Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual — page 17
ASSEMBLY
1.
See
for tail lamp assembly.
2.
See
7.18 TURN SIGNALS AND RUNNING LIGHTS
for
turn signal bracket assembly.
NOTE
See
. If fender support (16) has been removed,
do not tighten luggage rack hardware until rest of fender has
been installed.
3.
Assemble fender:
a.
Place fender support (16) into position in fender (9).
b.
Install but do not tighten luggage rack hardware. See
4.
Install fender support covers (1) using fender mounting
fasteners (4). Snug but do not fully tighten fasteners at
this time.
INSTALLATION
TORQUE VALUE
FASTENER
28.5-36.6 Nm
21-27 ft-lbs
Fender, rear, support
fasteners, upper: FLSTN
40.7-47.5 Nm
30-35 ft-lbs
Fender, rear, support
fasteners, lower-front, 1st
torque: FLSTN
51.5-56.9 Nm
38-42 ft-lbs
Fender, rear, support
fasteners, lower-front, final
torque: FLSTN
1.
See
. Carefully place the fender into position.
Install fender supports using hardware and brackets
shown.
a.
Tighten fasteners (3, 4) to 21-27 ft-lbs (28.5-36.6 Nm).
b.
Tighten fasteners (2) to an initial torque of 30-35 ft-
lbs (40.7-47.5 Nm).
c.
Loosen fasteners (2) and final-tighten to 38-42 ft-lbs
(51.5-56.9 Nm).
2.
Tighten luggage rack fasteners. See
.
3.
See
. Install nylon fastener (3) into electronic
control module tray (2) and fender.
4.
Connect the harness at connector [7] (1).
5.
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)
6.
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)
7.
Check turn signal and lamp operation.
1
2
3
sm03296
1. Fender
2. Fender support
3. Wire conduit
Figure 2-118. Rear Fender Wire Routing: FLSTN
2013 Softail Service: Chassis 2-105
2.34
REAR FENDER WIRE CONDUIT
INSTALLATION
1.
Remove wire terminals from harness connectors.
2.
Remove wire harness from conduit.
3.
Remove old conduit from fender.
4.
Thoroughly clean inside surface of fender with soap and
water until it is free of dirt, oil, or other debris.
5.
Dry the surface, then wipe the area where conduit will be
placed with isopropyl alcohol. Allow to dry completely.
6.
Slide tail lamp wiring harness through
new
conduit and
install wire terminals into connector housings. See
for more information.
7.
See
. Remove protective strip covering
adhesive on conduit.
8.
See
. Lightly position the conduit in place.
9.
See
. Using a wallpaper corner roller (avail-
able at most home improvement stores), roll along conduit
to purge the air from between the adhesive and the fender.
NOTES
•
Do NOT rub the conduit to make it adhere to the fender.
This will not do an adequate job of purging the air from
between the adhesive and fender.
•
Once the adhesive is in place, it requires 72 hours to fully
cure. Continue with installation but do NOT pull or try to
reposition the conduit during this period.
1
2
sm03297
1. Conduit
2. Protective strip
Figure 2-119. Removing Protective Strip From Conduit
1
2
sm03298
1. Conduit
2. Wallpaper corner roller
Figure 2-120. Purging Air Between Adhesive and Fender
FLSTF/B
FLSTC
FLSTN
FXST
1
2
3
4
4
5
1
1
sm03299b
1. 1.15 in. (29.2 mm)
2. 8.00 in. (203.2 mm)
3. 0.75 in. (19.1 mm)
4. 3.00 in. (76.2 mm)
5. 2.25 in. (57.2 mm)
Figure 2-121. Conduit Placement
2-106 2013 Softail Service: Chassis
2.35
FOOTBOARDS AND FOOTRESTS
RIDER FOOTBOARDS
TORQUE VALUE
FASTENER
6.8-9.0 Nm
60-80
in-lbs
Rider footboard screws
Removal
1.
See
. Remove pivot screws (5) and nuts (3).
2.
Remove footboard from motorcycle.
Installation
1.
See
. Install footboard and secure with pivot
screws (5) and nuts (3).
2.
Tighten screws to 60-80
in-lbs
(6.8-9.0 Nm).
7
8
9
10
6
5
4
3
2
1
11
sm07018
1. Rubber pad (left side)
2. Footboard (left side)
3. Pivot screw nut (2 each side)
4. Fastener (3)
5. Pivot screw (2 each side)
6. Bracket
7. Rubber pad (right side)
8. Footboard (right side)
9. Bracket
10. Clip
11. Screw (3)
Figure 2-122. Rider Footboards (Typical)
RIDER FOOTREST
TORQUE VALUE
FASTENER
39.4-46.1 Nm
29-34 ft-lbs
Rider footrest support screws
Removal
See
. Remove retaining ring (1) and clevis pin (4).
Pull footrest (3) and spring washer (2) from support (6 or 7).
Installation
1.
See
. If support (6 or 7) was removed, install
with screws (5). Tighten to 29-34 ft-lbs (39.4-46.1 Nm).
2.
Place footrest (3) and spring washer (2) into position on
support (6).
3.
Install clevis pin (4) and
new
retaining ring (1).
1
3
4
2
5
6
7
sm07025
1. Retaining ring
2. Spring washer
3. Footrest
4. Clevis pin
5. Screw (3)
6. Bracket, left side
7. Bracket, right side
Figure 2-123. Rider Footrests
PASSENGER FOOTREST
TORQUE VALUE
FASTENER
33.9-40.7 Nm
25-30 ft-lbs
Footrest support screw, pas-
senger, left-side: FLSTN
33.9-40.7 Nm
25-30 ft-lbs
Footrest support screw, pas-
senger
Removal
See
. Remove retaining ring (1) and clevis pin (4).
Pull footrest (3) and spring washer (2) from support (6).
2013 Softail Service: Chassis 2-107
Installation
1.
FLSTN:
see
. If support (8) was removed,
install support and tighten screw (7) to 25-30 ft-lbs (33.9-
40.7 Nm).
2.
See
. If support (6) was removed, install with
screw (5). Tighten to 25-30 ft-lbs (33.9-40.7 Nm).
3.
Place footrest (3) and spring washer (2) into position on
support (6).
4.
Install clevis pin (4) and
new
retaining ring (1).
1
2
3
4
5
6
7
8
sm07023
1. Retaining ring
2. Spring washer
3. Footrest
4. Clevis pin
5. Screw
6. Support
7. Screw (FLSTN, left side only)
8. Support (FLSTN, left side only)
Figure 2-124. Passenger Footrests
2-108 2013 Softail Service: Chassis
2.36
JIFFY STAND
CLEANING
The jiffy stand locks when placed in the full forward (down)
position with vehicle weight on it. If the jiffy stand is not
in the full forward (down) position with vehicle weight on
it, the vehicle can fall over which could result in death or
serious injury. (00006a)
Always park motorcycle on a level, firm surface. An
unbalanced motorcycle can fall over, which could result
in death or serious injury. (00039a)
Be sure jiffy stand is fully retracted before riding. If jiffy
stand is not fully retracted, it can contact the road surface
causing a loss of vehicle control, which could result in
death or serious injury. (00007a)
1.
Block motorcycle underneath frame so both wheels are
raised off the ground.
2.
See
. Inspect clevis pin (1) and bushings (2).
If covered with dirt, wipe dirt off with a shop towel and
spray clevis pin and bushings with ANTI-SEIZE LUB-
RICANT.
3.
Move jiffy stand (9, 10) forward and back to infuse LUBRI-
PLATE 110 into mating parts.
4.
Check that jiffy stand operates correctly before using.
1
2
3
4
2
6
11
12
5
7
8
9
10
sm03301
1. Clevis pin
2. Bushing (2)
3. Spring
4. Spring bracket
5. Jiffy stand bracket
6. Pretzel clip
7. Fastener (3)
8. Bumper
9. Jiffy stand (all but FLSTN, FLS)
10. Jiffy stand (FLSTN, FLS)
11. Sensor (HDI models)
12. Screw, sensor (HDI models)
Figure 2-125. Jiffy Stand
SENSOR: HDI MODELS
TORQUE VALUE
FASTENER
10.8-16.3 Nm
96-144
in-lbs
Jiffy stand sensor screw
1.
See
. Make a note of harness routing for ease
of assembly. Disconnect sensor connector located behind
the regulator.
2.
Remove any cable anchors and cable straps.
3.
Remove screw (12) and remove sensor (11).
2013 Softail Service: Chassis 2-109
4.
Installation is in reverse of removal. Tighten screw (12) to
96-144
in-lbs
(10.8-16.3 Nm).
REMOVAL
Block or jack vehicle under frame in a way that the vehicle
will not fall over. Failure to properly block and/or raise the
vehicle could result in death or serious injury. (00462c)
1.
Detach shifter linkage.
2.
See
. Remove the three fasteners (7) from
jiffy stand bracket (5).
3.
Detach spring (3) from jiffy stand and spring bracket (4).
4.
Remove pretzel clip (6) from clevis pin (1).
5.
Remove clevis pin and bushings (2) to free jiffy stand from
jiffy stand bracket.
INSTALLATION
TORQUE VALUE
FASTENER
33.9-40.7 Nm
25-30 ft-lbs
Jiffy stand bracket assembly
screws
If leg stop is incorrectly installed, excessive wear can allow
vehicle to fall when rested on jiffy stand, which could result
in death or serious injury. (00479b)
1.
See
. Install bracket.
a.
Apply LUBRIPLATE 110 to clevis pin (1).
b.
Place jiffy stand into position.
c.
Install lower bushing (2) on clevis pin (1).
d.
Install clevis pin (1) through jiffy stand (9, 10) and jiffy
stand bracket (5).
e.
Place top bushing (2) on clevis pin (1).
f.
Install pretzel clip (6) in clevis pin (1).
g.
Attach spring (3) to jiffy stand (9,10) and spring
bracket (4). When properly installed, hook on spring
side connected to bracket faces upward.
h.
Install jiffy stand and bracket assembly with three
fasteners (7). Tighten to 25-30 ft-lbs (33.9-40.7 Nm).
2.
Attach shifter linkage.
3.
Check that jiffy stand operates correctly before using.
2-110 2013 Softail Service: Chassis
2.37
FORK LOCK
REMOVAL
1.
Remove steering stem. See
2.
See
. Remove set screw (1).
3.
Insert key (3) in lock (2) and turn partially.
4.
Wiggle lock and pull until enough of the lock comes out
to get a grip with pliers or other suitable tool.
5.
Remove fork lock by pulling on lock until it is removed.
INSTALLATION
NOTES
•
There is an internal boss in the left side of the steering
head opposite the external boss. The end of the lock fits
into this internal boss.
•
See
. There is a flat (1) in the bottom of the
lock into which the set screw fits. This flat must be at the
bottom when the lock is installed.
•
When the lock is correctly installed, a forward-facing flat
(2) on the lock will fit against a flat inside the external lock
boss and the face of the lock will be flush with the face of
the external boss.
1.
Grease the end of the lock (the part that goes into the
internal boss) and slide lock into external boss.
2.
Insert steering stem into frame. See
NOTE
Stem must be in locked fork position.
3.
Move steering stem into locked fork position. Rotate
steering stem slightly, while fully installing lock.
4.
See
. Apply LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT (blue) to
set screw (1) and install.
5.
Insert key in the lock and tighten set screw (1) until lock
begins to bind; then back set screw out 1/2 turn.
6.
Seal screw with a good quality sealant.
7.
Finish steering stem installation including installing upper
fork clamp and handlebars. See
.
2
3
1
sm03302
1. Set screw
2. Lock
3. Key
Figure 2-126. Fork Lock Installation
1
2
3
sm03303
1. Set screw flat
2. Flat
3. Lock left side
Figure 2-127. Fork Lock
2013 Softail Service: Chassis 2-111
2.38
SEAT AND STRAP RETENTION NUT
REPLACEMENT
NOTE
If the retention washer is removed, the retention nut will fall
through the fender. The procedure below lifts the retention nut
up through the fender on the cable strap for ease of replace-
ment.
1.
Slide retention nut over tapered end of cable strap so that
larger O.D. of nut rests on cable strap eyelet.
2.
From bottom of rear fender, feed cable strap up through
fender hole.
3.
See
. With tab (1) on retention nut (2) seated
in notch of fender hole, pull up on cable strap to hold nut
snug against underside of rear fender.
4.
From the side opposite the tab, slide on the retention
washer (3) to lock the position of the retention nut.
1
2
3
sm03304
1. Tab
2. Retention nut
3. Retention washer
Figure 2-128. Seat Retention Nut
2
2
3
1
sm03305
1. Bracket for seat/pillion
2. Retention nut and retention nut washer
3. Seat strap (FXST/C/B/D style shown)
Figure 2-129. Retention Nut In Use
2-112 2013 Softail Service: Chassis
2.39
SEAT: FLS, FXS, FXST, FXSB
REPLACEMENT
Removal
1.
See
. Remove seat mounting screw from top
of rear fender.
2.
See
. Push seat rearward to free tongue at
front of seat from slot or bracket in frame back.
3.
Two-up seats: gently slide seat out of grab strap.
4.
Remove seat from frame.
Installation
1.
Two-up seats: slide seat into grab strap.
2.
Place seat on frame back.
3.
Slide seat toward front of motorcycle until the tongue locks
into the bracket or slot in the frame back.
4.
Push seat forward until rear fender seat retention nut is
centered in hole of mounting bracket.
5.
Hand-tighten the seat mounting screw.
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)
6.
Pull up on seat to verify that it is properly secured.
om01308
Figure 2-130. Seat Tongue (typical)
2
7
7
1
7
8
4
3
7
5
4
6
6
6
om00139f
5.
1.
Seat (FLS)
Seat (FXS)
2.
6.
Seat (FXST)
Grab strap
7.
3.
Seat mounting screw
Seat (FXSB)
4.
8.
Pillion (FXSB)
Seat mounting nut (2)
Figure 2-131. Seat: FXS/FXST/FXSB/FLS
2013 Softail Service: Chassis 2-113
2.40
SEAT: FLSTN, FLSTF, FLSTFB, FLSTC
REMOVAL AND INSTALLATION
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)
See
. The passenger seat attaches with a single
screw (1) at the rear and engages the seat mounting fasteners
(6) at the front.
To remove seat (7, 8, 9), remove passenger seat (2, 3, 4) and
seat mounting fasteners (6). When installing seat, insert tang
at front of seat into the channel in the frame and install seat
mounting nuts. Install passenger seat.
1
1
1
4
5
6
9
3
2
5
6
8
6
7
sm03311
6.
1.
Seat mounting fastener (2)
Screw
2.
7.
Passenger seat (FLSTN)
Seat (FLSTN)
8.
3.
Seat (FLSTF/B)
Passenger seat (FLSTF/B)
4.
9.
Passenger seat (FLSTC)
Seat (FLSTC)
5. Seat strap
Figure 2-132. Seat: FLSTN/FLSTF/FLSTFB/FLSTC
2-114 2013 Softail Service: Chassis
2.41
LUGGAGE RACK: FLSTN
REMOVAL AND INSTALLATION
TORQUE VALUE
FASTENER
16.3-19.0 Nm
12-14 ft-lbs
Luggage rack rear fasteners:
FLSTN
10.8-13.6 Nm
96-120
in-lbs
Luggage rack front fasteners:
FLSTN
1.
Remove seat. See
2.40 SEAT: FLSTN, FLSTF, FLSTFB,
.
2.
Remove front fasteners (1) and rear fasteners (3) to detach
luggage rack (2) from fender.
3.
Place luggage rack on fender.
4.
Install, but do not tighten front fasteners.
5.
Install rear fastener. Tighten to 12-14 ft-lbs (16.3-19.0
Nm).
6.
Tighten front fasteners to 96-120
in-lbs
(10.8-13.6 Nm).
1
2
3
sm03312
1. Front fasteners
2. Luggage rack
3. Rear fastener
Figure 2-133. Luggage Rack
2013 Softail Service: Chassis 2-115
2.42
SADDLEBAGS: FLSTC
REMOVAL
1.
See
. Remove acorn nut (7) and washer (8)
from lower support.
2.
Remove flange nuts and washers (5) from inside
saddlebag.
3.
Lift saddlebag away from motorcycle. Remove nuts (1)
and studs (4) if necessary.
INSTALLATION
TORQUE VALUE
FASTENER
28.5-36.6 Nm
21-27 ft-lbs
Fender support studs: FLSTC
13.6-16.3 Nm
120-144
in-lbs
Saddlebag flange nuts: FLSTC
13.6-16.3 Nm
120-144
in-lb
s
Saddlebag lower bracket
acorn nut: FLSTC
NOTES
•
See
. On FLSTC models, there are no
washers between studs (4) and sissybar sideplate (3).
•
If replacing isolator (9), long (silver) threads face
saddlebag and short (yellow) threads face support.
1.
If removed, install studs (4) and tighten nuts (1) behind
fender support (2) to 21-27 ft-lbs (28.5-36.6 Nm).
2.
Install flange nuts and washers (5) inside saddlebags.
Tighten to 120-144
in-lbs
(13.6-16.3 Nm).
3.
Install lower bracket acorn nut (7) and washer (8). Tighten
to 120-144
in-lb
s (13.6-16.3 Nm).
2-116 2013 Softail Service: Chassis
4
6
7
8
9
10
2
1
3
5
sm03313a
6.
1.
Saddlebag
Nut
2.
7.
Fender support
Acorn nut
8.
3.
Washer
Sissy bar sideplate
4.
9.
Stud
Isolator
10.
5.
Lower front support
Flange nut and washer
Figure 2-134. Saddlebags: FLSTC
2013 Softail Service: Chassis 2-117
2.43
WINDSHIELD: FLSTC
REMOVAL
1.
See
. Use a finger to raise the wireform latch
springs on each side of the windshield.
2.
Standing at the front of the vehicle, gently pull the top of
the windshield until the upper notches (2) on the side
brackets are free of the upper grommets.
3.
Carefully raise the windshield until the lower notches (3)
in the side brackets are free of the lower grommets.
4.
Remove windshield from vehicle.
INSTALLATION
1.
See
. Lower the windshield into position until
the lower notches (3) are seated on the lower grommets.
2.
Standing at the front of the vehicle, gently push the top of
the windshield toward the rear until the upper notches (2)
fully engage the upper grommets.
3.
Push down on the wireform latch springs (1) so that they
overhang the rubber grommets. If some adjustment is
necessary, loosen the retaining bolts and rotate the latch
springs into the proper position.
1
2
3
sm03314
1. Wireform latch spring (2)
2. Upper notch (2)
3. Lower notch (2)
Figure 2-135. Windshield: FLSTC
2-118 2013 Softail Service: Chassis
2.44
SAREE GUARD: INDIA MODELS
LEFT SIDE REMOVAL AND INSTALLATION
TORQUE VALUE
FASTENER
28.5-36.6 Nm
21-27 ft-lbs
Saree guard fasteners, lower
left
28.5-36.6 Nm
21-27 ft-lbs
Saree guard nut, upper left
28.5-36.6 Nm
21-27 ft-lbs
Saree guard fasteners, upper
left
40.7-47.5 Nm
30-35 ft-lbs
Fender support fasteners - 1st
torque
51.5-56.9 Nm
38-42 ft-lbs
Fender support fasteners -
final torque
Removal
1.
See
. Loosen fender support fasteners (1).
2.
Remove three fasteners (2).
3.
Remove nut (3) located behind strut cover.
4.
Remove upper saree guard.
5.
Remove screws (4) and lower saree guard.
Installation
1.
Install lower saree guard and screws (4) with washers and
nuts. Tighten to 21-27 ft-lbs (28.5-36.6 Nm).
2.
Set upper saree guard into position and install nut (3)
finger tight.
3.
Loosely install three fasteners (2).
4.
Tighten nut (3) to 21-27 ft-lbs (28.5-36.6 Nm).
5.
Tighten fasteners (2) to 21-27 ft-lbs (28.5-36.6 Nm).
6.
Tighten fender support fasteners (1) to an initial torque of
30-35 ft-lbs (40.7-47.5 Nm). Loosen fasteners and final-
tighten to 38-42 ft-lbs (51.5-56.9 Nm).
1
4
2
3
sm07520
1. Fender support fastener (2)
2. Fastener (3)
3. Nut
4. Screws (3)
Figure 2-136. Left Saree Guards
RIGHT SIDE REMOVAL AND INSTALLATION
TORQUE VALUE
FASTENER
28.5-36.6 Nm
21-27 ft-lbs
Saree guard nut, right
28.5-36.6 Nm
21-27 ft-lbs
Saree guard fasteners, right
40.7-47.5 Nm
30-35 ft-lbs
Fender support fasteners - 1st
torque
51.5-56.9 Nm
38-42 ft-lbs
Fender support fasteners -
final torque
Removal
1.
See
. Loosen fender support fasteners (3).
2.
Remove three fasteners (2).
3.
Remove nut (1) located behind strut cover
4.
Remove saree guard.
Installation
1.
Set saree guard into position and install nut (1) finger tight.
2.
Loosely install three fasteners (2).
3.
Tighten nut (1) to 21-27 ft-lbs (28.5-36.6 Nm).
4.
Tighten fasteners (2) to 21-27 ft-lbs (28.5-36.6 Nm).
5.
Tighten fender support fasteners (3) to an initial torque of
30-35 ft-lbs (40.7-47.5 Nm). Loosen fasteners and final-
tighten to 38-42 ft-lbs (51.5-56.9 Nm).
2013 Softail Service: Chassis 2-119
3.3
SERVICE WEAR LIMITS
GENERAL
Wear limits are given here as a guideline for measuring used
engine components. Replace components when they exceed
values listed here.
Table 3-15. Rocker Arm/Rocker Arm Shaft
REPLACE IF WEAR EXCEEDS
ROCKER ARM/ROCKER
ARM SHAFT
MM
IN
0.089
0.0035
Shaft fit in bushing (loose)
0.635
0.025
End clearance
0.089
0.0035
Shaft fit in rocker arm
support (loose)
Table 3-16. Hydraulic Lifter
REPLACE IF WEAR EXCEEDS
HYDRAULIC LIFTER
MM
IN
0.152
0.006
Fit in crankcase
0.038
0.0015
Roller fit
0.559
0.022
Roller end clearance
Table 3-17. Cam Support Plate
REPLACE IF WEAR EXCEEDS
ITEM
MM
IN
1.52 min.
0.060 min.
Cam chain tensioner shoe
thickness
21.704
0.8545
Crankshaft bore max-
imum ID
27.998
1.1023
Camshaft bore
0.25
0.010
Flatness
Table 3-18. Oil Pump
REPLACE IF WEAR
EXCEEDS
OIL PUMP
MM
IN
0.10
0.004
Rotor tip clearance
0.025
0.001
Rotor thickness variation
0.38-0.64
0.015-0.025
Rotor protrusion (pump
assembled)
Table 3-19. Cylinder Head
REPLACE IF
CYLINDER HEAD
MM
IN
Less than 0.05
Less than
0.002
Valve guide press fit in head
Less than 0.05
Less than
0.002
Valve seat press fit in head
1.57
0.062
Valve seat width (max)
0.80
0.031
Valve margin (min)
52.55
2.069
Valve stem protrusion (max)
0.15
0.006
Head warpage (max)
Table 3-20. Cylinder
REPLACE IF WEAR EXCEEDS
CYLINDER
MM
IN
0.051
0.002
Taper
0.051
0.002
Out of round
0.152
0.006
Warpage of gasket sur-
faces: top
0.102
0.004
Warpage of gasket or O-
ring surfaces: base
Table 3-21. Cylinder Bore (Twin Cam 96)
REPLACE IF WEAR EXCEEDS
CYLINDER BORE
MM
IN
95.301
3.752
Standard
95.428
3.757
0.005 in oversize
95.555
3.762
0.010 in oversize
2013 Softail Service: Engine 3-5
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