Harley Davidson 2018 softail models. Service manual — page 1
94000529 - 2018 HARLEY-DAVIDSON® SERVICE
MANUAL: SOFTAIL® MODELS
Foreword
Foreword
General
Manual Layout
How to Use This Service Manual
Preparation For Service
Use Genuine Replacement Parts
Shop Practices
Cleaning
Disposal and Recycling
Tools and Materials
Product Registered Marks
H-D U.S.A., LLC Trademark Information
Contents
Safety
Safety
Safety
Maintenance
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
General
Servicing a Motorcycle
Secure the Motorcycle for Service
MAINTENANCE SCHEDULE
General -[JPN]
FUEL AND OIL
Fuel
Gasoline Blends
Engine Lubrication
Winter Lubrication
REPLACE ENGINE OIL AND FILTER
Check Engine Oil Level
Change Oil and Oil Filter
REPLACE PRIMARY CHAINCASE LUBRICANT
Change Primary Chaincase Lubricant
REPLACE TRANSMISSION LUBRICANT
Check Transmission Lubricant
Change Transmission Lubricant
INSPECT TIRES AND WHEELS
General
Tires
Wheel Bearings
Wheel Spokes
LUBRICATE CABLES AND CHASSIS
General
Lubrication Points
INSPECT BRAKES
Inspect
Replace Front Brake Pads
Replace Rear Brake Pads
CHECK AND REPLACE BRAKE FLUID
Check Brake Fluid Level
Drain and Replace Fluid
CHECK AND ADJUST CLUTCH
Check and Adjust
REBUILD FRONT FORK AND REPLACE OIL
Rebuild and Replace Fork Oil
ADJUST AND LUBRICATE STEERING HEAD BEARINGS
Prepare
Check and Adjust
Lubricate
Complete
INSPECT FUEL LINES AND FITTINGS
Inspect
INSPECT AND LUBRICATE JIFFY STAND
Inspect and Lubricate
INSPECT AND ADJUST DRIVE BELT AND SPROCKETS
Inspect
Measure Drive Belt Deflection
Adjust Belt
ADJUST SUSPENSION
Adjust Shock Absorber
INSPECT EXHAUST SYSTEM
Leak Check
INSPECT AIR FILTER
Remove
Clean and Inspect
Install
INSPECT BATTERY
Prepare
Remove
Install
Clean and Inspect
Voltage Test
Storage
Complete
CLEAN AND INSPECT SPARK PLUGS
Prepare
Remove
Clean and Inspect
Install
Complete
Storage
Place in Storage
Remove from Storage
Troubleshooting
Engine
Lubrication System
Electrical System
Transmission
Handling
BRAKES
Chassis
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
Specifications
Chassis
VEHICLE IDENTIFICATION NUMBER (VIN)
Vehicle Identification Number (VIN)
FRONT WHEEL
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
REAR WHEEL
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
WHEEL LACING
Wheel Lacing: Angle Flange Hub
CHECKING AND TRUING WHEELS
General
Checking Wheel Runout
Laced Wheel Rim Offset
True Laced Wheels
SEALED WHEEL BEARINGS
Prepare
Inspect
Remove
Install
Complete
TIRES
General
Prepare
Remove
Clean, Inspect and Repair
Install
Check Tire Runout
Balance
Complete
WHEEL ALIGNMENT
Prepare
Inspect
Adjust
Complete
FRONT BRAKE MASTER CYLINDER
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
FRONT BRAKE CALIPER
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
REAR BRAKE MASTER CYLINDER
Prepare
Remove
Install
Disassemble and Assemble: Master Cylinder
Complete
REAR BRAKE CALIPER
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
BRAKE LINES
Front Brake Line: Non-ABS
Rear Brake Line: Non-ABS
Brake Line: Front Master Cylinder (ABS)
Brake Line: Front Caliper (ABS)
Front ABS Lines
Brake Line: Rear Master Cylinder to ABS Module
Brake Line: Rear Caliper To ABS Module
ABS MODULE
General
Prepare
Remove
Install
Complete
BLEED BRAKES
Drain
Fill and Bleed
LEFT SIDE COVER
Remove
Install
RIGHT SIDE COVER
Remove
Install
FRONT FORK
Check For Oil Leak
Prepare
Remove
Install
Disassemble and Assemble: Standard
Disassemble and Assemble: Inverted, Left Side
Disassemble and Assemble: Inverted, Right Side
Complete
STEERING HEAD/FORK STEM AND BRACKET ASSEMBLY
Prepare
Remove
Clean and Inspect
Install
Complete
FORK LOCK
Prepare
Remove
Install
Complete
REAR FORK
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
BELT GUARDS
Prepare
Remove
Install
Complete
REAR SHOCK ABSORBER
Prepare
Remove
Clean and Inspect
Install
Disassemble and Assemble: Rear Shock Adjuster
Complete
CLUTCH CONTROL
Prepare
Remove
Clean and Inspect
Install
Disassemble
Assemble
Complete
HEADLAMP NACELLE
Prepare
Remove
Install
Complete
FAIRING
Remove and Install
Disassemble and Assemble
WINDSHIELD
Remove
Install
Disassemble
Assemble
HAND GRIPS
Remove
Install
HANDLEBAR
Prepare
Remove
Install
Disassemble
Assemble
Complete
MIRRORS
Remove
Install
FRONT FENDER
Remove
Install
Disassemble
Assemble
REAR FENDER
Prepare
Remove
Install
Disassemble and Assemble: Full Fender
Disassemble and Assemble: Chopped Fender Without License Plate Bracket
Lighting
Disassemble and Assemble: Chopped Fender With License Plate Bracket Lighting
Complete
REAR FENDER WIRE CONDUIT
Prepare
Remove
Install
Complete
SAREE GUARD
Remove
Install
FRONT LICENSE PLATE BRACKET
Remove
Install
REAR LICENSE PLATE BRACKET
General
Standard
Center Mount
Center Mount With Lighting
LEFT FOOT CONTROLS
Prepare
Remove
Install
Disassemble and Assemble: Footboard
Disassemble and Assemble: Footpeg
Complete
RIGHT FOOT CONTROLS
Remove and Install: Forward Foot Controls
Remove and Install: Mid Foot Controls
Disassemble and Assemble: Footboard
Disassemble and Assemble: Footpeg
PASSANGER FOOTRESTS
Remove
Install
JIFFY STAND
Prepare
Remove
Install
Disassemble
Assemble
Complete
SEAT
Remove
Install
FRAME CROSSMEMBER
Prepare
Remove
Install
Complete
SADDLEBAGS
Remove and Install: Standard
Remove and Install: Quick Disconnect
Disassemble and Assemble: Standard
Disassemble and Assemble: Quick Disconnect
MEDALLIONS, BADGES, TANK EMBLEMS AND ADHESIVE STRIPS
Remove
Install
Engine
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
Specifications
Engine
SERVICE WEAR LIMITS
ENGINE OIL FLOW
Operation
OIL PUMP OPERATION
General
Operation
BREATHER OPERATION
General
Oil Pressure
Operation
Oil Pressure Check
Troubleshooting
Typical Symptoms
Compression Test
Cylinder Leakdown Test
Measure Crankshaft Runout
Diagnose Valve Train Noise
Diagnose Smoking Engine or High Oil Consumption
CRIMP CLAMPS
Remove
Install
OIL COOLER
Prepare
Remove
Install
Oil Check Valve
Complete
OIL COOLANT LINES
Prepare
Remove
Install
Complete
FRONT ENGINE MOUNT
Prepare
Remove and Install: Lower Front Engine Mount
Remove and Install: Upper Front Engine Mount
Complete
LEFT SIDE ENGINE MOUNT
Prepare
Remove
Install
Complete
UPPER ROCKER COVERS
Prepare
Remove
Install
Complete
BREATHERS
Prepare
Remove
Install
Complete
LOWER ROCKER COVERS
Prepare
Remove
Install
Complete
ROCKER ARMS
Prepare
Remove
Clean and Inspect
Install
Complete
PUSHRODS, LIFTERS AND COVERS
Prepare
Remove
Clean and Inspect
Inspect Lifters
Assemble Pushrod Cover
Install
Complete
CYLINDER HEADS
Prepare
Remove
Clean
Install
Disassemble
Clean and Inspect
Valve and Seat Repair
Assemble
Complete
CYLINDERS
Prepare
Remove
Install
Clean and Inspect
Deglaze Cylinder
Complete
PISTONS
Prepare
Remove
Install
Disassemble
Clean and Inspect
Check Piston Ring Gap
Assemble
Complete
CAM COMPARTMENT AND COMPONENTS
Prepare
Remove and Install: Camshaft Cover
Remove
Inspect Cam Component
Install
Complete
Camshaft Needle Bearings
Oil Pump
Prepare
Remove
Disassemble and Inspect
Assemble
Install
Complete
REPLACE ENGINE
Prepare
Remove
Install
Complete
Crankcase
Prepare
Disassemble
Clean and Inspect
Assemble
Repair Right Crankcase Half
Repair Left Crankcase Half
Sprocket Shaft Bearing Inner Race
Cylinder Studs
Plugs and Oil Fittings
Complete
FLYWHEEL AND CONNECTING RODS
Symptoms
Prepare
Inspect
Complete
OIL PAN
Prepare
Remove
Install
Complete
Drive and Transmission
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
Specifications
Drive Specifications
Transmission Specifications
SERVICE WEAR LIMITS
TRANSMISSION OPERATION
Power Flow
DRIVE BELT
Prepare
Remove
Install
Complete
SHIFTER LINKAGE
Shifter Rod
Foot Shift Lever
Shifter Rod Lever, Front
CLUTCH RELEASE COVER
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
PRIMARY CHAINCASE COVER
Prepare
Remove
Install
Complete
DRIVE COMPONENTS
Prepare
Remove
Install
Complete
CLUTCH
Prepare
Disassemble and Assemble: Clutch Pack
Disassemble and Assemble: Hub
Complete
PRIMARY CHAINCASE HOUSING
Prepare
Remove
Inspect
Install
Mainshaft Bearing and Seal
Mainshaft Bearing Inner Race
Shifter Shaft Bushing
Complete
ENGINE OIL FILL SPOUT
Prepare
Remove
Install
Complete
TRANSMISSION SPROCKET
Prepare
Remove
Clean and Inspect
Install
Complete
Transmission
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
MAIN DRIVE GEAR AND BEARING
Prepare
Remove
Clean and Inspect
Install
Replace Needle Bearings
Replace Mainshaft Seal
Complete
TRANSMISSION CASE
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
Fuel and Exhaust
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
SPECIFICATIONS
Specifications
AIR CLEANER BACKPLATE ASSEMBLY
Prepare
Remove and Install: Round
Remove and Install: Oval
Complete
CONSOLE
Prepare
Remove and Install: Dual Instrument
Remove and Install: Single Instrument with Panel
Remove and Install: Single Instrument without Panel
Complete
DECORATIVE FUEL CAP
Remove
Install
FUEL PRESSURE TEST
Prepare
Test
Complete
PURGE FUEL LINE
Prepare
Lift Rear Of Fuel Tank
Purge
Secure Fuel Tank
Complete
FUEL LINE
Prepare
Remove
Install
Complete
FUEL TANK
Prepare
Remove
Install
Complete
FUEL PUMP
Prepare
Remove
Clean and Inspect
Install
Disassemble
Assemble
Complete
VENT TUBE
Prepare
Remove
Install
Complete
VAPOR VALVE
Prepare
Remove
Install
Complete
TEMPERATURE MANIFOLD ABSOLUTE PRESSURE (TMAP) SENSOR
Prepare
Remove
Install
Complete
TWIST GRIP SENSOR (TGS)
Prepare
Remove
Install
Complete
FUEL INJECTORS
Prepare
Remove
Install
Complete
INDUCTION MODULE
Prepare
Remove
Install
Disassemble
Assemble
Complete
INTAKE LEAK TEST
Leak Tester
Procedure
HEATED OXYGEN SENSORS (HO2S)
Prepare
Remove
Install
Complete
MUFFLERS
Prepare
Remove
Install
Complete
EXHAUST SYSTEM
Prepare
Remove
Install
Disassemble and Assemble: Standard
Disassemble and Assemble: Upswept
Disassemble and Assemble: Two Into One
Complete
PURGE SOLENOID: CALIFORNIA EMISSIONS
Prepare
Remove
Install
Complete
CHARCOAL CANISTER: CALIFORNIA EMISSIONS
Remove
Install
PURGE LINES: CALIFORNIA EMISSIONS
Prepare
Remove
Install
Complete
Electrical
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
SPECIFICATIONS
Specifications
FUSES
Prepare
Remove
Install
Complete
POWER DISCONNECT
Main Fuse
Negative Battery Cable
STARTER
Prepare
Remove
Install
Complete
ALTERNATOR
Prepare
Remove
Install
Complete
VOLTAGE REGULATOR
Prepare
Remove
Install
Complete
SPARK PLUG CABLES
Remove
Install
IGNITION COIL
Prepare
Remove
Install
Complete
HANDLEBAR CONTROL MODULES
General
Solder Procedure
LEFT HAND CONTROL MODULE (LHCM)
Prepare
Remove
Install
Switch Caps
Clutch Switch Replacement
Complete
RIGHT HAND CONTROL MODULE (RHCM)
Prepare
Remove
Install
Switch Caps
Front Brake Switch Replacement
Complete
INSTRUMENT MODULE (IM)
General
Prepare
Remove and Install: Handlebar Mount
Remove and Install: Console With Panel
Remove and Install: Console Without Panel
Remove and Install: Dual Instrument
Complete
TACHOMETER
Prepare
Remove
Install
Complete
INDICATOR LAMPS
Prepare
Remove
Install
Complete
OIL PRESSURE SWITCH
Prepare
Remove
Install
Complete
NEUTRAL INDICATOR SWITCH
Prepare
Remove
Install
Complete
HORN
Prepare
Remove
Install
Disassemble
Assemble
Complete
HEADLAMP
Bulb Replacement: Standard Round
Bulb Replacement: Nacelle Mounted
Bulb Replacement: Oblong
Bulb Replacement: Horizontal
Prepare
Remove and Install: Standard Round
Remove and Install: Nacelle Mounted
Remove and Install: Oblong
Remove and Install: Horizontal
Align
Adjust
Complete
FRONT LIGHT BAR
Prepare
Remove and Install: Standard Lighting
Remove and Install: Integrated LED Lighting
Complete
AUXILIARY LAMPS
Bulb Replacement
Prepare
Remove and Install: Standard Lighting
Remove and Install: Integrated LED Lighting
Align
Adjust
Complete
FRONT TURN SIGNAL LAMPS
Bulb Replacement
Prepare
Remove and Install: Handlebar Mount
Remove and Install: Light Bar Mount
Complete
REAR TURN SIGNAL LAMPS
Bulb Replacement
Prepare
Remove and Install: Fender Mount
Remove and Install: Light Bar Mount
Remove and Install: Center Mount
Complete
TAIL LAMP
Bulb Replacement
Prepare
Remove and Install: Standard
Remove and Install: Tombstone
Remove and Install: License Plate Bracket Mount
Remove and Install: Center Mount
Complete
REAR STOPLAMP SWITCH
Prepare
Remove
Install
Complete
LICENSE PLATE LAMP
Bulb Replacement
Prepare
Remove and Install: Center Mount
Remove and Install: License Plate Bracket Mount
Remove and Install: Side Mount
Complete
TERMINATING RESISTOR
Prepare
Remove
Install
Complete
ELECTRONIC CONTROL MODULE (ECM)
Prepare
Remove
Install
Complete
BODY CONTROL MODULE (BCM)
Prepare
Remove
Install
Complete
SECURITY SYSTEM ACTIVATION
Activation
Fob Assignment
PERSONAL IDENTIFICATION NUMBER (PIN)
General
Changing the PIN
SECURITY SYSTEM MAINTENANCE
Service Mode
Transport Mode
Fob Battery
Security Siren Battery
SECURITY SIREN
Prepare
Remove
Install
Complete
SECURITY SYSTEM ANTENNA
Prepare
Remove
Install
Complete
CRANKSHAFT POSITION SENSOR (CKP)
Prepare
Remove
Install
Complete
ENGINE TEMPERATURE (ET) SENSOR
Prepare
Remove
Install
Complete
KNOCK SENSOR (KS)
Prepare
Remove
Install
Complete
AUTOMATIC COMPRESSION RELEASE (ACR)
Prepare
Remove
Install
Complete
VEHICLE SPEED SENSOR (VSS)
Prepare
Remove
Install
Complete
FRONT WHEEL SPEED SENSOR (WSS)
Prepare
Remove
Install
Complete
REAR WHEEL SPEED SENSOR (WSS)
Prepare
Remove
Install
Complete
JIFFY STAND SENSOR (JSS)
Prepare
Remove
Install
Complete
FRONT ELECTRICAL CADDY
Prepare
Remove
Install
Complete
USB CADDY
Prepare
Remove
Install
Disassemble
Assemble
Complete
ECM CADDY
Prepare
Remove
Install
Complete
BCM CADDY
Prepare
Remove
Install
Complete
REAR LIGHTING CADDY
Prepare
Remove
Install
Complete
BATTERY TRAY
Prepare
Remove
Install
Complete
ENGINE GROUND CABLE
Prepare
Remove
Install
Complete
ENGINE WIRE HARNESS
Prepare
Remove
Install
Complete
BACKBONE WIRE HARNESS
Prepare
Remove
Install
Complete
MAIN WIRE HARNESS
Prepare
Remove
Install
Disassemble
Assemble
Complete
Wiring
WIRING DIAGRAMS
General
Wiring Diagrams
WIRE HARNESS CONNECTORS
General
Connector End Views
Reference
GLOSSARY
Acronyms and Abbreviations
METRIC CONVERSION
Conversion Table
FLUID CONVERSION
United States System
Metric System
British Imperial System
This manual has been created to inform Harley-Davidson technicians about the construction of Harley-Davidson products
and the latest tested and approved maintenance and repair techniques.
Safety
Refer to the Safety section before performing any procedures on a vehicle.
Sections
This service manual is organized into chapters, sections and topics. Each section is laid out in the following manner:
Prepare
Remove
Install
Disassemble (if applicable)
Clean/Inspect (if applicable)
Assemble (if applicable)
Complete
Topics
The purpose of the Prepare topics is to to provide an outline of procedures required before beginning a specific task.
Links to the necessary procedures are provided in the topic.
The Remove and Install topics allow the technician to only remove and install the component - which may be all that
is required. If a component can be repaired, Disassemble, Assemble and Clean/Inspect topics are provided as
appropriate.
Complete topics provide a list of procedures that need to be performed to return the vehicle to ride-ready condition. If
additional removal procedures need to be performed, move to the next section without performing the Complete topics
in the current section.
Procedural Steps
Each topic contains steps to complete the procedure. These steps are laid out in numeric and alpha steps.
The purpose of the numeric steps is to provide the experienced technician with high-level information to complete the
procedure.
The alpha steps provide a less-experienced technician with step-by-step instructions to perform the procedure.
Symbol Identification
Symbols are used in some graphics to provide information about parts. Refer to Table 1 for symbol definitions.
Table 1. Symbols
SYMBOL
DESCRIPTION
Apply Lubricant: Indicates a part that should be lubricated during installation.
Discard/Do Not Reuse: Indicates a part that must be replaced with a new part during installation.
Apply Sealant: Indicates a part that must be installed with a threadlocker or sealant.
Special Tool: Indicates that a special tool is recommended.
Measure: Indicates a part that should be measured or gauged to verify that it is within
specification.
Cross-References and Page Numbers
A cross-reference shown as 2.2 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.2 SPECIFICATIONS. All
pages contain a chapter number followed by a page number. For example, page 3-5 refers to page 5 in Chapter 3.
Item References and Quantities
In figure legends and tables, the number in parentheses that follows the part name indicates the quantity of that part
necessary for one complete assembly.
Example:
2. Rocker cover screw (4)
In a procedure step or paragraph, the number in parentheses that follows a part name indicates the legend item of the
part in the figure referenced by the text.
Example:
1. Remove rocker cover screws (2).
Acronyms and Abbreviations
Acronyms and abbreviations are used in this document. See the Acronyms and Abbreviations for a list of acronyms,
abbreviations and definitions.
Start each job with a clean work area.
Clean the motorcycle before work begins.
Gather any tools, instruments and parts needed for the job before work begins.
Carefully read all related service information, including service bulletins, before service work begins.
WARNING
Harley-Davidson parts and accessories are designed for Harley-Davidson motorcycles. Using non-Harley-Davidson
parts or accessories can adversely affect performance, stability or handling, which could result in death or serious
injury. (00001b)
To achieve satisfactory and lasting repairs, carefully follow the service manual instructions and use only genuine Harley-
Davidson replacement parts.
Removing Parts
Always use blocking or proper stands to support the part that has been hoisted. If a part cannot be removed, verify that
all bolts and attaching hardware have been removed. Verify that no parts are in the way of the part being removed.
Always tag hoses, wiring or tubes to verify proper installation.
Cleaning
Thoroughly clean all parts to be reused before assembly. Clean parts promote better component operation and longer
life. Seals, filters and covers used in this vehicle keep out extraneous dirt and dust. Keep these items in good
condition to guarantee satisfactory operation. See Cleaning.
Checking Torques on Fasteners
Check torque using a torque wrench set to the minimum specification for that fastener. If the fastener does not rotate,
the torque has been maintained. If the fastener rotates, remove it to determine if it has a threadlocking agent.
If it has a threadlocking agent, clean all material from the threaded hole. Replace the fastener with a new one or clean
the original fastener threads and apply the appropriate threadlocking product. Install and tighten the fastener to
specification.
If the fastener does not use a threadlocking agent, install and tighten it to specification.
General
Any cleaning method may be used as long as it does not result in parts damage. Thorough cleaning is necessary for
proper parts inspection. Strip rusted paint areas to bare metal before priming and repainting.
Always clean around lines or covers before they are removed. When cleaning parts:
Plug, tape or cap holes and openings to keep out dirt, dust and debris.
Clean and inspect all parts as they are removed.
Cover all clean parts with clean lint-free cloth, paper or other material.
Verify that the part is clean when installed.
Cleaning Threads and Threaded Holes
Always verify cleanliness of blind holes before assembly. Tightening a screw with dirt, water or oil in the hole can
cause castings to crack or break.
To attain proper clamp load, always clean fastener threads and threaded holes prior to assembly.
NOTE
Never use a thread-cutting tap or die to clean threads.
Clean all threadlocking material from fastener threads and threaded holes.
Use a wire brush or thread-chasing die to clean fastener threads.
Use a thread chaser to clean threaded holes.
Use PJ1 cleaner or equivalent to remove all traces of oil and contaminants from threads.
Clear all threaded holes with low-pressure compressed air.
Cleaning Plastic and Rubber Parts
Never use cleaners containing chlorine or ammonia on plastic parts. Chlorine will cause parts to become distorted and
brittle resulting in cracks. Ammonia will cause cloudiness and brittleness in windshields and cause non-painted parts
to form a white haze.
Before cleaning, protect rubber parts (such as hoses, boots and electrical insulation) from cleaning solutions. Use a
grease-proof barrier material. Remove the rubber part if it cannot be properly protected.
Rust or Corrosion Removal
Remove rust and corrosion with a wire brush, abrasive cloth, sand blasting, vapor blasting or rust remover. Use buffing
crocus cloth on highly polished parts that are rusted.
Bearings
Wash bearings in a non-flammable petroleum cleaning solution. Never use a solution that contains chlorine. Knock out
packed lubricant by tapping the bearing against a wooden block. Wash bearings again.
WARNING
Using compressed air to "spin dry" bearings can cause bearing to fly apart, which could result in death or serious
injury. (00505b)
Cover bearings with a clean shop towel. Allow bearings to air dry. Do not spin bearings while they are drying. Never
use compressed air to dry bearings.
When dry, coat bearings with clean oil. Wrap bearings in clean paper.
Many communities maintain facilities for recycling used fluids, plastics and metals. Dispose of or recycle used oil,
lubricants, fuel, coolant, brake fluid and batteries in accordance with local regulations.
WARNING
Read and follow warnings and directions on all products. Failure to follow warnings and directions can result in death
or serious injury. (00470b)
Some service procedures require the use of tools designed for a specific purpose. These tools should be used when and
as recommended.
When reference is made in this manual to a brand name product, tool or instrument, an equivalent product, tool or
instrument may be substituted.
Special Tools
Special tools mentioned in this manual with a part number that begins with an "HD", "J" or "B" must be purchased,
serviced or warrantied through a Harley-Davidson dealer.
Specific use of special tools is not discussed in this manual. Refer to the tool instruction sheet for instructions. If the
tool instructions are misplaced, a copy can be obtained online at H-Dnet.com > My Toolbox > Edit > Bosch Tool Site.
LOCTITE Sealing and Threadlocking Products
Some procedures in this manual call for the use of LOCTITE products. If you have any questions regarding LOCTITE
product usage or retailer/wholesaler locations, contact Loctite Corp. at www.loctite.com.
Apple, Alcantara S.p.A., Allen, Amp Multilock, Bluetooth, Brembo, City Navigator, Delphi, Deutsch, Dunlop, Dynojet, Fluke,
G.E. Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N,
Magnaflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin, MPZ, Mulitilock, nano, NGK, Novus, Packard,
Pirelli, Permatex, Philips, PJ1, Pozidriv, Road Tech, Robinair, S100, Sems, SiriusXM, Snap-on, Teflon, Threadlocker,
Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto and XM Satellite Radio are among the trademarks of their
respective owners.
Bar & Shield, Boom!, Cross Bones, Cruise Drive, CVO, Digital Tech, Digital Technician, Digital Technician II, Dyna, Electra
Glide, Evolution, Fat Bob, Fat Boy, Forty-Eight, Glaze, Gloss, H-D, H-Dnet.com, Harley, Harley-Davidson, HD, Heritage
Softail, Iron 883, Low Rider, Milwaukee-Eight, Night Rod, Nightster, Night Train, Profile, Reflex, Revolution, Road Glide,
Road King, Road Tech, Rocker, Screamin' Eagle, Seventy-Two, Softail, Sportster, Street Glide, Street Rod, Sun Ray,
Sunwash, Super Glide, SuperLow, Supersmart, Switchback, SYN3, TechLink, TechLink II, Tour-Pak, Tri Glide, Twin Cam
88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam 103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, Twin-
Cooled, Ultra Classic, V-Rod, VRSC and Harley-Davidson Genuine Motor Parts and Genuine Motor Accessories are
among the trademarks of H-D U.S.A., LLC.
All photographs, illustrations and procedures may not necessarily depict the most current model or component, but are
based on the latest production information available at the time of publication.
Since product improvement is our continual goal, Harley-Davidson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring obligation.
Harley-Davidson service manuals are intended for use by professional, qualified and experienced technicians. Attempting
the procedures found within this manual without the proper training, tools and equipment could result in death or injury to
you or others. This could also damage the vehicle, or cause the vehicle to operate improperly.
Safety is always the most important consideration when performing any job.
Always have a complete understanding of the task.
Use common sense.
Use proper tools for the task.
Protect yourself and bystanders with approved eye protection.
Harley-Davidson does not evaluate or advise the technicians of every way in which service might be performed, or all
possible hazardous consequences of every method, or undertaken such a broad evaluation. Before using a tool not
recommended by Harley-Davidson, make sure that technician or rider safety will not be jeopardized as a result.
Warnings against the use of specific service methods which could damage the motorcycle or render it unsafe are stated in
this manual. These warnings are not all-inclusive. Inadequate safety precautions could result in death or serious injury.
Safety Messages
Statements in this manual preceded by the following words are of special significance.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
(00119a)
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
(00139a)
NOTICE
NOTICE indicates a potentially hazardous situation which, if not avoided, may result in property damage. (00140b)
NOTE
Refers to important information. It is recommended that you take special notice of these items.
Customer Safety
WARNING
The rider's safety depends upon proper motorcycle service and maintenance. If a procedure in this manual is not
within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the
procedure. Improper service or maintenance could result in death or serious injury. (00627b)
Proper service and repair is important for the safe, reliable operation of all mechanical products. The service
procedures recommended and described in this manual are effective methods for performing service operations and
are essential to your customer's safety and the reliable and safe operation of your customer's vehicle.
Personal Protection
WARNING
Always wear safety glasses or goggles when performing service or maintenance procedures. Flying objects or
materials can cause serious eye injury or death.Wear protective gear that is appropriate to the situation. Helmets,
gloves, boots and other protective clothing can prevent serious injury or death.Wear ear protection when loud
noises are present. Loud noises can damage ears and cause hearing loss. (00628b)
Tool Safety
Some of these service operations require the use of tools specially designed for the purpose. Follow the
manufacturer's suggested usage and safety instructions. If using a tool other than that recommended by Harley-
Davidson, be sure that the tool is appropriate for the service or maintenance procedure and is being used in
accordance with the tool's safety instructions.
Product Safety
WARNING
Read and follow warnings and directions on all products. Failure to follow warnings and directions can result in
death or serious injury. (00470b)
When reference is made to a specific brand name product, tool or instrument, an equivalent product, tool or
instrument may be substituted.
Some referenced or recommended products contain chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm as indicated on the product label or at the point of purchase.
Hazardous Materials
WARNING
Read and follow warnings and directions on all products. Failure to follow warnings and directions can result in
death or serious injury. (00470b)
Keep hazardous products out of the reach of children.
Many products (oils, lubricants, solvents, sealants and cleaners, etc.) can cause death or serious injury if inhaled,
absorbed, injected, ingested or improperly contacted. If hazardous contact is made with a product, follow the
instructions on the product label and, if necessary, contact poison control or a medical facility.
Some products are flammable and/or explosive as indicated on the product label or at the point of purchase. Keep
these products away from flame and intense heat.
Some products are corrosive as indicated on the product label. Wear appropriate protective gear to prevent skin
contact. Use service covers to prevent damage to cosmetic surfaces on the motorcycle.
Some products contain chemicals known to the State of California to cause cancer and birth defects or other
reproductive harm as indicated on the product label or at the point of purchase.
Fuel
WARNING
Keep gasoline away from ignition sources. Gasoline is extremely flammable and highly explosive and, if ignited,
could result in death or serious injury. (00634b)
Stop the engine when refueling or servicing the fuel system.
Do not allow open flame, sparks, radiant heat or other ignition sources near gasoline.
Do not store motorcycle with gasoline in tank within the home or garage where ignition sources, such as open
flames, pilot lights, sparks or electric motors are present.
Do not overfill fuel tank. Allow for fuel expansion .
Do not use gasoline as a cleaner or solvent.
Gasoline can leak or drain from loosened or improperly tightened fuel fittings or from removed fuel components.
Clean spilled gasoline immediately. Dispose of waste materials properly.
Battery
WARNING
Read and follow warnings and directions on all products. Failure to follow warnings and directions can result in
death or serious injury. (00470b)
Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working with batteries. Keep batteries out of the reach of children.
Do not remove warning label attached to top of battery.
Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals
known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after
handling.
Coolant
Coolant contains toxic chemicals which could cause death or serious injuries if ingested. Do not induce vomiting.
Call a physician immediately.
Irritation to skin or eyes can occur from vapors or direct contact. Flush thoroughly with water if contact is made.
Use in a well ventilated area.
Hydraulic (Brake) Fluid
Direct contact with brake fluid to the eyes can cause irritation. Flush thoroughly with water if contact is made. Do
not swallow brake fluid. Swallowing brake fluid can cause digestive discomfort. Call a physician immediately.
Brake fluid will cause cosmetic damage to painted surfaces. Always use caution and protect surfaces from spills
whenever brake work is performed.
Engine Oil
Prolonged or repeated contact with used motor oil may be harmful to skin and could cause skin cancer. Promptly
wash affected areas with soap and water.
Do not swallow oil. If swallowed, do not induce vomiting. Contact a physician immediately.
Direct contact with eyes can cause irritation. Flush thoroughly with water if contact is made. Contact a physician if
irritation persists.
Electrical Systems
WARNING
Improper service or maintenance of the electrical system can cause damage to the electrical system. This may
result in component failure. In certain situations, a component failure during operation could lead to a loss of
control, which could result in death or serious injury. (00637b)
Always use replacement fuses that are of the specified type and amperage rating.
Do NOT pull on electrical wires. Pulling on electrical wires may damage wire conductivity.
Route wires and harnesses properly to prevent chafing, stripping, pinching, crimping or cutting wires. Damaged
wires can cause short circuits and component damage or failure.
Do NOT overload the vehicle's charging system. If the electrical accessories consume more electrical current than
the charging system can produce, the battery may be discharged and cause damage to the motorcycle's electrical
system.
Do NOT exceed the maximum amperage rating of the fuse or circuit breaker protecting a modified circuit.
Avoid directly heating electrical system components other than the connectors on which heat shrink work is being
performed.
FASTENER
TORQUE VALUE
NOTES
Air cleaner cover screw, single screw
5.6-7.3 N·m
2.20 INSPECT AIR FILTER, Install
cover
(50-65 in-lbs)
Apply LOCTITE 243 (blue) to the
threads of screw.
Air cleaner cover screws, five-screw
5.4-8.1 N·m
2.20 INSPECT AIR FILTER, Install
cover
(48-72 in-lbs)
Apply LOCTITE 243 (blue) to the
threads of screw. Tighten in a star
pattern.
Air cleaner cover screws, oval cover
5.7-6.8 N·m
2.20 INSPECT AIR FILTER, Install
(50-60 in-lbs)
Air cleaner trim insert screws
3-3.6 N·m
2.20 INSPECT AIR FILTER, Install
(27-32 in-lbs)
Air filter element screws, round cover
5.4-8.1 N·m
2.20 INSPECT AIR FILTER, Install
(48-72 in-lbs)
Axle nut, rear
128.8-142.4
2.17 INSPECT AND ADJUST DRIVE
N·m (95-105 ft-
BELT AND SPROCKETS, Adjust
lbs)
Belt
Battery, positive cable, screw
8-12 N·m
2.21 INSPECT BATTERY, Install
(6-9 ft-lbs)
Brake master cylinder, front,
1-1.2 N·m
2.11 CHECK AND REPLACE BRAKE
reservoir cover screws
(9-11 in-lbs)
FLUID, Check Brake Fluid Level
Brake master cylinder, rear, reservoir
1-2 N·m
2.11 CHECK AND REPLACE BRAKE
cover screws
(9-18 in-lbs)
FLUID, Check Brake Fluid Level
Clutch hub jamnut
8.1-13.6 N·m
2.12 CHECK AND ADJUST
(72-120 in-lbs)
CLUTCH, Check and Adjust
Clutch inspection cover screws (All
9.5-12.2 N·m
2.6 REPLACE PRIMARY
except FLSB)
(84-108 in-lbs)
CHAINCASE LUBRICANT, Change
Primary Chaincase Lubricant
Torque sequence
Clutch inspection cover screws
2.8-3.9 N·m
2.6 REPLACE PRIMARY
(FLSB)
(25-35 in-lbs)
CHAINCASE LUBRICANT, Change
Primary Chaincase Lubricant
Torque sequence
Engine oil drain plug
19-28.5 N·m
2.5 REPLACE ENGINE OIL AND
(14-21 ft-lbs)
FILTER, Change Oil and Oil Filter
Fork stem pinch bolt
21.7-27.1 N·m
2.14 ADJUST AND LUBRICATE
(16-20 ft-lbs)
STEERING HEAD BEARINGS,
Check and Adjust
Front brake pad hanger pin
14.7-19.6 N·m
2.10 INSPECT BRAKES, Replace
(11-14 ft-lbs)
Front Brake Pads
Lower fork bracket pinch bolt
21.7-27.1 N·m
2.14 ADJUST AND LUBRICATE
(16-20 ft-lbs)
STEERING HEAD BEARINGS,
Check and Adjust
Primary chaincase drain plug
19-28.5 N·m
2.6 REPLACE PRIMARY
(14-21 ft-lbs)
CHAINCASE LUBRICANT, Change
Primary Chaincase Lubricant
Spark plug
10-15 N·m
2.22 CLEAN AND INSPECT SPARK
(89-133 in-lbs)
PLUGS, Install
Spoke nipple
6.2 N·m
2.8 INSPECT TIRES AND WHEELS,
(55 in-lbs)
Wheel Spokes
Transmission drain plug
19-28.5 N·m
2.7 REPLACE TRANSMISSION
(14-21 ft-lbs)
LUBRICANT, Change Transmission
Lubricant
Transmission filler plug/dipstick
2.8-8.5 N·m
2.7 REPLACE TRANSMISSION
(25-75 in-lbs)
LUBRICANT, Check Transmission
Lubricant
Transmission filler plug/dipstick
2.8-8.5 N·m
2.7 REPLACE TRANSMISSION
(25-75 in-lbs)
LUBRICANT, Change Transmission
Lubricant
WARNING
Perform the service and maintenance operations as indicated in the regular service interval table. Lack of regular
maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in
death or serious injury. (00010a)
Perform necessary set-up tasks before customer delivery. See applicable model year predelivery and set-up instructions.
The performance of new motorcycle initial service is required to keep warranty in force and to verify proper emissions
systems operation. See General.
Inspect motorcycle regularly for additional maintenance needs. Routinely check components between regular maintenance
intervals. Always inspect motorcycle after periods of storage before riding.
Perform all of the checks in the PRE-RIDING CHECKLIST in the owner's manual following any service procedure. Operate
the motorcycle to perform any final check or adjustments. If all is correct, the vehicle is ready to return to the customer.
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