Harley Davidson 2005 touring models. Service repair manual — page 67
HOME
NOTE
16. Test ride motorcycle. If brake feels spongy, remove mas-
ter cylinder reservoir cover and repeat procedure as nec-
The integral bleed fitting on the banjo bolt is for manufacturing
essary.
use only. As the part is not sold, use the same style banjo bolt
used on the other ports of the ABS module if replacement
17. Install right side saddlebag. See Section 2.25 SADDLE-
becomes necessary.
BAG, INSTALLATION, in the 2005 Touring Models Ser-
vice Manual (Part No. 99483-05).
3. Alternately tighten banjo bolts to 17-22 ft-lbs (23.0-29.8
Nm).
1WARNING
ROUTING DEVICES
Be sure there is sufficient clearance between the shock
absorber and the brake line to the rear brake caliper. Any
Brake Manifold (Steering Head)
contact can cause chafing of the brake line during move-
ment of the rear suspension system resulting in fluid
Removal
leaks and loss of hydraulic pressure, which could cause
death or serious injury.
1. Drain brake fluid. See DRAINING/FILLING/BLEEDING
HYDRAULIC BRAKE FLUID, FRONT BRAKE SYSTEM,
4.
Stand the motorcycle upright so that the rear master cyl-
on the next page.
inder reservoir is level.
2. Remove banjo bolts to release brake lines from brake
5. Remove bleeder cap from bleeder valve on rear brake
manifold at right side of steering head. Discard steel/rub-
caliper. Install end of a clear plastic tube over bleeder
ber washers.
valve. Place free end of tube in a suitable container.
3. Remove two flange screws to release brake manifold
from wellnuts in steering head.
CAUTION
To prevent dirt and other contaminants from entering the
Installation
master cylinder reservoir, thoroughly clean the cover
before removal.
1. Align holes in brake manifold with wellnuts in right side of
steering head and start two flange screws.
6. Remove two Phillips screws to release cover from rear
master cylinder reservoir.
2. Alternately tighten flange screws to 90-110 in-lbs (10.2-
7. Slowly depress and release brake pedal several times to
12.4 Nm).
build up hydraulic pressure.
3. Start top banjo bolt (with three new steel/rubber wash-
8. Slowly depress brake pedal and hold.
ers) to secure brake lines to brake manifold. Be sure to
position fitting on rear section of brake line (from ABS
9. Open bleeder valve about 1/2 turn. Brake fluid will flow
module) inboard of fitting on front section (to front brake
from bleeder valve through plastic tube.
calipers).
10. Close bleeder valve when brake pedal has moved 1/2 to
3/4 of its full range of travel.
4. Start bottom banjo bolt
(with three new steel/rubber
washers) to secure brake lines to brake manifold. Be
11. Release brake pedal and allow it to slowly return to its
sure to position fitting on rear section of brake line (to
normal operating position.
ABS module) inboard of fitting on front section (from front
12. Repeat steps
7-11 until a solid column of fluid is
master cylinder).
observed in the plastic tube.
5. Alternately tighten banjo bolts to 17-22 ft-lbs (23.0-29.8
13. Remove plastic tube and tighten bleeder valve to 80-100
Nm).
in-lbs (9.0-11.3 Nm). Install bleeder cap.
6. Add brake fluid and bleed system. See DRAINING/FILL-
14. Add brake fluid to the master cylinder reservoir until the
ING/BLEEDING HYDRAULIC BRAKE FLUID, FRONT
fluid level is about 1/8 inch (3.2 mm) from the top.
BRAKE SYSTEM, on the next page.
15. Install the master cylinder reservoir cover. Install two
Phillips screws to fasten the cover to the reservoir.
Tighten the screws to 6-8 in-lbs (0.7-0.9 Nm).
Aluminum Guide (Rear Frame Downtube)
Removal
1WARNING
1. Remove T45 TORX screw to release aluminum guide
After repairing the brake system, test brakes at low
and saddlebag guard from weldment on rear frame
speed. If brakes are not operating properly, testing at
downtube.
high speeds can cause loss of control, which could
result in death or serious injury. (00289a)
2. Remove aluminum guide and rubber spacer.
Appendix A: Anti-Lock Brake System A-57
HOME
Installation
9465
3
4
1.
With the slotted side forward, position aluminum guide
inboard of weldment on rear frame downtube.
2.
Insert T45 TORX screw through saddlebag guard and
weldment and start into aluminum guide.
3.
Seat three brake lines in slot of aluminum guide and then
1
insert rubber spacer between brake lines and rear frame
downtube.
4.
Tighten T45 TORX screw to 15-20 ft-lbs (20-27 Nm). See
2
Figure A-50.
DRAINING/FILLING/BLEEDING
HYDRAULIC BRAKE FLUID
1. Compressed Air Connection
2. Brake Bleeder Tube Rubber Fitting
General
3. Lever
4. Wireform
With the single exception of the brake line from the ABS
module to the rear brake caliper, always completely drain the
Figure A-53. Vacuum Brake Bleeder
associated brake system whenever any brake line must be
(Snap-On Part No. BB200A)
removed.
NOTE
If only removing the brake line from the ABS module to the
rear brake caliper, see ABS MODULE TO REAR BRAKE
CAUTION
CALIPER, REMOVAL, for details.
DOT 4 brake fluid will damage painted and molded-in
color surfaces it comes in contact with. Always use cau-
When refilling and bleeding the brake system, use only
tion and protect surfaces from spills whenever brake
Harley-Davidson DOT 4 BRAKE FLUID, Part No. 99953-99A
work is performed. Failure to comply can result in cos-
(12 ounce bottle), from a sealed container.
metic damage. (00239a)
IMPORTANT NOTE
IMPORTANT NOTE
The shelf life of a bottle of unopened DOT 4 brake fluid is
Immediately wipe up any brake fluid spillage with a clean,
one year. The shelf life of an uncontaminated bottle that
dry, soft cloth. Follow up by thoroughly wiping affected
has been opened and then resealed is one week.
area with a clean, damp, soft cloth (small spills) or wash-
ing with a soap and water solution (large spills).
NOTE
Exchange the brake fluid in the front and rear brake systems
at least once every two years. See EXCHANGING HYDRAU-
FRONT BRAKE SYSTEM
LIC BRAKE FLUID for more information.
Draining
1.
Obtain Basic Vacuum Brake Bleeder (Snap-On Part No.
1CAUTION
BB200A) and connect to a compressed air source (80-
Direct contact of DOT 4 brake fluid with eyes can cause
120 psi). See Figure A-53.
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
CAUTION
Swallowing large amounts of DOT 4 brake fluid can
cause digestive discomfort. If swallowed, obtain medical
If a different brake bleeder is selected, be sure that it
attention. Use in well ventilated area. KEEP OUT OF
uses parts that are compatible with DOT 4 brake fluid.
REACH OF CHILDREN. (00240a)
DOT 4 brake fluid is corrosive and can damage certain
rubbers and plastics.
A-58
Appendix A: Anti-Lock Brake System
HOME
3.
Pay careful attention to the level of the fluid in the master
CAUTION
cylinder reservoir. To avoid drawing air into the brake
lines, always add fluid to the master cylinder reservoir
Monitor the level of brake fluid in the canister during use.
before it empties.
Do not allow canister to become overfilled. Overfilling
canister will cause excess fluid to be discharged through
4.
Close bleeder valve when a solid column of fluid is
the overflow valve.
observed in the brake bleeder tube.
5.
Disengage wireform from brake bleeder lever to stop
vacuum.
1WARNING
6.
Remove rubber fitting on brake bleeder tube from
Never reuse brake fluid collected in the canister of the
bleeder valve.
brake bleeder. Use of contaminated brake fluid may
adversely affect braking ability and lead to brake failure
7.
Install rubber fitting on bleeder valve of second front
which could result in death or serious injury.
brake caliper.
8.
Add brake fluid to master cylinder reservoir until fluid
2. Remove bleeder cap from bleeder valve on front brake
level is about 1/8 inch (3.2 mm) from the top.
caliper. Place rubber fitting on brake bleeder tube over
bleeder valve.
9.
Depress lever at top of brake bleeder to start vacuum.
Slide wireform over lever to hold in the ON postion.
3.
Resting motorcycle on jiffy stand, turn front wheel as
necessary until the master cylinder reservoir is level.
10.
Open bleeder valve about 1/2 turn.
11.
Pay careful attention to the level of the fluid in the master
CAUTION
cylinder reservoir. To avoid drawing air into the brake
lines, always add fluid to the master cylinder reservoir
To prevent dirt and other contaminants from entering the
before it empties.
master cylinder reservoir, thoroughly clean the cover
before removal.
12.
Close bleeder valve when a solid column of fluid is
observed in the brake bleeder tube.
4. Remove two Phillips screws to release cover from front
13.
Disengage wireform from brake bleeder lever to stop
master cylinder reservoir.
vacuum.
5. Depress lever at top of brake bleeder to start vacuum.
14.
Remove rubber fitting on brake bleeder tube from
Slide wireform over lever to hold in the ON postion.
bleeder valve.
6. Open bleeder valve about 1/2 turn. Brake fluid will flow
15.
Tighten bleeder valves to 80-100 in-lbs (9.0-11.3 Nm).
from bleeder valve through brake bleeder tube.
Install bleeder caps.
7. When only air is drawn through brake bleeder tube, dis-
16.
Add brake fluid to the master cylinder reservoir until the
engage wireform from brake bleeder lever to stop vac-
fluid level is about 1/8 inch (3.2 mm) from the top.
uum.
17.
Install the master cylinder reservoir cover. Install two
8. Close bleeder valve and remove rubber fitting on brake
Phillips screws and tighten to 6-8 in-lbs (0.7-0.9 Nm).
bleeder tube.
9. Remove bleeder cap from bleeder valve on second front
1WARNING
brake caliper and install rubber fitting on brake bleeder
tube.
After repairing the brake system, test brakes at low
speed. If brakes are not operating properly, testing at
10. Depress lever at top of brake bleeder to start vacuum.
high speeds can cause loss of control, which could
Slide wireform over lever to hold in the ON postion.
result in death or serious injury. (00289a)
11. Open bleeder valve about 1/2 turn. Brake fluid will flow
from bleeder valve through brake bleeder tube.
18. Test ride motorcycle. If brake feels spongy, remove mas-
ter cylinder reservoir cover and repeat procedure as nec-
12. When only air is drawn through brake bleeder tube, dis-
essary.
engage wireform from brake bleeder lever to stop vac-
uum.
REAR BRAKE SYSTEM
Filling/Bleeding
Draining
1. Add brake fluid to master cylinder reservoir until fluid
1. Remove right side saddlebag. See Section 2.25 SAD-
level is about 1/8 inch (3.2 mm) from the top.
DLEBAG, REMOVAL, in the 2005 Touring Models Ser-
2. Depress lever at top of brake bleeder to start vacuum.
vice Manual (Part No. 99483-05). For best results, move
Slide wireform over lever to hold in the ON postion.
saddlebag forward slightly before lifting.
Appendix A: Anti-Lock Brake System A-59
HOME
2.
Obtain Basic Vacuum Brake Bleeder (Snap-On Part No.
2.
Depress lever at top of brake bleeder to start vacuum.
BB200A) and connect to a compressed air source (80-
Slide wireform over lever to hold in the ON postion.
120 psi). See Figure A-53.
3.
Pay careful attention to the level of the fluid in the master
cylinder reservoir. To avoid drawing air into the brake
CAUTION
lines, always add fluid to the master cylinder reservoir
before it empties.
If a different brake bleeder is selected, be sure that it
4.
Close bleeder valve when a solid column of fluid is
uses parts that are compatible with DOT 4 brake fluid.
observed in the brake bleeder tube.
DOT 4 brake fluid is corrosive and can damage certain
rubbers and plastics.
5.
Disengage wireform from brake bleeder lever to stop
vacuum.
CAUTION
6.
Remove rubber fitting on brake bleeder tube from
bleeder valve.
Monitor the level of brake fluid in the canister during use.
7.
Tighten bleeder valve to 80-100 in-lbs (9.0-11.3 Nm).
Do not allow canister to become overfilled. Overfilling
Install the bleeder cap.
canister will cause excess fluid to be discharged through
the overflow valve.
8.
Add brake fluid to the master cylinder reservoir until the
fluid level is about 1/8 inch (3.2 mm) from the top.
1WARNING
9.
Install the master cylinder reservoir cover. Install two
Phillips screws and tighten to 6-8 in-lbs (0.7-0.9 Nm).
Never reuse brake fluid collected in the canister of the
brake bleeder. Use of contaminated brake fluid may
1WARNING
adversely affect braking ability and lead to brake failure
which could result in death or serious injury.
After repairing the brake system, test brakes at low
speed. If brakes are not operating properly, testing at
3. Remove bleeder cap from bleeder valve on rear brake
high speeds can cause loss of control, which could
caliper. Place rubber fitting on brake bleeder tube over
result in death or serious injury. (00289a)
bleeder valve.
10. Test ride motorcycle. If brake feels spongy, remove mas-
NOTE
ter cylinder reservoir cover and repeat procedure as nec-
The integral bleed fitting on the rear top port of the ABS mod-
essary.
ule is for manufacturing use only. Any attempt to use the fit-
11. Install right side saddlebag. See Section 2.25 SADDLE-
ting to drain, fill and/or bleed the rear brake system will
BAG, INSTALLATION, in the 2005 Touring Models Ser-
produce unsatisfactory results.
vice Manual (Part No. 99483-05).
4. Stand the motorcycle upright so that the master cylinder
reservoir is level.
EXCHANGING HYDRAULIC BRAKE
CAUTION
FLUID
To prevent dirt and other contaminants from entering the
master cylinder reservoir, thoroughly clean the cover
before removal.
NOTE
Exchange the brake fluid in the front and rear brake systems
5.
Remove two Phillips screws to release cover from rear
at least once every two years. Use only Harley-Davidson
master cylinder reservoir.
DOT 4 BRAKE FLUID, Part No. 99953-99A (12 ounce bottle),
6.
Depress lever at top of brake bleeder to start vacuum.
from a sealed container.
Slide wireform over lever to hold in the ON postion.
IMPORTANT NOTE
7.
Open bleeder valve about 1/2 turn. Brake fluid will flow
from bleeder valve through brake bleeder tube.
The shelf life of a bottle of unopened DOT 4 brake fluid is
one year. The shelf life of an uncontaminated bottle that
8.
When only air is drawn through brake bleeder tube, dis-
has been opened and then resealed is one week.
engage wireform from brake bleeder lever to stop vac-
uum.
FRONT BRAKE SYSTEM
Filling/Bleeding
1.
Obtain Basic Vacuum Brake Bleeder (Snap-On Part No.
1.
Add brake fluid to master cylinder reservoir until fluid
BB200A) and connect to a compressed air source (80-
level is about 1/8 inch (3.2 mm) from the top.
120 psi). See Figure A-53.
A-60
Appendix A: Anti-Lock Brake System
HOME
12.
Remove bleeder cap from bleeder valve on second front
CAUTION
brake caliper. Place rubber fitting on brake bleeder tube
over bleeder valve.
If a different brake bleeder is selected, be sure that it
uses parts that are compatible with DOT 4 brake fluid.
13.
Depress lever at top of brake bleeder to start vacuum.
DOT 4 brake fluid is corrosive and can damage certain
Slide wireform over lever to hold in the ON postion.
rubbers and plastics.
14.
Open bleeder valve about 1/2 turn. Brake fluid will flow
from bleeder valve through brake bleeder tube.
CAUTION
15.
Pay careful attention to the level of the fluid in the master
cylinder reservoir. To avoid drawing air into the brake
Monitor the level of brake fluid in the canister during use.
lines, always add fluid to the master cylinder reservoir
Do not allow canister to become overfilled. Overfilling
before it empties.
canister will cause excess fluid to be discharged through
the overflow valve.
16.
When the darker fluid in the brake bleeder tube is
replaced by a column of lighter fluid, and the column of
lighter fluid is solid without air bubbles, close the bleeder
1WARNING
valve.
Never reuse brake fluid collected in the canister of the
17.
Disengage wireform from brake bleeder lever to stop
brake bleeder. Use of contaminated brake fluid may
vacuum.
adversely affect braking ability and lead to brake failure
which could result in death or serious injury.
18.
Remove rubber fitting on brake bleeder tube from
bleeder valve.
2. Remove bleeder cap from bleeder valve on front brake
19.
Tighten bleeder valve to 80-100 in-lbs (9.0-11.3 Nm).
caliper. Place rubber fitting on brake bleeder tube over
Install the bleeder cap.
bleeder valve.
20.
Add brake fluid to the master cylinder reservoir until the
3.
Resting motorcycle on jiffy stand, turn front wheel as
fluid level is about 1/8 inch (3.2 mm) from the top.
necessary until the master cylinder reservoir is level.
21.
Install the master cylinder reservoir cover. Install two
Phillips screws and tighten to 6-8 in-lbs (0.7-0.9 Nm).
CAUTION
To prevent dirt and other contaminants from entering the
1WARNING
master cylinder reservoir, thoroughly clean the cover
before removal.
After repairing the brake system, test brakes at low
speed. If brakes are not operating properly, testing at
4.
Remove two Phillips screws to release cover from front
high speeds can cause loss of control, which could
master cylinder reservoir.
result in death or serious injury. (00289a)
5.
Depress lever at top of brake bleeder to start vacuum.
22. Test ride motorcycle. If brake feels spongy, remove mas-
Slide wireform over lever to hold in the ON postion.
ter cylinder reservoir cover and repeat procedure as nec-
6.
Open bleeder valve about 1/2 turn. Brake fluid will flow
essary.
from bleeder valve through brake bleeder tube.
7.
Pay careful attention to the level of the fluid in the master
REAR BRAKE SYSTEM
cylinder reservoir. To avoid drawing air into the brake
lines, always add fluid to the master cylinder reservoir
1. Remove right side saddlebag. See Section 2.25 SAD-
before it empties.
DLEBAG, REMOVAL, in the 2005 Touring Models Ser-
8.
When the darker fluid in the brake bleeder tube is
vice Manual (Part No. 99483-05). For best results, move
replaced by a column of lighter fluid, and the column of
saddlebag forward slightly before lifting.
lighter fluid is solid without air bubbles, continue proce-
2. Obtain Basic Vacuum Brake Bleeder (Snap-On Part No.
dure until most of one 12 ounce bottle is drawn through
BB200A) and connect to a compressed air source (80-
the system, and then close the bleeder valve.
120 psi). See Figure A-53.
9.
Disengage wireform from brake bleeder lever to stop
vacuum.
CAUTION
10.
Remove rubber fitting on brake bleeder tube from
If a different brake bleeder is selected, be sure that it
bleeder valve.
uses parts that are compatible with DOT 4 brake fluid.
11.
Tighten bleeder valve to 80-100 in-lbs (9.0-11.3 Nm).
DOT 4 brake fluid is corrosive and can damage certain
Install the bleeder cap.
rubbers and plastics.
Appendix A: Anti-Lock Brake System A-61
HOME
11. Remove rubber fitting on brake bleeder tube from
CAUTION
bleeder valve.
Monitor the level of brake fluid in the canister during use.
12. Tighten bleeder valve to 80-100 in-lbs (9.0-11.3 Nm).
Do not allow canister to become overfilled. Overfilling
Install the bleeder cap.
canister will cause excess fluid to be discharged through
13. Add brake fluid to the master cylinder reservoir until the
the overflow valve.
fluid level is about 1/8 inch (3.2 mm) from the top.
14. Install the master cylinder reservoir cover. Install two
1WARNING
Phillips screws and tighten to 6-8 in-lbs (0.7-0.9 Nm).
Never reuse brake fluid collected in the canister of the
brake bleeder. Use of contaminated brake fluid may
1WARNING
adversely affect braking ability and lead to brake failure
which could result in death or serious injury.
After repairing the brake system, test brakes at low
speed. If brakes are not operating properly, testing at
3. Remove bleeder cap from bleeder valve on rear brake
high speeds can cause loss of control, which could
caliper. Place rubber fitting on brake bleeder tube over
result in death or serious injury. (00289a)
bleeder valve.
15.
Test ride motorcycle. If brake feels spongy, remove mas-
NOTE
ter cylinder reservoir cover and repeat procedure as nec-
The integral bleed fitting on the rear top port of the ABS mod-
essary.
ule is for manufacturing use only. Any attempt to use the fit-
16.
Install right side saddlebag. See Section 2.25 SADDLE-
ting to drain, fill and/or bleed the rear brake system will
BAG, INSTALLATION, in the 2005 Touring Models Ser-
produce unsatisfactory results.
vice Manual (Part No. 99483-05).
4. Stand the motorcycle upright so that the master cylinder
reservoir is level.
CAUTION
To prevent dirt and other contaminants from entering the
master cylinder reservoir, thoroughly clean the cover
before removal.
5.
Remove two Phillips screws to release cover from rear
master cylinder reservoir.
6.
Depress lever at top of brake bleeder to start vacuum.
Slide wireform over lever to hold in the ON postion.
7.
Open bleeder valve about 1/2 turn. Brake fluid will flow
from bleeder valve through brake bleeder tube.
8.
Pay careful attention to the level of the fluid in the master
cylinder reservoir. To avoid drawing air into the brake
lines, always add fluid to the master cylinder reservoir
before it empties.
9. When the darker fluid in the brake bleeder tube is
replaced by a column of lighter fluid, and the column of
lighter fluid is solid without air bubbles, continue proce-
dure until most of one 12 ounce bottle is drawn through
the system, and then close the bleeder valve.
10. Disengage wireform from brake bleeder lever to stop
vacuum.
A-62
Appendix A: Anti-Lock Brake System
Table Of Contents
SUBJECT
PAGE NO.
A.1 Specifications
A-1
A.2 ABS System Introduction
A-3
A.3 Diagnostic Introduction
A-7
A.4 Special Tools
A-8
A.5 ABS Self Diagnostics
A-9
A.6 Initial/Final Diagnostic Check
A-12
A.7 No ABS Lamp At Key On
A-14
A.8 ABS Lamp On Continuously
A-17
A.9 Front Wheel Speed Sensor: DTC 1-1, 1-2
A-20
A.10 Rear Wheel Speed Sensor: DTC 1-3, 1-4
A-25
A.11 Front/Rear Tone Ring: DTC 2-1, 2-3
A-30
A.12 Solenoid: DTC 3-1, 3-2, 3-3, 3-4
A-32
A.13 Front/Rear Caliper: DTC 4-1, 4-3
A-35
A.14 Motor (Pump)/Relay: DTC 5-1, 5-2, 5-3, 5-4
A-37
A.15 Battery Voltage: DTC 6-1, 6-2
A-40
A.16 Tires: DTC 7-1
A-43
A.17 ABS Module: DTC 8-1
A-45
A.18 Service Procedures
A-47
ANTI-LOCK BRAKES A
MAINTENANCE
1
Table Of Contents
SUBJECT
PAGE NO.
1.1 Hydraulic Clutch
1-1
1.2 Engine Lubrication
1-3
1.3 Critical Fasteners
1-4
NOTE
This section provides information unique to FLHTCSE2 model motorcycles. Any informa-
tion not presented in this supplement can be found in the Touring Models Service Manual.
HOME
HYDRAULIC CLUTCH
1.1
GENERAL
WARNING
1
The clutch is hydraulically actuated. The hand lever actuated
Do NOT allow dirt or debris to enter the clutch master cyl-
master cylinder creates pressure in the clutch fluid line that
inder reservoir. Dirt or debris in the reservoir can cause
activates a secondary clutch actuator mounted in the clutch
improper operation of the clutch and equipment damage.
release cover. The secondary clutch actuator piston extends
(00205a)
and contacts a pushrod which releases the clutch.
1WARNING
CAUTION
Direct contact of D.O.T. 4 brake fluid with eyes can cause
D.O.T. 4 hydraulic brake fluid is used in the hydraulic
irritation. Avoid eye contact. In case of eye contact flush
clutch. Do not use other types of fluids as they are not
with large amounts of water and get medical attention.
compatible and could cause equipment damage.
Swallowing large amounts of D.O.T. 4 brake fluid can
(00353a)
cause digestive discomfort. If swallowed, obtain medical
attention. Use in well ventilated area. KEEP OUT OF
REACH OF CHILDREN. (00240a)
CHECKING AND CORRECTING
1.
Stand motorcycle upright (not leaning on jiffy stand) on a
CLUTCH FLUID LEVEL
level surface. Turn handlebars to the right if necessary,
so top of clutch master cylinder reservoir is level.
Even though a clear sight glass in the reservoir cover indi-
cates a low clutch fluid, it is also possible to remove the cover
2.
See Figure 1-1. Remove two screws (4), clutch master
to verify fluid level.
cylinder reservoir cover (2) and cover gasket (3).
1WARNING
10948
D.O.T. 4 brake fluid will damage painted and molded-in
2
4
color surfaces it comes in contact with. Always use cau-
tion and protect surfaces from spills whenever brake
work is performed. Failure to comply can result in cos-
metic damage. (00239a)
1
3
1.
Clutch Master Cylinder Reservoir
2.
Reservoir Cover
3.
Cover Gasket
4.
Screws (2)
Figure 1-1. Clutch Master Cylinder Reservoir
2005 FLHTCSE2: Maintenance
1-1
HOME
3.
See Figure 1-2. Verify fluid level in the clutch master cyl-
inder is at FILL LEVEL mark at top of ledge on rear
CAUTION
inside wall of reservoir.
Clutch fluid volume in reservoir actually increases with
clutch wear. Do NOT overfill reservoir.
8835
4.
If necessary, add D.O.T. 4 HYDRAULIC BRAKE FLUID,
(Part No. 99953-99A) to master cylinder reservoir. Fluid
level should not exceed FILL LEVEL.
5.
See Figure 1-1. Carefully place cover gasket (3) and res-
ervoir cover (2) on clutch master cylinder reservoir and
secure with two screws (4).
6.
Tighten screws to 6-8 in-lbs (0.68-0.90 Nm).
Figure 1-2. Fill Level (reservoir cover removed as viewed
from front of motorcycle)
1-2
2005 FLHTCSE2: Maintenance
HOME
ENGINE LUBRICATION
1.2
GENERAL
CAUTION
Your motorcycle comes equipped with Screamin’ Eagle SYN3
Do not switch lubricant brands indiscriminately because
Synthetic Motorcycle Lubricant. If SYN3 is not available and
some lubricants interact chemically when mixed. Use of
addition of motor oil is required, the first choice would be to
inferior lubricants can damage the engine. (00184a)
add H-D® 360 SAE 20W50 to the SYN3 for engine lubrica-
Refer to Table 1-1. If it is necessary to add oil and Screamin’
tion. Although H-D 360 is compatible with SYN3, we suggest
Eagle® SYN3 Synthetic Motorcycle Lubricant is not available,
the mixture of the fluids be changed as soon as possible.
use an oil certified for diesel engines.
If H-D 360 is not available, the second choice would be to add
Acceptable diesel engine oil designations include:
an acceptable diesel engine oil. We again suggest the mix-
ture of the fluids be changed as soon as possible. DO NOT
•
CF-4
add diesel engine oil to the primary chaincase or transmis-
•
CG-4
sion.
•
CH-4
To switch lubricant to H-D 360, completely drain the SYN3
•
CI-4
before filling with H-D 360. A residual amount of fluid will
remain. It is not required to flush out the residual fluid.
The preferred viscosities for the diesel engine oils, in
descending order are:
•
20W50
1CAUTION
•
15W40
Prolonged or repeated contact with used motor oil may
be harmful to skin and could cause skin cancer. Promptly
•
10W40
wash affected areas with soap and water.
At the first opportunity, see a Harley-Davidson dealer to
change back to 100 percent Harley-Davidson oil.
1CAUTION
If swallowed, do not induce vomiting. Contact a physi-
cian immediately. In case of contact with eyes, immedi-
ately flush with water. Contact a physician if irritation
persists.
Table 1-1. Recommended Engine Oils
HARLEY-DAVIDSON
HARLEY-DAVIDSON
LOWEST AMBIENT
COLD WEATHER STARTS
VISCOSITY
TYPE
RATING
TEMPERATURE
BELOW 50˚ F (10˚ C)
Screamin’ Eagle®
SAE 20W50
HD 360
Above 40˚ F (4˚ C)
Excellent
SYN3 Synthetic
Motorcycle Lubricant
HD Multi-grade
SAE 10W40
HD 360
Below 40˚ F (4˚ C)
Excellent
HD Multi-grade
SAE 20W50
HD 360
Above 40˚ F (4˚ C)
Good
HD Regular heavy
SAE 50
HD 360
Above 60˚ F (16˚ C)
Poor
HD Extra heavy
SAE 60
HD 360
Above 80˚ F (27˚ C)
Poor
2005 FLHTCSE2: Maintenance
1-3
HOME
CRITICAL FASTENERS
1.3
Refer to Table 1-2. Tighten all critical fasteners, except head
INSPECTION
bolts, to service manual specifications. Replace any dam-
aged or missing hardware.
Inspect critical fasteners, except head bolts:
Table 1-2. Critical Fasteners
COMPONENT
FASTENER
TORQUE
Axle
Front axle nut
50-55 ft-lbs
68-75 Nm
Rear axle cone nut
95-105 ft-lbs
129-142 Nm
Brakes
Banjo bolts
17-22 ft-lbs
23.1-29.8 Nm
Brake bleeders
80-100 in-lbs
9.1-11.3 Nm
Front brake disc mounting screws
16-24 ft-lbs
21.7-32.5 Nm
Front brake caliper mounting bolts
28-38 ft-lbs
38.0-51.6 Nm
Brake caliper pad pins
180-200 in-lbs
20.4-22.6 Nm
Rear brake disc mounting screws
30-45 ft-lbs
40.7-61.1 Nm
Rear master cylinder mounting nut
30-40 ft-lbs
40.7-54.3 Nm
Reservoir cover screws
6-8 in-lbs
0.68-0.90 Nm
Front forks
Axle holder nuts
132-180 in-lbs
14.9-20.4 Nm
Hand controls
Clutch master cylinder/handlebar clamp
60-80 in-lbs
6.8-9.0 Nm
Brake master cylinder/handlebar clamp screws
60-80 in-lbs
6.8-9.0 Nm
Upper/lower switch housing screws
35-45 in-lbs
4.0-5.1 Nm
Handlebars
Lower clamp (riser) bolts
30-40 ft-lbs
40.7-54.3 Nm
Pivot shaft
Locknuts
40-45 ft-lbs
54.3-61.1 Nm
Swingarm bracket bolts
34-42 ft-lbs
46.1-57.0 Nm
Engine
Engine mounting bracket to cylinder head bolts
35-40 ft-lbs
47.5-54.3 Nm
Top stabilizer link to top engine mounting bracket bolt
18-22 ft-lbs
24.4-29.9 Nm
Top stabilizer link to frame weldment bolt
18-22 ft-lbs
24.4-29.9 Nm
Front stabilizer link to frame weldment bolt
18-22 ft-lbs
24.4-29.9 Nm
Front stabilizer link to front engine mounting bracket
18-22 ft-lbs
24.4-29.9 Nm
bolt
Center front engine mounting bracket to rubber mount
15-20 ft-lbs
20.4-27.1 Nm
bolt
Front engine mount to frame crossmember bolts
15-20 ft-lbs
20.4-27.1 Nm
Engine to front engine mounting bracket bolts
33-38 ft-lbs
44.8-51.6 Nm
Engine to transmission bolts
30-35 ft-lbs
40.7-47.5 Nm
Clutch
Banjo bolts
17-22 ft-lbs
23.1-29.9 Nm
Clutch fluid line flare nut
80-115 in-lbs
9.0-13.0 Nm
Secondary actuator bleeder valve
80-100 in-lbs
9.0-11.3 Nm
Reservoir cover screws
6-8 in-lbs
0.68-0.90 Nm
1-4
2005 FLHTCSE2: Maintenance
Table Of Contents
CHASSIS
2
SUBJECT
PAGE NO.
2.1 Specifications
2-1
2.2 Torque Values (table)
2-2
2.3 Vehicle Identification Number (V.I.N.)
2-3
2.4 Rear Wheel
2-4
2.5 Rear Brake Pads
2-5
2.6 Footboards and Controls
2-7
2.7 Front Axle Covers
2-10
2.8 Lower Triple Clamp Cover
2-11
2.9 Handlebars
2-12
2.10 Clutch Master Cylinder/Reservoir
2-18
2.11 Clutch Hand Lever
2-22
2.12 Clutch Fluid Line
2-23
2.13 Seat
2-27
2.14 Rider Backrest
2-28
2.15 Removable Passenger Backrest
2-29
2.16 Removable Tour-Pak
2-31
2.17 Saddlebag Supports
2-38
2.18 Muffler End Cap
2-40
NOTE
This section provides information unique to FLHTCSE2 model motorcycles. Any informa-
tion not presented in this supplement can be found in the Touring Models Service Manual.
HOME
SPECIFICATIONS
2.1
Table 2-1. Dimensions
Table 2-3. Capacities
ITEM
IN.
MM
ITEM
U.S.
METRIC
Wheel Base
63.5
1613
Fuel Tank
Total
5 Gal.
18.9 Liters
Overall Length
96.9
2461
Reserve
0.9 Gal.
3.4 Liters
Overall Width
38.5
977.9
Oil Tank with filter
4 Quarts
3.78 Liters
Road Clearance
4.21
106.9
Transmission *
20-24 Ounces
591-710 Milliliters
Overall Height
53.27
1353
Primary Chaincase *
32 Ounces
946 Mililiters
Saddle Height*
26.9
683
Left
Right
Left
Right
Front Fork
* With 180 Lb. Rider
10.6 oz
10.6 oz
314 ml
314 ml
* Approximate capacity
Table 2-2. Weight
ITEM
LBS.
KG
DRY WEIGHT**
808
367
GVWR
1259
571
GAWR - Front
500
227
GAWR - Rear
827
375
** As shipped from the factory
NOTE
Gross Vehicle Weight Rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding Gross Axle Weight
Ratings (GAWR) are given on a label located on the inside of
the right front frame downtube.
2005 FLHTCSE2: Chassis
2-1
HOME
TORQUE VALUES
2.2
ITEM
TORQUE
NOTES
Brake caliper pad pins
180-200 in-lbs
20.4-22.6 Nm
page
2-6
Brake fluid reservoir cover
6-8 in-lbs
0.68-0.90 Nm
page
2-6
Brake pedal acorn nut
25-29 ft-lbs
33.9-39.4 Nm
page
2-9
Brake pedal cover screws
20-22 in-lbs
2.3-2.5 Nm
page
2-9
Clutch fluid line flare nut
80-115 in-lbs
9.0-13.0 Nm
page
2-25, 2-26
Clutch master cylinder banjo bolt
17-22 ft-lbs
23.1-29.9 Nm
page
2-21, 2-25, 2-26
Clutch reservoir cover screws
6-8 in-lbs
0.7-0.9 Nm
page
2-21, 2-25, 2-26
Clutch secondary actuator bleeder valve
80-100 in-lbs
9.0-11.3 Nm
page
2-21, 2-25, 2-26
Docking bushing screw
15-20 ft-lbs
20.4-27.1 Nm
page
2-30, 2-34
Fender Mounting Screw
15-20 ft-lbs
20.4-27.1 Nm
page
2-30, 2-34
Footboard pivot bolt
84-108 in-lbs
9.5-12.2 Nm
page
2-7
Front axle cover set screw
60-84 in-lbs
6.8-9.5 Nm
page
2-10
Front saddlebag support bracket screw
15-20 ft-lbs
20.4-27.1 Nm
page
2-38
Handlebar control lever clamp screw
60-80 in-lbs
6.8-9.0 Nm
page
2-17, 2-21
Handlebar switch housing screw
35-45 in-lbs
4.0-5.1 Nm
page
2-17
Handlebar top clamp
12-16 ft-lbs
16.3-20.3 Nm
page
2-16
Mirror acorn nut
12 ft-lbs
16.3 Nm
page
2-17
Muffler bracket screw
96-144 in-lbs
10.9-16.3 Nm
page
2-39
Passenger footboard bracket screw
15-18 ft-lbs
20.4-24.4 Nm
page
2-9
Rear axle cone nut
95-105 ft-lbs
128.9-142.4 Nm
page
2-4
Rear saddlebag support bracket screws
15-20 ft-lbs
20.4-27.1 Nm
page
2-38
Rider footboard bracket screw
30-35 ft-lbs
40.7-47.5 Nm
page
2-7
Saddlebag filler strip screws
15-20 ft-lbs
20.4-27.1 Nm
page
2-34, 2-39
Shift lever clamp bolts
90-110 in-lbs
10.2-12.4 Nm
page
2-9
Shift lever peg
12-14 ft-lbs
16.3-18.9 Nm
page
2-9
Tour-Pak to detachable bracket screws
96-120 in-lbs
10.8-13.5 Nm
page
2-35
Triple clamp cover backside fasteners
70-110 in-lbs
7.9-12.4 Nm
page
2-11
Triple clamp lower Allen head fastener
120-180 in-lbs
13.6-20.4 Nm
page
2-11
Upper Saddlebag Bracket Screw
15-20 ft-lbs
20.4-27.1 Nm
page
2-30, 2-32, 2-38
2-2
2005 FLHTCSE2: Chassis
HOME
VEHICLE IDENTIFICATION NUMBER (V.I.N.)
2.3
Sample V.I.N. as it appears on the steering head
-
GENERAL
1HD1PKE155Y500001
Sample abbreviated V.I.N. as it appears on the left crankcase
See Figure 2-1. The full 17 digit serial, or Vehicle Identifica-
- PKE5500001
tion Number (V.I.N.) is stamped on the right side of the frame
backbone at the rear of the steering head (and under the
NOTE
main harness conduit). A label bearing the VIN code is also
affixed to the left side of the steering head.
Always give the full 17 digit Vehicle Identification Number
when ordering parts or making any inquiry about your motor-
An abbreviated V.I.N. is stamped on the left side crankcase at
cycle.
the base between the cylinders.
1
2
3
4
5
6
7
8
9
10
1
HD
1
PK E
1
5
5
Y
500001
Figure 2-1. Vehicle Identification Number (example)
Table 2-1. Harley-Davidson 2005 FLHTCSE2 Model V.I.N. Description
ITEM
DESCRIPTION
POSSIBLE VALUES
1
Market destination
1=Domestic, 5=International
2
Manufacturer
HD=Harley-Davidson
3
Motorcycle type
1=Heavyweight motorcycle
4
Model
see model V.I.N. code table below
5
Engine type
E= 1690 c.c. Fuel injected
6
Introduction date
1=Regular, 2=Mid-year, 3=California
7
VIN check digit
Can be 0-9 or X
8
Model year
5=2005
9
Assembly plant
Y=York, PA.
10
Sequential number (last 6 digits)
varies
Table 2-2. 2005 FLHTCSE2 Model V.I.N. Codes
10528
CODE
MODEL NAME
PK
FLHTCSE2
Figure 2-2. Abbreviated V.I.N. Location
2005 FLHTCSE2: Chassis
2-3
HOME
REAR WHEEL
2.4
3.
Coat the axle with LOCTITE ANTI-SEIZE.
REMOVAL
4.
Tilt the bottom of the tire to the right.
1.
Block motorcycle under frame so rear wheel is off the
5.
Orient the axle to the lowest cam position and angle the
ground.
axle to match angle of rear wheel.
2.
Remove saddlebags. See SADDLEBAG in Touring Mod-
6.
With the larger OD on the outboard side, hold external
els Service Manual.
spacer between the rear fork and belt sprocket. Slide the
3.
Remove mufflers. See REAR WHEEL in Touring Models
axle through left side of rear swingarm, external spacer,
Service Manual.
and sprocket into the wheel hub.
7.
When the axle emerges from the hub, straighten the
4.
Remove e-clip from groove on right end of rear axle.
wheel and push axle through short external spacer, cali-
5.
Remove cone nut and adjuster cam from axle.
per bracket and rear fork.
6.
Using a soft mallet, gently tap end of axle towards left
8.
Rotate flat on threaded end of axle to the top. With the
side to loosen.
thumb down and the cam forward, install adjuster cam
7.
Pull the axle out to saddlebag support.
on end of axle.
8.
To clear the saddlebag support, rotate the axle to lowest
9.
Apply a thin film of LOCTITE ANTI-SEIZE to inboard
cam position and push the bottom of the tire to the right
side of cone nut. Install cone nut on axle, but finger
to angle the assembly in the fender with the left end of
tighten only.
axle tilted down.
10.
Verify that adjuster cam just contacts weld nub on both
9.
Pull the axle the rest of the way out.
sides of rear fork. If necessary push wheel forward
10. Pull wheel to release brake disc from caliper. Pry inner
slightly to achieve the desired result. Snug the cone nut
and outer brake pads back for additional clearance. If
to 15-20 ft-lbs (20.4-27.1 Nm).
necessary, use a putty knife with a wide thin blade to
11.
Lower motorcycle to ground.
avoid scratching the brake disc.
12.
Rotate weld nut on left side of axle in a clockwise direc-
NOTE
tion.
Do not operate the rear brake pedal with the rear wheel
13.
Check belt deflection. See DRIVE BELT under SCHED-
removed or the caliper pistons may be forced out. Reseating
ULED MAINTENANCE PROCEDURES.
pistons requires disassembly of the caliper.
14.
When belt deflection is within specifications, hold weld
11. Move wheel forward to slip belt off sprocket and remove
nut and final tighten cone nut to 95-105 ft-lbs (128.9-
wheel from rear fork.
142.4 Nm).
15.
With the flat side out, install new e-clip in axle groove.
NOTE
Removal of the rear wheel can be also facilitated by remov-
16.
Install mufflers. See REAR WHEEL in the Touring Mod-
ing the lower shock bolts and dropping the rear fork below
els Service Manual.
the saddlebag support brackets. This provides access to the
rear axle.
1WARNING
Whenever a wheel is installed and before moving the
INSTALLATION
motorcycle, pump brakes to build brake system pres-
sure. Insufficient pressure can adversely affect brake
1.
Place rear wheel in rear swingarm. Slide wheel forward
performance, which could result in death or serious
and slip belt over sprocket.
injury. (00284a)
17. Press rear brake pedal several times to set brake pads.
1WARNING
18. Install saddelbags. See SADDLEBAG in the Touring
Never bend belt forward into a loop smaller than the
Models Service Manual.
drive sprocket diameter. Never bend belt into a reverse
loop. Over bending can damage belt resulting in prema-
ture failure, which could cause loss of control and death
or serious injury. (00339a)
2.
Seat caliper on anchor weldment of rear swingarm. Posi-
tion wheel in rear fork, so that brake disc is centered
between brake pads.
2-4
2005 FLHTCSE2: Chassis
HOME
REAR BRAKE PADS
2.5
GENERAL
8695
1
Follow service instructions for INSPECTION, BRAKE DISC
THICKNESS/WARPAGE, BRAKE PADS, and BRAKE LINE/
HOSE INSPECTION under REAR BRAKE CALIPER in Tour-
2
ing Models Service Manual.
Procedures for rear brake pad replacement are similar. How-
ever, the brake pads must be rotated along the arc of the
brake disc to clear the disc rivets and spring washers during
brake pad removal and installation.
REPLACEMENT
1.
Raise the rear wheel off the ground.
3
2.
Remove right side saddlebag. See SADDLEBAGS,
REMOVAL in Touring Models Service Manual.
3.
See Figure 2-3. Loosen both pad pins (2), but do not
1.
Bridge bolt
remove.
2.
Pad pin
3.
Spring washer and rivet
4.
Remove two Phillips screws to release cover from rear
master cylinder reservoir.
Figure 2-3. Rear Brake Disc and Caliper
CAUTION
o0035x0x
As the pistons are pushed back into the caliper, fluid
level may rise more than 1/8 inch (3.2 mm) and overflow
the reservoir. Watch the fluid level as the pistons are
retracted and remove fluid from the reservoir if neces-
Inner brake pad
Outer brake pad
sary.
5.
Pry the inner pad back pushing the pistons into their
bores. Use a putty knife with a wide thin blade to avoid
scoring or scratching the brake disc.
1
2
CAUTION
Do not completely pull pad pins from caliper during the
next step. Completely removing pad pins at this time will
make assembly difficult.
6.
Once the pistons have been retracted, pull the pad pins
part way out to free the inside pad.
7.
Slide the inside pad along the arc of the brake disc to
3
remove pads from calipers. Note the orientation of the
1.
Two tabs
pad.
2.
Single tab
3.
Curved portion faces rear
1WARNING
Figure 2-4. Rear Brake Pad Orientation
Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation
could result in death or serious injury. (00111a)
8.
See Figure 2-4. Orient new inner brake pad against the
brake disc. Curved portion must face rear of motorcycle.
2005 FLHTCSE2: Chassis
2-5
HOME
9.
Hold brake pad against brake disc and rotate the rear
20. Verify that brake fluid level is 1/8 inch (3.2 mm) below top
wheel to rotate the pad forward into caliper.
of reservoir with master cylinder in a level position. Add
D.O.T. 4 HYDRAULIC BRAKE FLUID (Part No. 99953-
10. Install pad pins, but do not fully tighten.
99A), if necessary. Install master cylinder reservoir
11. Pump rear brake pedal to move inside pistons out until
cover. Install two Phillips screws to fasten cover to reser-
they contact inner brake pad.
voir and tighten to 6-8 in-lbs (0.68-0.90 Nm).
12. Pry the outside pad back pushing the pistons into their
21. Install right side saddlebag. See SADDLEBAGS,
bores. Use a putty knife with a wide thin blade to avoid
INSTALLATION in Touring Models Service Manual.
scoring or scratching the brake disc.
22. Test operation of brake lamp with the rear brake applied
13. Verify that inner pad is captured between brake disc and
and the ignition/light key switch turned to IGNITION.
pistons.
14. Completely remove pad pins to free outer brake pad.
1WARNING
Note the orientation of the outer brake pad.
15. Orient new outer brake pad against the brake disc.
After repairing the brake system, test brakes at low
Curved portion of pad must face rear of motorcycle.
speed. If brakes are not operating properly, testing at
high speeds can cause loss of control, which could
16. Hold brake pad against brake disc and rotate the rear
result in death or serious injury. (00289a)
wheel to rotate the pad forward into caliper. If the inside
pad moved during the previous step, reinstall.
23. Test ride motorcycle. If the brakes fell spongy, bleed the
17. Inspect pad pins and clean or replace as required.
brake lines. See BLEEDING HYDRAULIC BRAKE
LINES in Touring Models Service Manual.
18. Install two pad pins and tighten to 180-200 in-lbs (20.4-
22.6 Nm).
1WARNING
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insuffi-
cient pressure can adversely affect brake performance,
which could result in death or serious injury. (00279a)
19. Pump rear brake pedal to move pistons out until they
contact both brake pads. Verify piston location against
pads.
2-6
2005 FLHTCSE2: Chassis
HOME
FOOTBOARDS AND CONTROLS
2.6
RIDER FOOTBOARDS
Installation
1.
See Figure 2-7. Install left front footboard bracket (13)
NOTES
with washer
(14), lockwasher
(15) and screw
(20).
Tighten screw only finger-tight at this time.
● Unless the inserts or bottom assemblies are being
replaced, they do not have to be removed from footboard
2.
Install left rear footboard bracket (22) with screws (21),
brackets.
lock washer (23) and nut (24). Tighten screws to 30-35
ft-lbs (40.7-47.5 Nm).
● See Figure 2-5. The right and left footboard frame
3.
Install left footboard bottom assembly (10) onto foot-
mounts allow a small variance in height and angle of
board brackets. Install and tighten pivot bolts (12) and
footboards. If footboard brackets are to be removed,
locknuts (11) to 84-108 in-lbs (9.5-12.2 Nm).
make note of their position in adjustment holes in frame
mounts before removing them. Make sure to reinstall
4.
Tighten left front footboard bracket screw (20) to 30-35
footboard brackets in same positions.
ft-lbs (40.7-47.5 Nm).
5.
Install right footboard brackets (16, 19) with washers
(14), lockwashers (15), and screws (20). Tighten screws
cse0007x2x
only finger-tight at this time.
6.
Install right footboard bottom assembly (17) onto foot-
board brackets. Install and tighten pivot bolts and lock-
nuts to 84-108 in-lbs (9.5-12.2 Nm).
7.
Tighten right footboard bracket screws (20) to 30-35 ft-
lbs (40.7-47.5 Nm).
8.
Moisten footboard cover rubber collars with soapy water.
9.
With left footboard bottom assembly in up position, hold
new footboard insert assembly (9) in position.
10.
From underside of footboard use a pliers to pull each
rubber collar through footboard hole.
11.
Repeat for right side footboard.
CAUTION
Avoid contacting chrome surfaces with abrasive materi-
als (stones, sand, etc.) as damage will result.
Figure 2-5. Footboard Position Adjustment Holes
Removal
10518
1.
Position motorcycle upright on a suitable lift so that
weight of vehicle is not resting on jiffy stand.
2.
See Figure 2-6. With footboards in up position, use a
screwdriver to work cover rubber collars out through
footboards. Remove insert assemblies.
3.
See Figure 2-7. Remove right footboard pivot bolts (12)
and locknuts (11), and remove footboard bottom assem-
bly (17).
4.
Remove screws (20), lockwashers (15), washers (14)
and right front and rear footboard brackets (16, 19).
5.
Remove left footboard pivot bolts, nuts and remove foot-
board bottom assembly (10).
6.
Remove screws (21), lockwasher (23), nut (24) and left
Figure 2-6. Footboard Cover Rubber Collars
rear footboard bracket (22).
7.
Remove screw (20), lockwasher (15), washer (14) and
left front footboard bracket (13).
2005 FLHTCSE2: Chassis
2-7
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