Harley Davidson 2011 Touring Models. Service Manual — page 24
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)
7.
See
. Install
new
retaining rings (1).
8.
Install
new
O-ring (4) into groove in main drive gear.
sm03044
Figure 6-41. Pressing in Seal
sm02302
Figure 6-42. Installing Transmission Side Needle Bearing
in Main Driver Gear
MAINSHAFT SEAL REPLACEMENT
TOOL NAME
PART NUMBER
MAIN DRIVE GEAR SEAL INSTALLER
HD-47933
See
. If the mainshaft seal was not installed with
the main drive gear needle bearings (or if a faulty seal is dis-
covered with the main drive gear installed in the transmission
case), the seal can be installed using the MAIN DRIVE GEAR
SEAL INSTALLER (Part No. HD-47933).
1
2
sm03045
1. Driver
2. Seal protector sleeve
Figure 6-43. Main Drive Gear Seal Installer (Part No.
HD-47933)
1.
Remove the damaged seal using a seal remover or rolling
head pry bar.
2.
Inspect bore to be sure it is clean and smooth.
3.
See
. Place the seal protector sleeve (1) over
the end of the mainshaft. Lightly lubricate the protector
sleeve and seal ID with clean transmission oil.
4.
Verify that the garter spring is in place on the lip of the
new
oil seal. Apply a light coat of H-D 20W-50 engine oil
to the seal lip.
5.
Squarely seat the mainshaft seal (2) on the seal protector
sleeve with the garter spring facing the bearing.
6.
See
. Using MAIN DRIVE GEAR SEAL
INSTALLER (Part No. HD-47933), hand press seal onto
mainshaft and into end of main drive gear. A rubber mallet
may be used to lightly tap driver, if necessary. Seal is
properly installed when seal driver contacts end of main
drive gear.
2
1
sm03048
1. Seal protector sleeve
2. Seal
Figure 6-44. Seal Protector Sleeve
6-24 2011 Touring Service: Transmission
sm03049
Figure 6-45. Seal Driver
INSTALLATION
TOOL NAME
PART NUMBER
INSTALLER CUP
HD-35316-12
CROSS PLATE
HD-35316-3A
8 IN. BOLT
HD-35316-4A
12 IN. BOLT
HD-35316-5
WASHER
HD-35316-7
BEARING DRIVER
HD-35316-8
INSTALLER
HD-47856-1
PILOT
HD-47856-2
ADAPTER
HD-47856-3
NUT
HD-47856-6
CROW'S FOOT WRENCH
HD-47856-7
Improper tightening of sprocket nut can cause drive
component damage. (00541b)
Installing Main Drive Gear Bearing
NOTE
CROSS PLATE (Part No. HD-35316-3A) will retrofit to earlier
transmissions. Note that one end of cross plate is stamped,
"UP 6 SPEED". Mount cross plate with this end pointing up for
6 speed transmissions.
1.
See
. Place CROSS PLATE (Part No. HD-
35316-3A) (2) on right side of transmission case as shown,
and secure with two screws (3). Position cross plate so
that large bolt hole in cross plate is lined up with center of
main drive gear bearing bore in left side of transmission
case.
2.
Apply a light coat of graphite lubricant to the threads of 12
IN. BOLT (Part No. HD-35316-5) (1) and install through
cross plate and main drive gear bearing bore.
3.
At left side of case, place main drive gear bearing (4),
BEARING DRIVER (Part No. HD-35316-8) (5), BEARING
(6), FLAT WASHER (7) and NUT (8) over end of bolt.
4.
Tighten nut until main drive gear bearing bottoms against
lip cast into transmission case bearing bore.
1
2
8
7
4
3
6
5
sm03051
1. 12 in. bolt
2. Cross plate
3. Screw (2)
4. Main drive gear bearing
5. Bearing driver
6. Bearing
7. Flat washer
8. Nut
Figure 6-46. Installing Main Drive Gear Bearing (Typical)
Installing Main Drive Gear
NOTE
See
. Make sure new O-ring (4) is installed onto
main drive gear (3). Lubricate O-ring with clean engine oil
before installing drive gear into transmission case.
1.
See
. Apply a light coat of graphite lubricant
to the threads of 8 IN. BOLT (Part No. HD-35316-4A) (1)
and insert through WASHER (Part No. HD-35316-7) (2)
and main drive gear (3). Insert assembly into transmission
case, through main drive gear bearing.
2.
At outside of case, place INSTALLER CUP (Part No. HD-
35316-12) (5), BEARING (6), FLAT WASHER (7) and NUT
(8) over end of bolt.
3.
Tighten nut until main drive gear contacts main drive gear
bearing.
NOTE
See
. In next step, bearing retaining ring must be
installed with the flat side facing the bearing and the opening
in the ninety degree range shown.
2011 Touring Service: Transmission 6-25
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)
4.
See
. Install
new
retaining ring (2).
6
7
8
5
4
2
1
3
sm03052
1. 8 in. bolt
2. Washer
3. Main drive gear
4. O-ring
5. Installer cup
6. Bearing
7. Flat washer
8. Nut
Figure 6-47. Installing Main Drive Gear (Typical)
sm03053
Figure 6-48. Retaining Ring Opening
Installing Main Drive Gear Large Seal
1.
See
. From outside of crankcase, install
PILOT (Part No. HD-47856-2) over end of main drive gear
bearing inner race.
2.
Coat lips of
new
main drive gear seal with transmission
lubricant.
3.
See
. Place seal over pilot with garter spring
facing bearing, and position seal squarely in end of
crankcase bore.
NOTE
ADAPTER (Part No. HD-47856-3) and main drive gear have
right-hand threads.
4.
See
. Thread ADAPTER (Part No. HD-47856-
3) onto end of main drive gear until it contacts main drive
gear.
1
2
sm03057
1. Pilot
2. Retaining Ring
Figure 6-49. Install Pilot
sm03058
Figure 6-50. Place Main Drive Gear Seal Over Pilot
6-26 2011 Touring Service: Transmission
sm03059
Figure 6-51. Install Adapter
5.
See
. Slide INSTALLER (Part No. HD-47856-
1) (1) over adapter until cupped end of installer is flat
against seal.
6.
Thread NUT (Part No. HD-47856-6) (2) onto end of
adapter, until it tightens against installer.
7.
See
. Place CROW'S FOOT WRENCH (Part
No. HD-47856-7) (1) with 1/2 inch drive breaker bar (2)
on large nut. Place an adjustable wrench (3) on flats of
hex head cast into end of adapter.
8.
Holding adjustable wrench, tighten large nut with crow's
foot wrench until outer face of seal is flush with outer edge
of transmission bore.
NOTE
It is acceptable to recess seal as much as 0.030 in. (0.762 mm)
below outer edge of bore. Seal depth will be controlled by tool.
9.
Remove nut, installer, adapter and pilot.
10. Install side door and transmission components. See
6.6 TRANSMISSION ASSEMBLY, Installation
.
11. Install sprocket and drive belt. See
. Do not adjust belt at this time.
12. Install the bearing inner race on the transmission main-
shaft. See
6.6 TRANSMISSION ASSEMBLY, Assembly
13. Install the primary chaincase housing. See
CHAINCASE HOUSING, Installation
14. Install the clutch assembly, primary chain, chain tensioner
assembly and compensating sprocket components. See
5.4 DRIVE COMPONENTS, Installation
15. Install the primary chaincase cover. See
.
16. Adjust the drive belt. See
SPROCKETS, Setting Belt Deflection
.
17. Install exhaust system. See
1
2
sm03061
1. Installer
2. Nut
Figure 6-52. Installer and Nut
1
3
2
sm03062
1. Crow's foot wrench
2. 1/2 inch breaker bar
3. Adjustable wrench
Figure 6-53. Press Seal Into Crankcase
2011 Touring Service: Transmission 6-27
6.8
TRANSMISSION CASE
REMOVAL
Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)
1.
Disconnect battery, negative (-) cable first.
2.
Drain engine oil. See
3.
Drain transmission lubricant. See
LUBRICANT, Transmission Lubrication
.
4.
Remove starter. See
5.
Remove transmission assembly. See
.
6.
Remove oil pan. See
When lifting a motorcycle using a jack, be sure jack con-
tacts both lower frame tubes where down tubes and lower
frame tubes converge. Never lift by jacking on cross-
members, oil pan or other housings. Failure to comply can
cause serious damage resulting in the need to perform
major repair work. (00586c)
7.
Position jack across lower frame to support rear of
motorcycle. Slide wooden blocks beneath the crankcase
to support the weight of the engine and transmission
assembly.
8.
Remove rear fork. See
.
9.
Disconnect
vehicle
speed
sensor
(VSS).
See
7.23 VEHICLE SPEED SENSOR (VSS), VSS
10. Disconnect neutral switch. See
11. Remove fastener from ground post at top of transmission
case and remove battery negative ring terminal.
12. Move O2 sensor, starter solenoid, neutral switch and VSS
harness out of the way.
13. Mark splines on shift arm and shift shaft to assist in
assembly. Remove shift arm from shift shaft.
14. In a crosswise pattern, remove four fasteners that connect
transmission to engine.
NOTE
See
. Do not use a hammer to remove transmission.
If the transmission sticks or binds on the ring dowels, gently
pry away from crankcase using the indent.
15. Move transmission rearward until two ring dowels in lower
flange are free of crankcase. Remove transmission case
from left side of the motorcycle.
sm03566
Figure 6-54. Transmission Case Pry Point
INSTALLATION
1.
Install
new
ground post at top of transmission case.
Tighten ground post until snug.
NOTE
A new transmission case comes with the shifter shaft sleeve
and seal, centering screw, countershaft needle bearing and
main drive gear bearing and seal installed.
2.
Thoroughly wipe all engine oil from pockets in crankcase
flange.
3.
Install
new
engine-to-transmission gasket engaging two
index pins in holes of transmission flange.
4.
Verify that transmission dowels are seated. Place trans-
mission case into position behind crankcase. Mate engine
and transmission flanges.
5.
Install and tighten fasteners.
a.
Shorter bolts are installed at the top, longer fasteners
are installed at the bottom. Using a crosswise pattern,
hand tighten
fasteners.
b.
See
. Tighten bolts in the sequence shown
to 15 ft-lbs (20.3 Nm) in the same crosswise pattern.
c.
Final tighten bolts to 34-39 ft-lbs (46.1-52.9 Nm).
6.
Install oil pan. See
7.
Install rear fork. See
8.
Install shift arm on shift shaft. Align marks made during
disassembly.
9.
Install transmission and side door assembly. See
6.6 TRANSMISSION ASSEMBLY, Installation
10. Connect battery ground (-) cable to ground post at top of
transmission case. Tighten securely.
11. Adjust drive belt tension. See
12. Install primary chaincase. See
6-28 2011 Touring Service: Transmission
13. Install drive components. See
.
NOTE
The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.
14. Install primary chaincase cover. See
15. Install neutral switch and tighten to 120-180
in-lbs
(13.6-
20.3 Nm).
16. Install VSS and tighten screw to 84-132
in-lbs
(9.5-14.9
Nm).
17. Mate VSS, O2 sensors, starter solenoid and neutral switch
connectors to main harness.
18. Install starter. See
19. Install the exhaust system. See
20. Clean transmission drain plug and install. Tighten to 14-
21 ft-lbs (19.0-28.5 Nm). Place motorcycle in an upright
position. Fill transmission to proper level with fresh trans-
mission fluid. See
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)
21. Fill primary. See
1.9 PRIMARY CHAINCASE LUBRICANT,
Changing Primary Chaincase Lubricant
.
22. Fill engine oil. See
1.6 ENGINE OIL AND FILTER, Chan-
.
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
23. Connect battery cables.
4
2
1
3
sm02180
Figure 6-55. Transmission Housing to Crankcase Torque
Sequence
DISASSEMBLY
Shifter Arm Assembly
1.
See
. After removing door assembly, remove
screw (8) and shifter rod lever (9) from the shifter pawl
lever assembly (1).
2.
Remove retaining ring (7), washer (6) and seal (5). Discard
retaining ring and seal. Pull shifter pawl lever assembly
out of the transmission case.
3.
Inspect sleeve (2) inside transmission case.
CLEANING AND INSPECTION
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)
1.
Clean all parts in solvent except the case and main drive
gear needle bearings. Blow parts dry with low pressure
compressed air.
NOTE
Never wash the transmission case and needle bearings with
solvent. Normal cleaning methods will wash dirt or other con-
taminants into the bearing case (behind the needles) leading
to bearing failure.
2.
See
. Inspect the shifter pawl lever assembly
(1) for wear. Replace assembly if pawl ends are damaged.
Replace centering spring (3) if elongated.
2011 Touring Service: Transmission 6-29
3.
Inspect the shifter spring (4). Replace if the spring fails to
hold the pawl on the cam pins.
4.
Thoroughly clean the oil pan with solvent.
5.
Inspect preformed transmission top cover vent hose for
nicks, cuts or general deterioration. Replace as necessary.
Use low-pressure compressed air to verify that hose and
fitting are unobstructed.
4
1
2
3
5
7
8
11
9
6
10
sm03066
1. Shifter pawl lever assembly
2. Sleeve (inside transmission case)
3. Shift lever centering spring
4. Shifter shaft lever spring
5. Seal
6. Washer
7. Retaining ring
8. Screw
9. Shifter rod lever
10. Washer
11. Screw
Figure 6-56. Shifter Arm Assembly
ASSEMBLY
Countershaft Needle Bearing Replacement
1.
Find a suitable bearing driver 1.25 in. (31.75 mm) in dia-
meter.
2.
From the outside of the transmission case place the needle
bearing open end first next to the bearing bore. Hold the
driver squarely against the closed end of the bearing and
tap the bearing into place. The bearing is properly posi-
tioned when it is driven inward flush with the outside sur-
face of the case or to a maximum depth of 0.030 in. (0.76
mm).
3.
Lubricate the bearing with Screamin' Eagle Assembly Lube
(Part No. 94971-09.)
Shifter Pawl Lever Assembly
1.
See
. Verify that sleeve (2) is inside transmis-
sion case.
2.
See
. Slide shifter lever centering spring (3)
over shaft of shifter pawl lever assembly (2). Align opening
on spring with tab on lever.
3.
Place shifter shaft lever spring (4) on shifter pawl lever
assembly.
NOTE
Do not bend shifter shaft lever spring more than necessary for
assembly.
4.
See
. Insert the assembly into the transmission
case.
5.
See
. Verify that pin sits inside shifter shaft
lever spring.
6.
See
. Install a
new
seal. Install washer (1) and
a
new
retaining ring (2).
NOTE
In next step, shifter rod lever must be installed so angle of lever
is toward front of vehicle, one spline from vertical.
7.
See
. Install shifter rod lever (9) on the shifter
pawl lever assembly shaft end using screw (8). Tighten
to 18-22 ft-lbs (24.4-29.8 Nm).
2
1
4
3
sm03067
1. Pawl (part of shifter pawl lever assembly)
2. Shifter pawl lever assembly
3. Shifter lever centering spring
4. Shifter shaft lever spring
Figure 6-57. Shifter Pawl Lever Assembly
6-30 2011 Touring Service: Transmission
4
2
1
3
sm03068
1. Washer (with seal behind)
2. Retaining ring
3. Shifter shaft lever
4. Pin
Figure 6-58. Shifter Shaft Lever, Exterior View
sm03069
Figure 6-59. Shifter Shaft Lever Spring
2011 Touring Service: Transmission 6-31
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
ELECTRICAL
7.1
FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.
NOTES
TORQUE VALUE
FASTENER
7.29 GAUGES AND INSTRUMENTS: FAIRING
MODELS, 2 Inch Diameter Gauges: Fuel Level,
Ambient Air Temperature, Voltmeter, Oil Pressure
1.1-2.3 Nm
10-20
in-lbs
2 inch diameter gauge nuts
7.21 AUTOMATIC COMPRESSION RELEASE
(ACR), Installation/Apply three equally spaced dots
of LOCTITE 246 THREADLOCKER MEDIUM
STRENGTH/HIGH TEMPERATURE around lower
third of threads
14.9-20.3 Nm
11-15 ft-lbs
Automatic compression release (ACR)
7.13 AUXILIARY LAMPS AND BRACKETS, Auxil-
iary Lamp Bracket
20-27 Nm
15-20 ft-lbs
Auxiliary lamp bracket to fork bracket
screws (FLHTC/U, FLHTK)
7.13 AUXILIARY LAMPS AND BRACKETS, Auxil-
iary Lamp Bracket
8.1-12.2 Nm
72-108
in-lbs
Auxiliary lamp bracket to fork bracket
stud acorn nuts (FLHR/C)
7.10 STARTER, Installation
6.8-7.9 Nm
60-70
in-lbs
Battery terminal bolt
7.22 ALTERNATOR, Installation
6.8-7.9 Nm
60-70
in-lbs
Battery terminal bolt
7.8 ELECTRICAL CADDIES, Battery Tray
8.1-10.9 Nm
72-96
in-lbs
Battery tray screws
7.40 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation
8.1-12.2 Nm
72-108
in-lbs
Brake clamp fasteners
7.33 ADVANCED AUDIO SYSTEM, Radio
4.0-5.1 Nm
35-45
in-lbs
CB module to radio screw
7.33 ADVANCED AUDIO SYSTEM, CB Module
4.0-5.1 Nm
35-45
in-lbs
CB module to radio screw
7.20 CRANKSHAFT POSITION SENSOR
(CKP), Installation
10.2-13.6 Nm
90-120
in-lbs
CKP sensor mount screw
7.31 GAUGES AND INSTRUMENTS: ROAD KING
MODELS, Speedometer
4.1-6.8 Nm
36-60
in-lbs
Console-to-tank screw
7.32 INDICATOR LAMPS: ROAD KING
MODELS, Indicator Lamps
4.1-6.8 Nm
36-60
in-lbs
Console-to-tank screw
7.18 FAIRING CAP SWITCHES: FORK MOUNTED
FAIRING MODELS, Installation
2.8-3.4 Nm
25-30
in-lbs
Fairing cap screws
7.33 ADVANCED AUDIO SYSTEM, Front Fairing
Speakers
2.5-3.2 Nm
22-28
in-lbs
Fairing speaker lower screw (FLHX,
FLHTC/U)
7.33 ADVANCED AUDIO SYSTEM, Front Fairing
Speakers
4.0-5.7 Nm
35-50
in-lbs
Fairing speaker upper screws (FLHX,
FLHTC/U)
7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Road King Models
4.1-6.8 Nm
36-60
in-lbs
Fork lock screws (Road King)
7.15 FENDER TIP LAMPS, Front Fender Tip Lamp
2.3-2.8 Nm
20-25
in-lbs
Front fender tip lamp bracket screws
7.15 FENDER TIP LAMPS, Front Fender Tip Lamp
Jumper Harness
2.3-2.8 Nm
20-25
in-lbs
Front fender tip lamp bracket screws
7.15 FENDER TIP LAMPS, Front Fender Tip Lamp
Jumper Harness
1.1-1.7 Nm
10-15
in-lbs
Front fender tip lamp trim strip tee bolt
nuts
7.16 TURN SIGNAL LAMPS, Front Turn Signal
Lamp
20-27 Nm
15-20 ft-lbs
Front turn signal lamp mounting bracket
screws (Bullet Style; fork mounted)
7.16 TURN SIGNAL LAMPS, Front Turn Signal
Lamp
4.1-6.8 Nm
30-60
in-lbs
Front turn signal lamp mounting bracket
screws (FLHR/C, FLHT/C/U)
7.16 TURN SIGNAL LAMPS, Front Turn Signal
Lamp
20-27 Nm
15-20 ft-lbs
Front turn signal lamp-to-bracket
fastener: Bullet Style; fork mounted
2011 Touring Service: Electrical 7-1
NOTES
TORQUE VALUE
FASTENER
7.33 ADVANCED AUDIO SYSTEM, Front Headset
Receptacle
4.1-6.8 Nm
36-60
in-lbs
Fuel tank console screws
7.6 IGNITION COIL, Installation
5.7-10.2 Nm
50-90
in-lbs
Ground terminal nut
7.40 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Left Side Handlebar Switches
8.1-12.2 Nm
72-108
in-lbs
Handlebar clamp to clutch lever bracket
screws
7.40 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation
8.1-12.2 Nm
72-108
in-lbs
Handlebar clamp to clutch lever bracket
screws
7.40 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Right Side Handlebar Switches
8.1-12.2 Nm
72-108
in-lbs
Handlebar clamp to master cylinder
screws
7.40 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Right Side Handlebar Switches
4.0-5.0 Nm
35-45
in-lbs
Handlebar switch housing screws
7.40 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Left Side Handlebar Switches
4.0-5.0 Nm
35-45
in-lbs
Handlebar switch housing screws
7.40 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation
4.0-5.0 Nm
35-45
in-lbs
Handlebar switch housing screws
7.40 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation
4.0-5.0 Nm
35-45
in-lbs
Handlebar switch housing screws
7.35 MAIN WIRING HARNESS, Installation: All
Models (Part 1)/(10 mm)
5.7-10.2 Nm
50-90
in-lbs
Harness ground stud flange nuts
7.35 MAIN WIRING HARNESS, Installation: All
Models (Part 1)/(10 mm)
5.7-10.2 Nm
50-90
in-lbs
Harness ground stud flange nuts
7.12 HEADLAMP: ROAD GLIDE, Headlamp
Adjuster Assembly
4.0-5.1 Nm
35-45
in-lbs
Headlamp adjuster mounting screw (dual
headlamp models)
7.11 HEADLAMP: ALL EXCEPT ROAD
GLIDE, Headlamp: Single Headlamp Models
1.0-2.0 Nm
9-18
in-lbs
Headlamp door screw
7.12 HEADLAMP: ROAD GLIDE, Headlamp
Adjuster Assembly
1.7-2.8 Nm
15-25
in-lbs
Headlamp mounting screw (dual head-
lamp models)
7.12 HEADLAMP: ROAD GLIDE, Headlamp Bulb
Replacement: Dual Headlamp Models
1.7-2.8 Nm
15-25
in-lbs
Headlamp mounting screw (dual head-
lamp models)
7.11 HEADLAMP: ALL EXCEPT ROAD
GLIDE, Headlamp: Single Headlamp Models
2.5-3.6 Nm
22-32
in-lbs
Headlamp retaining screws (Fairing
equipped)
7.11 HEADLAMP: ALL EXCEPT ROAD
GLIDE, Headlamp: Single Headlamp Models
1.0-2.0 Nm
9-18
in-lbs
Headlamp retaining screws (Non-fairing
equipped)
7.27 HORN, Installation
9.0-13.6 Nm
80-120
in-lbs
Horn bracket acorn nut
7.27 HORN, Installation
9.0-11.3 Nm
80-100
in-lbs
Horn stud flange nut
7.6 IGNITION COIL, Installation
3.6-4.5 Nm
32-40
in-lbs
Ignition coil screws
7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Fairing Models
9.6-13.0 Nm
85-115
in-lbs
Ignition switch housing nut
7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Fairing Models
4.1-6.8 Nm
36-60
in-lbs
Ignition switch housing screws
7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Road King Models
2.3-3.4 Nm
20-30
in-lbs
Ignition switch screws (Road King)
7.19 INSTRUMENT NACELLE SWITCHES:
FRAME MOUNTED FAIRING MODELS, Installation
2.8-4.0 Nm
25-35
in-lbs
Instrument bezel screws
7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Road King Models
4.1-6.8 Nm
36-60
in-lbs
Instrument console screws
7.19 INSTRUMENT NACELLE SWITCHES:
FRAME MOUNTED FAIRING MODELS, Installation
20-27 Nm
15-20 ft-lbs
Instrument nacelle to fork bracket screws
7.19 INSTRUMENT NACELLE SWITCHES:
FRAME MOUNTED FAIRING MODELS, Installation
20-27 Nm
15-20 ft-lbs
Instrument nacelle to fork bracket screws
7.8 ELECTRICAL CADDIES, Left Side Caddy
8.1-10.9 Nm
72-96
in-lbs
Left electrical caddy fastener
7-2 2011 Touring Service: Electrical
NOTES
TORQUE VALUE
FASTENER
7.16 TURN SIGNAL LAMPS, Rear Turn Signal
Lamps Bracket
6.8-9.0 Nm
60-80
in-lbs
License plate bracket screws
7.16 TURN SIGNAL LAMPS, Rear Turn Signal
Lamps Bracket
6.8-9.0 Nm
60-80
in-lbs
License plate bracket screws
7.24 NEUTRAL SWITCH, Installation
13.6-20.3 Nm
120-180
in-lbs
Neutral switch
7.25 OIL PRESSURE SWITCH AND
SENDER, Installation
10.8-16.3 Nm
96-144
in-lbs
Oil pressure sender
7.25 OIL PRESSURE SWITCH AND
SENDER, Installation
10.8-16.3 Nm
96-144
in-lbs
Oil pressure switch
7.33 ADVANCED AUDIO SYSTEM, Radio
4.0-5.1 Nm
35-45
in-lbs
Radio (storage box) to support bracket
screws
7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Fairing Models
4.0-5.1 Nm
35-45
in-lbs
Radio support bracket screws
7.14 TAIL LAMP, Rear Fender Lights Harness: all
except FLHX, FLTRX
6.8-10.9 Nm
60-96
in-lbs
Rear fender lights harness stud plate
flange nuts
7.15 FENDER TIP LAMPS, Rear Fender Tip Lamp
2.3-2.8 Nm
20-25
in-lbs
Rear fender tip lamp screws
7.26 STOPLIGHT SWITCHES, Rear Stoplight
Switch/Use Loctite Pipe Sealant with Teflon 565
16.3-20.3 Nm
12-15 ft-lbs
Rear stoplight switch
7.16 TURN SIGNAL LAMPS, Rear Turn Signal
Lamps Bracket/Use LOCTITE High Strength
Threadlocker 271 (red)
9.5-16.3 Nm
84-144
in-lbs
Rear turn signal lamps bracket screws
7.16 TURN SIGNAL LAMPS, Rear Turn Signal
Lamps Bracket/Use LOCTITE High Strength
Threadlocker 271 (red)
9.5-16.3 Nm
84-144
in-lbs
Rear turn signal lamps bracket screws
7.16 TURN SIGNAL LAMPS, Rear Turn Signal
Lamp
3.4-5.6 Nm
30-50
in-lbs
Rear turn signal lamp-to-rear turn signal
lamps bracket screws
7.10 STARTER, Solenoid
7.3-9.0 Nm
65-80
in-lbs
Solenoid contact post jamnut
7.10 STARTER, Drive Assembly
7.9-10.2 Nm
70-90
in-lbs
Solenoid ring terminal nut
7.29 GAUGES AND INSTRUMENTS: FAIRING
MODELS, Speedometer
1.1-2.3 Nm
10-20
in-lbs
Speedometer bracket screws
7.10 STARTER, Drive Assembly
10.2-12.4 Nm
90-110
in-lbs
Starter end cover screw
7.10 STARTER, Installation/Apply a drop of Loctite
Threadlocker 243 (blue) to the threads.
33.9-36.6 Nm
25-27 ft-lbs
Starter mounting screw
7.10 STARTER, Solenoid
7.9-10.2 Nm
70-90
in-lbs
Starter ring terminal hex nut
7.10 STARTER, Installation
7.9-10.2 Nm
70-90
in-lbs
Starter terminal post nut
7.10 STARTER, Drive Assembly
4.4-7.3 Nm
39-65
in-lbs
Starter through bolts
7.22 ALTERNATOR, Installation/Always use new
screws
6.2-8.5 Nm
55-75
in-lbs
Stator mounting screws
7.29 GAUGES AND INSTRUMENTS: FAIRING
MODELS, Tachometer
1.1-2.3 Nm
10-20
in-lbs
Tachometer bracket screws
7.14 TAIL LAMP, Circuit Board/Chrome Base
4.5-5.4 Nm
40-48
in-lbs
Tail lamp circuit board/chrome base
screw
7.14 TAIL LAMP, Tail Lamp Bulb Replacement
2.3-2.7 Nm
20-24
in-lbs
Tail lamp screws
7.14 TAIL LAMP, Circuit Board/Chrome Base
2.3-2.7 Nm
20-24
in-lbs
Tail lamp screws
7.14 TAIL LAMP, Rear Fender Lights Harness: all
except FLHX, FLTRX
2.3-2.7 Nm
20-24
in-lbs
Tail lamp screws
7.14 TAIL LAMP, Rear Fender Lights Harness:
FLHX, FLTRX
2.3-2.7 Nm
20-24
in-lbs
Tail lamp screws
7.15 FENDER TIP LAMPS, Rear Fender Tip Lamp
2.3-2.7 Nm
20-24
in-lbs
Tail lamp screws
7.16 TURN SIGNAL LAMPS, Rear Turn Signal
Lamp
2.3-2.7 Nm
20-24
in-lbs
Tail lamp screws
2011 Touring Service: Electrical 7-3
NOTES
TORQUE VALUE
FASTENER
7.8 ELECTRICAL CADDIES, Top Caddy
8.1-10.9 Nm
72-96
in-lbs
Top caddy clamp screws
7.13 AUXILIARY LAMPS AND BRACKETS, Auxil-
iary Lamp Housing
4.1-6.8 Nm
36-60
in-lbs
Turn signal lamp mounting bracket
screws
7.13 AUXILIARY LAMPS AND BRACKETS, Auxil-
iary Lamp Housing
20.3-24.4 Nm
15-18 ft-lbs
Turn signal lamp to auxiliary lamp stud
locknut
7.3 VOLTAGE REGULATOR, Installation
7.9-11.3 Nm
70-100
in-lbs
Voltage regulator locknuts
7.23 VEHICLE SPEED SENSOR (VSS), VSS
9.5-14.9 Nm
84-132
in-lbs
VSS fastener
7-4 2011 Touring Service: Electrical
7.2
SPECIFICATIONS: ELECTRICAL
SPECIFICATIONS
Table 7-1. Ignition
DATA
IGNITION
1000 ± 50 RPM
Idle speed
12 mm
Spark plug size
0.038-0.043 in.
Spark plug gap
0.97-1.09 mm
Harley-Davidson
No. 6R12
(no substitute)
Spark plug type
0.5-0.7 ohms
Ignition coil primary resistance
5500-7500 ohms
Ignition coil secondary resistance
Table 7-2. Fuses
AMPS
FUSE
40
Main fuse
15
Brakes
15
Accessory
15
P&A
15
Radio power/siren
15
ECM power
15
Ignition
15
Engine control: active exhaust (HDI only)
15
Lighting
15
Instruments
15
Headlamp
30
ABS
2
P&A ignition
15
Fuel pump
15
Battery
15
Power outlet (if equipped)
15
Radio memory
Table 7-3. Charging System
DATA
CHARGING SYSTEM
28 amp hour/405 CCA
Battery
16-23 VAC per 1000 RPM
Alternator AC voltage output
0.1-0.2 ohms
Alternator stator coil resistance
14.3-14.7
@
75 °F (24 °C)
Regulator voltage output @ 3600
RPM
35-50 amps
Regulator amperes @ 3000 RPM
Table 7-4. Starter Specifications
STARTER DATA
3000 rpm (min) @ 11.5 V
Free speed
90 A (max) @ 11.5 V
Free current
200 A (max) @ 68 °F
Cranking current
8.0 ft-lbs (10.8 Nm) @ 2.4 V
Stall torque
Table 7-5. Starter Service Wear Limits
mm
in
ITEM
11.0
0.443
Brush length (minimum)
0.41
0.016
Commutator runout
28.98
1.141
Commutator diameter (minimum)
0.203
0.008
Commutator mica depth (minimum)
2011 Touring Service: Electrical 7-5
7.3
VOLTAGE REGULATOR
REMOVAL
1.
Remove main fuse. See
2.
Remove locknuts from studs on lower frame crossmember.
Lift voltage regulator off studs. Allow voltage regulator to
hang upside down at front of lower frame crossmember.
3.
See
. Pull away locking latch and remove socket
of voltage regulator connector [77] (2).
4.
Pull away locking latch and remove socket of stator con-
nector [46] (1).
INSTALLATION
1.
See
. Install stator connector [46] (1). Secure
connector with locking latch (3).
2.
Install voltage regulator connector [77] (2). Secure con-
nector with locking latch (3).
3.
See
. Install voltage regulator with locknuts on
studs and tighten to 70-100
in-lbs
(7.9-11.3 Nm).
4.
Make sure wires are properly secured.
5.
Install main fuse. See
6.
Test charging system.
2
1
sm03470a
1. Stator connector [46]
2. Voltage regulator output connector [77]
Figure 7-1. Voltage Regulator (Left Side View)
2
3
1
sm03471
1. Stator [46A]
2. Voltage regulator [77A]
3. Locking latch
Figure 7-2. Voltage Regulator (Bottom View)
7-6 2011 Touring Service: Electrical
7.4
ELECTRONIC CONTROL MODULE (ECM)
ECM
Removal
1.
Remove seat. See
.
2.
Free ECM from top caddy.
3.
Disconnect ECM connector. See
SEALED 73-TERMINAL ECM CONNECTOR
.
NOTE
Internal latches are not fully disengaged until locking bar is in
the fully released position. Forcing socket housing with latches
partially engaged will result in connector damage.
Installation
1.
Connect ECM connector. See
SEALED 73-TERMINAL ECM CONNECTOR
.
NOTE
Pin and socket housings must be fully engaged before locking
bar is rotated to the latched position. Forcing locking bar without
full engagement will result in connector damage.
2.
Secure ECM in top caddy. Verify holes engage two index
pins on right side of top caddy.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
3.
Install seat. See
NOTE
After installing ECM, the password learn procedure must be
performed.
4.
Perform password learn procedure. See
.
2011 Touring Service: Electrical 7-7
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