Harley Davidson 2018 softail models. Service manual — page 2

Special Tools

Description

Part Number

Qty.

FAT JACK

HD-45968

WARNING

Be sure to check capacity rating and condition of hoists, slings, chains and cables before use. Exceeding capacity

ratings or using lifting devices that are in poor condition can lead to an accident, which could result in death or serious

injury. (00466c)

Always use blocking or proper stands to support motorcycle.

Set Motorcycle Upright

1. Place motorcycle upright on a level surface or suitable lift if available.

2. Verify that motorcycle is level.

3. Secure with tie-downs.

Raise Front or Rear Wheel for Service

1. Verify that motorcycle is level.

2. Use a FAT JACK (Part Number:HD-45968) or similar to raise the motorcycle to service a front or rear wheel.

3. Secure with tie-downs.

Regular Service Intervals

Service must be performed at specified intervals to keep your Harley-Davidson motorcycle operating at peak

performance. Refer to Table 1.

NOTE

The use of parts and service procedures other than Harley-Davidson approved parts and service procedures

may void the limited warranty. Any alterations to the emission system components, such as the intake and

exhaust system, may be in violation of motor vehicle laws.

Some countries, such as Brazil, may require all regular maintenance to be performed by an authorized

Harley-Davidson dealer for your limited warranty to remain in effect. Check with your authorized Harley-

Davidson dealer.

Some countries, such as Brazil, may require additional annual (or semi-annual) regular maintenance steps to

be performed to keep your limited warranty in effect and/or comply with vehicle regulations. Check with your

authorized Harley-Davidson dealer as well as the motorcycle regulations in your country.

After completing the final service interval, repeat the service schedule starting at the 8000 km (5000 mi)

interval.

Whenever a vehicle is in for maintenance, always check for and complete recalls and open product programs.

Whenever a vehicle is in for maintenance, always verify that the latest calibration is installed.

Table 1. Regular Service Intervals: Harley-Davidson Softail Models

ITEM

1000

5000

10000

15000

20000

25000

30000

35000

40000

45000

50000

SERVICED

1600

8000

16000

24000

32000

40000

48000

56000

64000

72000

80000

Check

operation of

electrical

equipment

and

switches

Check front

tire

pressure,

inspect

tread

Check front

wheel

spoke

torque (if

equipped)

Inspect front

brake fluid

level

Check

DOT4 front

brake fluid

for moisture

Adjust

steering

head

bearings

Lubricate

steering

head

bearings

Inspect

windshield

bushings (if

applicable)

Check

upper and

lower

switch

housing

screw

torque

Check

clutch lever

handlebar

clamp

screw

torque

Check

master

cylinder

handlebar

clamp

screw

torque

Inspect air

cleaner,

service as

required

Replace

engine oil

and filter

Clean and

inspect oil

cooler

Replace

primary

chaincase

lubricant

Replace

transmission

lubricant

Inspect oil

lines and

brake

system for

leaks,

contact, or

abrasion

Inspect fuel

lines and

fittings for

leaks,

contact or

abrasion

Inspect rear

brake fluid

level

Check DOT

4 rear

brake fluid

for moisture

Inspect

brake pads

and discs

for wear

Check front

axle torque

Inspect and

lubricate

jiffy stand

Check

clutch

adjustment

Check,

adjust and

lubricate

brake and

clutch

controls

Check rear

wheel

spoke

torque (if

equipped)

Check rear

tire

pressure,

inspect

tread

Check rear

fork spacer

bolt torque

Inspect

drive belt

and

sprockets,

adjust belt

Check rear

axle nut

torque

Inspect

exhaust

system for

leaks,

cracks, and

loose or

missing

fasteners or

exhaust

shields

Battery

Check battery, terminal torque and clean connections annually.

Spark plugs

Replace spark plugs every two years or every 48,000 km (30000 mi), whichever comes first.

Front forks

Disassemble, inspect, rebuild front forks and replace fork oil every 80,000 km (50000 mi).

Fuel filter

Replace fuel filter every 161,000 km (100000 mi).

Brake

Flush brake and clutch systems and replace DOT 4 hydraulic brake and clutch fluids every two

system

years or sooner if moisture content is 3% or greater

Road test to

verify

component

and system

functions

NOTES:

1. Perform annually or at specified intervals, whichever comes first.

2. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools,

service

data and are mechanically qualified.

3. Perform spoke tension check at the 2,000 km (1000 mi), 8,000 km (5000 mi), 32,000 km (20000

mi) services and every 24,000 km (15000 mi) interval thereafter. Not all vehicles are equipped with

spoke wheels. Consult appropriate topic in service manual.

4. Perform maintenance more frequently in severe riding conditions (such as extreme temperatures,

dusty environments, mountainous or rough roads, long storage conditions, short runs, heavy stop/go

traffic or poor fuel quality).

5. For torque instructions, see Shop Practices in the service manual.

6. Disassemble, lubricate and inspect every 48,000 km (30000 mi).

Maintenance Records

Maintain a record of this service to keep your new motorcycle limited warranty in force. Refer to Table

2. Table 2. Owner's Maintenance Records

SERVICE MILE

DATE

DEALER

TECHNICIAN

INTERVAL

NUMBER

NAME

SIGNATURE

1,600 km (1,000 mi)

8,000 km (5,000 mi)

16,000 km (10,000 mi)

24,000 km (15,000 mi)

32,000 km (20,000 mi)

40,000 km (25,000 mi)

48,000 km (30,000 mi)

56,000 km (35,000 mi)

64,000 km (40,000 mi)

72,000 km (45,000 mi)

80,000 km (50,000 mi)

Always use a good quality unleaded gasoline. Octane ratings are usually found on the pump. Refer to Table 1.

WARNING

Avoid spills. Slowly remove filler cap. Do not fill above bottom of filler neck insert, leaving air space for fuel expansion.

Secure filler cap after refueling. Gasoline is extremely flammable and highly explosive, which could result in death or

serious injury. (00028a)

WARNING

Use care when refueling. Pressurized air in fuel tank can force gasoline to escape through filler tube. Gasoline is

extremely flammable and highly explosive, which could result in death or serious injury. (00029a)

Modern service station pumps dispense a high flow of gasoline into a motorcycle fuel tank. This can cause air entrapment

and pressurization.

Table 1. Octane Rating

SPECIFICATION

RATING

Pump Octane (R+M)/2

91 (95 RON)

Harley-Davidson motorcycles are designed to get the best performance and efficiency using unleaded gasoline. Most

gasoline is blended with alcohol and/or ether to create oxygenated blends. The type and amount of alcohol or ether added

to the fuel is important.

NOTICE

Do not use gasoline that contains methanol. Doing so can result in fuel system component failure, engine damage

and/or equipment malfunction. (00148a)

Gasoline/METHYL TERTIARY BUTYL ETHER (MTBE) blends are a mixture of gasoline and as much as 15 percent

MTBE. Gasoline/MTBE blends use in your motorcycle is approved.

ETHANOL fuel is a mixture of ethanol (grain alcohol) and unleaded gasoline and can have an impact on fuel mileage.

Fuels with an ethanol content of up to 10 percent may be used in your motorcycle without affecting vehicle

performance. U.S. EPA regulations currently indicate that fuels with 15 percent ethanol (E15) are restricted from use in

motorcycles at the time of this publication. Some motorcycles are calibrated to operate with higher ethanol

concentrations to meet the fuel standards in certain countries.

REFORMULATED OR OXYGENATED GASOLINES (RFG) describes gasoline blends that are specifically designed to

burn cleaner than other types of gasoline. This results in fewer tailpipe emissions. They are also formulated to

evaporate less when filling the tank. Reformulated gasolines use additives to oxygenate the gas. Your motorcycle will

run normally using this type of fuel. Harley-Davidson recommends using it whenever possible as an aid to cleaner air

in our environment.

Do not use racing fuel or fuel containing methanol. Use of these fuels will damage the fuel system.

Using fuel additives other than those approved for use by Harley-Davidson may damage the engine, fuel system and

other components.

Some gasoline blends might adversely affect starting, performance or fuel efficiency. If any of these problems are

experienced, try a different brand of gasoline or gasoline with a higher octane blend.

CAUTION

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. (00358b)

CAUTION

If engine oil is swallowed, do not induce vomiting. Contact a physician immediately. In case of contact with eyes,

immediately flush with water. Contact a physician if irritation persists. (00357d)

NOTICE

Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of

inferior lubricants can damage the engine. (00184a)

Engine oil is a major factor in the performance and service life of the engine. Use the proper grade of oil for the lowest

temperature expected before the next oil change. Refer to Table 1.

This motorcycle was originally equipped with GENUINE HARLEY-DAVIDSON H-D 360 MOTORCYCLE OIL 20W50. H-D

360 is the preferred oil under normal operating conditions. If operation under extreme cold or heat are expected, refer to

Table 1 for alternative choices.

If H-D 360 is not available, add oil certified for diesel engines. Acceptable designations include: CH-4, CI-4 and CJ-4. The

preferred viscosities, in descending order are: 20W50, 15W40 and 10W40.

At the first opportunity, see an authorized dealer to change back to 100 percent Harley-Davidson oil.

Table 1. Recommended Engine Oils

TYPE

VISCOSITY

RATING

LOWEST

COLD-WEATHER

AMBIENT

STARTS BELOW

TEMPERATURE

50 °F (10 °C)

Screamin' Eagle SYN3 Full Synthetic

SAE

HD 360

Above -1 °C

Excellent

Motorcycle Lubricant

20W50

(30.2 °F)

Genuine Harley-Davidson H-D 360

SAE

HD 360

Above 4 °C

Good

Motorcycle Oil

20W50

(39.2 °F)

Genuine Harley-Davidson H-D 360

SAE 50

HD 360

Above 16 °C

Poor

Motorcycle Oil

(60.8 °F)

Genuine Harley-Davidson H-D 360

SAE 60

HD 360

Above 27 °C

Poor

Motorcycle Oil

(80.6 °F)

Change engine oil often in colder climates. If motorcycle is frequently ridden less than 24 km (15 mi), in ambient

temperatures below 16 °C (60 °F), reduce oil change intervals to 2,400 km (1500 mi).

NOTE

Lower ambient temperatures require more frequent oil changes.

Water vapor is a normal by-product of combustion . During cold-weather operation, some water vapor condenses to liquid

form on the cool surfaces inside the engine. In freezing weather, this water becomes slush or ice. If the engine is not

warmed to operating temperature, accumulated slush or ice blocks the oil lines and causes engine damage. Over time,

water will accumulate, mix with the engine oil and form a sludge that is harmful to the engine.

If the engine is allowed to warm to normal operating temperature, most of the water evaporates and exits through the

crankcase breather.

CAUTION

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. (00358b)

NOTICE

Do not overfill oil. Doing so can result in oil carryover to the air cleaner leading to equipment damage and/or equipment

malfunction. (00190b)

NOTE

Check engine oil level at each complete fuel refill.

Oil Level Cold Check

1. Place vehicle on level ground resting on the jiffy stand.

NOTE

Oil level on a cold engine should never be above the midway point.

2. See Figure 1. Check engine oil level.

a. Remove filler plug/dipstick.

b. Wipe off the dipstick.

c. Insert the dipstick and tighten into the fill spout.

d. Remove filler plug/dipstick.

e. See Figure 2. Check oil level. The correct cold oil level is midway (2) between the ADD QT (1) and

FULL HOT (3) marks on the dipstick.

3. If oil level is at or below the ADD QT mark, add only enough oil to bring the level to the ADD QT mark.

4. Start and idle engine on jiffy stand for two minutes. Turn off engine.

5. Check oil level. Add only enough to bring level midway between the ADD QT (1) and FULL HOT (3).

Oil Level Hot Check

NOTICE

Do not allow hot oil level to fall below Add/Fill mark on dipstick. Doing so can result in equipment damage and/or

equipment malfunction. (00189a)

NOTE

Perform engine oil level hot check only with engine oil at normal operating temperature.

1. Ride motorcycle until engine oil reaches at least 93 °C (199.3 °F) or higher.

2. Allow engine to idle for 1-2 minutes on jiffy stand. Turn off engine.

3. See Figure 1. Check oil level.

a. Remove filler plug/dipstick.

b. Wipe off the dipstick.

c. Insert the dipstick and tighten into the fill spout.

d. Remove filler plug/dipstick.

e. See Figure 2. Check oil level. Oil level must register between the ADD QT and FULL HOT marks on

the dipstick.

4. If oil level is at or below the ADD QT mark, add only enough oil to bring the level to the FULL HOT mark. Do

not overfill.

Figure 1. Engine Oil Filler Plug

ADD QT mark

Cold check level

FULL HOT mark

Figure 2. Engine Oil Dipstick

Special Tools

Description

Part Number

Qty.

OIL FILTER WRENCH

94686-00

OIL FILTER WRENCH

94863-10

WARNING

Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely

affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d)

NOTICE

Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of

inferior lubricants can damage the engine. (00184a)

Change engine oil at the first 1,600 km (1000 mi) for a new engine. After the initial service, change oil at regular

intervals in normal service at warm or moderate temperatures. Refer to General.

Change oil at more frequent intervals in cold weather or severe operating conditions. See Winter Lubrication.

1. Run motorcycle until engine is at normal operating temperature. Turn off engine.

2. Remove filler plug/dipstick.

NOTE

Replace drain plug O-ring.

3. See Figure 1. Remove the oil drain plug (2) and O-ring. Allow oil to drain completely.

NOTE

Use P&A Oil Catcher (Part No. 62700199) or equivalent to keep drain oil off crankcase when removing oil filter.

Residual drain oil could falsely appear as a crankcase oil leak at a later time.

1. Remove the oil filter using oil filter wrench and hand tools.

Do not use with air tools.

Special Tool: OIL FILTER WRENCH (94863-10) Special

Tool: OIL FILTER WRENCH (94686-00)

2. Clean the oil filter mount flange.

3. Clean any residual oil for crankcase and transmission

housing.

4. See Figure 2. Install new oil filter.

a. Lubricate gasket with a thin film of clean engine oil.

b. Install new oil filter.

c. Hand-tighten oil filter one-half to three-quarters of a

turn after gasket first contacts filter mounting surface.

Do NOT use oil filter wrench for installation.

5. Install engine oil drain plug and new O-ring.

Torque: 19-28.5 N·m (14-21 ft-lbs) Engine oil drain plug

NOTE

Use the proper grade of oil for the lowest temperature

expected before the next oil change. Refer to

Recommended Engine Oils for recommended oil.

6. Add an initial volume of engine oil. Refer to Table 1.

Table 1. Initial Oil Fill

ITEM

QUANTITY

Engine oil initial fill

3.8 L (4.0 qt)

10. Verify proper oil level. See Check Engine Oil Level.

a. Perform engine oil level cold check.

b. Start engine and carefully check for oil leaks around drain plug and oil filter.

c. Perform engine oil level hot check.

Figure 1. Engine Oil Drain Plug

Figure 2. Lubricating New Oil Filter Gasket

1. Run motorcycle until engine is at normal operating

temperature. Turn off engine.

WARNING

Be sure that no lubricants or fluids get on tires,

wheels or brakes when changing fluid. Traction can

be adversely affected, which could result in loss of

control of the motorcycle and death or serious

injury. (00047d)

2. Secure motorcycle upright (not leaning on jiffy stand) on a

level surface.

3. See Figure 1. Drain primary chaincase.

4. Clean drain plug magnet. If plug has excessive debris,

inspect the condition of chaincase components.

5. Install drain plug and new O-ring. Tighten.

Torque: 19-28.5 N·m (14-21 ft-lbs) Primary chaincase

drain plug

Figure 1. Removal/Installation of Chaincase Drain Plug

6. See Figure 3. Remove screws (3) and clutch inspection

cover (2).

7. Remove seal (1). Wipe oil from primary cover and groove

in inspection cover.

NOTE

FLSB has seal installed on groove in primary cover.

NOTICE

Do not overfill the primary chaincase with lubricant.

Overfilling can cause rough clutch engagement,

incomplete disengagement, clutch drag and/or

difficulty in finding neutral at engine idle. (00199b)

8. Add lubricant.

a. Pour specified amount of FORMULA+

TRANSMISSION AND PRIMARY CHAINCASE

LUBRICANT through clutch inspection cover opening.

Refer to Table 1.

b. See Figure 2. Proper level is approximately at bottom

of pressure plate OD.

Table 1. Primary Chaincase Lubricant

AMOUNT*

DRY FILL**

WET FILL***

Wide Primary

1.36

1.24

Narrow Primary

1.18

1.06

* Amount is approximate. Fill to bottom of pressure plate OD with vehicle upright.

** Cover was removed and installed.

*** Lubricant was drained through the drain plug only.

Figure 2. Primary Chaincase Lubricant Level

9. Install clutch inspection cover and new seal:

a. See Figure 3. Install new seal (1) in groove in cover.

b. Secure clutch inspection cover with screws with

captive washers (3).

c. See Figure 4. Tighten in sequence shown.

Torque: 9.5-12.2 N·m (84-108 in-lbs) Clutch

inspection cover screws (All except FLSB)

Torque: 2.8-3.9 N·m (25-35 in-lbs) Clutch inspection

cover screws (FLSB)

Seal

Clutch inspection cover

Screw and captive washer (5)

Figure 3. Clutch Cover (Typical)

Figure 4. Clutch Cover Tightening Sequence

NOTE

Check transmission fluid with the motorcycle at ambient temperature. Inspect transmission dipstick O-ring. Replace if

necessary.

Park motorcycle on a level surface on jiffy stand.

Remove right side cover. See Remove

See Figure 1. Remove transmission filler plug/dipstick.

Wipe dipstick clean.

Install filler plug/dipstick until O-ring contacts the case. Do

not tighten.

See Figure 2. Remove filler plug/dipstick. Check lubricant

level on dipstick. Proper oil level is between the Add (A)

(1) and Full (F) (2) marks.

NOTICE

Mixing mineral-based lubricants with SYN-3 in the

transmission can damage the transmission.

(00452b)

If lubricant level is low, add recommended Harley-

Davidson lubricant to bring level to between the A mark

and the F marks. Refer to Table 1.

Install filler plug/dipstick. Tighten to .

Torque: 2.8-8.5 N·m (25-75 in-lbs) Transmission filler

plug/dipstick

Install right side cover. See Install

Figure 1. Transmission Filler Plug/Dipstick Location

Add (A)

Full (F)

Figure 2. Transmission Lubricant Level

Table 1. Transmission Lubricant

MODEL

LUBRICANT

All

FORMULA+ TRANSMISSION AND PRIMARY CHAIN

LUBRICANT

See Transmission Filler Plug/Dipstick Location.

Remove transmission filler plug/dipstick.

WARNING

Be sure that no lubricants or fluids get on tires,

wheels or brakes when changing fluid. Traction can

be adversely affected, which could result in loss of

control of the motorcycle and death or serious

injury. (00047d)

See Figure 1. Remove transmission drain plug. Drain

transmission.

Clean and inspect drain plug and O-ring.

NOTICE

Do not over-tighten filler or drain plug. Doing so

could result in a lubricant leak. (00200b)

Install drain plug with new O-ring. Tighten. Do not over-

tighten.

Torque: 19-28.5 N·m (14-21 ft-lbs) Transmission drain

plug

Fill the transmission with recommended Harley-Davidson

lubricant. Refer to Transmission Lubricant.

Volume: 0.83 L (28 fl oz)

Check lubricant level. Add enough lubricant to bring the

level between the add (A) and full (F) marks. See

Transmission Lubricant Level.

Install filler plug/dipstick. Tighten.

Torque: 2.8-8.5 N·m (25-75 in-lbs) Transmission filler

plug/dipstick

Figure 1. Transmission Drain Plug

WARNING

Match tires, tubes, rim strips or seals, air valves and caps to the correct wheel. Contact a Harley-Davidson dealer.

Mismatching can lead to tire damage, allow tire slippage on the wheel or cause tire failure, which could result in death

or serious injury. (00023c)

WARNING

Harley-Davidson front and rear tires are not the same. Interchanging front and rear tires can cause tire failure, which

could result in death or serious injury. (00026a)

NOTE

Tubeless tires are used on all Harley-Davidson cast wheels.

Tire sizes are molded on the tire sidewall. Inner tube sizes are printed on the tube.

Store new tires on a horizontal tire rack. Avoid stacking new tires in a vertical stack. The weight of the stack

compresses the tires and crushes the beads.

Tire Pressure

WARNING

Be sure tires are properly inflated, balanced, undamaged, and have adequate tread. Inspect your tires regularly

and see a Harley-Davidson dealer for replacements. Riding with excessively worn, unbalanced, improperly

inflated, overloaded or damaged tires can lead to tire failure and adversely affect stability and handling, which

could result in death or serious injury. (00014b)

Check tire pressure:

As part of the pre-ride checklist. At

every scheduled service interval.

1. Check tire pressures when tires are cold. Compare with specifications. Refer to Table 1.

NOTE

Harley-Davidson does not perform any testing with only nitrogen in tires. Harley-Davidson neither recommends

nor discourages the use of pure nitrogen to inflate tires.

Tread

WARNING

Replace tire immediately with a Harley-Davidson specified tire when wear bars become visible or only 1 mm

(1/32 in) tread depth remains. Riding with a worn tire could result in death or serious injury. (00090c)

Check tire tread:

As part of the pre-ride checklist.

At every scheduled service interval.

1. Inspect each tire for punctures, cuts and breaks.

2. See Figure 1 , Figure 2 and Figure 3. Inspect each tire for wear. Replace tires before they reach the tread

wear indicators.

Indicator

Tread wear bar

Figure 1. Tread Wear Indicator: Michelin Tires

Figure 2. Dunlop Sidewall Tread Wear Indicator Bar Locator

Figure 3. Dunlop Tread Wear Indicator Bar Appearance

Table 1. Specified Tires

MODEL

MOUNT

SIZE

SPECIFIED TIRE

PRESSURE (COLD 20 °C

(68.0 °F)) ⁽¹⁾

PSI

KPA

FLDE

front

16 in

Dunlop D402F MT90/16 WW

248

FLFB/S

front

18 in

Michelin Scorcher 11 160/60R18

248

FLHC/S, FLSL

front

16 in

Dunlop D401F 130/90B16 BW

248

FXBB

front

19 in

Dunlop D401F 100/90B19 BW

207

FXBR/S

front

21 in

Michelin Scorcher 11 130/60B21

248

FXFB/S

front

16 in

Dunlop D429F 150/80B16 BW

248

FXLR

front

19 in

Michelin Scorcher 31 110/90B19

207

FLSB

front

18 in

Michelin Scorcher 31 130/70B18

248

FLDE

rear

16 in

Dunlop D402 MU85B16 WW

276

FLFB/S, FXBR/S

rear

18 in

Michelin Scorcher 11 240/40R18

290

FLHC/S, FLSL,

rear

16 in

Dunlop D401 150/80B16 BW

276

FXBB

FXFB/S

rear

16 in

Dunlop 180/70B16 BW

276

FXLR

rear

16 in

Michelin Scorcher 31 180/70B16

276

FLSB

rear

16 in

Michelin Scorcher 31 180/70B16

276

(1) Tire pressure varies with changes in ambient and tire temperature. Check pressure with tires cold 20 °C (68 °F). Increase tire

pressure by 6.9 kPa (1 psi) for every 10 °F (5 °C) in ambient air temperature above this point.

Inspect

Tread wear indicators appear on tire tread surfaces when 0.8 mm (0.031 in) or less of tire tread remains. Always

replace tires before the tread wear indicators appear on the surface of the tire.

See Tread Wear Indicator: Michelin Tires or Dunlop Sidewall Tread Wear Indicator Bar Locator. The locations of

tread wear indicators are identified by the marks on the tire sidewalls.

When to Replace Tires

New tires are needed if:

Tread wear indicators become visible on the tread surfaces.

Tire cords or fabric become visible through cracked sidewalls, snags or deep cuts.

A bump, bulge or split in the tire.

A puncture, cut or other damage to the tire that cannot be repaired.

NOTE

Replace bearings in sets only. See Prepare.

1. Replace when bearings exceed end play service wear limit of 0.051 mm (0.002 in).

2. Inspect any time the wheels are removed.

a. Inspect the play of the wheel bearings by hand while they are in the wheel.

b. Rotate the inner bearing race and check for abnormal noise.

c. Make sure that bearing rotates smoothly.

3. Check wheel bearings and axle spacers for wear and corrosion. Excessive play or roughness indicates worn

bearings.

Special Tools

Description

Part Number

Qty.

SPOKE TORQUE WRENCH

HD-48985

SPOKE WRENCH

HD-94681-80

WARNING

Spokes that are too tight can draw nipples through the rim or distort hub flanges. Spokes that are too loose can

continue to loosen when put in service. Either condition can adversely affect stability and handling, which could

result in death or serious injury. (00286a)

WARNING

Do not over-tighten spoke nipples. Protruding spoke nipples can damage rim seal, resulting in rapid tire

deflation, which could cause death or serious injury. (00611c)

NOTICE

When lifting a motorcycle using a jack, be sure jack contacts both lower frame tubes where down tubes and lower

frame tubes converge. Never lift by jacking on cross-members, oil pan, mounting brackets, components or

housings. Failure to comply can cause serious damage resulting in the need to perform major repair work. (00586d)

Identify Wheel Spoke Groups

NOTE

Spokes are grouped in sets of four.

1. Raise the wheel.

2. See Figure 1. Starting at the valve stem, identify the first group of four spokes (1-4).

3. Using a different color for each spoke in the group, draw an alignment mark across the spoke nipple and onto

the rim.

4. Continue around the wheel marking the rest of the spokes the same as they were marked in the previous

steps.

Adjust Wheel Spokes

NOTE

Do not tighten spoke more than one-quarter turn past alignment mark. If more tension is needed, label

spoke and check after completing rest of wheel.

Do not use the spoke torque wrench to loosen spokes. Use SPOKE WRENCH (Part Number:HD-94681-80)

to loosen spokes.

1. See Figure 1. Starting with the first group of spokes, loosen spoke (1) one-quarter turn using SPOKE

WRENCH (Part Number:HD-94681-80).

2. Using SPOKE TORQUE WRENCH (Part Number:HD-48985) tighten spoke (1) to the value listed in Table 1.

a. While tightening, if the torque wrench clicks before the alignment marks align, continue to turn the

spoke nipple until the marks align.

b. If the marks align and torque specification has not been reached, tighten the spoke nipple until the

correct torque is achieved. Do not turn spoke nipple more than one-quarter turn past alignment mark.

3. Repeat previous two steps for spoke (4) in the same group.

4. Continue around the wheel checking spokes 1 and 4 until all groups are done.

5. Repeat procedure for spokes (2, 3) in each group.

NOTE

When checking any spokes that were labeled, make sure to use the original alignment mark.

6. Check spokes, if any, that were labeled as not reaching the proper torque value after tightening one-quarter

turn past alignment mark.

a. Loosen spoke one-quarter turn past original alignment mark using SPOKE WRENCH (Part

Number:HD-94681-80).

b. While tightening, if the torque wrench clicks before the alignment marks align, continue to turn the

spoke nipple until the marks align.

c. If the marks align and torque specification has not been reached, tighten the spoke nipple until the

correct torque is achieved. Do not turn spoke nipple more than one-quarter turn past alignment mark.

7. True the wheel. See General.

Table 1. Spoke Nipple Torque Specification

RIM TYPE

MINIMUM TORQUE

All

6.2 N·m (55 in-lbs)

Figure 1. Tightening Laced Wheels (typical)

Inspect and lubricate the following items according to General.

If service is on muddy or dusty roads, clean and lubricate at shorter intervals.

Consumables

Description

Part Number

Size

ANTI-SEIZE LUBRICANT

98960-97

29.6 ml (1 fl oz)

CCI #20 BRAKE GREASE

42830-05

29.6 ml (1 fl oz)

HARLEY LUBE

94968-09

7.5 ml (½ fl oz)

SPECIAL PURPOSE GREASE

99857-97A

414 ml (14 fl oz)

See Figure 1 for general location of lubrication points.

Front brake hand lever: Use grease on front brake lever

pivot pin hole and end of piston that contacts brake lever.

See Prepare.

CCI #20 BRAKE GREASE (42830-05)

NOTE

HARLEY LUBE (94968-09) is formulated to be

compatible with the clutch cable lining. Use of other

lubricants could damage clutch cable lining.

Clutch cable: Pour two drops of lube into clutch cable

housing. See Prepare.

HARLEY LUBE (94968-09)

Clutch hand lever: Lubricate clutch lever pivot pin hole.

See Prepare.

HARLEY LUBE (94968-09)

Jiffy stand: Lubricate clevis pin and spring hook groove.

See Prepare.

ANTI-SEIZE LUBRICANT (98960-97)

Steering head bearings: Lubricate steering head

bearings. See Prepare.

SPECIAL PURPOSE GREASE (99857-97A)

Fork lock: Lubricate lock internal components. HARLEY

LUBE (94968-09)

Front brake hand lever

Clutch cable

Clutch hand lever

Jiffy stand

Steering head bearings

Fork lock

Figure 1. Lubrication Points

Special Tools

Description

Part Number

Qty.

DOT 4 BRAKE FLUID MOISTURE

HD-48497-A

TESTER

Consumables

Description

Part Number

Size

DOT 4 BRAKE FLUID

99953-99A

355 ml (12 fl oz)

NOTICE

Do not allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause

improper operation and equipment damage. (00205c)

NOTE

At every service, check moisture content of fluid using DOT 4 BRAKE FLUID MOISTURE TESTER (Part

Number:HD-48497-A). Follow the instructions included with tool.

Flush brake system and replace DOT 4 BRAKE FLUID (99953-99A) fluid every two years or sooner if brake

fluid test shows moisture content is 3% or greater.

Fluid should never need to be added or removed from the system during normal wear, except for fluid

replacement as specified in the maintenance schedule.

Fluid level in reservoir will decrease with brake wear. Reservoir volume is adequate to provide fluid to the wear

limits of the pads and rotors.

Check brake pads and discs:

At every scheduled service interval. When

removed during service procedures.

Brake Pads

WARNING

Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation

could result in death or serious injury. (00111a)

CAUTION

Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush

with large amounts of water and get medical attention. Swallowing large amounts of DOT 4 brake fluid can

cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF

REACH OF CHILDREN. (00240b)

NOTICE

DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and

protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.

(00239c)

See Figure 1. Replace brake pads (3) if friction material is at or below 1.02 mm (0.04 in) above the backplate (4).

Always replace both pads in a caliper as a set. See Inspect.

When checking the brake pads and discs, inspect the brake hoses for correct routing and any signs of damage.

Brake Disc

Minimum acceptable thickness is stamped on side of disc.

Maximum brake disc lateral runout and warpage is 0.2 mm (0.008 in) when measured near the outside diameter.

Replace disc if warped, badly scored or worn beyond service limit. See Prepare or Prepare.

Front brake caliper (viewed from below)

Brake disc

Brake pads

Backplate

Rear brake caliper (viewed from above)

Rear brake caliper mounting bracket

Figure 1. Brake Pad Inspection

Remove

1. Remove front caliper. See Prepare.

2. See Figure 1. Remove brake pad hanger pins (3).

3. Remove brake pads.

NOTE

Loosening the reservoir cap allows air to escape

and helps prevent contamination. It also helps

prevent fluid from squirting out of reservoir.

4. Remove brake pad spring (4).

5. Loosen front master cylinder reservoir cap.

NOTE

As pistons are pushed back into caliper, verify that

fluid does not overflow reservoir. Remove fluid if

necessary.

6. Using the old brake pad and a C-clamp, retract the

pistons fully into the caliper.

Install

WARNING

Always replace brake pads in

complete sets for correct and

safe brake operation. Improper

brake operation could result in

death or serious injury.

(00111a)

Install new pads into caliper.

NOTE

See Figure 1. Brake pad spring

(4) must be installed with the

stamped arrow facing up.

Loosely install new brake pad hanger

pins (3) and new brake pad spring

(4).

Install front caliper. See Prepare.

Tighten brake pad hanger pins.

Torque: 14.7-19.6 N·m (11-14 ft-lbs)

Front brake pad hanger pin

5. Pump brakes to move pistons out until brake pads

contact rotor. Verify piston location against pads. If the

front wheel is off the ground, rotate wheel to check for

excessive brake pad drag.

6. Check fluid level in brake master cylinder reservoir. See

Check Brake Fluid Level.

WARNING

After repairing the brake system, test brakes at

low speed. If brakes are not operating properly,

testing at high speeds can cause loss of control,

which could result in death or serious injury.

(00289a)

7. Test brakes.

NOTE

Avoid making hard stops for the first 160 km

(100 mi) in order to wear in the brakes properly.

a. Turn ignition switch ON. Check operation of rear

lamps.

b. Test ride motorcycle. If brakes feel spongy, bleed

brakes . See Check Brake Fluid Level.

Caliper mounting bolt (2)

WSS (Wheel speed sensor) cable retainer - ABS

(Anti-lock braking system) only

Brake pad hanger pin (2)

Brake pad spring

Figure 1. Front Brake Caliper

Remove

See Figure 1. Remove rear caliper (1). See Prepare.

Remove brake pad hanger pins (2).

a. Inspect brake pad hanger pins for damage or wear,

replace if needed.

Remove brake pads (4).

NOTE

Loosening the reservoir cap allows air to escape

and helps prevent contamination. It also helps

prevent fluid from squirting out of reservoir.

Loosen rear master cylinder reservoir cap.

NOTE

As pistons are pushed back into caliper, verify that

fluid does not overflow reservoir. Remove fluid if

necessary.

Using the old brake pad and a C-clamp, retract the

pistons fully into the caliper.

Inspect brake pad retainer spring (5). Replace if

needed.

See Figure 1 and Rear Caliper Mounting Bracket.

Remove retainer clip (3) from rear caliper mounting

bracket.

Rear caliper

Brake pad hanger pin (2)

Retainer clip

Brake pad (2)

Brake pad retaining spring

Figure 1. Rear Brake Pads

Install

1. See Figure 1. Install brake pad retaining spring (5).

WARNING

Always replace brake pads in complete sets for

correct and safe brake operation. Improper brake

operation could result in death or serious injury.

(00111a)

Install new brake pads (4).

Install brake pad hanger pin (2). Hand tighten.

NOTE

Hanger pins are torqued after caliper is installed on

vehicle.

See Figure 1 and Rear Caliper Mounting Bracket.

Install new retainer clip (3) onto rear caliper mounting

bracket.

Install rear caliper. See Prepare.

Pump brakes to move pistons out until brake pads

contact rotor. Verify piston location against pads. If the

rear wheel is off the ground, rotate wheel to check for

excessive brake pad drag.

Check fluid level in rear brake master cylinder reservoir.

See Check Brake Fluid Level.

WARNING

After repairing the brake system, test brakes at

low speed. If brakes are not operating properly,

testing at high speeds can cause loss of control,

which could result in death or serious injury.

(00289a)

NOTE

Avoid making hard stops for the first 160 km

(100 mi) in order to wear in the brakes properly.

Test brakes.

a. Turn ignition switch ON. Check operation of rear

brake lamps.

b. Test ride motorcycle. If brakes feel spongy, bleed

brakes. See Drain.

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Harley Davidson 2018 softail models. Service manual — page 2

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