Harley Davidson 2011 Touring Models. Service Manual — page 4
Table 1-2. Recommended Engine Oils
COLD WEATHER
STARTS BELOW 50 °F
(10 °C)
LOWEST AMBIENT
TEMPERATURE
H-D RATING
VISCOSITY
H-D TYPE
Excellent
Below 40 °F (4 °C)
HD 360
SAE 10W40
H-D Multi-grade
Excellent
Above 40 °F (4 °C)
HD 360
SAE 20W50
Screamin' Eagle SYN3
Synthetic Motorcycle
Lubricant
Good
Above 40 °F (4 °C)
HD 360
SAE 20W50
Screamin' Eagle Syn-
thetic Blend Motorcycle
Engine Oil
Good
Above 40 °F (4 °C)
HD 360
SAE 20W50
H-D Multi-grade
Poor
Above 60 °F (16 °C)
HD 360
SAE 50
H-D Regular Heavy
Poor
Above 80 °F (27 °C)
HD 360
SAE 60
H-D Extra Heavy
WINTER LUBRICATION
In colder climates, the engine oil should be changed often. If
motorcycle is used frequently for short trips, less than 15 mi
(24 km), in ambient temperatures below 60 °F (16 °C), oil
change intervals should be reduced to 1500 mi (2400 km).
Motorcycles used only for short runs must have a thorough
tank flush-out before
new
oil is put in. The tank flush-out should
be performed by an authorized dealer or qualified technician.
NOTE
The further below freezing the temperature drops, the shorter
the oil change interval should be.
Water vapor is a normal by-product of combustion in any
engine. During cold weather operation, some of the water vapor
condenses to liquid form on the cool metal surfaces inside the
engine. In freezing weather this water will become slush or ice
and, if allowed to accumulate too long, may block the oil lines
and cause damage to the engine.
If the engine is run frequently and allowed to thoroughly warm
up, most of this water will become vapor again and will be
blown out through the crankcase breather.
If the engine is not run frequently and allowed to thoroughly
warm up, this water will accumulate, mix with the engine oil
and form a sludge that is harmful to the engine.
1-8 2011 Touring Service: Maintenance
1.4
BULB REQUIREMENTS
GENERAL
Use the table to identify the bulb location and part number.
Refer to
NOTE
The speedometer, tachometer, odometer and indicator lamps
are illuminated with LEDs. LEDs are non-repairable. The entire
assembly must be replaced if an LED fails.
Table 1-3. Bulb Chart
HARLEY-DAVIDSON
PART NUMBER
CURRENT
DRAW
AMPERAGE
BULBS
REQUIRED
DESCRIPTION
(ALL LAMPS 12 VOLT)
LAMP
68329-03
4.58/5.0
1
FLHTC/U, FLHR/C, FLHX, FLHTK
Headlamp
68329-03
4.58/5.0
2
FLTRX, FLTRU
53436-97
0.32
1
Position lamp, international
68167-04
0.59/2.10
1
Tail/stop lamp, FLHX, FLTRX
Tail and stop
lamp
68168-89A
2.25/0.59
2
Front/running
Turn signal lamp
68572-64B
1.75
2
Front international
68163-84
1.75
2
Front, FLHX (HDI)
68572-64B
2.25
2
Rear, FLHR, FLHRC, FLHTC,
FLHTCU, FLHTK, FLTRU (all)
68168-89A
2.25/0.59
2
Rear, FLHX, FLTRX (domestic)
N/A
N/A
LED
Rear, FLHX, FLTRX (international)*
68163-84
1.75
2
Rear, FLHX, FLTRX (Canadian)
53788-06 (right side)
0.14
N/A
Tour-Pak side lamps*
Additional lighting
53789-06 (left side)
0.14
FLHTCU, FLHTK, FLTRU
68165-64
0.59/2.10
2
Tour-Pak tail/stop lamps
68193-95
0.30
1
Fender tip lamps, front
69375-06 (FLHX, FLTRX)
N/A
N/A
Fender tip lamps, rear*
59672-09 (all but FLHX, FLTRX)
53436-97
0.37
1
License plate lamp international
52441-95
0.35
2
License plate lamp FLHX, FLTRX
domestic
68453-05
2.1
2
Auxiliary lamps
68851-98
2.7
2
Fog lamps international
Instrument panel is illuminated with LEDs. Replace entire assembly upon
failure.
High beam indicator
Instrument panel
lamps
Oil pressure indicator
Neutral indicator
Turn signal indicator
N/A
N/A
N/A
Speedometer
Gauge lamps
FLHR/C
N/A
N/A
N/A
Odometer
Illuminated with LEDs. Replace assembly upon failure.
Fuel gauge*
N/A
N/A
N/A
Engine
2011 Touring Service: Maintenance 1-9
Table 1-3. Bulb Chart
HARLEY-DAVIDSON
PART NUMBER
CURRENT
DRAW
AMPERAGE
BULBS
REQUIRED
DESCRIPTION
(ALL LAMPS 12 VOLT)
LAMP
N/A
N/A
N/A
Speedometer
Gauge lamps
FLHTC/U
N/A
N/A
N/A
Tachometer
FLTRX
67445-00
0.24
1
Voltmeter
FLTRU
FLHX
67445-00
0.24
1
Oil pressure gauge
FLHTK
FLHTC/U, FLHTK, FLHX, FLTRX,
FLTRU
67445-00
0.24
1
Air temperature gauge
FLHTC/U, FLHTK, FLHX, FLTRX,
FLTRU
67445-00
0.24
1
Fuel gauge
Illuminated with LEDs. Replace entire assembly upon failure.
Items with *
1-10 2011 Touring Service: Maintenance
1.5
MAINTENANCE SCHEDULE
GENERAL
The table below lists the periodic maintenance requirements
for Touring model motorcycles. If you are familiar with the
procedures, just refer to the table for the recommended service
interval. If necessary, see the quick reference table (
.)
for the required specifications.
If more detailed information is needed, turn to the sections
which follow for step-by-step instructions.
Also, throughout this manual, you will be instructed to use
various lubricants, greases and sealants. Refer to
for the correct part numbers of these items.
Table 1-4. Regular Service Intervals: 2011 Touring Models
NOTES
50000 MI
80000 KM
45000 MI
72000 KM
40000 MI
64000 KM
35000 MI
56000 KM
30000 MI
48000 KM
25000 MI
40000 KM
20000 MI
32000 KM
15000 MI
24000 KM
10000 MI
16000 KM
5000 MI
8000 KM
1000 MI
1600 KM
PROCEDURE
ITEM SERVICED
X
X
X
X
X
X
X
X
X
X
X
Replace
Engine oil and filter
1, 3
X
X
X
X
X
X
X
X
X
X
X
Inspect for leaks,
contact or abrasion
Oil lines and brake
system
X
X
X
X
X
X
X
X
X
X
Inspect, service as
required
Air cleaner
X
X
X
X
X
X
X
X
X
X
X
Check pressure,
inspect tread
Tires
1, 5
X
X
X
X
X
Check torque
Wheel spokes (if
equipped)
X
X
X
X
X
X
Replace
Primary chaincase
lubricant
X
X
X
Replace
Transmission lub-
ricant
1
X
X
X
X
X
X
X
X
X
X
X
Check adjustment
Clutch
1
X
X
X
X
X
X
X
X
X
X
X
Inspect, adjust belt
Drive belt and
sprockets
7
Inspect for wear
Compensator
sprocket isolators
1
X
X
X
X
X
X
X
X
X
X
X
Check and lub-
ricate
Brake and clutch
controls
1
X
X
X
X
X
X
X
X
X
X
X
Inspect and lub-
ricate
Jiffy stand
1, 3
X
X
X
X
X
X
X
X
X
X
X
Inspect for leaks,
contact or abrasion
Fuel lines and fit-
tings
1
X
X
Replace
Fuel tank filter
4
X
X
X
X
X
X
X
X
X
X
X
Inspect sight glass
Brake fluid
X
X
X
X
X
X
X
X
X
X
X
Inspect for wear
Brake pads and
discs
X
X
X
X
X
X
X
X
Inspect
Spark plugs
X
X
Replace
X
X
X
X
X
X
X
X
X
X
X
Check operation
Electrical equip-
ment and switches
1, 6
X
Replace
Front fork oil
X
X
X
X
X
Lubricate
Steering head
bearings
1, 2
X
X
Adjust
1
X
X
X
X
X
X
X
X
X
X
X
Check pressure,
operation and
leakage
Air suspension
1
X
X
X
X
X
Inspect
Windshield bush-
ings (if applicable)
X
X
X
X
X
X
X
X
X
X
X
Lubricate hinges
and latches
Fuel door, Tour-
Pak, saddlebags (if
equipped)
1
X
X
X
X
X
X
Check tightness
Critical fasteners
3
Check battery and
clean connections
Battery
3
X
X
X
X
X
X
X
X
X
X
X
Inspect for leaks,
cracks, and loose
or missing
fasteners or heat
shields
Exhaust system
2011 Touring Service: Maintenance 1-11
Table 1-4. Regular Service Intervals: 2011 Touring Models
NOTES
50000 MI
80000 KM
45000 MI
72000 KM
40000 MI
64000 KM
35000 MI
56000 KM
30000 MI
48000 KM
25000 MI
40000 KM
20000 MI
32000 KM
15000 MI
24000 KM
10000 MI
16000 KM
5000 MI
8000 KM
1000 MI
1600 KM
PROCEDURE
ITEM SERVICED
X
X
X
X
X
X
X
X
X
X
X
Verify component
and system func-
tions
Road test
1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified.
NOTES:
2. Disassemble, lubricate and inspect every 50,000 miles (80,000 kilometers).
3. Perform annually or at specified intervals, whichever comes first.
4. Change D.O.T. 4 brake fluid and flush system every two years.
5. Perform spoke tension check at the 1000, 5000, 20,000 mile (1600, 8000, 32000 kilometer) services and every 15,000 mile (24000 kilometer)
interval thereafter. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service manual.
6. Replace fork oil and inspect every 50,000 miles (80,000 kilometers).
7. Perform at each rear tire change.
Table 1-5. Quick Reference Maintenance Chart
DATA
SPECIFICATION
ITEM SERVICED
14-21 ft-lbs (19.0-28.5 Nm)
Drain plug torque
Engine oil and filter
4 qt. (3.8 L)
Oil capacity *
Hand tighten 1/2-3/4 turn after gasket contact
Filter
63798-99A
Chrome filter part number
63731-99A
Black filter part number
FORMULA+ TRANSMISSION AND PRIMARY
CHAIN LUBRICANT (Part No. 99851-05)
Lubricant type and capacity
Primary chain lubricant
or
SYN3 20W50 OIL (Part No. 99824-03/00QT)
Wet: 38 oz. (1124 ml)
Dry: 45 oz. (1331 ml)
14-21 ft-lbs (19.0-28.5 Nm)
Primary chaincase drain plug torque
1/2-1 turn
Adjuster screw free play
Clutch adjustment
72-120
in-lbs
(8.1-13.6 Nm)
Adjuster screw locknut torque
1/16-1/8 in. (1.6-3.2 mm)
Free play at hand lever
84-108
in-lbs
(9.5-12.2 Nm)
Clutch inspection cover torque
Dipstick at FULL with motorcycle on jiffy stand and
filler plug resting on threads.
Lubricant level
Transmission lubricant
FORMULA+ TRANSMISSION AND PRIMARY
CHAIN LUBRICATION (Part No. 99851-05)
Lubricant type and capacity
or
SYN3 20W50 OIL (Part No. 99824-03/00QT)
32 oz (0.95 liters)
14-21 ft-lbs (19.0-28.5 Nm)
Transmission drain plug torque
25-75
in-lbs
(2.8-8.5 Nm)
Transmission filler plug/dipstick torque
Front: 36 psi (248 kPA)
Pressure: solo rider or with passenger
Tire pressure and wear
Rear: 40 psi (276 kPA)
Replace if less than 1/32 in. (0.8 mm) of tread
pattern
Wear
55
in-lbs
(6.2 Nm) minimum
Spoke nipple torque
Wheel spokes
99953-99A (12 oz.)
D.O.T. 4 hydraulic brake fluid part number
Brake fluid level (Check
sight glass. If fluid is low,
remove reservoir cover
and re-check.)
Front: 0.20 in. (5.0 mm)
Rear: 0.26 in. (6.5 mm)
Fluid level (from top of master cylinder reservoir)
Front: 10-12
in-lbs
(1.1-1.4 Nm)
Master cylinder reservoir cover screw torque
Rear: 12-15
in-lbs
(1.4-1.7 Nm)
1-12 2011 Touring Service: Maintenance
Table 1-5. Quick Reference Maintenance Chart
DATA
SPECIFICATION
ITEM SERVICED
0.016 in. (0.4 mm)
Minimum brake pad thickness
Brake pads and discs
75-102
in-lbs
(8.5.-11.5 Nm)
Brake caliper pad pin torque
Front: 0.18 in. (4.5 mm)
Minimum brake disc thickness
Rear: 0.25 in. (6.3 mm)
0.008 in. (0.20 mm)
Maximum brake disc lateral runout (warpage)
10 lb. (4.5 kg)
Upward force applied at midpoint of bottom belt
strand
Drive belt deflection
3/8-7/16 in. (9.5-11.1 mm)
FLHR/C, FLHTC/U, FLHTK, FLTRU
1/4-5/16 in. (6.4-7.9 mm)
FLHX, FLTRX
108-132
in-lbs
(12.2-14.9 Nm)
Air cleaner cover bracket screw torque
Air cleaner
36-60
in-lbs
(4.1-6.8 Nm)
Air cleaner cover screw torque
LOCTITE MEDIUM STRENGTH THREADLOCKER
243 (BLUE)
Air cleaner cover screw Threadlocker
Part No. 99642-97 (6 ml)
Harley® Lube Part No. 94968-09
Lubricant part number
Clutch cable
35-45
in-lbs
(4.0-5.1 Nm)
Handlebar switch housing screw torque
HD-6R12
Type
Spark plugs
0.038-0.043 in. (0.97-1.09 mm)
Gap
12-18 ft-lbs (16.3-24.4 Nm)
Torque
See
Amount
Front fork oil
HYDRAULIC FORK OIL (TYPE E)
Type and part number
Part No. 99884-80 (16 oz.)
60-70
in-lbs
(6.8-7.9 Nm)
Terminal bolt torque
Battery
72-96
in-lbs
(8.1-10.9 Nm)
Top caddy screw torque
* Capacity is approximate. When changing oil, initially add 3.5 qt. (3.3 L). Run engine until warm. Check and fill as necessary.
Table 1-6. Lubricants, Greases, Sealants
PACKAGE
PART NUMBER
ITEM
1 oz squeeze tube
98960-97
SILVER GRADE ANTI-SEIZE
squeeze packet
42830-05 (included in master cylinder
rebuild kit)
CCI #20 Brake Grease
12 oz. bottle
99953-99A
D.O.T. 4 Brake Fluid
1 oz squeeze tube
99861-02
Electrical Contact Lubricant
1 qt bottle
99851-05
Genuine Harley-Davidson Formula+
Transmission and Primary Chaincase
Lubricant
1 qt bottle
99816-2050/00QT
Genuine Harley-Davidson
H-D 360 20W50 Oil
1 qt bottle
99813-09
Screamin' Eagle 20W50 Synthetic Blend
Motorcycle Engine Oil
1 qt bottle
99824-03/00QT
SYN3 20W50 Full Synthetic Oil
squeeze packet
42820-04
G40M Brake Grease
1.9 oz squeeze tube
99650-02
Gray High Performance Sealant
3.5 oz tube
99653-85
HYLOMAR Gasket and Thread Sealant
2011 Touring Service: Maintenance 1-13
Table 1-6. Lubricants, Greases, Sealants
PACKAGE
PART NUMBER
ITEM
6 ml squeeze tube
99818-97
Loctite Pipe Sealant With Teflon 565
Loctite Prism Primer (770)
Loctite Prism Superbonder (411)
Loctite Superbonder 420 Adhesive
6 ml squeeze tube
99642-97
Loctite Threadlocker 243 (blue)
6 ml squeeze tube
94759-99
Loctite Threadlocker 262 (red)
10 ml bottle
98618-03
Loctite Threadlocker 272
4 oz. bottle
94971-09
Screamin' Eagle Assembly Lube
14 oz. cartridge
99857-97
Special Purpose Grease
1/4 fl. oz
94968-09
Harley® Lube
16 oz bottle
99884-80
Type "E" Hydraulic Fork Oil
1-14 2011 Touring Service: Maintenance
1.6
ENGINE OIL AND FILTER
CHECKING OIL LEVEL
Check engine oil level at each complete fuel refill.
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)
Oil level cannot be accurately measured on a cold engine.
For pre-ride inspection, with motorcycle leaning on jiffy
stand on level ground, oil should register on dipstick
between arrows when engine is cold. Do not add oil to
bring the level to the FULL mark on a COLD engine.
(00185a)
Do not overfill oil tank. Doing so can result in oil carryover
to the air cleaner leading to equipment damage and/or
equipment malfunction. (00190a)
Oil Level Cold Check
1.
For pre-ride inspection, place vehicle on level ground and
rest the vehicle on its jiffy stand (unless sidecar is
attached).
2.
See
. Remove filler plug/dipstick and wipe off
the dipstick. Insert the dipstick and tighten into the fill
spout.
NOTE
The oil level marks for checking with motorcycle upright or on
jiffy stand are on the same side of the dipstick. Be sure to use
the correct portion of dipstick when checking oil level.
3.
See
. Remove the dipstick and verify the level
of the oil. The correct oil level should register midway (2)
between the FULL and ADD marks on the dipstick.
NOTE
If oil level is at or below the ADD mark, add only enough oil to
bring the level to the middle of the two marks on the dipstick.
Oil Level Hot Check
NOTES
•
The engine will require a longer warm up period in colder
weather.
•
Engine oil level hot check should be performed only when
engine is at normal operating temperature.
1.
Ride motorcycle until engine is at normal operating tem-
perature.
2.
Place vehicle on level ground and rest the vehicle on its
jiffy stand (unless sidecar is attached). Allow engine to
idle for 1-2 minutes. Turn engine off.
3.
See
. Remove filler plug/dipstick and wipe off
the dipstick. Insert the dipstick and tighten into the fill
spout.
NOTE
The oil level marks for checking with motorcycle upright or on
jiffy stand are on the same side of the dipstick. Be sure to use
the correct portion of dipstick when checking oil level.
4.
See
. Remove the dipstick and note the level
of the oil. The level should be between the ADD (1) and
FULL (3) marks. Add oil as necessary to bring the level
to the FULL mark on the dipstick. Do not overfill.
NOTE
Refer to
. Use only recommended oil specified in
1.3 FUEL AND OIL, Engine Lubrication
5.
Start engine and carefully check for oil leaks around drain
plug and oil filter.
sm05693
Figure 1-1. Engine Oil Filler Cap
1
3
2
sm05900
1. ADD QT (lower) mark
2. Cold check level
3. FULL (hot check) mark
Figure 1-2. Engine Oil Dipstick
2011 Touring Service: Maintenance 1-15
8
1
2
3
4
5
6
7
sm00068a
1. First gear
2. Second gear
3. Third gear
4. Fourth gear
5. Fifth gear
6. Sixth gear
7. Mainshaft
8. Countershaft
Figure 6-1. Transmission Power Flow
6-4 2011 Touring Service: Transmission
6.4
SHIFTER LINKAGE
SHIFTER ROD
The shifter rod is set at the factory and should not need
adjustment under normal circumstances. However, if full
engagement or full lever travel is not achieved, adjust the shifter
rod.
NOTE
To ensure proper gear engagement and avoid possible damage
to transmission, the shift levers should not contact the footboard
when shifting.
1.
See
. Remove locknut, lockwasher and flat
washer to free front end of shifter rod from inner shift arm.
2.
Loosen locknuts (1) and adjust rod (2) as necessary.
3.
Install flat washer, lockwasher and locknut to fasten front
end of shifter rod to inner shift arm.
4.
Tighten locknuts (1) to 80-120
in-lbs
(9.0-13.6 Nm).
1
1
2
sm03667
1. Locknut (2)
2. Shifter rod
Figure 6-2. Shifter Rod
2011 Touring Service: Transmission 6-5
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