Harley Davidson FLHRC 2006. Maintenance & Repair Manual — page 7

HOME

Protective Cap

Hex Nut

Air Valve and Mounting Bracket

Air Inlet Tee

Shock Air Inlet Tube

Compression Fitting

Left Shock

Right Shock

f2017x2x

Figure 2-91. Rear Air Suspension System

2-76

2006 Touring: Chassis

HOME

1WARNING

Air Inlet

Tee

Exercise caution when bleeding air from the air valve.

Moisture combined with lubricant (either from shock

assembly or drip oiler in the air compressor lines) may

be ejected onto the rear wheel, tire and/or brake compo-

nents and adversely affect traction and/or braking effi-

ciency, which could result in death or serious injury.

REAR AIR SUSPENSION

f2041x2x

Valve Head

Adjust the rear shock air suspension pressure by adding or

removing air from the air valve located just below the frame

Figure 2-93. Air Valve Assembly

cover on the left side of the vehicle. See Figure 2-90. Always

adjust pressures with the vehicle on the jiffy stand.

Depress pin in valve to bleed air from shocks. To

purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)

before releasing air.

REMOVAL/INSTALLATION

Depress collar on compression fitting and pull out

Remove and replace components as necessary. Check for

air tube. See inset of Figure 2-91. Inspect the tube

air leaks as follows:

end for burrs or damage. If either condition is

observed, snip off the end of the tube and insert it

Remove left side saddlebag. See Section 2.26 SAD-

back into the compression fitting until it bottoms.

DLEBAG, REMOVAL.

Gently tug on tube to verify that it is locked in place.

Remove protective cap from air valve. Install the no-loss

Pressurize rear air suspension system and check

air gauge and set to correct pressure. See Table 2-6.

for leaks. If leakage continues, proceed to step 5(d).

Remove the gauge and wait overnight.

Recheck air pressure. If no leakage is observed, move

Depress collar on compression fitting and pull out

to step 8. If a loss of 5-10 psi (34.5-68.9 kPa) is noted,

air tube. Remove compression fitting from shock

then proceed to step 4.

absorber.

Pressurize rear air suspension system and check for

Apply PIPE SEALANT WITH TEFLON to the

leaks as described below.

threads of a new compression fitting and install in

shock absorber.

Insert air tube into the compression fitting until it

Compression Fitting

bottoms. Gently tug on tube to verify that it is locked

Spray or brush a light film of soapy water on the com-

in place.

pression fitting at the top of each shock absorber. If no

Pressurize rear air suspension system and check

leakage is observed, move to step 6. If leakage is noted,

for leaks. If no leakage is observed, move to step 8.

proceed as follows:

If leakage continues, proceed to step 6.

Air Valve Assembly

Spray or brush a light film of soapy water into the valve

head and where the air tubes exit the air inlet tee. If leak-

age is not observed at either location, move to step 7. If

leakage is noted, proceed as follows:

a. If leakage is at the air inlet tee, proceed to step 6(b).

If leakage is at the valve head, proceed to step 6(e).

b. Depress pin in valve to bleed air from shocks. To

purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)

Figure 2-92. Air Suspension Pump and Gauge

before releasing air.

(Part No. HD-34633A)

2006 Touring: Chassis

2-77

HOME

Depress collar on air inlet tee and pull out air tube.

d. Cut bulk tube to proper length.

Inspect the tube end for burrs or damage. If either

e. Insert new tubes into air inlet tee. Install opposite

condition is observed, snip off the end of the tube

end of tubes into compression fittings.

and insert it back into the air inlet tee until it bot-

toms. Gently tug on tube to verify that it is locked in

Pressurize rear air suspension system.

place. Repeat step with remaining tube.

g. Install seat. See Section

2.25 SEAT, INSTALLA-

Pressurize rear air suspension system and check

TION.

for leaks. If no leakage is observed, move to step 8.

If leakage continues, proceed to step 6(e).

Install protective cap on air valve.

Using a valve core tool, verify that valve core is

Install left side saddlebag. See Section 2.26 SADDLE-

BAG, INSTALLATION.

properly tightened. If leakage continues, proceed to

step 6(f).

Depress pin in valve to bleed air from shocks. To

purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)

before releasing air.

Remove hex nut from valve head. See Figure 2-91.

Push on valve head to free air valve assembly from

mounting bracket. See Figure 2-93.

Depress collars on air inlet tee and pull out air

tubes.

Insert air tubes into air inlet tee of new air valve

assembly.

From inboard side, insert valve head through hole in

mounting bracket. Install hex nut on valve head (flat

side facing inboard). Tighten nut to 40-50 in-lbs

(4.5-5.6 Nm).

Pressurize rear air suspension system and check

for leaks.

If no leakage is observed, move to step 8. If leakage

continues, reinstall old air valve assembly and pro-

ceed to step 7.

Air Tubes

Inspect air tubes for kinks, cuts, holes, chafing or other

damage that may result in air leaks. If tube replacement

is necessary, proceed as follows:

a. Remove seat. See Section 2.25 SEAT, REMOVAL.

b. Depress pin in valve to bleed air from shocks. To

purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)

before releasing air.

c. Depress collars on air inlet tee and pull out air

tubes. Remove opposite end of tubes from com-

pression fittings. See Figure 2-91.

2-78

2006 Touring: Chassis

HOME

REAR SHOCK ABSORBERS

2.19

ADJUSTMENT

For the correct air pressure, see Section 2.18 REAR AIR

SUSPENSION.

REMOVAL

NOTE

If replacing both shock absorbers, remove and install one

shock at a time. Remove and install the second shock only

after the first shock is installed, but before the air suspension

system is pressurized.

Place the motorcycle on a hydraulic center stand with

the rear wheel raised off the ground.

f1449a2x

Remove saddlebags. See Section 2.26 SADDLEBAG,

REMOVAL.

Figure 2-94. Depress Collar on Fitting

and Pull Out Air Inlet Tube

1WARNING

Exercise caution when bleeding air from the air valve.

f2010x2x

Moisture combined with lubricant (either from shock

assembly or drip oiler in the air compressor lines) may

be ejected onto the rear wheel, tire and/or brake compo-

nents and adversely affect traction and/or braking effi-

ciency, which could result in death or serious injury.

Remove protective cap from air valve. Using a no-loss

AIR SUSPENSION PUMP AND GAUGE (Part No. HD-

34633), add 3-5 psi (20.7-34.5 kPa) to purge lines of any

oil.

Depress pin in valve to bleed air from shocks.

Depress collar on compression fitting to release air tube.

See Figure 2-94.

Remove the upper shock mounting bolt with lockwasher

and flat washer. See lower frame of Figure 2-95.

Remove the lower shock mounting bolt with lockwasher

and flat washer. Remove the shock absorber assembly

from the motorcycle.

Compression Fitting

Shock Absorber

Air Inlet Tube

Frame Boss

CAUTION

Figure 2-95. Remove Upper Shock Mounting Bolt

Never lay the shock absorber down. Always keep the

(Left Side View)

shock absorber upright in a fully vertical position. Lay-

ing the shock absorber down with the air line removed

can cause the oil to drain out through the compression

fitting. Any loss of oil requires replacement of the shock

absorber.

2006 Touring: Chassis

2-79

HOME

DISASSEMBLY

INSTALLATION

NOTE

CAUTION

Air shocks are not repairable. Replace the shocks if dam-

aged, worn or any sign of leakage is observed.

Never lay the shock absorber down. Always keep the

shock absorber upright in a fully vertical position. Lay-

ing the shock absorber down with the air line removed

can cause the oil to drain out through the compression

CLEANING AND INSPECTION

fitting. Any loss of oil requires replacement of the shock

absorber.

Examine the rubber mounting bushings for cracks or

Install lockwasher and flat washer on the lower shock

wear. Examine the shock for leaks. The unit should not

mounting bolt. Insert bolt through the shock bottom

leak and should compress slightly easier than it extends.

bushing.

Compare the action of the shock with a new one to judge

if it is worn. Replace the shock if necessary.

Apply two or three drops of Loctite Medium Strength

Threadlocker 243 (blue) to threads.

Clean and examine the shock mounting hardware.

Replace parts that are worn or damaged.

Start bolt into rear swingarm mount. Tighten bolt to 35-

40 ft-lbs (47-54 Nm).

Install lockwasher and flat washer on the upper shock

mounting bolt. Insert bolt through the shock upper bush-

ASSEMBLY

ing

Apply two or three drops of Loctite Medium Strength

NOTE

Threadlocker 243 (blue) to threads.

If the compression fittings were removed, apply PIPE SEAL-

Start bolt into frame boss. Tighten bolt to 33-35 ft-lbs

ANT WITH TEFLON to the threads before assembly.

(45-48 Nm).

Insert air tube into compression fitting until it bottoms.

Gently tug on tube to verify that it is locked in place.

NOTE

If replacing both shock absorbers, remove and install the

other shock at this time.

Pressurize rear air suspension system and check for

leaks. For the correct air pressure, see Section 2.18

REAR AIR SUSPENSION.

Install saddlebags. See Section

2.26 SADDLEBAG,

INSTALLATION.

2-80

2006 Touring: Chassis

HOME

REAR SWINGARM

2.20

REMOVAL

Remove saddlebags. See Section 2.26 SADDLEBAG,

REMOVAL.

Remove socket screw with lockwasher to remove pas-

senger footboard from rear swingarm bracket. Repeat

step on opposite side of motorcycle.

Remove left side muffler as follows:

a. Open worm drive clamps to remove heat shield

from crossover pipe in front of muffler.

b. Using a bungee cord, tie the muffler to the lower

saddlebag support rail.

c. Loosen TORCA clamp between crossover pipe and

muffer.

NOTE

To facilitate removal, spray PB Blaster or other suitable pene-

trating oil in and around joint of exhaust pipes. For best

results, be sure to allow sufficient time for the penetrating oil

f2006x2x

to work.

d. Remove two screws (with lockwashers) to detach

muffler from lower saddlebag support rail.

e. Remove bungee cord to release muffler from lower

Pivot Shaft

Rubber Mount

saddlebag support rail.

Locknut

Slot

On models equipped with low profile shock absorbers

Figure 2-96. Remove Rear Swingarm Bracket

(FLHS and FLHX), remove left side lower saddlebag

(Left Side View)

support rail as follows:

a. Remove outside T40 TORX screw (and flange nut)

to release saddlebag support rail from saddlebag

10.

Remove caliper from anchor weldment on rear swing-

support bracket.

arm, and carefully hang over lower saddlebag support

rail.

b. Remove T40 TORX screw to release opposite end

of saddlebag support rail from frame weldment.

11.

Roll wheel forward and slip belt off sprocket. Move wheel

out from beneath rear fender.

Place the motorcycle on a hydraulic center stand. Slide

a block of wood beneath the oil pan to support the

12.

Remove belt guard from bottom of left side swingarm.

weight of the transmission once the pivot shaft is

First remove two rear screws, and then loosen front

removed.

screw. Push belt guard toward the front of the motorcy-

cle until screw engages large end of slot, and then

Standing on right side of motorcycle, remove E-clip from

remove.

groove at end of axle.

Remove cone nut and adjuster cam from axle.

13.

Remove lower shock mounting bolt (with lockwasher and

flat washer) to release shock absorber from rear swing-

Using a soft mallet, gently tap end of axle towards left

arm mount. Repeat step on opposite side of motorcycle.

side to loosen. Catching external spacers on right and

left side of hub, pull axle free of wheel and rear

14.

Remove two bolts (with lockwashers) to free rear swing-

swingarm.

arm bracket from left side of motorcycle frame. See Fig-

Pull wheel to release brake disc from caliper. Pry inner

ure 2-96.

and outer brake pads back for additional clearance, if

15.

Moving to right side of motorcycle, leave rear swingarm

necessary. Use a putty knife with a wide thin blade to

bracket installed, but remove decorative chrome plug.

avoid scoring or scratching the brake disc.

2006 Touring: Chassis

2-81

HOME

f1903x2x

Anchor Weldment

Wood Block

Large Socket

Socket Extension

Smaller Socket

Ram

Figure 2-97. Press Out Drive Side Bearing

16. Open two cable clips on T-studs at top of right side swin-

garm. Free rear brake line hose from cable clips.

f1967x2x

Spacer

NOTE

For best results, insert blade of small screwdriver into gap at

side of clip and gently rotate end of screwdriver to pop open.

17. Holding left side nut within rubber mount, remove right

side locknut from end of pivot shaft. Remove cup

washer.

Bearing

18. Using a suitable drift, tap pivot shaft toward left side of

motorcycle.

19. Moving to left side, pull pivot shaft assembly (pivot shaft,

locknut, cup washer, rubber mount and outer spacer) out

of transmission mount and left side swingarm. See

Figure 2-101.

20. Standing at rear of motorcycle, work rear swingarm free

of transmission mount and rear swingarm brackets.

21. Remove outer spacer from right side swingarm tube.

22. Remove rubber mount from behind right side swingarm

Figure 2-98. Press Spacer Into Bearing

bracket.

Place swingarm on its side, so that the brake side is on

DISASSEMBLY/ASSEMBLY

top. The brake side is easily recognized by the anchor

weldment for mounting of the brake caliper.

Support the swingarm with a block of wood and a large

Bearing Removal

socket as shown in Figure 2-97. Verify that assembly is

square and the bearing bore is completely vertical.

Move rear swingarm to an hydraulic press.

2-82

2006 Touring: Chassis

HOME

b. With the nose topside, center one of the drivers

under ram of hydraulic press.

c. Place bearing over nose of driver. With the collar

Drive Side

Brake Side

topside, place spacer over nose and into bearing.

Driver

See Figure 2-98.

d. Apply pressure to spacer until it bottoms in bearing.

e. Repeat step to assemble second swingarm bearing.

Install assembled bearings into rear swingarm. Proceed

as follows:

a. Place swingarm on its side, so that the brake side is

on top. The brake side is easily recognized by the

anchor weldment for mounting of the brake caliper.

Figure 2-99. Rear Swingarm Bearing Installer (HD-45327)

b. With the spacer inboard, insert bearing into out-

board side of brake side swingarm tube.

Brake Side

f1909x2x

c. Insert driver stamped “Brake Side” into swingarm

Driver

tube until it contacts installed bearing. Center driver

under ram and press on brake side bearing until

shoulder on tool makes contact with casting of swin-

garm. See Figure 2-100.

d. Remove tool and turn rear swingarm over. With the

spacer inboard, insert bearing into outboard side of

Anchor

drive side swingarm tube.

Weldment

e. Insert driver stamped “Drive Side” into swingarm

tube until it contacts installed bearing. Center driver

under ram and press on drive side bearing until it

bottoms. Shoulder on tool will not make contact

with casting of swingarm.

Remove tool from swingarm. Remove swingarm

from hydraulic press.

Pivot Shaft Disassembly

Figure 2-100. Press In Brake Side Bearing

Partially install locknut on right side of pivot shaft. Install

second locknut on right side until it contacts the first.

Holding first locknut to prevent rotation of shaft, remove

left side locknut. See Figure 2-101.

Slide driver handle (or long socket extension) through

the brake side swingarm tube and bearing until it con-

Remove cup washer, rubber mount and outer spacer.

tacts driver (or smaller socket) placed on inboard side of

Remove right side locknuts from pivot shaft.

drive side bearing.

Center driver handle (or long socket extension) under

ram and press drive side bearing from rear swingarm.

Pivot Shaft Assembly

Remove tools from rear swingarm. Turn swingarm over

With larger OD outboard, slide outer spacer onto left

and repeat steps 3-5 to press out brake side bearing.

side of pivot shaft until counterbore contacts shoulder on

shaft.

Install rubber mount with the flat side inboard toward

Bearing Installation

outer spacer.

Obtain new rear swingarm bearings. Bearings and spac-

Install cup washer with the concave side facing in toward

ers must be assembled before installation. Proceed as

the rubber mount.

follows:

Apply two drops of Loctite Medium Strength Thread-

a. Obtain REAR SWINGARM BEARING INSTALLER

locker 243 (blue) to threads of left side locknut, and then

(HD-45327). See Figure 2-99.

start on shaft.

2006 Touring: Chassis

2-83

HOME

c. With the concave side inboard, slide cup washer

Right Side

onto end of pivot shaft.

2, 3

d. Install locknut on pivot shaft. Holding left side nut on

pivot shaft, tighten locknut to 40-45 ft-lbs (54-61 Nm).

Now hold right side nut and tighten left side locknut

using the same torque value.

e. Carefully raise swingarm up and down slightly to

verify movement (and that assembly is not in a

bind).

f1914x2x

Install decorative chrome plug in right side rear

swingarm bracket.

g. Moving to left side of motorcycle, rotate the rubber

Pivot Shaft

Rubber Mount

mount so that the slot is between the eleven and

Locknut

Outer Spacer

twelve o’clock positions. Install left side swingarm

Cup Washer

bracket fitting index tab into rubber mount slot. See

Figure 2-96.

Figure 2-101. Pivot Shaft Assembly

h. Install two bolts (with lockwashers) to secure left

side swingarm bracket to motorcycle frame. Tighten

bolts to 34-42 ft-lbs (46-57 Nm).

Partially install locknut on right side of pivot shaft. Install

second locknut on right side until it contacts the first.

Install lockwasher and flat washer on the lower shock

Holding second locknut to prevent rotation of shaft,

mounting bolt. Insert bolt through the shock bottom

tighten left side locknut to 40-45 ft-lbs (54-61 Nm).

bushing. Apply two or three drops of Loctite Medium

Strength Threadlocker 243 (blue) to threads. Start bolt

Remove right side locknuts from pivot shaft.

into rear swingarm mount. Tighten bolt to 35-40 ft-lbs

(47-54 Nm). Repeat step on opposite side of motorcycle.

Install belt guard at bottom of left side swingarm. Push

INSTALLATION

belt guard toward the rear of the motorcycle until front

screw engages small end of slot. Install two rear screws,

and then tighten front screw.

With the slot on the outboard side between the twelve

and one o’clock positions, install rubber mount behind

Capture rear brake line hose in two cable clips at top of

rear swingarm bracket on right side of motorcycle. Be

right side swingarm. Snap cable clips closed.

sure that index tab cast on inboard side of bracket fully

Place wheel in rear swingarm. Slide wheel far enough

engages slot in rubber mount.

forward to slip belt over sprocket and then slide the

Place outer spacer into right side swingarm tube.

wheel back.

With the belt on the inboard side of the left side swing-

CAUTION

arm, work the rear swingarm into position between the

transmission mount and the rear swingarm brackets.

Do not bend or fold belt backward or into loops smaller

Use a rubber mallet and carefully tap swingarm into

than 5 inches (127 mm) in diameter. Sharp bending can

position, if necessary.

weaken the belt and cause premature failure.

The pivot shaft secures the rear swingarm and transmis-

Seat caliper on anchor weldment of rear swingarm. Posi-

sion to the motorcycle frame. See Figure 2-101. Install

tion wheel in swingarm, so that brake disc is centered

the pivot shaft as follows:

between brake pads.

10. Coat the axle with Loctite ANTI-SEIZE LUBRICANT.

a. Coat pivot shaft with Loctite ANTI-SEIZE LUBRI-

CANT.

11. With the larger OD on the outboard side, hold external

spacer between rear swingarm and belt sprocket. Slide

b. From left side of motorcycle, slide pivot shaft

axle through left side of rear swingarm, external spacer,

assembly (pivot shaft, locknut, cup washer, rubber

and belt sprocket into wheel hub.

mount and outer spacer) through left side swingarm

and transmission mount. After exiting right side

12. When axle emerges from hub on brake disc side of

swingarm, guide end of pivot shaft through holes in

wheel, push axle through short external spacer, caliper

rubber mount and right side swingarm bracket.

bracket and right side of rear swingarm.

2-84

2006 Touring: Chassis

HOME

Torque Wrench

CAUTION

Axle Nut Torque Adapter

(HD-47925)

Since any extension can act as a torque multiplier, the

torque wrench must be perpendicular to the torque

adapter when the cone nut is tightened. The 90 degree

orientation between the tools cancels the multiplier

90°

effect and prevents the cone nut from being over-tight-

ened. If the torque adapter is kept inline with the torque

wrench, the multiplier effect is in force and parts damage

will occur.

c. Verify that adjuster cam just contacts weld nub on

both sides of rear swingarm. If necessary, push

wheel forward slightly to achieve the desired result.

Snug the cone nut to 15-20 ft-lbs (20-27 Nm). See

f2369x2x

Figure 2-103.

16.

Obtain the BELT TENSION GAUGE (HD-35381A), or

install adapter (HD-35381-3) on old style gauge. See

Figure 2-104.

Apply 10 lbs. (4.5 kg) of force at the midpoint of the bot-

tom belt strand. At the loosest spot in the belt, deflection

should be as follows:

Table 2-7. Belt Deflection in the Air

Orientation

Inches

Millimeters

9292

Motorcycle Upright

3/16 - 1/4

4.8

- 6.4

With Rear Wheel in the Air

Figure 2-102. Install Tool Perpendicular to Torque Wrench

NOTE

See Section 1.10 DRIVE BELT for belt deflection specification

with motorcycle on jiffy stand.

13. Rotate axle so that the flat on the threaded end is top-

17.

If belt is too tight, move to step

18 to increase belt

side. With the thumb down and the cam forward, install

deflection. If belt is too loose, reduce belt deflection as

adjuster cam on end of axle.

described below:

a. Rotate weld nut on left side of axle in a clockwise

14. Apply a thin film of ANTI-SEIZE LUBRICANT to the

direction.

inboard side of the cone nut avoiding contact with

threads. Install cone nut on axle, but finger tighten only.

b. Check belt deflection. Apply 10 lbs. (4.5 kg) of force

at the midpoint of the bottom belt strand. Belt

15. Obtain torque wrench with 1/2 inch drive head and AXLE

deflection should be within the range specified in

NUT TORQUE ADAPTER (HD-47925). Proceed as fol-

Table 2-7.

lows:

c. If belt is still too loose, repeat steps 17(a) through

NOTE

17(b). If belt is now too tight, move to step 18.

The Axle Nut Torque Adapter simplifies the belt adjustment

18.

If belt is too tight, increase belt deflection as follows:

procedure by allowing the cone nut to be properly tightened

without having to remove the right side muffler. The tool also

a. Rotate weld nut on left side of axle in a counter-

can be used to loosen the cone nut, as well as rotate the

clockwise direction.

weld nut on the left side.

b. Push wheel forward slightly so that adjuster cam

just contacts weld nub on both sides of rear swing-

a. Install torque adapter perpendicular to torque

arm. See Figure 2-103.

wrench as shown in Figure 2-102.

c. Check belt deflection. Apply 10 lbs. (4.5 kg) of force

b. Insert tool up between rear wheel and muffler to

at the midpoint of the bottom belt strand. Belt

capture cone nut. For best clearance with muffler,

deflection should be within the range specified in

be sure torque adapter is on the outboard side.

Table 2-7.

2006 Touring: Chassis

2-85

HOME

LEFT SIDE

RIGHT SIDE

Increase

Reduce

Belt

Deflection

8398

8407

Weld Nut

Cone Nut

Weld Nub

E-Clip

Adjuster Cam

Figure 2-103. Move Rear Wheel Forward Until Adjuster Cams Just Contact Weld Nubs

d. If belt is still too tight, repeat steps 18(a) through

23.

On models equipped with low profile shock absorbers

18(c). If belt is now too loose, move to step 17.

(FLHS and FLHX), install left side lower saddlebag sup-

port rail as follows:

19. Holding weld nut on left side of axle, tighten cone nut on

a. At rear left side of motorcycle, start outside T40

right side to 95-105 ft-lbs (128.8-142.4 Nm).

TORX screw (and flange nut) to fasten saddlebag

support rail to saddlebag support bracket.

NOTE

b. Start T40 TORX screw to fasten opposite end of

If the axle moves during tightening of the cone nut, then the

saddlebag support rail to frame weldment.

belt deflection procedure must be restarted.

c. Alternately tighten screws to

15-20 ft-lbs

(20-27

Nm).

20. Recheck belt deflection to verify that it is still within spec-

ification.

If the belt deflection is not within specification, loosen

cone nut and then snug to 15-20 ft-lbs (20-27 Nm)

before returning to step 17.

21. With the flat side out, install new E-clip in groove on right

side of axle.

22. Depress rear brake pedal several times to set brake

pads to proper operating position within caliper.

1WARNING

Belt Tension Gauge (Part No. HD-35381A)

After servicing brakes and before moving motorcycle,

pump brakes to build brake system pressure. Insuffi-

Belt Tension Gauge Adapter (Part No. HD-35381-3)

cient pressure can adversely affect brake performance,

which could result in death or serious injury. (00279a)

Figure 2-104. Obtain Belt Tension Gauge

2-86

2006 Touring: Chassis

HOME

24. Install left side muffler as follows:

that screw is on the outboard side in the most

accessible position and then tighten to 20-40 in-lbs

NOTE

(2.3-4.5 Nm).

TORCA clamps have eliminated the need for silicone or

g. Remove bungee cord from muffler.

graphite tape during assembly. To ensure sealing integrity

and prevent the possibility of leakage, always discard

NOTE

TORCA clamps whenever they are removed.

Verify that the exhaust pipes and heat shields do not contact

a. Slide new TORCA clamp onto free end of crossover

the motorcycle frame or any mounted components. Contact

pipe.

will cancel the effect of the rubber isolation mounts and trans-

mit vibration to the rider.

b. Using a bungee cord, tie muffler to lower saddlebag

support rail. Install muffler on crossover pipe. Place

25. Install socket screw with lockwasher to fasten passenger

TORCA clamp into position between crossover pipe

footboard to rear swingarm bracket. Tighten screw to 30-

and muffler.

35 ft-lbs (40.7-47.5 Nm). Repeat step on opposite side

c. Install two screws (with lockwashers) to fasten the

of motorcycle.

muffler to the lower saddlebag support rail. Alter-

26. Install saddlebags. See Section

2.26 SADDLEBAG,

nately tighten screws to 96-144 in-lbs (10.8-16.3

INSTALLATION.

Nm).

NOTE

d. Verify that exhaust pipes are in alignment and do

At the required service interval (see Section 1.2 MAINTE-

not contact the motorcycle frame or mounted com-

NANCE SCHEDULE), remove the decorative chrome plugs

ponents.

in the rear swingarm brackets and check the torque on the

e. Tighten the TORCA clamp to 45-60 ft-lbs (61-81

pivot shaft locknuts. See Figure 2-105. Holding right side nut

Nm).

on the pivot shaft, tighten left side locknut to 40-45 ft-lbs (54-61

Open worm drive clamps and install heat shield on

Nm). Then hold left side nut and tighten right side locknut

crossover pipe. Position each worm drive clamp so

using the same torque value.

f1787x2x

Rear Swingarm Bracket

Pivot

Shaft

Passenger Footboard

Locknut

f2073x2x

Bracket

L(eft) Side Casting

Chrome Plug

Stamp

Figure 2-105. Remove Chrome Plugs and Check Pivot Shaft Locknut Torque (Left Side View)

2006 Touring: Chassis

2-87

HOME

THROTTLE CABLES (NON-CRUISE)

2.21

Slide rubber boot off throttle cable adjuster mechanism.

ADJUSTMENT

See Figure 2-106. Holding cable adjuster with a 3/8 inch

wrench, loosen jam nut turning in a clockwise direction.

Back jam nut away from cable adjuster until it stops. Turn

NOTE

cable adjuster clockwise until it contacts jam nut. Repeat

For throttle and idle cable adjustment or replacement on

procedure on idle cable adjuster.

cruise equipped models, see Section 8.31 CRUISE CON-

Point the front wheel straight ahead. Gently turn the

TROL (FLHRC, FLHTCU, FLTR).

throttle grip so that the throttle is wide open (fully coun-

terclockwise) and then hold in position. Now turn the

The throttle control must operate freely without binding. With

cable adjuster counterclockwise until the throttle cam

the tension adjuster screw backed off, the throttle grip must

stop just touches the stop plate on the carburetor/induc-

freely return to the closed (idle) position. The throttle control

tion module. See Figure 2-107. Release the throttle grip,

also must open and close freely when the front wheel is

turn cable adjuster counterclockwise an additional 1/2-1

turned to both the right and left fork stops. If the throttle grip

full turn, and then tighten the jam nut against the cable

does not return to the idle position freely, check the adjuster

adjuster. Cover cable adjuster mechanism with rubber

screw tension. If the adjuster screw is backed off, inspect the

boot.

cables for short bends.

Turn the front wheel full right. Turn the idle cable adjuster

counterclockwise until the cable housing just touches

the spring in the cable guide (as seen through slot).

1WARNING

Work the throttle grip to verify that the throttle cable

Do not overtighten the tension adjuster screw. An over-

returns to the idle position when released. If the cable

tightened screw will prevent the engine from automati-

does not return to idle, turn the cable adjuster clockwise

cally returning to idle in an emergency situation. This

slightly until the correct response is achieved. Tighten

can lead to loss of vehicle control, which could result in

jam nut against the cable adjuster and cover cable

death or serious injury.

adjuster mechanism with rubber boot.

Throttle Cable Adjuster

Idle Cable Adjuster

Jam Nut

Throttle Grip

f1376b2x

Tension Adjuster Screw

Figure 2-106. Throttle Cable Assembly - Throttle Side (FLHR)

2-88

2006 Touring: Chassis

HOME

Throttle Cable Guide

Throttle Cam Stop

Stop Plate

Idle Cable Guide

Cable Housing

Spring

Cable Barrel End

Throttle Wheel

f1381a2x

Figure 2-107. Throttle Cable Assembly - Carburetor Side

REMOVAL

f1225x2x

THROTTLE SIDE

CAUTION

Do not remove the switch housing assembly without first

placing the 5/32 inch (4.0 mm) cardboard insert between

the brake lever and lever bracket. Removal without the

insert may result in damage to the rubber boot and

plunger of the Front Stoplight Switch.

NOTE

Use the eyelet of an ordinary cable strap if the cardboard

insert is not available.

Place the cardboard insert between the brake lever and

lever bracket. See Figure 2-108.

Using a T25 TORX drive head, remove the upper and

Figure 2-108. Install Cardboard Insert

lower switch housing screws.

Using a T27 TORX drive head, loosen the upper screw

securing the handlebar clamp to the master cylinder

Remove the brass ferrules from the notches on

the

housing. Remove the lower clamp screw with flat

inboard side of the throttle control grip. Remove the fer-

washer.

rules from the cable end fittings.

2006 Touring: Chassis

2-89

HOME

Remove the friction shoe from the end of the tension

adjuster screw.

7961

NOTE

The friction shoe is a loose fit and may fall out or become dis-

lodged if the lower switch housing is turned upside down or

shaken.

Remove the throttle control grip from the end of the han-

dlebar.

Throttle

Cable Insert

Pull the crimped inserts at the end of the throttle and idle

(Silver)

cable housings from the lower switch housing.

Idle

Cable Insert

For best results, use a rocking motion while pulling.

(Gold)

Place a drop of light oil on the retaining rings, if neces-

sary. Remove the cables from the switch housing.

Figure 2-109. Install Throttle/Idle Cables

in Lower Switch Housing

CARBURETOR/INDUCTION MODULE SIDE

Inspect the cables for damage or wear. Replace the

cables if frayed, kinked or bent.

Remove the air cleaner and backplate. See Section 4.5

Obtain tube of Lubit-8 Tufoil Chain and Cable Lube (HD

AIR CLEANER, REMOVAL.

Part No. 94968-85TV- 1/4 fl. oz.). Insert pin of tube

between throttle cable and cable housing. Squirt a few

Raise fuel tank to access cables in area of frame back-

drops of lubricant into cable housing moving pin around

bone. For carbureted models, see Section 4.7 FUEL

cable OD. Repeat the procedure squirting a few drops

TANK (CARBURETED), PARTIAL REMOVAL, FLHX,

between the idle cable and cable housing.

FLHT, or FLHR/S. For fuel injected models, see Section

9.4 FUEL TANK

(FUEL INJECTED), PARTIAL

REMOVAL, FLHXI, FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

Carbureted: Using a needle nose pliers, carefully pull

INSTALLATION

idle cable barrel from upper inboard hole in throttle

wheel. Pull throttle cable barrel from remaining hole.

Release idle and throttle cables from guides in throttle

THROTTLE SIDE

cable bracket. See Figure 2-107.

Induction Module: Using a needle nose pliers, carefully

Apply a light coating of graphite to the handlebar and

pull idle cable barrel from upper hole in throttle wheel.

inside surface of the switch housings.

Pull throttle cable barrel from lower hole. Using slots,

Push the throttle and idle cables into the lower switch

release idle and throttle cables from guides in throttle

housing until they snap in place. See Figure 2-109. Pro-

cable bracket. See Figure 2-111.

ceed as follows:

Free cables from J-clamp riveted to right side of frame

Note the different diameter inserts crimped into the end

backbone.

of the throttle and idle cable housings.

If present, remove screw (with flat washer) to release J-

Push the larger diameter insert (silver) on the throttle

clamp from wellnut in right side of steering head.

cable housing into the larger hole in front of the tension

Remove J-clamp from cables.

adjuster screw.

Push the smaller diameter insert (gold) on the idle cable

housing into the smaller hole at the rear of the tension

adjuster screw.

CLEANING AND INSPECTION

NOTE

To aid assembly, place a drop of light oil on the retaining

Clean all parts in a non-flammable cleaning solvent and

rings of the crimped inserts. Always replace the retaining

blow dry with compressed air.

rings if damaged or distorted.

2-90

2006 Touring: Chassis

HOME

Position the brake lever/master cylinder assembly

inboard of the switch housing assembly engaging the

tab on the lower switch housing in the groove at the top

of the brake lever bracket.

Align the holes in the handlebar clamp with those in the

master cylinder housing and start the lower screw (with

flat washer). Position for rider comfort. Beginning with

the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0

Nm) using a T27 TORX drive head.

10. Using a T25 TORX drive head, tighten the lower and

upper switch housing screws to 35-45 in-lbs (4-5 Nm).

NOTE

Always tighten the lower switch housing screw first so that

any gap between the upper and lower housings is at the front

of the switch assembly.

11. Remove the cardboard insert between the brake lever

and lever bracket.

12. Turn the Ignition/Light Key Switch to IGNITION and

apply brake lever to test operation of brake lamp.

f1474x2x

CARBURETOR/INDUCTION MODULE SIDE

Throttle Grip

Groove

Route the throttle and idle cables as follows:

Idle Cable

Notch

FLHX, FLHT/C: Route the cables downward following

Throttle Cable

Ferrule

the brake line to the inner fairing. Pass the cables

through the inner fairing grommet and then loop them

Figure 2-110. Install Throttle/Idle Cables

toward the rear along the right side of the steering head.

FLHR/C: Route the cables downward following the right

handlebar to the handlebar clamp shroud. Pass the

With the concave side facing upward, install the friction

cables through the opening in the shroud and then loop

shoe so that the pin hole is over the point of the adjuster

them toward the rear along the right side of the steering

screw.

head. Capture cables in J-clamp and then start screw

(with flat washer) to fasten J-clamp to wellnut in right

NOTE

side of steering head. Tighten screw to 9-18 in-lbs (1.0-

The friction shoe is a loose fit and may fall out or become dis-

2.0 Nm).

lodged if the lower switch housing is turned upside down or

shaken.

Route the throttle and idle cables rearward along the

right side of the frame backbone. After passing through

Slide the throttle control grip over the end of the right

J-clamp riveted to frame backbone, route cables down-

handlebar until it bottoms against the closed end. Rotate

ward to carburetor/induction module.

the grip so that the ferrule notches are at the top. To pre-

vent binding, pull the grip back about 1/8 inch (3.2 mm).

Carbureted: Install sleeve on throttle cable housing into

shorter cable guide in throttle cable bracket. Drawing

Position the lower switch housing beneath the throttle

throttle cable downward, fit barrel end into lower out-

control grip. Install the brass ferrules onto the cables so

board hole in throttle wheel. Install sleeve and spring on

that the end fittings seat in the ferrule recess. Seat the

idle cable housing into longer cable guide inserting bar-

ferrules in their respective notches on the throttle control

rel end into upper inboard hole in throttle wheel. See

grip. Verify that the cables are captured in the grooves

Figure 2-107.

molded into the grip. See Figure 2-110.

Induction Module: Install sleeve on throttle cable hous-

Position the upper switch housing over the handlebar

ing into cable guide at top of throttle cable bracket.

and lower switch housing. Verify that the wire harness

Drawing throttle cable downward, fit barrel end into lower

conduit runs in the depression at the bottom of the han-

hole in throttle wheel. Install sleeve and spring on idle

dlebar.

cable housing into cable guide at bottom of throttle cable

Start the upper and lower switch housing screws, but do

bracket inserting barrel end into upper hole in throttle

not tighten.

wheel. See Figure 2-111.

2006 Touring: Chassis

2-91

HOME

LUBRICATION

f2363x9x

Idle Cable

Guide

See REMOVAL, THROTTLE SIDE, in this section, steps

Throttle Cable

1-5.

Guide

Move upper switch housing to the side in order to access

lower housing.

1CAUTION

Lubit-8 Tufoil Chain and Cable Lube contains detergents.

Keep out of reach of children. Contact with eyes may

result in minor or moderate injury.

Obtain tube of Lubit-8 Tufoil Chain and Cable Lube (HD

Part No. 94968-85TV- 1/4 fl. oz.). Insert pin of tube

between throttle cable and cable housing inside lower

switch housing. Squeeze tube to squirt a quantity of

lubricant into cable housing moving pin around cable

OD. See Figure 2-112.

Repeat the procedure squirting a quantity of lubricant

between the idle cable and cable housing.

Figure 2-111. Throttle Cable Assembly -

Induction Module Side

See INSTALLATION, THROTTLE SIDE, in this section,

steps 3-12.

Turn the Ignition/Light Key Switch to IGNITION and

Tighten cables as necessary to keep barrel ends from

apply brake lever to test operation of brake lamp.

dislodging. Verify that cables are seated in channel of

throttle wheel. Verify operation by turning throttle grip

and observing cable action. Adjust throttle cables as

described under ADJUSTMENT.

Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER

PARTIAL REMOVAL), INSTALLATION (AFTER PAR-

Insert

Lubricant

TIAL REMOVAL), or FLHR/S. For fuel injected models,

Here

see Section

9.4 FUEL TANK

(FUEL INJECTED),

INSTALLATION (AFTER PARTIAL REMOVAL), FLHXI,

FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

Install the air cleaner assembly. See Section 4.5 AIR

CLEANER, INSTALLATION.

7958

Figure 2-112. Right Handlebar Lower Switch Housing

2-92

2006 Touring: Chassis

HOME

CLUTCH CABLE

2.22

ADJUSTMENT

f1140axx

See Section 1.8 CLUTCH ADJUSTMENT.

REMOVAL

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

To access the clutch release cover assembly, remove

right side exhaust system. See Section 2.38 EXHAUST

SYSTEM, REMOVAL.

Remove the magnetic drain plug at the bottom right side

of the oil pan and drain the transmission lubricant into a

suitable container. Remove the filler plug/dipstick.

Slide rubber boot off clutch cable adjuster. Holding cable

Retaining Ring

adjuster with 1/2 inch wrench, loosen jam nut using 9/16

Pivot Pin

inch wrench. Back jam nut away from cable adjuster.

Clutch Lever Bracket

Move adjuster toward jam nut to introduce free play at

Hand Lever

Flat Washer

hand lever. See Figure 2-113.

Bushing

Handlebar Clamp

Remove retaining ring from pivot pin groove at bottom of

Anti-Rattle Spring

10. Anchor Pin

clutch lever bracket. Remove pivot pin.

and Screw

11. Clutch Cable

T27 TORX Screw

12. O-Ring

Remove clutch hand lever from clutch lever bracket. If

necessary, remove two T27 TORX screws (with flat

washers) to release handelbar clamp from clutch lever

Figure 2-114. Clutch Hand Lever Assembly

bracket.

Remove anchor pin and clutch cable eyelet from clutch

f1896x7x

hand lever. See Figure 2-114.

Remove six socket head screws and washers to free

clutch release cover from transmission case. Remove

and discard gasket. See Figure 2-115.

f1440x6x

Retaining Ring

Inner Ramp

Clutch Cable

Coupling

Cable Fitting

Rubber Boot

Cable Adjuster

Figure 2-115. Clutch Release Cover Assembly

Jam Nut

Cable End

Figure 2-113. Clutch Cable Adjuster Mechanism

2006 Touring: Chassis

2-93

HOME

1WARNING

Right Frame

f1472b2x

Downtube

Wear safety glasses or goggles when removing or

installing retaining rings. Retaining rings can slip from

the pliers and could be propelled with enough force to

cause serious eye injury. (00312a)

Remove retaining ring securing ball and ramp mech-

anism to clutch release cover.

10. Lift inner ramp out of clutch release cover and turn the

assembly over so that ball sockets are facing outboard.

Remove hook of ramp from button on coupling. Remove

coupling from clutch cable end.

11. Remove balls from outer ramp sockets. Remove outer

ramp from clutch release cover.

12. Unscrew the cable fitting from the clutch release cover.

Remove clutch cable and fitting.

13. Cut cable strap in hole of crossbrace to free clutch cable

from right frame downtube. See Figure 2-116. Continue

as follows:

Cable Strap

FLHR/C/S: Remove T40 TORX screw with flat washer

(FLHRS) or acorn nut (FLHR/C) to release clutch cable

Figure 2-116. Clutch Cable Routing (Right Side View)

from P-clamp fastened to upper fork bracket. See Figure

2-117.

FLTR: Release clutch cable from cable clip anchored in

hole on left side of instrument nacelle.

FLHX, FLHT/C/U: Remove the outer fairing. See Sec-

tion 2.30 UPPER FAIRING/WINDSHIELD (FLHX, FLHT/

C/U), OUTER FAIRING/WINDSHIELD, REMOVAL. Cut

cable strap to release clutch cable from left fairing

bracket. See Figure 2-118.

14. Remove clutch cable from motorcycle.

NOTE

If ball and ramp or throwout bearing and clutch pushrod need

service, see Section 7.5 CLUTCH RELEASE COVER.

Clamp

f2257x2x

INSTALLATION

Figure 2-117. Clutch Cable Routing - FLHR/C

(Left Side View)

See Figure 2-114. Insert clutch cable eyelet into groove

of clutch hand lever aligning eyelet with hole without

bushing. Insert anchor pin through lever and eyelet.

FLHR/C/S: Capture clutch cable in P-clamp and fasten

Insert lever into groove of clutch lever bracket fitting

to upper fork bracket using T40 TORX screw with flat

sleeve at end of cable housing into bore on inboard side

washer (FLHRS) or acorn nut (FLHR/C). Orient P-clamp

of bracket.

as shown in Figure 2-117. On left side of steering head,

run cable downward between engine guard and front of

Align hole in hand lever with hole in bracket and install

left frame downtube.

pivot pin. Install retaining ring in pivot pin groove.

If removed, install two T27 TORX screws (with flat wash-

FLTR: Capture clutch cable in cable clip and anchor clip

ers) to secure handlebar clamp to clutch lever bracket.

in hole on left side of instrument nacelle. Run cable for-

See Figure 2-114. Starting with the top screw, tighten

ward and then rearward beneath instrument nacelle fol-

screws to 60-80 in-lbs (6.8-9.0 Nm).

lowing left side of steering head. Run cable downward

between engine guard and front of left frame downtube.

Start clutch cable routing as follows:

2-94

2006 Touring: Chassis

HOME

11. Place inner ramp (ball socket side down) over balls in

9421

outer ramp sockets.

1WARNING

Wear safety glasses or goggles when removing or

installing retaining rings. Retaining rings can slip from

the pliers and could be propelled with enough force to

cause serious eye injury. (00312a)

12. Install the retaining ring so that the opening is to the right

of the outer ramp tang slot in the clutch release cover.

Cable

13. Verify that the two locating dowels are in place on the

Strap

right side of the transmission case. Hang a new gasket

on the dowels.

14. Holding the clutch release cover in position, install six

Figure 2-118. Secure Clutch Cable to Fairing Bracket

socket head screws. Tighten screws to 84-132 in-lbs

(9.5-14.9 Nm).

FLHX, FLHT/C/U: Feed clutch cable through grommet

15. Tighten clutch cable fitting to 36-60 in-lbs (4-7 Nm).

on left side of inner fairing. Route cable on inboard side

of left fairing bracket between upper and lower wings of

radio

(or storage box) support bracket. Cable strap

clutch cable to left fairing bracket using oblong hole at

8496

this location. See Figure 2-118. Run cable downward

along left side of steering head, and then between

engine guard and front of left frame downtube. Install the

outer fairing. See Section 2.30 UPPER FAIRING/WIND-

SHIELD (FLHX, FLHT/C/U), OUTER FAIRING/WIND-

SHIELD, INSTALLATION.

Complete clutch cable routing as follows:

All Models: Continue downward progression while

crossing to right side of motorcycle and then run cable

between outboard side of voltage regulator and inboard

side of right frame downtube. Threading cable strap

through hole in crossbrace, secure clutch cable to down-

tube as shown in Figure 2-116. Following inboard side of

frame downtube, route cable between bottom of cam

cover and top of lower frame tube to area of clutch

release cover.

Figure 2-119. Clutch Release Cover

Inspect cable fitting O-ring and replace if damaged or

deformed. Install clutch cable fitting into clutch release

OMF50

cover. See Figure 2-115. Do not tighten cable fitting at

this time.

Place outer ramp in clutch release cover recess with

tang in cover slot.

Apply a multi-purpose grease to the balls and outer

ramp sockets. Place a ball in each of three outer ramp

sockets.

10.

Hold coupling with button facing outboard. Place cable

O-Ring

end in recess of coupling. With ball sockets facing out-

board, place hook of inner ramp on button of couplng.

Holding inner ramp and coupling together, turn the

Figure 2-120. Transmission Lubricant Filler Plug/Dipstick

assembly over.

2006 Touring: Chassis

2-95

Была ли эта страница вам полезна?

Да!Нет

4 посетителя считают эту страницу полезной.

Harley Davidson FLHRC 2006. Maintenance & Repair Manual — page 7

Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.