Harley Davidson 2018 softail models. Service manual — page 25
1
Alignment mark
2
Control module seam
Figure 2. Hand Control Module Alignment (Typical)
5. Install switch housing screws. Tighten.
Torque: 4-5.1 N·m (35-45 in-lbs) Handlebar switch
housing screws
6. Place front electrical caddy into frame, and install frame
plug.
7. See Front Electrical Caddy Connectors. Connect
RHCM connectors (6 and 7).
8. See Brake Line Clamps. Install brake line 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 RHCM and Brake Switch Retainer. From inside the
switch housing, remove screws (3) and retainer (1).
3. Remove brake switch (2) from housing.
4. Cut wires flush at inoperative brake switch.
5. If new brake switch wires have terminals installed, cut
wires at terminal end.
6. Remove 6.4-7.9 mm (0.25-0.31 in) 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 General.
9. See RHCM and Brake Switch Retainer. Install brake
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 right handlebar switch housing. See Install.
1. Install front brake controls on handlebar. See Prepare.
2. Install fuel tank. Prepare
3. Install main fuse. See Main Fuse.
4. Install seat. See Remove.
Both the ECM (Electronic control module) and the IM (Instrument module) retain the odometer value. If the IM is
replaced, the new IM will display the odometer value stored in the ECM. The new IM will lock to the mileage stored in
the ECM after 50 km (31 mi) have been accumulated. The trip B odometer will display the countdown mileage.
If the IM is installed on another vehicle after it has locked to the ECM, the odometer will display "VIN ERR" on the new
vehicle. If the IM is removed from the vehicle before the countdown reaches zero, it will reset the mileage countdown
to 50 km (31 mi). This mileage countdown allows for a road test to verify that IM replacement was the proper repair.
1. Console mounted: Remove console. See Prepare.
2. Handlebar mounted: Remove upper clamp of
handlebars. See Prepare.
Remove
1. See Figure 1. Remove IM (Instrument module) (2).
a. Remove screws (3).
b. Remove IM from upper clamp (1).
1
Upper clamp
2
IM
3
Screw (4)
Figure 1. IM: FXBB, FXBR, FXBRS
Install
1.
NOTE
Verify that gasket does not twist while installing IM
See Figure 1. Install IM (2).
a. Align IM in upper clamp (1).
b. Install screws (3). Tighten.
Torque: 1.4-1.9 N·m (12-17 in-lbs) IM to upper
clamp screw
Remove
1. See Figure 1. Disconnect IM (Instrument module)
connector (2).
2. Remove back clamp from IM.
a. Pry between the tabs (1) and back clamp (3).
b. Raise and release back clamp from IM. Remove
back clamp from IM.
3. Remove IM.
4. Remove gasket.
1
Tabs
2
IM connector
3
Back clamp
Figure 1. Console: FLDE, FLHC, FLHCS, FLSL, FLFB, FLFBS (Typical)
Install
1. Install gasket onto console.
2. Install IM.
NOTE
Verify that gasket does not twist while installing IM.
3. See Figure 1. Install back clamp.
a. Press on back clamp (3) until three tabs (1) engage
on back of IM.
4. Connect IM connector (2).
Remove
1. See Figure 1. Remove screws (2).
2. Remove harness from clip (1).
3. Remove IM (Instrument module) assembly.
4. See Figure 2. Disconnect IM connector (2).
5. See Figure 3. Pushing from the bottom of the IM (1),
separate the IM from the housing (3).
6. Remove gasket (2).
1
Harness clip
2
Screw (2)
Figure 1. Console: FXFB, FXFBS
1
IM
2
IM connector
3
Housing
Figure 2. IM and Housing: FXFB. FXFBS
1
IM
2
Gasket
3
Housing
Figure 3. IM: FXFB, FXFBS
Install
1.
NOTE
Verify that gasket does not twist while installing IM.
See Figure 3. Install gasket (2) onto IM (1).
2. Install IM into housing (3).
3. See Figure 2. Connect IM connector (2).
4. Install IM assembly into console.
5. See Figure 1. Install screws (2). Tighten. Torque:
2.3-2.8 N·m (20-25 in-lbs) Housing to IM screw
6. Install harness into clip (1).
Remove
1. See Figure 1. Disconnect IM (Instrument module)
connector (2).
2. Remove IM screws (4).
3. See Figure 2. Remove IM (2).
4. Remove IM gasket (3).
1
Tachometer connector
2
IM connector
3
IM
4
IM screw (2)
5
Tachometer screw (2)
6
Tachometer
Figure 1. Console: FXLR
1
Tachometer
2
IM
3
IM gasket
4
Tachometer gasket
Figure 2. IM and Tachometer: FXLR
Install
1. See Figure 2. Install IM gasket (3) on IM (2).
2. Install IM into console.
3. See Figure 1. Install IM screws (4). Tighten.
Torque: 1.1-2.3 N·m (10-20 in-lbs) IM screw
4. Connect IM connector (2).
1. Handlebar mounted: Install upper clamp of handlebars.
See Prepare.
2. Console mounted: Install console. See Prepare.
1. Remove console. See Prepare.
1. See Figure 1. Disconnect tachometer connector (1).
2. Remove tachometer screws (5).
1
Tachometer connector
2
IM (Instrument module) connector
3
IM
4
IM screw (2)
5
Tachometer screw (2)
6
Tachometer
Figure 1. Console: FXLR
3. See Figure 2. Remove tachometer (1).
4. Remove tachometer gasket (4).
1
Tachometer
2
IM
3
IM gasket
4
Tachometer gasket
Figure 2. IM and Tachometer: FXLR
1. See IM and Tachometer: FXLR. Install tachometer
gasket (3) on tachometer (2).
2. Install tachometer into console.
3. See Console: FXLR. Install tachometer screws (4).
Tighten.
Torque: 1.1-2.3 N·m (10-20 in-lbs) tachometer screw
4. Connect tachometer connector (2).
1. Install console. See Prepare.
1. Remove main fuse. See Main Fuse.
2. Remove seat. See Remove.
3. Remove console. See Prepare.
1. See Indicator Lamps. Disconnect connector (1).
2. Discard cable strap (2).
3. Remove screws (3).
4. Remove indicator lamp assembly (4).
1. Install indicator lamp assembly (4).
2. Install screws (3). Tighten.
Torque: 2.26-3.39 N·m (20-30 in-lbs) Indicator lamp,
screw
3. Install new cable strap (2).
4. Connect connector (1).
1
Connector
2
Cable strap
3
Screw (4)
4
Indicator lamp assembly
Figure 1. Indicator Lamps
1. Install console. See Prepare.
2. Install seat. See Remove.
3. Install main fuse. See Main Fuse.
1. Remove main fuse. See Main Fuse.
2. FXFB: Loosen exhaust pipes at cylinder heads. See
Prepare.
1. See Oil Pressure Switch. Disconnect connector (2).
2. Remove switch (1).
1. See Figure 1. Install switch (1). Tighten.
Torque: 17-23 N·m (13-17 ft-lbs) Switch, Oil Pressure
2. Connect connector (2).
1
Switch
2
Connector
Figure 1. Oil Pressure Switch
1. FXFB: Tighten exhaust pipes at cylinder heads. See
Prepare.
2. Install main fuse. See Main Fuse.
1. Remove main fuse. See Main Fuse.
2. Remove right side cover. See Remove.
1.
NOTE
Wires are interchangeable.
See Neutral Indicator Switch. Disconnect wires (1) from
switch.
2. Remove switch (2).
1. See Figure 1. Install new switch (2). Tighten.
Torque: 13.6-20.3 N·m (120-180 in-lbs) Switch, Neutral
Indicator
2.
NOTE
Wires are interchangeable.
Connect harness wires (1).
1
Wires
2
Switch
Figure 1. Neutral Indicator Switch
1. Install right side cover. See Remove.
2. Install main fuse. See Main Fuse.
1. Remove main fuse. See Main Fuse.
1. See Horn. Remove horn.
a. Remove narrow screws (3).
b. Remove wide screw (2).
c.
Remove horn assembly (1).
d. Disconnect wire connectors (4).
1. See Figure 1. Install horn.
a. Connect wire connectors (4).
b. Position horn assembly (1).
c. Install wide screw (2). Tighten.
Torque: 9.4-12 N·m (7-9 ft-lbs) Horn, Wide Mounting
Screw
d. Install narrow screws (3). Tighten.
Torque: 3-3.7 N·m (27-33 in-lbs) Horn, Narrow
Mounting Screw
1
Horn assembly
2
Wide screw
3
Narrow screw (2)
4
Wire connector (2)
Figure 1. Horn
1. See Horn Assembly. Remove screws (1) and bracket (3).
1. See Figure 1. Install screws (1) and bracket (3). Tighten.
Torque: 7-8 N·m (5-6 ft-lbs) Horn, Bracket Screw
1
Screw (2)
2
Horn assembly
3
Bracket
Figure 1. Horn Assembly
1. Install main fuse. See Main Fuse.
Remove
1. See Figure 1. Remove screw and nut (1).
2. Remove bezel (2).
3.
7-inch headlamp only: Remove screws (10) and
retainer (9).
4.
5-3/4 headlamp only: Remove spacer (8).
5. Remove headlamp (3) from housing (7).
6. Disconnect connector (6).
7. Remove screws (5).
8. Remove isolator bracket (4).
Install
1.
See Figure 1. Position isolator bracket (4) on headlamp
(3).
2.
Install screws (5). Tighten.
Torque: 8.8-10.8 N·m (6.5-8.0 ft-lbs) Headlamp isolator
bracket screw
3.
NOTE
Use alignment tabs on components.
5-3/4 inch headlamp only: Install spacer (8) on
headlamp (3).
4.
Connect connector (6).
5.
NOTE
Use alignment tabs on components.
Install headlamp (3) into housing (7).
6.
7-inch headlamp only: Install retainer (9) and screws
(10). Tighten.
Torque: 2-2.5 N·m (18-22 in-lbs) Headlamp retainer
screw
7.
Install bezel (2).
8.
Install screw and nut (1). Tighten.
Torque: 1-1.6 N·m (9-14 in-lbs) Headlamp bezel screw
1
Screw and nut
2
Bezel
3
Headlamp
4
Isolator bracket
5
Screw (4)
6
Connector
7
Housing
8
Spacer (5-3/4 inch headlamp only)
9
Retainer (7-inch headlamp only)
10
Screw (3) (7-inch headlamp only)
Figure 1. Round Headlamp
Remove
1. See Figure 1. Remove screw (1).
2.
NOTE
Bezel is under pressure from isolators (3),
disassemble slowly.
Remove bezel (2).
3. Remove screws (5).
4. Remove retainer (6).
5. Remove headlamp (7).
6. Disconnect connector (11).
7. Remove ground strap screw (12)
Install
1.
NOTE
Check gasket (8) is properly installed on retainer.
See Figure 1. Install retainer (6) to headlamp (7).
2. Position ground strap (10).
3. Install screw (12). Tighten.
Torque: 8.8-10.8 N·m (6.5-8.0 ft-lbs) Headlamp ground
strap screw
4. Connect connector (11).
5. Install headlamp (7).
6. Install screws (5). Tighten.
Torque: 1.9-2.8 N·m (17-25 in-lbs) Headlamp, nacelle
mounted, retainer screw
7. Install bezel (2). Insert gasket (8) behind lip of bezel.
8. Install screw (1). Tighten.
Torque: 2.8-3.6 N·m (25-32 in-lbs) Headlamp, nacelle
mounted, bezel screw
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