Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual — page 5

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1

sm03096

7.

1.

Gasket

Screw

2.

8.

Air cleaner cover

Backplate

9.

3.

Breather hose (2)

Seal ring

4.

10.

Screw (3)

Air cleaner assembly: oval

11.

5.

Air cleaner assembly: round

Bracket

6. Filter element

Figure 1-6. Air Cleaner Assembly

INSTALLATION

TORQUE VALUE

FASTENER

4.5-6.8 Nm

40-60

in-lbs

Air cleaner bracket screws

4.1-6.8 Nm

36-60

in-lbs

Air cleaner cover screw

1.

See

Figure 1-7

. Position

new

gasket on backplate.

2.

Oval air cleaner:

See

Figure 1-8

. Insert two breather

hoses into the holes in back of the filter element and place
the element back into position. Attach breather hoses to
breather screws on backplate.

3.

Round air cleaner:

Place filter element back into position

on backplate and then insert two breather hoses into the
holes on front of the filter element. Place breather hoses
on breather screws on backplate.

4.

See

Figure 1-6

. Install air filter element and bracket.

a.

Make sure gasket holes are aligned with backplate
holes.

b.

Use three screws (4) to secure bracket and filter ele-
ment. Tighten to 40-60

in-lbs

(4.5-6.8 Nm).

5.

Install air filter cover (2).

a.

Apply a drop of LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to threads
of air cleaner cover screw (1).

b.

Install air cleaner cover using screw. Tighten to 36-60

in-lbs

(4.1-6.8 Nm).

HOME

2013 Softail Service: Maintenance 1-19

sm02454a

Figure 1-7. Gasket (Typical)

sm02455

Figure 1-8. Breather Tubes on Backside of Filter

EXHAUST SYSTEM LEAK CHECK

Check the exhaust system for leaks at every scheduled service
interval as follows:

1.

Check entire exhaust system for loose or missing
fasteners, fractured pipe clamps or brackets and obvious
signs of leakage (carbon tracks at pipe joints, etc.).

2.

Check for loose or fractured heat shields. Repair or replace
as necessary.

3.

Start engine, cover muffler ends with clean, dry shop
towels and listen for audible signs of exhaust leakage.

4.

Correct any leaks detected.

Exhaust System Leakage

If an exhaust system leak is evident at a muffler or header pipe
connection, disassemble and clean all mating surfaces. See

4.17 EXHAUST SYSTEM

.

•

Replace any damaged components and assemble.

•

If leak continues, disassemble and apply Permatex Ultra
Copper or LOCTITE 5920 FLANGE SEALANT. If not
available, use an equivalent oxygen sensor/catalyst-safe
alternative.

•

Assemble components. Wipe off any excess sealant.

•

Follow sealant product instructions and allow adequate
curing time before operating vehicle.

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1-20 2013 Softail Service: Maintenance

1.8

TIRES AND WHEELS

GENERAL

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)

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)

Install new seal before mounting tire. Riding motorcycle
without seal in place can sever valve stem causing rapid
air loss leading to the loss of control, which could result
in death or serious injury. (00622b)

Always maintain proper tire pressure as specified in

Table 1-7

.

Do not load tires beyond GAWR specified in

Table 2-4

and

Table 2-5

. Underinflated, over-inflated or overloaded tires can

fail.

Use only tires listed in

Table 1-7

.

NOTE

ABS equipped motorcycles must always use properly inflated
tires and wheels that are the same as the original equipment.
The ABS system 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 effect its ability to detect and prevent lockups.

Operating with inflation pressure other than those specified in

Table 1-7

can reduce ABS performance.

TIRES

Use only Harley-Davidson specified tires. See a Harley-
Davidson dealer. Using non-specified tires can adversely
affect stability, handling or braking, which could result in
death or serious injury. (00024b)

NOTES

•

Tubeless tires are used on all Harley-Davidson cast and
disc wheels, and tubeless profile laced wheels with MTM
designation.

•

Tire sizes are molded on the tire sidewall. Inner tube sizes
are printed on the tube.

•

New tires should be stored on a horizontal tire rack. Avoid
stacking new tires in a vertical stack. The weight of the
stack compresses the tires and closes down the beads.

Check tire pressure and tread:

•

As part of the pre-ride inspection.

•

At every scheduled service interval.

1.

Inspect each tire for punctures, cuts and breaks.

2.

Inspect each tire for wear. Replace tires before they reach
the tread wear indicator bars.

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)

NOTE

Missing indicator wear bars represent less than 1/32 in. (0.8
mm) tread pattern depth remaining.

3.

Check for proper front and rear tire pressures when tires
are cold. Compare results against

Table 1-7

.

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.

Table 1-7. Specified Tires

PRESSURE (COLD)

SPECIFIED TIRE

SIZE

MOUNT

MODEL

kPa

psi

248

36

Dunlop D402F MT90B16

16 in

front

FLSTC, FLS

248

36

Dunlop D402F MT90B16

16 in

front

FLSTN, FLSTC (whitewall)

248

36

Dunlop D408F 140/75R17

17 in

front

FLSTF, FLSTFB

207

30

Dunlop D408F MH90-21

21 in

front

FXST

HOME

2013 Softail Service: Maintenance 1-21

Table 1-7. Specified Tires

PRESSURE (COLD)

SPECIFIED TIRE

SIZE

MOUNT

MODEL

kPa

psi

207

30

Dunlop D402F MH90-21

21 in

front

FXS

248

36

Dunlop D408F 130/60B21

21 in

front

FXSB

276

40

Dunlop D401 150/80B16

16 in

rear

FLSTC

276

40

Dunlop D402 MU85B16

16 in

rear

FLSTN, FLSTC (whitewall)

276

40

Dunlop D402 MU85B16

16 in

rear

FXS, FLS

290

42

Dunlop D407 200/55R17

17 in

rear

FLSTF, FXST, FLSTFB

290

42

Dunlop D407 240/40R18

18 in

rear

FXSB

TIRE REPLACEMENT

Inspection

Replace tire immediately with a Harley-Davidson specified
tire when wear bars become visible or only 1/32 in (0.8
mm) tread depth remains. Riding with a worn tire could
result in death or serious injury. (00090c)

Harley-Davidson tires are equipped with wear bars that run
horizontally across the tread. When a tire is worn to the point
that the wear bars are visible, or 1/32 in. (0.8 mm) tread depth
remains, the tire can:

•

Be more easily damaged leading to tire failure.

•

Provide reduced traction.

•

Adversely affect stability and handling.

Arrows on tire sidewalls pinpoint location of wear bar indicators.

When To Replace Tires

New

tires are needed if any of the following conditions exist:

1.

Tread wear indicator bars become visible on the tread
surfaces.

2.

Tire cords or fabric become visible through cracked side-
walls, snags or deep cuts.

3.

A bump, bulge or split in the tire.

4.

Puncture, cut or other damage to the tire that cannot be
repaired.

NOTES

•

When installing tires on rims, do not rely on tread design
to determine direction of rotation. Always be sure the
rotational arrows molded into the sidewalls point in the
direction of rotation when the vehicle is moving forward.

•

Never install a tire and inner tube on a laced rim with
TUBELESS and MTM designations etched into the rim.
These rims are specially designed for tubeless use only.

•

Replace rim strip and rim seal whenever the tire is
removed.

WHEEL BEARINGS

NOTE

Replace bearings in sets only. See

2.8 SEALED WHEEL

BEARINGS

.

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 finger while
they are in the wheel.

b.

Rotate the inner bearing race and check for abnormal
noise.

c.

Make sure bearing rotates smoothly.

3.

Check wheel bearings and axle spacers for wear and
corrosion. Excessive play or roughness indicates worn
bearings.

WHEEL SPOKES

TOOL NAME

PART NUMBER

SPOKE TORQUE WRENCH

HD-48985

SPOKE NIPPLE WRENCH

HD-94681-80

TORQUE VALUE

FASTENER

6.2 Nm

55

in-lbs

Spoke nipple

Spokes that are too tight can draw nipples through the rim
or distort hub flanges. Spokes that are too loose can
continue to loosen when put in service. Either condition
can adversely affect stability and handling, which could
result in death or serious injury. (00286a)

Do not over tighten spoke nipples. Protruding spoke
nipples can damage rim seal, resulting in rapid tire defla-
tion, which could cause death or serious injury. (00611b)

HOME

1-22 2013 Softail Service: Maintenance

Countershaft

NOTES

•

If removing countershaft without removing the mainshaft,
hold countershaft 3rd and 4th gear shift dog up while
pressing countershaft out of bearing housing bearings.

•

Do not press directly on the end of the countershaft. Place
a spacer such as a washer between the end of the coun-
tershaft and the press ram.

1.

Press countershaft out of bearing housing bearings.

2.

See

6.8 TRANSMISSION CASE

for bearing housing

bearing replacement.

3.

See

Figure 6-18

. Remove washer (1), countershaft 1st

gear (2) and bearing.

NOTE

See

Figure 6-19

. Note the direction that the 2nd gear locking

ring is installed.

4.

Remove countershaft 2nd gear lock ring.

5.

See

Figure 6-20

. Remove securing segments (1). Remove

dog ring (3), guiding hub (2), countershaft 2nd gear (4)
and bearing.

2

1

sm03020a

1. Washer
2. Countershaft 1st gear

Figure 6-18. Countershaft 1st Gear

sm03021

Figure 6-19. Lock Ring

1

4

1

2

3

sm03022

1. Securing segment
2. Guiding hub
3. Dog ring
4. Countershaft 2nd gear

Figure 6-20. Securing Segment

NOTE

See

Figure 6-21

. Note the direction that the 3rd gear locking

ring is installed.

6.

Remove countershaft 3rd gear lock ring.

7.

See

Figure 6-22

. Remove securing segments (1), internal

spline washer (2), countershaft 3rd gear (3) and bearing.

NOTE

See

Figure 6-23

. Note the direction that the 4th gear locking

ring is installed.

8.

Remove 4th gear lock ring (1), securing segments, dog
ring (3), guiding hub (2) and countershaft 4th gear (4) and
bearing.

HOME

6-16 2013 Softail Service: Transmission

NOTE

The countershaft 5th gear and 6th gear are integral parts of
the shaft. Damage to either gear requires countershaft
replacement.

sm03023

Figure 6-21. Third Gear Lock Ring

1

2

3

1

sm03024

1. Securing segment
2. Internal spline washer
3. Countershaft 3rd gear

Figure 6-22. Countershaft Third Gear

4

2

3

1

sm03025a

1. 4th gear lock ring
2. Guiding hub
3. Dog ring
4. Countershaft 4th gear

Figure 6-23. Countershaft Assembly

Removing Bearing Housing Bearings

NOTE

Always replace bearing housing bearing if the shaft is pressed
out.

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)

1.

See

Figure 6-24

. Remove the retaining rings (1).

2.

Press the bearings out of the bearing housing.

HOME

2013 Softail Service: Transmission 6-17

8

7

6

5

4

3

2

1

sm02582

1. Locknut (2)
2. Retaining ring (2)
3. Bearing (2)
4. Bearing housing
5. Bearing housing gasket
6. O-ring
7. Transmission dipstick
8. Transmission case

Figure 6-24. Bearing Housing Bearings

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 with solvent. Dry parts with low pressure
compressed air.

2.

Check gear teeth for damage. Replace gears that are
pitted, scored, rounded, cracked or chipped.

3.

Inspect the engaging dogs and pockets on the dog rings.
Replace the dog rings if dogs and/or pockets are rounded,
battered or chipped.

4.

Inspect guiding hubs. Replace guiding hubs if splines are
rounded, battered or chipped.

5.

Inspect shift fork shafts. Replace if bent or damaged.

6.

Inspect shift forks for wear or signs of overheating.
Replace a shift fork if it is excessively worn or shows signs
of overheating.

7.

See

Figure 6-25

. Using a small square, verify the shift

forks are square. If shift fork does not rest directly on the
square, then it is bent and must be replaced.

8.

Inspect shift drum and bearing. Replace shift drum
assembly if drum or bearing are damaged.

9.

Clean shift cam lock plate mounting holes in transmission
bearing housing.

10. Inspect bearing housing bearings. Bearings must rotate

freely without drag. Replace the bearings if pitted, grooved
or if the shafts were removed.

sm03006

Figure 6-25. Checking Fork

ASSEMBLY

TOOL NAME

PART NUMBER

TRANSMISSION SHAFT RETAINING
RING PLIERS

J-5586A

TORQUE VALUE

FASTENER

115.3-128.8

Nm

85-95 ft-lbs

Mainshaft/countershaft nuts

13.6-17.0 Nm

120-150

in-lbs

Shift drum detent arm fastener

6.4-7.1 Nm

57-63

in-lbs

Shift drum lock plate fasteners

Installing Bearing Housing Bearings

NOTES

•

Always replace bearing housing bearing if the shaft was
pressed out.

•

Always use a plate to support the bearing housing when
pressing in bearings.

•

When pressing new bearings into bearing housing, press
on the outside diameter of the bearing side with the num-
bers stamped on it.

1.

Support the bearing housing from the opposite side at the
bearing bores with a flat plate.

2.

Position

new

bearing over bore with number side UP.

3.

Press the outer diameter of the bearing until the bearing
seats in the bore.

HOME

6-18 2013 Softail Service: Transmission