Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual — page 15
2.20
REAR FORK
REMOVAL
1.
Remove the rear wheel, rear brake caliper, and caliper
mounting bracket. See
2.
Remove the belt guard. See
3.
All But FXSB:
See
. Remove bolt (1) from
splash guard (2). Lift up on lower tabs and pull lower end
of splash guard rearward. Remove splash guard from rear
fork.
4.
FXSB:
Pull splash guard away from rear fork.
5.
Remove the rear shock absorber bolts and washers (8)
only. See
NOTE
When removing pivot shaft, make note of spacer position on
each side of transmission. Spacers differ slightly in length from
each other and must be installed on the same side from which
they were removed. Refer to
6.
Remove pivot shaft (4) and two spacers (11, 12). Remove
the two bushings (10) inside the spherical bearings (7).
The rear fork can now be removed from the frame.
2013 Softail Service: Chassis 2-73
7
6
2
15
1
3
4
8
11
12
5
9
10
10
7
6
14
13
sm03250b
11.
6.
1.
Spacer, left
Retaining ring (2)
Bolt: all but FXSB (2)
2.
12.
7.
Splash guard
Spacer, right
Bearing (2)
8.
3.
13.
Bolt and washer (2)
Rear fork
Pivot shaft nut
14.
9.
4.
Washer
Rear shock (2)
Pivot shaft
5.
15.
10.
Washer
Jounce bumper
Bushing (2)
Figure 2-84. Rear Fork
CLEANING AND INSPECTION
The spherical bearings are lifetime lubricated. No further
attention other than cleaning is required. The sleeve type
spherical bearings, if not damaged, will last the life of the
motorcycle.
Clean the bearing bore with a clean shop towel, removing any
dirt or grit adhering to the bearing surface.
Rough check the rear fork for correct alignment. Replace the
rear fork if bent.
PIVOT BEARING REPLACEMENT
1.
Remove the rear fork from the vehicle. See
NOTE
The retaining ring fits into a machined groove on the bearing
and can be removed with the bearing.
2-74 2013 Softail Service: Chassis
2.
Press out the fork pivot bearing with a suitable driver from
the center of the fork toward the outside.
3.
Install a
new
retaining ring onto a
new
bearing.
4.
Position the bearing assembly against the outboard side
of the rear fork pivot boss with the retaining ring outboard.
5.
Press the bearing assembly into the rear fork pivot boss
using a suitable driver.
6.
Repeat for the other side.
7.
Install rear fork on vehicle. See
INSTALLATION
TORQUE VALUE
FASTENER
122-149 Nm
90-110 ft-lbs
Pivot shaft nut
1.
See
. Install jounce bumper (15), if removed.
2.
Place rear fork (3) in the frame so that the bores in the
frame align with the bores in the fork. Insert the bushings
(10) into the spherical bearings (7) from the inside.
3.
Install pivot shaft (4).
a.
Apply ANTI-SEIZE LUBRICANT to pivot shaft.
NOTE
Spacers differ slightly in length from each other and must
be installed on the same side from which they were
removed. Spacers are identified by the number of
machined lines. Refer to
.
b.
From the right side, install pivot shaft (4) and spacers
(11, 12) with spacer collars facing transmission case.
c.
Apply LOCTITE 262 HIGH STRENGTH THREAD-
LOCKER AND SEALANT (red) to threads of pivot
shaft nut. Install and tighten pivot shaft nut to 90-110
ft-lbs (122-149 Nm).
NOTE
Proper pivot shaft tightening is important to maintain rear fork
alignment.
4.
Check for freedom of rotation of the rear fork around the
bearings and that the fork and frame side members have
not been distorted when the pivot shaft nut was tightened.
5.
Install the evaporative canister (California models). See
4.19 EVAPORATIVE EMISSIONS CONTROL SYSTEM
.
6.
Install splash guard (2). Install bolts (1), if equipped.
7.
Install caliper mounting bracket, rear wheel and brake
caliper. See
8.
Install both rear shock absorbers (9) using bolts and
washers (8). See
.
Table 2-18. Transmission Spacer Sizes
NUMBER OF
MACHINED
LINES
MM
IN.
VEHICLE
LEFT OR RIGHT
SIDE
2
49.43
1.946
Left side
1
39.85
1.569
Right side
2013 Softail Service: Chassis 2-75
2.21
THROTTLE CONTROL
REMOVAL/DISASSEMBLY
1.
See
. Loosen cable adjuster jamnuts (1). Screw
throttle cable adjuster until it is as short as possible.
Remove the two screws that hold the handlebar housing
together to separate the upper and lower housings.
2.
Unhook the ferrules and cables from the throttle grip and
lower housing.
3.
Remove air cleaner assembly. See
.
4.
Disconnect throttle cables from induction module. See
4.11 INDUCTION MODULE, Removal
5.
See
. Pull the cables from the housing by pla-
cing a drop of oil on the retaining ring that holds the cable
in the housing, then firmly pull the bent tubing portion of
the cable out of the housing using a rocking motion.
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.
Wash all components in non-flammable cleaning solvent.
Blow parts dry with low pressure compressed air.
2.
Replace the control cables if frayed, kinked or bent.
3.
Put one or two drops of oil into the housing of each control
cable.
ASSEMBLY/INSTALLATION
TORQUE VALUE
FASTENER
4.0-5.1 Nm
35-45
in-lbs
Throttle control housing
screws
1.
Apply a light coating of graphite to the handlebar and
inside surface of the housings.
2.
See
. Attach the control cable assemblies to
the lower housing.
a.
Push the silver insert of the throttle cable (1) housing
into the hole in front of the tension adjuster screw.
b.
Push the gold diameter insert of the idle cable (5)
housing into the hole at the rear of the tension adjuster
screw.
c.
Install adjusting screw, spring and friction pad in the
lower housing if they were removed.
3.
Position the throttle grip on the handlebar. Place the lower
housing on the throttle. Position the ferrules and retaining
rings over the cable balls and seat them in the throttle
notches.
1
2
sm03254
1. Adjuster jamnuts
2. Colored inserts
Figure 2-85. Handlebar Throttle Control
5
4
3
2
1
sm01084a
1. Throttle cable (silver insert, front hole)
2. Groove in throttle grip
3. Notch
4. Brass ferrule
5. Idle cable (gold insert, rear hole)
Figure 2-86. Throttle Cable Attachment
Do not tighten throttle friction adjustment screw to the
point where the engine will not return to idle automatically.
Over-tightening can lead to loss of vehicle control, which
could result in death or serious injury. (00031b)
4.
Fasten upper housing to lower housing using two screws.
Tighten to 35-45
in-lbs
(4.0-5.1 Nm).
Pinched throttle cables can restrict throttle response,
which could result in loss of control and death or serious
injury. (00423b)
2-76 2013 Softail Service: Chassis
5.
Make sure throttle cables are routed below the handlebars
and behind the fork bracket. They continue under the fuel
tank through two cable clamps and back to throttle body.
6.
Install
throttle
cables
on
induction
module.
See
4.11 INDUCTION MODULE, Installation
.
7.
Adjust throttle cables. See
.
8.
Install air cleaner. See
.
2013 Softail Service: Chassis 2-77
2.22
CLUTCH CONTROL
REMOVAL
1.
Loosen clutch adjuster so clutch cable is fully slack. See
.
2.
See
. Remove the retaining ring (2) and pivot
pin (4). Remove the clutch cable anchor pin (1) from the
hand lever.
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)
3.
Drain transmission lubricant and remove fill plug dipstick.
Remove transmission side cover. See
.
4.
See
. Note position of retaining ring (1)
opening. Retaining ring opening must be positioned in
approximately the same location during assembly. Remove
retaining ring.
5.
Pull inner ramp (2) and ramp coupling (3) out of side cover.
Hold inner and outer ramps together to keep balls from
falling free.
6.
Rotate the inner ramp to a position which will allow the
coupling to be disconnected from the inner ramp lever
arm. Disconnect coupling from inner ramp. Disconnect
cable end (4) from coupling.
7.
Back out threaded cable fitting (5) from side cover.
INSTALLATION
1.
See
. Insert anchor pin (1) through handle and
clutch cable clevis (3).
2.
Place handle in bracket and install pivot pin (4) and
retaining ring (2).
3.
Check that clutch cable is properly routed.
a.
Route clutch cable across the front of handlebars for
the following model: FXST. Route clutch cable behind
handlebars for the following models: FLSTF/B,
FLSTC, FLSTN.
b.
Route cable down to clamp on left frame downtube.
c.
Route cable under engine mount spacer, gear cover,
and through bracket.
d.
Route cable to transmission cover.
4.
See
. Install
new
O-ring on end of clutch cable
threads. Apply a drop of LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT (blue) to
clutch cable fitting and screw fitting into clutch release
cover. Do not tighten at this time.
5.
Connect cable end to ramp coupling (3). Rotate ramps for
best access and install coupling on inner ramp (2). Place
ramp assembly in position in side cover.
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
6.
Install retaining ring (1). Position retaining ring opening to
the right of the outer ramp tang (the stop that prevents
rotation).
7.
Place
new
gasket on side cover and install, fully tightening
the clutch cable fitting. See
8.
Place a few drops of oil inside cable housing.
NOTE
Anchor pin does not require lubrication.
9.
Adjust clutch cable. See
.
3
1
4
2
sm02481
1. Anchor pin
2. Retaining ring
3. Clevis
4. Pivot pin
Figure 2-87. Clutch Cable Installation
2-78 2013 Softail Service: Chassis
1
3
2
5
4
sm03259
1. Retaining ring
2. Inner ramp
3. Ramp coupling
4. Clutch cable
5. Cable fitting
Figure 2-88. Clutch Cable Connection
2013 Softail Service: Chassis 2-79
2.23
HANDLEBARS: FLSTC, FLSTN, FLS, FXST
REMOVAL
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
2.
Place blanket or protective cover over front of fuel tank to
protect against scratches and other damage.
3.
Remove front master cylinder, right handlebar switch
assembly, and throttle. See
4.
Remove clutch control and left handlebar switch assembly.
See
7.37 LEFT HANDLEBAR CONTROL MODULE
NOTE
Original equipment grip is glued in place and must be cut off.
Remove grip only if necessary.
5.
Remove left handlebar grip.
6.
See
. Remove upper handlebar clamp
fasteners (2).
a.
FLSTC/FXST:
remove upper handlebar clamp (4).
b.
FLSTN/FLS:
remove upper handlebar clamp (3).
7.
Remove handlebar (1).
8.
If removing lower handlebar clamps (6), remove two lower
handlebar clamp fasteners (13), lockwashers (12), and
lower handlebar clamps from upper fork bracket (10).
Replace bushings (8) if necessary.
5
7
8
10
8
11
12
13
9
6
3
4
2
1
sm03252b
1. Handlebar
2. Upper handlebar clamp fastener (4)
3. Upper handlebar clamp (FLSTN/FLS)
4. Upper handlebar clamp (FLSTC/FXST)
5. Wire harness retainer (4)
6. Lower handlebar clamp (2)
7. Upper cup washer (2)
8. Bushing (2)
9. Spacer (2)
10. Upper fork bracket (typical)
11. Lower cup washer (2)
12. Lockwasher (2)
13. Lower handlebar clamp fastener (2)
Figure 2-89. Handlebars: All but FLSTF/FLSTFB/FXS
2-80 2013 Softail Service: Chassis
INSTALLATION
TORQUE VALUE
FASTENER
16.3-20.3 Nm
12-15 ft-lbs
Handlebar clamp rear
fasteners: FLSTC, FLSTN,
FLS, FXST
16.3-20.3 Nm
12-15 ft-lbs
Handlebar clamp front
fasteners: FLSTC, FLSTN,
FLS, FXST
40.7-54.3 Nm
30-40 ft-lbs
Handlebar clamp fasteners,
lower: FLSTC, FLSTN, FLS,
FXST
1.
See
. If lower handlebar clamps (6) were
removed, install lockwashers (12) on lower handlebar
clamp fasteners (13).
NOTE
In next step, make sure cup washers (7, 11), bushings (8) and
spacer (9) are in position in upper fork bracket (10).
2.
Slide lower handlebar clamp fasteners through upper fork
bracket.
3.
Loosely install lower handlebar clamps to upper fork
bracket using lower handlebar clamp fasteners.
4.
See
. Place handlebars on lower handlebar
clamps. Install upper handlebar clamps. Install but do not
tighten clamp fasteners.
5.
Using knurled areas of handlebar as a guide, center
handlebars between lower handlebar clamps.
NOTE
On some models, knurled areas of handlebar will be completely
hidden by upper handlebar clamp and will not be visible at all
when handlebar is centered properly.
6.
Raise handlebars to normal riding position and hold in
position.
7.
Secure handlebars in clamp:
a.
Hand tighten two front screws (4).
b.
Tighten rear fasteners (3) to 12-15 ft-lbs (16.3-20.3
Nm).
c.
Final tighten two front screws (4) to 12-15 ft-lbs (16.3-
20.3 Nm). Slight gap between upper and lower clamps
should exist at front.
8.
See
. Tighten lower handlebar clamp fasteners
(15) to 30-40 ft-lbs (40.7-54.3 Nm).
9.
Install right and left switch assemblies, throttle control,
clutch lever assembly, and front master cylinder assembly.
See
7.36 RIGHT HANDLEBAR CONTROL MODULE
and
7.37 LEFT HANDLEBAR CONTROL MODULE
.
10. Test front brake lever for pressure and operation.
11. Test throttle for correct operation. Adjust as required. See
12. Install main fuse.
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)
13. Install seat.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
14. Turn the ignition/light key switch to IGNITION and test
lights and switches for proper operation.
15. Apply brake lever to test stop light lamp.
1
2
3
5
4
sm03256
1. Lower clamp (2)
2. Cast-in spacers (2)
3. Rear screw (2)
4. Front screw (2)
5. Upper clamp
Figure 2-90. Handlebar Riser
2013 Softail Service: Chassis 2-81
2.24
HANDLEBARS: FLSTF/B
REMOVAL
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
2.
See
. Remove acorn nut (1) and washer (2).
3.
Remove instrument console and allow to hang off the left
side. Suspend console using an elastic cord or piece of
small rope to prevent strain on the harness.
4.
Unplug fuel gauge connector located under the fuel tank.
5.
Remove fuel tank fasteners, vent hose, and fuel supply
fitting. Slide fuel tank back to access electrical connectors.
See
6.
Place blanket or protective cover over front of fuel tank to
protect against scratches and other damage.
7.
Disconnect all left and right side hand control connectors
from main harness.
NOTE
Make note of wire colors and locations in connector before
removal to aid during installation.
8.
Identify wire locations and remove terminals from hand
control connector housings (left hand control connector
[24], right hand control connector [22]). See
for connector informa-
tion.
9.
Remove terminals from turn signal lamp multilock con-
nector. See
A.20 TYCO 070 MULTILOCK UNSEALED
for connector information.
10. Remove front master cylinder, right handlebar switch
assembly, and throttle. See
11. Remove clutch control and left handlebar switch assembly.
See
7.37 LEFT HANDLEBAR CONTROL MODULE
NOTE
Original equipment grip is glued in place and must be cut off
to remove. Remove grip only if necessary.
12. Remove left handlebar grip.
13. Remove switch housings, turn signals and wiring from
handlebars.
14. See
. Remove upper handlebar clamp
fasteners (2) and upper handlebar clamps (3).
15. Remove handlebars.
16. If removing lower handlebar clamps (4), remove two lower
handlebar clamp fasteners (12), lockwashers (11), washers
(10), and lower handlebar clamps from upper fork bracket
(8).
2
1
sm02750a
1. Acorn nut
2. Washer
Figure 2-91. Instrument Console
2-82 2013 Softail Service: Chassis
1
3
4
5
8
6
9
10
6
11
12
7
2
sm03257a
1. Handlebar
2. Upper handlebar clamp fastener (4)
3. Upper handlebar clamp
4. Lower handlebar clamp (2)
5. Upper cup washer (2)
6. Bushing (2)
7. Spacer (2)
8. Upper fork bracket
9. Lower cup washer (2)
10. Washer
11. Lockwasher (2)
12. Lower handlebar clamp fastener (2)
Figure 2-92. Handlebars: FLSTF/B
INSTALLATION
TORQUE VALUE
FASTENER
16.3-24.4 Nm
12-18 ft-lbs
Handlebar upper clamp
fasteners; FLSTF/B
40.7-54.2 Nm
30-40 ft-lbs
Handlebar lower clamp
fastener; FLSTF/B
NOTE
The turn signal wires enter the switch housings through a relief
grommet in the housing. The turn signals must be supported
throughout this procedure to prevent pulling the grommet or
the turn signal wires out of the housing.
1.
Repair or replace switches, turn signal switches, wires
and grommets as necessary.
NOTE
For handlebar switch repair procedures, see
.
2.
Wrap wire ends and open ends of conduit with electrical
tape.
3.
Cut a length of mechanics wire to use as a leader.
4.
Lay mechanics wire along the wire harnesses so a few
inches overlap and secure using electrical tape.
5.
If necessary, replace grommets on handlebars wire
openings.
6.
Lubricate wire conduits with glass cleaner.
7.
See
. Thread the wire leaders through the
handlebar grommets and out the center hole.
8.
Pull wire bundles through to the handlebar center hole.
9.
Loosely install left and right switch housings.
10. Pull slack from wire harnesses and remove the tape and
mechanics wire.
2013 Softail Service: Chassis 2-83
sm03258
Figure 2-93. Wire Leader in Handlebars (handlebars
removed from motorcycle)
11. See
. If lower handlebar clamps (4) were
removed, install washers (10), and lockwashers (11) on
lower handlebar clamp fasteners (12).
12. Slide lower handlebar clamp fasteners through upper fork
bracket (8).
13. Loosely install lower handlebar clamps to upper fork
bracket using lower handlebar clamp fasteners.
14. Place handlebars (1) on lower handlebar clamps. Install
upper handlebar clamps (3). Install but do not tighten
clamp fasteners.
15. Insert wires into proper locations in wire connector hous-
ings. See
for connector/wire
assignments.
16. Connect left and right hand control connectors [22, 24].
17. Connect turn signal connector [31].
18. Slide fuel tank into position and install fuel tank fasteners.
Connect vent hose and fuel supply fitting. See
.
19. Connect fuel gauge connector [117].
20. Install instrument console and secure with washer and
acorn nut.
21. Using knurled areas of handlebar as a guide, center
handlebars between lower handlebar clamps.
NOTE
On some models, knurled areas of handlebar will be completely
hidden by upper handlebar clamp when handlebar is centered
properly.
22. Raise handlebars to normal riding position and hold in
position.
NOTE
Gap between upper and lower clamps should be equal front
and rear.
23. Tighten front and rear fasteners to 12-18 ft-lbs (16.3-24.4
Nm).
24. See
. Remove one lower handlebar clamp
fastener (12). Apply LOCTITE 262 HIGH STRENGTH
THREADLOCKER AND SEALANT (red) to fastener
threads.
25. Install fastener and tighten to 30-40 ft-lbs (40.7-54.2 Nm).
Repeat for other fastener.
2
2
1
sm03982b
1. Clamping surface
2. Range marks
Figure 2-94. Left Hand Control Assembly to Handlebar
Alignment
2-84 2013 Softail Service: Chassis
1
2
2
sm04496a
1. Clamping surface
2. Range marks
Figure 2-95. Right Hand Control Assembly to Handlebar
Alignment
NOTE
See
or
. When installing left and right
handlebar switch assemblies, make sure that clamping surface
(1) stays within the range marks (2) or damage to the wires
will occur.
26. Install clutch control, front master cylinder, left handlebar
switch assembly, and right handlebar switch assembly.
Align housings and tighten fasteners. See
or
.
27. Install main fuse.
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)
28. Install seat.
29. Test throttle for correct operation. Adjust as required. See
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
30. Turn the ignition/light key switch to IGNITION and test
lights and switches for proper operation.
31. Apply brake lever to test stop light lamp.
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)
32. Test front brake lever for pressure and operation.
2013 Softail Service: Chassis 2-85
2.25
HANDLEBARS: FXS
REMOVAL
NOTE
Handlebars are not adjustable. There is a flat above the
threaded shaft to prevent rotation.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
2.
See
. Remove console.
3.
Remove fuel tank fasteners, vent hose, fuel supply fitting
and fuel pump connector. Slide fuel tank back to access
electrical connectors. See
.
4.
Place blanket or protective cover over front of fuel tank to
protect against scratches and other damage.
5.
See
7.37 LEFT HANDLEBAR CONTROL MODULE
and
7.36 RIGHT HANDLEBAR CONTROL MODULE
. Discon-
nect all left and right side hand control connectors from
main harness. It is not necessary to remove connectors
from wiring.
6.
Remove front master cylinder, right handlebar switch
assembly, and throttle. See
7.
Remove clutch control and left handlebar switch assembly.
See
7.37 LEFT HANDLEBAR CONTROL MODULE
NOTE
Original equipment grip is glued in place and must be cut off
to remove. Remove grip only if necessary.
8.
Remove left handlebar grip.
9.
Remove switch housings, turn signals and wiring from
handlebars.
NOTE
See
. Nut (4) is a one time use only nut. If it is
removed, it must be replaced.
10. Remove nut (4) and washer (3) securing handlebar (1) to
upper fork bracket (2).
11. Remove handlebars.
1
5
6
2
3
4
sm07162a
1. Handlebar (right side shown)
2. Upper fork bracket
3. Washer
4. Nut
5. Flat on handlebar
6. Flat on bracket
Figure 2-96. Handlebar: FXS
INSTALLATION
TORQUE VALUE
FASTENER
122-149 Nm
90-110 ft-lbs
Handlebar nut: FXS
1.
Repair or replace switches, turn signal switches and wires
as necessary.
NOTE
For handlebar switch repair procedures, see
.
2.
See
. Line up flat on handlebar (5) with flat on
upper fork bracket (6). Insert handlebar into fork bracket.
NOTE
Do not reuse nut (4). Use only a new nut.
3.
Install washer (3) and
new
nut (4). Tighten nut to 90-110
ft-lbs (122-149 Nm).
4.
Wrap wire ends and open ends of conduit with electrical
tape.
5.
Cut a length of mechanics wire to use as a leader.
6.
Lay mechanics wire along the wire harnesses so a few
inches overlap and secure using electrical tape.
7.
Lubricate wire conduits with glass cleaner or isopropyl
alcohol.
8.
Thread the wire leaders through the handlebar grommets
and out the hole.
9.
Pull wire bundles through to the handlebar hole.
10. Loosely install left and right switch housings.
2-86 2013 Softail Service: Chassis
11. Pull slack from wire harnesses and remove the tape and
mechanics wire.
12. Connect left and right hand control connectors [22, 24].
13. Connect turn signal connector [31].
14. Slide fuel tank into position and install fuel tank fasteners.
Connect vent hose and fuel supply fitting. See
.
15. Install console. See
.
2
2
1
sm03982b
1. Clamping surface
2. Range marks
Figure 2-97. Left Hand Control Assembly to Handlebar
Alignment
1
2
2
sm04496a
1. Clamping surface
2. Range marks
Figure 2-98. Right Hand Control Assembly to Handlebar
Alignment
NOTE
See
or
. When installing left and right
handlebar switch assemblies, make sure that clamping surface
(1) stays within the range marks (2) or damage to the wires
will occur.
16. Install clutch control, front master cylinder, left handlebar
switch assembly, and right handlebar switch assembly.
Align housings and tighten fasteners. See
or
.
17. Install main fuse.
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)
18. Install seat.
19. Test throttle for correct operation. Adjust as required. See
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
20. Turn the ignition/light key switch to IGNITION and test
lights and switches for proper operation.
21. Apply brake lever to test stop light lamp.
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)
22. Test front brake lever for pressure and operation.
2013 Softail Service: Chassis 2-87
2.26
HANDLEBARS: FXSB
REMOVAL
Handlebars
NOTE
Note conduit routing and the location of cable straps for
assembly.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
2.
See
. Remove console.
3.
Remove fuel tank fasteners, vent hose, fuel supply fitting
and fuel pump connector. Slide fuel tank back to access
electrical connectors. See
.
4.
Place blanket or protective cover over front of fuel tank to
protect against scratches and other damage.
5.
See
7.37 LEFT HANDLEBAR CONTROL MODULE
and
7.36 RIGHT HANDLEBAR CONTROL MODULE
. Discon-
nect all left and right side hand control connectors from
main harness. It is not necessary to remove connectors
from wiring.
6.
Remove front master cylinder, right handlebar switch
assembly, and throttle. See
7.
Remove clutch control and left handlebar switch assembly.
See
7.37 LEFT HANDLEBAR CONTROL MODULE
NOTE
Original equipment grip is glued in place and must be cut off
to remove. Remove grip only if necessary.
8.
Remove left handlebar grip.
9.
See
. Remove upper handlebar clamp
fasteners (2).
10. Remove the handlebar.
Lower Handlebar Clamps
1.
See
. Remove two lower handlebar clamp
fasteners (10), washers (9), cup washers (8) and lower
bushings (7).
2.
Remove lower handlebar clamps (3).
3.
Remove upper spacers (6), bushings (5) and upper cup
washers (4).
INSTALLATION
TORQUE VALUE
FASTENER
16.3-21.7 Nm
12-16 ft-lbs
Handlebar clamp front
fasteners
16.3-21.7 Nm
12-16 ft-lbs
Handlebar clamp rear
fasteners
40.7-54.3 Nm
30-40 ft-lbs
Lower handlebar clamp
fasteners
Lower Clamp
1.
See
. Install lower bushings (7), spacers (6),
upper bushings (5) and upper cup washers (4) in upper
fork bracket.
2.
Install washers (9) and lower cup washers (8) on lower
handlebar clamp fasteners (10).
3.
Install lower handlebar clamps and finger tighten lower
handlebar clamp fasteners.
2-88 2013 Softail Service: Chassis
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