Harley Davidson 2018 softail models. Service manual — page 24
1
Screw
2
Battery Cable
Figure 1. Negative Battery Cable Disconnect
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable
before proceeding. (00048a)
1. Remove right side cover. See Remove.
2. Remove battery. See Prepare.
3. All Except FLSL, FXBB, FXLR: Remove screw securing
shock adjustment knob to ABS bracket. See Prepare.
1. See . Remove positive cable (3).
2. Remove starter.
a. Disconnect connector (2) from solenoid.
b. Remove screws (1).
3. Discard O-ring (4).
Consumables
Description
Part Number
Size
LOCTITE 243 MEDIUM STRENGTH
99642-97
6 ml (¼ fl oz)
THREADLOCKER AND SEALANT
(BLUE)
1. See Figure 1. Install new O-ring (4).
a. Lubricate new O-ring with clean engine oil.
b. Install new O-ring (4).
2. Install starter.
a. Apply thread-locker to screws (1).
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-97)
b. Install screws. Tighten.
Torque: 29.8-32.5 N·m (22-24 ft-lbs) Starter, mounting
screw
c. Connect connector (2) to solenoid.
d. Install positive battery cable (3) to solenoid. Tighten.
Torque: 7.9-11.8 N·m (70-104 in-lbs) Solenoid nut
NOTE
Install battery cable at 3 o'clock position.
1
Screw (2)
2
Connector
3
Positive cable
4
O-ring
Figure 1. Starter
1. All Except FLSL, FXBB, FXLR: Install screw securing
shock adjustment knob to ABS bracket. See Prepare.
2. Install battery. See Prepare.
3. Install right side cover. See Remove.
1. Remove left side cover. See Remove.
2. Remove main fuse. See Main Fuse.
3. Remove left side rider foot control assembly. See
Prepare.
4. Drain primary chaincase. See Change Primary
Chaincase Lubricant.
5. Remove primary cover. See Prepare.
Special Tools
Description
Part Number
Qty.
ALTERNATOR ROTOR REMOVER
HD-52073
1
AND INSTALLER
1. See Figure 1. Disconnect connector (5) from voltage
regulator.
CAUTION
The high-output rotor contains powerful magnets.
Exercise caution to prevent possible hand injury
during removal and installation. (00558b)
2.
Remove rotor (4).
Special Tool: ALTERNATOR ROTOR REMOVER AND
INSTALLER (HD-52073)
3.
Discard cable strap securing stator wiring to voltage
regulator mounting bracket.
NOTE
The rubber molded stator connector (5) is not
serviceable.
4.
Remove and discard screws (2).
5.
See Figure 2. Remove grommet (2).
a. Use the end of an awl (1) or small screwdriver to
move grommet (2) away from crankcase.
b. Squirt isopropyl alcohol or glass cleaner into opening.
c. Repeat this step at one or two other locations around
grommet.
d. Push on the grommet from outside of crankcase while
pulling through the bore with needle nose pliers. Do
not pull on the wires unless the stator will be replaced.
6.
Draw harness and connector through crankcase bore as
stator is removed.
1
Stator
2
Screw (3)
3
Grommet
4
Rotor
5
Connector [47B]
Figure 1. Rotor and Stator
1
Awl
2
Grommet
3
Stator
Figure 2. Remove Grommet From Crankcase (Typical)
Special Tools
Description
Part Number
Qty.
ALTERNATOR ROTOR REMOVER
HD-52073
1
AND INSTALLER
1.
Install grommet.
a. Lubricate parts with glass cleaner or isopropyl
alcohol. Ribs of grommet must be clean and free of
dirt and oily residue.
b. Feed connector and harness through hole from inside
crankcase.
c. Push grommet into crankcase bore while carefully
pulling on outside cable.
d. Installation is complete when cable stop contacts
casting and capped rib of grommet exits crankcase
bore.
NOTE
Do not reuse stator mounting screws.
2.
See Figure 1. Secure stator to crankcase using new
screws (2). Tighten to:
Torque: 6.2-8.5 N·m (55-75 in-lbs) Stator mounting
screws
3.
See Figure 2. Secure stator wiring (2) to frame with new
cable strap (1). Verify that stator wire does not contact the
engine.
4.
Apply silicone based dielectric grease to connector.
5.
Install connector to voltage regulator. Engage locking latch.
NOTE
Install rotor slowly to prevent damaging rotor magnets.
Damaged magnet fragments can damage the stator.
CAUTION
The high-output rotor contains powerful magnets.
Exercise caution to prevent possible hand injury
during removal and installation. (00558b)
6. Install rotor.
Special Tool: ALTERNATOR ROTOR REMOVER AND
INSTALLER (HD-52073)
1
Stator
2
Screw (3)
3
Grommet
4
Rotor
5
Connector [47B]
Figure 1. Rotor and Stator
1
Anchored cable strap
2
Stator wiring
Figure 2. Harness Routing
1. Install primary cover. See Prepare.
2. Fill primary chaincase. See Change Primary Chaincase
Lubricant.
3. Install left side rider foot control assembly. See Prepare.
4. Install main fuse. See Main Fuse.
5. Install left side cover. See Remove.
1. Remove left side cover. See Remove.
2. Remove main fuse. See Main Fuse.
1. See Voltage Regulator Remove screws (1).
2. Remove voltage regulator (2).
3. Disconnect voltage regulator connectors (3).
1. See Figure 1. Connect voltage regulator connectors (3).
2. Align voltage regulator (2) to mounting bracket.
3. Install screws (1). Tighten.
Torque: 12-14 N·m (106-124 in-lbs) Voltage regulator,
screw
1
Screw (2)
2
Voltage regulator
3
Connector (2)
Figure 1. Voltage Regulator
1. Install main fuse. See Main Fuse.
2. Install left side cover. See Remove.
WARNING
Disconnecting spark plug cable with engine running can result in electric shock and death or serious injury. (00464b)
NOTE
Remove cable end by pulling on rubber boot only. Do not pull on cable or damage can result.
Pull and twist simultaneously to remove rubber boot.
1. See Spark Plug Cable. Remove cables retainers (5).
2. Remove cables (1-4) from ignition coil.
3. Remove boot from spark plugs.
4. Remove cables.
1. See Figure 1. Route and connect long cables (3, 4) to
right spark plugs.
2. Connect short cables (1, 2) to left spark plugs.
3. Connect cables to ignition coil.
4.
NOTE
Make sure spark plug cables do not make contact with
rocker cover screw heads.
See Figure 2. Install cables retainers (5).
5. Verify spark plug cable routing.
1
Left rear
2
Left front
3
Right front
4
Right rear
5
Cable retainer (2)
Figure 1. Spark Plug Cable
1
Front left spark plug
2
Rear left spark plug
3
Front right spark plug
4
Rear right spark plug
5
Cable retainer (2)
Figure 2. Spark Plug Cable Routing: (Fuel tank removed for clarity)
1. Remove main fuse. See Main Fuse.
1. See Ignition Coil Connector. Disconnect ignition coil
connector (3).
2. See Ignition Coil. Disconnect spark plug cables (1)
3. Remove screw (2).
4. Remove ignition coil (3).
1. See Figure 2. Install ignition coil (3).
2. Install screw (2). Tighten.
Torque: 15-19 N·m (11-14 ft-lbs) Ignition coil, screw
3. Connect spark plug cables (1). See Remove
4. See Figure 1. Connect ignition coil connector.
1
Front left
2
Front right
3
Ignition coil connector
4
Ignition coil back
5
Rear right
6
Rear left
Figure 1. Ignition Coil Connector
1
Spark plug cable (4)
2
Screw
3
Ignition coil
Figure 2. Ignition Coil
1. Install main fuse. See Main Fuse.
The left and right hand control modules are non-repairable.
The clutch switch and brake switch are hard-wired to the control modules.
The clutch switch and brake switch are replaceable. This section details the proper method for soldering new switches.
For removal and installation procedures, see Front Brake Switch Replacement or Clutch Switch Replacement.
Special Tools
Description
Part Number
Qty.
ROBINAIR HEAT GUN
HD-25070
1
ULTRA TORCH UT-100
HD-39969
1
HEAT SHIELD ATTACHMENT
HD-41183
1
1. Push conduit back to better access wires and avoid damaging conduit with radiant heating device. Secure conduit
with cable strap.
2. Strip 12.7 mm (0.5 in) of insulation off switch wires. Twist stripped ends of switch wires until all strands are tightly
coiled.
3. Cut dual wall heat shrink tubing, supplied in repair kit into 25.4 mm (1.0 in) segments. Slide tubing over each wire of
new switch assembly.
4. Splice existing and new switch wires, matching wire colors. Solder the spliced connections. For best results, splice
one wire at a time.
5. Center the heat shrink tubing over the soldered splices.
WARNING
Be sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating device.
Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a)
Avoid directing heat toward any fuel system component. Extreme heat can cause fuel ignition/explosion resulting in
death or serious injury.
Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is
being performed.
Always keep hands away from tool tip area and heat shrink attachment.
6. See Figure 1. Use ULTRA TORCH UT-100 (Part Number:HD-39969) or ROBINAIR HEAT GUN (Part
Number:HD-25070) with HEAT SHIELD ATTACHMENT (Part Number:HD-41183) or equivalent. Uniformly heat
the heat shrink tubing to insulate and seal the soldered connections. Apply heat just until the meltable sealant
exudes out both ends of tubing and assumes a smooth cylindrical appearance.
7. Inspect solder connection.
a. Inspect the melted sealant for solder beads.
b. Excess solder or heat can force out some solder with the melted sealant.
c. Remove any solder found.
d. Briefly heat the connection to reseal the tubing if solder beads were removed.
e. Use less solder or reduce heating time or intensity when doing subsequent splices.
WARNING
Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
1
Ultra Torch UT-100
2
Robinair Heat Gun
3
Heat Shield Attachment
Figure 1. Radiant Heating Devices
1. Remove seat. See Remove.
2. Purge fuel system. See Prepare.
3. Remove main fuse. See Main Fuse.
4. Remove fuel tank. See Prepare.
5. Detach clutch control clamp from handlebar. See Prepare.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before
proceeding. (00251b)
1. See Figure 1. Remove brake line clamp screws.
2. See Figure 2. Remove front electrical caddy from left side
of frame.
3. Disconnect LHCM (Left hand control module) connector
(9).
Figure 1. Brake Line Clamps
1
Console
2
Heated hand grip
3
Twist grip
4
WSS (Wheel speed sensor)
5
Right turn signal
6
RHCM (Right hand control module) [22-2]
7
RHCM [22-1]
8
Headlamp
9
LHCM
10
Left turn signal
Figure 2. Front Electrical Caddy Connectors
4. Cruise Control Models: See Figure 3. Remove clip (2)
and switch (1).
5. Remove LHCM housing.
a. Remove upper and lower switch housing screws.
b. Remove upper switch housing.
c. See Figure 4. Remove screws (3) and retainer (1).
d. Remove clutch switch (2) and LHCM from lower
switch housing.
1
Switch
2
Clip
Figure 3. Cruise Switch
1
Retainer
2
Clutch switch
3
Screw (2)
Figure 4. LHCM and Clutch Switch Retainer
6.
NOTE
Verify that there is enough wire to work at both ends
of handlebar with scrap wire installed through
handlebar.
Remove control module.
a. Attach scrap wire to control module connector.
b. Pull control module wiring through handlebar.
c. Disconnect scrap wire from old control module
connector.
1. Route LHCM (Left hand control module) wires through
handlebar.
a. Attach scrap wire to new LHCM wiring.
b. Pull LHCM wiring through handlebar.
c. Remove scrap wire.
2. See LHCM and Clutch Switch Retainer. Place switch
assembly into position on lower switch housing.
3. Install clutch switch (2).
4.
NOTE
Handlebar-mounted turn singles: See Figure
1. Verify that turn signal wiring (1) is routed
through opening (2).
Always tighten lower switch housing screw first,
so that any gap between upper and lower
housings is at front of switch.
See LHCM and Clutch Switch Retainer. Install retainer
(1) with screws (3). Tighten.
Torque: 0.9-1.1 N·m (8-10 in-lbs) Handlebar switch
assembly retainer screws
5. See Figure 2. Install upper and lower switch housing.
Align seam (2) with alignment mark (1).
1
Turn signal wiring
2
Slot in control module
Figure 1. Turn Signal Routing (Typical)
1
Alignment mark
2
Control module seam
Figure 2. Hand Control Module Alignment (Typical)
6. Install switch housing screws. Tighten.
Torque: 4-5.1 N·m (35-45 in-lbs) Handlebar switch
housing screws
7. Cruise Control Models: See Cruise Switch. Install
switch (1) and clip (2).
8. See Front Electrical Caddy Connectors. Connect
LHCM connector (9).
9. Place front electrical caddy into frame, and install frame
plug.
10. See Brake Line Clamps. Install brake clamp screws.
Tighten.
Torque: 4.1-5.4 N·m (36-48 in-lbs) Brake line clamp
screw
1. Remove handlebar switch housing. See Remove.
2. Remove switch cap:
a. Rocker switch caps: See Figure 1. Entering from the end, carefully pry between the switch cap and switch
plunger. Remove switch cap.
3. Install switch cap:
a. Rocker switch caps: Hook new cap on one end and rotate into place. An audible snap will be heard when
securely installed.
4. Install switch housing. See Install.
1
Remove cap
2
Install cap
Figure 1. Replace Switch Caps (Typical)
1. Remove upper switch housing cover. See Remove.
2. See . From inside the switch housing, remove screws (3)
and retainer (1).
3. Remove clutch switch (2) from housing.
4. Cut wires flush at inoperative clutch switch.
5. If new clutch switch wires have terminals installed, cut
wires at terminal end.
6. Remove 0.25-0.31 in (6.4-7.9 mm) of insulation from each
wire end.
7. Cut two pieces of dual wall heat shrink tubing to 12.7 mm
(0.5 in).
8. Solder wires together and cover with heat shrink tubing.
See .
9. See LHCM and Clutch Switch Retainer. Install clutch
switch (2) into housing. Install retainer (1) and screws (3).
Tighten.
Torque: 0.9-1.1 N·m (8-10 in-lbs) Handlebar switch
assembly retainer screws
10. Assemble left handlebar switch housing. See Install.
1. Install clutch controls on handlebar. See Prepare.
2. Install fuel tank. See Prepare.
3. Install main fuse. See Main Fuse.
4. Install seat. See Remove.
1. Remove seat. See Remove.
2. Purge fuel system. See Prepare.
3. Remove main fuse. See Main Fuse.
4. Remove fuel tank. See Prepare.
5. Detach front brake clamp from handlebar. See Prepare.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before
proceeding. (00251b)
1. See Figure 1. Remove brake line clamp screws.
2. See Figure 2. Remove front electrical caddy.
3. Disconnect RHCM (Right hand control module)
connectors (6 and 7).
Figure 1. Brake Line Clamps
1
Console
2
Heated hand grip
3
Twist grip
4
WSS (Wheel speed sensor)
5
Right turn signal
6
RHCM [22-2]
7
RHCM [22-1]
8
Headlamp
9
LHCM (Left hand control module)
10
Left turn signal
Figure 2. Front Electrical Caddy Connectors
4. Remove RHCM housing.
a. Remove upper and lower switch housing screws.
b. Remove upper switch housing.
c. See Figure 3. Remove screws (3) and retainer (1).
d. Remove brake switch (2) and RHCM from lower
switch housing.
1
Retainer
2
Brake switch
3
Screw (2)
Figure 3. RHCM and Brake Switch Retainer
5.
NOTE
Verify that there is enough wire to work at both ends
of handlebar with scrap wire installed through
handlebar.
Remove control module.
a. Attach scrap wire to control module connector.
b. Pull control module wiring through handlebar.
c. Disconnect scrap wire from old control module
connector.
1.
Route RHCM (Right hand control module) wires through
handlebar.
a. Attach scrap wire to new RHCM wiring.
b. Pull RHCM wiring through handlebar.
c. Remove scrap wire.
2.
See RHCM and Brake Switch Retainer. Place switch
assembly into position on lower switch housing. Install
brake switch (2).
3.
NOTE
Handlebar-mounted turn singles: See Figure
1. Verify that turn signal wiring (1) is routed
through opening (2).
Always tighten lower switch housing screw first,
so that any gap between upper and lower
housings is at front of switch.
See RHCM and Brake Switch Retainer. Install retainer
(1) with screws (3). Tighten.
Torque: 0.9-1.1 N·m (8-10 in-lbs) Handlebar switch
assembly retainer screws
4.
See Figure 2. Install upper and lower switch housing.
Align seam (2) with alignment mark (1).
1
Turn signal wiring
2
Slot in control module
Figure 1. Turn Signal Routing (Typical)
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