4) from ignition coil.

3. Remove boot from spark plugs.

4. Remove cables.
INSTALL

1. See Figure 7-10. Route and connect long cables (3, 4) to

right spark plugs.

1. Left rear
2. Connect short cables (1, 2) to left spark plugs.
2. Left front
3. Right front
3. Connect cables to ignition coil.
4. Right rear
5. Cable retainer (2)
Figure 7-10. Spark Plug Cable

1061493

1. Front left spark plug 4. Rear right spark plug

2. Rear left spark plug 5. Cable retainer (2)
3. Front right spark plug
Figure 7-11. Spark Plug Cable Routing: (Fuel tank removed for clarity)

94000936 7-13
IGNITION COIL 7.9
PREPARE __________________________ _

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

REMOVE _______________________________

1. See Figure 7-12. Disconnect ignition coil connector (3).

2. See Figure 7-13. Disconnect spark plug cables (1)

3. Remove screw (2).

4. Remove ignition coil (3).

INSTALL _______________________________
1. See Figure 7-13. Install ignition coil (3).

FASTENER TORQUE VALUE

Ignition coil, screw 11-14 ft-lbs 15--19 N-m
2. Install screw (2). Tighten.

Torque: 11-14 ft-lbs (15--19 N-m) Ignition coil, screw

3. Connect spark plug cables (1). See SPARK PLUG CABLES

(Page 7-13)

4. See Figure 7-12. Connect ignition coil connector.

COMPLETE

1. Install main fuse. See POWER DISCONNECT

(Page 7-7).

7-14 94000936
HANDLEBAR CONTROL MODULES 7.10
GENERAL 6. See Figure 7-14. Use ULTRA TORCH UT-100 (PART
NUMBER: HD-39969) or ROBINAIR HEAT GUN (PART
• The left and right hand control modules are non-repairable. NUMBER: HD-25070) with HEAT SHIELD ATTACHMENT
(PART NUMBER: HD-41183) or equivalent. Uniformly heat
• The clutch switch and brake switch are hard-wired to the the heat shrink tubing to insulate and seal the soldered
control modules. connections. Apply heat just until the meltable sealant
exudes out both ends of tubing and assumes a smooth
• The clutch switch and brake switch are replaceable. This
cylindrical appearance.
section details the proper method for soldering new switches.
For removal and installation procedures, see Front Brake 7. Inspect solder connection.
Switch Replacement (Page 7-22) or Clutch Switch
a. Inspect the melted sealant for solder beads.
Replacement (Page 7-19).
b. Excess solder or heat can force out some solder with the
SOLDER PROCEDURE 11 12 melted sealant.

PART NUMBER TOOL NAME c. Remove any solder found.

HD-25070 ROBINAIR HEAT GUN d. Briefly heat the connection to reseal the tubing if solder
HD-39969 ULTRA TORCH UT-100 beads were removed.
HD-41183 HEAT SHIELD ATTACHMENT e. Use less solder or reduce heating time or intensity when
doing subsequent splices.

A WARNING
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

1. Push conduit back to better access wires and avoid

damaging conduit with radiant heating device. Secure
conduit with cable strap.

2. Strip 0.5 in (12.7 mm) of insulation off switch wires. Twist

stripped ends of switch wires until all strands are tightly
coiled.
3. Cut dual wall heat shrink tubing, supplied in repair kit into 1.0
in (25.4 mm) segments. Slide tubing over each wire of new
switch assembly.

4. Splice existing and new switch wires, matching wire colors.

Solder the spliced connections. For best results, splice one
wire at a time.
5. Center the heat shrink tubing over the soldered splices.
A WARNING
Be sure to follow manufacturer's instructions when using the
UltraTorch UT-100 or any other radiant heating device.
Failure to follow manufacturer's instructions can cause a
fire, which could result in death or serious injury. (00335a)
12 Avoid directing heat toward any fuel system component.
Extreme heat can cause fuel ignition/explosion resulting in
death or serious injury.
■ Avoid directing heat toward any electrical system component
other than the connectors on which heat shrink work is being
performed.
• Always keep hands away from tool tip area and heat shrink
attachment.

94000936 7-15
LEFT HAND CONTROL MODULE (LHCM) 7.11
PREPARE

1. Remove seat. See SEAT (Page 3-142).

2. Purge fuel system. See PURGE FUEL LINE (Page 6-12).

3. Remove main fuse. See POWER DISCONNECT (Page 7-7).

4. Remove fuel tank. See FUEL TANK (Page 6-14).

5. Detach clutch control clamp from handlebar. See CLUTCH

CONTROL (Page 3-91 ).

REMOVE

A WARNING

To prevent accidental vehicle start-up, which could cause

death or serious injury, remove main fuse before proceeding.
(00251b)

1. See Figure 7-15. Remove brake line clamp screws.

2. See Figure 7-16. Remove front electrical caddy from left side
of frame.

3. Record locations of cable straps securing LHCM harness.

4. Discard cable straps securing LHCM harness.

1. Console
2. Heated hand grip
5. Disconnect Left Hand Control Module (LHCM) connector (9).
3. Twist grip
4. WSS
5. Right turn signal
6. Right Hand Control Module (RHCM) [22-2]
7. RHCM [22-1]
8. Headlamp
9. LHCM
10. Left turn signal
Figure 7-16. Front Electrical Caddy Connectors

6. Cruise Control Models: See Figure 7-17. Remove clip (2)

and switch (1).

7. Remove LHCM housing.

a. Remove upper and lower switch housing screws.

Figure 7-15. Brake Line Clamps
b. Remove upper switch housing.

c. See Figure 7-18. Remove screws (3) and retainer (1).

d. Remove clutch switch (2) and LHCM from lower

switch housing.

7-16 94000936
 1. Internally wired handlebars: Route LHCM wires through
handlebar.

a. Attach scrap wire to new LHCM wiring.

b. Pull LHCM wiring through handlebar.

c. Remove scrap wire.

2. Externally wired handlebars: Attach using anchors.

3. See Figure 7-18. Place switch assembly into position on

lower switch housing.
1. Switch
2. Clip _________________________ 4. Install clutch switch (2).
Figure 7-17. Cruise Switch
5. NOTE
• Handlebar-mounted turn singles: See Figure 7-19.
Verify that turn signal wiring (1) is routed through
opening (2).
• Always tighten lower switch housing screw first, so
that any gap between upper and lower housings is at
front of switch.

See Figure 7-18. Install retainer (1) with screws (3). Tighten.
Torque: 8-10 in-lbs (0.9-1.1 N-m) Handlebar switch
assembly retainer screws

6. See Figure 7-20. Install upper and lower switch housing.

Align seam (2) with alignment mark (1).

Figure 7-18. LHCM and Clutch Switch Retainer

8. NOTE
Verify that there is enough wire to work at both ends of
handlebar with scrap wire installed through handlebar.

Internally wired handlebars: Remove control module.

a. Attach scrap wire to control module connector.

b. Pull control module wiring through handlebar.

c. Disconnect scrap wire from old control module

connector.

9. Externally wired handlebars: Remove control module.

a. Release module wiring from anchors.

INSTALL
FASTENER TORQUE VALUE
Brake line clamp screw 36-48 in-lbs 4.1-5.4 N-m
Handlebar switch assembly 8-10 in-lbs 0.9-1.1 N-m
retainer screws
Handlebar switch housing 35-45 in-lbs 4-5.1 N-m
screws

94000936
 sm08521 5. Install switch housing.

is01405a

Figure 7-20. Hand Control Module Alignment (Typical)

1. Alignment mark
2. Control module seam

7. Install switch housing screws. Tighten.

Torque: 35--45 in-lbs (4-5.1 N-m) Handlebar switch
housing screws
8. Cruise Control Models: See Figure 7-17. Install switch (1)
1. Switch cap installed correctly
and clip (2).
2. Switch cap removal from shaft
3. Switch cap removal from pivot pin
9. See Figure 7-16. Connect LHCM connector (9). 4. Switch cap installation on to pivot pin
5. Switch cap installation onto shaft
10. Place front electrical caddy into frame, and install frame Figure 7-21. Switch Cap Removal and Replacement
plug.
Cruise Switch Cap
11. See Figure 7-15. Install brake clamp screws. Tighten.
1. See Figure 7-22. Remove cap.
Torque: 3^48 in-lbs (4.1-5.4 N-m) Brake line clamp
screw a. Remove clip (2).

12. Install new cable straps in locations recorded in Remove. b. Remove cap (1).

SWITCH CAPS

2. Install cap.
Rocker Switch Caps
1. Remove handlebar switch housing. a. Install cap.

2. NOTE b. Install clip.

There are small pins and springs under some caps.
Springs and pins could be lost during cap removal or c. Verify cap is secure.
installation. Figure 7-22. Cruise Switch Cap
is08688

Remove switch cap.

a. See Figure 7-21. Carefully pry switch cap up off pin

(2) on side of switch.

b. Pry switch cap up and away from pin (3) on opposite

side.

3. Install switch cap.

a. Place cap onto switch, angling hole over pin (4).

1. Cap
b. Carefully press switch cap down onto opposite pin 2. Clip
(5) , rocking cap until snapping into place.

4. Verify proper operation.

94000936
7-18
CLUTCH SWITCH REPLACEMENT 8. Solder wires together and cover with heat shrink tubing.
9. See Figure 7-18 . Install clutch switch (2) into housing. Install
FASTENER TORQUE VALUE retainer (1) and screws (3). Tighten.
Handlebar switch assembly 8-10 in-lbs 0.9-1.1 N-m Torque: 8-10 in-lbs (0.9-1.1 N-m) Handlebar switch
retainer screws assembly retainer screws
1. Remove upper switch housing cover. See Remove (Page 7- 10. Assemble left handlebar switch housing. See Install (Page
16).
7-17).

2. See Figure 7-18. From inside the switch housing, remove COMPLETE
screws (3) and retainer (1).

1. Install clutch controls on handlebar. See CLUTCH

3. Remove clutch switch (2) from housing. CONTROL (Page 3-91).

4. Cut wires flush at inoperative clutch switch.

2. Install fuel tank. See FUEL TANK (Page 6-14).

5. If new clutch switch wires have terminals installed, cut wires 3. Install main fuse. See POWER DISCONNECT (Page 7-7).
at terminal end.

4. Install seat. See SEAT (Page 3-142).

6. Remove 0.25-0.31 in (6.4-7.9 mm) of insulation from each
wire end.

7. Cut two pieces of dual wall heat shrink tubing to 12.7 mm

(0.5 in).

94000936
7-19
RIGHT HAND CONTROL MODULE (RHCM) 7.12
PREPARE ______________________ ___

1. Remove seat. See SEAT (Page 3-142).

2. Purge fuel system. See PURGE FUEL LINE (Page 6-12).

3. Remove main fuse. See POWER DISCONNECT (Page 7-7).

4. Remove fuel tank. See FUEL TANK (Page 6-14).

5. Detach front brake clamp from handlebar. See FRONT

BRAKE MASTER CYLINDER (Page 3-35).

REMOVE ___________________

A WARNING

To prevent accidental vehicle start-up, which could cause death

or serious injury, remove main fuse before proceeding. (00251b)

1. See Figure 7-23. Remove brake line clamp screws.

2. See Figure 7-24. Remove front electrical caddy.

3. Record locations of cable straps securing RHCM harness.

4. Discard cable straps securing RHCM harness.

5. Disconnect RHCM connectors (6 and 7).

1. Console
2. Heated hand grip
3. Twist grip
4. WSS
5. Right turn signal
6. RHCM [22-2]
7. RHCM [22-1]
8. Headlamp
9. LHCM
10. Left turn signal

Figure 7-24. Front Electrical Caddy Connectors

6. Remove RHCM housing.

a. Remove upper and lower switch housing screws.

b. Remove upper switch housing.

c. See Figure 7-25. Remove screws (3) and retainer (1).

d. Remove brake switch (2) and RHCM from lower

switch housing.

7-20 94000936
 NOTE
Handlebar-mounted turn singles: See Figure 7-26.
Verify that turn signal wiring (1) is routed through
opening (2).
Always tighten lower switch housing screw first, so
that any gap between upper and lower housings is at
front of switch.

See Figure 7-25. Install retainer (1) with screws (3). Tighten.
Torque: 8-10 in-lbs (0.9-1.1 N-m) Handlebar switch
assembly retainer screws

5. See Figure 7-27. Install upper and lower switch housing.

Align seam (2) with alignment mark (1).

6. Install switch housing screws finger tight.

7. Set right hand grip end play.

a. Move RHCM assembly inboard to remove grip end

play.
Figure 7-25. RHCM and Brake Switch Retainer
7. NOTE
b. Move switch housing outboard to specification.
Verify that there is enough wire to work at both ends of 0.039-0.079 in (1-2 mm)
handlebar with scrap wire installed through handlebar.

Internally wired handlebars: Remove control module.

a. Attach scrap wire to control module connector.

b. Pull control module wiring through handlebar.

c. Disconnect scrap wire from old control module

connector.

8. Externally wired handlebars: Remove control module.

a. Release module wiring from anchors.

INSTALL

sm08521

FASTENER TORQUE VALUE

Brake line clamp screw 36-48 in-lbs 4.1-5.4 N-m
Handlebar switch assembly 8-10 in-lbs 0.9-1.1 N-m
retainer screws
Handlebar switch housing 3^45 in-lbs 4-5.1 N-m
screws

1. Internally wired handlebars: Route RHCM wires through

handlebar.

a. Attach scrap wire to new RHCM wiring.

b. Pull RHCM wiring through handlebar.

c. Remove scrap wire.

2. Externally wired handlebars: Attach using anchors.

Figure 7-27. Hand Control Module Alignment (Typical)
1. Alignment mark
3. See Figure 7-25. Place switch assembly into position on 2. Control module seam
lower switch housing. Install brake switch (2).

94000936
8. Install switch housing screws. Tighten.
is01405a
Torque: 3^45 in-lbs (4-5.1 N-m) Handlebar switch
housing screws
9. Verify right hand grip has slight inboard-outboard movement.

10. Verify right hand grip rotates and returns freely.

11. Place front electrical caddy into frame, and install frame
plug.

12. See Figure 7-24. Connect RHCM connectors (6 and 7).

13. See Figure 7-23. Install brake line clamp screws. Tighten.
Torque: 36--48 in-lbs (4.1-5.4 N-m) Brake line clamp
screw

14. Install new cable straps in locations recorded in REMOVE.

SWITCH CAPS __________________________

1. Switch cap installed correctly
Rocker Switch Caps 2. Switch cap removal from shaft
3. Switch cap removal from pivot pin
1. Remove handlebar switch housing. See Remove (Page 7-
4. Switch cap installation on to pivot pin
16).
5. Switch cap installation onto shaft ___________
Figure 7-28. Switch Cap Removal and Replacement
2. NOTE
FRONT BRAKE SWITCH REPLACEMENT
There are small pins and springs under some caps.
Springs and pins could be lost during cap removal or
installation.
FASTENER TORQUE VALUE
Handlebar switch assembly 8-10in-lbs 0.9—1.1 N-m
Remove switch cap.
retainer screws

a. See Figure 7-28. Carefully pry switch cap up off pin (2) 1. Remove upper switch housing cover. See Remove (Page 7-
on side of switch. 2o).

b. Pry switch cap up and away from pin (3) on opposite 2. See Figure 7-25 . From inside the switch housing, remove
side. screws (3) and retainer (1).

3. Remove brake switch (2) from housing.

3. Install switch cap.

a. Place cap onto switch, angling hole over pin (4). 4. Cut wires flush at inoperative brake switch.

b. Carefully press switch cap down onto opposite pin (5), 5. If new brake switch wires have terminals installed, cut wires
rocking cap until snapping into place. at terminal end.

4. Verify proper operation. 6. Remove 6.4-7.9 mm (0.25-0.31 in) of insulation from each
wire end.
5. Install switch housing. See Install (Page 7-17).
7. Cut two pieces of dual wall heat shrink tubing to 12.7 mm
(0.5 in).

8. Solder wires together and cover with heat shrink tubing. See
HANDLEBAR CONTROL MODULES (Page 7-15).

9. See Figure 7-25. Install brake switch (2) into housing. Install
retainer (1) and screws (3). Tighten.
Torque: 8-10 in-lbs (0.9-1.1 N-m) Handlebar switch
assembly retainer screws

10. Assemble right handlebar switch housing. See Install (Page

7-21).

94000936
7-22
COMPLETE 2. Install fuel tank. Refer to FUEL TANK (Page 6-14).

3. Install main fuse. See POWER DISCONNECT (Page 7-7).

1. Install front brake controls on handlebar. See FRONT BRAKE
MASTER CYLINDER (Page 3-35).
4. Install seat. See SEAT (Page 3-142).

94000936
INSTRUMENT MODULE (IM) 7.13
GENERAL

• Both the ECM and the Instrument Module (IM) retain the
odometer value. If the IM is replaced, the new IM will display
the odometer value stored in the ECM. The new IM will lock to
the mileage stored in the ECM after 31 mi (50 km) have been
accumulated. The trip B odometer will display the countdown
mileage.
• If the IM is installed on another vehicle after it has locked to
the ECM, the odometer will display "VIN ERR" on the new
vehicle. If the IM is removed from the vehicle before the
countdown reaches zero, it will reset the mileage countdown
to 31 mi (50 km). This mileage countdown allows for a road
test to verify that IM replacement was the proper repair.
PREPARE

1. FXLRS: Remove fairing. See FAIRING (Page 3-99).

2. Console mounted: Remove console. See CONSOLE (Page

Figure 7-29. IM: Handlebar Mounted, Rectangular Handlebar
6-8).
mounted, round
3. Handlebar mounted, rectangular: Remove upper clamp of Remove
handlebars. See HANDLEBAR (Page 3-109).
1. See Figure 7-30. Remove IM (1).
REMOVE AND INSTALL: HANDLEBAR MOUNT
________________________ ____ _ a. Remove screws (6).

Handlebar mounted, rectangular b. Remove cover (5).

FASTENER TORQUE VALUE c. Disconnect connector (4).

IM, rectangular, handlebar 12-17 in-lbs 1.4-1.9 N-m
d. Remove IM (1) from handlebar clamp (3).
clamp screws
IM, round.cover screws 12-17 in-lbs 1.4-1.9 N-m
e. Remove gasket (2).
Install
Remove
1. See Figure 7-30. Install lM (1).
1. See Figure 7-29. Remove IM (2).

a. Remove screws (3). a. Install gasket (2).

b. Install IM in handlebar clamp (3).

b. Disconnect connector.
c. Connect connector (4).
c. Remove IM from upper clamp (1).
d. Align cover (5) with IM.
Install
e. Install screws (6). Tighten.
1. NOTE Torque: 12-17 in-lbs (1.4-1.9 N-m) IM, round.cover
Verify that gasket does not twist while installing IM screws

See Figure 7-29. Install lM (2).

a. Connect connector.

b. Align IM in upper clamp (1).

c. Install screws (3). Tighten.

Torque: 12-17 in-lbs (1.4-1.9 N-m) IM, rectangular,
handlebar clamp screws

94000936
7-24
 1. IM
2. Gasket
3. Handlebar bracket clamp
4. Connector
5. Cover
6. Screw (2)
Figure 7-30. IM: Handlebar Mounted, Round
Figure 7-31. Console: FLHCS, FLFBS (Typical) Install
REMOVE AND INSTALL: CONSOLE WITH 1. Install gasket onto console.
PANEL
2. Install IM.
Remove NOTE
Verify that gasket does not twist while installing IM.
1. See Figure 7-31. Disconnect IM connector (2).

3. See Figure 7-31. Install back clamp.

2. Remove back clamp from IM.

a. Press on back clamp (3) until three tabs (1) engage on

a. Pry between the tabs (1) and back clamp (3).
back of IM.
b. Raise and release back clamp from IM. Remove back
clamp from IM.
4. Connect IM connector (2).

3. Remove IM.
REMOVE AND INSTALL: CONSOLE WITHOUT
PANEL ________________________________
4. Remove gasket.

FASTENER TORQUE VALUE

Housing to IM screw 20-25 in-lbs 2.3-2.8 N-m

Remove
1. See Figure 7-32. Remove screws (2).

2. Remove harness from clip (1).

3. Remove IM assembly.

4. See Figure 7-33. Disconnect IM connector (2).

5. See Figure 7-34. Pushing from the bottom of the IM (1),
separate the IM from the housing (3).

94000936
6. Remove gasket (2).

Figure 7-32. Console: FXFBS

COMPLETE

Figure 7-33. IM and Housing: FXFBS

1. Handlebar mounted, rectangular: Install upper clamp of

handlebars. See HANDLEBAR (Page 3-109).

2. Console mounted: Install console. See CONSOLE (Page

6-8).

3. FXLRS: Install fairing. See Refer to FAIRING (Page 3-99)..

1. NOTE
Verify that gasket does not twist while installing IM.

See Figure 7-34. Install gasket (2) onto IM (1).

2. Install IM into housing (3).

3. See Figure 7-33. Connect IM connector (2).

4. Install IM assembly into console.

5. See Figure 7-32. Install screws (2). Tighten.

Torque: 20-25 in-lbs (2.3-2.8 N-m) Housing to IM screw

6. Install harness into clip (1).

94000936
7-26
INDICATOR LAMPS 7.14

APPLICABILITY 4. Connect connector (1).

2022 HERITAGE CLASSIC 114 (FLHCS)

PREPARE

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

2. Remove seat. See SEAT (Page 3-142).

3. Remove console. See CONSOLE (Page 6-8).

REMOVE ___________________

1. See Figure 7-35. Disconnect connector (1).

2. Discard cable strap (2).

3. Remove screws (3).

4. Remove indicator lamp assembly (4).

INSTALL_______________
FASTENER TORQUE VALUE
Indicator lamp, screw 20-30 in-lbs 2.26-3.39 N-m
1. Install indicator lamp assembly (4).
1. Connector
Figure 7-35. Indicator Lamps 2. Cable strap
COMPLETE 3. Screw (4)
4. Indicator lamp assembly
2. Install screws (3). Tighten.
1. Install console. See CONSOLE (Page 6-8).
Torque: 20-30 in-lbs (2.26-3.39 N-m) Indicator lamp,
screw 2. Install seat. See SEAT (Page 3-142).

3. Install new cable strap (2).

3. Install main fuse. See POWER DISCONNECT (Page 7-7).

94000936
7-27
OIL PRESSURE SWITCH 7.15
PREPARE

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

REMOVE _______________________________

1. See Figure 7-36. Disconnect connector (2).

2. Remove switch (1).

INSTALL ______________________
1. See Figure 7-36. Install switch (1). Tighten.

FASTENER TORQUE VALUE

Switch, Oil Pressure 13-17 ft-lbs 17-23 N-m
Torque: 13-17 ft-lbs (17-23 N-m) Switch, Oil Pressure

2. Connect connector (2).

Figure 7-36. Oil Pressure Switch

COMPLETE

1. Install main fuse. See POWER DISCONNECT (Page 7-7).

7-28
94000936
NEUTRAL INDICATOR SWITCH 7.16
PREPARE
1. Remove left side cover. See LEFT SIDE COVER (Page 3- Connect harness wires (1).
63).

2. Remove main fuse. See POWER DISCONNECT (Page 7-7).

3. Remove right side cover. See RIGHT SIDE COVER (Page

3-64).

4. Place transmission in NEUTRAL.

REMOVE _ ___________

1. NOTE
Wires are interchangeable.

See Figure 7-37. Disconnect wires (1) from switch (2).

2. Remove switch and O-ring.

INSTALL
1. Wires
2. Switch
Figure 7-37. Neutral Indicator Switch
COMPLETE ______________________
FASTENER TORQUE VALUE
Switch, Neutral Indicator 126-180 in-lbs 13.6-20.3 N-m
1. Verify transmission is in NEUTRAL. 1. Install right side cover. See Refer to RIGHT SIDE COVER
(Page 3-64)..

2. See Figure 7-37. Install new switch (2) and O-ring. Tighten. 2. Install main fuse. See POWER DISCONNECT (Page 7-7).
Torque: 126-180 in-lbs (13.6-20.3 N-m) Switch, Neutral
Indicator 3. Install left side cover. See LEFT SIDE COVER (Page 3-63).

3. NOTE Wires are interchangeable.

94000936 7-29
HORN 7.17
PREPARE _ DISASSEMBLE

1. Remove main fuse. See POWER DISCONNECT (Page 7-7). 1. See Figure 7-39. Remove screws (1) and bracket (3).

REMOVE _______________________________ ASSEMBLE __________________________

1. See Figure 7-38. Remove horn. FASTENER TORQUE VALUE

Horn, Bracket Screw 62-71 in-lbs 7--8 N-m
a. Remove narrow screws (3).
1. See Figure 7-39. Install screws (1) and bracket (3). Tighten.
b. Remove wide screw (2). Torque: 62-71 in-lbs (7--8 N-m) Horn, Bracket Screw

c. Remove horn assembly (1).

d. Disconnect wire connectors (4).

INSTALL _______________________________

a. Connect wire connectors (4).

FASTENER TORQUE VALUE
Horn, Narrow Mounting Screw 27-33 in-lbs 3-3.7 N-m
Horn, Wide Mounting Screw 84-108 in-lbs 9.5-12.2 N-m
1. See Figure 7-38. Install horn.

b. Position horn assembly (1).

c. Install wide screw (2). Tighten.

Torque: 84-108 in-lbs (9.5-12.2 N-m) Horn, Wide
Mounting Screw
d. Install narrow screws (3). Tighten.
Torque: 27-33 in-lbs (3-3.7 N-m) Horn, Narrow
Mounting Screw

COMPLETE

1. Install main fuse. See POWER DISCONNECT (Page 7-7).

7-30 94000936
HEADLAMP 7.18
BULB REPLACEMENT: STANDARD ROUND 8. Install screw and nut (1). Tighten.
Torque: 9-14 in-lbs (1-1.6 N-m) Headlamp bezel screw
FASTENER TORQUE VALUE
Headlamp bezel screw 9-14 in-lbs 1-1.6 N-m
Headlamp isolator bracket 6.5-8.0 ft-lbs 8.8-10.8 N-m
screw
Headlamp retainer screw 18-22 in-lbs 2-2.5 N-m
Prepare
1. Remove headlamp housing. See Remove And Install:
Standard Round in this section.

Remove
1. See Figure 7-40. Remove screw and nut (1).

2. Remove bezel (2).

3. 7-inch headlamp only: Remove screws (10) and retainer

(9) .

4. 5-3/4 headlamp only: Remove spacer (8).

5. Remove headlamp (3) from housing (7).

6. Disconnect connector (6).

7. Remove screws (5).

8. Remove isolator bracket (4).

Install
1. See Figure 7-40. Position isolator bracket (4) on headlamp
(3).

2. Install screws (5). Tighten.

Torque: 6.5-8.0 ft-lbs (8.8-10.8 N-m) Headlamp isolator
bracket screw

3. NOTE Use alignment tabs on

components.
Complete
5-3/4 inch headlamp only: Install spacer (8) on headlamp
(3). 1. Install headlamp housing. See Remove And Install: Standard
Round in this section.
4. Connect connector (6).
BULB REPLACEMENT: LED ROUND
APPLICABILITY
5. NOTE Use alignment tabs on
components. • 2022 LOW RIDERS (FXLRS)
0
Install headlamp (3) into housing (7).
FASTENER TORQUE VALUE
Headlamp to headlamp bracket 98-120 in-lbs 10.8-13.6 N-m
6. 7-inch headlamp only: Install retainer (9) and screws screw
(10) . Tighten.
Torque: 18-22 in-lbs (2-2.5 N-m) Headlamp retainerscrew

7. Install bezel (2).

7-31
94000936
Remove BULB REPLACEMENT: NACELLE
MOUNTED ___________ _ _
1. Remove fairing. See FAIRING (Page 3-99).
FASTENER TORQUE VALUE
2. See Figure 7-41. Disconnect headlamp connector (1).
Headlamp, nacelle mounted, 25-32 in-lbs 2.8-3.6 N-m
bezel screw
3. See Figure 7-42. Remove screws (2).
Headlamp, nacelle mounted, 17-25 in-lbs 1.9-2.8 N'm
retainer screw
4. Remove headlamp (1).

Install Remove
1. See Figure 7-42. Position headlamp (1). 1. See Figure 7-43. Remove screw (1).

2. Install screws (2). Tighten. 2. NOTE

Torque: 96-120 in-lbs (10.8-13.6 N-m) Headlamp to Bezel is under pressure from isolators (3), disassemble
slowly.
headlamp bracket screw

3. See Figure 7-41. Connect headlamp connector (1). Remove bezel (2).

4. Install fairing. See FAIRING (Page 3-99). 3. Remove screws (5).

4. Remove retainer (6).

5. Remove headlamp (7).

6. Disconnect connector (10).

Install
1. NOTE
Check gasket (8) is properly installed on retainer.

See Figure 7-43. Install retainer (6) to headlamp (7).

2. Connect connector (10).

3. Install headlamp (7).

4. Install screws (5). Tighten.

Torque: 17-25 in-lbs (1.9--2.8 N-m) Headlamp, nacelle
mounted, retainer screw

5. Install bezel (2). Insert gasket (8) behind lip of bezel.

6. Install screw (1). Tighten.

Torque: 25-32 in-lbs (2.8-3.6 N-m) Headlamp, nacelle

mounted, bezel screw

Figure 7-42. Headlamp Screws

94000936
7-32
 1. Screw
2. Bezel
3. Isolator (2)
4. Nacelle BULB REPLACEMENT: HORIZONTAL
5. Screw (3)
6. Retainer See Remove and Install: Horizontal (Page 7-37) for bulb
7. Headlamp replacement.
8. Gasket
9. Mounting ring BULB REPLACEMENT: FIXED FAIRING
10. Connector
Figure 7-43. Nacelle Mounted Headlamp See Remove and Install: Fixed Fairing (Page 7-38) for bulb
BULB REPLACEMENT: OBLONG replacement.

PREPARE
FASTENER TORQUE VALUE
1. Remove main fuse. See POWER DISCONNECT (Page 7-7).
Headlamp (Oblong) mounting 10-13 ft-lbs 13.5--17.6 N-m
screw
2. Remove associated parts:
Remove
• Round headlamp: Remove fuel tank. See FUEL TANK (Page
1. See Figure 7-44. Remove screw (3). 6-14).

2. Remove headlamp (1). • Model with windshield: Remove windshield. See

WINDSHIELD (Page 3-106).
3. Disconnect connector (2). • Model with nacelle: Remove nacelle. See HEADLAMP
Install NACELLE (Page 3-96).

1. See Figure 7-44. Connect connector (2). • Model with steered fairing: Remove fairing. See FAIRING
(Page 3-99).
2. Install headlamp (1).
REMOVE AND INSTALL: STANDARD ROUND
3. Install screw (3). Tighten.
Torque: 10-13 ft-lbs (13.5--17.6 N-m) Headlamp (Oblong)
mounting screw
FASTENER TORQUE VALUE
Headlamp, round, locknut 27-32 ft-lbs 36.6-43.3 N-m

Remove
1. Disconnect headlamp connector. See FRONT ELECTRICAL
CADDY (Page 7-87).

2. See Figure 7-45. Remove locknut (6) and flat washer (5).

3. Remove screw (2) and flat washer (3).

4. Remove headlamp (1).

94000936
 Install
1059233
2. Install screws (2). Tighten.
Torque: 20-25 ft-lbs (27.1-33.9 N-m) Headlamp mounting
bracket to lower fork bracket

3. Connect headlamp connector (1).

4. Install fairing. See FAIRING (Page 3-99).

1. 5 314 or 7-inch headlamp

2. Screw
3. Washer
4. Mounting bracket
5. Washer
6. Locknut
Figure 7-45. Round Headlamp (Typical)

Install
1. See Figure 7-45. Install headlamp (1).

2. Install screw (2) and flat washer (3).

3. Install flat washer (5) and locknut (6). Tighten.

Torque: 27-32 ft-lbs (36.6--43.3 N-m) Headlamp, round,
locknut

4. Connect headlamp connector. See FRONT ELECTRICAL

CADDY (Page 7-87).

REMOVE AND INSTALL: LED ROUND

APPLICABILITY
j^j • 2022 LOW RIDER S (FXLRS)

FASTENER TORQUE VALUE

Headlamp bracket to head- 27-32 ft-lbs 36.6--43 N-m
lamp mounting bracket bolt
Headlamp mounting bracket to 20-25 ft-lbs 27.1-33.9 N-m
lower fork bracket
Lower fairing bracket screw 96-120 in-lbs 10.8-13.6 N-m
1. See Figure 7-47. Position headlamp assembly (1).
Remove Disassemble
1. Remove fairing. See FAIRING (Page 3-99). 1. Remove headlamp. See Bulb Replacement: LED Round in
this section.
2. See Figure 7-46. Disconnect headlamp connector (1).
2. See Figure 7-48. Remove lower fairing bracket.
3. See Figure 7-47. Remove screws (2).
a. Remove screws (3).
4. Remove headlamp assembly (1).
b. Remove lower fairing bracket.

94000936
7-34
3. See Figure 7-49. Remove headlamp bracket (1).

a. Remove bolt (5), washers (2) and nut (3).

b. Remove headlamp bracket.

4. See Figure 7-50. Remove stand-offs (1) and grommets

(2) .

Assemble
1. See Figure 7-50. Install grommets (2) and stand-offs (1 ).

a. Install grommets.

b. Install stand-offs.

2. See Figure 7-49. Install headlamp bracket (1).

a. Position headlamp bracket on headlamp mounting

bracket (4).

b. Install Bolt (5), washers (2), and nut (3). lighten.

Torque: 27-32 ft-lbs (36.6-43 N-m) Headlamp bracket
to headlamp mounting bracket bolt NOTE
Verify a washer is on each side of the headlamp bracket.

3. See Figure 7-48. Install lower fairing bracket (2).

a. Position lower fairing bracket.

b. Install screws (3). lighten.

Torque: 96-120 in-lbs (10.6-13.6 N-m) Lower fairing
bracket screw

4. Install headlamp. See Bulb Replacement: LED Round in this

section.

94000936
 4. Install nacelle. See HEADLAMP NACELLE (Page 3-96).

REMOVE AND INSTALL: OBLONG _________

FASTENER TORQUE VALUE

Headlamp, oblong, bracket-to- 16-20 ft-lbs 21.6-27.1 N-m
fork clamp screws
Headlamp, oblong, isolator 33-43 in-lbs 3.7-49 N-m
screws
Headlamp, oblong, mounting 10-13 ft-lbs 13.6-17.6 N-m
screw
Wireform screw, headlamp, 10-12 ft-lbs 13.5-16.2 N-m
oblong,

Remove
Figure 7-50. Headlamp Bracket Grommets, Stand-Offs
1. FXBRS:See Figure 7-52. Remove clutch cable from wireform
REMOVE AND INSTALL: NACELLE (5).
MOUNTED
2. Disconnect connector (1).
FASTENER TORQUE VALUE
3. FXBRS: Remove headlamp assembly.
Headlamp mounting ring screw 16-20 ft-lbs 21.6-27.1 N-m

a. Remove screws (2).

Remove b. Remove headlamp assembly.
1. Remove nacelle. See HEADLAMP NACELLE (Page 3-96).
c. Remove screw and wireform(5), if necessary.
2. Remove headlamp. See Bulb Replacement in this section.
4. Remove headlight.
3. See Figure 7-51. Remove screw and washer (2).
4. Remove mounting ring (1 ). a. Remove screw (3).
b. Remove headlamp (4).

5. See Figure 7-53. Disassemble mounting bracket.

a. Remove screws (5) and spacers (4).

b. Discard isolators (3).

Install
1. See Figure 7-53. Assemble mounting bracket.

a. Assemble bracket (1), new isolators (3) and clevis (2).

b. Install spacers (4) and screws (5). Tighten.

Torque: 33-43 in-lbs (3.7-4.9 N-m) Headlamp,
oblong, isolator screws

2. See Figure 7-52. Install headlamp to bracket.

a. Install headlamp (4).

Install b. Install screw (3). Tighten.

Torque: 10-13 ft-lbs (13.6-17.6 N-m) Headlamp,
1. See Figure 7-51. Install mounting ring (1).
oblong, mounting screw

2. Install screw and washer (2). Tighten.

Torque: 16-20 ft-lbs (21.6-27.1 N-m) Headlamp mounting
ring screw

3. Install headlamp. See Bulb Replacement in this section.

94000936
7-36
3. FXBRS: Install headlamp assembly.

a. Install wireform and screw (5), if removed. Tighten.

Torque: 10-12 ft-lbs (13.6-16.2 N-m) Wireform screw,
headlamp, oblong,
b. Install headlamp assembly.

c. Install screws (2). Tighten.

Torque: 16-20 ft-lbs (21.6-27.1 N-m) Headlamp,
oblong, bracket-to-fork clamp screws
4. Connect connector (1).
5. FXBRS: Install clutch cable into wireform (5).

REMOVE AND INSTALL: HORIZONTAL FASTENER TORQUE VALUE

Headlamp nacelle, screw 16-20 ft-lbs 21.6-27.1 N-m
Headlamp, upper triple clamp 11-14 ft-lbs 16-19 N-m
mounted, screw

Remove
1. See Figure 7-54. Remove screws (1).

2. Remove nacelle (2).

3. See Figure 7-55. Remove screws (1).

4. Disconnect connector (3).

5. Remove headlamp (2).

94000936
 FASTENER TORQUE VALUE
Headlamp, fixed fairing, retain- 22-32 in-lbs 2.5-3.6 N-m
er screws
Remove
1. Remove bezel.

a. See Figure 7-56. Rotate bezel (3) counterclockwise to

disengage hooks.

b. Remove bezel.

2. Remove headlamp assembly.

a. Remove screws (1).

b. Remove headlamp assembly (5).

3. Remove headlamp.

a. See Figure 7-57. Disconnect connector (1).

b. Remove screws (2).

c. Remove Headlamp (3).

4. Disassembly headlamp bracket, if needed.

a. See Figure 7-58. Remove screws (4) and washers

(3) .

b. Remove support ring (2), springs (5) and support plate

(1).

Install
1. Assembly headlamp bracket.
1. Screw (3)
2. Headlamp a. See Figure 7-58. Place support ring (2) and springs
3. Connector (5) on support plate (1).
Figure 7-55. Headlamp
b. Install washers (3) and screws (4).
Install
c. Tighten screws evenly (4) to specification (6).
1. See Figure 7-55. Install headlamp (2).
Length/Dimension/Distance: 0.85 in (21.59 mm)

2. Connect connector (3). 2. Install headlamp.

3. Install screws (1). Tighten. a. See Figure 7-57. Position headlamp (3) in bracket
Torque: 11-14 ft-lbs (15-19 N-m) Headlamp, upper triple (4) .
clamp mounted, screw
b. Install screws (2). Tighten.
4. See Figure 7-54. Install nacelle (2).
Torque: 84-108 in-lbs (9.49-12.2 N-m) Headlamp,
fixed fairing, Bracket-to-lamp screws
5. Install screws (1). Tighten.
c. Connect connector (1).
Torque: 16-20 ft-lbs (21.6-27.1 N-m) Headlamp nacelle,
screw
d. See Figure 7-56. Install headlamp assembly (5).
REMOVE AND INSTALL: FIXED FAIRING _
e. Install screws (1). Tighten.
Torque: 22-32 in-lbs (2.5-3.6 N-m) Headlamp, fixed
fairing, retainer screws
FASTENER TORQUE VALUE
00
T
o
00

c
■
n
W

Headlamp, fixed fairing, 9.49-12.2 N-m

Bracket-to-lamp screws

7-38 94000936
3. Install bezel.

a. Line bezel tabs (4) left of fairing tabs (2).

b. Press in bezel and turn clockwise.

1. Screw (3)
2. Fairing Tab (3)
3. Bezel
4. Bezel tab (3)
5. Headlamp assembly
Figure 7-56. Headlamp Bezel 1. Support plate
2. Support ring
3. Washers (3)
4. Screw (3)
5. Spring (3)
6. 21.59 mm (0.85 in)
Figure 7-58. Headlamp Support Ring
ALIGN

A WARNING

The automatic-on headlamp feature provides increased visibility

of the rider to other motorists. Be sure headlamp is on at all
times. Poor visibility of rider to other motorists can result in death
or serious injury. (00030b)

1. Connector
2. Screw (4) Prepare
3. Headlamp
1. Check tire pressure.
4. Bracket
Figure 7-57. Headlamp Assembly
2. Adjust rear shock preload for rider and intended load.

3. Fill fuel tank or add an equal amount of ballast.

Check Alignment
1. See Figure 7-59. Park the motorcycle on a line (1)
perpendicular to the wall.

2. Set vehicle distance from wall to front axle.

25 ft (7.6 m)

3. Draw a vertical centerline (2) on the wall aligned with line (1).

4. NOTE
The upper lens half of LED is the low beam.

94000936
 With the motorcycle loaded, point the front wheel straight 2. Tighten horizontal adjustment screw:
forward at wall.
a. FXBBS, FXST:
a. All except FXFBS: Measure the distance (4) from the Torque: 20-25 ft-lbs (27.1-33.9 N-m) Headlamp
floor to the center of headlamp. FXBBS, FXST horizontal adjustment screw

b. FXFBS: Measure the distance (4) from the floor to the 3. Loosen vertical adjustment screw (1). Adjust headlamp
center of low beam. vertically until beam centers on horizontal line.

5. Draw a horizontal line (5) through vertical line (2) using the 4. Tighten vertical adjustment screw (1):
same height measurement as low beam bulb centerline (4).
Torque: 27-32 ft-lbs (36.6-43.3 N-m) Headlamp FXBBS,
FXST, FXLRS, FLSB vertical adjustment screw
6. Align the top of the hot spot to horizontal line (5) with
headlamp set to low beam.
7. Adjust headlamp, if necessary.

ADJUST FXBRS, FXFBS

1. See Figure 7-61 and Figure 7-62. Loosen vertical adjustment
screw (3). Adjust headlamp vertically until beam centers on
horizontal line.
FASTENER TORQUE VALUE
20-25 ft-lbs 27.1-33.9 N-m 2. Tighten vertical adjustment screw (3):
Headlamp FXBBS, FXST hori-
zontal adjustment screw
a. FXBRSSee Figure 7-61.
Headlamp FXBBS, FXST, 27-32 ft-lbs 36.6--43.3 N-m
FXLRS, FLSB vertical adjust- Torque: 10-13 ft-lbs (13.5--17.6 N-m) Headlamp
ment screw FXBRS, vertical adjustment screw
Headlamp FXBRS, vertical 10-13 ft-lbs 13.5-17.6 N-m b. FXFBSSee Figure 7-62.
adjustment screw
Torque: 11-14 ft-lbs (14.9-19 N-m) Headlamp FXFBS
Headlamp FXFBS vertical ad- 11-14 ft-lbs 14.9-19 N-m
vertical adjustment screw
justment screw

Round
1. All except FLSB, FXLRS and FXLRST: See Figure 7-60.
Loosen horizontal adjustment screw (2). Adjust headlamp
horizontally to direct light beam straight ahead.
NOTE
Not all headlamps have a horizontal adjustment.

7-40 94000936
 2. Rotate horizontal adjustment screw (1). Adjust headlamp
1061286
horizontally to direct light beam straight ahead.

3. Rotate vertical adjustment screw (2). Adjust headlamp

vertically until beam centers on horizontal line.

4. Install trim ring.

a. Align trim ring hooks (4) with docking points (5).

1. Horizontal adjusters
2. Vertical adjuster
3. Trim ring
4. Trim ring hooks (3)
1. Headlamp
2. Mounting bracket (typical)
3. Screw b. Rotate trim ring clockwise into position.

5. Docking points (3)

Figure 7-62. Headlamp Adjustment: FXFBS Figure 7-64. Headlamp: FXLRST
FLFBS COMPLETE ____________________
1. See Figure 7-63. Rotate horizontal adjustment screw (1).
Adjust headlamp horizontally to direct light beam straight 1. Install associated parts:
ahead.
• Round headlamp: Install fuel tank. See FUEL TANK (Page
2. Rotate vertical adjustment screw (2). Adjust headlamp 6-14).
vertically until beam centers on horizontal line. • Model with windshield: Install windshield. See
WINDSHIELD (Page 3-106).
• Model with nacelle: Install nacelle. See HEADLAMP
NACELLE (Page 3-96).
• Model with steered fairing: Install fairing. See FAIRING
(Page 3-99).

2. Install main fuse. See POWER DISCONNECT (Page 7-7).

A WARNING

Be sure that all lights and switches operate properly before

operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

3. Test headlamp for proper operation.

FXLRST
1. See Figure 7-64. Rotate trim ring (3) counterclockwise to
disengage hooks and remove.

94000936
4. Align headlamp. See Align in this section.

94000936
7-42
FRONT LIGHT BAR 7.19

APPLICABILITY 4. See Figure 7-67. Remove screws (1) and clamps (2).

5. Remove left and right turn signals (3, 4).

• 2022 HERITAGE CLASSIC 114 (FLHCS)
0

PREPARE
Prepare
1. Remove main fuse. See TOWER DISCONNECT (Page 7-7).

2. Remove fuel tank. See FUEL TANK (Page 6-14).

REMOVE AND INSTALL: STANDARD

LIGHTING
APPLICABILITY
• 2022 HERITAGE CLASSIC 114 (FLHCS)
0
FASTENER TORQUE VALUE
Front light bar mounting screw 20-25 ft-lbs 27.1-33.9 N-m
Front light bar, bracket screw 16-20 ft-lbs 21.7-27.1 N-m
Front light bar, clamp screw 6-10 in-lbs 0.67-1.1 N-m

Remove
1. Disconnect right and left turn signal connectors. See FRONT
ELECTRICAL CADDY (Page 7-87).

3. Remove light bar.

2. See Figure 7-65. Remove screws (1).

Disassemble
1. See Figure 7-66. Discard cable strap (3).

2. Remove screws (2) and bracket (1).

3. Remove auxiliary lamp housings. See AUXILIARY LAMPS

(Page 7-45). Assemble
1. See Figure 7-67. Install left and right turn signals (3, 4).

94000936 7-43
2. Install screws (1) and clamps (2). Tighten.
Torque: 6-10 in-lbs (0.67-1.1 N-m) Front light bar, clamp
screw

3. Install auxiliary lamp housings. See AUXILIARY LAMPS

(Page 7-45).

4. See Figure 7-66. Install screws (2) and bracket (1). Tighten.
Torque: 16-20 ft-lbs (21.7-27.1 N-m) Front light bar, bracket
screw

5. Install new cable strap (3).

Install
1. Install light bar.
2. See Figure 7-65. Install screws (1). Tighten.
Torque: 20-25 ft-lbs (27.1-33.9 N-m) Front light bar
mounting screw

3. Connect right and left turn signal connectors. See FRONT

ELECTRICAL CADDY (Page 7-87).

COMPLETE

Complete
1. Install fuel tank. See FUEL TANK (Page 6-14).

2. Install main fuse. See POWER DISCONNECT (Page 7-7).

7-44 94000936
AUXILIARY LAMPS 7.20

APPLICABILITY PREPARE

2022 HERITAGE CLASSIC 114 (FLHCS) 1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

2. Remove bulb. See Bulb Replacement (Page 7-45).

BULB REPLACEMENT
REMOVE AND INSTALL: STANDARD
FASTENER TORQUE VALUE LIGHTING ______________________________
APPLICABILITY
Auxiliary lamp bezel nut 9-12 in-lbs 1.07-1.36 N-m
• 2022 HERITAGE CLASSIC 114 (FLHCS)
Bulb
0
Remove FASTENER TORQUE VALUE
Auxiliary lamp nut 19-23 ft-lbs 25.76--31.18Nm
1. See Figure 7-68. Remove screw (1) and nut (2).

2. Remove bezel (3). Remove

1. See Figure 7-69. Disconnect pins (4) from connector (2).
3. Remove LED lamp (4).

2. Remove nut (3).

4. Disconnect connector (5).
Install 3. Remove housing (1).
1. See Figure 7-68. Connect connector (5).

2. Install LED lamp (4) in alignment ring (6).

3. Install bezel (3).

4. Install screw (1) and nut (2). Tighten.

Torque: 9-12 in-lbs (1.07-1.36 N-m) Auxiliary lamp bezel
nut

Signal

Figure 7-68. LED Auxiliary Lamp Install

1. See Figure 7-69. Install housing (1).

94000936 7-45
2. Position housing. Install nut (3) and tighten.
Torque: 19-23 ft-lbs (25.76-31.18 N-m) Auxiliary lamp nut

3. Connect pins (4) to connector (2). See electrical diagnostic

manual.

4. Align auxiliary lamps. See Align in this section.

ALIGN _________________________________
1. Headlamp centerline
2. Left auxiliary lamp centerline
Check Alignment 3. Right auxiliary lamp centerline
4. Left auxiliary lamp beam area
1. Place vehicle facing target wall as described in Align section
5. Right auxiliary lamp beam area
of Headlamp. See HEADLAMP (Page 7-31). 6. Headlamp low beam area

2. Check headlamp alignment. Adjust if necessary. Figure 7-70. Headlamp Pattern: LED Type with Auxiliary
Lamps

FASTENER TORQUEVALUE
Auxiliary lamp nut 19-23 ft-lbs 25.7-31.1 N-m

ADJUST _________________________ ___

Auxiliary Lamp Adjustment

NOTE
Have a person weighing roughly the same as the principal
rider sit on the motorcycle.

1. With the vehicle upright and a rider seated on the motorcycle,

measure the distance from the floor to the centerline of each
auxiliary lamps.

2. See Figure 7-70. Mark the center of the headlamp high beam
by making a vertical line through the horizontal line already
drawn on the wall. Properly adjusted, the beam should
project an equal area of light to the left and right of the
vertical centerline (1).

3. Measure the horizontal distance from the headlamp vertical

centerline to the vertical centerline of each auxiliary lamp.

4. Mark the auxiliary lamp horizontal and vertical centerline (2,

3) on the wall.

5. NOTE
Minimize auxiliary lamp movement while tightening to
maintain alignment. Signal
COMPLETE ___________
Adjust auxiliary lamps.

a. Remove bulb. See Auxiliary Lamps in this section. 1. Install bulb. See Bulb Replacement (Page 7-45).

b. See Figure 7-71. Loosen nut (3). 2. Install main fuse. See POWER DISCONNECT (Page 7-7).

c. Adjust housing (1). A WARNING

d. While holding auxiliary lamp housing (1) steady, tighten
Be sure that all lights and switches operate properly before
nut (3)
operating motorcycle. Low visibility of rider can result in
Torque: 19-23 ft-lbs (25.7-31.1 N-m) Auxiliary lamp death or serious injury. (00316a)
nut
e. Install bulb. See Auxiliary Lamps in this section.

6. Verify auxiliary lamp alignment.

7-46 94000936
3. Check operation of all lamps.

94000936 7-47
FRONT TURN SIGNAL LAMPS 7.21

BULB REPLACEMENT b. Loosen locknut (3) and remove ball stud (6) from turn
signal.

Incandescent FXBBS, FXST Only

1. See Figure 7-72. Replace bulb.
1. See Figure 7-74. Remove front turn signals.

a. Remove lens.
a. Loosen ball stud clamp (6) completely.

b. Replace bulb. b. Loosen jam nut (8).

c. Remove ball stud (7) from turn signal (9 or 10).

All
1. Remove hand control module from handlebar.

a. Left hand control module: See LEFT HAND CONTROL

MODULE (LHCM) (Page 7-16).

b. Right hand control module: See RIGHT HAND

CONTROL MODULE (RHCM) (Page 7-20).

2. Disconnect left or right turn signal connector. See FRONT

ELECTRICAL CADDY (Page 7-87).

3. NOTE
Verify that there is enough scrap wire to work both ends of
handlebar when wiring is routed through handlebar.
c. Install lens.

PREPARE

Prepare Route turn signal wires through handlebar.

1. Remove main fuse. See POWER DISCONNECT (Page 7-7). a. Attach scrap wire to turn signal connector.

2. Remove fuel tank if needed. See FUEL TANK (Page 6-14). b. Pull turn signal wiring through handlebar.

c. Disconnect scrap wire from old turn signal connector.

3. Frame mounted fairing models: Remove outer fairing shell.
Attach scrap wire to new turn signal wiring.
See FAIRING: FRAME MOUNTED (Page 3-102).

REMOVE AND INSTALL: HANDLEBAR MOUNT Install

All
Remove
1. NOTE
FASTENER TORQUE VALUE Verify that there is enough scrap wire to work both ends
of handlebar when wiring is routed through handlebar.
Handlebar-mounted turn signal, 96-144 in-lbs 10.8-16.3 N-m
ball stud clamp
Route turn signal wires through handlebar.
Handlebar-mounted turn signal, 50-70 in-lbs 5.6-7.9 N-m
ball stud jam nut
a. Disconnect scrap wire from old turn signal connector.
Handlebar-mounted turn signal, 50-70 in-lbs 5.6-7.9 N-m Attach scrap wire to new turn signal wiring.
ball stud locknut
Handlebar-mounted turn signal, 3-5 ft-lbs 4-6.7 N-m b. Pull new turn signal wiring through handlebar.
ball stud set screw
All Except FXBBS, FXST c. Remove scrap wire.

1. See Figure 7-73. Remove front turn signals. 2. Install hand control module to handlebar.

a. Left hand control module: See LEFT HAND CONTROL

7-48 94000936
 MODULE (LHCM) (Page 7-16).
a. Loosen set screw (7).

7-49
94000936
 b. Right hand control module: See RIGHT HAND CONTROL
MODULE (RHCM) (Page 7-20).

3. Connect left or right turn signal connector. See FRONT

ELECTRICAL CADDY (Page 7-87).

FXBBS, FXST Only

NOTE
When installing right side turn signal assembly, do not cover
brake lever pivot pin.

1. See Figure 7-74. Install front turn signals.

a. Install ball stud (7) to turn signal (9 or 10) and tighten

jamnut (8).
Torque: 50-70 in-lbs (5.6-7.9 N-m)
Handlebar-mounted turn signal, ball stud jam nut
b. Tighetn ball stud clamp (6).
Torque: 96-144 in-lbs (10.8-16.3 N-m)
Handlebar-mounted turn signal, ball stud clamp
c. Verify turn signal is positioned properly.

All Except FXBBS, FXST

NOTE
When installing right side turn signal assembly, do not cover
brake lever pivot pin.

1. See Figure 7-73. Install front turn signal.

a. Install ball stud (6) to turn signal and tighten locknut

(3).
Torque: 50-70 in-lbs (5.6-7.9 N-m)
Handlebar-mounted turn signal, ball stud locknut
b. Tighten set screw (7).
Torque: 3--5 ft-lbs (4-6.7 N-m) Handlebar-mounted
turn signal, ball stud set screw
c. Verify turn signal is positioned properly.

7-50 94000936
 1372254

1. Mirror 7. Ball stud

2. Right brake lever 8. Jam nut
3. Ball receptacle nut 9. Right turn signal
4. Left clutch lever 10. Left turn signal
5. Ball receptacle plate 11. Lockwasher
6. Ball stud clamp 12. Acorn nut
Figure 7-74. Front Turn Signal (FXBBS, FXST)
InStaM
REMOVE AND INSTALL: FIXED FAIRING InsfaM MOUNT
1. Install turn signal lamp.
a. See Figure 7-76. Install wiring cable through opening in
standoff (5).
FASTENER TORQUE VALUE
Turn signal, frame mounted 15-18 ft-lbs 20.34-24.4 N-m b. Re-pin connector.
fairing, screw
c. Route connector (3) through fairing bracket opening (2).
Remove
1. Remove turn signal lamp.
a. See Figure 7-75. Disconnect connector (1). d. Position standoff (5) on turn signal (4).

b. Remove screw (2). e. See Figure 7-75. Install screw (2). Tighten.
Torque: 15-18 ft-lbs (20.34-24.4 N-m) Turn signal,
c. Remove turn signal (3).
frame mounted fairing, screw
d. See Figure 7-76. Remove wiring cable from standoff
f. Connect connector (1).
(5) .

e. De-pin connector.

f. Remove standoff.

7-51
94000936
 1. Screw
2. Fairing bracket opening
1. Connector 3. Connector
2. Screw 4. Turn signal
3. Turn signal 5. Standoff
Figure 7-75. Front Turn Signal

Figure 7-76. Front Turn Signal Assembly

COMPLETE

Complete
1. Frame mounted fairing models: Install outer fairing shell.
See Remove and Install: Outer Fairing Shell (Page 3-102)

2. Install fuel tank if removed. See FUEL TANK (Page 6-14).

3. Install main fuse. See POWER DISCONNECT (Page 7-7).

A WARNING
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in death or
serious injury. (00316a)

4. Check operation of all lamps.

7-52 94000936
 REAR TURN SIGNAL LAMPS 7.22
BULB REPLACEMENT

Incandescent
1. See Figure 7-77. Replace bulb.

a. Remove lens.

b. Replace bulb.

c. Install lens.

PREPARE

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

2. Remove seat if needed. See SEAT (Page 3-142).

3. If removing both turn signals, remove rear fender if needed.

See REAR FENDER (Page 3-116).

Remove 4. Remove rear lighting assembly if model has rear lighting

assembly. See Remove and Install: Rear Lighting Assembly
1. See Figure 7-78. Remove lens (1). (Page 7-57).

2. Remove LED assembly (3). REMOVE AND INSTALL: FENDER MOUNT

3. Disconnect connector (4).
Install
FASTENER TORQUE VALUE
1. Connector connector (4). Fender Support, Screw 42-46 ft-lbs 57-62 N-m
Rear Turn Signal, Fender 15-18 ft-lbs 20-24 N-m
2. Align LED assembly (3) to housing. Press evenly until fully Mount, Screw
seated.
Rear Turn Signal, Fender 21-27 ft-lbs 28-37 N-m
Support, Screw
3. Inspect gasket (2) on lens (1). Replace if needed.
Remove
4. Install lens (1) with removal notch at the bottom. 1. See Figure 7-79. Disconnect connector(s).

A WARNING a. Right Signal: Disconnect connector (1).

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in death or b. Left Signal: Disconnect connectors (2, 3).
serious injury. (00316a)
2. See Figure 7-80. Remove fender support.
5. Check operation of all lamps.
a. Remove screws (2).
b. Remove screws (4) and washers (3).

c. Remove fender support (1).

94000936 7-53
3. See Figure 7-81. Remove harness.

a. Remove and discard wire retention pads (1).

b. Remove harness (2).

4. See Figure 7-82. Disassemble turn signal.

NOTE
Not all left signal assemblies will have a license plate
mounting support.

a. Left Signal: Remove screw (1) and washer (2).

Disassemble license plate mounting support (3), lamp
mounting support (4) and turn signal (5).

b. Right Signal: Remove screw (6) and washer (7).

Disassemble lamp mounting support (8) and turn
signal (9).

Install
1. See Figure 7-82. Assemble turn signal.
NOTE
Not all left signal assemblies will have a license plate
mounting support.

a. Left Signal: Assemble license plate mounting support

(3), lamp mounting support (4) and turn signal (5).
Install screw (1) and washer (2). Tighten.

Torque: 15-18 ft-lbs (20-24 N-m) Rear Turn Signal,

Fender Mount, Screw

b. Right Signal: Assemble lamp mounting support (8) and

turn signal (9). Install screw (6) and washer (7).
Tighten.
Torque: 15-18 ft-lbs (20-24 N-m) Rear Turn Signal,
Fender Mount, Screw
2. See Figure 7-81. Install harness.

a. Route harness (2) through fender support (3).

b. Install new wire retention pads (1).

3. See Figure 7-80. Install fender support.

a. Install fender support (1), washers (3) and screws (4).

Tighten.
Torque: 42-46 ft-lbs (57-62 N-m) Fender Support,
Screw
b. Install screws (2). Tighten.
Torque: 21-27 ft-lbs (25-37 N-m) Rear Turn Signal,
Fender Support, Screw
4. See Figure 7-79. Connect connector(s).

a. Right Signal: Connect connector (1).

b. Left Signal: Connect connectors (2, 3).

7-54 94000936
 c.
Remove screws (1 ).

d. Remove turn signal housing (6).

Install
1. Install turn signal housing.

a. See Figure 7-84. Apply threadlocker to screws (1).

LOCTITE 262HIGH STRENGTH THREADLOCKER
AND SEALANT (RED) (94759-99)

b. Install screws (1 ). Tighten.

Torque: 10-13 ft-lbs (14.12-17.74 N-m) Rear turn
signal, rear lighting assembly, screw
c. Route cable (3) as shown through bracket opening.

d. Install new cable straps (2).

e. See Figure 7-83. Install new cable straps (4).

1. Screw
1. Hole
2. Washer
3. License plate mounting support 2. Tail lamp bracket
3. Turn signal connector (2)
4. Lamp mounting support
4. Cable strap (2)
5. Left turn signal housing
Figure 7-83. Turn Signal Lamp Connector
6. Screw
7. Washer
8. Lamp mounting support
1. Screw (2)
9. Right turn signal housing
Figure 7-82. Turn Signal Assembly

REMOVE AND INSTALL: REAR LIGHTING

ASSEMBLY

FASTENER TORQUE VALUE

Rear turn signal, rear lighting 10-13ft-lbs 14.12-17.74Nm
assembly, screw

CONSUMABLE PART NUMBER

LOCTITE 262 HIGH 94759-99
STRENGTH
THREADLOCKER 2. Cable strap (2)
AND SEALANT 3. Cable (2)
(RED) 4. Gasket
5. Connector (2)
Remove
6. Turn signal housing (2) ___________
1. Remove rear tail lamp lighting assembly. See TAIL LAMP Figure 7-84. Turn Signal Assembly
(Page 7-57).
REMOVE AND INSTALL: LIGHT BAR MOUNT
2. Remove turn signal housing.

a. See Figure 7-83. Remove cable straps (4) and discard. FASTENER TORQUE VALUE
Rear Turn Signal, Light Bar 16-20 ft-lbs 22-27 N-m
b. See Figure 7-84. Remove cable straps (2) and discard.
Mount, Screw

94000936 7-55
Remove

1. See Figure 7-85. Remove screws (1).

2. Disconnect connector(s) (2).

3. Remove light bar (3).

Install

1. See Figure 7-85. Position light bar (3).

2. Connect connector(s) (2).

3. Install screws (1). Tighten.

Torque: 16-20 ft-lbs (22-27 N-m) Rear Turn Signal, Light
Bar Mount, Screw

1.Screw (2)
2.Connector (2)
3.Light Bar
Figure 7-85. Incandescent Light Bar
REMOVE AND INSTALL: CENTER MOUNT

FASTENER TORQUE VALUE

Rear Turn Signal, Center 15-18 ft-lbs 20-24 N-m 1. Support bracket assembly
Mount, Screw 2. Wire harness
3. License plate holder
Remove 4. Screw and washer
5. Signal mounting support
1. See Figure 7-86. Disconnect connectors (1-3).
6. Turn signal housing
Figure 7-87. Center Mount Turn Signal
2. Disconnect pins from 4-pin connector (1 or 2). See electrical
diagnostic manual.
Install
3. Remove and disassemble rear fender. See REAR FENDER
1. See Figure 7-87. Assemble left or right turn signal.
(Page 3-116).

Assemble signal mounting support (5) and turn signal

4. See Figure 7-87. Remove wire harness (2) from support a.
housing (6).
bracket assembly (1) and license plate holder (3).
b. Install washer and screw (4). Tighten.
5. Disassemble left or right turn signal.
Torque: 15--18 ft-lbs (20-24 N-m) Rear Turn Signal,
Center Mount, Screw
a. Remove screw and washer (4).
2. Route wire harness (2) through license plate holder (3) and
b. Disassemble signal mounting support (5) and turn support bracket assembly (1).
signal housing (6).

94000936 7-56
3. Assemble and install rear fender. See REAR FENDER (Page COMPLETE _____________________________
3-116). 2. Install rear fender, if removed. See REAR FENDER (Page 3-
116).
4. See Figure 7-86. Connect pins to 4-pin connector (1 or 2).
See electrical diagnostic manual. 3. Install seat, if removed. See SEAT (Page 3-142).

5. Connect connectors (1-3). 4. Install main fuse. See POWER DISCONNECT (Page 7-7).

1. Install rear lighting assembly, if removed. See Remove and

Install: Rear Lighting Assembly (Page 7-57).

7-57
94000936
TAIL LAMP 7.23

BULB REPLACEMENT

FASTENER TORQUE VALUE

Tail Lamp Lens Screw 20-24 in-lbs 2.3-2.7 N-m

Bulb Replacement
• LED Tombstone: LED bulb is not replaceable. Replace
housing.
• LED License plate mount: LED bulb is not replaceable.
Replace housing.
• LED Center mount with lighting: LED bulb is not replaceable.
Replace housing.

Standard
1. See Figure 7-88 and Figure 7-89. Replace tail lamp lighting. Figure 7-89. Standard Incandescent Tail Lamp
PREPARE
a. Remove screws (1). 7).

b. Remove lens (2).

2. Remove seat. See SEAT (Page 3-142).
c. Disconnect connector (3).
REMOVE AND INSTALL: REAR LIGHTING
d. Incandescent: Remove bulb (4).
ASSEMBLY
FASTENER TORQUE VALUE
Tail lamp bracket, screw 40-48 in-lbs 4.5-5.4 N-m
2. Install tail lamp lighting.

a. Incandescent: Install bulb (4). Remove

b. Connect connector (3).
1. Remove tail lamp. See Bulb Replacement (Page 7-57).
c. Install lens (2).
2. Remove tail lamp assembly.
d. Install screws (1). Tighten.
Torque: 20-24 in-lbs (2.3-2.7 N-m) Tail Lamp Lens a. See Figure 7-90. Remove tail lamp connector (4) from
Screw tail lamp bracket (1).

b. Disconnect turn signal connectors (5).

c. Remove screw (2).

d. Remove tail lamp assembly.

e. See Figure 7-91. Remove gasket (2). Inspect for
damage and replace as necessary.

3. Remove wiring harness.

a. See Figure 7-92. Remove cable straps (1).

b. Remove cable strap (2).

c. Disconnect Right and left turn connectors (3,4).

d. Disconnect tail lamp connector (5).

e. See Figure 7-93. Remove cable (1) from conduit (2)
and clip (3).

1. Remove main fuse. See POWER DISCONNECT (Page 7-

7-58 94000936
 f. Remove wiring harness.

Install
1. Install wiring harness.

a. See Figure 7-93. Route wiring harness (1) through

hole in fender.

b. Install wiring harness in conduit (2) and behind

clip (3).

c. See Figure 7-92. Connect left turn signal

connector (3). 1. Tail lamp assembly
2. Gasket
d. Connect right turn signal connector (4).
3. Cable strap anchor
e. Connect tail lamp connector (5). Figure 7-91. Tail Lamp Gasket

f. Install cable strap (2).

g. Install cable straps (1).

2. See Figure 7-91. Install new cable strap anchor (3).

3. Install gasket (2).

4. Install tail lamp assembly (1).

a. See Figure 7-90. Route tail lamp wiring harness
through opening (3).

b. Install screw (2). Tighten.

Torque: 40-48 in-lbs (4.5-5.4 N-m) Tail lamp

bracket, screw
Cable Strap (2)
c. Connect turn signal connectors (5). Cable Strap
Left turn signal connector
d. Install tail lamp connector (4). Right turn signal connector
Tail lamp connector Access
e. Install tail lamp. See Bulb Replacement (Page 7- hole
Figure 7-92. Rear Lighting Assembly Harness
57).
1657530
f. Test tail lamp and turn signals.

1. Wiring harness
2. Conduit
3. Clip _________
Figure 7-93. Under Fender Harness Routing
REMOVE AND INSTALL:. STANDARD

1. Tail lamp bracket FASTENER TORQUE VALUE

2. Screw
Tail lamp lens screw 20-24 in-lbs 2.3-2.7 N-m
3. Opening
4. Tail lamp Connector Tail lamp, circuit board screw 40-48 in-lbs 4.5-5.4 N-m
5. Turn signal connector (2) ____________
Figure 7-90. Rear Tail Lamp Assembly Base Replacement
1. See Figure 7-94. Remove screw (1) and base assembly (2).

94000936
7-59
 2. Disconnect 4-pin multilock connector (3).

3. See Figure 7-96. Disconnect two 2-pin connectors (2).

4. See Figure 7-98. Disconnect 6-pin connector (4).

5. See Figure 7-97. Remove screw, pin housing (1) and circuit
board (2).

6. Remove base from fender.

7. Install new base to rear fender.

8. Install circuit board/pin housing to base with screw, nut and

washer. Tighten.
Torque: 40-48 in-lbs (4.5-5.4 N-m) Tail lamp, circuit board
screw

9. See Figure 7-98. Install connectors to circuit board.

10. Install lens to base with screws. Tighten.

Torque: 20-24 in-lbs (2.3-2.7 N-m) Tail lamp lens screw

Figure 7-

Figure 7-94. Standard Tail Lamp

1.
2.
3.
4.

7-60 94000936
REMOVE AND INSTALL: LICENSE PLATE
BRACKET MOUNT

FASTENER TORQUE VALUE

License plate holder, screw 60-----80 in-lbs 6.8-9 N-m
License plate, tail lamp, screw 10-20 in-lbs 1.1-2.3 N-m

Remove
1. See Figure 7-99. Disconnect license plate connector (1).

2. Disconnect pins from connector (1). See electrical diagnostic

manual.

3. See Figure 7-100. Discard cable straps (1).

4. Remove screws (2).

5. Remove license plate holder (3).

6. Remove wire bundle (4) from frame.

7. See Figure 7-101. Remove screws (1) and washers (2).

8. Remove tail lamp (3).

Install
1. See Figure 7-101. Install tail lamp (3).

2. Install screws (1) and washers (2). Tighten.

Torque: 10-20 in-lbs (1.1-2.3 N-m) License plate, tail lamp,

screw

3. See Figure 7-100. Route wire bundle (4) through frame.

4. Install license plate holder (3).

5. Install screws (2). Tighten.

Torque: 60-80 in-lbs (6.8-9 N-m) License plate holder,
screw

6. Route harness and install new cable straps (1).

7. Connect pins to connector (1). See electrical diagnostic

manual.

8. See Figure 7-99. Connect license plate connector (1).

94000936 7-61
REMOVE AND INSTALL: CENTER MOUNT

FASTENER TORQUE VALUE

License plate, center mount, 10-20 in-lbs 1.1-2.25 N-m
tail lamp screw
Remove
1. See Figure 7-102. Disconnect connector (3).

2. Disconnect pins from connector (3). See electrical diagnostic

manual.

3. Remove and disassemble rear fender. See REAR FENDER

(Page 3-116).

4. See Figure 7-103. Remove harness (2) from support bracket

assembly (1).

5. See Figure 7-104. Remove screws (1) and washers (2).

6. Remove tail lamp (3).

7-62 94000936
 Install
1128421
1. See Figure 7-104. Install tail lamp (3).

2. Install screws (1) and washers (2). lighten.

Torque: 10-20 in-lbs (1.1-2.25 N-m) License plate, center
mount, tail lamp screw

3. See Figure 7-103. Route harness (2) through support

bracket assembly (1 ).

4. Assemble and install rear fender. See REAR FENDER

(Page 3-116).

5. See Figure 7-104. Connect pins to connector (3). See

electrical diagnostic manual.

6. Connect connector (3).

COMPLETE

1. Install seat. See SEAT (Page 3-142).

2. Install main fuse. See POWER DISCONNECT (Page 7-7).

1. Screw (2)
2. Washer (2)
3. Tail lamp _______________________
Figure 7-104. LED Center Mount

94000936
7-63
REAR STOPLAMP SWITCH 7.24
PREPARE ______________________________

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

REMOVE

NOTICE

DOT 4 brake fluid will damage painted and body panel

surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is
performed. Failure to comply can result in cosmetic damage.
(00239c)

1. See Figure 7-105. Remove connectors (1).

2. Remove switch (2).

INSTALL ______________________

FASTENER TORQUE VALUE

Rear stoplamp switch 12-15 ft-lbs 16.3-20.3 N-m COMPLETE
1. Install main fuse. See POWER DISCONNECT (Page 7-7).
CONSUMABLE PART NUMBER
LOCTITE 565 99818-97 A WARNING
THREAD SEALANT
After repairing the brake system, test brakes at low speed. If
1. Apply LOCTITE® 565 to threads of switch. brakes are not operating properly, testing at high speeds
Consumable: LOCTITE 565 THREAD SEALANT (99818-97) can cause loss of control, which could result in death or
serious injury. (00289a)
2. See Figure 7-105. Install switch (2). Tighten.

Torque: 12-15 ft-lbs (16.3--20.3 N-m) Rearstop/amp switch 2. Bleed brake system. See BLEED BRAKES (Page 3-61).

3. Install connectors (1 ).

7-64 94000936
LICENSE PLATE LAMP 7.25

BULB REPLACEMENT

FASTENER TORQUE VALUE

License plate, center mount, 10-20 in-lbs 1.1-2.25 N-m
lamp housing screw
Bulb Replacement
• Standard Tail Lamp: Replace tail lamp bulb. See TAIL LAMP
(Page 7-57).
• LED Tombstone: LED bulb is not replaceable. Replace
housing. See TAIL LAMP (Page 7-57).
• LED License Plate Mount: LED bulb is not replaceable.
Replace housing. See TAIL LAMP (Page 7-57).
• LED Center Mount: LED bulb is not replaceable. Replace
housing. See TAIL LAMP (Page 7-57).
• LED Rear Lighting Assembly: Replace rear tail lamp bulb. See
Bulb Replacement, Rear Lighting Assembly in REAR TURN
SIGNAL LAMPS (Page 7-52).

Incandescent Bulb Center Mount: Figure 7-107. Removing License Plate Lamp Housing Cover

Remove
1. See Figure 7-106. Remove screws (1) and washers (2).

2. Rotate lamp housing (3) to face upward.

3. See Figure 7-107. Insert the tip of a small flat bladed

screwdriver (3) into each slot (2). Gently disengage housing
from cover.

4. See Figure 7-108. Gently pull bulb (2) straight out of socket.

1. Screw (2)
2. Washer (2)
1058689

Figure 7-108. Center Mount Bulb Replacement

3. Lamp housing ______ _____________________

Figure 7-106. Center Mount Lamp Housing (Typical)

94000936
7-65
Install
1. See Figure 7-108. Push new light bulb (2) into socket.

2. See Figure 7-107. Install lamp housing to cover.

3. Position lamp housing (3).

4. See Figure 7-106. Install screws (1) and washers (2).
Tighten.
Torque: 10--20 in-lbs (1.1-2.25 N-m) License plate, center
mount, lamp housing screw

7-66 94000936
 1058989
PREPARE
1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

2. Remove seat. See SEAT (Page 3-142).

REMOVE AND INSTALL: CENTER MOUNT

FASTENER TORQUE VALUE

License plate, center mount, 10-20 in-lbs 1.1-2.25 N-m
lamp housing screw
Remove
1. See Figure 7-109. Disconnect connector (3).

2. Disconnect pins from 3-pin connector (3). See electrical 2. Install screws (1) and washers (2). Tighten.
diagnostic manual. Torque: 10-20 in-lbs (1.1-2.25 N-m) License plate, center
mount, lamp housing screw
3. Remove rear fender. See REAR FENDER (Page 3-116). 3. See Figure 7-110. Route harness (2) through inner fender
sup
4. See Figure 7-110. Remove harness (2) from inner fender 1058689
port
support assembly (1). asse
mbly
5. See Figure 7-111. Remove screws (1) and washers (2). (1).
6. Remove lamp housing (3).
4. I
nstal
l
rear
fend
er.
See
REA
R
FEN
DER
(Pag
e 3-
116)
.

5. See Figure 7-109. Connect pins to 3-pin connector (3). See

electrical diagnostic manual.

6. Connect connector (3).

1. Inner fender support assembly

2. Harness
Figure 7-110. Inner Fender Support Assembly (Typical)

1. Screw (2)
2. Washer (2)
3. Lamp housing
Figure 7-111. Center Mount Lamp Housing (Typical)

Install
1. See Figure 7-111. Install lamp housing (3).

94000936
7-67
REMOVE AND INSTALL: LICENSE PLATE
BRACKET MOUNT

FASTENER TORQUE VALUE

License plate holder, screw 60-80 in-lbs 6.8-9 N-m
License plate, LED housing, 10-20 in-lbs 1.1-2.3 N-m
screw
Remove
1. See Figure 7-112. Disconnect license plate connector (1).

2. Disconnect pins from connector (1). See electrical diagnostic

manual.

3. See Figure 7-113. Discard cable straps (1).

4. Remove screws (2).

5. Remove license plate holder (3).

Figure 7-112. License Plate Light Connector
6. Remove wire bundle (4) from frame.

7. See Figure 7-114. Remove screws (1) and washers (2).

8. Remove LED housing (3).

Install
1. See Figure 7-114. Install LED housing (3).

2. Install screws (1) and washers (2). Tighten.

Torque: 10-20 in-lbs (1.1-2.3 N-m) License plate, LED

housing, screw

3. See Figure 7-113. Route wire bundle (4) through frame.

4. Install license plate holder (3).

5. Install screws (2). Tighten.

Torque: 60-80 in-lbs (6.8-9 N-m) License plate holder,
screw

6. Route harness and install new cable straps (1).

7. Connect pins to connector (1). See electrical diagnostic

manual.

8. See Figure 7-112. Connect license plate connector (1).

7-68 94000936
 c.
Remove screws (4) and cover (5).

d. Remove lamp (3) with harness.

Install
1. See Figure 7-118. Assemble turn signal.

a. Install lamp (3).

b. Install cover (5) and screws (4). Tighten.

Torque: 8-16 in-lbs (0.9-1.8 N-m) License Plate
Lamp Cover, Screw
c. Route harness, assemble license plate mounting
support and turn signal. See REAR TURN SIGNAL
LAMPS (Page 7-52).

d. Install screw (1) and washer (2).

Torque: 15-18 ft-lbs (20-24 N-m) Rear Turn Signal,
Fender Mount, Screw
Figure 7-114. License Plate Mount LED Housing
2. See Figure 7-115. Connect pins to connector (2). See
REMOVE AND INSTALL: SIDE MOUNT electrical diagnostic manual.

FASTENER TORQUE VALUE 3. See Figure 7-117. Install harness.

Fender Support, Screw 42-46 ft-lbs 57-62.3 N-m
8-16 in-lbs 0.9-1.8 N-m a. Route harness (2) through fender support (4).
License Plate Lamp Cover,
Screw
b. Install new wire retention pads (1).
Rear Turn Signal, Fender 15-18 ft-lbs 20-24 N-m
Mount, Screw
4. See Figure 7-116. Install fender support.
Remove
a. Install fender support (1), washers (3) and screws (4).
1. See Figure 7-115. Disconnect connectors. Tighten.

a. License Plate: Disconnect connector (2). Torque: 42-46 ft-lbs (57-62.3 N-m) Fender Support,
Screw
b. Left Signal: Disconnect connectors (1). b. Install screws (2). Tighten.

2. See Figure 7-116. Remove left fender support. Torque: 21-27 ft-lbs (28-37 N-m) Fender Support,
Screw

a. Remove screws (2). 5. See Figure 7-115. Connect connectors.

b. Remove screws (4) and washers (3).
a. License Plate: Disconnect connector (2).
c. Remove fender support (1).
b. Left Signal: Disconnect connectors (1).
3. See Figure 7-117. Remove harness.

a. Discard wire retention pads (1).

b. Remove harness (2).

4. See Figure 7-115. Disconnect pins from connector (2). See

electrical diagnostic manual.

5. See Figure 7-118. Disassemble turn signal.

a. Remove screw (1) and washer (2).

b. Disassemble license plate mounting support and turn

signal.

94000936 7-69
Figure 7-115. License Plate Lamp Connector
1052511

1. Fender support
2. Screw, long or short (2)
3. Washer (2)
4. Screw (2)
Figure 7-116. Right Fender Support

Figure 7-118. Turn Signal Assembly

COMPLETE

1. Install seat. See SEAT (Page 3-142).

2. Install main fuse. See POWER DISCONNECT (Page 7-7).

7-70 94000936
TERMINATING RESISTOR 7.26

PREPARE

1. Remove left side cover. See LEFT SIDE COVER (Page 3-

63).

2. Remove main fuse. See POWER DISCONNECT (Page 7-7).

REMOVE _______________________________

1. See Figure 7-119. Remove terminating resistor.

INSTALL

1. See Figure 7-119. Install terminating resistor.

COMPLETE

1. Install main fuse. See POWER DISCONNECT (Page 7-7).

2. Install left side cover. See LEFT SIDE COVER (Page 3-63).

94000936 7-71
ELECTRONIC CONTROL MODULE (ECM) 7.27
PREPARE

PART NUMBER TOOL NAME

HD-48650 DIGITAL TECHNICIAN II
NOTE
Always calibrate replaced ECM with DIGITAL TECHNICIAN II
(PART NUMBER: HD-48650).

1. Remove seat. See SEAT (Page 3-142).

2. Remove main fuse. See POWER DISCONNECT (Page 7-7).

REMOVE ________________________ ______

Figure 7-121. ECM
1. Release and move sub caddy (1). b. Install ECM into caddy.

a. See Figure 7-120. Remove screw (3). 2. Install sub caddy mounting bracket.

b. Release sub caddy lock (2). a. See Figure 7-120. Route sub caddy into position.
b. Push and lock into position the rear sub caddy lock
c. Route sub caddy out-of-way.
(2).
2. Remove ECM.
c. Install screw (3). Tighten
a. See Figure 7-121. Slide ECM forward.
Torque: 36--60 in-lbs (4.1--6.8 N-m) Sub caddy screw
b. Pull ECM from caddy to gain clearance to remove COMPLETE _____________________________
connector.

1. Install seat. See SEAT (Page 3-142).

c. Disconnect ECM connector.
2. Install main fuse. See POWER DISCONNECT (Page 7-7).
d. Remove ECM.

INSTALL
FASTENER TORQUE VALUE
Sub caddy screw 36-60 in-lbs 4.1-6.8 N-m
1. Install ECM.

a. See Figure 7-121. Connect ECM connector. Verify

connector lock is engaged.

7-72 94000936
 BODY CONTROL MODULE (BCM) 7.28
PREPARE

PART NUMBER TOOL NAME

HD-48650 DIGITAL TECHNICIAN II
NOTE
Always calibrate replaced Body Control Module (BCM) with
DIGITAL TECHNICIAN II (PART NUMBER: HD-48650).

1. Remove seat. See SEAT (Page 3-142).

2. Disconnect negative battery cable. See POWER

DISCONNECT (Page 7-7).

3. Remove battery tray. See BATTERY TRAY (Page 7-97).

1. BCM battery power [259]
REMOVE 2. BCM
3. Caddy
Figure 7-123. BCM [259]
1. Remove BCM. c. Connect BCM [242] (1).

a. See Figure 7-122. Disconnect BCM [242] (1). COMPLETE ____________________________

b. See Figure 7-123. Move BCM out of caddy. 1. Install battery tray. See BATTERY TRAY (Page 7-97).
NOTE
If rotating the BCM to access components behind 2. Connect negative battery cable. See POWER
BCM, do not disconnect BCM battery power or DISCONNECT (Page 7-7).
remove BCM.
3. Install seat. See SEAT (Page 3-142).
c. Disconnect BCM battery power [259] (1).
d. Remove BCM (2).

INSTALL

1. NOTE
When installing battery power connector verify seal
does not roll.

Install BCM.

a. See Figure 7-123. Connect BCM battery power [259]

(1).

b. See Figure 7-122. Install BCM (2) into caddy (3).

94000936 7-73
SECURITY SYSTEM ACTIVATION 7.29
ACTIVATION • When assigning a fob, keep the fob within 3 ft (1 m) of the
vehicle seat.
Activation consists of assigning two fobs to the system and
entering an initial PIN. See Figure 7-124. Follow the menu prompts to scan the fob serial
number with the bar code reader. Alternatively, enter the number
NOTE using the keyboard. Use DIGITAL TECHNICIAN II (PART
If the fob is lost or inoperable, the PIN allows the owner to NUMBER: HD-48650) to assign fob and enter initial PIN.
disarm the system. See PERSONAL IDENTIFICATION NOTE
NUMBER (PIN) (Page 7-73). Each fob has a unique serial number. Attach fob label to a
blank NOTES page in the owner's manual for reference.
1. Configure the security system by assigning both fobs to the
vehicle.
2. Configure the security system by entering a PIN picked by
the owner.

Record the PIN in the owner's manual. Instruct the customer to

carry a copy (use the wallet card found in the owner's manual).
See PERSONAL IDENTIFICATION NUMBER (PIN) (Page 7-73).

Once the system has been activated, it "arms" within 5 seconds

of switching the IGN switch to OFF and no motorcycle motion.

FOB ASSIGNMENT 13 14

PART NUMBER TOOL NAME

HD-48650 DIGITAL TECHNICIAN II

Use DIGITAL TECHNICIAN II (PART NUMBER: HD-48650) to

assign both fobs to the vehicle.

NOTE
14 Choose the correct fob type. Choosing incorrectly at the
beginning of the process will result in a failure to assign
the fob. This can be mistakenly diagnosed as a bad fob or
SCM.

7-74 94000936
 PERSONAL IDENTIFICATION NUMBER (PIN) 7.30
GENERAL Modifying an Existing PIN
If a PIN was previously entered, the odometer will display the
The PIN consists of five digits. Each digit can be any number
equivalent digit. Each additional press of the left turn switch will
from 1 through 9. There can be no zeros (0) in the PIN. Use the
increment the digit.
PIN to disarm the security system in case the fob becomes
unavailable. Examples:

CHANGING THE PIN __________ • To advance from 5 to 6, press and release the left turn switch
1 time.
The rider can change the PIN at any time. Refer to Table 7-9. • To advance from 8 to 2, press and release the left turn switch
3 times (9-1-2).

Table 7-9. Changing the PIN

STEP ACTION WAIT FOR CONFIRMATION NOTES
NO.
1 Select a 5-digit (1 thru 9) PIN and record
on the wallet card from owner's manual.

With an assigned fob present, turn the

2
OFF/RUN switch to OFF.
3 Turn the OFF/RUN switch to RUN.
4 Cycle the OFF/RUN switch twice: RUN
-OFF-RUN-OFF-RUN.
5 Press left turn signal switch two times. ENTER PIN will scroll through the
odometer window.
6 Press right turn signal switch one time Turn signals will flash three times.
and release. Current PIN will appear in odometer.
The first digit will be flashing.
7 Enter first digit of new PIN by pressing
and releasing the left turn signal switch
until the selected digit appears.
Press right turn signal switch one time The new digit will replace the current in
8
and release. odometer window.
9 Enter second digit of selected PIN by
pressing and releasing the left turn
signal switch until the selected digit is
present.
Press right turn signal switch one time The new digit will replace the current in
10
and release. odometer window.
11 Enter third digit of the selected PIN by
pressing and releasing the left turn
signal switch until the selected digit is
present.
Press right turn switch one time and The new digit will replace the current in
12
release. odometer window.
13 Enter fourth digit of new PIN by pressing
and releasing the left turn signal switch
until the selected digit is present.
14 Press right turn switch one time and The new digit will replace the current in
release. odometer window.
15 Enter fifth digit of the new PIN by
pressing and releasing the left turn
signal switch until the selected digit is
present.
Press right turn switch one time and The new digit will replace the current in
16
release. odometer window.
17 Turn the OFF/RUN switch OFF, then Pushing the OFF/RUN switch to OFF
turn the ignition switch to OFF. stores the new PIN in the module.

94000936 7-75
SECURITY SYSTEM MAINTENANCE 7.31
SERVICE MODE 3. Close the case.
a. Align case halves.
PART NUMBER TOOL NAME b. Snap case halves together.
HD-48650 DIGITAL TECHNICIAN II
With a fob present, the security system can be configured for
service by disabling the security system with DIGITAL
TECHNICIAN II (PART NUMBER: HD-48650).

Once disabled, the vehicle can be operated without an assigned

fob present. To maintain the service mode, the assigned fobs
must be kept out of range. If the fob appears in range, the service
mode is cancelled.

TRANSPORT MODE ______________________

It is possible to arm the security system without enabling the

motion detector for one ignition cycle. The motorcycle can be
moved in an armed state. The motorcycle cannot be turned on or
started while in transport mode until the fob is present.

To Enter Transport Mode

1. With security fob present, set the OFF/RUN switch to RUN.
2. Set the OFF/RUN switch to OFF.
SECURITY SIREN BATTERY
3. Simultaneously press both the left and the right turn signal
switches within five seconds of turning the OFF/RUN switch
to OFF. Battery Replacement Schedule
4. Following a single flash, the turn signals flash three times to The siren internal 9 V battery is rechargeable and does not
indicate that the system is armed in transport mode. require regular replacement. Battery life under normal conditions
is approximately 3-6 years.
To Exit Transport Mode NOTE
With the fob present, set the OFF/RUN switch to RUN to disarm If the motorcycle battery is less than 12.5 V, the internal
the system and exit transport mode. siren battery may not charge.

FOB BATTERY __________________________

Battery Replacement
Battery Replacement Schedule 1. Disarm system. Remove siren.
2. See Figure 7-126. With a small screwdriver, push the catches
Replace the fob battery every year. (1) in through the two slots (2) in the end of the siren.
Release the battery cover (3).
Battery Replacement
NOTE
1. Open the fob case. • For protection against corrosion, battery terminals and
a. See Figure 7-125. Place a thin blade in the thumbnail slot battery clip are covered with a special grease. Do not
(1). wipe away this substance. Apply all available existing
grease to terminals on new battery
b. Twist the blade to separate cases.
• Use only a 9 V nickel metal hydride battery in the siren.
NOTE
3. Replace 9 volt battery (4) by removing old battery from
Use a CR2032 or equivalent battery.
polarized battery clip.
2. Install a new battery with the positive side up. 4. Recharge and install or install a new 9 volt nickel metal
hydride battery.
a. Push the latch (3) away from the battery.
5. Install cover (3).
b. Lift the battery from the side opposite the latch.
c. Verify that the metal tabs will firmly contact battery. Bend a. Carefully replace the rubber seal (5) on the cover.
up slightly if necessary. b. Align battery cover with case placing round corners on
cover away from connector [142A] (6).
d. Install the battery against the latch with the positive side
up. Drop into place. c. Snap cover into place.

7-76 94000936
6. Install siren and check operation. Two chirps after an arming
command indicate a working siren.

1. Catch (2)
2. Slot (2)
3. Cover
4. 9V battery
5. Rubber seal
6. Connector [142A]
Figure 7-126. Battery Compartment

94000936 7-77
SECURITY SIREN 7.32
PREPARE 1068099

1. Remove right side cover. See RIGHT SIDE COVER (Page 3-

64).

2. Disconnect negative battery cable. See POWER

DISCONNECT (Page 7-7).

3. Remove battery. See INSPECT BATTERY (Page 2-43).

4. Remove battery tray. See BATTERY TRAY (Page 7-97).

5. Rotate BCM out-of-way. See BODY CONTROL MODULE

(BCM) (Page 7-71).

REMOVE ______________________________

1. See Figure 7-127. Remove security siren (3).

2. Disconnect connector (4).

INSTALL ______________________________

1. First-time security siren is being installed: Disconnect

security siren connector (5) from back side of BCM caddy
(2).

2. See Figure 7-127. Connect connector (4).

3. Install security siren into front side of BCM caddy (7).

1. Sounder disc
a. Verify that sounder disc (1) is facing to the rear of the 2. Back side, BCM caddy
vehicle. 3. Security siren
4. Siren connector
5. Siren connector storage port
b. Place security siren into BCM caddy and press into
6. Retainer tab
place locking retainer tabs (6).
7. Front side, BCM caddy
Figure 7-127. Security Siren and BCM Caddy: (Removed
for clarity)
COMPLETE

1. Install BCM. See BODY CONTROL MODULE (BCM) (Page

7-71).

2. Install battery tray. See BATTERY TRAY (Page 7-97).

3. Install battery. See INSPECT BATTERY (Page 2-43).

4. Connect negative battery cable. See POWER

DISCONNECT (Page 7-7).

5. Install right side cover. See RIGHT SIDE COVER (Page 3-

64).

7-78 94000936
SECURITY SYSTEM ANTENNA 7.33
PREPARE ______________________________

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

2. Remove seat. See SEAT (Page 3-142).

REMOVE _____________ _

1. See Figure 7-128. Remove antenna (1).

a. Remove antenna from caddy.

b. Disconnect connector (2).

c. Remove antenna.
INSTALL _______ ____ _____ ____________

1. See Figure 7-128. Install antenna (1).

a. Connect connector (2).

b. Connect antenna to caddy.

COMPLETE

1. Install seat. See SEAT (Page 3-142).

2. Install main fuse. See POWER DISCONNECT (Page 7-7).

94000936 7-79
CRANKSHAFT POSITION SENSOR (CKP) 7.34
PREPARE ______________________________ b. Connect connector (1).

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

2. Remove voltage regulator. See VOLTAGE REGULATOR

(Page 7-12).

REMOVE _______________________________

1. Figure 7-129 Disconnect connector.

a. Disconnect connector (1).

b. Detach connector (1) from voltage regulator bracket.

2. Remove sensor.

a. Remove screw (2).

b. Remove sensor (3).

3. Figure 7-130 Discard O-ring. Figure 7-129. Crankshaft Position (CKP) Sensor

INSTALL _______________________________
FASTENER TORQUE VALUE
Sensor, CKP, screw 90-120 in-lbs 10.2-13.6 N-m

1. See Figure 7-130. Install new O-ring.

a. Lubricate new O-ring with clean engine oil.

b. Install new O-ring.

2. See Figure 7-129. Install sensor.

a. Install sensor (3).

COMPLETE

b. Install screw (2). Tighten. 1. Install voltage regulator. See VOLTAGE REGULATOR (Page
7-12).
Torque: 90-120 in-lbs (10.2-13.6 N-m) Sensor. CKP,
screw
2. Install main fuse. See POWER DISCONNECT (Page 7-7).
3. Connect connector.

a. Attach connector (1) to voltage regulator bracket.

7-80 94000936
ENGINE TEMPERATURE (ET) SENSOR 7.35
PREPARE ______________ INSTALL

1. Purge fuel system. See PURGE FUEL LINE (Page 6-12). FASTENER TORQUE VALUE
ET sensor 11-15 ft-lbs 14.9-21 N-m
2. Remove left side cover. See LEFT SIDE COVER (Page 3- 1. Install ET sensor. Tighten.
63).
Torque: 11-15 ft-lbs (14.9-21 N-m) ET sensor
3. Remove main fuse. See POWER DISCONNECT (Page 7-7). 2. Connect ET connector. See USB CADDY (Page 7-90).

4. Remove seat. See SEAT (Page 3-142). COMPLETE_____________________________

5. Remove fuel tank. See FUEL TANK (Page 6-14). 1. Install throttle body to induction module. See assemble in
INDUCTION MODULE (Page 6-27).
6. Remove air cleaner assembly. See AIR CLEANER
BACKPLATE ASSEMBLY (Page 6-4). 2. Install air cleaner assembly. See AIR CLEANER
BACKPLATE ASSEMBLY (Page 6-4).
7. Remove throttle body from induction module. See
disassemble in INDUCTION MODULE (Page 6-27). 3. Install fuel tank. See FUEL TANK (Page 6-14).

REMOVE 4. Install seat. See SEAT (Page 3-142).

1. See Figure 7-131. Disconnect ET connector. See USB 5. Install main fuse. See POWER DISCONNECT (Page 7-7).
CADDY (Page 7-90).
6. Install left side cover. See LEFT SIDE COVER (Page 3-63).
2. Remove sensor (3) from rear cylinder head.

1. Knock sensor
2. Screw
3. ET sensor (rear head only)
Figure 7-131. Cylinder Head Sensors

94000936 7-81
KNOCK SENSOR (KS) 7.36
PREPARE ______________________________ 2. Connect connector.

1. Purge fuel system. See PURGE FUEL LINE (Page 6-12).

2. Remove left side cover. See LEFT SIDE COVER (Page 3-

63).

3. Remove main fuse. See POWER DISCONNECT (Page 7-7).

4. Remove seat. See SEAT (Page 3-142).

5. Remove fuel tank. See FUEL TANK (Page 6-14).

REMOVE _______________________________

1. See Figure 7-132 . Remove screw (2).

2. Disconnect connector.
3. Remove sensor (1).
INSTALL _______________________________

COMPLETE
1. Install fuel tank. See FUEL TANK (Page 6-14).
FASTENER TORQUE VALUE
Knock sensor screw 13-17 ft-lbs 17.6-23 N-m 2. Install seat. See SEAT (Page 3-142).
1. See Figure 7-132. Install sensor (1).
3. Install main fuse. See POWER DISCONNECT (Page 7-7).
a. Install sensor against head casting as shown.
4. Install left side cover. See LEFT SIDE COVER (Page 3-63).
b. Install screw. Tighten.
Torque: 13-17 ft-lbs (17.6-23 N-m) Knock sensor
screw

7-82 94000936
AUTOMATIC COMPRESSION RELEASE (ACR) 7.37
PREPARE CONSUMABLE PART NUMBER
LOCTITE 246 HIGH Loctite 246
1. Purge fuel system. See PURGE FUEL LINE (Page 6-12). TEMPERATURE
MEDIUM
STRENGTH BLUE
2. Remove left side cover. See LEFT SIDE COVER (Page 3-
THREADLOCKER
63).
1. NOTE
3. Remove main fuse. See POWER DISCONNECT (Page 7-7). Ifinstalling new ACR, verify old copper seal washer does
not remain in cylinder head.
4. Remove seat. See SEAT (Page 3-142).
Verify copper seal washer is in place on ACR.
5. Remove fuel tank. See FUEL TANK (Page 6-14).
2. See Figure 7-134. Apply threadlocker.

6. Front ACR: Remove oil lines. See OIL COOLANT LINES Consumable: LOCTITE 246 HIGH TEMPERATURE
(Page 4-22). MEDIUM STRENGTH BLUE THREADLOCKER (Loctite
246)
REMOVE __ a. Identify a location around the threads of the ACR
approximately one-third distance from end.
1. Disconnect Automatic Compression Release (ACR)
PART NUMBER TOOL NAME b. See Figure 7-135. Apply three equally spaced dots of
HD-48498-B-1 ACR SOLENOID SOCKET threadlocker on threads.
connector.
3. Install by hand until finger-tight.

2. See Figure 7-136. Remove ACR. 4. See Figure 7-136. Use socket to tighten.
Special Tool: ACR SOLENOID SOCKET (HD-48498-B-1) Torque: 17-19 ft-lbs (23-26.4 N-m) ACR
Special Tool: ACR SOLENOID SOCKET (HD-48498-B-1)

5. Connect ACR connector.

1205500

Figure 7-133. ACR and Cylinder Head

Figure 7-134. Bottom Third

INSTALL
PART NUMBER TOOL NAME
HD-48498-B-1 ACR SOLENOID SOCKET
FASTENER TORQUEVALUE
ACR 17-19 ft-lbs 23-26.4 N-m

94000936 7-83
 Figure 7-136. ACR Solenoid Socket and ACR
COMPLETE

1. Front ACR: Install oil lines. See OIL COOLANT LINES

(Page 4-22).

2. Install fuel tank. See FUEL TANK (Page 6-14).

3. Install seat. See SEAT (Page 3-142).

4. Install main fuse. See POWER DISCONNECT (Page 7-7).

5. Install left side cover. See LEFT SIDE COVER (Page 3-63).

7-84 94000936
VEHICLE SPEED SENSOR (VSS) 7.38
PREPARE

1. Remove left side cover. See LEFT SIDE COVER (Page 3-

63).

2. Remove main fuse. See POWER DISCONNECT (Page 7-7).

3. Remove seat. See SEAT (Page 3-142).

4. Remove right side cover. See RIGHT SIDE COVER (Page

3-64).

5. Remove battery. See INSPECT BATTERY (Page 2-43).

REMOVE

1. See Figure 7-137. Disconnect connector (1).

2. Remove VSS.

Figure 7-137. Vehicle Speed Sensor

a. Remove screw (2).

b. Remove VSS (3).

INSTALL _________

FASTENER TORQUE VALUE

Sensor, vehicle speed, screw 100--120in-lbs 111.3--13.6 N-m
1. See Figure 7-137. Install VSS.
a. Install VSS (3).

b. Install screw (2). Tighten.

Torque: 100-120 in-lbs (11.3-13.6 N-m) Sensor,
vehicle speed, screw

2. Connect connector (1).

Figure 7-138. Vehicle Speed Sensor Assembly
COMPLETE ______________ __________

1. Install battery. See INSPECT BATTERY (Page 2-43).

2. Install right side cover. See RIGHT SIDE COVER (Page 3-

64).

3. Install seat. See SEAT (Page 3-142).

4. Install main fuse. See POWER DISCONNECT (Page 7-7).

5. Install left side cover. See LEFT SIDE COVER (Page 3-63).

94000936 7-85
FRONT WHEEL SPEED SENSOR (WSS) 7.39
PREPARE ___________ _ _ _

1. Remove left side cover. See LEFT SIDE COVER (Page 3-

63).

2. Remove main fuse. See POWER DISCONNECT (Page 7-7).

3. Remove fuel tank. See FUEL TANK (Page 6-14).

REMOVE _______________________________

1. Note location of cable straps and discard as needed.

2. See Figure 7-139. Remove brake line clamp screws.

3. See Figure 7-140. Detach WSS wire from clips (1).

4. Remove frame plug (2).

5. See Figure 7-141. Disconnect connector (1). 1. Clip (3)

6. Retract front axle until sensor is free. See FRONT WHEEL 2. Plug
(Page 3-12). Figure 7-140. Front Wheel Speed Sensor

INSTALL _______________________________

1. Align sensor and insert front axle. See FRONT WHEEL

(Page 3-12).

2. See Figure 7-141. Connect connector (1).

3. See Figure 7-140. Install frame plug (2).

4. Attach WSS wire to clips (1).

5. See Figure 7-139. Install brake line clamp screws.

6. Install new cable straps as needed.

Figure 7-141. Front Wheel Speed Sensor Connector

COMPLETE

1. Install fuel tank. See FUEL TANK (Page 6-14).

2. Install main fuse. See POWER DISCONNECT (Page 7-7).

3. Install left side cover. See LEFT SIDE COVER (Page 3-63).

7-86 94000936
REAR WHEEL SPEED SENSOR (WSS) 7.40
PREPARE 3. Install clamp (2).

1. Remove left side cover. See LEFT SIDE COVER (Page 3- a. Install WSS sensor wire into clamp.
63).
b. Install screw. Tighten.
2. Remove main fuse. See POWER DISCONNECT (Page 7-7). Torque: 24-36 in-lbs (2.7-4.1 N-m) Rear fork clamp
screw
3. Remove right side cover. See RIGHT SIDE COVER (Page
4. Attach WSS wire to clips (1).
3-64).
5. Install cable straps as needed.

REMOVE AND INSTALL: STANDARD FORK

Remove

FASTENER TORQUE VALUE

Rear fork clamp screw 24-36 in-lbs 2.7-4.1 N-m
1. Note location of cable straps. Remove as needed.

2. See Figure 7-142. Remove WSS wire from clips (1).

3. Remove clamp (2).

a. Remove screw from clamp.

b. Remove WSS wire from clamp.

4. Disconnect connector (3).

COMPLETE
5. Retract rear axle until sensor is free. See REAR WHEEL
(Page 3-16). 1. Install right side cover. See RIGHT SIDE COVER (Page 3-
64).
Install
2. Install main fuse. See POWER DISCONNECT (Page 7-7).
1. Align sensor and rear axle. See REAR WHEEL (Page 3-16).
3. Install left side cover. See LEFT SIDE COVER (Page 3-63).
2. See Figure 7-142. Connect WSS sensor connector (3).

94000936 7-87
JIFFY STAND SENSOR (JSS) 7.41
PREPARE ______________________________
4. Install new cable straps.

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

2. Remove jiffy stand. See JIFFY STAND (Page 3-140).

REMOVE ____________ __________________

1. See Figure 7-143. Disconnect connector (1).

2. NOTE
Make note of cable routing and cable strap locations.

Discard cable straps.

3. Remove screw (2).

4. Remove sensor (3).

INSTALL _______________________________
FASTENER TORQUE VALUE
JSS screw 20-25 in-lbs 2.3-2.8 N-m

1. See Figure 7-143. Install jiffy stand sensor (3).

2. Install screw (2). Tighten. COMPLETE

1. Remove jiffy stand. See JIFFY STAND (Page 3-140).
Torque: 20-25 in-lbs (2.3-2.8 N-m) JSS screw

3. Connect connector (1). 2. Remove main fuse. See POWER DISCONNECT (Page 7-7).

7-88 94000936
FRONT ELECTRICAL CADDY 7.42

PREPARE
3. See Figure 7-147. Remove frame plug and front electrical
caddy.
1. Purge fuel system. See PURGE FUEL LINE (Page 6-12).

2. Remove left side cover. See LEFT SIDE COVER (Page 3-

63).

3. Remove main fuse. See POWER DISCONNECT (Page 7-7).

4. Remove seat. See SEAT (Page 3-142).

5. Remove fuel tank. See FUEL TANK (Page 6-14).

REMOVE

1. See Figure 7-144. Disconnect backbone harness interconnect

[327].

1. Bottom fold
2. Center fold
3. Top fold
Figure 7-146. Front Electrical Caddy

2. Frame ground stud (2)

3. Backbone harness interconnect [327]
4. Security antenna [209]
5. Left rear Stop/Tail/Turn (STT) [19]
6. Right rear STT [18]
7. License Plate (LP) [40]
Figure 7-144. Main Harness Under Seat

2. See Figure 7-145. Remove brake line clamp screws.

94000936 7-89
 Figure 7-148. Front Electrical Caddy Frame Plug

1. Console
2. Heated hand grip
3. Twist grip
4. WSS
5. Right turn signal
Figure 7-149. Front Electrical Caddy Open
6. RHCM [22-2] 5. NOTE
7. RHCM [22-1] If needed, label each half of the remaining connectors on
8. Headlamp caddy.
9. LHCM
10. Left turn signal Figure 7-146 Remove center fold (2) connectors.
Figure 7-147. Front Electrical Caddy Connectors
4. See Figure 7-146. Open front electrical caddy. a. See Figure 7-150. Disconnect connectors.

b. See Figure 7-151. Using a small screwdriver (3), pry the

a. See Figure 7-146 and Figure 7-148. Unlock and open
connector locking tab (2) open.
bottom fold (1) that contains frame plug.

c. See Figure 7-152. Remove connector (2).

b. Remove frame plug.
d. Repeat for all connectors in center fold.
c. See Figure 7-146 and Figure 7-149. On top fold (3)
disconnect twist grip and headlamp connectors.

d. Remove twist grip and headlamp connectors from top

fold and position out-of-way.

e. Open caddy.

7-90 94000936
 1053575 II / / II1 I
6. Figure 7-146. Remove remaining connectors on bottom
fold (1).

a. Disconnect connectors.

b. With a wiggling motion, pull connectors from caddy.

INSTALL _____
/"ft? ru
FASTENER TORQUE VALUE
Brake line clamp screw 36-48 in-lbs 4.1-5.4 N-m
1 \MTS \A\Vi --------------- —• — —
M 1. See Figure 7-146. Install connectors into bottom fold (1).

2. Install connectors into center fold (2).

Figure 7-150. Center Fold Connectors a. Install connectors into caddy.

b. Connect the connectors.

3. See Figure 7-148. Install frame plug (2) onto caddy. Close
bottom fold (1).

4. See Figure 7-147. Close top fold and install headlamp (8)
and twist grip connectors (3).

5. Install front electrical caddy and frame plug into frame.

6. See Figure 7-145. Install brake line clamp screws. Tighten.

Torque: 36-48 in-lbs (4.1-5.4 N-m) Brake line clamp screw

7. See Figure 7-144. Connect backbone harness interconnect

[327].

COMPLETE

1. Install fuel tank. See FUEL TANK (Page 6-14).

2. Install seat. See SEAT (Page 3-142).

3. Install main fuse. See POWER DISCONNECT (Page 7-7).

4. Install left side cover. See LEFT SIDE COVER (Page 3-63).

Figure 7-152. Center Fold Unlocked Connector

a. Install connector into caddy.

b. Connect the connectors.

94000936 7-91
USB CADDY 7.43
PREPARE

1. Purge fuel system. See PURGE FUEL LINE (Page 6-12).

2. Remove left side cover. See LEFT SIDE COVER (Page 3-

63).

3. Remove main fuse. See POWER DISCONNECT (Page 7-

7).

4. Remove seat. See SEAT (Page 3-142).

5. Remove fuel tank. See FUEL TANK (Page 6-14).

1. See Figure 7-153. Remove wide screw (1).

REMOVE _________________ _____

4. See Figure 7-155. Slide USB caddy (2) forward and
disconnect USB caddy interconnect (1).
5. Remove USB caddy.

Figure 7-153. USB Caddy Front Screw (Typical)

2. See Figure 7-154. Disconnect ET connector (4).

3. Remove retainer pin (1).

INSTALL

FASTENER TORQUE VALUE

Wide mounting screw 84-108 in-lbs 9.5-12.2 N-m

1. See Figure 7-155. Slide USB caddy (2) from front of engine
and connect USB caddy interconnect (1).

a. See Figure 7-156. Verify main harness tab is installed into

main harness slot (5) on USB caddy.

2. See Figure 7-154. Install retainer pin (1).

3. Connect ET connector (4).

7-92 94000936
4. See Figure 7-153. Install wide screw (1). Tighten.
Torque: 84-108 in-lbs (9.5-12.2 N-m) Wide mounting screw

DISASSEMBLE

1. Remove horn assembly. See HORN (Page 7-30).

2. See Figure 7-157 Separate USB caddy.

a. Remove screws (4).

b. Separate USB caddy.

c. Remove harness (2).

FASTENER TORQUE VALUE

ASSEMBLE
USB caddy screw 14-17 in-lbs 1.6—1.9 N-m

1. Figure 7-157. Assemble USB lower (3) and upper (1) caddy.

a. Install harness (2) into lower USB caddy.

b. Align USB caddy upper and lower.

c. Install screws (4). Tighten.

Torque: 14-17 in-lbs (1.6-1.9 N-m) USB caddy screw

2. Install horn assembly. See HORN (Page 7-30).

COMPLETE

1. Install fuel tank. See FUEL TANK (Page 6-14).

2. Install seat. See SEAT (Page 3-142).

3. Install main fuse. See POWER DISCONNECT (Page 7-7).

94000936 7-93
 4. Install left side cover. See LEFT SIDE COVER (Page 3-63).

7-94 94000936
ECM CADDY 7.44
PREPARE 4. Align holes in battery tray and ECM caddy. Install push pin
retainers (7) from battery tray side.

1. Remove left side cover. See LEFT SIDE COVER (Page 3-

63). 5. Install small screw (5). Tighten.
Torque: 55--60 in-lbs (6.2--6.8 N-m) ECM caddy small
2. Remove right side cover. See RIGHT SIDE COVER (Page 3- screw
64).
6. Tighten large screws.

3. Remove seat. See SEAT (Page 3-142). Torque: 36--60 in-lbs (4.1--6.8 N-m) ECM caddy large
screw
4. Disconnect negative battery cable. See POWER 7. Install engine harness connector anchor to ECM caddy.
DISCONNECT (Page 7-7).
8. Connect engine harness connector (4).
5. Remove battery. See INSPECT BATTERY (Page 2-43).
9. Install frame ground wires.
6. Remove ECM. See ELECTRONIC CONTROL MODULE
(ECM) (Page 7-70).
10. Install anti-rotation bracket (3).
11. Install frame ground stud nuts (2). Tighten.
REMOVE
Torque: 50-90 in-lbs (5.7-10.2 N-m) Frame ground stud
nut
1. See Figure 7-158. Remove ECM caddy (1).

2. Remove frame ground stud nuts (2)

3. Remove anti-rotation bracket (3).

4. Remove ground wires.

5. Disconnect engine harness connector (4).

6. Remove engine harness connector anchor from ECM caddy.

7. Remove small screw (5).

8. Remove large screws (6).

9. From inside of battery tray, remove push pin retainers (7).

10. Detach evaporative emissions purge lines from ECM caddy,
if equipped.

11. Remove ECM caddy.

INSTALL

1. Attach evaporative emissions purge lines to ecm caddy, If

FASTENER TORQUE VALUE

ECM caddy large screw 36-60 in-lbs 4.1--6.8 N-m COMPLETE
ECM caddy small screw 55-60 in-lbs 6.2--6.8 N-m
Frame ground stud nut 50-90 in-lbs 5.7-10.2 N-m 1. Install ECM. See ELECTRONIC CONTROL MODULE (ECM)
(Page 7-70).
equipped.

2. Install battery. See INSPECT BATTERY (Page 2-43).

2. Install and align ECM caddy.

3. Connect negative battery cable. See POWER DISCONNECT

3. See See Figure 7-158.. Install large screws (6). Hand tighten.
(Page 7-7).

94000936 7-95
4. Install right side cover. See RIGHT SIDE COVER 5. Install left side cover. See LEFT SIDE COVER
(Page 3-64). (Page 3-63).

6. Install seat. See SEAT (Page 3-142).

7-96 94000936
BCM CADDY 7.45

PREPARE INSTALL

1. Remove right side cover. See RIGHT SIDE COVER (Page 1. Install BCM caddy.
3-64).
2. Security system without siren: Connect security siren.
2. Remove seat. See SEAT (Page 3-142).
a. Move BCM caddy forward.
3. Disconnect negative battery cable. See POWER b. Connect security siren connector to back side of BCM
DISCONNECT (Page 7-7). caddy.

4. Remove battery. See INSPECT BATTERY (Page 2-43). 3. Models without purge solenoid: Connect purge solenoid
connector to BCM caddy.
5. Remove battery tray. See BATTERY TRAY (Page 7-97).
COMPLETE
6. Remove BCM. See BODY CONTROL MODULE (BCM)
(Page 7-71).
1. Install BCM. See BODY CONTROL MODULE (BCM) (Page
7-71).
7. Models with purge solenoid: Remove purge solenoid. See
Fuel and Exhaust (Page 6-1).
2. Security system with siren: Install security siren. See
SECURITY SIREN (Page 7-76).
8. Security system with siren: Remove security siren. See
SECURITY SIREN (Page 7-76).
3. Models with purge solenoid: Install purge solenoid. See
PURGE SOLENOID: EVAPORATIVE EMISSIONS (Page 6-
REMOVE _______________________________
43).

1. Models without purge solenoid: Disconnect purge solenoid

4. Install battery tray. See BATTERY TRAY (Page 7-97).
connector from top side of BCM caddy.
5. Install battery. See INSPECT BATTERY (Page 2-43).
2. Security system without siren: Disconnect security siren
connector. 6. Connect negative battery cable. See POWER
DISCONNECT (Page 7-7).
a. Move BCM caddy forward,
7. Install right side cover. See RIGHT SIDE COVER (Page 3-
b. Disconnect security siren connector on back side of 64).
BCM caddy.
8. Install seat. See SEAT (Page 3-142).
3. Remove BCM caddy.

94000936 7-97
REAR LIGHTING CADDY 7.46

PREPARE

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

2. Remove seat. See SEAT (Page 3-142).

REMOVE _______________________________

1. See Figure 7-159. Remove security antenna (5).

2. Remove both STT connectors (1 and 2).

3. Remove LP connector.

4. Remove rear lighting caddy.

a. Remove push pin retainer (4).

b. Remove caddy.
1. STT connector (left)
2. STT connector (right)
3. LP connector
4. Push pin retainer
5. Security antenna
Figure 7-159. Rear Lighting Caddy
INSTALL

1. Install rear lighting caddy.

a. Position rear lighting caddy into place.

b. See Figure 7-159. Install push pin retainer (4).

2. Install LP connector (3).

3. Install both STT connectors (1 and 2).

4. Install security antenna (5).

COMPLETE __________________________

1. Install seat. See SEAT (Page 3-142).

2. Install main fuse. See POWER DISCONNECT (Page 7-7).

7-98 94000936
BATTERY TRAY 7.47

PREPARE ______________________________ 3. Install plastic fasteners securing ECM caddy to battery tray.

1. Remove main fuse. See Main Fuse (Page 7-7).

2. Remove right side cover. See RIGHT SIDE COVER (Page

3-64).

3. Remove battery. See INSPECT BATTERY (Page 2-43).

REMOVE

1. Remove plastic fasteners securing ECM caddy to battery

tray.

2. Remove plastic fasteners securing BCM caddy to battery

tray.

3. See Figure 7-160. Remove battery tray.

a. Remove screws (1).

b. Remove battery tray (2).

INSTALL _______________________________

FASTENER TORQUE VALUE

Battery tray screw 6-9 ft-lbs 8.1-12.2 N-m COMPLETE
1. See Figure 7-160. Install battery tray.
1. Install battery. See INSPECT BATTERY (Page 2-43).
a. Install battery tray (2).
2. Install right side cover. See RIGHT SIDE COVER (Page 3-
b. Install screws (1). Tighten. 64).
Torque: 6-9 ft-lbs (8.1-12.2 N-m) Battery tray screw
3. Install main fuse. See Main Fuse (Page 7-7).
2. Install plastic fasteners securing BCM caddy to battery tray.

94000936 7-99
ENGINE GROUND CABLE 7.48

PREPARE

1. Remove right side cover. See RIGHT SIDE COVER (Page

3-64).

2. Remove seat. See SEAT (Page 3-142).

3. Remove negative cable. See POWER DISCONNECT (Page

7-7).

4. Remove battery. See INSPECT BATTERY (Page 2-43).

5. Remove battery tray. See BATTERY TRAY (Page 7-97)

REMOVE

1. See Figure 7-161. Remove battery ground cable on rear

frame ground stud (1).
Figure 7-162. Battery Ground Cable: (Starter removed for clarity)
INSTALL

1. See Figure 7-162. Install battery ground cable on

FASTENER TORQUE VALUE

Frame ground stud nut 50-90 in-lbs 5.6-10.2 N-m
Transmission ground stud nut 72-96 in-lbs 8.1-10.9 N-m
transmission ground stud (3).

2. Install nut hand tight on transmission ground stud.

3. See Figure 7-161. Route battery ground cable to rear frame

ground stud. Install nut. Tighten.
Torque: 50-90 in-lbs (5.6-10.2 N-m) Frame ground stud
nut

4. Tighten transmission ground stud nut.

2. See Figure 7-162. Remove battery ground cable (1) on
Torque: 72-96 in-lbs (8.1-10.9 N-m) Transmission ground
transmission ground stud (3).
stud nut

COMPLETE _____________________________

1. Install battery tray. See BATTERY TRAY (Page 7-97)

2. Install battery. See INSPECT BATTERY (Page 2-43).

3. Install negative cables. See POWER DISCONNECT (Page

7-7).

4. Install seat. See SEAT (Page 3-142).

5. Install right side cover. See RIGHT SIDE COVER (Page 3-

64).

7-100 94000936
ENGINE WIRE HARNESS 7.49
PREPARE b. Disconnect Temperature, Intake Air I Manifold
Absolute Pressure (TMAP) (12).

1. Purge fuel system. See PURGE FUEL LINE (Page 6-12).

c. Disconnect front injector (10).

2. Remove left side cover. See LEFT SIDE COVER (Page 3- d. Disconnect rear injector (9).
63).
e. Disconnect front knock sensor (8).
3. Remove right side cover. See RIGHT SIDE COVER (Page
3-64). f. Disconnect front ACR (7).
2. Disconnect electrical connectors around rear cylinder/ECM
4. Remove main fuse. See POWER DISCONNECT (Page 7-7). area.

5. Remove seat. See SEAT (Page 3-142). a. Disconnect engine harness (2).

b. Disconnect engine harness interconnect (4).

6. Remove fuel tank. See FUEL TANK (Page 6-14).
c. Disconnect rear knock sensor (5).
7. Remove battery. See INSPECT BATTERY (Page 2-43).
d. Disconnect rear ACR (6).
8. Remove battery tray. See BATTERY TRAY (Page 7-97). 3. Disconnect electrical connectors around starter/BCM area.

9. Remove air filter. See INSPECT AIR FILTER (Page 2-40). a. Disconnect purge solenoid (1).
10. Remove air cleaner backplate. See AIR CLEANER
b. Disconnect rear HO2S (13).
BACKPLATE ASSEMBLY (Page 6-4).
c. Disconnect VSS (14).
11. Remove ECM. See ELECTRONIC CONTROL MODULE
4. Disconnect electrical connectors around voltage regulator/oil
(ECM) (Page 7-70).
pressure sensor area.

12. Remove coil. See IGNITION COIL (Page 7-14). a. Disconnect oil pressure sensor (16).

13. Remove left side engine mount. See LEFT SIDE ENGINE b. Disconnect front HO2S (17).
MOUNT (Page 4-26).
c. Disconnect JSS (18).
REMOVE ______________________
d. Disconnect Crankshaft Position (CKP) (19).
5. Remove engine wire harness.
1. NOTE
Remove cable strap anchors, wire harness anchors and
cable straps as necessary.

See Figure 7-163. Disconnect electrical connectors around

throttle body area.

a. Disconnect Electronic Throttle Control (ETC) (15).

94000936 7-101
 1. Purge solenoid 12. TMAP
2. Engine harness 13. Rear HO2S
3. ECM 14. Rear HO2S (depends on configuration)
4. Engine harness interconnect 15. vss
5. Rear knock sensor 16. ETC
6. Rear ACR 17. Front HO2S (depends on configuration)
7. Front ACR 18. Oil pressure sensor
8. Front knock sensor 19. Front HO2S
9. Rear injector 20. JSS
10. Front injector 21. CKP sensor
11. Coil
Figure 7-163. Engine Wire Harness
INSTALL _____________ 3. Connect electrical connectors around starter/BCM area.

1. Install engine wire harness. a. Connect VSS (14).

2. See See Figure 7-163.. Connect electrical connectors b. Connect rear HO2S (13).
around voltage regulator/oil pressure sensor area.
c. Connect purge solenoid (1).
a. Connect CKP (19). 4. Connect electrical connectors around rear cylinder/ECM
area.
b. Connect JSS (18).
a. Connect rear ACR (6).
c. Connect front HO2S (17).
b. Connect rear knock sensor (5).
d. Connect oil pressure sensor (16).

7-102 94000936
 c. Connect engine harness interconnect (4).

d. Connect engine harness (2).

5. Connect electrical connectors around throttle body area.

a. Connect front ACR (7).

b. Connect front knock sensor (8).

c. Connect rear injector (9).

d. Connect front injector (10).

e. Disconnect TMAP (12).

f. Connect ETC (15).

COMPLETE ____________________________

1. Install left side engine mount. See LEFT SIDE ENGINE

MOUNT (Page 4-26).

2. Install coil. See IGNITION COIL (Page 7-14).

3. Install ECM. See ELECTRONIC CONTROL MODULE
(ECM) (Page 7-70).

4. Install air cleaner backplate assembly. See AIR CLEANER

BACKPLATE ASSEMBLY (Page 6-4).

5. Install air filter. See INSPECT AIR FILTER (Page 2-40).

6. Install battery tray. See BATTERY TRAY (Page 7-97).

7. Install battery. See INSPECT BATTERY (Page 2-43).

8. Install fuel tank. See FUEL TANK (Page 6-14).

9. Install seat. See SEAT (Page 3-142).

10. Install main fuse. See POWER DISCONNECT (Page 7-7).

11. Install right side cover. See RIGHT SIDE COVER (Page 3-
64).

12. Install left side cover. See LEFT SIDE COVER (Page 3-63).

7-103
94000936
BACKBONE WIRE HARNESS 7.50
PREPARE ______________________________ c. Remove scrap wire.

2. Connect engine harness connector (4).

1. Purge fuel system. See PURGE FUEL LINE (Page 6-12).

3. Connect main harness connector (6).

2. Remove left side cover. See LEFT SIDE COVER (Page 3-
63).
4. Install cable strap (7).
3. Remove main fuse. See POWER DISCONNECT (Page 7-7).
5. Install under seat frame cover (2).
4. Remove seat. See SEAT (Page 3-142).
a. Align under seat frame cover to frame.
5. Remove fuel tank. See FUEL TANK (Page 6-14). b. Install screws (3). Hand tight.

REMOVE c. Install screw (1). Tighten

Torque: 20-30 in-lbs (2.3-3.4 N-m) Under seat frame
1. See Figure 7-164. Disconnect main harness connector (6). cover, front screw
d. Tighten screws (3).
2. Remove under seat frame cover.
Torque: 96-120 in-lbs (10.9-13.6 N-m) Under seat
frame, rear screws
a. Remove screws (1,3).
6. Install front electrical caddy and frame plug. See FRONT
b. Remove under seat frame cover (2). ELECTRICAL CADDY (Page 7-87).

3. Disconnect engine harness connector (4). 7. See Figure 7-165. Connect fairing connector (3), if equipped.

4. Remove cable strap (7). 8. Install brake clamp screws (2). Tighten.
Torque: 36-48 in-lbs (4.1-5.4 N-m) Brake line clamp screw
5. See Figure 7-165 Remove brake line clamp screws (2).

6. Disconnect fairing connector (3), if equipped.

7. Remove frame plug (1) and front electrical caddy. See
FRONT ELECTRICAL CADDY (Page 7-87).

8. Remove backbone wire harness.

a. See Figure 7-164. Attach scrap wire to backbone

harness (5) main harness connector (6).

b. Pull backbone wire harness through backbone.

c. Disconnect scrap wire from old backbone harness.

INSTALL

FASTENER TORQUE VALUE

Brake line clamp screw 36-48 in-lbs 4.1-5.4 N-m
Under seat frame cover, front 20-30 in-lbs 2.3-3.4 N-m
screw
Under seat frame, rear screws 96-120 in-lbs 10.9-13.6 N-m
1. Route backbone wire harness through backbone.

a. See Figure 7-164. Attach scrap wire to backbone

harness (5) main harness connector (6).

b. Pull backbone wire harness through backbone.

7-104 94000936
 1. Screw
2. Under seat frame cover
3. Screw (2)
4. Engine harness connector
5. Backbone harness
6. Main harness connector
7. Cable strap
Figure 7-164. Backbone Harness to Main Harness

COMPLETE

1. Install fuel tank. See FUEL TANK (Page 6-14).

2. Install seat. See SEAT (Page 3-142).

3. Install main fuse. See POWER DISCONNECT (Page 7-7).

4. Install left side cover. See LEFT SIDE COVER (Page 3-63).

94000936 7-105
 FAIRING WIRE HARNESS 7.51
REMOVE AND INSTALL: FRAME MOUNTED c. Disconnect left and right turn signal connectors (4,5).
FAIRING ________________________________
d. Remove cable strap anchors (3).

Prepare e. Remove fairing harness.

1. Remove main fuse. See POWER DISCONNECT (Page 7-7).

Install
2. Remove outer fairing shell. See FAIRING: FRAME 1. Install fairing harness.
MOUNTED (Page 3-102).
a. See Figure 7-166. Install cable strap anchors (3).
Remove
b. Install new cable straps if they were removed from the
1. Remove fairing harness. wiring harness.

a. See Figure 7-166. Remove connector anchor (6) from c. Connect left turn signal connector (4).
fairing.
d. Connect right turn signal connector (5).
b. Disconnect backbone harness connector (2).
e. Connect backbone harness connector (2).

f. Install connector anchor (6) to fairing.

Figure
1. 7-166. Fairing
Headlamp Wiring Harness
connector 4. Left turn signal connector
2. Backbone harness connector 5. Right turn signal connector
3. Cable strap anchors (6) 6. Connector anchor

Complete 2. Install main fuse. See POWER DISCONNECT

(Page 7-7).
1. Install outer fairing shell. See FAIRING: FRAME MOUNTED
(Page 3-102).

7-106 94000936
 MAIN WIRE HARNESS 7.52
PREPARE

1. Remove left side cover. See LEFT SIDE COVER (Page

3-63).

2. Remove right side cover. See RIGHT SIDE COVER

(Page 3-64).

3. Remove seat. See SEAT (Page 3-142).

4. Remove battery. See INSPECT BATTERY (Page 2-43).

5. Remove battery tray. See BATTERY TRAY (Page 7-97).

6. Remove ECM. See ELECTRONIC CONTROL MODULE
(ECM) (Page 7-70).

7. Remove ECM caddy. See ECM CADDY (Page 7-93).

REMOVE _________________ __ _

1. NOTE
Note locations of and remove cable strap anchors, wire 3. Neutral switch [131] (2)
harness anchors and cable straps as necessary. 4. Rear WSS [168]
5. Battery power starter stud
See Figure 7-167. Disconnect electrical connectors Figure 7-168. Main Harness Right Side
around voltage regulator.
3. See Figure 7-169. Disconnect electrical connectors
a. Disconnect voltage regulator (2). under seat.

b. Disconnect rear brake switch (1). a. Disconnect right rear STT lighting (6) and
remove from rear lighting caddy.

b. Disconnect left rear STT lighting (5) and remove

from rear lighting caddy.

c. Disconnect LP lighting (7) and remove from rear

lighting caddy.

d. Disconnect security antenna (4) and remove

from rear lighting caddy.

e. Remove both frame ground studs nuts (2).

Remove shunt and all ring terminals.

f. Disconnect engine harness (1 ).

g. Disconnect backbone harness interconnect (3).

1. Starter solenoid power [128]

2. ABS module [166]

2. See Figure 7-168. Disconnect electrical connectors

from right side.

a. If equipped: Disconnect ABS module (2).

b. Disconnect neutral switch (3).

c. Disconnect battery power on starter stud (5).

d. Disconnect starter solenoid power (1).

94000936 7-107
 b. Connect engine harness (1).

c. Install shunt and all ring terminals. Install both frame

ground studs nuts (2). Tighten.
Torque: 50-90 in-lbs (5.6-10.2 N-m) Frame ground
stud nut
d. Connect security antenna (4) and install onto rear
lighting caddy.

e. Connect LP lighting (7) and install onto rear lighting

caddy.

f. Connect left rear STT lighting (5) and install onto rear
lighting caddy.

g. Connect right rear STT lighting (6) and install onto

rear lighting caddy.

6. See Figure 7-168. Connect electrical connectors from right

side.

a. Connect starter solenoid power (1).

b. Connect battery power on starter stud (5).

c. Connect neutral switch (3).

d. If equipped: Connect ABS module (2).

7. See Figure 7-167. Connect electrical connectors around

4. Detach ECM caddy. See ECM CADDY (Page 7-93). voltage regulator.
5. Remove BCM. See BODY CONTROL MODULE (BCM)
(Page 7-71). a. Connect rear brake switch (1).

6. Remove main wire harness. b. Connect voltage regulator (2).

INSTALL COMPLETE __________________________

1. Install ECM caddy. See ECM CADDY (Page 7-93).

2. Install BCM. See BODY CONTROL MODULE (BCM) (Page
2. Install battery tray. See BATTERY TRAY (Page 7-97).
FASTENER TORQUE VALUE
Frame ground stud nut 50-90 in-lbs 5.6-10.2 N-m 3. Install battery. See INSPECT BATTERY (Page 2-43).
1. Route main wire harness into place. 4. Install ECM. See ELECTRONIC CONTROL MODULE
7-71). (ECM) (Page 7-70)

3. Install ECM caddy. See ECM CADDY (Page 7-93). 5. Install negative battery cable. See POWER DISCONNECT
(Page 7-7).
4. Install ECM. See ELECTRONIC CONTROL MODULE
(ECM) (Page 7-70). 6. Install right side cover. See RIGHT SIDE COVER (Page 3-
64).
5. See Figure 7-169. Connect electrical connectors under seat.
7. Install left side cover. See LEFT SIDE COVER (Page 3-63).
a. Connect backbone harness interconnect (3).
8. Install seat. See SEAT (Page 3-142).

7-108 94000936
SUBJECT PAGE NO.
A.1 WIRING DIAGRAMS ................................................................................................................A-1
A.2 WIRE HARNESS CONNECTORS ............................................................................................A-29

WIRING
NOTES
WIRING DIAGRAMS A.1

GENERAL

Wire Color Codes

Wire traces on wiring diagrams are labeled with alpha codes.
Refer to Table A-1.

For Solid Color Wires: See Figure A-2. The alpha code
identifies wire color.

For Striped Wires: The code is written with a slash (/) between
the solid color code and the stripe code. For example, a trace
labeled GN/Y is a green wire with a yellow stripe.
!
Wiring Diagram Symbols
—►
See Figure A-1. On wiring diagrams and in service/repair
instructions, connectors are identified by a number in brackets [].
The letter inside the brackets identifies whether the housing is a .. - °
socket or pin housing.

A=Pin: The letter A and the pin symbol after a connector number
identifies the pin side of the terminal connectors.

B=Socket: The letter B and the socket symbol after a connector 1. Connector number
number identifies the socket side of the terminal connectors. 2. Terminal code (A=pin, B=socket)
Other symbols found on the wiring diagrams include the
3. Solid wire color
following:
4. Striped wire color
Diode: The diode allows current flow in one direction only in a 5. Socket symbol
circuit. 6. Pin symbol
7. Diode
Wire break: The wire breaks are used to show option variances 8. Wire break
or page breaks. 9. No connection
10. Circuit to/from
No Connection: Two wires crossing over each other in a wiring
11. Splice
diagram that are shown with no splice indicating they are not
12. Ground
connected together.
13. Twisted pair
Circuit to/from: This symbol indicates a more complete circuit Figure A-1. Connector/Wiring Diagram Symbols
diagram on another page. The symbol is also identifying the
direction of current flow. 1437959

Splice: Splices are where two or more wires are connected

together along a wiring diagram. The indication of a splice only
indicates that wires are spliced to that circuit. It is not the true
location of the splice in the wiring harness.

Ground: Grounds can be classified as either clean or dirty

grounds. Clean grounds are identified by a (BK/GN) wire and are
normally used for sensors or modules.

NOTE
Clean grounds usually do not have electric motors, coils or
anything that may cause electrical interference on the
ground circuit.

Dirty grounds are identified by a (BK) wire and are used for 1. Battery
components that are not as sensitive to electrical interference. 2. Battery tender
3. System power
Twisted pair: This symbol indicates the two wires are twisted 4. Main
together in the harness. This minimizes the circuit's Figure A-2. Fuse Blocks and Socket
electromagnetic interference from external sources. If repairs are Terminals
necessary to these wires they should remain as twisted wires.

94000936 A-1
 Table A-1. Wire Color Codes WIRING DIAGRAMS
ALPHA CODE WIRE COLOR
BE Blue Refer to the table below for wiring diagram information.
BK Black
BN Brown
GN Green
GY Gray
LBE Light Blue
LGN Light Green
0 Orange
PK Pink
R Red
TN Tan
V Violet
w White
Y Yellow

WIRING DIAGRAM LIST

FIGURE NUMBER

Power Distribution (Except FXLRST): 2022 Softail Figure A-3.

Power Distribution (FXLRST): 2022 Softail Figure A-4.
Sensor Grounds: 2022 Softail Figure A-5.

Front Lighting and Hand Controls: 2021 Softail Figure A-6.

Ground Circuit (Except FXLRST): 2022 Softail Figure A-7.
Ground Circuit (FXLRST): 2022 Softail Figure A-8.
Front Lighting and Hand Controls: 2022 Softail Figure A-9.
Fairing Harness (FXLRST): 2022 Softail Figure A-10.
Backbone Harness (Except FXLRST) 1 of 3: 2022 Softail Figure A-11.

Backbone Harness (FXLRST) 1 of 3: 2022 Softail Figure A-12.

Engine Harness 2 of 3: 2022 Softail Figure A-13.
Main Harness 3 of 3: 2022 Softail Figure A-14.
Rear Lighting: 2022 Softail Figure A-15.

A-2 94000936
 143576
5 Headlamp
Left Aux Left Front Lamp Right Aux Right Front Lamp
Tum Lamp Tum Lamp

00 gY[38B-2] 0
I
Battery Power

BK <o]
A [31 LB]
0
[±]A[38B]
[T|'f'[38A] A[31RB]
'f'[31RA]
t[31LA] [242AJ-J, -J,[259A] Y
[ofr Fuse
Block
[242B]Y [259B]
[
M ai n ; Battery ) Tender ) fjo
Battery System

r 4OA ( SA r 7.5A ( 7
Power
P o
SA
[264B]

2022 HARLEY-DAVIDSON® SERVICE MANUAL (94000936)

vQ JSB
8.
[141A] [141B] [91B]
|,(.[281B]
Voltage
Battery
Tender
Regulator

1
RN
O/GY o
Fuel
Pump t/Y^7] DLC

d -J,[329A] Y
[78B] [78A]

[327AJ-J, [T]-J,[145A]
2-J,[77A] Y RGNj~S~jj~i~j~
|T]Y[145B] [329B]
[327B]Y[T] [77B]

[24B] [24A]
i
i
H
[78B] [78A]

[T]^[19A]
a
Bank2 Sensorl
Except FLHC/S, FXLRS [138A] [138B]

[T]YM8B] [T]Y[40B] [T]Y[40B] a

'f'[166A] V/GN
Bankl Sensorl
(Except Canada) 5
[203RA] [203RB]

Rear J
EHCJ
k k ACR
(ABS Only) A [94B] Y A [94B] [203FA] [203FB]

[94A] ^[94A]
Front
-V/GN fnm i 0
[341RAJ [341RB]
1 -J,[93A] [T|Y[93B] 2 -J,[93A] |T]Yt93B] Post-Cat H02S
"V/GN Bank 1 Sensor 2
(If Equipped)

0 0 [340RA] [340RB]

Post-Cat H02S
Tail Lamp Tail Lamp
N
(H[IE Bank 2 Sensor 2
(If Equipped)

Power Distribution (Except FXLRST): 2022 Softail

2022 HARLEY-DAVIDSON® SERVICE MANUAL: SOFTAIL® MODELS (94000936)
Power Distribution (FXLRST): 2022 Softail
Power Distribution (FXLRST): 2022 Softail
2022 HARLEY-DAVIDSON® SERVICE MANUAL: SOFTAIL® MODELS (94000936)
 1572593

2022 HARLEY-DAVIDSON® SERVICE MANUAL: SOFTAIL® MODELS (94000936)

 [31RB]

Without AUX Right Directional

Lamps and Running 'iiT
Lamp
,K

Right Directional
and Running
@
v

Lamp

With AUX Lamps

73RA 73R

Right AUX
Lamp

[73RA] [73RB]

See
Backbone
Harness
Headlamp
(1 of 3)

[31LB]

Without AUX Left Directional

■ BE JT
Lamps and Running v/ BHI 2
Lamp

With AUX Lamps

Left AUX
Lamp

[73LA] [73LB]

Front Lighting and Hand Controls: 2022 Softail

2022 HARLEY-DAVIDSON® SERVICE MANUAL: SOFTAIL® MODELS (94000936)
 1572593

ili
ili ili

[19B-2]A[ [40B-2]A 3 [18B-2]A

[19A-2]1'!fl [40A-2]1'ifl [18A-2]tcp

ili * *
ili ili
x
□
Left X □
LP X i
□

Turn Signal Stopfrail Turn Signal

Lamp

Ground Circuit (Except FXLRST): 2022 Softail

2022 HARLEY-DAVIDSON® SERVICE MANUAL: SOFTAIL® MODELS (94000936)

 1572593

ili ili ili

[19B-2]A[ [40B-2]A 3 [18B-2]A

[19A-2]1'!fl [40A-2]1'ifl [18A-2]tcp

ili *
ili ili
A A A
Left LP i

Turn Signal Stopfrail Turn Signal

Lamp

Ground Circuit (FXLRST): 2022 Softail

2022 HARLEY-DAVIDSON® SERVICE MANUAL: SOFTAIL® MODELS (94000936)

 [31RB]

Without Right Directional

AUX Lamps and Running
Lamp
vtfi
■BK HI

Headlamp
Right Directional
and Running
Lamp

With AUX Lamps

f73RAl f73C

Right AUX
Lamp

[73RA] [73RB]

Except FXLRST See

Backbone
Harness (1 of
3)

[31LB]

Without Left Directional

AUX Lamps and Running
BE
Lamp
rr
BNI 2

BK
[38B]

rn
See
Headlamp Fairing Harness

With AUX Lamps

[73LA] [73LB]

Left AUX
Lamp

Front Lighting and Hand Controls: 2022 Softail

2022 HARLEY-DAVIDSON® SERVICE MANUAL: SOFTAIL® MODELS (94000936)
2022 HARLEY-DAVIDSON® SERVICE MANUAL: SOFTAIL® MODELS (94000936)
 1575974 [39A] [39B]

IM
(12-way connector W/0
Indicator bar)

Main
Harness (3
of 3)

[122B-1]}..L] [2])..[122B-2] I 90A]

Hom Engine
Temperature
Fuel Pump

Backbone Harness (Except FXLRST) 1 of 3: 2022 Softail

2022 HARLEY-DAVIDSON® SERVICE MANUAL: SOFTAIL® MODELS (94000936)
 Main
Harness (3
of 3)

Backbone Harness (FXLRST) 1 of 3: 2022 Softail

2022 HARLEY-DAVIDSON® SERVICE MANUAL: SOFTAIL® MODELS (94000936)
 Front Knock Rear Knock Front Fuel Rear Fuel Injector Post-Cat H02S Post-Cat H02S
Sensor Pre-Cat H02S Bank 1 Pre-Cat H02S Bank 2 Bank 1 Sensor 2 Bank 2 Sensor 2
Sensor Injector
TCA TMAP vss Sensor 1 Sensor 1 (If Equipped) (If Equipped)

[133A]^[ [SSAI^L [211 A] 4/ [80A] 4, [65A]^ [315 A] [84B]X [85B] X

[316AU [84A] Y
[133B]YpT 2 3I [83B]Y[/
[211B] Y
[SOBJY; [65B] Y [315B] Y [85A] Y
[316B] Y

[138B]X|
[137B]YHTT [341 B]X [340B] X |
[138A]t| [137A] Y[~T~2~3~4~ [341 A] Y [340A]Y

Main
Harness (3
of 3)
BK/GNI

[328A]

= R/wq 1
ZGN/W^ 2 =
BK/W^ 3 *
R/GY 4 4 =Backbone
GY/wq 5Harness (1 of
IBK/GY ^ 6 3)

= Y/Wl| e

[78BJ
AI
[78A] Y

[79A]^ ii II 111 X[203RB] Y

12 |120B] X 1 2 3 [95B] X A B [203FBJX 1 2
[79B] Y [203RA]
12 |120A]Y 1 2 3 [95A] Y A B [203FA] Y 1 2
System Power
Purge Solenoid

l II
l
I*
-6
Il
> 25 8
"CL
P
Rear

f
CKP Purge Front
Sensor Solenoid ACR ACR
ECM

Engine Harness 2 of 3: 2022 Softail

2022 HARLEY-DAVIDSON® SERVICE MANUAL: SOFTAIL® MODELS (94000936)
 Security
Siren
(Optional)

Rear
Brake Switch

Mam Harness 3 of 3: 2022 Softail

2022 HARLEY-DAVIDSON® SERVICE MANUAL: SOFTAIL® MODELS (94000936)
 Rear Lighting

Left & Right RearSTT

[18B] & [19B] >- HDI Only

See Main
Harness (3 of
3)

Except FLDE, FLHC/S, FXLRST

[40B)
>-
See Main
Harness (3 of
3)

Except FLDE FLHC/S, FXLRST

Brake Light
[40B]

See Main
Harness (3 of
3)

7J ).J94B]

[18B] [18B-2] --<

>-
KillU Right Rear
Directional
Lamp

[40B) [40B-2]
>- -C
See Main T]» BE H
■ BE! 1
Harness (3 of BE/R ■ Tail/LP/Stop
3) ■ BE/Rl 2
[18B] & [19B] 7fBK* ■ BKM

>- [19B] [19B-2]

SeeMain >-
Harness ___ „ , Left Rear
(3of3)
BBEN " BEN ^ | D irectional
Lamp

*
BK
“=

Rear Lighting: 2022 Softail

2022 HARLEY-DAVIDSON® SERVICE MANUAL: SOFTAIL® MODELS (94000936)
NOTES
WIRE HARNESS CONNECTORS A.2

GENERAL Connector Number

On wiring diagrams and in service instructions, connectors are
Function/Location identified by a number in brackets.

All vehicle connectors are identified by their function and Repair Instructions
location. Refer to Table A-2.
The repair instructions in Appendix B of the electrical diagnostic
Place and Color manual (EDM) are by connector type. Refer to Table A-2.

The place (number of wire cavities of a connector housing) and

color of the connector can also aid identification.

Table A-2. Softail Connector Locations

NO. DESCRIPTION TYPE TERMINAL LOCATION
PROBE COL-
OR
[18] Right rear stop, tail and turn 4-place JAE MX19 Sealed (BK) Yellow Under seat
assembly
[18-2] Right rear turn 4-place JAE MX19 Sealed (BK) Yellow Inside stop lamp (FLHC/S)
[19] Left rear stop, tail and turn as- 4-place JAE MX19 Sealed (BK) Yellow Under seat
sembly
[19-2] Left rear turn 4-place JAE MX19 Sealed (BK) Yellow Inside stop lamp (FLHC/S)
[20] Console harness 4-way JST JWPF Sealed (BK) Yellow Inside frame behind grommet
[22-1] Right hand controls 4-place JAE MX19 Sealed (BK) Yellow Caddy inside left frame behind
grommet
[22-2] Right hand controls 2-place JAEMX19 Sealed (BK) Yellow Under frame in front of front cylinder
[24] Left hand controls 4-place JAE MX19 Sealed (BK) Yellow Under frame in front of front cylinder
[31L] Left front turn signal/auxiliary 4-way JAE MX19 Sealed (GY) Yellow Caddy inside left frame behind
lamp grommet
[31R] Right front turn signal/auxiliary 4-way JAE MX19 Sealed (GY) Yellow Under frame in front of front cylinder
lamp
[38] Headlamp 4-place Deutsch DTM Sealed Brown Caddy inside left frame behind
(BK) (FXBR/S, FXFR/S) grommet
[38-2] Headlamp 4-way Delphi 150 Metri-Pack Gray Inside headlamp nacelle
(BK)
[39] IM 12-place Delphi Micro 64 Sealed BOB IM
(GY) (except FXBR/S, FXBBS) Yellow
6-place JST JWPF Sealed (BK)
(FXBR/S, FXBBS)

[40] Center rear lighting 3-place Tyco MCON 1.2 Sealed Gray Under seat
(BK)
[40-2] Tail lamp 4-place JAEMX19 Sealed (BK) Yellow Inside light bar
[47] Voltage regulator to stator 3-place Dekko (BK) Green Back of voltage regulator
[64] Fuse block 6-way Purple/Red Behind left side cover
[65] vss 3-place Delphi GT 150 3.5 Gray Top of transmission under battery
Sealed (BK)
[73L] Left auxiliary lamps 2-way Delphi 280 Metri-Pack Purple Inside auxiliary/fog lamps sealed
(BK)
[73R] Right auxiliary lamps 2-way Delphi 280 Metri-Pack Purple Inside auxiliary/fog lamps sealed
(BK)
[77] Voltage regulator 2-place Dekko (BK) Green Back of voltage regulator
[78] ECM 81-way Delphi (BK) BOB Behind left side cover under fuse block
caddy
[79] CKP sensor 2-place Deutsch DTM Sealed Brown Back of voltage regulator bracket
(BK)
[80] TMAP 4-place Tyco MCON 1.2 Sealed Gray Top of induction module
(BK)
[83] Ignition coil 3-place Delphi GT 150 Sealed Gray Rear of coil
(BK)
[84] Front fuel injector 2-place Delphi GT 150 3.5 Gray Beneath fuel tank
Sealed (GY)

94000936
A-29
 NO. DESCRIPTION TYPE TERMINAL LOCATION
Table A-2. Softail Connector Locations
PROBE COL-
OR
[85] Rear fuel injector 2-place Delphi GT 150 3.5 Gray Beneath fuel tank
Sealed (GY)
[90] ET sensor 2-place Tyco MCON 1.2 Sealed Gray Under frame below fuel tank
(GY)
[91] DLC 6-place Deutsch DT Sealed (GY) Black Behind left side cover

[93] Tail lamp 4-way Tyco 070 Multilock Un- Gray Circuit board under tail lamp as
sealed (BK) sembly
[94] Rear fender lights harness in 6-place Tyco 070 Multilock Un- Gray Circuit board under tail lamp as
circuit board sealed (BK) sembly (FLHC)
[95] Purge solenoid 2-place Delphi 150 Metri-pack Gray Under seat in front of rear fender
Sealed (BK)
[100] Fairing interconnect 16-way Molex MX150 Gray Inside fairing
[108] Tachometer 12-place Delphi Micro 64 Sealed BOB Behind tachometer
(GY)
[120] Oil pressure switch 3-place Delphi GT 150 3.5 (BK) Gray Front right crankcase
[121-1] Rear brake switch Push-on molded terminals (BK) Red Right side of engine behind voltage
regulator
[121-2] Rear brake switch Push-on molded terminals (BK) Red Right side of engine behind voltage
regulator
[122] Horn Flag terminals (BK) Red USB caddy under frame in front of
front cylinder
[128] Starter solenoid Tyco Insulated Spade terminal Red Top of starter
(W)
[131-1] Neutral switch Right Angle Push On Molded Top of transmission
(BK)
[131-2] Neutral switch Right Angle Push On Molded Top of transmission
(BK)
[133] JSS 3-place Molex MX 150 Sealed Gray Back of voltage regulator bracket
(BK)
[137] HO2S rear 4-place Molex MX 150 Sealed Gray Under seat in front of battery
(BK)
[138] HO2S front 4-place Molex MX 150 Sealed Gray Behind voltage regulator
(BK)
[141] Fuel pump and sender 4-place Molex MX150 Sealed Gray USB caddy under frame in front of
(BK) front cylinder
[142] Security siren (optional) 3-place Delphi GT 150 3.5 Gray Electrical panel behind fender exten-
Sealed (BK) sion
[145] Engine harness 6-way Molex MX 150 Sealed Gray Under seat
(BK)
[166] ABS EHCU 18-place Tyco MCON 1.2 Sealed BOB Behind right side cover
(BK)
[167] Front WSS 2-place JAEMX19 Sealed (GY) Yellow Under frame in front of front cylinder
[168] Rear WSS 2-place Deutsch DTM Sealed Brown Behind right side cover
(BK)
[203FA] ACR (front) 2-place Tyco Superseal 1.5 Gray Under frame below fuel tank
Sealed
[203RA] ACR (rear) 2-place Tyco Superseal 1.5 Gray Under frame below fuel tank
Sealed
[204] TGS 6-place JST JWPF Sealed Yellow Caddy inside left frame behind
grommet
[209] Security antenna 2-place Molex MX 64 Unsealed Light Blue Under seat
(BK)
[211] TCA 6-way Delphi GT 150 Sealed Gray Right side of engine (induction mod-
(BK) ule)
[242] BCM 48-place Molex CMC Sealed BOB Front of rear wheel behind splash
(BK) guard
[259] BCM battery power 1-place Delphi 800 Metri-pack Red Front of rear wheel behind splash
Sealed (BK) guard
[264] USB 2-way Deutsch DT (GY) Black USB caddy under frame in front of
front cylinder
[281] Battery tender 2-way over mold (BK) Behind left side cover

A-30 94000936
 Table A-2. Softail Connector Locations
NO. DESCRIPTION TYPE TERMINAL LOCATION
PROBE COL-
OR
[315] Front knock sensor 2-way Kostal MLK 1.2 Light blue Under fuel tank
[316] Rear knock sensor 2-way Kostal MLK 1.2 Light blue Under fuel tank
[319] Terminating resistor 2-way Delphi GT 150 (BK) Gray Behind left side cover
(325] P&A accessory 3-way Molex MX150 (BK) Gray Behind left side cover
[327] Backbone harness interconnect 20-way Molex MX150 (BK) Gray Under seat
[328] Engine harness interconnect 8-way JST JWPF Sealed (BK) Yellow Under fuel tank behind rear cylinder
[329] USB caddy interconnect 8-way Molex MX150 Gray USB caddy under frame in front of
front cylinder
[340] Post HO2S Bank 2 4-place Molex MX 150 Sealed Gray Right side of engine
[341] Post HO2S Bank 1 4-place Molex MX 150 Sealed Gray Right side of engine
[GND1] Rear ground stud Ring terminals Under seat
[GND2] Front ground stud (Regulator)
[GND2A] Front ground stud
ed03671
CONNECTOR END VIEWS

Table A-3. Right Rear Turn Signal [18]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 - N/C
2 BE/BN Right rear turn signal [BJ-< [AJ^
3 - N/C
4 BK Ground
Figure A-18. Left Rear Turn Signal [19]

Table A-6. Left Rear Turn Signal [19-2]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 - N/C
2 BEN Left rear turn signal
3 BK Ground
4 - N/C
ed03805

Table A-4. Right Rear Turn Signal [18-2]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 - N/C
2 BE/BN Right rear turn signal
3 BK Ground
4 - N/C
Figure A-19. Left Rear Turn Signal [19-2]

Table A-7. Console Harness [20]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 R/O Battery fuse
2 BK/GN Ground
3 W/R CAN high
4 W/BK CAN low

Table A-5. Left Rear Turn Signal [19]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 - N/C
2 BE/BN Left rear turn signal
3 - N/C
4 BK Ground

A-31
 Table A-8. RHCM [22-1] Table A-12. Front Left Turn [31L-2]
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 R/O Battery fuse 1 BE Position
2 BK Ground 2 BE/PK Left front turn signal
3 W/R CAN high 3 BK Ground
4 W/BK CAN low 4 - N/C

Table A-9. RHCM [22-2] Table A-13. Front Right Turn Signal [31R]
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 W/GY Engine stop switch 1 BE Position
2 - N/C 2 BE/O Right front turn signal
3 BK Ground
4 BE/BK AUX/fog

Table A-10. LHCM [24]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 R/O Battery fuse Table A-14. Front Right Turn Signal [31R-2]
2 BK Ground TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
3 W/R CAN high 1 BE Position
4 W/BK CAN low 2 BE/O Right front turn signal
3 BK Ground
4 - N/C

Table A-11. Front Left Turn Signal [31L] Figure A-27. Front Right Turn Signal [31R-2]
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 BE Position Table A-15. Headlamp [38]
2 BE/PK Left front turn signal TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
3 BK Ground 1 BE Running/position lamp
4 BE/BK AUX/fog 2 BE/Y Low beam
3 BE/W High beam
4 BK Ground

Figure A-24. Front Left Turn Signal [31L]

94000936
A-32
Table A-16. Headlamp [38-2] Table A-19. Center Lighting [40A]
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
A BK Ground 1 BE Running/position lamps
B BE/Y Low beam 2 BE/R Brake lamp power
C BE/W High beam 3 BK Ground
D BE Running/position lamp

Table A-20. Center Lighting [40B]

Table A-17. IM [39] (12 place connector) TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION 1 BE Running/position lamps
1 W/O Oil pressure indicator 2 BE/R Brake lamp power
2 W/R CAN high 3 BK Ground
3 - N/C
4 BE/W High beam indicator
5 R/O Battery fuse
6 w Neutral indicator
7 BK/GN Ground
8 W/BK CAN low
9 - N/C
10 BE/PK Left turn indicator
11 w Indicator type ID
12 BE/O Right turn indicator

Table A-21. Stop Tail Lamp [40-2)

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 BE Position
2 BE/R Brake lamp power
3 BK Ground
4 - N/C

Table A-18. IM [39) (6 place connector)

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 R/O Battery fuse
2 BK/GN Ground
3 BK Spare „
4 W/R CAN +
5 W/BK CAN low
6 BK H-D link Table A-22. Stator [47]
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 BK Stator
2 BK Stator
3 BK Stator

94000936
A-33
Table A-23. Fuse Block [64]
Table A-26. Left Auxiliary/Fog Lamps [73L-2]
TERMINAL WIRECOLOR CIRCUIT DESCRIPTION
TERMINAL WIRECOLOR CIRCUIT DESCRIPTION
1 BK Ground
1 R Battery
2 BE/BK Front running/fog light power
2 R/O Battery fuse
3 R Battery
4 R Tender fuse
5 R/GR System power
6 V/G System power
A R Battery/main fuse
B R Battery/main fuse
1437959

Figure A-39. Left Auxiliary/Fog Lamps [73L-2]

Table A-27. Auxiliary/Fog Lamps [73R]

TERMINAL WIRECOLOR CIRCUIT DESCRIPTION
A BK Ground
B GY/BK Front running/fog light power

Figure A-36. Fuse Block [64]

Table A-24. VSS [65]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
A R/W 5 Volt sensor power Table A-28. Right Auxiliary/Fog Lamp [73R-2]
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
B LGN/Y VSS input
1 BK Ground
C BK/GN Sensor ground
2 BE/BK Front running/fog light power

Figure A-41. Right Auxiliary/Fog Lamp [73R-2]

Table A-25. Auxiliary/Fog Lamps [73L]
TERMINAL WIRECOLOR CIRCUIT DESCRIPTION Table A-29. Voltage Regulator [77]
TERMINAL WIRECOLOR CIRCUIT DESCRIPTION
A BK Ground
B GY/BK Front running/fog light power P R Battery
N BK Ground

94000936
A-34
94000936
A-35
 Table A-30. ECM [78] Table A-30. ECM [78]
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 - N/C 59 TN/Y Post-cat HO2S bank 2 sensor 2
2 BK/GN Ground
3 BK/GN Ground 60 - N/C
4 - N/C 61 - N/C
5 R/GN System power 62 - N/C
6 GN/Y Front fuel injector (53 - N/C
7 GY/Y Rear fuel injector (54 - N/C
8 LBE/R Rear ACR 65 BK/W HO2S sensor ground
9 - N/C 656 R/GY 5V sensor power 2
10 - N/C 87 R/O 5A battery fuse
11 BK Crank position sensor 658 - N/C
12 - N/C 69 - N/C
13 - N/C 70 R/W 5V sensor power 1
14 BK/O Pre-cat heater ground bank 1 71 - N/C
sensor1 72 GN/GY Intake air temperature
15 - N/C 73 BKN Post-cat 02 heater bank 2
16 LGN/BK Purge solenoid sensor2
17 - N/C 74 BK/GY 5V sensor ground 2
18 - N/C 75 - N/C
19 - N/C 76 - N/C
20 GY/O Throttle motor lo 77 - N/C
21 GN/O Throttle motor hi 78 - N/C
22 - N/C 79 - N/C
23 BK/PK Pre-cat heater ground bank 2 BN/O Post-cat 02 heater bank 1
80
sensor1 sensor 2
24 GN/BE Front coil out 81 - N/C
25 LGN/R Front ACR
GY/R Post-cat 02 sensor bank 1
26
sensor 2
27 GYN Throttle position sensor 2
28 - N/C
29 BK/W 5V sensor ground 1
30 R Crank position sensor +
31 Y/W Fuel level
32 W/O Oil pressure
33 - N/C
34 LGN/GY Jiffy stand Figure A-43. ECM [78] Table A-31. CKP Sensor [79]
35 - N/C TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
36 BN/W Front knock sensor HI 1 R CKP sensor high
37 LGN/W Front knock sensor LO 2 BK CKP sensor low
38 W/BK CAN low
39 W/R CAN high
40 - N/C
41 GN/W Twist grip sensor 1
42 GY/W Twist grip sensor 2
43 GY/BE Rear coil out
44 - N/C
45 BNN Rear knock sensor HI
46 LGNN Rear knock sensor LO
47 GN/BN Pre-cat HO2S bank 1 sensor
1
48 GY/BN Pre-cat HO2S bank 2 sensor
1 Table A-32. TMAP [80]
49 GY/GN Coolant sensor TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
50 - N/C 1 GY MAP input
51 LGN/Y Vehicle speed 2 R/GY 5V sensor power 2
52 GNN Throttle position sensor 1 3 GN/GY IAT
53 GY TMAP pressure in 4 BK/GY 5V sensor ground 2
54 - N/C
55 GN Engine temp sensor
56 - N/C
57 - N/C
58 - N/C

94000936
A-36
 ed04042 ed04040

[A] ^

Figure A-45. TMAP [80] Figure A-49. ET Sensor [90]

Table A-33. Ignition Coil [83] Table A-37. OBD [91C]

TERMINAL WIRECOLOR CIRCUIT DESCRIPTION TERMINAL WIRECOLOR CIRCUIT DESCRIPTION
A GY/BE Rear ignition coil 1 - N/C
B R/GN System power 2 W/R CAN high
C GN/BE Front ignition coil 3 BK Ground
ed03695
4 R/Y Accessory power
5 W/BK CAN low
6 - N/C

Figure A-46. Ignition Coil [83]

Table A-34. Front Fuel Injector [84]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
A R/GN System power
B GN/Y Rear fuel injector Table A-38. [93]
ed03574 TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 BE Running light power
2 O/W Accessory power
3 R/Y Brake lamp power
4 BK Ground

Figure A-47. Front Fuel Injector [84]

Table A-35. Rear Fuel Injector [85]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
A R/GN System power
B GY/Y Front fuel injector
ed03574

Table A-39. Stop Tail Lamp [94]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 - N/C
2 BE/BN Right rear turn signal
3 BE Running lights power
4 BE/R Brake lamp power
5 BEN Left rear turn signal
6 BK Ground
Figure A-48. Rear Fuel Injector [85]

Table A-36. ET Sensor [90]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 GN ET sensor
2 BK/W 5V sensor ground

Figure A-52. Stop Tail Lamp [94]

94000936 A-37
 Table A-40. Purge Solenoid [95] ed03709
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
A V/GR System power
B LGN/BK Purge solenoid

Figure A-55. Tachometer [108]

Table A-43. Oil Pressure Switch [120]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 BK/W 5V sensor ground
2 R/W 5V sensor power
3 W/O Oil pressure
Table A-41. Fairing Interconnect [100]
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 BE Position lamp
2 BE/PK Front left turn signal
3 BK Ground
4 BE/BK N/C
5 - N/C
6 - N/C
7 BK Ground
8 BE/Y Low beam headlamp
9 BE/W High beam headlamp
10 BE Position lamp Table A-44. Rear Brake Switch [121-1] [121-2]
11 R/Y N/C TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
12 - N/C 1 BE/GN Rear brake switch
13 BE Position lamp 1 BK Ground
14 BE/O Front right turn signal
15 BK Ground
16 BE/PK N/C

Figure A-57. Rear Brake Switch [121-1] [121-2] Table A-45. Horn

[122-1] [122-2]
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 RN Horn power
Table A-42. Tachometer [108] BK Ground
1
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 - N/C
2 W/R CAN +
3 - N/C
4 - N/C
5 R/O Battery power
6 - N/C
7 BK/GN Ground
8 W/BK CAN -
9 - N/C
10 - N/C
11 - N/C Table A-46. Starter Solenoid [128]
12 - N/C TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 R/BK Starter solenoid power

A-38 94000936
Table A-47. Neutral Switch [131-1] [131-2] Table A-51. Fuel Pump [141]
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 w Neutral switch input 1 R/BN Fuel pump power
1 BK Ground 2 W/Y Fuel level sender
3 BK/W 5V sensor ground
4 BK Ground

Table A-48. Jiffy Stand [133]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 R/W 5 Volt sensor power Table A-52. Security Siren (Optional) [142]
2 LGN/GY JSS signal TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
3 BK/GN Sensor ground 1 R/O Power
2 W/GN Security siren
3 BK Ground

Table A-49. HO2S Rear [137]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 V/GN Fuse system power Table A-53. Engine Harness [145]
2 BK/PK Rear HO2S heater ground TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
3 GY/BN Rear HO2S 1 R/O Battery power
4 BK/W 5 Volt sensor ground 2 R/GN System power
3 W/R CAN +
4 W/BK CAN-
5 BK/GN Ground
6 V/GN System power

Table A-50. HO2S Front [138]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 V/GN Fuse system power
2 BK/O Front HO2S heater ground
3 GN/BN Front HO2S
4 BK/W 5 Volt sensor ground

94000936
A-39
 Table A-54. ABS [166] ed03669

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BK/GN Ground
2 W/R CAN high
3 O/BK Front WSS low
4 BE/BK Switched aux lamp PWR
5 - N/C
6 - N/C
Figure A-70. Front ACR [203F]
7 - N/C
8 - N/C
Table A-58. Rear ACR [203R]
9 R Battery power
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
10 BK Ground
1 R/GN System power
11 W/BK CAN low
2 LBE/R ACR enable
12 O/BE Front WSS high ed03669
13 O/PK Rear WSS high
14 O/BN Rear WSS low
15 - N/C
16 - N/C
17 - N/C
18 R Battery power

Figure A-71. Rear ACR [203R]

Table A-59. TGS [204A]

TERMINAL WIRECOLOR CIRCUIT DESCRIPTION
1 R/W 5V sensor power 1
2 GN/W TGS 1
3 BK/W 5V sensor ground 1
Table A-55. Front WSS [167] 4 R/GY 5V sensor power 2
5 GY/W TGS2
6 BK/GY 5V sensor ground 2
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 O/BE Front WSS high
2 O/BK Front WSS low
ed03731

Table A-60. TGS [204B]

Figure A-68. Front WSS [167] Table A-56. Rear WSS [168] TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION 1 R 5V sensor power 1
1 O/PK Rear WSS high 2 w TGS 1
2 O/BN Rear WSS low 3 BK 5V sensor ground 1
4 R 5V sensor power 2
5 w TGS2
6 BK 5V sensor ground 2

Table A-57. ACR [203]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 R/GN System power
2 LGN/R ACR enable

A-40
 Table A-61. Security Antenna [209] Table A-63. BCM [242]
TERMINAL WIRECOLOR r CIRCUIT DESCRIPTION TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 R Security antenna high H2 W/GN Security siren
2 BK Security antenna low H3 - N/C
H4 - N/C
J1 - N/C
J2 BE/O Right front turn signal
J3 BE Running lights
J4 BE/PK Left front turn signal
K1 - N/C
K2 BE/BN Right rear turn signal
K3 BE/R Brake lamp power
K4 BEN Left rear turn signal
L1 - N/C
L2 R/BK Starter solenoid power
Table A-62. TCA [211]
L3 R/GN System power
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
L4 BE/BK Front running/Fog light power
A GY/O ETC low
M1 - N/C
B BK/W 5V sensor ground 1
M2 R/Y Accessory power
C GNN TPS 1
M3 BE/W High beam power
D R/W 5V sensor power 1
M4 BE/Y Low beam power
E GYN TPS 2
F GN/O ETC high

Figure A-76. BCM [242] Table A-64. BCM Power [259]

Table A-63. BCM [242]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
A1 - N/C
A2 R Security antenna high
A3 - N/C
A4 BK Security RF antenna
B1 - N/C
B2 BK Security antenna low
B3 - N/C
B4 - N/C
C1 - N/C Figure A-77. BCM Power [259]
C2 - N/C
C3 - N/C Table A-65. USB Interconnect [264]
C4 W/GY Engine stop switch input TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
D1 - N/C 1 R/Y Accessory power
D2 W/R CAN high 2 BK Ground
D3 Neutral switch input 1085865
w
D4 - N/C
E1 - N/C
E2 W/BK CAN low
E3 W/O Oil pressure switch input
E4 RN Horn power
F1 - N/C
F2 - N/C
F3 BE/GN Brake switch input
F4 R/BN Fuel pump power Figure A-78. USB Interconnect [264]
G1 - N/C
G2 O/W ABS wake Table A-66. Battery Tender [281]
G3 - N/C TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
G4 BK/GN Sensor ground 1 R Battery power
H1 - N/C 2 BK Ground

94000936 A-41
Table A-67. Front Knock Sensor [315]
Table A-71. Backbone Harness Interconnect [327A]
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
TERMINAL WIRECOLOR CIRCUIT DESCRIPTION
1 R/BN Fuel pump power
1 LGNN Front knock sensor LO
2 RN Horn power
2 BN/W Front knock sensor HI
ed04043
3 R/Y Accessory power
4 R/O Battery fuse
5 BE Position lamp
6 BE/BK AUX/fog lamps
7 BK/GN Ground
8 BK Ground
9 - N/C
10 BE/Y Low beam
[B]-< 11 BE/W High beam
Figure A- 12 W/R CAN +
J^<0. Knock 13 W/BK CAN-
Sensor
Table A-^iB. Rear Knock Sensor [316] 14 - N/C
TERMINAL |WIRECOLOR CIRCUIT DESCRIPTION 15 - N/C
1 LGNN Rear knock sensor LO 16 O/BE Front WSS +
2 | BNN Rear knock sensor HI 17 O/BK Front WSS -
ed04043
18 BE/O Front right turn
19 BE/PK Front left turn
20 W/GY Run/stop switch

Figure A-81. Knock Sensor

Table A-69. Termination Resistor [319]

TERMINAL WIRECOLOR CIRCUIT DESCRIPTION Figure A-84. Backbone Harness Interconnect [327A]
A W/R CAN High
B W/BK CAN Low
ed04046

Figure A-85. Backbone Harness Interconnect [327B]

[B]--<
Table A-72. Engine Harness Interconnect [328]
Figure A-82. Termination Resistor [319] TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 R/W 5V sensor power 1
Table A-70. P&A Accessory [325] 2 GN/W TGS 1
TERMINAL WIRECOLOR CIRCUIT DESCRIPTION 3 BK/W 5V sensor ground 1
1 R/Y Accessory power 4 R/GY 5V sensor power 2
2 BK Ground 5 GY/W TGS2
3 - N/C BK/GY 5V sensor ground 2
6
7 GN Engine temperature
8 Y/W Fuel level

94000936
A-42
 Table A-74. Light Bar Interconnect [331] (4 place connect-
or)

TERMINAL WIRECOLOR CIRCUIT DESCRIPTION

3 BEN Left rear turn signal
4 BK Ground

Figure A-86. Engine Harness Interconnect [328]

Table A-73. USB Caddy Interconnect [329]

TERMINAL WIRECOLOR CIRCUIT DESCRIPTION
1 BK Ground
2 BK/W 5V sensor ground 1
3 GN Engine temperature Figure A-88. Light Bar Interconnect [331] (4 place connector)
4 R/Y Accessory power
5 RN Horn power
6 BK/W 5V sensor ground 1 Table A-75. Light Bar Interconnect [331] (6 place connector)
7 Y/W Fuel level
8 R/BN Fuel pump power TERMINAL WIRECOLOR CIRCUIT DESCRIPTION
1 BK Ground
2 BE/BN Right rear turn signal
3 BEN Left rear turn signal
4 BE/R Brake light power
5 BE Running light power

Table A-74. Light Bar Interconnect [331] (4 place connect-

or)
TERMINAL WIRECOLOR CIRCUIT DESCRIPTION
1 BE/BN Right rear turn signal Figure A-89. Light Bar Interconnect [331] (6 place connect-
2 BK Ground or)

94000936 A-43
NOTES
SUBJECT PAGE NO.
B.1 GLOSSARY ................................................................................................................................. B-1
B.2 METRIC CONVERSION .............................................................................................................. B-4
B.3 FLUID CONVERSION ................................................................................................................ B-5

REFERENCE
NOTES
GLOSSARY B.1

ACRONYMS AND ABBREVIATIONS

Refer to the table below for a list of common acronyms and

abbreviations.
Table B-1. Acronyms and Abbreviations
ACRONYM OR ABBREVIATION DESCRIPTION
A Amperes
AAT Ambient air temperature
ABS Anti-lock braking system
AC Alternating current
ACC Accessory position on ignition switch
ACR Automatic compression release
IAGM Absorbed glass mat (battery)
Ah Ampere-hour
AIS Active intake solenoid
ARH Adaptive Ride Height
AWG American wire gauge
B+ Battery voltage
bar Bar
BAS Bank angle sensor
BCM Body control module
BMU Battery Management Unit
BOB Breakout box
BTDC Before top dead center
o Celsius (Centigrade)
c
CA California
CAL Calibration
CAN Controller area network
CB Tx CB send transmission
CB Rx CB receive transmission
cc Cubic centimeters
CCA Cold cranking amps
ccw Counterclockwise
CKP Crankshaft position
cm Centimeters
cm3 Cubic centimeters

cw Clockwise
DC Direct current
DLC Data link connector
DOM Domestic
DOT Department of Transportation
DTC Diagnostic trouble code
DVOM Digital volt ohm meter
ECM Electronic control module
ECT Engine coolant temperature
ECU Electronic control unit
EEPROM Electrically erasable programmable read only memory
EFI Electronic fuel injection
EHCU Electro hydraulic control unit
EPTC Electronic Powertrain Controller
ET Engine temperature
ETC Electronic throttle control
EVAP Evaporative emissions control system
EVPT Electric Vehicle Powertrain
“F Fahrenheit
fl oz Fluid ounce
FPS Fuel pressure sensor
ft Feet
ft-lbs Foot pounds
FTP Flash to pass
g Gram

94000936 B-1
 Table B-1. Acronyms and Abbreviations
ACRONYM OR ABBREVIATION DESCRIPTION
gal Gallon
GAWR Gross axle weight rating
GND Ground (electrical)
GPS Global positioning system
GVWR Gross vehicle weight rating
HCU Hydraulic control unit
HDI Harley-Davidson International
HD-Link Networking system
H-DSSS Harley-Davidson smart security system
HFM Hands-free mode
HFSM Hands-free security module
Hg Mercury
H02S Heated oxygen sensor
hp Horsepower
hr Hour
IAC Idle air control
IAT Intake air temperature
IC Instrument cluster
ID Inside diameter
IGN Ignition lighUkey switch position
IM Instrument module
IMU Inertial Measurement Unit
in inch
in3 Cubic inch
INJ PW Injector pulse width
INTCM Intercom
in-lbs Inch pounds
JSS Jiffy stand sensor
kg Kilogram
km Kilometer
km/h Kilometers per hour
kPa Kilopascal
kW Kilowatt
KS Knock sensor
L Liter
lb Pounds
LCD Liquid crystal display
LED Light emitting diode
LH Left hand
LHCM Left hand control module
LP License plate
LT Left
mA Milliampere
MAP Manifold absolute pressure
max Maximum
MCM Motor Control Module
mi Mile
min Minimum
mL Milliliter
mm Millimeter
mph Miles per hour
ms Millisecond
Nm Newton-meter
NIM Navigation interface module
NiMH Nickel metal hydride
N/A Not applicable
02 Oxygen
OBC Onboard Charger
OD Outside diameter
OEM Original equipment manufacturer
oz Ounce
P&A Parts and Accessories
Part No. Part number

B-2 94000936
 Table B-1. Acronyms and Abbreviations
ACRONYM OR ABBREVIATION DESCRIPTION
PIN Personal identification number
PND Personal navigation device
psi Pounds per square inch
PWM signal Pulse width modulated signal
qt Quart
RAD Radio
RCM Reverse control module
RDS Radio data system
RES Reserve mark on fuel supply valve
RESS Rechargeable Energy Storage System
RFF Roller Finger Follower
RH Right hand
RHCM Right hand control module
rpm Revolutions per minute
RT Right
s Seconds
SCFH Cubic feet per hour at standard conditions
SOARS Satellite digital audio radio service
SPDO Speedometer
SPKR Speaker
STT Stop/tail/turn
TA Traffic announcement
TCA Throttle control actuator
TCU Telemetry Control Unit
TDC Top dead center
TGS Twist grip sensor
TPMS Tire pressure monitoring system
TPS Throttle position sensor
TSM Turn signal module
TSSM Turn signal/security module
TT Telltale
USB Universal serial bus
V Volt
VAC Volts of alternating current
VDC Volts of direct current
VIN Vehicle identification number
VR Voice recognition
vsc Vehicle Security Advisory Controller
vss Vehicle speed sensor
w Watt
WA Weather alert
WHIM Wireless headset interface module
wss Wheel speed sensor

94000936 B-3
CONVERSION TABLE
METRIC CONVERSION B.2

Table B-2. Metric Conversions

MILLIMETERS to INCHES (MM x 0.03937 = IN) INCHES to MILLIMETERS (IN x 25.40 = MM)
mm in mm in mm in mm in in mm in mm in mm in mm
1 .0039 25 .9842 58 2.283 91 3.582 .001 .025 .6 15.240 1-15/16 49.21 3-5/16 84.14
.2 .0078 26 1.024 59 2.323 92 3.622 .002 .051 5/8 15.875 2 50.80 3-3/8 85.72
.3 .0118 27 1.063 60 2.362 93 3.661 .003 .076 11/16 17.462 2-1/16 52.39 3.4 86.36
.4 .0157 28 1.102 61 2.401 94 3.701 .004 .102 .7 17.780 21 53.34 3-7/16 87.31
,5 .0197 29 1.142 62 2.441 95 3.740 .005 .127 3/4 19.050 2-1/8 53.97 3-1/2 88.90
.6 .0236 30 1.181 63 2.480 96 3.779 .006 .152 .8 20.320 2-3/16 55.56 3-9/16 90.49
.7 .0275 31 1.220 64 2.519 97 3.819 .007 .178 13/16 20.638 2.2 55.88 3.6 91.44
8 .0315 32 1.260 65 2.559 98 3.858 ,008 203 7/8 22,225 2-1/4 57.15 3-5/8 92.07
.9 .0354 33 1.299 66 2,598 99 3.897 .009 229 ,9 22.860 2.3 58.42 3-11/16 93.66
1 .0394 34 1.338 67 2.638 100 3.937 .010 .254 15/16 23.812 2-5/16 58.74 3.7 93.98
2 .0787 35 1.378 68 2.677 101 3.976 1/64 .397 1 25.40 2-3/8 60.32 3-3/4 95 25
3 .1181 36 1.417 69 2.716 102 4.016 .020 508 1-1/16 26.99 2.4 60.96 3.8 96.52
4 .1575 37 1.456 70 2.756 103 4.055 .030 .762 1.1 27.94 2-7/16 61.91 3-13/16 96.84
5 .1968 38 1.496 71 2.795 104 4.094 1/32 794 1-1/8 28.57 2-1/2 63.50 3-7/8 98.42
6 .2362 39 1.535 72 2.834 105 4.134 .040 1 016 1-3/16 30.16 2-9/16 65.09 3.9 99.06
7 .2756 40 1.575 73 2.874 106 4.173 .050 1 270 1.2 30.48 2.6 66.04 3-15/16 100.01
8 .3149 41 1.614 74 2.913 107 4.212 .060 1.524 1-1/4 31.75 2-5/8 66.67 4 101.6
9 .3543 42 1.653 75 2.953 108 4.252 1/16 1.588 1.3 33.02 2-11/16 68.26 4-1/16 102.19
10 .3937 43 1.693 76 2.992 109 4.291 .070 1.778 1-5/16 33 34 27 68.58 4.1 104 14
11 .4331 44 1.732 77 3.031 110 4.331 .080 2.032 1-3/8 34.92 2-3/4 69.85 4-1/8 104.77
12 .4724 45 1.772 78 3.071 111 4.370 .090 2.286 1.4 35.56 2.8 71.12 4-3/16 106.36
13 .5118 46 1.811 79 3.110 112 4.409 .1 2.540 1-7/16 36.51 2-13/16 7144 42 106.68
14 .5512 47 1.850 80 3.149 113 4.449 1/8 3.175 1-1/2 38.10 2-7/8 73.02 4-1/4 107.95
15 .5905 48 1 890 81 3 189 114 4.488 3/16 4.762 1-9/16 39.69 2.9 73.66 4.3 109.22
16 .6299 49 1.929 82 3.228 115 4.527 2 5,080 1.6 40 64 2-15/16 74.61 4-5/16 109.54
17 .6693 50 1 968 83 3 268 116 4.567 1/4 6.350 1-5/8 41.27 3 76.20 4-3/8 111.12
18 .7086 51 2.008 84 3.307 117 4.606 3 7,620 1-11/16 42 86 3-1/16 77.79 4.4 111.76
19 .7480 52 2.047 85 3 346 118 4.645 5/16 7.938 1.7 43.18 3.1 78.74 4-7/16 112.71
20 .7874 53 2.086 86 3.386 119 4.685 3/8 9.525 1-3/4 44.45 3-1/8 79.37 4-1/2 114.30
21 .8268 54 2 126 87 3.425 120 4.724 4 10.160 1.8 45.72 3-3/16 80.96 4-9/16 115.89
22 .8661 55 2.165 88 3.464 121 4 764 7/16 11.112 1-13/16 46.04 3.2 81.28 4.6 116.84
23 .9055 56 2.205 89 3 504 122 4 803 1/2 12.700 1-7/8 47.62 3-1/4 82.55 4-5/8 117.47
24 ,9449 57 2.244 90 3.543 123 4.842 9/16 14.288 19 48.26 3.3 83.82 4-11/16 119.06

B-4 94000936
FLUID CONVERSION B.3

UNITED STATES SYSTEM BRITISH IMPERIAL SYSTEM

Unless otherwise specified, all fluid volume measurements in this Fluid volume measurements in this manual do not include the
manual are expressed in United States (U.S.) units-of-measure. British Imperial (Imp.) system equivalents. The following
See below: conversions exist in the British Imperial system:

• 1 pint (U.S.) = 16 fluid ounces (U.S.) • 1 pint (Imp.) = 20 fluid ounces (Imp.)
• 1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.) • 1 quart (Imp.) = 2 pints (Imp.)
• 1 gallon (U.S.) = 4 quarts (U.S.)= 128 fl. oz. (U.S.) • 1 gallon (Imp.) = 4 quarts (Imp.)
METRIC SYSTEM Although the same unit-of-measure terminology as the U.S.
system is used in the British Imperial (Imp.) system, the actual
Fluid volume measurements in this manual include the metric volume of each British Imperial unit-of-measure differs from its
system equivalents. In the metric system, 1 liter (L) = 1,000 U.S. counterpart. The U.S. fluid ounce is larger than the British
milliliters (mL). To convert between U.S. units-of-measure and Imperial fluid ounce. However, the U.S. pint, quart, and gallon
metric units-of-measure, refer to the following: are smaller than the British Imperial pint, quart, and gallon,
respectively. To convert between U.S. units and British Imperial
■ fluid ounces (U.S.) x 29.574 = milliliters units, refer to the following:
• pints (U.S.) x 0.473 = liters • fluid ounces (U.S.) x 1.042 = fluid ounces (Imp.)
• quarts (U.S.) x 0.946 = liters • pints (U.S.) x 0.833 = pints (Imp.)
• gallons (U.S.) x 3.785 = liters • quarts (U.S.) x 0.833 = quarts (Imp.)
• milliliters x 0.0338 = fluid ounces (U.S.) • gallons (U.S.) x 0.833 = gallons (Imp.)
• liters x 2.114 = pints (U.S.) • fluid ounces (Imp.) x 0.960 = fluid ounces (U.S.)
• liters x 1.057 = quarts (U.S.) • pints (Imp.) x 1.201 = pints (U.S.)
• liters x 0.264 = gallons (U.S.) • quarts (Imp.) x 1.201 = quarts (U.S.)
• gallons (Imp.) x 1.201 = gallons (U.S.)

94000936 B-5
NOTES
TOOLS
Part Number TOOLNAME NOTES
14900102 SPANNER WRENCH KIT 2.18 ADJUST SUSPENSION, Adjust Shock
Absorber
93979-10 MAGNETIC LIFTER HOLDERS 4.22 CAM COMPARTMENT AND COMPONENTS,
Remove
94686-00 OIL FILTER WRENCH 2.5 REPLACE ENGINE OIL AND FILTER, Change
Oil and Oil Filter
94863-10 OIL FILTER WRENCH 2.5 REPLACE ENGINE OIL AND FILTER, Change
Oil and Oil Filter
B-42571 FORK SEAL DRIVER AND DUST BOOT 3.20 FRONT FORK, Disassemble and Assemble:
INSTALLER (43MM) Inverted, Left Side
3.20 FRONT FORK, Disassemble and Assemble:
Inverted, Right Side
B-45525 VALVE GUIDE HONE 4.19 CYLINDER HEADS, Clean and Inspect
B-49312 CYLINDER HEAD HOLDING FIXTURE 4.19 CYLINDER HEADS, Disassemble
4.19 CYLINDER HEADS, Assemble
BB200A BASIC VACUUM BRAKE BLEEDER 3.17 BLEED BRAKES, Drain
3.17 BLEED BRAKES, Fill and Bleed
HD-25070 ROBINAIR HEAT GUN 4.18 PUSHRODS, LIFTERS AND COVERS,
Remove
4.25 CRANKCASE, Sprocket Shaft Bearing Inner
Race
7.10 HANDLEBAR CONTROL MODULES, Solder
Procedure
HD-33223-1 CYLINDER COMPRESSION GAUGE 4.7 TROUBLESHOOTING, Compression Test
HD-33416 UNIVERSAL DRIVER HANDLE 3.21 STEERING HEAD/FORK STEM AND
BRACKET ASSEMBLY, Clean and Inspect

TOOLS
HD-34736-B VALVE SPRING COMPRESSOR 4.19 CYLINDER HEADS, Disassemble
4.19 CYLINDER HEADS, Assemble
HD-34751 CLEANING BRUSH 4.19 CYLINDER HEADS, Clean and Inspect
4.19 CYLINDER HEADS, Assemble
HD-34902-B BIG-TWIN MAINSHAFT PRIMARY BEARING RACE 4.25 CRANKCASE, Sprocket Shaft Bearing Inner
REMOVER AND INSTALLER Race
HD-34902-C BEARING RACE REMOVER AND INSTALLER KIT 5.11 PRIMARY CHAINCASE HOUSING, Mainshaft
Bearing Inner Race
HD-35316-D MAIN DRIVE GEAR REMOVER AND INSTALLER 5.15 MAIN DRIVE GEAR AND BEARING, Remove
SET 5.15 MAIN DRIVE GEAR AND BEARING, Install
HD-35381-A BELT TENSION GAUGE 2.17 INSPECT AND ADJUST DRIVE BELT AND
SPROCKETS, Measure Drive Belt Deflection
HD-35667-A CYLINDER LEAKDOWN TESTER 4.7 TROUBLESHOOTING, Cylinder Leakdown Test

HD-39301-A STEERING HEAD BEARING RACE REMOVER 3.21 STEERING HEAD/FORK STEM AND
BRACKET ASSEMBLY, Clean and Inspect
HD-39969 ULTRA TORCH UT-100 7.10 HANDLEBAR CONTROL MODULES, Solder
Procedure
HD-41137 HOSE CLAMP PLIERS 4.8 CRIMP CLAMPS, Install
HD-41177 FORK TUBE HOLDER 3.20 FRONT FORK, Disassemble and Assemble:
Standard
3.20 FRONT FORK, Disassemble and Assemble:
Inverted, Left Side
3.20 FRONT FORK, Disassemble and Assemble:
Inverted, Right Side
HD-41182 FUEL PRESSURE GAUGE 6.5 FUEL PRESSURE TEST, Test
HD-41183 HEAT SHIELD ATTACHMENT 7.10 HANDLEBAR CONTROL MODULES, Solder
Procedure
HD-41417 PROPANE ENRICHMENT KIT 6.16 INTAKE LEAK TEST, Leak Tester
HD-42325-C CAMSHAFT NEEDLE BEARING 4.22 CAM COMPARTMENT AND COMPONENTS,
REMOVER/INSTALLER Camshaft Needle Bearings
HD-42326-B CRANKSHAFT GUIDE 4.25 CRANKCASE, Assemble

94000936 I
TOOLS
Part Number TOOLNAME NOTES
HD-44060D WHEEL BEARING INSTALLER/REMOVER 3.8 SEALED WHEEL BEARINGS, Remove
3.8 SEALED WHEEL BEARINGS, Install
HD-44358 FLYWHEEL SUPPORT FIXTURE 4.25 CRANKCASE, Sprocket Shaft Bearing Inner
Race
HD-45305 FORK SEAL DRIVER 3.20 FRONT FORK, Disassemble and Assemble:
Standard
HD-45322 VALVE GUIDE SEAL INSTALLER 4.19 CYLINDER HEADS, Assemble
HD-45966 FRONT FORK COMPRESSOR 3.20 FRONT FORK, Disassemble and Assemble:
Inverted, Left Side
HD-45968 FAT JACK 2.2 GENERAL, Secure the Motorcycle for Service
4.12 FRONT ENGINE MOUNT, Prepare
HD-46281 BEARING REMOVER/INSTALLER TOOL 3.23 REAR FORK, Disassemble and Assemble:
Standard
HD-46282A FINAL DRIVE SPROCKET LOCKING TOOL 5.13 TRANSMISSION SPROCKET, Remove
5.13 TRANSMISSION SPROCKET, Install
HD-47250 INTAKE MANIFOLD WRENCH 6.15 INDUCTION MODULE, Remove
6.15 INDUCTION MODULE, Install
HD-47852 INNER FORK NUT REMOVER/INSTALLER 3.20 FRONT FORK, Disassemble and Assemble:
Inverted, Right Side
HD-47856 MAIN DRIVE GEAR SEAL INSTALLER KIT 5.15 MAIN DRIVE GEAR AND BEARING, Install
HD-47910 MAINSHAFT LOCKNUT WRENCH 5.13 TRANSMISSION SPROCKET, Remove
5.13 TRANSMISSION SPROCKET, Install
HD-47925 AXLE NUT TORQUE ADAPTER 2.17 INSPECT AND ADJUST DRIVE BELT AND
SPROCKETS, Adjust Belt
3.5 REAR WHEEL, Remove
HD-47932 MAIN DRIVE GEAR BEARING AND SEAL 5.15 MAIN DRIVE GEAR AND BEARING, Replace
INSTALLATION TOOL Needle Bearings
HD-47933 MAIN DRIVE GEAR SEAL INSTALLER 5.15 MAIN DRIVE GEAR AND BEARING, Replace
Mainshaft Seal
HD-47941 CRANKSHAFT/CAMSHAFT SPROCKET LOCKING 4.22 CAM COMPARTMENT AND COMPONENTS,
TOOL Remove
4.22 CAM COMPARTMENT AND COMPONENTS,
Install
HD-47977 PRIMARY DRIVE LOCKING TOOL 5.9 DRIVE COMPONENTS, Remove
5.9 DRIVE COMPONENTS, Install
HD-48497-A DOT 4 BRAKE FLUID MOISTURE TESTER 2.10 INSPECT BRAKES, Inspect
2.11 CHECK AND REPLACE BRAKE FLUID, Check
Brake Fluid Level
HD-48498-B-1 ACR SOLENOID SOCKET 7.37 AUTOMATIC COMPRESSION RELEASE
(ACR), Remove
7.37 AUTOMATIC COMPRESSION RELEASE
(ACR), Install
HD-48648 REAR BRAKE PISTION REMOVAL TOOL 3.14 REAR BRAKE CALIPER, Disassemble
HD-48650 DIGITAL TECHNICIAN II 3.15 BRAKE LINES, Brake Line: Front Master
Cylinder (ABS)
3.15 BRAKE LINES, Brake Line: Front Caliper (ABS)
3.16 ABS MODULE, Install
3.17 BLEED BRAKES, Fill and Bleed
7.27 ELECTRONIC CONTROL MODULE (ECM),
Prepare
7.28 BODY CONTROL MODULE (BCM), Prepare
7.29 SECURITY SYSTEM ACTIVATION, Fob
Assignment
7.31 SECURITY SYSTEM MAINTENANCE, Service
Mode

HD-48856-B AXLE ALIGNMENT PLUGS 3.10 WHEEL ALIGNMENT, Inspect

II 94000936
TOOLS
Part Number TOOL NAME NOTES
HD-48985 SPOKE TORQUE WRENCH 2.8 INSPECT TIRES AND WHEELS, Wheel Spokes
3.7 CHECKING AND TRUING WHEELS, True Laced
Wheels

HD-50549 BORESCOPE 4.7 TROUBLESHOOTING, Compression Test

4.7 TROUBLESHOOTING, Cylinder Leakdown Test

HD-51069-17 NOSE ADAPTER 4.21 PISTONS, Install

HD-51069-2 PISTON PIN RETAINING RING INSTALLER 4.21 PISTONS, Install
HD-51337 SHIFTER SHAFT SEAL INSTALLATION TOOL 5.16 TRANSMISSION CASE, Assemble
HD-52064 LEFT MAIN BEARING OIL SEAL INSTALLATION 4.25 CRANKCASE, Assemble
TOOL
HD-52071 MAIN BEARING REMOVER AND INSTALLER 4.25 CRANKCASE, Repair Right Crankcase Half
4.25 CRANKCASE, Repair Left Crankcase Half
HD-52073 ALTERNATOR ROTOR REMOVER AND 7.6 ALTERNATOR, Remove
INSTALLER 7.6 ALTERNATOR, Install
HD-52252 CRANKSHAFT LOCKING TOOL 4.7 TROUBLESHOOTING, Cylinder Leakdown Test

HD-52351 12MM TORQUE ADAPTER 3.14 REAR BRAKE CALIPER, Install

3.15 BRAKE LINES, Front ABS Lines
3.15 BRAKE LINES, Brake Line: Rear Caliper to
ABS Module
HD-52369 E-CLIP TOOL 3.40 LEFT FOOT CONTROLS, Disassemble and
Assemble: Footboard
3.40 LEFT FOOT CONTROLS, Disassemble and
Assemble: Footpeg
3.41 RIGHT FOOT CONTROLS, Disassemble and
Assemble: Footboard
3.41 RIGHT FOOT CONTROLS, Disassemble and
Assemble: Footpeg
3.42 PASSENGER FOOTRESTS, Remove
3.42 PASSENGER FOOTRESTS, Install
HD-52977 17MM OXYGEN SENSOR SOCKET 6.17 HEATED OXYGEN SENSORS (HO2S),
Remove
6.17 HEATED OXYGEN SENSORS (HO2S), Install
HD-59000B FORK OIL LEVEL GAUGE 3.20 FRONT FORK, Disassemble and Assemble:
Standard
3.20 FRONT FORK, Disassemble and Assemble:
Inverted, Left Side
3.20 FRONT FORK, Disassemble and Assemble:
Inverted, Right Side
HD-94660-2 PILOT 5.13 TRANSMISSION SPROCKET, Remove
5.13 TRANSMISSION SPROCKET, Install
HD-94681-80 SPOKE WRENCH 2.8 INSPECT TIRES AND WHEELS, Wheel Spokes
3.7 CHECKING AND TRUING WHEELS, Laced
Wheel Rim Offset
3.7 CHECKING AND TRUING WHEELS, True Laced
Wheels

HD-95637-46B WEDGE ATTACHMENT 4.25 CRANKCASE, Sprocket Shaft Bearing Inner

Race
HD-96333-51F PISTON RING COMPRESSOR 4.20 CYLINDERS, Install
HD-96921-52D OIL PRESSURE TEST GAUGE KIT 4.6 OIL PRESSURE, Oil Pressure Check
HD-97225-55C SPROCKET SHAFT BEARING INSTALLER 4.25 CRANKCASE, Assemble
4.25 CRANKCASE, Sprocket Shaft Bearing Inner
Race
HD-99500-80 WHEEL TRUING STAND 3.7 CHECKING AND TRUING WHEELS, Checking
Wheel Runout

94000936 Ill
TOOLS
Part Number TOOL NAME NOTES
3.7 CHECKING AND TRUING WHEELS, Laced
Wheel Rim Offset
3.7 CHECKING AND TRUING WHEELS, True Laced
Wheels
TA360 TORQUE ANGLE GAUGE 5.13 TRANSMISSION SPROCKET, Install

IV 94000936
Torque Values
FASTENER TORQUE VALUE NOTES
Fairing, frame mounted, inner fairing screws 96-144 in-lbs 10.8-16.3 N-m 3.29 FAIRING: FRAME MOUNTED, Re-
move and Install: Fairing Supports
ABS Module bracket screw 96-119 in-lbs 10.8-13.5 N-m 3.16 ABS MODULE, Install
ABS Module frame screw 96-119 in-lbs 10.8-13.5 N-m 3.16 ABS MODULE, Install
ACR 17-19 ft-lbs 23-26.4 N-m 7.37 AUTOMATIC COMPRESSION RE-
LEASE (ACR), Install
Air filter cover screw, cone 18-24 in-lbs 2-2.7 N-m 2.20 INSPECT AIR FILTER, Remove and
Install: Cone
Air filter cover screw, single screw cover 50-65 in-lbs 5.6-7.3 N-m 2.20 INSPECT AIR FILTER, Remove and
Install: Round
Apply LOCTITE 243 (blue) to the threads of
screw.
Air filter cover screws, five-screw cover 48-72 in-lbs 5.4-8.1 N-m 2.20 INSPECT AIR FILTER, Remove and
Install: Round
Apply LOCTITE 243 (blue) to the threads of
screw. Tighten in a star pattern.
Air filter cover screws, oval cover 50-60 in-lbs 5.7-6.8 N-m 2.20 INSPECT AIR FILTER, Remove and
Install: Oval
Air filter element screws, round 48-72 in-lbs 5.4-8.1 N-m 6.3 AIR CLEANER BACKPLATE AS-
SEMBLY, Remove and Install: Round
Air filter element screws, round cover 48-72 in-lbs 5.4-8.1 N-m 2.20 INSPECT AIR FILTER, Remove and
Install: Round
Air filter trim insert screws 27-32 in-lbs 3-3.6 N-m 2.20 INSPECT AIR FILTER, Remove and

TORQUE VALUES
Install: Oval
Auxiliary lamp bezel nut 9-12 in-lbs 1.07-1.36 N-m 7.20 AUXILIARY LAMPS, Bulb Replace-
ment
Auxiliary lamp nut 19-23 ft-lbs 25.76-31.18 N-m 7.20 AUXILIARY LAMPS, Remove and
Install: Standard Lighting
Axle nut, rear 95-105 ft-lbs 128.8-142.4 N-m 2.17 INSPECT AND ADJUST DRIVE BELT
AND SPROCKETS, Adjust Belt
Backplate breather screw, cone 22-24 ft-lbs 30-32.5 N-m 6.3 AIR CLEANER BACKPLATE AS-
SEMBLY, Remove and Install: Cone
Backplate cover screw, cone 43-53 in-lbs 4.9-6 N-m 6.3 AIR CLEANER BACKPLATE AS-
SEMBLY, Remove and Install: Cone
Backplate screws, oval 50-60 in-lbs 5.6-6.8 N-m 6.3 AIR CLEANER BACKPLATE AS-
SEMBLY, Remove and Install: Oval
Backplate to throttle body screw, cone 55-60 in-lbs 6.2-6.8 N-m 6.3 AIR CLEANER BACKPLATE AS-
SEMBLY, Remove and Install: Cone
Balancer bearing screw 80-110 in-lbs 9-12.4 N-m 4.25 CRANKCASE, Repair Right Crankcase
Half
Banjo bolt 21-23 ft-lbs 29-31 N-m 3.17 BLEED BRAKES, Fill and Bleed
Banjo bolt to ABS module 17-19 ft-lbs 23.1-25.8 N-m 3.15 BRAKE LINES, Front ABS Lines
Banjo bolt to ABS module, rear 17-19 ft-lbs 23.1-25.8 N-m 3.15 BRAKE LINES, Brake Line: Rear
Master Cylinder to ABS Module
Banjo bolt to brake caliper, rear 21-23 ft-lbs 29-31 N-m 3.15 BRAKE LINES, Brake Line: Rear
Caliper to ABS Module
Banjo bolt to master cylinder, rear 21-23 ft-lbs 29-31 N-m 3.15 BRAKE LINES, Brake Line: Rear
Master Cylinder to ABS Module
Battery ground cable to transmission 66-114 in-lbs 7.5-12.9 N-m 5.16 TRANSMISSION CASE, Install
Battery tray screw 6-9 ft-lbs 8.1-12.2 N-m 7.47 BATTERY TRAY, Install
Battery, negative cable, screw 60-70 in-lbs 6.8-7.9 N-m 7.4 POWER DISCONNECT, Negative
Battery Cable
Battery, positive cable, screw 60-70 in-lbs 6.78-7.91 N-m 2.21 INSPECT BATTERY, Install
Belt guard, lower screw 70-80 in-lbs 7.9-9 N-m 3.24 BELT GUARDS, Remove and Install:
Standard
Belt guard, upper screw 70-80 in-lbs 7.9-9 N-m 3.24 BELT GUARDS, Remove and Install:
Standard

94000936 5
Torque Values
FASTENER TORQUE VALUE NOTES
Bleeder screw 35-61 in-lbs 3.9-6.9 N-m 3.17 BLEED BRAKES, Fill and Bleed
Brake caliper, front, bridge bolt 14-18 ft-lbs 19.6-24.5 N-m 3.12 FRONT BRAKE CALIPER, Assemble
Brake line bracket, rear, screw 24-35 in-lbs 2.7-4 N-m 3.15 BRAKE LINES, Brake Line: Rear
Master Cylinder to ABS Module
Brake line clamp screw 36-48 in-lbs 4.1-5.4 N-m 7.11 LEFT HAND CONTROL MODULE
(LHCM), Install
Brake line to caliper, rear, P-clamp screw 24-35 in-lbs 2.7-4 N-m 3.15 BRAKE LINES, Brake Line: Rear
Caliper to ABS Module
Brake line to master cylinder, rear, P- clamp 24-35 in-lbs 2.7-4 N-m 3.15 BRAKE LINES, Brake Line: Rear
screw Master Cylinder to ABS Module
Brake line tube nuts, manifold 128-173 in-lbs 14.5-19.5 N-m 3.15 BRAKE LINES, Brake Line: Front
Master Cylinder (ABS)
Brake line, P-clamp, screw 36-48 in-lbs 4.1-5.4 N-m 3.15 BRAKE LINES, Brake Line: Front
Master Cylinder (ABS)
Brake master cylinder, front, reservoir cover 9-18 in-lbs 1-2 N-m 2.11 CHECK AND REPLACE BRAKE
screws FLUID, Check Brake Fluid Level
Brake master cylinder, rear, mounting 18-22 ft-lbs 24.4-29.9 N-m 3.13 REAR BRAKE MASTER CYLINDER,
screws Install
Brake master cylinder, rear, reservoir cover 9-18 in-lbs 1-2 N-m 2.11 CHECK AND REPLACE BRAKE
screws FLUID, Check Brake Fluid Level
Brake master cylinder, reservoir cover 9-18 in-lbs 1-2 N-m 3.17 BLEED BRAKES, Fill and Bleed
screw
Brake pedal linkage, mid control, front, 15-18 ft-lbs 20.3-24.4 N-m 3.41 RIGHT FOOT CONTROLS, Remove
screw and Install: Mid Foot Controls
Brake pedal linkage, mid control, rear, 15-18 ft-lbs 20.3-24.4 N-m 3.41 RIGHT FOOT CONTROLS, Remove
screw and Install: Mid Foot Controls
Brake pedal pivot, footboard control, screw. 18-22 ft-lbs 24.5-30 N-m 3.41 RIGHT FOOT CONTROLS, Remove
and Install: Footboards
Brake pedal pivot, forward control, screw 18-22 ft-lbs 24.4-29.8 N-m 3.41 RIGHT FOOT CONTROLS, Remove
and Install: Forward Foot Controls
Brake pedal pivot, mid control, screw 10-14 ft-lbs 13.6-19 N-m 3.41 RIGHT FOOT CONTROLS, Remove
and Install: Mid Foot Controls
Breather bolts, oval 22-24 ft-lbs 29.8-32.5 N-m 6.3 AIR CLEANER BACKPLATE AS-
SEMBLY, Remove and Install: Oval metric

Breather bolts, round 22-24 ft-lbs 29.8-32.5 N-m 6.3 AIR CLEANER BACKPLATE AS-
SEMBLY, Remove and Install: Round
Breather screw 90-120 in-lbs 10.2-13.6 N-m 4.15 BREATHERS, Install
Cam chain tensioner fasteners 90-120 in-lbs 10.2-13.6 N-m 4.22 CAM COMPARTMENT AND COM-
PONENTS, Install
Cam needle bearing installation maximum 25 ft-lbs 33.9 N-m 4.22 CAM COMPARTMENT AND COM-
torque PONENTS, Camshaft Needle Bearings
Cam support plate screws 90-120 in-lbs 10.2-13.6 N-m 4.22 CAM COMPARTMENT AND COM-
PONENTS, Install
Camshaft cover screws 90-120 in-lbs 10.2-13.6 N-m 4.22 CAM COMPARTMENT AND COM-
PONENTS, Remove and Install: Camshaft
Cover
Camshaft sprocket screw, 1st torque 15.0 ft-lbs 20.3 N-m 4.22 CAM COMPARTMENT AND COM-
PONENTS, Install
See procedure to verify alignment specific-
ation before tightening. Apply LOCTITE 262
HIGH STRENGTH THREADLOCKER AND
SEALANT (red).
Camshaft sprocket screw, alignment check 15.0 ft-lbs 20.3 N-m 4.22 CAM COMPARTMENT AND COM-
torque PONENTS, Install

6 94000936
Torque Values
FASTENER TORQUE VALUE NOTES
See procedure to verify alignment specific-
ation before tightening.
Camshaft sprocket screw, final torque 34 ft-lbs 46.1 N-m 4.22 CAM COMPARTMENT AND COM-
PONENTS, Install
Camshaft timer cover screws 25--35 in-lbs 2.8--4 N-m 4.22 CAM COMPARTMENT AND COM-
PONENTS, Remove and Install: Camshaft
Cover
Charcoal canister bracket to engine case 72-96 in-lbs 8.1-10.8 N-m 6.21 CHARCOAL CANISTER: EVAPOR-
screws ATIVE EMISSIONS, Install
Charcoal canister to bracket screws 30-36 in-lbs 3.4--4.1 N-m 6.21 CHARCOAL CANISTER: EVAPOR-
ATIVE EMISSIONS, Install
Clutch cable fitting 90-120 in-lbs 10.2-13.6 N-m 5.6 CLUTCH RELEASE COVER, Install
Clutch cable lever screw 60-80 in-lbs 6.8-9 N-m 3.26 CLUTCH CONTROL, Install
Clutch hub jamnut 72-120 in-lbs 8.1-13.6 N-m 2.12 CHECK AND ADJUST CLUTCH,
Check and Adjust
Clutch hub mainshaft nut 70-80 ft-lbs 94.9-108.5 N-m 5.9 DRIVE COMPONENTS, Install
Clutch inspection cover screws 25-35 in-lbs 2.8-3.9 N-m 2.6 REPLACE PRIMARY CHAINCASE
LUBRICANT, Change Primary Chaincase
Lubricant
Torque sequence
Clutch release cover screws 132-156 in-lbs 14.9-17.6 N-m 5.6 CLUTCH RELEASE COVER, Install
Compensating sprocket bolt, 1st torque 100 ft-lbs 135.6 N-m
5.9 DRIVE COMPONENTS, Install
Loosen then final tighten
Compensating sprocket bolt, final torque 175 ft-lbs 237.3 N-m 5.9 DRIVE COMPONENTS, Install
Console screw (Front) 30-50 in-lbs 3.4-5.6 N-m 6.4 CONSOLE, Remove and Install: Single
Instrument with Panel
Console screw (Rear) 25-30 in-lbs 2.8-3.4 N-m 6.4 CONSOLE, Remove and Install: Single
Instrument with Panel
Console screw, , rear, no instrument 25-30 in-lbs 2.8-3.4 N-m 6.4 CONSOLE, Remove and Install: No
Instrument
Console screw, front, no instrument 30-50 in-lbs 3.4-5.6 N-m 6.4 CONSOLE, Remove and Install: No
Instrument
Console screws 40-50 in-lbs 4.5--5.6 N-m 6.4 CONSOLE, Remove and Install: Single
Instrument without Panel
Crankcase oil check valve or plug with 0- 18-22 ft-lbs 24.4-29.8 N-m 4.10 OIL CHECK VALVE, Install
ring
Crankcase screws, first torque 120 in-lbs 13.6 N-m 4.25 CRANKCASE, Assemble
Crankcase screws, last torque 15—19 ft-lbs 20.3-25.8 N-m 4.25 CRANKCASE, Assemble
Crankcase tapered plugs 120-144 in-lbs 13.6-16.3 N-m 4.25 CRANKCASE, Plugs and Oil Fittings
Crankshaft sprocket screw, 1st torque 15.0 ft-lbs 20.3 N-m 4.22 CAM COMPARTMENT AND COM-
PONENTS, Install
Apply LOCTITE 262 HIGH STRENGTH
THREADLOCKER AND SEALANT (red)
Crankshaft sprocket screw, alignment check 15.0 ft-lbs 20.3 N-m 4.22 CAM COMPARTMENT AND COM-
torque PONENTS, Install
See procedure to verify alignment specific-
ation before tightening.
Crankshaft sprocket screw, final torque 24 ft-lbs 32.5 N-m 4.22 CAM COMPARTMENT AND COM-
PONENTS, Install
Cylinder head nut torque step 1. 20-30 ft-lbs 27.1--40.7 N-m 4.19 CYLINDER HEADS, Install
Apply ENGINE OIL to new cylinder head
bolt washers and threaded portion of the
cylinder head bolts. See procedure for
torque sequence.
Cylinder head nut torque step 2. Loosen -360° -360° 4.19 CYLINDER HEADS, Install
one turn.
Cylinder head nut torque step 3. 9-11 ft-lbs 12.2-14.9 N-m 4.19 CYLINDER HEADS, Install

94000936 7
Torque Values
FASTENER TORQUE VALUE NOTES
Cylinder head nut torque step 4. 25-27 ft-lbs 33.9-36.6 N-m 4.19 CYLINDER HEADS, Install
Cylinder head nut torque step 5. Tighten go° go° 4.19 CYLINDER HEADS, Install
additional degree value.
Cylinder stud 120-240 in-lbs 13.6-27.1 N-m 4.25 CRANKCASE, Cylinder Studs
Cylinder temperature sensor 120-180 in-lbs 13.6-20.3 N-m 4.19 CYLINDER HEADS, Assemble
Drive belt slot spacer screw, 1st torque 50-55 ft-lbs 68-75 N-m 5.4 DRIVE BELT, Install
Drive belt slot spacer screw, final torque 65-70 ft-lbs 88-95 N-m 5.4 DRIVE BELT, Install
ECM caddy large screw 36-60 in-lbs 4.1-6.8 N-m 7.44 ECM CADDY, Install
ECM caddy small screw 5^^0 in-lbs 6.2-6.8 N-m 3.45 FRAME CROSSMEMBER, Install
ET sensor 11-15 ft-lbs 14.9-21 N-m 7.35 ENGINE TEMPERATURE (ET)
SENSOR, Install
Engine mount bolt, front, lower 50-55 ft-lbs 67.8-74.5 N-m 4.12 FRONT ENGINE MOUNT, Remove
and Install: Lower Front Engine Mount
Engine mount pinch bolt, front, lower 8-9 ft-lbs 10.2-12.2 N-m 4.12 FRONT ENGINE MOUNT, Remove
and Install: Lower Front Engine Mount
Engine mount screw, front, upper engine 45-50 ft-lbs 61-67.8 N-m 4.12 FRONT ENGINE MOUNT, Remove
bracket and Install: Upper Front Engine Mount
Engine mount screw, front, upper frame 45-50 ft-lbs 61-67.8 N-m 4.12 FRONT ENGINE MOUNT, Remove
bracket and Install: Upper Front Engine Mount
Engine mount screw, front, upper frame 45-50 ft-lbs 61-67.8 N-m 4.12 FRONT ENGINE MOUNT, Remove
bracket-to-engine bracket and Install: Upper Front Engine Mount
Engine mount screw, left side, bracket-to- 45-50 ft-lbs 61-67.8 N-m 4.13 LEFT SIDE ENGINE MOUNT, Install
frame
Engine mount screw, left side, bracket-to- 28-33 ft-lbs 38-44.7 N-m 4.13 LEFT SIDE ENGINE MOUNT, Install
head
Engine oil drain plug 14-21 ft-lbs 19-28.5 N-m 2.5 REPLACE ENGINE OIL AND FILTER,
Change Oil and Oil Filter
Engine oil fill spout screw. 100-120 in-lbs 11.3-13.6 N-m 5.12 ENGINE OIL FILL SPOUT, Install
Exhaust bracket screws 40-50 ft-lbs 54.2-67.8 N-m 6.19 EXHAUST SYSTEM, Install
Exhaust shield clamps 20--40 in-lbs 2.3-4.5 N-m 6.19 EXHAUST SYSTEM, Disassemble and
Assemble: Standard
Exhaust shield screws 108-132 in-lbs 12.2-14.9 N-m 6.19 EXHAUST SYSTEM, Disassemble and
Assemble: Upswept
Exhaust support clamp screw 40-50 ft-lbs 54.2-67.8 N-m 6.19 EXHAUST SYSTEM, Install
Exhaust to engine flange nuts 100-120 in-lbs 11.3-13.6 N-m 6.19 EXHAUST SYSTEM, Install
Fairing windshield screw 32--40 in-lbs 3.6--4.5 N-m 3.28 FAIRING, Disassemble and Assemble

Fairing, frame mounted, air deflector screws 25-30 in-lbs 2.8-3.4 N-m 3.29 FAIRING: FRAME MOUNTED, Re-
move and Install: Air Deflector
Fairing, frame mounted, air deflector screws 25-30 in-lbs 2.8-3.4 N-m 3.29 FAIRING: FRAME MOUNTED, Re-
move and Install: Outer Fairing Shell
Fairing, frame mounted, air duct screws 4.5-5.5 in-lbs 0.51-0.62 N-m 3.29 FAIRING: FRAME MOUNTED, Disas-
semble and Assemble: Inner Fairing Shell
Fairing, frame mounted, bracket screws 48-60 in-lbs 5.4-6.8 N-m 3.29 FAIRING: FRAME MOUNTED, Disas-
semble and Assemble: Inner Fairing Shell
Fairing, frame mounted, fairing mount to 20-27 ft-lbs 27-37 N-m 3.29 FAIRING: FRAME MOUNTED, Re-
steering head locknut move and Install: Fairing Supports
Fairing, frame mounted, inner fairing screws 96-144 in-lbs 10.8-16.3 N-m 3.29 FAIRING: FRAME MOUNTED, Re-
move and Install: Inner Fairing Shell
Fairing, frame mounted, lower mount 16-20 ft-lbs 21.7-27.1 N-m 3.29 FAIRING: FRAME MOUNTED, Re-
screws move and Install: Inner Fairing Shell
Fairing, frame mounted, lower support 48-60 in-lbs 5.4-6.8 N-m 3.29 FAIRING: FRAME MOUNTED, Re-
screws move and Install: Inner Fairing Shell
Fairing, frame mounted, mount screws 71-84 in-lbs 8-9.5 N-m 3.29 FAIRING: FRAME MOUNTED, Re-
upper move and Install: Fairing Supports

8 94000936
Torque Values
FASTENER TORQUE VALUE NOTES
Fairing, frame mounted, outer fairing screws 25-30 in-lbs 2.8-3.4 N-m 3.29 FAIRING: FRAME MOUNTED, Re-
move and Install: Outer Fairing Shell
Fairing, inner screw 32--40 in-lbs 3.6--4.5 N-m 3.28 FAIRING, Disassemble and Assemble

Fairing, screw-on, inner fairing screws 35-62 in-lbs 4-7 N-m 3.28 FAIRING, Remove and Install: Screw-
On
Fairing, screw-on, lower bracket screws 97-120 in-lbs 11-13.6 N-m 3.28 FAIRING, Remove and Install: Screw-
On
Fairing, screw-on, screws 20-30 in-lbs 2.3-3.4 N-m 3.28 FAIRING, Remove and Install: Screw-
On
Fairing, screw-on, upper bracket screws 35-62 in-lbs 4-7 N-m 3.28 FAIRING, Remove and Install: Screw-
On
Fender Support, Screw 42-46 ft-lbs 57-62 N-m 7.22 REAR TURN SIGNAL LAMPS, Re-
move and Install: Fender Mount
Foot support bracket, forward control, left 40--45 ft-lbs 54-61 N-m 3.40 LEFT FOOT CONTROLS, Remove
side, screw and Install: Forward Foot Controls
Foot support bracket, forward control, right 400--45 ft-lbs 54.2-61 N-m 3.41 RIGHT FOOT CONTROLS, Remove
side, screw and Install: Forward Foot Controls
Foot support bracket, left side, screw 40--45 ft-lbs 54.2-61 N-m 3.40 LEFT FOOT CONTROLS, Install
Foot support bracket, mid control, left side, 40--45 ft-lbs 54-61 N-m 3.40 LEFT FOOT CONTROLS, Remove
screw and Install: Mid Foot Controls
Foot support bracket, mid control, right side, 40--45 ft-lbs 54.2-61 N-m 3.41 RIGHT FOOT CONTROLS, Remove
screw and Install: Mid Foot Controls
Footboard assembly, left side, mounting 40--45 ft-lbs 54-61 N-m 3.40 LEFT FOOT CONTROLS, Remove
screw and Install: Footboards
Footboard assembly, right side, mounting 40--45 ft-lbs 54-61 N-m 3.41 RIGHT FOOT CONTROLS, Remove
screw and Install: Footboards
Fork bracket, lower, pinch bolt 16-20 ft-lbs 21.7-27.1 N-m 3.20 FRONT FORK, Install
Models with two lower pinch bolts per side:
Alternately tighten until specification is met.
Fork bracket, upper, pinch bolt 16-20 ft-lbs 21.7-27.1 N-m 3.20 FRONT FORK, Install
Fork damper tube screw, front 30-37 ft-lbs 40-50 N-m 3.20 FRONT FORK, Disassemble and
Assemble: Standard
Fork stem pinch bolt 16-20 ft-lbs 21.7-27.1 N-m 3.21 STEERING HEAD/FORK STEM AND
BRACKET ASSEMBLY, Install
Fork stem pinch bolt - 16-20 ft-lbs 21.7-27.1 N-m 2.14 ADJUST AND LUBRICATE STEER-
ING HEAD BEARINGS, Check and Adjust
Fork stem screw, 1st torque 160-168 in-lbs 18.1-19 N-m 3.21 STEERING HEAD/FORK STEM AND
BRACKET ASSEMBLY, Install
Fork stem screw, final torque - All except 62--68 in-lbs 7-7.7 N-m 3.21 STEERING HEAD/FORK STEM AND
FXLRS,FXLRST BRACKET ASSEMBLY, Install
Fork stem screw, final torque - FXLRS, 110-122 in-lbs 12.4-13.8 N-m 3.21 STEERING HEAD/FORK STEM AND
FXLRST BRACKET ASSEMBLY, Install
Fork tube plug to damper nut , right side, 13-16 ft-lbs 17.5-22.5 N-m 3.20 FRONT FORK, Disassemble and
inverted Assemble: Inverted, Right Side
Fork tube plug to damper nut, left side, in- 13-16 ft-lbs 17.5-22.5 N-m 3.20 FRONT FORK, Disassemble and
verted Assemble: Inverted, Left Side
Fork tube plug, left side, inverted 22-28 ft-lbs 30-40 N-m 3.20 FRONT FORK, Disassemble and
Assemble: Inverted, Left Side
Fork tube plug, right side, inverted 22-30 ft-lbs 30--40 N-m 3.20 FRONT FORK, Disassemble and
Assemble: Inverted, Right Side
Fork tube plug, standard 22-59 ft-lbs 30-80 N-m 3.20 FRONT FORK, Disassemble and
Assemble: Standard
Fork, left side, inverted, cartridge screw 13-17 ft-lbs 17.5-22.5 N-m 3.20 FRONT FORK, Disassemble and
Assemble: Inverted, Left Side
Fork, right side, inverted, inner fork nut 69-83 ft-lbs 93-113N-m 3.20 FRONT FORK, Disassemble and
Assemble: Inverted, Right Side

94000936 9
Torque Values
FASTENER TORQUE VALUE NOTES
Forward Foot Control shift lever pinch screw 9-12 ft-lbs 12.2-16.3 N-m 5.5 SHIFTER LINKAGE, Shifter Rod
Lever, Front
Forward Foot Control shifter rod to front 120-168 in-lbs 13.6-19 N-m 5.5 SHIFTER LINKAGE, Shifter Rod
shifter rod lever
Forward Foot Control shifter rod to rear 120-168 in-lbs 13.6-19 N-m 5.5 SHIFTER LINKAGE, Shifter Rod
shifter rod lever
Forward Foot Control shifter rod to shifter 120-168 in-lbs 13.6-19 N-m 5.5 SHIFTER LINKAGE, Shifter Rod Lever,
rod lever Front
Forward foot control with footboards shift 108-144 in-lbs 12.2-16.3 N-m 5.5 SHIFTER LINKAGE, Foot Shift Lever
lever pinch screw
Forward foot control with footpegs shift lever 18-22 ft-lbs 24.4-29.8 N-m 5.5 SHIFTER LINKAGE, Foot Shift Lever
pinch screw
Forward or Mid Foot Control shifter peg 96-144 in-lbs 10.9-16.3 N-m 5.5 SHIFTER LINKAGE, Foot Shift Lever
screw
Forward or Mid Foot Control shifter rod 84-132 in-lbs 9.5---14.9 N-m 5.5 SHIFTER LINKAGE, Shifter Rod
jamnut
Forward or Mid Foot Control shifter rod to 120-168 in-lbs 13.6-19 N-m 5.5 SHIFTER LINKAGE, Shifter Rod
shifter rod lever
Frame crossmember mounting screws 17-20 ft-lbs 23.1-27.1 N-m 3.45 FRAME CROSSMEMBER, Install
Frame ground stud nut 50-90 in-lbs 5.7-10.2 N-m 7.44 ECM CADDY, Install
Front ABS brake line P-clamp screw 36-48 in-lbs 4.1-5.4 N-m 3.15 BRAKE LINES, Front ABS Lines
Front ABS brake line to front brake line 128-173 in-lbs 14.5-19.5 N-m 3.15 BRAKE LINES, Front ABS Lines
Front brake caliper banjo bolt 14-18 ft-lbs 19-24.4 N-m 3.12 FRONT BRAKE CALIPER, Install
Front brake caliper bleeder screw 35-61 in-lbs 3.9--6.9 N-m 3.12 FRONT BRAKE CALIPER, Assemble
Front brake caliper bridge bolt 14-18 ft-lbs 19.6-24.5 N-m 3.12 FRONT BRAKE CALIPER, Install
Front brake caliper mounting bolts 28-38 ft-lbs 38-51.5 N-m 3.12 FRONT BRAKE CALIPER, Install
Front brake caliper pad hanger pin 11-14 ft-lbs 14.7-19.6 N-m 3.12 FRONT BRAKE CALIPER, Install
Front brake disc screw 16-24 ft-lbs 22-33 N-m 3.4 FRONT WHEEL, Assemble
Front brake line screw 36--48 in-lbs 4.1-5.4 N-m 3.15 BRAKE LINES, Brake Line: Front
Caliper (ABS)
Front brake line screw 36--48 in-lbs 4.1-5.4 N-m 3.15 BRAKE LINES, Front Brake Line: Non-
ABS
Front brake master cylinder banjo bolt - 24-25 ft-lbs 32-34 N-m 3.11 FRONT BRAKE MASTER CYLINDER,
Dual disk front brake Install
Front brake master cylinder banjo bolt - 21-23 ft-lbs 29-31 N-m 3.11 FRONT BRAKE MASTER CYLINDER,
Single disk front brake Install
Front brake pad hanger pin 11-14 ft-lbs 14.7-19.6 N-m 2.10 INSPECT BRAKES, Replace Front
Brake Pads
Front fender mounting screw (typical) 16-21 ft-lbs 22-28 N-m 3.34 FRONT FENDER, Install
Front fender mounting screw, FXBBS/FXST 16-21 ft-lbs 22-28 N-m 3.34 FRONT FENDER, Install

Front fender mounting screw, FXFBS 72-96 in-lbs 8.1-10.8 N-m 3.34 FRONT FENDER, Install
Front fender mounting screw, 72-96 in-lbs 8.1-10.8 N-m 3.34 FRONT FENDER, Install
FXLRS/FXLRST
Front fender side trim nut 10-15 in-lbs 1.1-1.7 N-m 3.34 FRONT FENDER, Assemble
Front fender to bracket screw, FXFBS 36-48 in-lbs 4.1-5.4 N-m 3.34 FRONT FENDER, Install
Front fork bottom mount pinch bolt 11-15 ft-lbs 15-20 N-m 3.4 FRONT WHEEL, Install
Front fork side mount pinch bolt 21-25 ft-lbs 28-34 N-m 3.4 FRONT WHEEL, Install
Front licence plate clamp bracket screws 1-1 ft-lbs 1.1-1.7 N-m 3.38 FRONT LICENSE PLATE BRACKET,
Install
Front licence plate one hole bracket screw 25-30 ft-lbs 34-40.7 N-m 3.38 FRONT LICENSE PLATE BRACKET,
Install
Front licence plate two hole bracket screws 16-20 ft-lbs 21.7-27 N-m 3.38 FRONT LICENSE PLATE BRACKET,
Install

10 94000936
Torque Values
FASTENER TORQUE VALUE NOTES
Front light bar mounting screw 20-25 ft-lbs 27.1-33.9 N-m 7.19 FRONT LIGHT BAR, Remove and
Install: Standard Lighting
Front light bar, bracket screw 16-20 ft-lbs 21.7-27.1 N-m 7.19 FRONT LIGHT BAR, Remove and
Install: Standard Lighting
Front light bar, clamp screw 6-10 in-lbs 0.67-1.1 N-m 7.19 FRONT LIGHT BAR, Remove and
Install: Standard Lighting
Front wheel axle 70-75 ft-lbs 94.9-101.6 N-m 3.4 FRONT WHEEL, Install
Fuel line to fuel rail screw 22-40 in-lbs 2.5-4.5 N-m 6.7 FUEL LINE, Install
Fuel pump assembly screws 40-45 in-lbs 4.5-5 N-m 6.9 FUEL PUMP, Install
Fuel rail screws 31-49 in-lbs 3.5-5.5 N-m 6.14 FUEL INJECTORS, Install
Fuel tank mounting screw 28-32 ft-lbs 38-43.4 N-m 6.6 PURGE FUEL LINE, Secure Fuel Tank
Fuel tank, vent screws 11-13 ft-lbs 15-18 N-m 6.8 FUEL TANK, Install
HO2S (Heated oxygen sensor) 12-14 ft-lbs 16.3-19 N-m 6.17 HEATED OXYGEN SENSORS
(HO2S), Install
Handlebar clamp gap limiting fasteners 12-16 ft-lbs 16.3-21.7 N-m 3.32 HANDLEBAR, Disassemble and As-
semble: Standard
Handlebar clamp open gap fasteners 12-16 ft-lbs 16.3-21.7 N-m 3.32 HANDLEBAR, Disassemble and As-
semble: Standard
Handlebar switch assembly retainer screws 8-10 in-lbs 0.9-1.1 N-m 7.11 LEFT HAND CONTROL MODULE
(LHCM), Install
Handlebar switch clamp screw 60-80 in-lbs 6.8-9 N-m 3.11 FRONT BRAKE MASTER CYLINDER,
Install
Handlebar switch housing screws 35-45 in-lbs 4-5.1 N-m 7.11 LEFT HAND CONTROL MODULE
(LHCM), Install
Handlebar-mounted turn signal, ball stud 96-144 in-lbs 10.8-16.3 N-m 7.21 FRONT TURN SIGNAL LAMPS, Re-
clamp move and Install: Handlebar Mount
Handlebar-mounted turn signal, ball stud 50-70 in-lbs 5.6-7.9 N-m 7.21 FRONT TURN SIGNAL LAMPS, Re-
jam nut move and Install: Handlebar Mount
Handlebar-mounted turn signal, ball stud 50-70 in-lbs 5.6-7.9 N-m 7.21 FRONT TURN SIGNAL LAMPS, Re-
locknut move and Install: Handlebar Mount
Handlebar-mounted turn signal, ball stud set 3-5 ft-lbs 4-6.7 N-m 7.21 FRONT TURN SIGNAL LAMPS, Re-
screw move and Install: Handlebar Mount
Headlamp (Oblong) mounting screw 10-13 ft-lbs 13.5-17.6 N-m 7.18 HEADLAMP, Bulb Replacement:
Oblong
Headlamp FXBBS, FXST horizontal adjust- 20-25 ft-lbs 27.1-33.9 N-m 7.18 HEADLAMP, Adjust
ment screw
Headlamp FXBBS, FXST, FXLRS, FLSB 27-32 ft-lbs 36.6-43.3 N-m 7.18 HEADLAMP, Adjust
vertical adjustment screw
Headlamp FXBRS, vertical adjustment 10-13 ft-lbs 13.5-17.6 N-m 7.18 HEADLAMP, Adjust
screw
Headlamp FXFBS vertical adjustment screw 11-14 ft-lbs 14.9-19 N-m 7.18 HEADLAMP, Adjust

Headlamp bezel screw 9-14 in-lbs 1-1.6 N-m 7.18 HEADLAMP, Bulb Replacement:
Standard Round
Headlamp bracket to headlamp mounting 27-32 ft-lbs 36.6-43 N-m 7.18 HEADLAMP, Remove and Install: LED
bracket bolt Round
Headlamp isolator bracket screw 6.5-8.0 ft-lbs 8.8-10.8 N-m 7.18 HEADLAMP, Bulb Replacement:
Standard Round
Headlamp mounting bracket to lower fork 20-25 ft-lbs 27.1-33.9 N-m 7.18 HEADLAMP, Remove and Install: LED
bracket Round
Headlamp mounting ring screw 16-20 ft-lbs 21.6-27.1 N-m 7.18 HEADLAMP, Remove and Install:
Nacelle Mounted
Headlamp nacelle mounted, rear panel 85-104 in-lbs 9.6-11.7 N-m 3.27 HEADLAMP NACELLE, Install
bracket screw
Headlamp nacelle, screw 16-20 ft-lbs 21.6-27.1 N-m 7.18 HEADLAMP, Remove and Install:
Horizontal

94000936 11
Torque Values
FASTENER TORQUE VALUE NOTES
Headlamp nacelle, standard round, clamp 36--48 in-lbs 4.1-5.4 N-m 3.27 HEADLAMP NACELLE, Install
screw
Headlamp nacelle, standard round, trim 84-108 in-lbs 9.5-12.2 N-m 3.27 HEADLAMP NACELLE, Install
strip screw
Headlamp retainer screw 18-22 in-lbs 2-2.5 N-m 7.18 HEADLAMP, Bulb Replacement:
Standard Round
Headlamp to headlamp bracket screw 96-120 in-lbs 10.8-13.6 N-m 7.18 HEADLAMP, Bulb Replacement: LED
Round
Headlamp, fixed fairing, Bracket-to-lamp 84-108 in-lbs 9.49-12.2 N-m 7.18 HEADLAMP, Remove and Install:
screws Fixed Fairing
Headlamp, fixed fairing, retainer screws 22-32 in-lbs 2.5-3.6 N-m 7.18 HEADLAMP, Remove and Install:
Fixed Fairing
Headlamp, nacelle mounted, bezel screw 25-32 in-lbs 2.8-3.6 N-m 3.27 HEADLAMP NACELLE, Install
Headlamp, nacelle mounted, left side, cover 84-108 in-lbs 9.5-12.2 N-m 3.27 HEADLAMP NACELLE, Install
screw
Headlamp, nacelle mounted, retainer screw 17-25 in-lbs 1.9-2.8 N-m 7.18 HEADLAMP, Bulb Replacement:
Nacelle Mounted
Headlamp, nacelle mounted, right side, 84-108 in-lbs 9.5-12.2 N-m 3.27 HEADLAMP NACELLE, Install
cover screw
Headlamp, oblong, bracket-to-fork clamp 16-20 ft-lbs 21.6-27.1 N-m 7.18 HEADLAMP Remove and Install:
screws Oblong
Headlamp, oblong, isolator screws 33-43 in-lbs 3.7--4.9 N-m 7.18 HEADLAMP Remove and Install:
Oblong
Headlamp, oblong, mounting screw 10-13 ft-lbs 13.6-17.6 N-m 7.18 HEADLAMP, Remove and Install:
Oblong
Headlamp, round, locknut 27-32 ft-lbs 36.6-43.3 N-m 7.18 HEADLAMP Remove and Install:
Standard Round
Headlamp, upper triple clamp mounted, 11-14 ft-lbs 15-19 N-m 7.18 HEADLAMP Remove and Install:
screw Horizontal
Horn, Bracket Screw 62-71 in-lbs 7-8 N-m 7.17 HORN, Assemble
Horn, Narrow Mounting Screw 27-33 in-lbs 3-3.7 N-m 7.17 HORN, Install
Horn, Wide Mounting Screw 84-108 in-lbs 9.5-12.2 N-m 7.17 HORN, Install
Housing to IM screw 20-25 in-lbs 2.3-2.8 N-m 7.13 INSTRUMENT MODULE (IM), Remove
and Install: Console Without Panel
Hub cap screw 16-24 ft-lbs 22-33 N-m 3.4 FRONT WHEEL, Assemble
IM, rectangular, handlebar clamp screws 12-17 in-lbs 1.4—1.9 N-m 7.13 INSTRUMENT MODULE (IM), Remove
and Install: Handlebar Mount
IM, round,cover screws 12-17 in-lbs 1.4—1.9 N-m 7.13 INSTRUMENT MODULE (IM), Remove
and Install: Handlebar Mount
Ignition coil, screw 11-14 ft-lbs 15-19 N-m 7.9 IGNITION COIL, Install
Indicator lamp, screw 20-30 in-lbs 2.26-3.39 N-m 7.14 INDICATOR LAMPS, Install
Induction module bracket 66-84 in-lbs 7.5-9.5 N-m 6.15 INDUCTION MODULE, Assemble
Induction module flange adapter screws 96-156 in-lbs 10.9-17.6 N-m 6.15 INDUCTION MODULE, Install metric

Intake tube screw, cone 66-72 in-lbs 7.5-8.1 N-m 6.3 AIR CLEANER BACKPLATE AS-
SEMBLY, Remove and Install: Cone
JSS screw 20-25 in-lbs 2.3-2.8 N-m 7.41 JIFFY STAND SENSOR (JSS), Install
Jiffy stand screws 40--45 ft-lbs 54.2-61 N-m 3.43 JIFFY STAND, Install
Knock sensor screw 13-17 ft-lbs 17.6-23 N-m 4.19 CYLINDER HEADS, Assemble
License Plate Lamp Cover, Screw 8-16 in-lbs 0.9-1.8 N-m 7.25 LICENSE PLATE LAMP, Remove and
Install: Side Mount
License plate bracket inner mounting 18-21 in-lbs 2.03-2.37 N-m 3.39 REAR LICENSE PLATE BRACKET,
screws Center Mount
License plate bracket outer mounting 63-77 in-lbs 7.11-8.69 N-m 3.39 REAR LICENSE PLATE BRACKET,
screws Center Mount

12 94000936
Torque Values
FASTENER TORQUE VALUE NOTES
License plate holder screw 63-77 in-lbs 7.11-8.69 N-m 3.39 REAR LICENSE PLATE BRACKET,
Center Mount With Lighting
License plate holder, screw 60-80 in-lbs 6.8-9 N-m 7.23 TAIL LAMP, Remove and Install: Li-
cense Plate Bracket Mount
License plate standard assembly bolt 62-89 in-lbs 7-10 N-m 3.39 REAR LICENSE PLATE BRACKET,
Standard
License plate standard mount screws 71-97 in-lbs 8-11 N-m 3.39 REAR LICENSE PLATE BRACKET,
Standard
License plate, LED housing, screw 10-20 in-lbs 1.1-2.3 N-m 7.25 LICENSE PLATE LAMP, Remove and
Install: License Plate Bracket Mount
License plate, center mount, lamp housing 10-20 in-lbs 1.1-2.25 N-m 7.25 LICENSE PLATE LAMP, Bulb Re-
screw placement
License plate, center mount, tail lamp screw 10-20 in-lbs 1.1-2.25 N-m 7.23 TAIL LAMP, Remove and Install:
Center Mount
License plate, tail lamp, screw 10-20 in-lbs 1.1-2.3 N-m 7.23 TAIL LAMP, Remove and Install: Li-
cense Plate Bracket Mount
Lifter anti-rotation device screw 90-120 in-lbs 10.2-13.6 N-m 4.18 PUSHRODS, LIFTERS AND COVERS,
Install
Lifter cover screws 132-156 in-lbs 14.9-17.6 N-m 4.18 PUSHRODS, LIFTERS AND COVERS,
Install
Lower fairing bracket screw 96-120 in-lbs 10.8-13.6 N-m 7.18 HEADLAMP, Remove and Install: LED
Round
Lower fork bracket pinch bolt 16-20 ft-lbs 21.7-27.1 N-m 2.14 ADJUST AND LUBRICATE STEER-
ING HEAD BEARINGS, Check and Adjust
Lower rocker cover screws 90-120 in-lbs 10.2-13.6 N-m 4.16 LOWER ROCKER COVERS, Install
Lower rocker cover stud 90-120 in-lbs 10.2-13.6 N-m 4.14 UPPER ROCKER COVERS, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to
screws.
Lower shock screw 70-75 ft-lbs 94.9-101.7 N-m 3.25 REAR SHOCK ABSORBER, Install
Master brake cylinder yoke 11-14 ft-lbs 14.7-19.6 N-m 3.13 REAR BRAKE MASTER CYLINDER,
Disassemble and Assemble: Master Cylin-
der
Master cylinder bracket to frame screw 30-40 ft-lbs 40.7-54.2 N-m 3.13 REAR BRAKE MASTER CYLINDER,
Install
Master cylinder, rear, banjo bolt 14-18 ft-lbs 19-24.4 N-m 3.13 REAR BRAKE MASTER CYLINDER,
Install
Mid Foot Control shifter rod lever pinch 18-22 ft-lbs 24.4-29.8 N-m 5.5 SHIFTER LINKAGE, Shifter Rod Lever,
screw Front
Mid Foot Control shifter rod to shifter rod 120-168 in-lbs 13.6-19 N-m 5.5 SHIFTER LINKAGE, Shifter Rod
lever
Mid foot control shift lever pinch screw 24-28 ft-lbs 32.5-38 N-m 5.5 SHIFTER LINKAGE, Foot Shift Lever
Mirror mounting nut 96-144 in-lbs 10.8-16.3 N-m 3.33 MIRRORS, Install
Muffler clamp 38-43 ft-lbs 51.5-58.3 N-m 6.18 MUFFLERS, Install
Muffler end cap screws 96-120 in-lbs 10.8-13.6 N-m 6.18 MUFFLERS, Install
Muffler intermediate exhaust shield screw 108-132 in-lbs 12.2-14.9 N-m 6.19 EXHAUST SYSTEM, Disassemble and
Assemble: Two Into One
Muffler screws 120-144 in-lbs 13.6-16.3 N-m 6.18 MUFFLERS, Install
Muffler shield clamps 20-40 in-lbs 2.3-4.5 N-m 6.19 EXHAUST SYSTEM, Disassemble and
Assemble: Standard
Oil cooler cover screw 32-42 in-lbs 3.6-47 N-m 4.9 OIL COOLER, Install
Oil cooler screw 84-102 in-lbs 9.5-11.5 N-m 4.9 OIL COOLER, Install
Oil line manifold screws 90-120 in-lbs 10.2-13.6 N-m 4.11 OIL COOLANT LINES, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
Oil pan fasteners 132-156 in-lbs 14.9-17.6 N-m 4.27 OIL PAN, Install

94000936 13
Torque Values
FASTENER TORQUE VALUE NOTES
Torque sequence; LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND
SEALANT (blue) with used fasteners
Oil pump screws, 1st torque 12-60 in-lbs 1.4-6.8 N-m 4.22 CAM COMPARTMENT AND COM-
PONENTS, Install
Oil pump screws, final torque 90-120 in-lbs 10.2-13.6 N-m 4.22 CAM COMPARTMENT AND COM-
PONENTS, Install
Oil return tube screw 100-120 in-lbs 11.3-13.6 N-m 5.16 TRANSMISSION CASE, Assemble
One piece seat grab strap screw 60-90 in-lbs 6.8-10.16 N-m 3.44 SEAT, Install
Passenger footpeg support screw 38-47 ft-lbs 51.5----63.7 N-m 3.42 PASSENGER FOOTRESTS, Install
Piston jet screws 25--35 in-lbs 2.8-3.9 N-m 4.25 CRANKCASE, Repair Right Crankcase
Half
Primary chain tensioner fasteners 21-24 ft-lbs 28.5-32.6 N-m 5.9 DRIVE COMPONENTS, Install
Primary chaincase drain plug 14-21 ft-lbs 19-28.5 N-m 2.6 REPLACE PRIMARY CHAINCASE
LUBRICANT, Change Primary Chaincase
Lubricant
Primary chaincase sealing screws 26-28 ft-lbs 35.3-38 N-m 5.11 PRIMARY CHAINCASE HOUSING,
Install
Primary cover screws 144-156 in-lbs 16.3-17.6 N-m 5.8 PRIMARY CHAINCASE COVER, Install
See sequence in the procedure

Rear Turn Signal, Center Mount, Screw 15—18 ft-lbs 20-24 N-m 7.22 REAR TURN SIGNAL LAMPS, Re-
move and Install: Center Mount
Rear Turn Signal, Fender Mount, Screw 15—18 ft-lbs 20-24 N-m 7.22 REAR TURN SIGNAL LAMPS, Re-
move and Install: Fender Mount
Rear Turn Signal, Fender Support, Screw 21-27 ft-lbs 28-37 N-m 7.22 REAR TURN SIGNAL LAMPS, Re-
move and Install: Fender Mount
Rear Turn Signal, Light Bar Mount, Screw 16-20 ft-lbs 22-27 N-m 7.22 REAR TURN SIGNAL LAMPS, Re-
move and Install: Light Bar Mount
Rear brake caliper banjo bolt 21-23 ft-lbs 29-31 N-m 3.14 REAR BRAKE CALIPER, Install
Rear brake caliper pad hanger pin 11-14 ft-lbs 14.7-19.6 N-m 3.14 REAR BRAKE CALIPER, Install
Rear brake disc screws 30-45 ft-lbs 40.7-61 N-m 3.5 REAR WHEEL, Assemble
Rear brake line bracket screws 24-36 in-lbs 2.7-4.1 N-m 3.15 BRAKE LINES, Rear Brake Line: Non-
ABS
Rear brake line clamp screws 24-36 in-lbs 2.7-4.1 N-m 3.15 BRAKE LINES, Rear Brake Line: Non-
ABS
Rear caliper sleeve screw 15—18 ft-lbs 20.3-24.4 N-m 3.14 REAR BRAKE CALIPER, Install
Rear caliper slider bolt 15—18 ft-lbs 20.3-24.4 N-m 3.14 REAR BRAKE CALIPER, Install
Rear fender inner mount screw 21-27 ft-lbs 28.4-37 N-m 3.35 REAR FENDER, Disassemble and
Assemble: Chopped Fender Without Li-
cense Plate Bracket Lighting
Rear fender mounting screw 42-46 ft-lbs 57-62.5 N-m 3.35 REAR FENDER, Remove and Install:
Standard
Rear fender support screw 21-27 ft-lbs 28.4-37 N-m 3.35 REAR FENDER, Disassemble and
Assemble: Chopped Fender Without Li-
cense Plate Bracket Lighting
Rear fender support screws 21-27 ft-lbs 28.4-37 N-m 3.35 REAR FENDER, Disassemble and
Assemble: Chopped Fender Without Li-
cense Plate Bracket Lighting
Rear fender support screws 21-27 ft-lbs 28.4-37 N-m 3.35 REAR FENDER, Disassemble and
Assemble: Full Fender
Rear fork clamp screw 24-36 in-lbs 2.7-4.1 N-m 7.40 REAR WHEEL SPEED SENSOR
(WSS), Remove and Install: Standard Fork
Rear fork pivot shaft nut, 1st torque 25-30 ft-lbs 34-41 N-m 5.4 DRIVE BELT, Install
Rear fork pivot shaft nut, 2nd torque 1-48 in-lbs 0.1-5.4 N-m 5.4 DRIVE BELT, Install

14 94000936
Torque Values
FASTENER TORQUE VALUE NOTES
Rear fork pivot shaft nut, 3rd torque 154-170 ft-lbs 209-230 N-m 5.4 DRIVE BELT, Install
Rear fork pivot shaft nut, final torque 154-170 ft-lbs 209-230 N-m 3.23 REAR FORK, Remove and Install
Rear fork pivot shaft nut, first torque 25-30 ft-lbs 34-41 N-m 3.23 REAR FORK, Remove and Install
Rear fork pivot shaft nut, second torque 1-48 in-lbs 0.1-5.4 N-m 3.23 REAR FORK, Remove and Install
Rear fork pivot shaft nut, third torque 154-170 ft-lbs 209-230 N-m 3.23 REAR FORK, Remove and Install
Rear fork pivot shaft pinch bolt 18-20 ft-lbs 24-27 N-m 3.23 REAR FORK, Remove and Install
Rear shock adjuster knob screw 26.6-44.3 in-lbs 3-5 N-m 3.25 REAR SHOCK ABSORBER, Disas-
semble and Assemble: Rear Shock Adjuster

Rear sprocket screws, final torque 77-83 ft-lbs 104.4-112.5 N-m 3.5 REAR WHEEL, Assemble
Rear sprocket screws, first torque 60 ft-lbs 81.3 N-m 3.5 REAR WHEEL, Assemble
Rear stoplamp switch 12-15 ft-lbs 16.3-20.3 N-m 7.24 REAR STOPLAMP SWITCH, Install
Rear turn signal, rear lighting assembly, 10-13 ft-lbs 14.12-17.74 N-m 7.22 REAR TURN SIGNAL LAMPS, Re-
screw move and Install: Rear Lighting Assembly
Riser flange nuts 30-40 ft-lbs 40.7-54.3 N-m 3.32 HANDLEBAR, Remove and Install:
Standard
Rocker shaft screw 23-27 ft-lbs 31.2-36.6 N-m 4.17 ROCKER ARMS, Install
Saddle bag, docking bracket screw 38-47 ft-lbs 52-64 N-m 3.24 BELT GUARDS, Remove and Install:
Standard
Saddlebag docking rod 13-15 ft-lbs 17-21 N-m 3.46 SADDLEBAGS, Disassemble and
Assemble: Quick Disconnect
Saddlebag hinge screw 18-25 in-lbs 2-2.8 N-m 3.46 SADDLEBAGS, Disassemble and
Assemble: Standard
Saddlebag indicator flag cover screw 24-36 in-lbs 2.7-4.1 N-m 3.46 SADDLEBAGS, Disassemble and
Assemble: Quick Disconnect
Saddlebag latch assembly 10-15 in-lbs 1.1-1.7 N-m 3.46 SADDLEBAGS, Disassemble and
Assemble: Quick Disconnect
Saddlebag latch lever screw 20-30 in-lbs 2.3-3.4 N-m 3.46 SADDLEBAGS, Disassemble and
Assemble: Quick Disconnect
Saddlebag left side mounting bracket 97-124 in-lbs 11-14 N-m 3.46 SADDLEBAGS, Remove and Install:
grommet screw Quick Disconnect
Saddlebag locking knob cover screw 97-120 in-lbs 11-13.6 N-m 3.46 SADDLEBAGS, Disassemble and
Assemble: Quick Disconnect
Saddlebag locking knob screw 97-120 in-lbs 11-13.6 N-m 3.46 SADDLEBAGS, Disassemble and
Assemble: Quick Disconnect
Saddlebag lockset nut 45--55 in-lbs 5.1—6.2 N-m 3.46 SADDLEBAGS, Disassemble and
Assemble: Standard
Saddlebag right side mounting bracket 96-120 in-lbs 10.9-13.6 N-m 3.46 SADDLEBAGS, Remove and Install:
grommet screw Standard
Saddlebag strike screw 20-30 in-lbs 2.3-3.4 N-m 3.46 SADDLEBAGS, Disassemble and
Assemble: Quick Disconnect
Saddlebag tether screw 45-55 in-lbs 5.1-6.2 N-m 3.46 SADDLEBAGS, Disassemble and
Assemble: Quick Disconnect
Saddlebag tether stud 45--55 in-lbs 5.1—6.2 N-m 3.46 SADDLEBAGS, Disassemble and
Assemble: Quick Disconnect
Saddlebag tether to lid screw 8-15 in-lbs 0.9-1.7 N-m 3.46 SADDLEBAGS, Disassemble and
Assemble: Standard
Saddlebag, left side, mounting bracket 96-120 in-lbs 10.9-13.6 N-m 3.46 SADDLEBAGS, Remove and Install:
grommet screw Standard
Saddlebag, left side, mounting bracket 38-47 ft-lbs 52-64 N-m 3.46 SADDLEBAGS, Remove and Install:
screw Standard
Saddlebag, mounting screw 21-27 ft-lbs 29-37 N-m 3.46 SADDLEBAGS, Remove and Install:
Standard
Saddlebag, mounting bolt 21-27 ft-lbs 29-37 N-m 3.46 SADDLEBAGS, Remove and Install:
Quick Disconnect

94000936 xv
Torque Values
FASTENER TORQUE VALUE NOTES
Saddlebag, right side, mounting bracket 97-124 in-lbs 11-14 N-m 3.46 SADDLEBAGS, Remove and Install:
grommet screw Quick Disconnect
Saree lower guard top screw 71-80 in-lbs 8-9 N-m 3.37 SAREE GUARD, Install
Saree lower guard lower screw 10-13 fl-lbs 14-18 N-m 3.37 SAREE GUARD, Install
Saree upper guard screw 21-27 fl-lbs 28-37 N-m 3.37 SAREE GUARD, Install
Seat mounting nut 9-15 in-lbs 1-1.7 N-m 3.44 SEAT, Install
Seat thumbscrew 15-30 in-lbs 1.7-3.4 N-m 3.44 SEAT, Install
Sensor, CKP, screw 90-120 in-lbs 10.2-13.6 N-m 7.34 CRANKSHAFT POSITION SENSOR
(CKP), Install
Sensor, vehicle speed, screw 100-120 in-lbs 11.3-13.6 N-m 7.38 VEHICLE SPEED SENSOR (VSS),
Install
Shift drum detent screw 120-150 in-lbs 13.6-17 N-m 5.14 TRANSMISSION, Assemble
Shift drum lock plate screws 57-63 in-lbs 6.4-7.1 N-m 5.14 TRANSMISSION, Assemble
Shift lever bracket screws 120-144 in-lbs 13.6-16.3 N-m 3.40 LEFT FOOT CONTROLS, Disas-
semble and Assemble: Footboard
Shifter pawl centering screw 18-23 ft-lbs 24.4-31.2 N-m 5.16 TRANSMISSION CASE, Assemble
Shifter rod lever pinch screw, 18-22 fl-lbs 24.4-29.8 N-m 5.16 TRANSMISSION CASE, Assemble
transmission lever
Shock adjuster mounting screw 90-114 in-lbs 10.2-12.9 N-m 3.45 FRAME CROSSMEMBER, Install
Shock pinch bolt 12-15 fl-lbs 16.3-20.3 N-m 3.25 REAR SHOCK ABSORBER, Install
Side cover screw, vertical screw 24-36 in-lbs 2.7—4.1 N-m 3.19 RIGHT SIDE COVER, Install
Side cover mounting stud 72-96 in-lbs 8.1-10.8 N-m 3.16 ABS MODULE, Install
Side cover screw, single screw 24-36 in-lbs 2.7—4.1 N-m 3.18 LEFT SIDE COVER, Install
Side cover, left side, bracket to frame 8-10 in-lbs 0.9-1.1 N-m 3.18 LEFT SIDE COVER, Install
screw
Side-mounted shock adjuster screw 90-114 in-lbs 10.2-12.9 N-m 3.25 REAR SHOCK ABSORBER, Install
Solenoid nut 80-90 in-lbs 9-10.2 N-m 7.5 STARTER, Install
Spark plug 86-108 in-lbs 9.7-12.2 N-m 2.22 CLEAN, INSPECT, REPLACE SPARK
PLUGS, Install
Splash guard screw 35-45 in-lbs 3.9-5.1 N-m 3.23 REAR FORK, Remove and Install
Spoke nipple 55 in-lbs 6.2 N-m 2.8 INSPECT TIRES AND WHEELS, Wheel
Spokes
Starter, mounting screw 22-24 ft-lbs 29.8-32.5 N-m 7.5 STARTER, Install
Stator mounting screws 55-75 in-lbs 6.2-8.5 N-m 7.6 ALTERNATOR, Install
Always use new screws
Sub caddy screw 36-60 in-lbs 4.1-6.8 N-m 7.27 ELECTRONIC CONTROL MODULE
(ECM), Install
Switch, Neutral Indicator 120-180 in-lbs 13.6-20.3 N-m 7.16 NEUTRAL INDICATOR SWITCH,
Install
Switch, Oil Pressure 13-17 ft-lbs 17-23 N-m 7.15 OIL PRESSURE SWITCH, Install
Tail Lamp Lens Screw 20-24 in-lbs 2.3-2.7 N-m 7.23 TAIL LAMP, Bulb Replacement
Tail lamp bracket, screw 40-48 in-lbs 4.5-5.4 N-m
7.23 TAIL LAMP, Remove and Install:
Rear Lighting Assembly
Tail lamp lens screw 20-24 in-lbs 2.3-2.7 N-m 7.23 TAIL LAMP, Remove and Install:
Standard
Tail lamp, circuit board screw 40-48 in-lbs 4.5-5.4 N-m 7.23 TAIL LAMP, Remove and Install:
Standard
Temperature manifold absolute pressure 23-39 in-lbs 2.5-4.5 N-m 6.12 TEMPERATURE MANIFOLD ABSO-
sensor (TMAP) screw LUTE PRESSURE (TMAP) SENSOR, In-
stall
Throttle body to manifold screws 35-53 in-lbs 4-6 N-m 6.15 INDUCTION MODULE, Assemble
Transmission bearing housing screws 22-25 ft-lbs 29.8-33.9 N-m 5.14 TRANSMISSION, Install
Transmission drain plug 14-21 ft-lbs 19-28.5 N-m 2.7 REPLACE TRANSMISSION LUBRIC-
ANT, Change Transmission Lubricant

XVI 94000936
Torque Values
FASTENER TORQUE VALUE NOTES
Transmission filler plug/dipstick 25-75 in-lbs 2.8-8.5 N-m 2.7 REPLACE TRANSMISSION LUBRIC-
ANT, Check Transmission Lubricant
Transmission ground stud nut 72-96 in-lbs 8.1-10.9 N-m 7.48 ENGINE GROUND CABLE, Install
Transmission mainshaft/countershaft 85--95 ft-lbs 115.3—128.8 N-m 5.14 TRANSMISSION, Assemble
locknuts
Transmission mounting bolts, 1st torque 15 ft-lbs 20.3 N-m 5.16 TRANSMISSION CASE, Install
Transmission mounting bolts, final 34-39 ft-lbs 46.1-52.9 N-m 5.16 TRANSMISSION CASE, Install
torque
Transmission sprocket lockplate screws 90-120 in-lbs 10.2-13.6 N-m 5.13 TRANSMISSION SPROCKET, Install
Lock patch, use 3-5 times
Transmission sprocket nut, 1st torque 100 ft-lbs 135.6 N-m 5.13 TRANSMISSION SPROCKET, Install
Apply LOCTITE 271 HIGH STRENGTH
THREADLOCKER (red) to last few
threads. Loosen one full turn after first
torque.
Transmission sprocket nut, 2nd torque 35 ft-lbs 47.5 N-m 5.13 TRANSMISSION SPROCKET, Install
Transmission sprocket nut, final torque 35-40° 35-40° 5.13 TRANSMISSION SPROCKET, Install
Do not loosen to align lockplate screws.
Transmission top cover 132-156 in-lbs 14.9-17.6 N-m 5.14 TRANSMISSION, Install
Turn signal, frame mounted fairing, 15—18 ft-lbs 20.34-24.4 N-m 7.21 FRONT TURN SIGNAL LAMPS, Re-
screw move and Install: Fixed Fairing Mount
USB caddy screw 14-17 in-lbs 1.6—1.9 N-m 7.43 USB CADDY, Assemble
Under seat frame cover, front screw 20-30 in-lbs 2.3-3.4 N-m 3.15 BRAKE LINES, Front ABS Lines
Under seat frame cover, rear screw 96-120 in-lbs 10.8-13.6 N-m 3.15 BRAKE LINES, Front ABS Lines
Under seat frame, rear screws 96-120 in-lbs 10.9-13.6 N-m 7.50 BACKBONE WIRE HARNESS, Install
Upper rocker cover screws 120-140 in-lbs 13.6-15.8 N-m 4.14 UPPER ROCKER COVERS, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
to screws.
Upper shock screw 80-90 ft-lbs 108.5--122 N-m 3.25 REAR SHOCK ABSORBER, Install
Valve stem nut 12-15 in-lbs 1.4—1.7 N-m 3.9 TIRES, Install
Voltage regulator bracket, screw 100-120 in-lbs 11.3-13.6 N-m 7.7 VOLTAGE REGULATOR, Install
Voltage regulator, screw 106-124 in-lbs 12-14 N-m 7.7 VOLTAGE REGULATOR, Install
Wear peg 30-42 in-lbs 3.4-4.7 N-m 3.40 LEFT FOOT CONTROLS, Disas-
semble and Assemble: Footboard
Wide mounting screw 84-108 in-lbs 9.5--12.2 N-m 7.43 USB CADDY, Install
Windshield acorn nuts 23-27 in-lbs 2.6-3 N-m 3.30 WINDSHIELD, Assemble
Windshield, frame mounted fairing, 5-7 in-lbs 0.6-0.8 N-m 3.29 FAIRING: FRAME MOUNTED, Re-
screws move and Install: Windshield
Wireform screw, headlamp, oblong, 10-12 ft-lbs 13.5-16.2 N-m 7.18 HEADLAMP, Remove and Install:
Oblong
saddlebag lock screw 15-20 in-lbs 1.7-2.3 N-m 3.46 SADDLEBAGS, Disassemble and
Assemble: Quick Disconnect

94000936 XVII
NOTES
Index
ABS Module Remove and Install ..........................................3-59 Brake Line, Front Master Cylinder, ABS .............................. 3-52
ABS Module, General ...........................................................3-59 Brake Line, Front, Non-ABS ................................................ 3-51
Adhesive Strips Remove and lnstall ....................................3-156 Brake Line, Rear Caliper to ABS Module ............................ 3-57
Adjust Auxiliary Lamps .........................................................7-46 Brake Line, Rear Master Cylinder to ABS Module ............... 3-56
Adjust Headlamp ..................................................................7-40 Brake Line, Rear, Non-ABS ................................................ 3-51
Air Cleaner, Cone, Remove and Install ...................................6-6 Brake Lines, Front ABS ....................................................... 3-54
Air Cleaner, Oval, Remove and lnstall ....................................6-5 Brake Master Cylinder, Disassemble and Assemble ........... 3-36
Air Cleaner, Round, Remove and Install .................................6-4 Brake Master Cylinder, Front, Clean and lnspect ................ 3-36
Air Filter, Clean and lnspect ..................................................2-42 Brake Master Cylinder, Front, Remove and lnstall .............. 3-35
Air Filter, Cone, Remove and lnstall ......................................2-41 Brake Master Cylinder, Rear, Disassemble and
Air Filter, Oval, Remove and Install .......................................2-40 Assemble ............................................................................ 3-43
Air Filter, Round, Remove and Install ...................................2-40 Brake Master Cylinder, Rear, Remove and lnstall ............... 3-42
Aligment, Adjust Wheel ....................................................... 3-34 Brake Pads, Front, Replace ................................................ 2-18
Align Auxiliary Lamps ...........................................................7-46 Brake Pads, Rear, Replace ................................................. 2-19
Align Headlamp ....................................................................7-39 Brake Switch, Front, Replacement ...................................... 7-22
Alignment, Inspect Wheel .....................................................3-33 Brake Switch, Rear, Stoplamp, Remove and lnstall ............ 7-63
Alpha Step .................................................................................. l Brake Troubleshooting ........................................................ 2-52
Alternator Remove and lnstall ...............................................7-10 Brakes, Fill and Bleed ......................................................... 3-61
Antenna, Security System, Remove and lnstall ....................7-77 Brakes, Fluid, Drain ............................................................. 3-61
Assemble Topic ......................................................................... I Brakes, Inspect ................................................................... 2-17
Automatic Compression Release Remove and lnstall .......... 7-81 Breather Operation.............................................................. 4-11
Auxiliary Lamps Adjust .........................................................7-46 Breathers Remove and lnstall ............................................. 4-29
Auxiliary Lamps Align ...........................................................7-46 Bulb Replacement, Front Turn Signal Lamps ....................... 7-48
Bulb Replacement, Headlamp, Fixed Fairing ....................... 7-33
BCM Caddy Remove and lnstall ...........................................7-95 Bulb Replacement, Headlamp, Horizontal ............................ 7-33
Bulb Replacement, Headlamp, LED Round ......................... 7-31
Auxiliary Lamps, Standard Lighting, Remove and lnstall..7-45
Bulb Replacement, Headlamp, Nacelle Mounted ................. 7-32
Bulb Replacement, Headlamp, Oblong ................................ 7-33
B Bulb Replacement, Headlamp, Standard Round .................. 7-31
Bulb Replacement, License Plate Lamp .............................. 7-64

INDEX
Backbone Wire Harness Remove and lnstall ......................7-102
Badges Remove and lnstall ................................................3-156 Bulb Replacement, Tail Lamp ............................................. 7-57
Balance Wheels ................................................................... 3-31
Battery ....................................................................... ....1-1,2-44
Battery Tray Remove and lnstall ...........................................7-97
Battery, Clean and lnspect ....................................................2-44 CAN Terminating Resistor Remove and lnstall .................... 7-69
Battery, Remove and Install ..................................................2-43 Cable Lubrication ................................................................ .2-16
Battery, Storage ....................................................................2-44 Caddy, BCM, Remove and lnstall......................................... 7-95
Battery, Voltage Test ............................................................2-44 Caddy, ECM, Remove and lnstall......................................... 7-93
Bearing, Wheel .....................................................................2-14 Caddy, Front Electrical, Remove and lnstall ......................... 7-87
Bearings, Wheel, Sealed, lnspect .........................................3-25 Caddy, Rear Lighting, Remove and lnstall ........................... 7-96
Bearings, Wheel, Sealed, Remove and lnstall ......................3-25 Caddy, USB, Remove and lnstall ......................................... 7-90
Belt Guards, Standard, Remove and lnstall ..........................3-85 Caliper, Front, Clean and Inspect ......................................... 3-40
Belt, Drive, Remove and lnstall ...............................................5-7 Caliper, Front, Disassemble and Assemble .......................... 3-39
Bleed Brakes, Drain 3-61 Caliper, Front, Remove and lnstall ....................................... 3-38
Bleed Brakes, Fill and Bleed .................................................3-61 Caliper, Rear, Clean and lnspect.......................................... 3-49
Body Control Module Remove and lnstall .............................7-71 Caliper, Rear, Disassemble and Assemble .......................... 3-48
Bracket, Front License Plate, Remove and lnstall ...............3-125 Caliper, Rear, Remove and lnstall ........................................ 3-46
Bracket, Rear License Plate, Center Mount With Lighting, Cam Compartment and Components lnspect ...................... .4-55
Disassemble and Assemble ................................................3-127 Cam Compartment and Components Remove and
Bracket, Rear License Plate, Center Mount, Disassemble and lnstall .................................................................................... 4-54
Assemble ............................................................................3-126 Cam Drive Components Inspect........................................... 4-55
Bracket, Standard Rear License Plate, Remove and Cam Drive Components Remove and Install ........................ 4-54
Install ..................................................................................3-126 Cam Support Plate Inspect .................................................. 4-55
Brake ......................................................................................1-1 Cam Support Plate Remove and Install ............................... 4-54
Brake Caliper, Front, Clean and Inspect ...............................3-40 Camshaft Cover Remove and lnstall .................................... 4-53
Brake Caliper, Front, Disassemble and Assemble ................3-39 Camshaft lnspect ................................................................. 4-55
Brake Caliper, Front, Remove and Install .............................3-38 Camshaft Needle Bearings .................................................. 4-57
Brake Caliper, Rear, Clean and lnspect ................................3-49 Camshaft Remove and Install .............................................. 4-54
Brake Caliper, Rear, Disassemble and Assemble.................3-48 Charcoal Canister Remove and Install ................................. 6-44
Brake Caliper, Rear, Remove and Install ..............................3-46 Chassis Lubrication ............................................................. 2-16
Brake Fluid Level, Check ..................................................... 2-21 Chassis Specifications ........................................................... 3-8
Brake Fluid, Drain and Replace ............................................2-22 Check Valve, Oil, Remove and lnstall .................................. 4-21
Brake Line, Front Caliper, ABS .............................................3-53 Clamps, Crimp, Remove and lnstall ..................................... 4-18
Cleaning ................................................................................. 11

XIX
Index
Clutch Control Clean and Inspect ........................................ 3-93 Drive Belt Deflection, Measure ............................................. 2-32
Clutch Control Disassemble and Assemble ......................... 3-94 Drive Belt Remove and lnstall ................................................ 5-7
Clutch Control Remove and Install ....................................... 3-91 Drive Belt and Sprockets, lnspect......................................... 2-31
Clutch Hub Disassemble and Assemble .............................. 5-25 Drive Belt, Adjust.................................................................. 2-33
Clutch Pack Disassemble and Assemble ............................. 5-22 Drive Components Remove and lnstall ............................... 5-18
Clutch Release Cover Clean and lnspect............................. 5-13 Drive Specification ................................................................. 5-3
Clutch Release Cover Remove and lnstall ........................... 5-12
Clutch Release Lever Disassemble and Assemble .............. 5-12
Clutch Release Push Rod Components ............................... 5-15
Clutch Remove and lnstall ................................................... 5-18
ECM Caddy Remove and lnstall................ .......................... 7-93
Clutch Service Wear Limits .................................................... 5-3
Electrical Specifications.......................................................... 7-5
Clutch Switch Replacement ................................................. 7-19
Electrical System Troubleshooting ....................................... 2-52
Clutch, Check and Adjust..................................................... 2-23
Electronic Control Module Remove and lnstall ..................... 7-70
Coil, Ignition, Remove and lnstall ......................................... 7-14
Emblems, Tank, Remove and lnstall .................................. 3-156
Compensating Sprocket Remove and lnstall ....................... 5-18
Engine .................................................................................... 1-1
Complete Topic........................................................................... l
Engine Ground Cable Remove and lnstall ............................ 7-98
Compression Test................................................................ 4-14
Engine Lubrication ................................................................. 2-5
Conduit, Rear Fender Wire, Remove and lnstall ................ 3-122
Engine Mount, Left Side, Remove and Install ....................... 4-26
Connecting Rods lnspect ..................................................... 4-75
Engine Mount, Lower Front, Remove and lnstall .................. 4-24
Connecting Rods Symptoms ............................................... 4-75
Engine Mount, Upper Front, Remove and lnstall .................. 4-24
Connector End Views .......................................................... A-31
Engine Oil Fill Spout Remove and lnstall.............................. 5-31
Console, No Instrument, Remove and lnstall ......................... 6-8
Engine Oil Flow ...................................................................... 4-7
Console, Single Instrument Without Panel, Remove and
Engine Oil and Filter, Change ................................................ 2-7
lnstall ..................................................................................... 6-9
Engine Oil and Filter, Check ................................................... 2-7
Console, Single Instrument, Remove and lnstall .................... 6-8
Engine Remove and Install .................................................. 4-62
Control Module, Left Hand, Clutch Switch Replacement...7-19
Engine Service Wear Limits ................................................... 4-5
Control Module, Left Hand, Remove and lnstall ................... 7-16
Engine Specifications ............................................................. 4-4
Control Module, Left Hand, Switch Caps ............................. 7-18
Engine Temperature Sensor Remove and lnstall ................. 7-79
Control Module, Right Hand, Front Brake Switch
Engine Troubleshooting ....................................................... 2-50
Replacement ................................................................... ....7-22
Engine Wire Harness Remove and lnstall ............................ 7-99
Control Module, Right Hand, Remove and lnstall................. 7-20
Exhaust System Leak Check ............................................... 2-39
Control Module, Right Hand, Switch Caps ........................... 7-22
Exhaust System Remove and lnstall .................................... 6-36
Control Modules, Handlebar, General .................................. 7-15
Exhaust System, Standard, Disassemble and Assemble..6-37
Control Modules, Handlebar, Solder Procedure ................... 7-15
Exhaust System, Two Into One, Disassemble and Assemble6-40
Controls, Left Foot, Remove and lnstall ............................. 3-128
Exhaust System, Upswept, Disassemble and Assemble..6-38
Controls, Right Foot, Forward, Remove and lnstall .............. 3-133
Controls, Right Foot, Mid, Remove and Install ................... 3-133
Coolant .................................................................................. 1-1 F
Cover, Left Side, Remove and Install ................................... 3-63
Cover, Right Side, Remove and lnstall ................................ 3-64 Fairing Disassemble and Assemble ................................... 3-100
Crankcase Clean and Inspect .............................................. 4-66 Fairing Remove and Install......................................... 3-99,3-100
Crankcase Disassemble and Assemble ............................... 4-65 Fairing Supports, Frame Mounted ...................................... 3-104
Crankcase, Left Half, Repair ................................................ 4-70 Fairing, Frame Mounted, Air Deflectors .............................. 3-102
Crankcase, Right Half, Repair ............................................. 4-68 Fairing, Frame Mounted, Inner Fairing Shell ...................... 3-104
Crankshaft Position Sensor Remove and lnstall .................. 7-78 Fairing, Frame Mounted, Outer Fairing Shell ..................... 3-102
Crankshaft Runout, Measure ............................................... 4-15 Fairing, Frame Mounted, Remove and lnstall ..................... 3-103
Crimp Clamps Remove and lnstall ....................................... 4-18 Fairing, Frame Mounted, Windshield .................................. 3-102
Crossmember, Frame, Remove and lnstall ........................ 3-144 Fender, Chopped Rear With License Plate Bracket Lighting,
Cylinder Heads Clean .......................................................... 4-38 Disassemble and Assemble ............................................... 3-120
Cylinder Heads Clean and Inspect ....................................... 4-41 Fender, Chopped Rear Without License Plate Bracket Lighting,
Cylinder Heads Disassemble and Assemble ....................... 4-39 Disassemble and Assemble ............................................... 3-117
Cylinder Heads Remove and Install ..................................... 4-38 Fender, Front, Disassemble and Assemble ........................ 3-114
Cylinder Leakdown Test ...................................................... 4-15 Fender, Front, Remove and Install ..................................... 3-113
Cylinder Studs ..................................................................... 4-73 Fender, Full Rear, Disassemble and Assemble ................. 3-116
Cylinder, Deglaze ................................................................ 4-46 Fender, Rear, Wire Conduit, Remove and lnstall ............... 3-122
Cylinders, Clean and Inspect ............................................... 4-45 Fender, Standard Rear, Remove and Install ...................... 3-116
Cylinders, Remove and Install ............................................. 4-44 Flywheel lnspect................................................................... 4-75
Flywheel Symptoms ............................................................. 4-75
Fob Battery .......................................................................... 7-74
Foot Controls, Left, Remove and Install ............................. 3-128

Deglaze Cylinder ................................................................. 4-46

Diagnose Smoking Engine or High Oil Consumption ........... 4-17
Diagnose Valve Train Noise .............................................. 4-16
Disassemble Topics .................................................................. .1

xx
Index
Foot Controls, Right, Forward, Remove and Install .............3-133 Harness, Main, Remove and lnstall .................................... 7-105
Foot Controls, Right, Mid, Remove and lnstall ....................3-133 Headlamp Adjustment .......................................................... 7-40
Footboard Disassemble and Assemble.................... 3-130,3-135 Headlamp Alignment ............................................................ 7-39
Footpeg Disassemble and Assemble ....................... 3-131,3-136 Headlamp Nacelle Remove and Install ................................ 3-96
Footrests, Passenger, Remove and Install ........................ 3-138 Headlamp, Bulb Replacement, Fixed Fairing ....................... 7-33
Fork Lock Remove and Install ............................................. 3-80 Headlamp, Bulb Replacement, Horizontal ............................ 7-33
Fork Stem and Bracket Assemble, Clean and inspect ........ 3-78 Headlamp, Bulb Replacement, LED Round ......................... 7-31
Fork Stem and Bracket Remove and Install ......................... 3-78 Headlamp, Bulb Replacement, Nacelle Mounted ................. 7-32
Fork,Front, Inverted Left-Side, Disassemble and Headlamp, Bulb Replacement, Oblong ................................ 7-33
Assemble ............................................................................. 3-70 Headlamp, Bulb Replacement, Standard Round .................. 7-31
Fork, Front, Inverted Right-Side, Disassemble and Headlamp, Fixed Fairing, Remove and lnstall ...................... 7-38
Assemble ............................................................................. 3-73 Headlamp, Horizontal, Remove and lnstall ........................... 7-37
Fork, Front, Remove and lnstall ........................................... 3-65 Headlamp, LED Round, Remove and lnstall ........................ 7-34
Fork, Rear, Remove and lnstall............................. .............3-81 Headlamp, Nacelle Mounted, Remove and lnstall ................ 7-36
Fork, Standard Front, Disassemble and Assemble .............. 3-66 Headlamp, Oblong, Remove and lnstall ............................... 7-36
Fork, Standard Rear, Disassemble and Assemble ............... 3-82 Headlamp, Standard Round, Remove and lnstall ................. 7-33
Frame Crossmember Remove and lnstall .......................... 3-144 Heads, Cylinder, Clean ........................................................ 4-38
Front Electrical Caddy Remove and lnstall .......................... 7-87 Heads, Cylinder, Clean and Inspect ..................................... 4-41
Front Fender Disassemble and Assemble ......................... 3-114 Heads, Cylinder, Disassemble and Assemble ...................... 4-39
Front Fender Remove and lnstall ....................................... 3-113 Heads, Cylinder, Remove and Install ................................... 4-38
Front Fork Remove and Install ............................................. 3-65 Heated Oxygen Sensors Remove and lnstall ....................... 6-32
Front Fork, Inverted Left-Side, Disassemble and Horn Disassemble and Assemble ........................................ 7-30
Assemble ............................................................................. 3-70 Horn Remove and lnstall ...................................................... 7-30
Front Fork, Inverted Right-Side, Disassemble and Hub, Angle Flange, Wheel Lacing ........................................ 3-19
Assemble ............................................................................. 3-73 Hydraulic Fluid ....................................................................... 1-1
Front Fork, Standard, Disassemble and Assemble .............. 3-66
Front License Plate Bracket Remove and lnstall ................ 3-125
Front Wheel Clean and Inspect ........................................... 3-13
Front Wheel Disassemble and Assemble ............................ 3-13
Front Wheel Remove and Install .......................................... 3-12 lcons ......................................................................................... l
Fual Injectors Remove and Install ........................................ 6-26 Ignition Coil Remove and lnstall ........................................... 7-14
Fuel ................................................................................. 1-1,2-5 Indicator Lamps Remove and lnstall .................................... 7-27
Fuel Line Remove and lnstall ............................................... 6-13 Induction Module Disassemble and Assemble ..................... 6-29
Fuel Line, Purge .................................................................. 6-12 Induction Module Remove and lnstall ................................... 6-27
Fuel Line, Vent Tube, Remove and Install ........................... 6-20 Injectors, Fuel, Remove and lnstall ...................................... 6-26
Fuel Pressure Test .............................................................. 6-11 Inspect Brakes ..................................................................... 2-17
Fuel Pump Clean and lnspect .............................................. 6-16 Install Topics .............................................................................. l
Fuel Pump Disassemble and Assemble............................... 6-17 lnstrment Module, Console Without Panel, Remove and
Fuel Pump Remove and Install ............................................ 6-16 lnstall .................................................................................... 7-25
Fuel Pump Specifications ...................................................... 6-3 Instrument Module, Console With Panel, Remove and
Fuel System, Vapor Valve, Remove and lnstall ................... 6-22 lnstall .................................................................................... 7-25
Fuel Tank Remove and lnstall ............................................. 6-14 Instrument Module, Handlebar Mount, Remove and
Fuel Tank, Lift Rear of ......................................................... 6-12 lnstall .................................................................................... 7-24
Fuel Tank, Secure ............................................................... 6-12 Intake Leak Test................................................................... 6-31
Fuses Remove and lnstall...................................................... 7-6
Harness, Engine, Remove and lnstall ................................. 7-99

Gasoline ................................................................................. 1-1 Jiffy Stand Remove and lnstall............................................ 3-140

Gasoline Blends ..................................................................... 2-5 Jiffy Stand Sensor Remove and lnstall ............................... 7-86
General ...................................................................................... I
General, Cable and Chassis Lubrication .............................. 2-16
Ground Cable, Engine, Remove andlnstall ..................... 7-98 K

Knock Sensor Remove and lnstall ...................................... 7-80

Hand Grips Remove and Install ......................................... 3-108 L

Handlebar Control Modules Solder Procedure ..................... 7-15
Handlebar Control Modules, General ................................... 7-15 Layout......................................................................................... l
Handlebar, Standard, Disassemble and Assemble ........... 3-110 Leak Test, lntake ................................................................. 6-31
Handlebar, Standard, Remove and lnsall ........................... 3-109 Left Foot Controls Remove and lnstall ............................... 3-128
Handling Troubleshooting .................................................... 2-52 Left Side Cover Remove and lnstall .................................... 3-63
Harness, Backbone, Remove and lnstall ............................ 7-102 License Plate Bracket,Front, Remove and lnstall............... 3-125
Jiffy Stand Disassemble and Assemble .............................. 3-140

XXI
Index
License Plate Bracket, Rear, Center Mount With Lighting, Offset, Laced Wheel Rim ......................................................3-22
Disassemble and Assemble ............................................... 3-127 Oil ...........................................................................................1-1
License Plate Bracket, Rear, Center Mount, Disassemble and Oil Check Valve Remove and lnstall .....................................4-21
Assemble ........................................................................... 3-126 Oil Consumption, High, Diagnose .........................................4-17
License Plate Bracket, Standard Rear, Remove and Oil Coolant Lines Remove and lnsall ....................................4-22
lnstall.................................................................................. 3-126 Oil Cooler and Downtube Remove and lnstall.......................4-19
License Plate Lamp Bulb Replacement ................................ 7-64 Oil Fill Spout, Engine, Remove and lnstall ............................5-31
License Plate Lamp, Center Mount, Remove and lnstall..7-65 Oil Flow, Engine .....................................................................4-7
License Plate Lamp, License Plate Bracket Mount, Remove Oil Leak Check, Front Fork ...................................................3-65
and lnstall ............................................................................. 7-66 Oil Pan Remove and lnstall ..................................................4-77
License Plate Lamp, Side Mount, Remove and lnstall ..........7-67 Oil Pressure Check ...............................................................4-12
Lifters Clean and lnspect ...................................................... 4-35 Oil Pressure Operation .........................................................4-12
Lifters lnspect ....................................................................... 4-35 Oil Pressure Switch Remove and lnstall ...............................7-28
Lifters Remove and Install .................................................... 4-34 Oil Pump Operation ..........................................................4-10
Light Bar, Standard Lighting, Remove and lnstall .................7-43 Oil Pump Operation, General ...........................................4-10
Lock, Fork, Remove and Install ......................................... 3-80 Oil Pump Remove and Install ...........................................4-59
Loctite ..................................................................................... 1II Oil Pump, Disassemble, Inspect and Assemble ................4-59
Lower Rocker Covers Remove and Install ........................... 4-30 Oil and Filter, Engine, Change ................................................2-7
Lubricant, Primary Chaincase, Change .................................. 2-9 Oil and Filter, Engine, Check ..................................................2-7
Lubricant, Transmission, Change ......................................... 2-11 Oil, Primary Chaincase, Change ..........................................2-9
Lubricant, Transmission, Check ........................................... 2-11 Order of Operation ...................................................................... I
Lubrication Points................................................................. 2-16 Oxygen Sensors, Heated, Remove and Install .....................6-32
Lubrication System Troubleshooting .................................... 2-51
Lubrication, Engine ................................................................ 2-5
Lubrication, Winter ................................................................. 2-6

Main Drive Gear and Bearing Disassemble and Passenger Footrests Remove and lnstall ...........................3-138
Assemble ............................................................................. 5-46 Piston Ring Gap Check ........................................................4-50
Main Drive Gear and Bearing Remove and lnstall ................ 5-45 Pistons Clean and lnspect ....................................................4-49
Main Wire Harness Remove and lnstall .............................. 7-105 Pistons Disassemble and Assemble .....................................4-49
Mainshaft Bearing Inner Race Remove and lnstall ............... 5-29 Pistons Remove and lnstall...................................................4-47
Mainshaft Bearing and Seal Remove and Install .................. 5-28 Plugs and Oil Fittings ............................................................4-73
Mainshaft Needle Bearing Remove and lnstall ..................... 5-47 Power Disconnect ...................................................................7-7
Mainshaft Seal Remove and lnstall ...................................... 5-48 Power Disconnect, Main Fuse ................................................7-7
Maintenance ........................................................................... 2-2 Prepare Topic ............................................................................ 1
Maintenance Schedule .......................................................... 2-3 Primary Chaincase Cover Remove and Install ......................5-17
Manifold Absolute Pressure Sensor, Temperature, Remove Primary Chaincase Housing Inspect .....................................5-27
and Install ............................................................................. 6-23 Primary Chaincase Housing, Mainshaft Bearing and Seal
Manual .................................................................................... 1,I Remove and lnstall ...............................................................5-28
Master Cylinder, Front Brake, Clean and Inspect ................. 3-36 Primary Chaincase Lubricant, Change ...................................2-9
Master Cylinder, Front Brake, Disassemble and Primary Chaincsae Housing Remove and lnstall ..................5-27
Assemble ............................................................................. 3-36 Pump, Oil, Operation ............................................................4-10
Master Cylinder, Front Brake, Remove and lnstall ................ 3-35 Purge Lines Remove and lnstall ...........................................6-45
Master Cylinder, Rear Brake, Disassemble and Purge Solenoid Remove and lnstall ......................................6-43
Assemble ............................................................................. 3-43 Pushrod Covers Assemble ...................................................4-35
Master Cylinder, Rear Brake, Remove and Install ................ 3-42 Pushrod Covers Clean and Inspect ......................................4-35
Medallions Remove and Install ........................................... 3-156 Pushrod Covers Remove and Install.....................................4-34
Mirrors Remove and lnstall ................................................. 3-112 Pushrods Clean and Inspect .................................................4-35
Motorcycle Storage .............................................................. 2-48 Pushrods Remove and lnstall ...............................................4-34
Mufflers Remove and Install ................................................. 6-34

Rear Fender Wire Conduit Remove and lnstall .................. 3-122

Rear Fender, Chopped With License Plate Bracket Lighting,
Nacelle, Headlamp, Remove and Install ............................... 3-96 Disassemble and Assemble ............................................... 3-120
Neutral Indicator Switch Remove and lnstall ......................... 7-29 Rear Fender, Chopped Wtihout License Plate Bracket Lighting,
Numeric Step.............................................................................. I Disassemble and Assemble ............................................... 3-117
Rear Fender, Full Fender, Disassemble and Assemble..3-116
Rear Fender, Standard, Remove and lnstall ..................... 3-116
Rear Fork Remove and lnstall.............................................. 3-81
Rear Fork, Standard, Disassemble and Assemble ............... 3-82

22
Index
Rear License Plate Bracket, Center Mount With Lighting Spark Plugs, Clean and lnspect ............................................ 2-46
Disassmeble and Assemble ............................................... 3-127 Spark Plugs, Remove and lnstall .......................................... 2-46
Rear License Plate Bracket, Center Mount, Disassemble and Special Tools ............................................................................ III
Assemble ........................................................................... 3-126 Specifications, Chassis ........................................................... 3-8
Rear License Plate Bracket, Standard, Remove and Specifications, Electrical ......................................................... 7-5
lnstall .................................................................................. 3-126 Specifications, Fuel Pump ...................................................... 6-3
Rear Lighting Caddy Remove and lnstall............................ 7-96 Spoke, Wheel Lacing, Angle Flange Hub. ... ................ 3-19
Rear Shock Absorber Disassemble and Assemble ............ 3-89 Spokes, Wheel ..................................................................... 2-14
Rear Shock Absorber Remove and Install ............................ 3-87 Sprocket Shaft Bearing Inner Race ...................................... 4-71
Rear Wheel Clean and lnspect ............................................. 3-18 Stand, Jiffy, Remove and lnstall.......................................... 3-140
Rear Wheel Disassemble and Assemble.............................. 3-18 Starter Remove and lnstall ..................................................... 7-9
Rear Wheel Remove and lnstall ........................................... 3-16 Steering Head Bearings, Check and Adjust .................... 2-27
Regulator, Voltage, Remove and lnstall................................ 7-12 Steering Head Bearings, Clean and Inspect ................... 3-78
Remove Topic ............................................................................ I Steering Head Bearings, Lubricate ....................................... 2-28
Resistor, Terminating (CAN), Remove and lnstall ................ 7-69 Steering Head Remove and lnstall ....................................... 3-78
Right Foot Controls, Forward, Remove and lnstall ............. 3-133 Stoplamp Switch, Rear, Remove and lnstall ......................... 7-63
Right Foot Controls, Mid, Remove and lnstall ..................... 3-133 Storage, Place Motorcycle in ................................................ 2-48
Right Side Cover Remove and Install ................................... 3-64 Storage, Remove Motorcycle from ....................................... 2-49
Ring Gap, Pistons, Check .................................................... 4-50 Symbols...................................................................................... I
Rocker Arms Clean and Inspect ........................................... 4-32
Rocker Arms Remove and lnstall ......................................... 4-32
Rocker Covers, Lower, Remove and Install.......................... 4-30
Rocker Covers, Upper, Remove and Install .......................... 4-27
Runout, Checking Wheel ...................................................... 3-21 Tail Lamp Bulb Replacement ................................................ 7-57
Runout, Tire, Check ............................................................. 3-30 Tail Lamp, Center Mount, Remove and Install ...................... 7-61
Assemble ........................................................................... 3-150 Tail Lamp, License Plate Bracket Mount, Remove and
Saddlebags, Quick Disconnect, Remove and lnstall ........... 3-146 lnstall .................................................................................... 7-60
Tail Lamp, Rear Lighting Assembly, Remove and Install...7-57
s Tail Lamp, Standard, Remove and lnstall ............................. 7-58
Saddlebags, Quick Disconnect, Disassemble and Tank Emblems Remove and lnstall .................................... 3-156
Saddlebags, Standard, Disassemble and Assemble .......... 3-148 Temerature Sensor, Engine, Remove and Install ................. 7-79
Saddlebags, Standard, Remove and lnstall ........................ 3-145 Temperature Manifold Absolute Pressure Sensor Remove and
Safety ..................................................................................... 1-1 lnstall .................................................................................... 6-23
Saree Guard Remove and lnstall........................................ 3-124 Terminating Resistor Remove and lnstall ............................. 7-69
Schedule, Maintenance .......................................................... 2-3 Test, Compression................................................................ 4-14
Seat Remove and lnstall..................................................... 3-142 Test, Cylinder Leakdown ...................................................... 4-15
Secure Motorcycle for Service ................................................ 2-2 Test, Fuel Pressure .............................................................. 6-11
Security Siren Battery ........................................................... 7-74 Test, Intake Leak .................................................................. 6-31
Security Siren Remove and lnstall ........................................ 7-76 Tire Runout, Check ............................................................... 3-30
Tires ..................................................................................... 3-29
Security System Activation ................................................... 7-72
Tires, Clean, Inspect and Repair. ......................................... 3-29
Security System Antenna Remove and lnstall ...................... 7-77
Tires, General ....................................................................... 2-13
Security System Maintenance .............................................. 7-74
Tires, lnspect ........................................................................ 2-14
Security System, Changing the PIN ..................................... 7-73
Tires, Remove and Install ..................................................... 3-28
Service Mode ....................................................................... 7-74
Tires, Replace ...................................................................... 2-14
Service Wear Limits, Engine .................................................. 4-5
Tool .......................................................................................... III
Servicing a New Motorcycle ................................................... 2-2
Trademarks .......................................................................... III,III
Shell, Inner Fairing, Frame Mounted Fairing ...................... 3-104
Transmission Case Clean and Inspect ................................. 5-52
Shell, Outer Fairing, Frame Mounted Fairing ...................... 3-102
Transmission Case Disassemble and Assemble .................. 5-51
Shift Lever, Foot, Remove and lnstall ................................... 5-10
Transmission Case Remove and lnstall ................................ 5-50
Shift Rod Lever, Front .......................................................... 5-10
Transmission Clean and Inspect ........................................... 5-40
Shifter Rod Remove and Install .............................................. 5-9
Transmission Disassemble and Assemble ........................... 5-36
Shifter Shaft Bushing Remove and Install ............................ 5-29
Transmission Lubricant, Change .......................................... 2-11
Shock Absorber, Adjust ........................................................ 2-35
Transmission Lubricant, Check ............................................. 2-11
Shock Absorber, Rear, Disassemble and Assemble .......... 3-89
Transmission Operation .......................................................... 5-5
Shock Absorber, Rear, Remove and Install .......................... 3-87
Transmission Remove and Install ......................................... 5-35
Shop Practices ...................................................................... II,III
Transmission Specifications ................................................... 5-3
Side Cover, Left, Remove and lnstall ................................... 3-63
Transmission Sprocket Remove and Install .......................... 5-32
Side Cover, Right, Remove and lnstall ................................. 3-64
Transmission Troubleshooting .............................................. 2-52
Siren, Security System, Remove and lnstall ......................... 7-76
Transport Mode .................................................................... 7-74
Smoking Engine, Diagnose .................................................. 4-17
Troubleshooting, Brakes ....................................................... 2-52
Soleniod, Purge, Remove and lnstall .................................... 6-43
Troubleshooting, Electrical System ....................................... 2-52
Spark Plug............................................................................ 2-46
Troubleshooting, Engine ....................................................... 2-50
Spark Plug Cables Remove and Install ................................ 7-13
Troubleshooting, Handling .................................................... 2-52
Troubleshooting, Lubrication System .................................. 2-51

23
Index
Troubleshooting, Transmission ............................................ 2-52
Truing Laced Wheels ........................................................... 3-23
Turn Signal Lamps, Front, Bulb Replacement ...................... 7-48
Turn Signal Lamps, Front, Fixed Fairing Mount ................... 7-50
Turn Signal Lamps, Front, Handlebar Mount, Remove and
install .................................................................................... 7-48
Turn Signal Lamps, Rear, Bulb Replacement ...................... 7-52
Turn Signal Lamps, Rear, Center Mout, Remove and
lnstall .................................................................................... 7-55
Turn Signal Lamps, Rear, Fender Mount, Remove and
lnstall ................................................................................... .'.7-52
Turn Signal Lamps, Rear, Light Bar Mount, Remove and
lnstall .................................................................................... 7-54
Turn Signal Lamps, Rear.Rear Lighting Assemlby, Remove
and lnstall ............................................................................. 7-54
Twist Grip Sensor Remove and Install .............................. 6-24 u

USB Caddy Remove and lnstall .......................................... 7-90

Upper Rocker Covers Remove and Install .......................... 4-27
Using the Manual ....................................................................... I

Valve Train Noise, Diagnose ................................................ 4-16

Valve and Seat Repair ......................................................... 4-41
Vapor Valve Remove and lnstall .......................................... 6-22
Vehicle Identification Number (VIN) ..................................... 3-10
Vehicle Speed Sensor Remove and lnstall .......................... 7-83
Voltage Regulator Remove and lnstall ................................ 7-12

Wear Limits, Service, Engine ................................................. 4-5

Wheel Alignment, Adjust ...................................................... 3-34
Wheel Alignment, lnspect ..................................................... 3-33
Wheel Bearings .................................................................... 2-14
Wheel Bearings, Sealed, lnspect.......................................... 3-25
Wheel Bearings, Sealed, Remove and lnstall ....................... 3-25
Wheel Lacing, Angle Flange Hub ......................................... 3-19
Wheel Speed Sensor, Front, Remove and lnstall ................. 7-84
Wheel Spokes ...................................................................... 2-14
Wheel, Front, Clean and lnspect .......................................... 3-13
Wheel, Front, Disassemble and Assemble ........................... 3-13
Wheel, Front, Remove and lnstall ........................................ 3-12
Wheel, Rear, Clean and lnspect ........................................... 3-18
Wheel, Rear, Disassemble and Assemble ........................... 3-18
Wheel, Rear, Remove and Install ....................................... 3-16
Wheels, Balance .................................................................. 3-31
Wheels, Checking Wheel Runout ......................................... 3-21
Wheels, Checking and Truing, General ................................ 3-21
Wheels, General .................................................................. 2-13
Wheels, Laced Rim Offset.................................................... 3-22
Wheels, Truing Laced .......................................................... 3-23
Windshield Disassemble and Assemble ............................. 3-106
Windshield Remove and lnstall .......................................... 3-106
Windshield, Frame Mounted Fairing ................................... 3-102
Winter Lubrication .................................................................. 2-6
Wire Conduit, Rear Fender, Remove and Install ................ 3-122
Wiring Diagrams..................................................................... A-2

XXIV 94000936_22_Soft_sm_b.pdf

Do not allow dirt or debris to enter the master cylinder

Index
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)
NOTE
• At every service, check moisture content of fluid using DOT 4 BRAKE FLUID MOISTURE TESTER (PART NUMBER: HD-
48497-A). Follow the instructions included with tool.
• Flush brake system and replace Harley-Davidson Platinum Label DOT 4 Brake Fluid (41800xxx) fluid every two years or
sooner if brake fluid test shows moisture content is 3% or greater.

• Fluid should never need to be added or removed from the system during normal wear; except for fluid replacement as
specified in the maintenance schedule.
• Fluid level in reservoir will decrease with brake wear. Reservoir volume is adequate to provide fluid to the wear limits of
the pads and rotors.

Check brake pads and discs:

• At every scheduled service interval.

• When removed during service procedures.

NOTE
When checking the brake pads and discs, inspect the brake
hoses for correct routing and any signs of damage.
NOTE
• Always install new piston rings.
• Always deglaze the cylinder before installing new rings.
• Insufficient ring gap may cause the ends to touch at operating temperatures. This causes ring breakage, cylinder scuffing
and/or piston seizure.
• Excessive ring gap causes high oil consumption and blow-by of exhaust gases resulting in contaminated oil and reduced
engine efficiency

1. See Figure 4-46. Check ring end gap of each ring before installing on piston.

a. Insert piston upside down into cylinder. Apply even downward force to align piston ring.
b. Measure the ring end gap with a feeler gauge. Refer to Table 4-13 .
NOTE
Piston ring position is identical for both pistons.

1. See Figure 4-47. Install three-piece oil control ring.

a. Install expander ring (1) with ends facing up (see inset).
b. Install bottom oil rail (2).
c. Install top oil rail (3).

NOTE
• Position the "N" marking on the compression rings to the top of the piston.
1. See Figure 6-18. Install new seal (4).

2. NOTE
• Fuel pumps used in 5 gallon fuel tanks are equipped with a flexible siphon tube (6), siphon tube must be routed to
opposite side of fuel tank during fuel pump installation.
• Do not bend float rod of fuel level sender. A bent float rod results in incorrect gauge readings.

Install fuel pump assembly.

a. Insert siphon tube into fuel tank, if equipped.

b. Insert fuel level sender float (2) into fuel tank.

c. Insert fuel pump assembly (5) half way into fuel tank.

d. Insert inlet strainer (3) into fuel tank.

e. Install fuel pump assembly.

f. Install screws (1).

Index
3. See Figure 6-19. Tighten in sequence shown.
Torque: 40-45 in-lbs (4.5-5 N-m) Fuel pump assembly
screws