Harley Davidson 2011 Touring Models. Service Manual — page 32
SUBJECT
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PAGE NO.
APPENDIX
C
ABS
C.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
C.2 ABS MODULE, Hydraulic Control Unit (HCU)
4.0-5.1 Nm
35-45
in-lbs
ABS ECU-to-HCU fastener
C.2 ABS MODULE, Electronic Control Unit (ECU)
4.0-5.1 Nm
35-45
in-lbs
ABS ECU-to-HCU fastener
C.2 ABS MODULE, Hydraulic Control Unit (HCU)
4.4-6.8 Nm
39-60
in-lbs
ABS module fastener
C.4 ABS BRAKE LINES, ABS Module to Front
Brake Calipers
23.1-25.8 Nm
17-19 ft-lbs
Banjo bleeder bolt to front calipers
C.2 ABS MODULE, Hydraulic Control Unit (HCU)
16.9-19.7 Nm
12.5-14.5 ft-lbs
Banjo bolt to ABS module
C.4 ABS BRAKE LINES, Front Master Cylinder to
ABS Module
16.9-19.7 Nm
12.5-14.5 ft-lbs
Banjo bolt to ABS module
C.4 ABS BRAKE LINES, ABS Module to Front
Brake Calipers
16.9-19.7 Nm
12.5-14.5 ft-lbs
Banjo bolt to ABS module
C.4 ABS BRAKE LINES, Rear Master Cylinder to
ABS Module
16.9-19.7 Nm
12.5-14.5 ft-lbs
Banjo bolt to ABS module
C.4 ABS BRAKE LINES, ABS Module to Rear
Brake Caliper
16.9-19.7 Nm
12.5-14.5 ft-lbs
Banjo bolt to ABS module
C.4 ABS BRAKE LINES, Front Master Cylinder to
ABS Module
16.9-19.7 Nm
12.5-14.5 ft-lbs
Banjo bolt to front master cylinder
C.4 ABS BRAKE LINES, ABS Module to Rear
Brake Caliper
23.1-25.8 Nm
17-19 ft-lbs
Banjo bolt to rear caliper
C.4 ABS BRAKE LINES, Rear Master Cylinder to
ABS Module
17.0-19.7 Nm
12.5-14.5 ft-lbs
Banjo bolt to rear master cylinder
C.4 ABS BRAKE LINES, Rear Master Cylinder to
ABS Module
9.0-11.3 Nm
80-100
in-lbs
Brake light switch bracket fastener
C.4 ABS BRAKE LINES, Front Master Cylinder to
ABS Module
2.3-3.4 Nm
20-30
in-lbs
Brake line bracket flange screw
C.4 ABS BRAKE LINES, ABS Module to Front
Brake Calipers
2.3-3.4 Nm
20-30
in-lbs
Brake line bracket flange screw
C.4 ABS BRAKE LINES, Rear Master Cylinder to
ABS Module
20-27 Nm
15-20 ft-lbs
Brake pedal shaft locknut
C.3 WHEEL SPEED SENSORS, Front Wheel
Speed Sensor
37.9-51.5 Nm
28-38 ft-lbs
Front brake caliper mounting screws
C.4 ABS BRAKE LINES, ABS Module to Front
Brake Calipers
13.6-20.3 Nm
120-180
in-lbs
Front brake line-to-lower fork bracket
fastener
C.4 ABS BRAKE LINES, Rear Master Cylinder to
ABS Module/Use Loctite Pipe Sealant with Teflon
565
16.3-20.3 Nm
12-15 ft-lbs
Rear brake light switch
C.4 ABS BRAKE LINES, Rear Master Cylinder to
ABS Module
14.2-17.0 Nm
126-150
in-lbs
Rear master cylinder-to-frame screws
2011 Touring Service: Appendix C ABS C-1
C.2
ABS MODULE
HYDRAULIC CONTROL UNIT (HCU)
TOOL NAME
PART NUMBER
DIGITAL TECHNICIAN II
HD-48650
BASIC VACUUM BRAKE BLEEDER
SNAP-ON BB200A
NOTE
The ABS module consists of the hydraulic control unit (HCU)
and the electronic control unit (ECU), each of which can be
serviced separately. Follow the procedure below to replace
the HCU or the entire ABS module assembly.
Removal
1.
Remove right side saddlebag. See
2.
Remove right side cover.
3.
Remove battery. See
NOTE
For
best
results,
use
the
BASIC
VACUUM
BRAKE
BLEEDER (Part No. Snap-On BB200A) or equivalent tool to
drain the brake systems.
4.
Drain brake systems.
5.
Disconnect ABS module electrical connector.
NOTE
Wrap banjo fittings with pieces of shop towel to absorb leakage
of residual brake fluid.
6.
See
. Remove four banjo bolts to release brake
lines from ABS module. Discard sealing washers.
This device is sensitive to electrostatic discharge (ESD).
Care must be taken to prevent exposure to ESD while
handling the electronic control unit (ECU) alone or when
mated to the hydraulic control unit (HCU). Always touch
the motorcycle frame or a grounded surface before hand-
ling. (00588b)
7.
See
. Remove three fasteners (3) to release
ABS module (2) from battery tray (1).
8.
Remove ABS module from motorcycle.
9.
Inspect three rubber mounts (5) for damage or deteriora-
tion. If replacement is necessary, proceed as follows:
a.
Remove bushing (4) from each side of rubber mount.
Remove rubber mount from battery tray.
b.
Install
new
rubber mount. Install bushing in each side
of rubber mount.
10. See
. Remove four fasteners (4) to separate
the HCU from the ECU.
1
2
3
4
sm06021
1. Front master cylinder-to-ABS module line
2. ABS module-to-front caliper line
3. ABS module-to-rear caliper line
4. Rear master cylinder-to-ABS module line
Figure C-1. ABS Module Connections
2
1
4
5
3
sm06014
1. Battery tray
2. ABS module
3. Fastener (3)
4. Bushing (6)
5. Rubber mount (3)
Figure C-2. ABS Module
C-2 2011 Touring Service: Appendix C ABS
Installation
This device is sensitive to electrostatic discharge (ESD).
Care must be taken to prevent exposure to ESD while
handling the electronic control unit (ECU) alone or when
mated to the hydraulic control unit (HCU). Always touch
the motorcycle frame or a grounded surface before hand-
ling. (00588b)
1.
See
. Install gasket (2) to ECU (3).
2.
Secure ECU to HCU using four fasteners (4). Tighten
fasteners to 35-45
in-lbs
(4.0-5.1 Nm).
3.
See
. Position ABS module (2) on battery tray
(1).
4.
Install three fasteners (3) and tighten to 39-60
in-lbs
(4.4-
6.8 Nm).
5.
See
. Install banjo fittings to their respective
ports on the ABS module using
new
sealing washers. Be
sure to route banjo fitting of brake line for front brake cal-
ipers beneath brake line from front master cylinder.
6.
Tighten banjo bolts to 12.5-14.5 ft-lbs (16.9-19.7 Nm).
7.
Connect ABS module electrical connector.
8.
Install battery. See
.
9.
If a
new
ABS module assembly or ABS module ECU were
installed, program the ECU using DIGITAL TECHNICIAN
II (Part No. HD-48650).
Any time the ABS module, either master cylinder, or any
line between a master cylinder and the ABS module is
disconnected or replaced, Digital Technician II must be
used during the brake bleeding procedure to verify all air
is removed from the system. Failure to do so could result
in air in the hydraulic brake system, reducing brake effi-
ciency, which could result in death or serious injury.
(00585b)
10. Fill and bleed brake systems. See
.
NOTE
For
best
results,
use
the
BASIC
VACUUM
BRAKE
BLEEDER (Part No. Snap-On BB200A) or equivalent tool.
11. To confirm that the brake systems are properly connected
and air is completely purged, install master cylinder
reservoir covers, connect motorcycle to DIGITAL TECH-
NICIAN II (Part No. HD-48650) and perform "ABS Service"
procedure.
12. Install right side cover.
13. Install right side saddlebag. See
After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
14. Operate motorcycle at low speeds and verify braking
systems operate properly.
ELECTRONIC CONTROL UNIT (ECU)
TOOL NAME
PART NUMBER
DIGITAL TECHNICIAN II
HD-48650
Removal
1.
Remove battery. See
NOTE
It is not necessary to remove the ABS module assembly to
replace the ABS ECU.
2.
Disconnect ABS module electrical connector.
This device is sensitive to electrostatic discharge (ESD).
Care must be taken to prevent exposure to ESD while
handling the electronic control unit (ECU) alone or when
mated to the hydraulic control unit (HCU). Always touch
the motorcycle frame or a grounded surface before hand-
ling. (00588b)
3.
See
. Remove four fasteners (4) and separate
ECU (3) from HCU (1).
2
3
4
1
sm06015
1. Hydraulic control unit (HCU)
2. Gasket
3. Electrical control unit (ECU)
4. Fastener (4)
Figure C-3. ABS Module Components
2011 Touring Service: Appendix C ABS C-3
Installation
This device is sensitive to electrostatic discharge (ESD).
Care must be taken to prevent exposure to ESD while
handling the electronic control unit (ECU) alone or when
mated to the hydraulic control unit (HCU). Always touch
the motorcycle frame or a grounded surface before hand-
ling. (00588b)
1.
See
. Install gasket (2) to ECU (3).
2.
Secure ECU to HCU using four fasteners (4). Tighten
fasteners to 35-45
in-lbs
(4.0-5.1 Nm).
3.
Install battery. See
.
4.
If a
new
ABS module ECU was installed, program the
ECU using DIGITAL TECHNICIAN II (Part No. HD-48650).
C-4 2011 Touring Service: Appendix C ABS
C.3
WHEEL SPEED SENSORS
FRONT WHEEL SPEED SENSOR
Removal
1.
Road King and Fork mounted fairing models:
Turn
front wheel to right fork stop. Reach under headlamp
nacelle or fairing cap (as equipped) on left side of steering
head and disconnect front wheel speed sensor connector.
Draw connector down through opening.
2.
Frame mounted fairing models:
Turn front wheel to right
fork stop. Gently pull cable to draw front wheel speed
sensor connector out left side of fairing bracket. Disconnect
connector.
3.
Cut cable straps to release front wheel speed sensor cable
from brake hose.
4.
See
. Release front wheel speed sensor cable
from clip as follows:
a.
Push on lip (1) at rear of clip to disengage from
bracket. Rotate tab (2) (stamped ABS) rearward until
clip is perpendicular to bracket and remove cable.
NOTE
If clip is not installed as described below, tab can slip out
of slot in bracket. If this occurs, remove caliper mounting
screws to release bracket from fork slider and then install
tab in slot. Install bracket and tighten screws to 28-38 ft-
lbs (37.9-51.5 Nm).
b.
Rotate tab (2) forward until clip is aligned with bracket
and apply pressure to tab until lip (1) engages.
5.
Retract axle until front wheel speed sensor is free. See
.
NOTE
The wheel speed sensor works in conjunction with the ABS
encoder bearing installed in the wheel hub. If necessary, see
for removal and installation
instructions.
Installation
NOTES
•
Always keep the wheel speed sensor away from magnetic
fields (such as magnetic parts trays, magnetic base dial
indicators, alternator rotors, etc.) or damage will occur.
Never pull wheel speed sensor cable taut or use to retain
wheel, axle or other components.
•
Install wheel speed sensor with index pin on the out-board
side or sensor will be damaged during installation.
1.
Push axle through
new
front wheel speed sensor and left
fork slider.
2.
Secure front wheel. See
. Be sure to
rotate front wheel speed sensor until index pin makes
contact with shoulder on fork slider as shown in
.
3.
Route wheel speed sensor cable up to lower fork bracket
following brake hose.
4.
Road King and Fork mounted fairing models:
Turn
front wheel to right fork stop. Feed connector up through
opening in front of lower fork bracket and connect to socket
housing.
5.
Frame mounted fairing models:
Turn front wheel to right
fork stop. Connect front wheel speed sensor connector
and feed connector under main harness conduit into left
side of fairing bracket.
6.
Secure the sensor cable and fender tip lamp wires using
three
new
cable straps as follows:
a.
On the brake hose lower crimp capturing front wheel
speed sensor cable and brake hose.
b.
Approximately midway between the upper and lower
brake hose crimps capturing front wheel speed sensor
cable, brake hose and front fender tip lamp wires, if
equipped.
c.
Approximately 2.5 in. (63.5 mm) below the brake hose
upper crimp capturing front wheel speed sensor cable,
brake hose and front fender tip lamp wires, if
equipped.
7.
See
. Install front wheel speed sensor cable in
clip as follows:
a.
Push on lip (1) at rear of clip to disengage from
bracket. Rotate tab (2) (stamped ABS) rearward until
clip (1) is perpendicular to bracket and install cable.
b.
Rotate tab (2) forward and apply pressure until lip (1)
engages. Gently tug on cable to verify that clip is
properly installed.
1
2
sm04204
1. Push lip to disengage
2. Push tab to engage
Figure C-4. Front Wheel Speed Sensor Cable Clip
2011 Touring Service: Appendix C ABS C-5
sm04027
Figure C-5. Front Wheel Speed Sensor Index Pin
REAR WHEEL SPEED SENSOR
Removal
1.
Remove right saddlebag. See
.
2.
Remove right side cover.
3.
Release rear wheel speed sensor connector from anchor
on right side battery tray. Disconnect connector.
4.
Rear wheel speed sensor cable and rear brake hose are
secured to the rear fork with two cable retainers. The
sensor cable is additionally secured to the brake hose with
a conduit clip. Free rear wheel speed sensor cable from
all three.
5.
Retract axle until rear wheel speed sensor is free. See
.
NOTE
The wheel speed sensor works in conjunction with the ABS
encoder bearing installed in the wheel hub. If necessary, see
for removal and installation
instructions.
Installation
NOTES
•
Always keep the wheel speed sensor away from magnetic
fields (such as magnetic parts trays, magnetic base dial
indicators, alternator rotors, etc.) or damage will occur.
Never pull wheel speed sensor cable taut or use to retain
wheel, axle or other components.
•
Install wheel speed sensor with index pin on the out-board
side or sensor will be damaged during installation.
1.
See
. Hold
new
rear wheel speed sensor in
place with index pin outboard toward rear fork, and push
axle through sensor, caliper bracket and right side of rear
fork.
2.
Secure rear wheel. See
. Rotate rear
wheel speed sensor until index pin makes contact with
caliper bracket at point shown in
3.
Route rear wheel speed sensor cable forward along top
of rear fork.
4.
Capture rear wheel speed sensor cable and brake hose
in rear cable clips on top of rear fork. Secure cable to brake
hose with conduit clip placed 1.25 in. (31.8 mm) ahead of
the rear brake hose crimp.
5.
Route cable to outboard right side of battery caddy. Con-
nect pin and socket housings and secure to anchor.
6.
Install right side cover.
7.
Install right saddlebag. See
sm04028
Figure C-6. Rear Wheel Speed Sensor Index Pin
C-6 2011 Touring Service: Appendix C ABS
C.4
ABS BRAKE LINES
FRONT MASTER CYLINDER TO ABS
MODULE
TOOL NAME
PART NUMBER
DIGITAL TECHNICIAN II
HD-48650
Removal
1.
Remove right side saddlebag. See
2.
Remove right side cover.
3.
Remove fuel tank. See
.
4.
Remove top caddy. See
5.
Road King models:
Remove right side headlamp nacelle.
See
2.44 HEADLAMP NACELLE: ROAD KING MODELS
.
6.
Fork mounted fairing models:
Remove outer fairing and
fairing cap. See
SHIELD: FORK MOUNTED FAIRING MODELS
and
, respectively.
7.
Frame mounted fairing models:
Remove bezel. See
2.39 INSTRUMENT BEZEL: FRAME MOUNTED FAIRING
MODELS
.
8.
Cut cable strap to release brake line from right handlebar
riser or right handlebar.
9.
See
. Cut cable strap (1) to release brake lines
(2, 3) from brake line bracket at right side of steering head.
10. See
. Release brake lines (2, 3) from wire trough
(1).
NOTE
Wrap banjo fittings with pieces of shop towel to absorb any
loss of brake fluid.
11. See
. Remove banjo bolt to release brake line
(1) from MF port of ABS module. Discard sealing washers.
12. Remove cover from master cylinder reservoir.
13. Remove banjo bolt to release brake line from master cyl-
inder reservoir. Hold suitable container under banjo bolt
bore to allow reservoir to drain. Discard sealing washers.
14. Remove brake line from motorcycle.
1
2
3
sm06019
1. Cable strap
2. Front master cylinder-to-ABS module line
3. ABS module-to-front caliper line
Figure C-7. Brake Line Bracket
2
1
3
sm06020
1. Wire trough
2. Front master cylinder-to-ABS module line
3. ABS module-to-front caliper line
Figure C-8. Brake Line Routing
2011 Touring Service: Appendix C ABS C-7
1
2
3
4
sm06021
1. Front master cylinder-to-ABS module line
2. ABS module-to-front caliper line
3. ABS module-to-rear caliper line
4. Rear master cylinder-to-ABS module line
Figure C-9. ABS Module Connections
Installation
1.
Position brake line along right side of wire trough with rear
banjo fitting adjacent to ABS module.
2.
Feed front section of brake line forward along right side
of steering head, past upper fork bracket, and to master
cylinder.
3.
Start banjo bolt with
new
sealing washers to secure brake
line to master cylinder.
4.
Start banjo bolt with
new
sealing washers to secure brake
line to MF port of ABS module.
5.
Secure brake line as follows:
a.
Road King and Frame mounted fairing models:
Loosely install
new
cable strap to secure handlebar
switch harness and brake hose to right handlebar
riser.
b.
Fork mounted fairing models:
Install
new
cable
strap 2.5 in. (63.5 mm) rear of fairing cap opening to
secure handlebar switch harness and brake line to
right handlebar.
6.
See
. Be sure lines are routed as shown and
secure with
new
cable strap (1) to brake line bracket at
right side of steering head.
NOTE
If installing new brake line bracket, tighten flange screw to
20-30 in-lbs (2.3-3.4 Nm).
7.
See
. Secure brake lines to wire trough.
8.
Tighten master cylinder banjo bolt to 12.5-14.5 ft-lbs (16.9-
19.7 Nm).
9.
Tighten ABS module banjo bolt to 12.5-14.5 ft-lbs (16.9-
19.7 Nm).
Any time the ABS module, either master cylinder, or any
line between a master cylinder and the ABS module is
disconnected or replaced, Digital Technician II must be
used during the brake bleeding procedure to verify all air
is removed from the system. Failure to do so could result
in air in the hydraulic brake system, reducing brake effi-
ciency, which could result in death or serious injury.
(00585b)
10. Fill and bleed brake system. See
.
11. To confirm that brake system is properly connected and
that all air is purged, connect motorcycle to DIGITAL
TECHNICIAN II (Part No. HD-48650) and perform "ABS
Service" procedure.
12.
Road King models:
Install right side headlamp nacelle.
See
2.44 HEADLAMP NACELLE: ROAD KING MODELS
13.
Fork mounted fairing models:
Install outer fairing and
fairing cap. See
SHIELD: FORK MOUNTED FAIRING MODELS
and
, respectively.
14.
Frame mounted fairing models:
Install bezel. See
2.39 INSTRUMENT BEZEL: FRAME MOUNTED FAIRING
MODELS
15. Install top caddy. See
16. Install fuel tank. See
17. Install right side cover.
18. Install right saddlebag. See
ABS MODULE TO FRONT BRAKE CALIPERS
TOOL NAME
PART NUMBER
DIGITAL TECHNICIAN II
HD-48650
Removal
1.
Remove right side saddlebag. See
.
2.
Remove right side cover.
3.
Remove fuel tank. See
4.
Remove top caddy. See
5.
Road King models:
Remove left side headlamp nacelle.
See
2.44 HEADLAMP NACELLE: ROAD KING MODELS
6.
Fork mounted fairing models:
a.
Remove
outer
fairing
and
fairing
cap.
See
2.34 UPPER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS
and
respectively.
b.
Remove front turn signal lamps or auxiliary lamps as
equipped. See
or
7.13 AUXILIARY LAMPS AND BRACKETS
.
c.
Remove chrome skirt.
C-8 2011 Touring Service: Appendix C ABS
7.
Frame mounted fairing models:
No disassembly
required.
8.
Cut three cable straps to release front wheel speed sensor
cable and front fender tip lamp wires (if equipped) from
left caliper brake hose.
9.
Cut cable strap to release brake line from right handlebar
riser or right handlebar.
10. See
. Cut cable strap (1) to release brake lines
(2, 3) from brake line bracket at right side of steering head.
11. Remove fastener securing front brake lines to the lower
fork bracket.
NOTE
Wrap banjo fittings with pieces of shop towel to absorb any
loss of brake fluid.
12. See
. Remove banjo bolt to release brake line
(2) from F port of ABS module. Discard sealing washers.
13. Remove banjo bleeder bolts to release brake lines to cal-
ipers. Discard sealing washers.
14. Pull brake line forward to remove from motorcycle.
Installation
1.
Feed brake line rearward below lower fork bracket and
along right side of steering head and wire trough.
2.
Secure caliper brake lines to lower fork bracket. Verify that
brake lines are equal distance from the left and right fork
sliders and that the crimp joints can not touch the fender.
Tighten fastener to 120-180
in-lbs
(13.6-20.3 Nm).
3.
Start banjo bleeder bolts with
new
sealing washers to
secure brake lines to calipers.
4.
See
. Route banjo fitting (2) under brake line
(1) and start banjo bolt with
new
sealing washers to secure
brake line to F port of ABS module.
5.
Secure brake line as follows:
a.
Road King and Frame mounted fairing models:
Loosely install
new
cable strap to secure handlebar
switch harness and brake hose to right handlebar
riser.
b.
Fork mounted fairing models:
Install
new
cable
strap 2.5 in. (63.5 mm) rear of fairing cap opening to
secure handlebar switch harness and brake line to
right handlebar.
6.
See
. Route lines as shown and secure with
new
cable strap (1) to brake line bracket at right side of
steering head.
NOTE
If installing new brake line bracket, tighten flange screw to
20-30 in-lbs (2.3-3.4 Nm).
7.
See
. Secure brake lines to wire trough.
8.
Tighten caliper banjo bleeder bolts to 17-19 ft-lbs (23.1-
25.8 Nm).
9.
Tighten ABS module banjo bolt to 12.5-14.5 ft-lbs (16.9-
19.7 Nm).
10. Secure the sensor cable and fender tip lamp wires using
three
new
cable straps as follows:
a.
On the brake hose lower crimp capturing front wheel
speed sensor cable and brake hose.
b.
Approximately midway between the upper and lower
brake hose crimps capturing front wheel speed sensor
cable, brake hose and front fender tip lamp wires, if
equipped.
c.
Approximately 2.5 in. (63.5 mm) below the brake hose
upper crimp capturing front wheel speed sensor cable,
brake hose and front fender tip lamp wires, if
equipped.
11. Fill and bleed brake system. See
.
12. To confirm that brake system is properly connected and
that all air is purged, connect motorcycle to DIGITAL
TECHNICIAN II (Part No. HD-48650) and perform "ABS
Service" procedure.
13.
Road King models:
Install left side headlamp nacelle.
See
2.44 HEADLAMP NACELLE: ROAD KING MODELS
14.
Fork mounted fairing models:
a.
Install chrome skirt. Do not capture brake line between
chrome skirt and front of steering head, as it may
become pinched or kinked when handlebar is turned.
Route brake line above chrome skirt as shown in
.
b.
Install front turn signal lamps or auxiliary lamps as
equipped. See
or
7.13 AUXILIARY LAMPS AND BRACKETS
.
c.
Install outer fairing and fairing cap. See
FAIRING AND WINDSHIELD: FORK MOUNTED
FAIRING MODELS
and
, respectively.
15. Install top caddy. See
16. Install fuel tank. See
17. Install right side cover.
18. Install right side saddlebag. See
.
sm04556
Figure C-10. Route Brake Line to Front Calipers Above
Chrome Skirt
2011 Touring Service: Appendix C ABS C-9
REAR MASTER CYLINDER TO ABS
MODULE
TOOL NAME
PART NUMBER
DIGITAL TECHNICIAN II
HD-48650
Removal
1.
Remove right side saddlebag. See
2.
Remove right side cover.
3.
Remove right side rider footboard. See
4.
See
. Free brake line from electrical harness
conduit clips (6).
5.
Remove terminals from rear brake light switch (4).
6.
Remove fastener (5) securing brake light switch bracket
to frame.
7.
Remove cable strap near middle frame downtube.
NOTE
Wrap banjo fittings with pieces of shop towel to absorb any
loss of brake fluid.
8.
See
. Remove banjo bolt (4) to release brake
line from MR port of ABS module. Discard sealing
washers.
9.
See
. Remove socket terminals from rear brake
light switch (4). Cut cable strap to free rear brake light
switch wires from lower frame tube, if necessary.
10. Remove fastener (5).
11. Stand motorcycle upright so rear master cylinder reservoir
is level.
NOTE
To prevent dirt and other contaminants from entering the master
cylinder reservoir, thoroughly clean the cover before removal.
12. Remove cover from master cylinder reservoir.
NOTE
Wrap banjo fittings with pieces of shop towel to absorb any
loss of brake fluid.
13. Remove banjo bolt (12) from master cylinder reservoir.
Hold suitable container under banjo bolt bore to allow
reservoir to drain. Discard sealing washers (11).
14. Using a clean shop cloth, wipe out any remaining fluid in
the master cylinder reservoir.
15. Remove screws (10) securing master cylinder to frame.
16. Remove locknut (8) with flat washer (7) and pull brake
pedal/master cylinder assembly from pedal shaft. Remove
and discard O-rings (9).
17. Remove brake line from motorcycle.
1
2
3
4
sm06021
1. Front master cylinder-to-ABS module line
2. ABS module-to-front caliper line
3. ABS module-to-rear caliper line
4. Rear master cylinder-to-ABS module line
Figure C-11. ABS Module Connections
C-10 2011 Touring Service: Appendix C ABS
1
2
3
4
6
5
8
7
9
9
11
10
12
sm06028
7.
1.
Flat washer
Sealing washers
2.
8.
Banjo bolt
Locknut
9.
3.
O-ring
Cable clips
4.
10.
Rear brake light switch
Fastener
11.
5.
Sealing washers
Fastener
6.
12.
Electrical harness conduit clips
Banjo bolt
Figure C-12. Rear ABS Brake Line Assembly
Installation
1.
Place rear brake line into approximate position along top
of lower right frame tube. From area of brake lamp switch,
feed brake line hose upward, inboard of downtube and
toward ABS module.
2.
See
. Start banjo bolt with
new
sealing
washers to secure brake line (4) to MR port of ABS
module.
NOTE
If installing new rear brake light switch, apply Loctite Pipe
Sealant with Teflon 565 to threads and start switch into rear
brake line. Using flats on switch, tighten to 12-15 ft-lbs (16.3-
20.3 Nm).
3.
See
. Align locating tab on brake light switch
bracket with slot in frame. Install fastener (5) and tighten
to 80-100
in-lbs
(9.0-11.3 Nm).
4.
Connect terminals onto rear brake light switch (4). If
removed, install
new
cable strap to secure rear brake light
switch wires.
2011 Touring Service: Appendix C ABS C-11
5.
Capture rear brake line to electrical harness conduit clips
(6).
6.
Apply a light coat of Wheel Bearing Grease (Part No.
99855-89) to the brake pedal shaft and bore. Install
new
O-rings (9) on each side of bore.
7.
Install brake pedal/master cylinder assembly on the pedal
shaft. Install flat washer (7) and
new
locknut (8) on pedal
shaft.
8.
Fasten master cylinder to frame. Tighten screws (10) to
126-150
in-lbs
(14.2-17.0 Nm).
9.
Tighten brake pedal shaft locknut (8) to 15-20 ft-lbs (20-
27 Nm).
10. Secure brake line to master cylinder reservoir using
new
sealing washers. Tighten banjo bolt (12) to 12.5-14.5 ft-
lbs (17.0-19.7 Nm).
11. Tighten banjo bolt to ABS module to 12.5-14.5 ft-lbs (16.9-
19.7 Nm).
Any time the ABS module, either master cylinder, or any
line between a master cylinder and the ABS module is
disconnected or replaced, Digital Technician II must be
used during the brake bleeding procedure to verify all air
is removed from the system. Failure to do so could result
in air in the hydraulic brake system, reducing brake effi-
ciency, which could result in death or serious injury.
(00585b)
12. Fill and bleed brake system. See
.
13. To confirm that brake system is properly connected and
all air is purged, install master cylinder reservoir cover,
connect motorcycle to DIGITAL TECHNICIAN II (Part
No. HD-48650) and perform "ABS Service" procedure in
the "Toolbox" menu.
14. Install right side rider footboard. See
.
15. Install right side cover.
16. Install right side saddlebag. See
ABS MODULE TO REAR BRAKE CALIPER
TOOL NAME
PART NUMBER
DIGITAL TECHNICIAN II
HD-48650
Removal
1.
Remove right side saddlebag. See
.
2.
Remove right side cover.
3.
See
. Free rear brake line hose from cable
clips (3) on rear fork.
4.
Remove conduit clip securing rear wheel speed sensor
cable to brake hose.
NOTE
Wrap banjo fittings with pieces of shop towel to absorb any
loss of brake fluid.
5.
See
. Remove banjo bolt to release brake line
(3) from R port of ABS module. Discard sealing washers.
6.
See
. Remove banjo bolt (2) from rear brake
caliper. Discard sealing washers (1).
7.
Remove brake line from channel on front of battery tray.
8.
Remove brake line from motorcycle.
Installation
1.
Place rear brake line into approximate position along top
of rear fork and up toward ABS module. Secure brake line
into channel on front of battery tray.
2.
See
. Capture rear brake line hose in two cable
clips (3) on rear fork.
3.
See
. Install banjo bolt (3) with
new
sealing
washers and tighten to 12.5-14.5 ft-lbs (16.9-19.7 Nm).
4.
See
. Install banjo bolt (2) with
new
sealing
washers and tighten to 17-19 ft-lbs (23.1-25.8 Nm).
5.
Install
new
conduit clip 1.25 in. (31.8 mm) in front of the
rear brake hose crimp capturing rear wheel speed sensor
cable to brake hose.
6.
Fill and bleed brake system. See
.
7.
To confirm that brake system is properly connected and
all air is purged, connect motorcycle to DIGITAL TECHNI-
CIAN II (Part No. HD-48650) and perform "ABS Service"
procedure.
8.
Install right side cover.
9.
Install right side saddlebag. See
.
C-12 2011 Touring Service: Appendix C ABS
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
APPENDIX
D
CONVERSIONS
D.1
METRIC CONVERSION
CONVERSION TABLE
Table D-1. Metric Conversions
INCHES to MILLIMETERS
(IN x 25.40 = MM)
MILLIMETERS to INCHES
(MM x 0.03937 = IN)
mm
in
mm
in
mm
in
mm
in
in
mm
in
mm
in
mm
in
mm
84.14
3-5/16
49.21
1-15/16
15.240
.6
.025
.001
3.582
91
2.283
58
.9842
25
.0039
.1
85.72
3-3/8
50.80
2
15.875
5/8
.051
.002
3.622
92
2.323
59
1.024
26
.0078
.2
86.36
3.4
52.39
2-1/16
17.462
11/16
.076
.003
3.661
93
2.362
60
1.063
27
.0118
.3
87.31
3-7/16
53.34
2.1
17.780
.7
.102
.004
3.701
94
2.401
61
1.102
28
.0157
.4
88.90
3-1/2
53.97
2-1/8
19.050
3/4
.127
.005
3.740
95
2.441
62
1.142
29
.0197
.5
90.49
3-9/16
55.56
2-3/16
20.320
.8
.152
.006
3.779
96
2.480
63
1.181
30
.0236
.6
91.44
3.6
55.88
2.2
20.638
13/16
.178
.007
3.819
97
2.519
64
1.220
31
.0275
.7
92.07
3-5/8
57.15
2-1/4
22.225
7/8
.203
.008
3.858
98
2.559
65
1.260
32
.0315
.8
93.66
3-11/16
58.42
2.3
22.860
.9
.229
.009
3.897
99
2.598
66
1.299
33
.0354
.9
93.98
3.7
58.74
2-5/16
23.812
15/16
.254
.010
3.937
100
2.638
67
1.338
34
.0394
1
95.25
3-3/4
60.32
2-3/8
25.40
1
.397
1/64
3.976
101
2.677
68
1.378
35
.0787
2
96.52
3.8
60.96
2.4
26.99
1-1/16
.508
.020
4.016
102
2.716
69
1.417
36
.1181
3
96.84
3-13/16
61.91
2-7/16
27.94
1.1
.762
.030
4.055
103
2.756
70
1.456
37
.1575
4
98.42
3-7/8
63.50
2-1/2
28.57
1-1/8
.794
1/32
4.094
104
2.795
71
1.496
38
.1968
5
99.06
3.9
65.09
2-9/16
30.16
1-3/16
1.016
.040
4.134
105
2.834
72
1.535
39
.2362
6
100.01
3-15/16
66.04
2.6
30.48
1.2
1.270
.050
4.173
106
2.874
73
1.575
40
.2756
7
101.6
4
66.67
2-5/8
31.75
1-1/4
1.524
.060
4.212
107
2.913
74
1.614
41
.3149
8
102.19
4-1/16
68.26
2-11/16
33.02
1.3
1.588
1/16
4.252
108
2.953
75
1.653
42
.3543
9
104.14
4.1
68.58
2.7
33.34
1-5/16
1.778
.070
4.291
109
2.992
76
1.693
43
.3937
10
104.77
4-1/8
69.85
2-3/4
34.92
1-3/8
2.032
.080
4.331
110
3.031
77
1.732
44
.4331
11
106.36
4-3/16
71.12
2.8
35.56
1.4
2.286
.090
4.370
111
3.071
78
1.772
45
.4724
12
106.68
4.2
71.44
2-13/16
36.51
1-7/16
2.540
.1
4.409
112
3.110
79
1.811
46
.5118
13
107.95
4-1/4
73.02
2-7/8
38.10
1-1/2
3.175
1/8
4.449
113
3.149
80
1.850
47
.5512
14
109.22
4.3
73.66
2.9
39.69
1-9/16
4.762
3/16
4.488
114
3.189
81
1.890
48
.5905
15
109.54
4-5/16
74.61
2-15/16
40.64
1.6
5.080
.2
4.527
115
3.228
82
1.929
49
.6299
16
111.12
4-3/8
76.20
3
41.27
1-5/8
6.350
1/4
4.567
116
3.268
83
1.968
50
.6693
17
111.76
4.4
77.79
3-1/16
42.86
1-11/16
7.620
.3
4.606
117
3.307
84
2.008
51
.7086
18
112.71
4-7/16
78.74
3.1
43.18
1.7
7.938
5/16
4.645
118
3.346
85
2.047
52
.7480
19
114.30
4-1/2
79.37
3-1/8
44.45
1-3/4
9.525
3/8
4.685
119
3.386
86
2.086
53
.7874
20
115.89
4-9/16
80.96
3-3/16
45.72
1.8
10.160
.4
4.724
120
3.425
87
2.126
54
.8268
21
116.84
4.6
81.28
3.2
46.04
1-13/16
11.112
7/16
4.764
121
3.464
88
2.165
55
.8661
22
117.47
4-5/8
82.55
3-1/4
47.62
1-7/8
12.700
1/2
4.803
122
3.504
89
2.205
56
.9055
23
119.06
4-11/16
83.82
3.3
48.26
1.9
14.288
9/16
4.842
123
3.543
90
2.244
57
.9449
24
2011 Touring Service: Appendix D Conversions D-1
D.2
FLUID CONVERSIONS
UNITED STATES SYSTEM
Unless otherwise specified, all fluid volume measurements in
this service manual are expressed in United States (U.S.) units-
of-measure. See below:
•
1 pint (U.S.) = 16 fluid ounces (U.S.)
•
1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.)
•
1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.)
METRIC SYSTEM
Fluid volume measurements in this service manual include the
metric system equivalents. In the metric system, 1 liter (L) =
1,000 milliliters (mL). Should you need to convert between U.S.
units-of-measure and metric units-of-measure, refer to the fol-
lowing:
•
fluid ounces (U.S.) x 29.574 = milliliters
•
pints (U.S.) x 0.473 = liters
•
quarts (U.S.) x 0.946 = liters
•
gallons (U.S.) x 3.785 = liters
•
milliliters x 0.0338 = fluid ounces (U.S.)
•
liters x 2.114 = pints (U.S.)
•
liters x 1.057 = quarts (U.S.)
•
liters x 0.264 = gallons (U.S.)
BRITISH IMPERIAL SYSTEM
Fluid volume measurements in this service manual do not
include the British Imperial (Imp.) system equivalents. The fol-
lowing conversions exist in the British Imperial system:
•
1 pint (Imp.) = 20 fluid ounces (Imp.)
•
1 quart (Imp.) = 2 pints (Imp.)
•
1 gallon (Imp.) = 4 quarts (Imp.)
Although the same unit-of-measure terminology as the U.S.
system is used in the British Imperial (Imp.) system, the actual
volume of each British Imperial unit-of-measure differs from its
U.S. counterpart. The U.S. fluid ounce is larger than the British
Imperial fluid ounce. However, the U.S. pint, quart, and gallon
are smaller than the British Imperial pint, quart, and gallon,
respectively. Should you need to convert between U.S. units
and British Imperial units, refer to the following:
•
fluid ounces (U.S.) x 1.042 = fluid ounces (Imp.)
•
pints (U.S.) x 0.833 = pints (Imp.)
•
quarts (U.S.) x 0.833 = quarts (Imp.)
•
gallons (U.S.) x 0.833 = gallons (Imp.)
•
fluid ounces (Imp.) x 0.960 = fluid ounces (U.S.)
•
pints (Imp.) x 1.201 = pints (U.S.)
•
quarts (Imp.) x 1.201 = quarts (U.S.)
•
gallons (Imp.) x 1.201 = gallons (U.S.)
D-2 2011 Touring Service: Appendix D Conversions
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