Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual — page 2

ENGINE

3.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter. . . . . . . ..3-1

3.2 SPECIFICATIONS

Specifications. . . . . . . . . . . . . . . . . ..3-3

3.3 SERVICE WEAR LIMITS

General. . . . . . . . . . . . . . . . . . . ...3-5

3.4 ENGINE OIL FLOW

Oil Feed. . . . . . . . . . . . . . . . . . . ..3-7
Top End. . . . . . . . . . . . . . . . . . . ...3-8
Bottom End. . . . . . . . . . . . . . . . . . .3-9
Chain Guide Bracket. . . . . . . . . . . . . . .3-11
Oil Return. . . . . . . . . . . . . . . . . . ..3-12

3.5 OIL PUMP OPERATION

General. . . . . . . . . . . . . . . . . . . .3-13
Operation. . . . . . . . . . . . . . . . . . ..3-13

3.6 BREATHER OPERATION

General. . . . . . . . . . . . . . . . . . . .3-15

3.7 OIL PRESSURE

Oil Pressure Indicator Lamp. . . . . . . . . . . .3-16
Checking Oil Pressure. . . . . . . . . . . . . ..3-16

3.8 TROUBLESHOOTING

Diagnosing Valve Train Noise. . . . . . . . . . ...3-18
Compression Test. . . . . . . . . . . . . . . .3-18
Cylinder Leakdown Test. . . . . . . . . . . . ...3-18
Diagnosing Smoking Engine or High Oil Consumption. .3-19

Check Prior To Cylinder Head Removal. . . . . 3-19
Check After Cylinder Head Removal. . . . . . .3-19

3.9 HOW TO USE THIS SECTION

Top End Repair. . . . . . . . . . . . . . . . .3-20
Bottom End Repair. . . . . . . . . . . . . . ...3-20
Typical Symptoms. . . . . . . . . . . . . . . .3-20

3.10 TOP END SERVICE

Engine in Chassis. . . . . . . . . . . . . . . .3-21
Engine Removed from Chassis. . . . . . . . . . 3-22

3.11 CAM COMPARTMENT SERVICE

Engine in Chassis. . . . . . . . . . . . . . . .3-23
Engine Removed From Chassis. . . . . . . . . ...3-24

3.12 STRIPPING MOTORCYCLE FOR
SERVICE

Procedure. . . . . . . . . . . . . . . . . . .3-25

3.13 ASSEMBLING MOTORCYCLE AFTER
SERVICE

Procedure. . . . . . . . . . . . . . . . . . .3-26

3.14 REMOVING ENGINE FROM CHASSIS

Procedure. . . . . . . . . . . . . . . . . . .3-27

3.15 INSTALLING ENGINE IN CHASSIS

Procedure. . . . . . . . . . . . . . . . . . .3-28

3.16 TOP END OVERHAUL: DISASSEMBLY

General. . . . . . . . . . . . . . . . . . . .3-30
Rocker Covers. . . . . . . . . . . . . . . . ..3-30
Rocker Arm Support Plate. . . . . . . . . . . . 3-30
Pushrods, Lifters and Covers. . . . . . . . . . ...3-32
Cylinder Head. . . . . . . . . . . . . . . . ...3-32
Cylinder. . . . . . . . . . . . . . . . . . . .3-33
Piston. . . . . . . . . . . . . . . . . . . . 3-34

3.17 BREATHER ASSEMBLY

Disassembly. . . . . . . . . . . . . . . . . .3-36
Cleaning and Inspection. . . . . . . . . . . . ...3-36
Assembly. . . . . . . . . . . . . . . . . . ..3-36

3.18 ROCKER ARM SUPPORT PLATE

Disassembly. . . . . . . . . . . . . . . . . .3-37
Cleaning and Inspection. . . . . . . . . . . . ...3-37

Inspection. . . . . . . . . . . . . . . . ..3-37
Rocker Shaft Fit. . . . . . . . . . . . . . .3-37
Rocker Arm Shaft to Bushing. . . . . . . . . 3-38
Replace Rocker Arm Bushings. . . . . . . . .3-38

Assembly. . . . . . . . . . . . . . . . . . ..3-39

3.19 PUSHRODS, LIFTERS AND COVERS

Disassembly. . . . . . . . . . . . . . . . . .3-40
Cleaning and General Inspection. . . . . . . . . .3-40
Lifter Inspection. . . . . . . . . . . . . . . . 3-41
Assembly. . . . . . . . . . . . . . . . . . ..3-41

3.20 CYLINDER HEAD

Disassembly. . . . . . . . . . . . . . . . . .3-42
Cleaning. . . . . . . . . . . . . . . . . . . 3-43
Inspection. . . . . . . . . . . . . . . . . . .3-43

Cylinder Head. . . . . . . . . . . . . . . 3-43
Valve Guides. . . . . . . . . . . . . . . .3-44
Valves. . . . . . . . . . . . . . . . . . 3-44
Valve Springs. . . . . . . . . . . . . . . .3-44
Tapered Keepers. . . . . . . . . . . . . ...3-44
Valve Seats. . . . . . . . . . . . . . . . 3-44

Valve Guide Replacement. . . . . . . . . . . . 3-44

Removal. . . . . . . . . . . . . . . . . 3-44
Installation. . . . . . . . . . . . . . . . .3-45

Valve and Seat Refacing. . . . . . . . . . . . ..3-48
Assembly. . . . . . . . . . . . . . . . . . ..3-50

3.21 CYLINDER

Cleaning. . . . . . . . . . . . . . . . . . . 3-52
Inspection. . . . . . . . . . . . . . . . . . .3-52
Deglazing Cylinder. . . . . . . . . . . . . . . 3-54
Boring and Honing Cylinder. . . . . . . . . . . ..3-54

3.22 PISTON

Disassembly. . . . . . . . . . . . . . . . . .3-56

Piston Rings. . . . . . . . . . . . . . . ..3-56

TABLE OF CONTENTS VII

TABLE OF CONTENTS

Cleaning. . . . . . . . . . . . . . . . . . . 3-56
Inspection. . . . . . . . . . . . . . . . . . .3-56
Assembly. . . . . . . . . . . . . . . . . . ..3-58

Checking Piston Ring Gap. . . . . . . . . . 3-58
Installing Piston Rings. . . . . . . . . . . ...3-58

3.23 TOP END OVERHAUL: ASSEMBLY

General. . . . . . . . . . . . . . . . . . . .3-60
Piston. . . . . . . . . . . . . . . . . . . . 3-60
Cylinder. . . . . . . . . . . . . . . . . . . .3-61
Cylinder Head. . . . . . . . . . . . . . . . ...3-63
Pushrods, Lifters and Covers. . . . . . . . . . ...3-67
Rocker Arm Support Plate. . . . . . . . . . . . 3-68
Breather and Rocker Cover. . . . . . . . . . . ..3-69

3.24 CAM COMPARTMENT AND
COMPONENTS

Cam Support Plate and Cover Removal. . . . . . ..3-70

Prepare Engine. . . . . . . . . . . . . . ..3-70
Cam Chain and Sprockets Removal. . . . . . .3-70
Cam Support Plate Removal. . . . . . . . . .3-71

Cam Support Plate Cleaning and Inspection. . . . . 3-72

Oil Pressure Valve. . . . . . . . . . . . . .3-72
Cam Support Plate. . . . . . . . . . . . . 3-72

Camshafts. . . . . . . . . . . . . . . . . . .3-73

Removal. . . . . . . . . . . . . . . . . 3-73
Installation. . . . . . . . . . . . . . . . .3-73

Oil Pressure Relief Valve. . . . . . . . . . . . ..3-75

Removal. . . . . . . . . . . . . . . . . 3-75
Inspection. . . . . . . . . . . . . . . . ..3-75
Installation. . . . . . . . . . . . . . . . .3-75

Cam Needle Bearings. . . . . . . . . . . . . ...3-75

Removal. . . . . . . . . . . . . . . . . 3-75
Installation. . . . . . . . . . . . . . . . .3-77

Cam Support Plate and Cover Installation. . . . . ...3-78

3.25 OIL PUMP

Removal. . . . . . . . . . . . . . . . . . . 3-82
Cleaning and Inspection. . . . . . . . . . . . ...3-82
Installation. . . . . . . . . . . . . . . . . . .3-83

3.26 CRANKCASE DISASSEMBLY AND
REPAIR

Crankcase Disassembly. . . . . . . . . . . . ...3-84
Counterbalancer Assembly. . . . . . . . . . . ..3-84
Cleaning and Inspection. . . . . . . . . . . . ...3-86
Right Crankcase Half. . . . . . . . . . . . . . 3-87

Chain Guide Screen. . . . . . . . . . . . ..3-87
Main Bearing Removal. . . . . . . . . . . ..3-87
Main Bearing Installation. . . . . . . . . . ...3-88
Piston Jets Removal. . . . . . . . . . . . ..3-88
Piston Jets Installation. . . . . . . . . . . ...3-88

Left Crankcase Half. . . . . . . . . . . . . . ..3-89

Main Bearing Removal. . . . . . . . . . . ..3-89
Main Bearing Installation. . . . . . . . . . ...3-90

Sprocket Shaft Bearing Inner Race. . . . . . . . ..3-90

Removal. . . . . . . . . . . . . . . . . 3-90
Installation. . . . . . . . . . . . . . . . .3-91

Cylinder Studs. . . . . . . . . . . . . . . . ..3-93

Removal. . . . . . . . . . . . . . . . . 3-93
Installation. . . . . . . . . . . . . . . . .3-93

Pipe Plugs and Oil Fittings. . . . . . . . . . . . 3-93

Removal/Installation. . . . . . . . . . . . ..3-93

3.27 FLYWHEEL AND CONNECTING RODS

General. . . . . . . . . . . . . . . . . . . .3-94

Symptoms. . . . . . . . . . . . . . . . ..3-94
No Oil Pressure. . . . . . . . . . . . . . .3-94
Vibration. . . . . . . . . . . . . . . . . 3-94

Inspection. . . . . . . . . . . . . . . . . . .3-94
Measuring Crankshaft Runout. . . . . . . . . . ..3-94

Crankshaft Installed. . . . . . . . . . . . ...3-94
Crankshaft Removed. . . . . . . . . . . . .3-95

3.28 COUNTERBALANCER ASSEMBLY
REPAIR

Cleaning, Inspection, and Repair. . . . . . . . . .3-97

General. . . . . . . . . . . . . . . . . ..3-97
Balance Shaft Removal. . . . . . . . . . . .3-97
Bearing Removal. . . . . . . . . . . . . ...3-98
Balance Shaft Installation. . . . . . . . . . ..3-98
Balance Shaft Support Bearings Removal. . . . 3-99
Balance Shaft Support Bearings Installation. . . .3-99
Front and Rear Balance Sprockets. . . . . . .3-100
Hydraulic Tensioners. . . . . . . . . . . ...3-100
Chain Tensioner Guides. . . . . . . . . . ..3-100
Balance Shaft Support. . . . . . . . . . . 3-100
Balance Chain. . . . . . . . . . . . . . .3-101

3.29 CRANKCASE ASSEMBLY

Counterbalancer Assembly Installation. . . . . . ..3-102
Crankcase. . . . . . . . . . . . . . . . . ...3-105

3.30 OIL TANK: ALL BUT FXSB

Removal and Disassembly. . . . . . . . . . . .3-108

Oil Tank. . . . . . . . . . . . . . . . . 3-108
Oil Line Fittings/Retainers. . . . . . . . . ...3-110

Installation. . . . . . . . . . . . . . . . . ...3-111

3.31 OIL TANK: FXSB

Removal and Disassembly. . . . . . . . . . . .3-112

Oil Tank. . . . . . . . . . . . . . . . . 3-112
Oil Line Fittings/Retainers. . . . . . . . . ...3-114

Installation. . . . . . . . . . . . . . . . . ...3-115

FUEL SYSTEM

4.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter. . . . . . . ..4-1

4.2 SPECIFICATIONS: FUEL SYSTEM

Specifications. . . . . . . . . . . . . . . . . ..4-3

4.3 AIR CLEANER ASSEMBLY

Removal. . . . . . . . . . . . . . . . . . . ..4-4
Installation. . . . . . . . . . . . . . . . . . ...4-4
Backplate Assembly: HDI Models. . . . . . . . . ..4-5

4.4 FUEL SUPPLY LINE

Purging Fuel Supply Line. . . . . . . . . . . . . 4-6
Disconnecting Fuel Supply Line. . . . . . . . . . .4-6

VIII TABLE OF CONTENTS

TABLE OF CONTENTS

4.5 FUEL PRESSURE TEST

General. . . . . . . . . . . . . . . . . . . ...4-7
Testing. . . . . . . . . . . . . . . . . . . . 4-7

4.6 FUEL TANK

General. . . . . . . . . . . . . . . . . . . ...4-9
Removal. . . . . . . . . . . . . . . . . . . ..4-9
Cleaning and Inspection. . . . . . . . . . . . ...4-10
Installation. . . . . . . . . . . . . . . . . . .4-11

4.7 CONSOLE: FXS, FXSB

Removal. . . . . . . . . . . . . . . . . . . 4-12
Installation. . . . . . . . . . . . . . . . . . .4-12

4.8 THROTTLE POSITION SENSOR (TPS)

General. . . . . . . . . . . . . . . . . . . .4-13
Removal. . . . . . . . . . . . . . . . . . . 4-13
Installation. . . . . . . . . . . . . . . . . . .4-13

4.9 INTAKE AIR TEMPERATURE SENSOR
(IAT)

General. . . . . . . . . . . . . . . . . . . .4-14
Removal. . . . . . . . . . . . . . . . . . . 4-14
Installation. . . . . . . . . . . . . . . . . . .4-14

4.10 ENGINE TEMPERATURE SENSOR (ET)

General. . . . . . . . . . . . . . . . . . . .4-15
Removal. . . . . . . . . . . . . . . . . . . 4-15
Installation. . . . . . . . . . . . . . . . . . .4-15

4.11 INDUCTION MODULE

Removal. . . . . . . . . . . . . . . . . . . 4-16
Installation. . . . . . . . . . . . . . . . . . .4-17

4.12 IDLE AIR CONTROL (IAC)

General. . . . . . . . . . . . . . . . . . . .4-18
Removal. . . . . . . . . . . . . . . . . . . 4-18
Installation. . . . . . . . . . . . . . . . . . .4-18

4.13 MANIFOLD ABSOLUTE PRESSURE
SENSOR (MAP)

Removal. . . . . . . . . . . . . . . . . . . 4-19
Installation. . . . . . . . . . . . . . . . . . .4-19

4.14 OXYGEN (O2) SENSOR

General. . . . . . . . . . . . . . . . . . . .4-20
Removal. . . . . . . . . . . . . . . . . . . 4-20

Front O2 Sensor. . . . . . . . . . . . . . 4-20
Rear O2 Sensor. . . . . . . . . . . . . . .4-20

Installation. . . . . . . . . . . . . . . . . . .4-20

Front O2 Sensor. . . . . . . . . . . . . . 4-20
Rear O2 Sensor. . . . . . . . . . . . . . .4-20

4.15 FUEL INJECTORS

General. . . . . . . . . . . . . . . . . . . .4-22
Removal. . . . . . . . . . . . . . . . . . . 4-22
Installation. . . . . . . . . . . . . . . . . . .4-22

4.16 FUEL PUMP AND FUEL GAUGE
SENDING UNIT

General. . . . . . . . . . . . . . . . . . . .4-24
Removal. . . . . . . . . . . . . . . . . . . 4-24
Vapor Valve. . . . . . . . . . . . . . . . . ...4-25
Disassembly and Assembly. . . . . . . . . . . ..4-26

Fuel Filter. . . . . . . . . . . . . . . . ...4-26
Regulator. . . . . . . . . . . . . . . . ...4-26
Inlet sock. . . . . . . . . . . . . . . . ...4-27
Fuel Pump. . . . . . . . . . . . . . . . .4-27

Installation. . . . . . . . . . . . . . . . . . .4-28

4.17 EXHAUST SYSTEM

Mufflers: FLSTC, FXST, FXSB. . . . . . . . . . .4-30

Removal. . . . . . . . . . . . . . . . . 4-30
Assembly. . . . . . . . . . . . . . . . ...4-30

System: FLSTC, FXST, FXSB. . . . . . . . . . ..4-30

Removal. . . . . . . . . . . . . . . . . 4-30
Installation. . . . . . . . . . . . . . . . .4-30

Mufflers: FLSTN, FLSTF/B, FLS, FXS. . . . . . . ..4-32

Removal. . . . . . . . . . . . . . . . . 4-32
Assembly. . . . . . . . . . . . . . . . ...4-32

System: FLSTN, FLSTF/B, FLS, FXS. . . . . . . ..4-32

Removal. . . . . . . . . . . . . . . . . 4-32
Installation. . . . . . . . . . . . . . . . .4-32

4.18 INTAKE LEAK TEST

General. . . . . . . . . . . . . . . . . . . .4-34
Leak Tester. . . . . . . . . . . . . . . . . ...4-34

Parts List. . . . . . . . . . . . . . . . . 4-34
Tester Assembly. . . . . . . . . . . . . . 4-34
Tester Adjustment. . . . . . . . . . . . . ..4-34

Procedure. . . . . . . . . . . . . . . . . . .4-34

4.19 EVAPORATIVE EMISSIONS CONTROL
SYSTEM

General. . . . . . . . . . . . . . . . . . . .4-36
Charcoal Canister. . . . . . . . . . . . . . . .4-37

Removal. . . . . . . . . . . . . . . . . 4-37
Installation. . . . . . . . . . . . . . . . .4-37

Purge Solenoid. . . . . . . . . . . . . . . . .4-37

Removal. . . . . . . . . . . . . . . . . 4-37
Installation. . . . . . . . . . . . . . . . .4-37

Hose Routing/Replacement. . . . . . . . . . . ..4-37

Fuel Tank Vent Hose. . . . . . . . . . . . .4-37
Purge Solenoid-to-Induction Module Tube. . . . 4-37
Charcoal Canister-to-Purge Solenoid Tube. . . ...4-38
Vent Tube-to-Charcoal Canister Tube. . . . . ...4-38

DRIVE

5.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter. . . . . . . ..5-1

5.2 SPECIFICATIONS: DRIVE

Specifications. . . . . . . . . . . . . . . . . ..5-2

5.3 PRIMARY CHAINCASE COVER

General. . . . . . . . . . . . . . . . . . . ...5-3
Removal. . . . . . . . . . . . . . . . . . . ..5-3

TABLE OF CONTENTS IX

TABLE OF CONTENTS

Installation. . . . . . . . . . . . . . . . . . ...5-3

5.4 DRIVE COMPONENTS

Removal. . . . . . . . . . . . . . . . . . . ..5-4
Installation. . . . . . . . . . . . . . . . . . ...5-6

5.5 PRIMARY CHAINCASE HOUSING

Removal. . . . . . . . . . . . . . . . . . . ..5-9
Inspection. . . . . . . . . . . . . . . . . . ...5-9
Mainshaft Bearing and Seal. . . . . . . . . . . ...5-9

Removal. . . . . . . . . . . . . . . . . ..5-9
Installation. . . . . . . . . . . . . . . . ...5-9

Mainshaft Bearing Inner Race. . . . . . . . . . ..5-10

Removal. . . . . . . . . . . . . . . . . 5-10
Installation. . . . . . . . . . . . . . . . .5-10

Installation. . . . . . . . . . . . . . . . . . .5-11

5.6 CLUTCH

Removal and Installation. . . . . . . . . . . . ..5-13
Clutch Pack Only. . . . . . . . . . . . . . . ..5-13

Partial Disassembly. . . . . . . . . . . . ...5-13
Cleaning And Inspection. . . . . . . . . . ...5-13
Assembly. . . . . . . . . . . . . . . . ...5-14

Clutch Pack and Bearing. . . . . . . . . . . . ..5-15

Complete Disassembly. . . . . . . . . . . ..5-15
Assembly. . . . . . . . . . . . . . . . ...5-16

5.7 TRANSMISSION SPROCKET

Removal. . . . . . . . . . . . . . . . . . . 5-18
Cleaning and Inspection. . . . . . . . . . . . ...5-19
Installation. . . . . . . . . . . . . . . . . . .5-19

5.8 DRIVE BELT

Removal. . . . . . . . . . . . . . . . . . . 5-21
Inspection. . . . . . . . . . . . . . . . . . .5-21
Installation. . . . . . . . . . . . . . . . . . .5-21

TRANSMISSION

6.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter. . . . . . . ..6-1

6.2 SPECIFICATIONS: TRANSMISSION

Specifications. . . . . . . . . . . . . . . . . ..6-2
Service Wear Limits. . . . . . . . . . . . . . . 6-2

6.3 TRANSMISSION

Power Flow. . . . . . . . . . . . . . . . . . .6-4

Neutral. . . . . . . . . . . . . . . . . . .6-4
First Gear. . . . . . . . . . . . . . . . . .6-4
Second Gear. . . . . . . . . . . . . . . ...6-4
Third Gear. . . . . . . . . . . . . . . . ...6-4
Fourth Gear. . . . . . . . . . . . . . . . .6-4
Fifth Gear. . . . . . . . . . . . . . . . . .6-4
Sixth Gear. . . . . . . . . . . . . . . . . 6-4

6.4 SHIFTER

Adjustment. . . . . . . . . . . . . . . . . . ..6-6
Shifter Rod Adjustment. . . . . . . . . . . . . ...6-6
Shift Lever Replacement. . . . . . . . . . . . . 6-6

6.5 CLUTCH RELEASE COVER

Removal and Disassembly. . . . . . . . . . . . .6-8
Cleaning and Inspection. . . . . . . . . . . . . .6-8
Assembly and Installation. . . . . . . . . . . . ...6-9

6.6 TRANSMISSION ASSEMBLY

Removal. . . . . . . . . . . . . . . . . . . 6-10
Disassembly. . . . . . . . . . . . . . . . . .6-11

Shifter Cam/Shifter Forks. . . . . . . . . . ..6-11
Mainshaft. . . . . . . . . . . . . . . . ...6-13
Countershaft. . . . . . . . . . . . . . . ..6-16
Removing Bearing Housing Bearings. . . . . ...6-17

Cleaning and Inspection. . . . . . . . . . . . ...6-18
Assembly. . . . . . . . . . . . . . . . . . ..6-18

Installing Bearing Housing Bearings. . . . . . .6-18
Countershaft. . . . . . . . . . . . . . . ..6-19
Mainshaft. . . . . . . . . . . . . . . . ...6-19
Shifter Cam/Shifter Forks. . . . . . . . . . ..6-20

Installation. . . . . . . . . . . . . . . . . . .6-22

6.7 MAIN DRIVE GEAR AND BEARING

Removal. . . . . . . . . . . . . . . . . . . 6-23
Cleaning and Inspection. . . . . . . . . . . . ...6-24

Needle Bearing Replacement. . . . . . . . ...6-25

Installation. . . . . . . . . . . . . . . . . . .6-26

Installing Main Drive Gear Bearing. . . . . . . 6-26
Installing Main Drive Gear. . . . . . . . . . .6-27
Installing Main Drive Gear Large Seal. . . . . ...6-27

6.8 TRANSMISSION CASE

Removal. . . . . . . . . . . . . . . . . . . 6-30
Installation. . . . . . . . . . . . . . . . . . .6-30
Disassembly. . . . . . . . . . . . . . . . . .6-31

Shifter Arm Assembly. . . . . . . . . . . . 6-31

Cleaning and Inspection. . . . . . . . . . . . ...6-31
Assembly. . . . . . . . . . . . . . . . . . ..6-32

Countershaft Needle Bearing Replacement. . . ..6-32
Shifter Pawl Lever Assembly. . . . . . . . . .6-32

ELECTRICAL

7.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter. . . . . . . ..7-1

7.2 SPECIFICATIONS: ELECTRICAL

Specifications. . . . . . . . . . . . . . . . . ..7-4

7.3 ELECTRICAL PANEL

General. . . . . . . . . . . . . . . . . . . ...7-5
Removal: All But FXSB. . . . . . . . . . . . . ...7-5
Installation: All But FXSB. . . . . . . . . . . . . 7-6
Removal: FXSB. . . . . . . . . . . . . . . . ..7-6
Installation: FXSB. . . . . . . . . . . . . . . ...7-6

7.4 ELECTRONIC CONTROL MODULE (ECM)

General. . . . . . . . . . . . . . . . . . . ...7-8
Removal: All But FXSB. . . . . . . . . . . . . ...7-8
Installation: All But FXSB. . . . . . . . . . . . . 7-8
Removal: FXSB. . . . . . . . . . . . . . . . ..7-8
Installation: FXSB. . . . . . . . . . . . . . . ...7-8

X TABLE OF CONTENTS

TABLE OF CONTENTS

3.1

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

3.29 CRANKCASE ASSEMBLY, Counterbalancer
Assembly Installation

56.9-63.7 Nm

42-47 ft-lbs

Balance shaft bolts

3.29 CRANKCASE ASSEMBLY, Counterbalancer
Assembly Installation

24.4-29.8 Nm

18-22 ft-lbs

Balance shaft support screws

3.23 TOP END OVERHAUL: ASSEMBLY, Breather
and Rocker Cover

13.6-17.6 Nm

120-156

in-lbs

Breather assembly screws

3.24 CAM COMPARTMENT AND COMPON-
ENTS, Cam Support Plate and Cover Installation

10.2-13.6 Nm

90-120

in-lbs

Cam chain tensioner fasteners

3.24 CAM COMPARTMENT AND COMPON-
ENTS, Cam Support Plate and Cover Installation

10.2-13.6 Nm

90-120

in-lbs

Cam cover screws

3.24 CAM COMPARTMENT AND COMPON-
ENTS, Cam Support Plate and Cover Installation

20.3 Nm

15 ft-lbs

Cam sprocket flange bolt, 1st torque

3.24 CAM COMPARTMENT AND COMPON-
ENTS, Cam Support Plate and Cover Installation

46.1 Nm

34 ft-lbs

Cam sprocket flange bolt, final torque

3.24 CAM COMPARTMENT AND COMPON-
ENTS, Cam Support Plate and Cover Installation

10.2-13.6 Nm

90-120

in-lbs

Cam support plate screws

3.28 COUNTERBALANCER ASSEMBLY
REPAIR, Cleaning, Inspection, and Repair

4.5-7.9 Nm

40-70

in-lbs

Counterbalance assembly bearing

3.29 CRANKCASE ASSEMBLY, Crankcase

13.6 Nm

120

in-lbs

Crankcase bolt, 1st torque

3.29 CRANKCASE ASSEMBLY, Crankcase

20.3-25.8 Nm

15-19 ft-lbs

Crankcase bolt, final torque

3.26 CRANKCASE DISASSEMBLY AND
REPAIR, Pipe Plugs and Oil Fittings

13.6-19.0 Nm

120-168

in-lbs

Crankcase oil fittings

3.26 CRANKCASE DISASSEMBLY AND
REPAIR, Pipe Plugs and Oil Fittings

13.6-16.3 Nm

120-144

in-lbs

Crankcase pipe plugs

3.24 CAM COMPARTMENT AND COMPON-
ENTS, Cam Support Plate and Cover Installation

20.3 Nm

15 ft-lbs

Crankshaft sprocket bolt, 1st torque

3.24 CAM COMPARTMENT AND COMPON-
ENTS, Cam Support Plate and Cover Installation

32.5 Nm

24 ft-lbs

Crankshaft sprocket bolt, final torque

3.23 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/ See procedure to tighten

13.6-16.3 Nm

120-144

in-lbs

Cylinder head bolts, 1st torque

3.23 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head

20.3-23.0 Nm

15-17 ft-lbs

Cylinder head bolts, 2nd torque

3.23 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head

90 degrees

90 degrees

Cylinder head bolts, final torque

3.13 ASSEMBLING MOTORCYCLE AFTER SER-
VICE, Procedure

47.5-54.2 Nm

35-40 ft-lbs

Cylinder head bracket bolts

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

47.5-54.2 Nm

35-40 ft-lbs

Cylinder head bracket bolts

3.26 CRANKCASE DISASSEMBLY AND
REPAIR, Cylinder Studs

13.6-27.1 Nm

120-240

in-lbs

Cylinder stud

3.21 CYLINDER, Inspection/ See procedure to
tighten

13.6-16.3 Nm

120-144

in-lbs

Cylinder torque plate bolts, 1st torque

3.21 CYLINDER, Inspection

20.3-23.0 Nm

15-17 ft-lbs

Cylinder torque plate bolts, 2nd torque

3.21 CYLINDER, Inspection

90 degrees

90 degrees

Cylinder torque plate bolts, final torque

HOME

2013 Softail Service: Engine 3-1

NOTES

TORQUE VALUE

FASTENER

3.31 OIL TANK: FXSB, Installation

4.1-6.8 Nm

36-60

in-lbs

Electrical panel fastener

3.30 OIL TANK: ALL BUT FXSB, Installation

4.1-6.8 Nm

36-60

in-lbs

Electrical panel fasteners

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

40.7-47.5 Nm

30-35 ft-lbs

Engine/transmission bracket bolts

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

61.0-67.8 Nm

45-50 ft-lbs

Engine mount bolt, top

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

27.1-33.9 Nm

20-25 ft-lbs

Engine mount bracket nuts, top

3.13 ASSEMBLING MOTORCYCLE AFTER SER-
VICE, Procedure

61.0-67.8 Nm

45-50 ft-lbs

Engine mounting bolt, upper

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

94.9-108.5 Nm

70-80 ft-lbs

Engine mounting bolts, front

3.23 TOP END OVERHAUL: ASSEMBLY, Push-
rods, Lifters and Covers

10.2-13.6 Nm

90-120

in-lbs

Lifter cover screws

3.24 CAM COMPARTMENT AND COMPON-
ENTS, Cam Support Plate and Cover Installation

4.5-5.1 Nm

40-45

in-lbs

Oil pump screws, 1st torque

3.24 CAM COMPARTMENT AND COMPON-
ENTS, Cam Support Plate and Cover Installation

10.2-13.6 Nm

90-120

in-lbs

Oil pump screws, final torque

3.31 OIL TANK: FXSB, Installation

16.3-20.3 Nm

12-15 ft-lbs

Oil tank bolts

3.26 CRANKCASE DISASSEMBLY AND
REPAIR, Right Crankcase Half

2.8-3.9 Nm

25-35

in-lbs

Piston jet screw

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

122-149.1 Nm

90-110 ft-lbs

Pivot shaft nut

3.26 CRANKCASE DISASSEMBLY AND
REPAIR, Right Crankcase Half

4.5-7.9 Nm

40-70

in-lbs

Right main bearing retaining screws

3.23 TOP END OVERHAUL: ASSEMBLY, Rocker
Arm Support Plate

24.4-29.8 Nm

18-22 ft-lbs

Rocker arm support plate bolts

3.23 TOP END OVERHAUL: ASSEMBLY, Breather
and Rocker Cover

20.3-24.4 Nm

15-18 ft-lbs

Rocker cover screws

3.23 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head

13.6-19.0 Nm

120-168

in-lbs

Rocker housing bolts

3.24 CAM COMPARTMENT AND COMPON-
ENTS, Camshafts

10.2-13.6 Nm

90-120

in-lbs

Secondary cam chain tensioner fastener

3.8 TROUBLESHOOTING, Compression Test

16.3-24.4 Nm

12-18 ft-lbs

Spark plug

3.30 OIL TANK: ALL BUT FXSB, Installation

4.1-5.4 Nm

36-48

in-lbs

Splash guard fastener

3.31 OIL TANK: FXSB, Installation

4.1-6.8 Nm

36-60

in-lbs

Splash guard fasteners

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

20.3 Nm

15 ft-lbs

Transmission mounting bolts, 1st torque

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

46.1-52.9 Nm

34-39 ft-lbs

Transmission mounting bolts, final torque

HOME

3-2 2013 Softail Service: Engine

3.2

SPECIFICATIONS

SPECIFICATIONS

Table 3-1. Engine: Twin Cam 96

SPECIFICATION

ITEM

2

Number of cylinders

4-cycle, 45 degree

V-Type, air cooled

Type

9.2:1

Compression ratio

95.3 mm

3.75 in

Bore

111.3 mm

4.38 in

Stroke

1585 cm

3

96.0 in

3

Displacement

Pressurized, dry sump

Lubrication system

Table 3-2. Engine: Twin Cam 103

SPECIFICATION

ITEM

2

Number of cylinders

4-cycle, 45 degree

V-Type, air-cooled

Type

9.6:1

Compression ratio

98.42 mm

3.875 in

Bore

111.12 mm

4.375 in

Stroke

1690 cm

3

103.0 in

3

Displacement

Pressurized, dry sump

Lubrication system

Table 3-3. Oiling System

DATA

OIL PUMP

Twin geroter, dual scavenge, crank

mounted and driven, internal oil pump,

dry sump

Type

30-38 psi (207-262 kN/m

2

) at 2000 rpm

and normal operating temperature of 230

°F (110 °C)

Pressure

5 micron media, filtered between pump

and engine

Filtration

Table 3-4. Rocker Arms Specifications

MM

IN

ROCKER ARMS

0.013-0.051

0.0005-0.0020

Shaft fit in bushing (loose)

0.08-0.33

0.003-0.013

End clearance

0.051-0.102

0.002-0.004

Bushing fit in rocker arm (tight)

Table 3-5. Rocker Arm Shaft Specifications

MM

IN

ROCKER ARM SHAFTS

0.018-0.056

0.0007-0.0022

Shaft fit in rocker arm support
plate (loose)

Table 3-6. Hydraulic Lifter Specifications

MM

IN

HYDRAULIC
LIFTERS

0.002-0.066

0.0009-0.0026

Fit in crankcase
(loose)

Table 3-7. Cylinder Head Specifications

MM

IN

CYLINDER HEAD

0.051-0.084

0.0022-0.0033

Valve guide in head (tight)

0.076-0.114

0.003-0.0045

Valve seat in head (tight)

51.36

2.022

Valve stem protrusion (min)

0-0.152

0-0.006

Head gasket surface (flatness)

Table 3-8. Valve Specifications

MM

IN

VALVES

0.0254-0.0762

0.001-0.003

Exhaust: fit in guide

0.0254-0.0762

0.001-0.003

Intake: fit in guide

1.02-1.58

0.040-0.062

Seat width

51.10-51.61

2.012-2.032

Stem protrusion from cylinder
head boss

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2013 Softail Service: Engine 3-3