Harley Davidson 2008 Touring Models. Service Manual — page 46
A.13
PACKARD 480 METRI-PACK CONNECTORS
480 METRI-PACK CONNECTOR REPAIR
General
A 480 Metri-Pack (P.E.D.) connector is frequently used for the
B+ (battery voltage) connector to power P&A accessories.
Referred to as Packard connectors, Metri-Pack connectors are
embossed with the initials P.E.D.
Separating Pin and Socket Housings
NOTE
Cut any cable strap anchoring the wire conduits of the pin
(accessory connector housing) and the socket (B+) housing.
See
. Using small flat blade screwdriver, depress
button (1) on pin housing (red wire) side of the connector and
pull apart the pin and socket housings.
Mating Pin and Socket Housings
Orient the latch on the socket housing to the button catch on
the pin housing and press the housings together.
Removing Socket Terminals
1.
See
. Bend back the latch (2) slightly and free
one side of secondary lock, then repeat to release the
opposite side. Rotate the secondary lock outward on hinge
to access terminal in chamber of connector housing.
2.
On the mating end of the connector, note the tang in the
square shaped opening centered next to the terminal.
Gently insert the point of a stick pin or large safety pin into
the opening (3) between the tang and the chamber wall
until it stops.
3.
Pivot the end of the pin toward the terminal body to
depress the tang.
4.
Remove the pin and then pull terminal out of the wire end
of connector housing.
5.
If necessary, crimp new terminals on wires. See
A.15 PACKARD METRI-PACK TERMINALS
Installing Socket Terminals
1.
Carefully bend the tang outward away from the terminal
body.
2.
With the tang on the same side as the square shaped
opening in the mating end of the connector housing, feed
terminal into wire end of connector housing until it "clicks"
in place.
3.
Verify that terminal will not back out of the chamber. A
slight tug on the cable will confirm that it is locked.
4.
Rotate the hinged secondary lock inward until latches fully
engage tabs on both sides of connector housing.
NOTE
If removed, install new anchored cable strap in O.E. location.
Tighten cable strap to capture conduit of both accessory con-
nector and B+ connector approximately 1.0 in. (25.4 mm) from
housings.
1
2
3
sm00031
1.
Button on pin housing
2.
Secondary lock latch
3.
Opening between tang and chamber wall
Figure A-43. 480 Metri-Pack Connector: Remove Socket
Terminal
2008 Touring Service: Appendix A Connector Repair A-27
2008 Touring Models Service Manual
NOTES
TORQUE VALUE
FASTENER
1.6 BRAKES, Fluid Inspection
0.8-1.1 Nm
7-10 in-lbs
Front master cylinder reservoir cover
screws
1.14 BLEEDING BRAKES, Procedure
0.8-1.1 Nm
7-10 in-lbs
Front master cylinder reservoir cover
screws
1.15 BRAKE PADS AND DISCS, Brake Pad
Replacement
0.8-1.1 Nm
7-10 in-lbs
Front master cylinder reservoir cover
screws
1.23 ENGINE MOUNTS, Inspection
20-27 Nm
15-20 Nm
Front rubber mount to frame cross-
member
2.11 VEHICLE ALIGNMENT, Method B
20-27 Nm
15-20 ft-lbs
Front rubber mount to frame cross-
member bolts
2.39 UPPER FAIRING AND WINDSHIELD:
FLTR, Outer Fairing
4.5-5.7 Nm
40-50 in-lbs
Front turn signal lamp bracket stud acorn
nuts (FLTR)
8.14 TURN SIGNAL LAMPS, Front Turn Signal
Lamp
4.1-6.8 Nm
30-60 in-lbs
Front turn signal lamp mounting bracket
screws (FLHR/C, FLHT/C/U)
8.14 TURN SIGNAL LAMPS, Front Turn Signal
Lamp
20-27 Nm
15-20 ft-lbs
Front turn signal lamp mounting bracket
screws (FLHX)
4.4 FUEL TANK, Fuel Supply Check Valve/Tube /
metric
29.8-35.3 Nm
22-26 ft-lbs
Fuel supply line quick-connect fitting
4.15 FUEL INJECTORS, Installation / metric
7.5-9.3 Nm
66-82 in-lbs
Fuel supply tube clamp screw
4.4 FUEL TANK, Installation
4.1-6.8 Nm
36-60 in-lbs
Fuel tank console screws
8.32 ADVANCED AUDIO SYSTEM, Front Headset
Receptacle
4.1-6.8 Nm
36-60 in-lbs
Fuel tank console screws
4.4 FUEL TANK, Installation
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank front screws
4.4 FUEL TANK, Installation
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank rear bracket screws
8.6 ELECTRICAL CADDIES, Battery Tray
5.7-10.2 Nm
50-90 in-lbs
Ground stud flange nut (10 mm)
2.28 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail
20.0-27.0 Nm
15-20 ft-lbs
Guard to frame screws
2.28 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail
20.0-27.0 Nm
15-20 ft-lbs
Guard to frame screws
4.9 TWIST GRIP SENSOR, Installation / metric
8-9 Nm
72-80 in-lbs
Handlebar clamp screws
2.24 HANDLEBARS, Adjustment
8-12 Nm
72-108 in-lbs
Handlebar clamp to clutch lever bracket
screws
8.39 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Left Side Handlebar Switches
8.0-12.0 Nm
72-108 in-lbs
Handlebar clamp to clutch lever bracket
screws
8.39 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation
8.0-12.0 Nm
72-108 in-lbs
Handlebar clamp to clutch lever bracket
screws
2.23 CLUTCH CABLE, Installation
6.8-9.0 Nm
60-80 in-lbs
Handlebar clamp to clutch lever bracket
T27 TORX screws
2.24 HANDLEBARS, Adjustment
8-9 Nm
72-80 in-lbs
Handlebar clamp to master cylinder
reservoir screws
8.39 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Right Side Handlebar Switches
8.0-9.0 Nm
72-80 in-lbs
Handlebar clamp to master cylinder
screws
8.39 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation
8.0-9.0 Nm
72-80 in-lbs
Handlebar clamp to master cylinder
screws
2.24 HANDLEBARS, Rubber Mounts
40.7-54.2 Nm
30-40 ft-lbs
Handlebar lower clamp bolts (risers)
1.2 MAINTENANCE SCHEDULE, General
4.0-5.1 Nm
35-45 in-lbs
Handlebar switch housing screw
4.9 TWIST GRIP SENSOR, Installation / metric
4-5 Nm
35-45 in-lbs
Handlebar switch housing screws
TORQUE VALUES XIII
2008 Touring Models Service Manual
NOTES
TORQUE VALUE
FASTENER
8.39 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Right Side Handlebar Switches
4.0-5.0 Nm
35-45 in-lbs
Handlebar switch housing screws
8.39 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Left Side Handlebar Switches
4.0-5.0 Nm
35-45 in-lbs
Handlebar switch housing screws
8.39 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation
4.0-5.0 Nm
35-45 in-lbs
Handlebar switch housing screws
8.39 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation
4.0-5.0 Nm
35-45 in-lbs
Handlebar switch housing screws
2.24 HANDLEBARS, Adjustment
21.7-27.1 Nm
16-20 ft-lbs
Handlebar upper clamp screws
2.24 HANDLEBARS, Installation
21.7-27.1 Nm
16-20 ft-lbs
Handlebar upper clamp screws
2.24 HANDLEBARS, Installation
21.7-27.1 Nm
16-20 ft-lbs
Handlebar upper clamp screws
8.33 WIRE TROUGH, Installation / metric (10 mm)
5.7-10.2 Nm
50-90 in-lbs
Harness ground ring terminal flange nuts
8.33 WIRE TROUGH, Installation / metric (10 mm)
5.7-10.2 Nm
50-90 in-lbs
Harness ground ring terminal flange nuts
8.34 MAIN WIRING HARNESS, Installation: All
Models (Part 1) / (10 mm)
5.7-10.2 Nm
50-90 in-lbs
Harness ground stud flange nuts
8.34 MAIN WIRING HARNESS, Installation: All
Models (Part 1) / (10 mm)
5.7-10.2 Nm
50-90 in-lbs
Harness ground stud flange nuts
2.46 FRONT FENDER, Installation
1.0-2.0 Nm
9-18 in-lbs
Headlamp door screw
8.9 HEADLAMP: ALL EXCEPT FLTR, Headlamp
Assembly
1.0-2.0 Nm
9-18 in-lbs
Headlamp door screw
2.45 HEADLAMP NACELLE: FLHR/C, Installation
1.0-2.0 Nm
9-18 in-lbs
Headlamp housing Phillips screws
2.45 HEADLAMP NACELLE: FLHR/C, Installation
1.0-2.0 Nm
9-18 in-lbs
Headlamp housing Phillips screws
2.46 FRONT FENDER, Installation
1.0-2.0 Nm
9-18 in-lbs
Headlamp housing screws (FLHR/C/S)
8.9 HEADLAMP: ALL EXCEPT FLTR, Headlamp
Assembly
1.0-2.0 Nm
9-18 in-lbs
Headlamp housing screws (FLHR/C)
2.45 HEADLAMP NACELLE: FLHR/C, Installation
1.7-2.3 Nm
15-20 in-lbs
Headlamp nacelle handlebar chrome
strip flange nut
2.45 HEADLAMP NACELLE: FLHR/C, Installation
1.1-2.3 Nm
10-20 in-lbs
Headlamp nacelle handlebar clamp
shroud Phillips screws
2.45 HEADLAMP NACELLE: FLHR/C, Installation
1.1-2.3 Nm
10-20 in-lbs
Headlamp nacelle handlebar clamp
shroud Phillips screws
2.45 HEADLAMP NACELLE: FLHR/C, Installation
8.1-12.2 Nm
72-108 in-lbs
Headlamp nacelle to fork bracket stud
acorn nuts
8.9 HEADLAMP: ALL EXCEPT FLTR, Headlamp
Assembly
2.6-3.2 Nm
23-28 in-lbs
Headlamp retaining ring screws (FLXH,
FLHT/C/U)
8.26 HORN, Installation
9.0-13.6 Nm
80-120 in-lbs
Horn bracket acorn nut
8.33 WIRE TROUGH, Installation
9.0-13.6 Nm
80-120 in-lbs
Horn bracket acorn nut to rubber mount
stud
4.12 INDUCTION MODULE, Installation / metric
48-54 Nm
35-40 ft-lbs
Horn bracket to cylinder head screws
8.34 MAIN WIRING HARNESS, Installation: All
Models (Part 1)
48-54 Nm
35-40 ft-lbs
Horn bracket to cylinder head screws
8.26 HORN, Installation
9.0-11.3 Nm
80-100 in-lbs
Horn stud flange nut
8.4 IGNITION COIL, Installation
9.5-16.3 Nm
84-144 in-lbs
Ignition coil bracket screws
8.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, FLHX, FLHT/C/U, FLTR
14.1-16.9 Nm
125-150 in-lbs
Ignition switch housing nut
8.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, FLHX, FLHT/C/U, FLTR
4.1-6.8 Nm
36-60 in-lbs
Ignition switch housing screws
XIV TORQUE VALUES
2008 Touring Models Service Manual
NOTES
TORQUE VALUE
FASTENER
8.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, FLHR/C
2.3-3.4 Nm
20-30 in-lbs
Ignition switch screws (FLHR/C)
8.19 INSTRUMENT NACELLE SWITCHES:
FLTR, Installation
2.8-4.0 Nm
25-35 in-lbs
Instrument bezel screws
2.40 INSTRUMENT BEZEL: FLTR, Bezel
2.8-4.0 Nm
25-35 in-lbs
Instrument bezel screws (FLTR)
8.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, FLHR/C
4.1-6.8 Nm
36-60 in-lbs
Instrument console screws
8.30 GAUGES AND INSTRUMENTS:
FLHR/C, Speedometer
4.1-6.8 Nm
36-60 in-lbs
Instrument console screws
8.31 INDICATOR LAMPS: FLHR/C, Indicator
Lights
4.1-6.8 Nm
36-60 in-lbs
Instrument console screws
8.19 INSTRUMENT NACELLE SWITCHES:
FLTR, Installation
20-27 Nm
15-20 ft-lbs
Instrument nacelle to fork bracket screws
8.19 INSTRUMENT NACELLE SWITCHES:
FLTR, Installation
20-27 Nm
15-20 ft-lbs
Instrument nacelle to fork bracket screws
2.41 INSTRUMENT NACELLE: FLTR, Instrument
Nacelle
20-27 Nm
15-20 ft-lbs
Instrument nacelle to fork bracket screws
(FLTR)
2.41 INSTRUMENT NACELLE: FLTR, Instrument
Nacelle
20-27 Nm
15-20 ft-lbs
Instrument nacelle to fork bracket screws
(FLTR)
2.5 REAR WHEEL COMPENSATOR, Isolator
Replacement / Always use new screws
74.6-88.1 Nm
55-65 ft-lbs
Isolator bowl hex screws
2.49 FOOTBOARDS AND FOOTRESTS, Rider
Footboards
20.3-27.1 Nm
15-20 ft-lbs
Jiffy stand bracket hex screws
2.50 JIFFY STAND, Jiffy Stand Bracket
20.3-27.1 Nm
15-20 ft-lbs
Jiffy stand bracket hex screws
2.50 JIFFY STAND, Jiffy Stand Bracket
20.3-27.1 Nm
15-20 ft-lbs
Jiffy stand bracket hex screws
2.50 JIFFY STAND, Jiffy Stand Interlock Sensor /
Use Loctite Medium Strength Threadlocker 243
(blue) if reusing screw
10.8-13.6 Nm
96-120 in-lbs
Jiffy stand interlock sensor screw
2.50 JIFFY STAND, Installation
20.3-27.1 Nm
15-20 ft-lbs
Jiffy stand leg stop hex screw
5.2 STARTER, Installation
16.3-20.3 Nm
12-15 ft-lbs
Keps nut
2.47 REAR FENDER, Installation
20-27 Nm
15-20 ft-lbs
License plate bracket to luggage rack
screws
3.16 TOP END OVERHAUL: ASSEMBLY, Push
Rods, Lifters and Covers
10.2-13.6 Nm
90-120 in-lbs
Lifter cover screws
5.3 STARTER SOLENOID, Solenoid Contacts
7.3-9.0 Nm
65-80 in-lbs
Long post jam nut
2.17 FRONT FORK, Installation
41-48 Nm
30-35 ft-lbs
Lower fork bracket pinch bolt
1.19 STEERING HEAD BEARINGS, Adjustment
41-48 Nm
30-35 ft-lbs
Lower fork bracket pinch bolts
C.3 ABS BRAKE LINES, ABS Module to Front
Brake Calipers
13.6-20.3 Nm
120-180 in-lbs
Lower fork bracket T40 TORX screw
8.34 MAIN WIRING HARNESS, Installation: All
Models (Part 1)
7.9-11.3 Nm
70-100 in-lbs
Lower frame crossmember stud locknut
7.5 TRANSMISSION ASSEMBLY, Assembly
61.0-74.6 Nm
45-55 ft-lbs
Mainshaft/countershaft nuts
1.2 MAINTENANCE SCHEDULE, General
0.8-1.1 Nm
7-10 in-lbs
Master cylinder reservoir cover
1.2 MAINTENANCE SCHEDULE, General
1.4-1.7 Nm
12-15 in-lbs
Master cylinder reservoir cover
2.12 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation
8-9 Nm
72-80 in-lbs
Master cylinder reservoir handlebar
clamp screws
TORQUE VALUES XV
2008 Touring Models Service Manual
NOTES
TORQUE VALUE
FASTENER
C.3 ABS BRAKE LINES, Rear Master Cylinder to
ABS Module
14-17 Nm
10.5-12.5 ft-lbs
Master cylinder to frame weldment
screws
2.25 MIRRORS, FLHX / metric
3.4-4.5 Nm
30-40 in-lbs
Mirror flange nut (FLHX)
2.25 MIRRORS, All Models Except FLHX / metric
6.8-10.8 Nm
60-96 in-lbs
Mirror stem acorn nut
7.7 TRANSMISSION CASE, Installation
13.6-20.3 Nm
120-180 in-lbs
Neutral switch
8.23 NEUTRAL SWITCH, Installation
13.6-20.3 Nm
120-180 in-lbs
Neutral switch
4.14 OXYGEN SENSORS (O2), Installation /
metric
40.7-59.7 Nm
30-44 ft-lbs
O2 sensor
3.29 OIL PAN, Installation
9.5-14.9 Nm
84-132 in-lbs
Oil pan screws
8.24 OIL PRESSURE SWITCH AND
SENDER, Installation
11-14 Nm
96-120 in-lbs
Oil pressure sender
8.24 OIL PRESSURE SWITCH AND
SENDER, Installation
11-14 Nm
96-120 in-lbs
Oil pressure switch
3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Cover and Cam Support Plate
4.5-5.1 Nm
40-45 in-lbs
Oil pump screws, initial torque
2.39 UPPER FAIRING AND WINDSHIELD:
FLTR, Outer Fairing
1.1-1.7 Nm
10-15 in-lbs
Outer fairing long screws (FLTR)
2.35 UPPER FAIRING AND WINDSHIELD: FLHX,
FLHT/C/U, Outer Fairing and Windshield
2.3-3.4 Nm
20-30 in-lbs
Outer fairing screws (FLHX, FLHT/C/U)
2.39 UPPER FAIRING AND WINDSHIELD:
FLTR, Outer Fairing
0.7-1.4 Nm
6-12 in-lbs
Outer fairing short screws (FLTR)
2.11 VEHICLE ALIGNMENT, Method A
40.7-47.5 Nm
30-35 ft-lbs
Passenger footboard/footrest socket
screw
2.11 VEHICLE ALIGNMENT, Method B
40.7-47.5 Nm
30-35 ft-lbs
Passenger footboard/footrest socket
screw
2.22 REAR FORK, Installation
40.7-47.5 Nm
30-35 ft-lbs
Passenger footboard/footrest socket
screw
2.49 FOOTBOARDS AND FOOTRESTS, Pas-
senger Footboard
40.7-47.5 Nm
30-35 ft-lbs
Passenger footboard/footrest socket
screw
2.49 FOOTBOARDS AND FOOTRESTS, Pas-
senger Footrest (FLHX)
40.7-47.5 Nm
30-35 ft-lbs
Passenger footboard/footrest socket
screw
2.49 FOOTBOARDS AND FOOTRESTS, Pas-
senger Footrest (FLHX) / Use Loctite Medium
Strength Threadlocker 243 (blue)
20-27 Nm
15-20 ft-lbs
Passenger footrest pad socket screw
(FLHX)
3.27 CRANKCASE, Right Crankcase Half
2.8-3.9 Nm
25-35 in-lbs
Piston jet screws
3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Cover and Cam Support Plate
46.1 Nm
34 ft-lbs
Primary cam sprocket flange bolts, final
torque
3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Cover and Cam Support Plate
20.3 Nm
15 ft-lbs
Primary cam sprocket flange bolts, initial
torque
3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Cover and Cam Support Plate
20.3 Nm
15 ft-lbs
Primary cam sprocket flange bolts, initial
torque
1.2 MAINTENANCE SCHEDULE, General
19.0-28.5 Nm
14-21 ft-lbs
Primary chaincase drain plug
1.9 PRIMARY CHAIN, Chaincase Lubricant:
Touring Models
19.0-28.5 Nm
14-21 ft-lbs
Primary chaincase drain plug
6.2 PRIMARY CHAINCASE COVER, Installation
12.2-13.6 Nm
108-120 in-lbs
Primary cover fasteners
8.32 ADVANCED AUDIO SYSTEM, Radio (Storage
Box)
4.0-5.1 Nm
35-45 in-lbs
Radio (storage box) to support bracket
screws
XVI TORQUE VALUES
2008 Touring Models Service Manual
NOTES
TORQUE VALUE
FASTENER
2.42 INNER FAIRING: FLTR, Installation
10.9-16.3 Nm
96-144 in-lbs
Radio bracket/inner fairing to fairing
bracket stud locknuts (FLTR)
8.34 MAIN WIRING HARNESS, Installation: FLHX,
FLHT/C/U (Part 2)
4.0-5.1 Nm
35-45 in-lbs
Radio mounting screw
8.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, FLHX, FLHT/C/U, FLTR
4.0-5.1 Nm
35-45 in-lbs
Radio support bracket screws
2.28 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail
3.0-6.0 Nm
30-50 in-lbs
Rail clamp screws
2.28 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail
8.0-14.0 Nm
72-120 in-lbs
Rail mount to guard screws
2.28 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail
20.0-27.0 Nm
15-20 ft-lbs
Rail to saddlebag support screws
2.28 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail
20.0-27.0 Nm
15-20 ft-lbs
Rail to saddlebag support screws
2.28 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail
20.0-27.0 Nm
15-20 ft-lbs
Rail to saddlebag support screws
2.11 VEHICLE ALIGNMENT, Method A
128.8-142.4 Nm
95-105 ft-lbs
Rear axle cone nut
2.11 VEHICLE ALIGNMENT, Method B
128.8-142.4 Nm
95-105 ft-lbs
Rear axle cone nut
1.13 REAR BELT DEFLECTION, Setting Belt
Deflection / For belt adjustment only
20-27 Nm
15-20 ft-lbs
Rear axle cone nut
1.13 REAR BELT DEFLECTION, Setting Belt
Deflection / Loosen 360° and retighten
128.8-142.4 Nm
95-105 ft-lbs
Rear axle cone nut
1.13 REAR BELT DEFLECTION, Setting Belt
Deflection / For belt adjustment only
20-27 Nm
15-20 ft-lbs
Rear axle cone nut
2.4 REAR WHEEL, Installation / metric
128.8-142.4 Nm
95-105 ft-lbs
Rear axle cone nut (final)
2.4 REAR WHEEL, Installation / metric
20-27 Nm
15-20 ft-lbs
Rear axle cone nut (preliminary)
2.4 REAR WHEEL, Installation / metric
20-27 Nm
15-20 ft-lbs
Rear axle cone nut (preliminary)
2.49 FOOTBOARDS AND FOOTRESTS, Rider
Footboards
20-27 Nm
15-20 ft-lbs
Rear bracket hex screws
C.3 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
4.18 EXHAUST SYSTEM, Installation
1-2 Nm
9-18 in-lbs
Rear cylinder head exhaust flange nut
4.18 EXHAUST SYSTEM, Assembly
11.3-13.6 Nm
100-120 in-lbs
Rear cylinder head exhaust flange nut,
final
4.18 EXHAUST SYSTEM, Assembly
1-2 Nm
9-18 in-lbs
Rear cylinder head exhaust flange nut,
initial
4.18 EXHAUST SYSTEM, Assembly
11.3-13.6 Nm
100-120 in-lbs
Rear cylinder head exhaust flange nut,
top
2.48 REAR FACIA: FLHX, Stud Plate / See next
entry if reusing stud plate
9.0 Nm
80 in-lbs
Rear facia flange nuts to new stud plate
(FLHX)
2.48 REAR FACIA: FLHX, Installation
3.4-5.1 Nm
30-45 in-lbs
Rear facia flange nuts to used stud plate
(FLHX)
2.48 REAR FACIA: FLHX, Installation
2.0-2.5 Nm
18-22 in-lbs
Rear facia lamp T20 TORX screws
(FLHX)
2.47 REAR FENDER, Installation
5.1-9.6 Nm
45-85 in-lbs
Rear fender bumper weld stud flange nut
8.12 TAIL LAMP, Rear Fender Lights Harness
6.8-10.9 Nm
60-96 in-lbs
Rear fender lights harness stud plate
flange nuts
TORQUE VALUES XVII
2008 Touring Models Service Manual
NOTES
TORQUE VALUE
FASTENER
2.47 REAR FENDER, Installation
20-27 Nm
15-20 ft-lbs
Rear fender mounting screws
1.6 BRAKES, Fluid Inspection
1.4-1.7 Nm
12-15 in-lbs
Rear master cylinder reservoir cover
screws
1.14 BLEEDING BRAKES, Procedure
1.4-1.7 Nm
12-15 in-lbs
Rear master cylinder reservoir cover
screws
1.15 BRAKE PADS AND DISCS, Brake Pad
Replacement
1.4-1.7 Nm
12-15 in-lbs
Rear master cylinder reservoir cover
screws
2.14 REAR BRAKE MASTER CYL-
INDER, Assembly and Installation
14-17 Nm
10.5-12.5 ft-lbs
Rear master cylinder to frame weldment
screws
2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line
14-17 Nm
10.5-12.5 ft-lbs
Rear master cylinder to frame weldment
screws
8.25 STOPLIGHT SWITCHES, Rear Stoplight
Switch / Use Loctite Pipe Sealant with Teflon 565
16.3-20.3 Nm
12-15 ft-lbs
Rear stoplight switch
2.11 VEHICLE ALIGNMENT, Method A
46-57 Nm
34-42 ft-lbs
Rear swingarm bracket bolts
2.11 VEHICLE ALIGNMENT, Method B
46-57 Nm
34-42 ft-lbs
Rear swingarm bracket bolts
2.22 REAR FORK, Installation
46-57 Nm
34-42 ft-lbs
Rear swingarm bracket bolts
2.11 VEHICLE ALIGNMENT, Method A
54-61 Nm
40-45 ft-lbs
Rear swingarm pivot shaft locknuts
2.11 VEHICLE ALIGNMENT, Method A
54-61 Nm
40-45 ft-lbs
Rear swingarm pivot shaft locknuts
2.11 VEHICLE ALIGNMENT, Method B
54-61 Nm
40-45 ft-lbs
Rear swingarm pivot shaft locknuts
2.11 VEHICLE ALIGNMENT, Method B
54-61 Nm
40-45 ft-lbs
Rear swingarm pivot shaft locknuts
2.22 REAR FORK, Disassembly and Assembly
54-61 Nm
40-45 ft-lbs
Rear swingarm pivot shaft locknuts
2.22 REAR FORK, Installation
54-61 Nm
40-45 ft-lbs
Rear swingarm pivot shaft locknuts
2.22 REAR FORK, Installation
54-61 Nm
40-45 ft-lbs
Rear swingarm pivot shaft locknuts
8.14 TURN SIGNAL LAMPS, Rear Turn Signal
Lamps Bracket / Use LOCTITE High Strength
Threadlocker 271 (red)
9.5-16.3 Nm
84-144 in-lbs
Rear turn signal lamps bracket screws
8.14 TURN SIGNAL LAMPS, Rear Turn Signal
Lamps Bracket / Use LOCTITE High Strength
Threadlocker 271 (red)
9.5-16.3 Nm
84-144 in-lbs
Rear turn signal lamps bracket screws
8.15 LICENSE PLATE LAMPS AND BRACKET:
FLHX, License Plate Bracket / Use LOCTITE High
Strength Threadlocker 271 (red)
9.5-16.3 Nm
84-144 in-lbs
Rear turn signal lamps bracket screws
8.14 TURN SIGNAL LAMPS, Rear Turn Signal
Lamp
3.4-5.6 Nm
30-50 in-lbs
Rear turn signal lamp to rear turn signal
lamps bracket screws
2.49 FOOTBOARDS AND FOOTRESTS, Rider
Footboards
41-48 Nm
30-35 ft-lbs
Rider footboard bracket socket screws
2.49 FOOTBOARDS AND FOOTRESTS, Rider
Footboards
41-48 Nm
30-35 ft-lbs
Rider footboard bracket socket screws
4.18 EXHAUST SYSTEM, Installation
41-48 Nm
30-35 ft-lbs
Rider footboard bracket socket screws
4.18 EXHAUST SYSTEM, Assembly
41-48 Nm
30-35 ft-lbs
Rider footboard bracket socket screws
2.49 FOOTBOARDS AND FOOTRESTS, Rider
Footboards
6.8-9.0 Nm
60-80 in-lbs
Rider footboard pivot bolt nut
3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Arm Support Plate
24.4-29.8 Nm
18-22 ft-lbs
Rocker arm support plate bolts
3.16 TOP END OVERHAUL: ASSEMBLY, Breather
Assembly
20.3-24.4 Nm
15-18 ft-lbs
Rocker cover bolts
XVIII TORQUE VALUES
2008 Touring Models Service Manual
NOTES
TORQUE VALUE
FASTENER
3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head
13.6-19.0 Nm
120-168 in-lbs
Rocker housing bolts
2.28 SADDLEBAG SERVICE, Saddlebag Hard-
ware
2.3-2.8 Nm
20-25 in-lbs
Saddlebag latch/check strap T15 TORX
screws
2.28 SADDLEBAG SERVICE, Saddlebag Hard-
ware
2.3-2.8 Nm
20-25 in-lbs
Saddlebag latch/check strap T15 TORX
screws
2.28 SADDLEBAG SERVICE, Saddlebag Hard-
ware
2.0-2.3 Nm
18-20 in-lbs
Saddlebag lid check strap T20 TORX
screws
2.26 SEAT, Seat: FLHR/C, FLHX, FLTR
6.8-10.8 Nm
60-96 in-lbs
Saddlebag mounting bracket screw
2.28 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail
7.0-11.0 Nm
60-96 in-lbs
Saddlebag mounting bracket screw
8.36 RADIO ANTENNA CABLE, FLHX, FLTR
6.8-10.8 Nm
60-96 in-lbs
Saddlebag mounting bracket screw
2.27 SADDLEBAGS, Installation
7-11 Nm
60-96 in-lbs
Saddlebag mounting bracket to
saddlebag support screws
2.48 REAR FACIA: FLHX, Rear Facia Lamp
6.8-10.8 Nm
60-96 in-lbs
Saddlebag mounting bracket to
saddlebag support screws
2.4 REAR WHEEL, Installation / metric
20-27 Nm
15-20 ft-lbs
Saddlebag rail to saddlebag support
bracket/frame screws
2.28 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail
20.0-27.0 Nm
15-20 ft-lbs
Saddlebag support to fender screws
6.4 PRIMARY CHAINCASE HOUSING, Installation
33.9-36.6 Nm
25-27 ft-lbs
Sealing fasteners
2.26 SEAT, Seat: FLHT
2.3-4.5 Nm
20-40 in-lbs
Seat mounting screw
2.26 SEAT, Seat: FLHTC/U
2.3-4.5 Nm
20-40 in-lbs
Seat mounting screw
2.26 SEAT, Seat: FLHR/C, FLHX, FLTR
2.3-4.5 Nm
20-40 in-lbs
Seat mounting screw
2.26 SEAT, Seat: FLHT
5.4-8.1 Nm
48-72 in-lbs
Seat strap screw
2.26 SEAT, Seat: FLHTC/U
5.4-8.1 Nm
48-72 in-lbs
Seat strap screw
3.25 COVER AND CAM SUPPORT PLATE, Cam-
shafts
11.3-13.6 Nm
100-120 in-lbs
Secondary cam chain tensioner fastener
7.5 TRANSMISSION ASSEMBLY, Assembly
13.6-17.0 Nm
120-150 in-lbs
Shift drum detent arm fastener
7.5 TRANSMISSION ASSEMBLY, Assembly
6.4-7.1 Nm
57-63 in-lbs
Shift drum lock plate fasteners
7.7 TRANSMISSION CASE, Assembly
24.4-29.8 Nm
18-22 ft-lbs
Shifter rod lever screw
7.3 SHIFTER LINKAGE, Shifter Rod
9.0-13.6 Nm
80-120 in-lbs
Shifter rod locknut
6.2 PRIMARY CHAINCASE COVER, Installation
24-30 Nm
18-22 ft-lbs
Shift lever fasteners
6.2 PRIMARY CHAINCASE COVER, Installation
10.2-12.4
90-110 in-lbs
Shift lever shaft fastener
2.21 REAR SHOCK ABSORBERS, Installation /
Use LOCTITE MEDIUM STRENGTH THREAD-
LOCKER 243 (blue)
47-54 Nm
35-40 ft-lbs
Shock bottom mounting bolt
2.22 REAR FORK, Installation / Apply two or three
drops of Loctite Medium Strength Threadlocker
243 (blue) to threads
47-54 Nm
35-40 ft-lbs
Shock bottom mounting bolt
2.21 REAR SHOCK ABSORBERS, Installation /
Use LOCTITE MEDIUM STRENGTH THREAD-
LOCKER 243 (blue)
45-48 Nm
33-35 ft-lbs
Shock top mounting bolt
7.5 TRANSMISSION ASSEMBLY, Installation
17.6-24.4 Nm
13-18 ft-lbs
Side door fasteners
5.2 STARTER, Field Coil Assembly
7.9-10.2 Nm
70-90 in-lbs
Solenoid ring terminal nut
1.18 SPARK PLUGS, Inspection
16.3-24.4 Nm
12-18 ft-lbs
Spark plug
1.2 MAINTENANCE SCHEDULE, General
16.3-24.4 Nm
12-18 ft-lbs
Spark plugs
TORQUE VALUES XIX
2008 Touring Models Service Manual
NOTES
TORQUE VALUE
FASTENER
2.37 INNER FAIRING: FLHX, FLHT/C/U, Installa-
tion
1.1-2.3 Nm
10-20 in-lbs
Speedometer/tachometer bracket screws
8.28 GAUGES AND INSTRUMENTS: FLHX,
FLHT/C/U, FLTR, Speedometer
1.1-2.3 Nm
10-20 in-lbs
Speedometer bracket screws
1.8 TIRES AND WHEELS, Wheel Spokes
6.2 Nm
55 in-lbs
Spoke nipple
2.7 WHEEL LACING: 16 INCH RIM, Procedure
6.2 Nm
55 in-lbs
Spoke nipple
2.9 TRUING LACED WHEELS, Radial Truing
6.2 Nm
55 in-lbs
Spoke nipple
1.2 MAINTENANCE SCHEDULE, General
6.2 Nm
55 in-lbs
Spoke nipples
2.11 VEHICLE ALIGNMENT, Method A
24-30 Nm
18-22 ft-lbs
Stabilizer link to frame weldment bolt
2.11 VEHICLE ALIGNMENT, Method B
24-30 Nm
18-22 ft-lbs
Stabilizer link to frame weldment bolt
2.11 VEHICLE ALIGNMENT, Method B
24-30 Nm
18-22 ft-lbs
Stabilizer link to frame weldment bolt
2.11 VEHICLE ALIGNMENT, Method A
24-30 Nm
18-22 ft-lbs
Stabilizer link to front engine mounting
bracket bolt
2.11 VEHICLE ALIGNMENT, Method B
24-30 Nm
18-22 ft-lbs
Stabilizer link to front engine mounting
bracket bolt
2.11 VEHICLE ALIGNMENT, Method A
24-30 Nm
18-22 ft-lbs
Stabilizer link to top engine mounting
bracket bolt
2.11 VEHICLE ALIGNMENT, Method B
24-30 Nm
18-22 ft-lbs
Stabilizer link to top engine mounting
bracket bolt
2.11 VEHICLE ALIGNMENT, Method B
24-30 Nm
18-22 ft-lbs
Stabilizer link to top engine mounting
bracket bolt
5.2 STARTER, Field Coil Assembly
10.2-12.4 Nm
90-110 in-lbs
Starter end cover screw
5.2 STARTER, Installation
33.9-36.6 Nm
25-27 ft-lbs
Starter mounting screw
5.2 STARTER, Installation
7.9-10.2 Nm
70-90 in-lbs
Starter terminal post nut
5.2 STARTER, Field Coil Assembly
4.4-7.3 Nm
39-65 in-lbs
Starter thru bolts
8.21 ALTERNATOR, Installation / Always use new
screws
6.2-8.5 Nm
55-75 in-lbs
Stator mounting screws
2.28 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail
20.0-27.0 Nm
15-20 ft-lbs
Support rail to frame screws
2.28 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail
8.0-11.0 Nm
70-100 in-lbs
Support rail to guard screw
2.28 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail
8.0-11.0 Nm
70-100 in-lbs
Support rail to guard screw
8.28 GAUGES AND INSTRUMENTS: FLHX,
FLHT/C/U, FLTR, Tachometer
1.1-2.3 Nm
10-20 in-lbs
Tachometer bracket screws
8.12 TAIL LAMP, Circuit Board/Chrome Base
4.5-5.4 Nm
40-48 in-lbs
Tail lamp circuit board/chrome base
screw
8.12 TAIL LAMP, Tail Lamp/Tail Lamp Bulb
2.3-2.7 Nm
20-24 in-lbs
Tail lamp screws
8.12 TAIL LAMP, Circuit Board/Chrome Base
2.3-2.7 Nm
20-24 in-lbs
Tail lamp screws
8.12 TAIL LAMP, Rear Fender Lights Harness
2.3-2.7 Nm
20-24 in-lbs
Tail lamp screws
8.13 FENDER TIP LAMPS, Rear Fender Tip Lamp
2.3-2.7 Nm
20-24 in-lbs
Tail lamp screws
8.14 TURN SIGNAL LAMPS, Rear Turn Signal
Lamp
2.3-2.7 Nm
20-24 in-lbs
Tail lamp screws
4.13 MANIFOLD ABSOLUTE PRESSURE
SENSOR (MAP), Installation / metric
9.5-12.2 Nm
84-108 in-lbs
T-MAP hex screw
1.23 ENGINE MOUNTS, Inspection
24-30 Nm
18-22 ft-lbs
Top/front stabilizer link eyelet
XX TORQUE VALUES
2008 Touring Models Service Manual
NOTES
TORQUE VALUE
FASTENER
1.23 ENGINE MOUNTS, Inspection
24-30 Nm
18-22 ft-lbs
Top/front stabilizer link eyelet
1.23 ENGINE MOUNTS, Inspection
24-30 Nm
18-22 ft-lbs
Top/front stabilizer link eyelet
1.23 ENGINE MOUNTS, Inspection
24-30 Nm
18-22 ft-lbs
Top/front stabilizer link eyelet
1.2 MAINTENANCE SCHEDULE, General
20-27 Nm
15-20 ft-lbs
Top caddy clamp screw
1.16 BATTERY MAINTENANCE, Battery: Touring
Models
20-27 Nm
15-20 ft-lbs
Top caddy clamp screw
8.6 ELECTRICAL CADDIES, Top Caddy
20-27 Nm
15-20 ft-lbs
Top caddy clamp screw
3.12 ASSEMBLING MOTORCYCLE AFTER
SERVICE, Procedure
24-30 Nm
18-22 ft-lbs
Top engine mounting bracket stabilizer
link to frame weldment bolt
3.14 INSTALLING ENGINE IN CHASSIS, Pro-
cedure
24-30 Nm
18-22 ft-lbs
Top engine mounting bracket stabilizer
link to frame weldment bolt
2.11 VEHICLE ALIGNMENT, Method A
48-54 Nm
35-40 ft-lbs
Top engine mounting bracket to front
cylinder head bolts
2.11 VEHICLE ALIGNMENT, Method B
48-54 Nm
35-40 ft-lbs
Top engine mounting bracket to front
cylinder head bolts
3.12 ASSEMBLING MOTORCYCLE AFTER
SERVICE, Procedure
41-48 Nm
30-35 ft-lbs
Top engine mounting bracket to front
cylinder head bolts
3.14 INSTALLING ENGINE IN CHASSIS, Pro-
cedure
41-48 Nm
30-35 ft-lbs
Top engine mounting bracket to front
cylinder head bolts
2.30 TOUR-PAK SERVICE, Lockset
2.8-4.0 Nm
25-35 in-lbs
Tour-Pak lockset hex nut
2.33 TOUR-PAK SPEAKER BOX:
FLHTCU, Speaker Box (FLHTCU)
2.8-4.0 Nm
25-35 in-lbs
Tour-Pak lockset hex nut
2.30 TOUR-PAK SERVICE, Lockset
3.4-5.1 Nm
30-45 in-lbs
Tour-Pak lockset jam nut
2.31 TOUR-PAK LIGHTS, Tour-Pak Lights Har-
ness
7.3-7.9 Nm
65-70 in-lbs
Tour-Pak metal plate flange nuts
2.29 TOUR-PAK, FLHTC
10.8-12.2 Nm
96-108 in-lbs
Tour-Pak mounting bolts
2.29 TOUR-PAK, FLHTCU
10.8-12.2 Nm
96-108 in-lbs
Tour-Pak mounting bolts
2.29 TOUR-PAK, Adjustment
10.8-12.2 Nm
96-108 in-lbs
Tour-Pak mounting bolts
2.30 TOUR-PAK SERVICE, Tether Brackets
4.5-6.8 Nm
40-60 in-lbs
Tour-Pak passenger backrest flange nuts
2.32 TOUR-PAK BACKREST, Passenger Backrest
4.5-6.8 Nm
40-60 in-lbs
Tour-Pak passenger backrest flange nuts
2.32 TOUR-PAK BACKREST, Passenger Backrest
Flap (FLHTCU)
2.4-2.7 Nm
21-24 in-lbs
Tour-Pak passenger backrest flap T25
TORX screws
2.31 TOUR-PAK LIGHTS, Side Marker Lights
(FLHTCU)
2.3-2.8 Nm
20-25 in-lbs
Tour-Pak side marker lights T15 TORX
screws
2.30 TOUR-PAK SERVICE, Hinges / Use Loctite
High Strength Threadlocker 262 (red)
2.3-2.8 Nm
20-25 in-lbs
Tour-Pak tether T15 TORX screw
2.30 TOUR-PAK SERVICE, Latches/Lockset
Catch / Use Loctite Medium Strength Threadlocker
243 (blue)
2.3-2.8 Nm
20-25 in-lbs
Tour-Pak tether T15 TORX screw
2.30 TOUR-PAK SERVICE, Latches/Lockset
Catch / Use Loctite Medium Strength Threadlocker
243 (blue)
2.3-2.8 Nm
20-25 in-lbs
Tour-Pak tether T15 TORX screw
2.30 TOUR-PAK SERVICE, Tether / Use Loctite
High Strength Threadlocker 262 (red)
2.3-2.8 Nm
20-25 in-lbs
Tour-Pak tether T15 TORX screw
1.2 MAINTENANCE SCHEDULE, General
19.0-28.5 Nm
14-21 ft-lbs
Transmission drain plug
1.10 TRANSMISSION LUBRICANT, Transmission
Lubrication: Touring Models
19.0-28.5 Nm
14-21 ft-lbs
Transmission drain plug
TORQUE VALUES XXI
2008 Touring Models Service Manual
NOTES
TORQUE VALUE
FASTENER
7.5 TRANSMISSION ASSEMBLY, Installation
19.0-28.5 Nm
14-21 ft-lbs
Transmission drain plug
7.7 TRANSMISSION CASE, Installation
19.0-28.5 Nm
14-21 ft-lbs
Transmission drain plug
3.29 OIL PAN, Installation / Clean plug before
installation
19.0-28.5 Nm
14-21 ft-lbs
Transmission drain plug w/o-ring
1.10 TRANSMISSION LUBRICANT, Transmission
Lubrication: Touring Models
2.8-8.5 Nm
25-75 in-lbs
Transmission filler/check plug
1.10 TRANSMISSION LUBRICANT, Transmission
Lubrication: Touring Models
2.8-8.5 Nm
25-75 in-lbs
Transmission filler/check plug
1.2 MAINTENANCE SCHEDULE, General
2.8-8.5 Nm
25-75 in-lbs
Transmission filler plug/dipstick
6.6 TRANSMISSION SPROCKET, Installation /
LOCTITE patch, use 3-5 times
9.5-12.2 Nm
84-108 in-lbs
Transmission lockplate screws
2.23 CLUTCH CABLE, Installation
19-28 Nm
14-21 ft-lbs
Transmission lubricant drain plug
2.23 CLUTCH CABLE, Installation
2.8-8.5 Nm
25-75 in-lbs
Transmission lubricant filler plug/dipstick
7.7 TRANSMISSION CASE, Installation
40.7-47.5 Nm
30-35 ft-lbs
Transmission mounting bolts, final torque
7.7 TRANSMISSION CASE, Installation
20.3 Nm
15 ft-lbs
Transmission mounting bolts, initial
torque
6.6 TRANSMISSION SPROCKET, Installation /
Right hand threads, initial torque only, apply several
drops of LOCTITE THREADLOCKER 271 (red) to
last few threads.
47.5 Nm
35 ft-lbs
Transmission sprocket nut
6.6 TRANSMISSION SPROCKET, Installation
47.5 Nm
35 ft-lbs
Transmission sprocket nut
3.14 INSTALLING ENGINE IN CHASSIS, Pro-
cedure
20.3 Nm
15 ft-lbs
Transmission to crankcase bolts
3.14 INSTALLING ENGINE IN CHASSIS, Pro-
cedure
46.1-52.9 Nm
34-39 ft-lbs
Transmission to crankcase bolts
7.5 TRANSMISSION ASSEMBLY, Installation
9.5-14.9 Nm
84-132 in-lbs
Transmission top cover
8.11 AUXILIARY LAMPS AND BRACKETS, Auxil-
iary Lamp Housing
4.1-6.8 Nm
36-60 in-lbs
Turn signal lamp to auxiliary lamp
bracket mount socket screws
8.11 AUXILIARY LAMPS AND BRACKETS, Auxil-
iary Lamp Housing
20.3-24.4 Nm
15-18 ft-lbs
Turn signal lamp to auxiliary lamp stud
locknut
8.11 AUXILIARY LAMPS AND
BRACKETS, Adjustment
4.1-6.8 Nm
36-60 in-lbs
Turn signal lamp to mounting bracket
screws
8.11 AUXILIARY LAMPS AND
BRACKETS, Adjustment
24.4 Nm
18 ft-lbs
Turn signal mounting bracket locknut
2.16 TIRES, Installation
1.4-1.7 Nm
12-15 in-lbs
Valve stem nut
2.11 VEHICLE ALIGNMENT, Method A
7.9-11.3 Nm
70-100 in-lbs
Voltage regulator locknuts
2.11 VEHICLE ALIGNMENT, Method B
7.9-11.3 Nm
70-100 in-lbs
Voltage regulator locknuts
8.21 ALTERNATOR, Installation
7.9-11.3 Nm
70-100 in-lbs
Voltage regulator locknuts
8.2 VOLTAGE REGULATOR, Installation
7.9-11.3 Nm
70-100 in-lbs
Voltage regulator locknuts and studs
7.7 TRANSMISSION CASE, Installation
9.5-14.9 Nm
84-132 in-lbs
VSS fastener
8.22 VEHICLE SPEED SENSOR (VSS), VSS
9.5-14.9 Nm
84-132 in-lbs
VSS Screw
2.35 UPPER FAIRING AND WINDSHIELD: FLHX,
FLHT/C/U, Outer Fairing and Windshield
2.8-3.4 Nm
25-30 in-lbs
Windshield screws (FLHX, FLHT/C/U)
2.39 UPPER FAIRING AND WINDSHIELD:
FLTR, Windshield
0.7-1.5 Nm
6-13 in-lbs
Windshield wellnut screws (FLTR)
2.44 WINDSHIELD: FLHR/C, Windshield Window
2.3-2.8 Nm
20-25 in-lbs
Windshield window T27 TORX screws
(Road King Models)
XXII TORQUE VALUES
2008 Touring Models Service Manual
NOTES
TORQUE VALUE
FASTENER
5.2 STARTER, Installation
2.3-4.5 Nm
20-40 in-lbs
Work drive clamp screw
TORQUE VALUES XXIII
1
150 Metri-Pack Connector
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24
4
480 Metri-Pack Connector
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-27
6
630 Metri-Pack Connector
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28
A
ABS Brake Lines
Front Master Cylinder to ABS Module. . . . . . . . . . . . C-5
ABS Module
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Active Exhaust/Intake (HDI)
Active Exhaust Valve. . . . . . . . . . . . . . . . . . . . . . . . 4-39
Active Exhaust (HDI)
Exhaust Valve Actuator. . . . . . . . . . . . . . . . . . . . . . 4-39
Exhaust Valve Actuator Cable. . . . . . . . . . . . . . . . . 4-39
Air Cleaner
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Air Cleaner and Exhaust System
Exhaust System Leak Check. . . . . . . . . . . . . . . . . . 1-16
Air Cleaner Filter
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Air Deflectors
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
Alternator
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59
AMP 1-Place Connector
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
AMP Multilock Connector
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Assembling Motorcycle after Stripping
After Cam Compartment Service. . . . . . . . . . . . . . . 3-24
After Top End Service. . . . . . . . . . . . . . . . . . . . . . . . 3-24
Audio Harness (FLHTCU)
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-108
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-107
Autofuse Electrical Connector. . . . . . . . . . . . . . . . . . . . . . A-7
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Auxiliary Lamp
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
B
Battery
Battery Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Charging Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Disconnection and Removal. . . . . . . . . . . . . . . . . . . 1-37
Installation and Connection. . . . . . . . . . . . . . . . . . . 1-37
Battery Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 1-37
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Voltmeter Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Battery Tray
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Belt Deflection
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Bleeding Brakes
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Bottom End Overhaul: Assembly
Cover and Cam Support Plate. . . . . . . . . . . . . . . . . 3-49
Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Bottom End Overhaul: Disassembly. . . . . . . . . . . . . . . . 3-43
Cover and Cam Support Plate. . . . . . . . . . . . . . . . . 3-43
Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Bottom End Service
Engine in Chassis (Cam Compartment Service). . . 3-21
Engine Removed (Flywheel Compartment Service or
Complete Engine Overhaul). . . . . . . . . . . . . . . . . . . 3-22
Brake Line (ABS)
ABS Module to Front Brake Calipers. . . . . . . . . . . . . C-6
ABS Module to Rear Brake Caliper. . . . . . . . . . . . . . C-9
Rear Master Cylinder to ABS Module. . . . . . . . . . . . C-8
Brake Pads and Discs
Brake Pad Replacement. . . . . . . . . . . . . . . . . . . . . . 1-32
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Brakes
Fluid Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Breather Assembly
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 3-54
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . 3-54
Removal Overview. . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Breather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Bulb Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Bulb Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
C
Cable and Chassis Lubrication
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
Jiffy Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
Steering Head Bearings. . . . . . . . . . . . . . . . . . . . . . 1-48
Cast Wheel Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Lateral Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
CB Antenna Cable
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-109
CB Loading Coil
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
CB Module
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
Chaincase Lubricant
Changing Chaincase Lubricant. . . . . . . . . . . . . . . . 1-20
Check Lubricant Level. . . . . . . . . . . . . . . . . . . . . . . 1-20
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Checking Cast Wheel Runout
Radial Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Checking Rim Runout
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Cigarette Lighter (FLHX, FLHT/C/U, FLTR)
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66
CKP Sensor
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
XXV
INDEX
Cleaning
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Cleaning Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Part Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Rust or Corrosion Removal. . . . . . . . . . . . . . . . . . . . 1-3
Clutch
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Clutch Pack and Bearing. . . . . . . . . . . . . . . . . . . . . 6-16
Clutch Pack Only. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Removal and Installation. . . . . . . . . . . . . . . . . . . . . 6-14
Clutch Cable
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
Clutch Release Cover
Assembly and Installation. . . . . . . . . . . . . . . . . . . . . . 7-6
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . 7-5
Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Conversions
Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Cover and Cam Support Plate
Cam Needle Bearings. . . . . . . . . . . . . . . . . . . . . . . 3-84
Camshafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 3-84
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 3-87
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 3-88
Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . 3-88
Oil Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . 3-84
Removal Overview. . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Crankcase
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 3-97
Cylinder Studs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Left Crankcase Half. . . . . . . . . . . . . . . . . . . . . . . . . 3-91
Removal Overview. . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Right Crankcase Half. . . . . . . . . . . . . . . . . . . . . . . . 3-90
Sprocket Shaft Bearing Inner Race. . . . . . . . . . . . . 3-94
Crank Position Sensor (CKP)
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
Critical Fasteners
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51
Cylinder
Boring and Honing. . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Deglazing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . 3-76
Removal Overview. . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Cylinder Head
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Inspection: Tapered Keepers. . . . . . . . . . . . . . . . . . 3-65
Inspection: Valve Guides. . . . . . . . . . . . . . . . . . . . . 3-64
Inspection: Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Inspection: Valve Seats. . . . . . . . . . . . . . . . . . . . . . 3-65
Inspection: Valve Springs. . . . . . . . . . . . . . . . . . . . . 3-64
Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . 3-72
Removal Overview. . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Valve and Seat Refacing. . . . . . . . . . . . . . . . . . . . . 3-69
Valve Guide Installation. . . . . . . . . . . . . . . . . . . . . . 3-66
Valve Guide Removal. . . . . . . . . . . . . . . . . . . . . . . . 3-65
D
Delphi Connector
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Deutsch Connector
Crimping Mini Terminals. . . . . . . . . . . . . . . . . . . . . . A-19
Crimping Solid Barrel Terminals. . . . . . . . . . . . . . . . A-17
Crimping Standard Terminals. . . . . . . . . . . . . . . . . . A-16
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Disassembly
Left Side Handlebar Switches. . . . . . . . . . . . . . . . 8-112
Right Side Handlebar Switches. . . . . . . . . . . . . . . 8-111
Drive Belt
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Drive Components
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
E
ECM
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Electrical Caddies
Battery Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Front Caddy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Left Side Caddy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Right Side Caddy. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Top Caddy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Electronic Fuel Injection (EFI)
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Engine
Removal From Chassis. . . . . . . . . . . . . . . . . . . . . . 3-25
Engine Mounts
Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52
Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52
Engine Oil
Grades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Temperature Recommendations. . . . . . . . . . . . . . . . 1-8
Winter Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Engine Oil and Filter
Changing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Engine Oil Flow
Bottom End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Oil Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Oil Return. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Top End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Engine Temperature Sensor (ET). . . . . . . . . . . . . . . . . . 4-20
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Evaporative Emissions Control
General Information. . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Evaporative Emissions Control (CA Models)
Charcoal Canister. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Exhaust System
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Exhaust Valve Actuator
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
XXVI INDEX
Exhaust Valve Actuator Cable
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
F
Fairing Cap Switches (FLHTC/U)
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Fender Tip Lamps
Front Fender. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Front Fender Tip Lamp Jumper Harness. . . . . . . . . 8-31
Rear Fender. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Fluid Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Flywheel/Connecting Rod
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . 3-97
Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . 3-98
Removal Overview. . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Footboards and Footrests
Passenger Footboard. . . . . . . . . . . . . . . . . . . . . . . 2-140
Passenger Footrest (FLHX). . . . . . . . . . . . . . . . . . 2-141
Rider Footboard. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138
Front Brake Caliper
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Front Brake Master Cylinder
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 2-36
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Front Brake Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Front Caddy
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Front Fender
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132
Front Fork
Changing Fork Oil. . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Front forks
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 2-51
Front Headset Receptacle
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74
Front Master Cylinder to ABS Module
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Front Wheel
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . 2-6
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Fuel and Oil
Gasoline Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fuel Filter
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Fuel Level Sender
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Fuel Pressure Regulator
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Fuel Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Fuel Pump and Fuel Level Sender Wire Harness
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Fuel Supply Check Valve/Tube
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Fuel Vapor Vent Tube
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Fuse Block
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Fuse Block Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26
Fuse Blocks
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
G
Gasoline
Octane Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Gauges/Instruments (FLHR/C/S)
Fuel Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70
Gauges-2 Inch Diameter
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-67
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-67
Glossary
Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . E-1
Glove Box Door and Hinge
Removal and Installation. . . . . . . . . . . . . . . . . . . . 2-126
Guages/Instrument (FLHX, FLHT/C/U, FLTR)
VSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61
H
Handlebars
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Left hand grip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Rubber mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
Handlebar Switch Assemblies
Assembly: Left Side Handlebar Switches. . . . . . . . 8-122
Assembly: Right Side Handlebar Switches. . . . . . 8-121
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111
General Repair Procedures. . . . . . . . . . . . . . . . . . 8-120
Specific Repair Procedures: Left Side Lower Switch
Housings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-117
Specific Repair Procedures: Right Side Lower Switch
Housings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-114
Specific Repair Procedures: Upper Switch Housings. 8-112
INDEX XXVII
Handlebar Switches
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-122
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111
Headlamp: All except FLTR
Headlamp Bulb Replacement. . . . . . . . . . . . . . . . . . 8-18
Headlamp (All except FLTR)
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Headlamp (FLTR)
Headlamp Bulb Replacement. . . . . . . . . . . . . . . . . . 8-20
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Headlamp Adjustment
FLHR/FLHT Models. . . . . . . . . . . . . . . . . . . . . . . . . 1-50
FLTR Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50
Headlamp Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49
Headlamp Nacelle (Road King Models)
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130
HFSM Antenna
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
Horn
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65
How to Use This Section
Bottom End Overhaul. . . . . . . . . . . . . . . . . . . . . . . . 3-17
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Subassembly Service and Repair. . . . . . . . . . . . . . 3-18
Top End Overhaul. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
I
Ignition/Light Key Switch and Fork Lock
FLHR/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
FLHX, FLHT/C/U, FLTR. . . . . . . . . . . . . . . . . . . . . . 8-47
Ignition Coil
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Indicator Lights (FLHR/C)
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-72
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-72
Indicator Lights (FLHX, FLHT/C/U, FLTR)
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-69
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-69
Induction Module
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Inner Fairing
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122
Inner Fairing: FLHX, FLHT/C/U
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
Inner Fairing: FLHX, FLHT/C/U
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
Instrument Bezel: FLTR
Removal and Installation. . . . . . . . . . . . . . . . . . . . 2-117
Instrument Nacelle
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119
Instrument Nacelle Switches (FLTR)
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
Intake Leak Test
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Leak Tester: Parts List. . . . . . . . . . . . . . . . . . . . . . . 4-40
Leak Tester: Tester Adjustment. . . . . . . . . . . . . . . . 4-40
Leak Tester: Tester Assembly. . . . . . . . . . . . . . . . . . 4-40
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Interconnect Harness
Installation (FLHX, FLHT/C/U). . . . . . . . . . . . . . . . . 8-97
Removal (FLHX, FLHT/C/U). . . . . . . . . . . . . . . . . . 8-94
Removal (FLTR). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98
Removal (FLTR). . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102
J
Jiffy Stand
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-143
Jiffy Stand Bracket. . . . . . . . . . . . . . . . . . . . . . . . . 2-144
Jiffy Stand Interlock Sensor. . . . . . . . . . . . . . . . . . 2-144
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-143
L
Laced Wheels
Truing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Left Side Caddy
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
License Plate Lamps/Bracket (FLHX)
Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
License Plate Bracket. . . . . . . . . . . . . . . . . . . . . . . . 8-43
License Plate Lamps. . . . . . . . . . . . . . . . . . . . . . . . 8-43
Light Bulbs
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Replacement Chart. . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Loctite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Lower Fairing/Engine Guard
Serrated Washer Replacement. . . . . . . . . . . . . . . 2-105
Lower Fairing and Engine Guard
Engine Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
Lower Fairing (FLHTCU). . . . . . . . . . . . . . . . . . . . 2-104
Lower Fork Bracket Cover/Air Dam
Air Dam (FLTR). . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Lubrication
Cable and Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
M
Main Drive Gear and Bearing
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 7-20
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Needle Bearing Replacement. . . . . . . . . . . . . . . . . 7-21
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Main Harness
Installation (All Models). . . . . . . . . . . . . . . . . . . . . . 8-93
Installation (FLHR/C). . . . . . . . . . . . . . . . . . . . . . . . 8-92
Installation (FLHX, FLHT/C/U). . . . . . . . . . . . . . . . . 8-92
Installation (FLTR). . . . . . . . . . . . . . . . . . . . . . . . . . 8-93
Removal (All Models). . . . . . . . . . . . . . . . . . . . . . . . 8-82
Removal (All Models). . . . . . . . . . . . . . . . . . . . . . . . 8-85
Maintenance Schedule
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Main Wiring Harness
Removal (FLHR/C). . . . . . . . . . . . . . . . . . . . . . . . . . 8-82
Removal (FLHX, FLHT/C/U). . . . . . . . . . . . . . . . . . 8-83
Removal (FLTR). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-85
Maxi-Fuse
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
XXVIII INDEX
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