Harley Davidson 2018 softail models. Service manual — page 11
9
Nut (4)
10
Bracket
Figure 1. Front Fenders
Full Fender
1. See Front Fender Disassembly (Typical). Remove
side trim.
a. Remove nuts (5).
b. Remove trim (6).
c.
Remove tee bolts (7) from trim.
2. Remove fender tip.
a.
Remove nuts (4).
b.
Remove tip (3).
3. Remove medallions (9). See Remove.
4. See Front Fender Disassembly (Typical). Remove
skirt trim.
a.
Remove nuts (8).
b.
Remove trim (1).
1. See Figure 1. Install skirt trim.
a. Position skirt trim (1) on fender (2).
b. Install nuts (8).
2. Install medallions.
a. Clean mounting surface. See Remove.
b. Remove adhesive backing from medallion (9).
c. Install medallion pressing firmly to make sure there is
good adhesion.
3. Install fender tip.
a. Position fender tip (3) on fender (2).
b. Install nuts (4).
4. Install side trim.
a. Loosely install tee bolt (7) and nut (5) on fender.
b. Slide side trim (6) on tee bolts.
c. Hold side trim tight to fender tip (3) and tighten nuts.
Torque: 1.1-1.6 N·m (10-14 in-lbs) Front fender side
trim nut
1
Skirt trim
2
Fender
3
Fender tip
4
Nut (3)
5
Nut (4)
6
Side trim (2)
7
Tee bolt (4)
8
Nut (3)
9
Medallion (2)
Figure 1. Front Fender Disassembly (Typical)
1. Remove main fuse. See Main Fuse.
2. Remove saddle bags, if equipped. See Remove and
Install: Standard.
3. Remove seat. See Remove.
1. See Rear Fender. Disconnect connectors (2, 3).
2. Discard cable strap(s) (1).
3. Remove fender.
a. Support rear fender.
b. Remove fender screws (4) and washers from both
sides.
c. Remove fender.
1. See Figure 1. Install rear fender.
a. Place fender into position.
b. Install screws (4) and washers. Tighten. Torque:
57-62 N·m (42-46 ft-lbs) Rear fender support
screws
2. Connect connectors (2, 3).
3. Install new cable strap(s) (1) into hole(s) on frame and
attach cable.
1
Cable strap
2
Connector (2)
3
Connector
4
Screw (4)
Figure 1. Rear Fender
Consumables
Description
Part Number
Size
LOCTITE 243 MEDIUM STRENGTH
99642-97
6 ml (¼ fl oz)
THREADLOCKER AND SEALANT
(BLUE)
Disassemble
1.
Remove rear fender lighting. See Bulb Replacement
and Bulb Replacement.
2.
NOTE
Rear fender wire conduit is not reusable.
Remove rear fender wire conduit, if necessary. See
Prepare.
3.
Remove license plate bracket mount. See General.
4.
See Figure 1. Remove fender support.
a. Remove screws (13).
b. Remove fender mounts (9,10).
c. Remove fender supports (11,12).
5.
Remove fender tip.
a.
Remove nuts (8).
b.
Remove fender tip (1).
6.
Remove seat retention nut.
a. Hold nut (7).
b. Remove clip (2).
c.
Remove nut.
d. If equipped, remove plugs (3).
7.
Remove stud plate.
a.
Remove washers (4).
b.
Remove stud plate (6).
Assemble
1. See Figure 1. Install stud plate.
a. Position stud plate (6) on fender.
b. Install washers (4).
2. Install seat retention nut.
a. Position nut (7) through fender.
b. Install clip (2).
c. If equipped, install plugs (3).
3. Install fender tip.
a. Position fender tip (1) on fender.
b. Install nuts (8).
4. Install fender supports.
a. Align holes on fender supports (11,12) with holes
in fender.
b. Place fender mounts (10) in the holes near rear of
fender.
c. Place fender mounts (9) in the holes near front of
fender.
d. Apply threadlock and Install screws (13). Tighten.
Torque: 28-37 N·m (21-27 ft-lbs) Rear fender
support screws
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
(99642-97)
5. Install license plate bracket mount. See General.
6. Install rear fender wire conduit. See Prepare.
7. Install fender lighting. See Bulb Replacement and
Bulb Replacement.
1
Fender tip
2
Clip
3
Plug (2)
4
Washer (2)
5
Reflector (2)
6
Stud plate
7
Nut
8
Nut (3)
9
Fender mount rear (2)
10
Fender mount front (2)
11
Left fender support
12
Right fender support
13
Fender support screw (8)
Figure 1. Full Fender
Consumables
Description
Part Number
Size
LOCTITE 243 MEDIUM STRENGTH
99642-97
6 ml (¼ fl oz)
THREADLOCKER AND SEALANT
(BLUE)
Disassemble
1.
Remove taillight, if equipped. See Bulb Replacement.
2.
Remove license plate bracket. See General.
3.
See Chopped Fender: W/O License Plate Bracket,
Chopped Fender: With Licence Plate Bracket, W/O
Inner Fender Mounting Screws or Chopped Fender:
With license Plate Bracket and Inner Fender Mount
Screws. Remove rear fender support.
a. Models equipped with inner fender mount
screws: Remove screws (13).
b. Remove screws (11).
c. Remove fender mounts (9).
d. Remove fender supports (7,10).
e. Remove license plate support bracket (12), if
equipped.
4.
Remove turn signals. See Bulb Replacement.
5.
Remove reflector bracket (2) and reflectors (1, 6).
a. Saw behind reflectors with mono-filament fishing
line or waxed dental floss.
6.
NOTE
Some fenders will have two seat retention nuts.
Remove seat retention nut.
a.
Hold nut (3).
b.
Remove clip (4).
7.
See Chopped Fender: With license Plate Bracket
and Inner Fender Mount Screws. Remove stud plate,
if equipped.
a.
Remove washers (15).
b.
Remove stud plate (14).
Assemble
1. See Chopped Fender: With license Plate Bracket
and Inner Fender Mount Screws. Install stud plate, if
equipped.
a. Position stud plate (14) on fender.
b. Install washers (15).
2.
See Chopped Fender: W/O License Plate Bracket,
Chopped Fender: With Licence Plate Bracket, W/O
Inner Fender Mounting Screws or Chopped Fender:
With license Plate Bracket and Inner Fender Mount
Screws. Install seat retention nut.
a.
Position nut (3).
b.
Install clip (4).
3.
Install reflector bracket (2) and reflectors (1, 6).
a. Clean mounting surface. See Remove.
b. Test fit reflector (1, 6).
c. Remove adhesive backing.
d. Install and press firmly to adhere.
4.
Install turn signals. See Bulb Replacement.
5.
See Chopped Fender: W/O License Plate Bracket.
Models without license plate support brackets:
Install rear fender supports.
NOTE
Before installing fender supports, route and secure
turn signal wire harnesses through fender supports.
See Bulb Replacement
a. Align holes on fender supports (7,10) with holes in
fender.
b. Place fender mounts (9) in holes on fender.
c. Install screws (11). Tighten.
Torque: 28-37 N·m (21-27 ft-lbs) Rear fender
support screw
6.
See Chopped Fender: With Licence Plate Bracket, W/
O Inner Fender Mounting Screws or Chopped
Fender: With license Plate Bracket and Inner Fender
Mount Screws. Models with license plate support
brackets: Install rear fender supports.
a. Align holes on bracket (12) with holes on fender and
insert fender mounts (9).
b. Align fender supports (7,10).
c. Models equipped with license plate bracket and
inner fender screws: Apply threadlock and install
screw (13) through license plate bracket. Tighten.
Torque: 28-37 N·m (21-27 ft-lbs) Rear fender inner
mount screw
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
(99642-97)
d. Apply threadlock and install screws (11). Tighten.
Torque: 28-37 N·m (21-27 ft-lbs) Rear fender
support screw
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
(99642-97)
7. Install license plate bracket. See General.
8. Install taillight if equipped. See Bulb Replacement.
1
Rear reflector
2
Reflector bracket
3
Seat retention nut (2)
4
Clip (2)
5
Plug
6
Side reflector (2)
7
Left fender support
8
Inner fender screw (2)
9
Fender mount (2)
10
Right fender support
11
Fender support screw (4)
Figure 1. Chopped Fender: W/O License Plate Bracket
1
Rear reflector
2
Reflector bracket
3
Seat retention nut
4
Clip
5
Plug
6
Side reflector (2)
7
Left fender support
8
Inner fender screw (2)
9
Fender mount (2)
10
Right fender support
11
Fender support screw (4)
12
License plate support bracket
Figure 2. Chopped Fender: With Licence Plate Bracket, W/O Inner Fender Mounting Screws
1
Rear reflector
2
Reflector bracket
3
Seat retention nut
4
Clip
6
Side reflector (2)
7
Left fender support
9
Fender mount (2)
10
Right fender support
11
Fender support screw (4)
12
License plate support bracket
13
Inner fender mount screw (2)
14
Stud plate
15
Washer (2)
Figure 3. Chopped Fender: With license Plate Bracket and Inner Fender Mount Screws
Consumables
Description
Part Number
Size
LOCTITE 243 MEDIUM STRENGTH
99642-97
6 ml (¼ fl oz)
THREADLOCKER AND SEALANT
(BLUE)
Disassemble
1. See Figure 1. Remove rear fender support.
a. Remove screws (10).
b. Remove saddlebag mounting bracket (9) and
spacer (8).
c. Remove fender mount bracket (6).
d. Remove fender supports (4, 7).
e. Remove inner bracket assembly (13).
2. Discard cable strap (12).
3. Remove seat retention nuts.
a.
Hold nut (2).
b.
Remove clip (1).
4. Disassemble inner bracket assembly (13).
a. Remove turn signals. See Bulb Replacement.
b. Remove taillight. See Bulb Replacement.
c. Disassemble license plate bracket. See General.
5. Remove reflectors (11).
a. Saw behind reflectors with mono-filament fishing
line or waxed dental floss.
Assemble
1. See Figure 1. Install reflectors (11).
a. Clean mounting surface. See Remove.
b. Test fit reflector.
c. Remove adhesive backing.
d. Install and press firmly to adhere.
2. Assemble inner bracket assembly (13).
a. Assemble license plate bracket. See General.
b. Install taillight. See Bulb Replacement.
c. Install turn signals. See Bulb Replacement.
3. Install seat retention nuts.
a.
Position nut (2).
b.
Install clip (1).
4. Insert new cable strap (12) into fender.
5. Install rear fender support.
a. Route harnesses through access hole in right side
of fender.
b. Install inner bracket assembly (13).
c. Route and secure harnesses with cable strap (12).
d. Install fender mount brackets (6).
e. Install fender supports (4, 7).
NOTE
Route harnesses under right fender support (7).
f. Install saddlebag mounting spacers (8) and
brackets (9).
g. Apply threadlocker and install screws (10). Tighten.
Torque: 28-37 N·m (21-27 ft-lbs) Rear fender
support screw
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
(99642-97)
1
Clip (2)
2
Seat retention nut (2)
3
Plug
4
Left fender support
5
Fender seat nut screw (2)
6
Fender mount bracket (2)
7
Right fender support
8
Saddlebag mounting spacer (4)
9
Saddlebag mounting bracket (4)
10
Screw (4)
11
Reflector (2)
12
Anchored cable strap
13
Inner bracket assembly
Figure 1. Chopped Fender: License Plate Bracket With Lights
COMPLETE
1. Install seat. See Remove.
2. Install saddle bags if removed. See Remove and
Install: Standard.
3. Install main fuse. See Prepare.
1. Remove rear fender. See Prepare.
2. Remove rear fender wire harness. See the electrical
diagnostic manual.
a. Remove wire terminals from harness connectors.
b. Remove wire harness from conduit.
1. Remove conduit.
a. Pull conduit from fender.
b. Thoroughly clean inside surface of fender with soap
and water until it is free of dirt, oil or other debris.
1. See Figure 1 , Figure 2 , Figure 3. Install wiring conduit.
a. Clean mounting surface. See Remove.
b. With the adhesive backing still in place, test fit the
conduit.
c. See Removing Protective Strip From Conduit and
Purging Air Between Adhesive and Fender.
Remove the adhesive backing (2).
d. Lightly position the conduit (1) in place.
e. Using a wallpaper roller (4), roll along conduit (3) to
purge the air from between adhesive and fender.
1
Distance 240 mm (9.45 in)
2
Distance 30 mm (1.18 in)
3
Distance 227 mm (8.94 in)
4
Distance 57 mm (2.24 in)
5
Grommet
6
Cable strap (2)
7
Tab
Figure 1. Fender Conduit Placement
1
Conduit
2
Protective strip
Figure 2. Removing Protective Strip From Conduit
3
Conduit
4
Wallpaper roller
Figure 3. Purging Air Between Adhesive and Fender
1. Install wiring harness.
a. Slide wiring harness through new conduit.
b. Install wire terminals into connector housings. See the
electrical diagnostic manual.
1. Install connectors to proper component and install rear
fender. See Prepare.
1. See Saree GuardsRemove upper saree guard.
a. Remove screws (1) and washers.
b. Remove guard (2).
2. Remove lower saree belt guard.
a.
Remove screws (3, 5).
b.
Remove guard (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 upper saree guard.
a. Place upper saree guard (2) in position.
b. Install threadlocker to screws (1).
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
(99642-97)
c. Install screws and washers. Tighten.
Torque: 28-37 N·m (21-27 ft-lbs) Saree upper guard
screw
2.
Install lower saree belt guard.
a. Place lower saree belt guard (4) in position with the
lower tab behind P-clamp (6).
b. Install threadlocker to screws (3,5).
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
(99642-97)
c. Install screws.
d. Tighten screw (3).
Torque: 8-9 N·m (71-80 in-lbs) Saree lower guard
top screw
e. Tighten screw (5).
Torque: 14-18 N·m (10-13 ft-lbs) Saree lower guard
lower screw
1
Screws (2)
2
Upper saree guard
3
Screw
4
Lower saree belt guard
5
Screw
6
P-clamp
Figure 1. Saree Guards
1. See License Plate Bracket. Remove front license plate
bracket.
a. Remove screw(s) (5,6,7, or 8), washer(s) (4) and
spacer (9), depending on the bracket.
b. Remove license plate bracket (1,2, or 3).
1. See License Plate Bracket. Install front license plate
bracket.
a. If equipped with two hole bracket (1), position bracket
on lower triple clamp. Install washers (4) and screws
(5). Tighten.
Torque: 22-27 N·m (16-20 ft-lbs) Front licence plate
two hole bracket screw
b. If equipped with slotted bracket (2) with short screw
(6), position bracket on lower triple clamp. Install
washer (4) and screw. Tighten.
Torque: 8-12 N·m (6-9 ft-lbs) Front licence plate
slotted bracket screw without spacer
c. If equipped with slotted bracket (2) with long screw
(7), position spacer (9) and bracket on lower triple
clamp. Install washer (4) and screw. Tighten.
Torque: 30-38 N·m (22-28 ft-lbs) Front licence plate
slotted bracket screw with spacer
d. If equipped with two tab bracket (3), position bracket
on lower triple clamp. Install screw (8). Tighten.
Torque: 30-38 N·m (22-28 ft-lbs) Front licence plate
two tab bracket screw
1
Two hole bracket
2
Slotted bracket
3
Two tab bracket
4
Washer
5
Button head screw (2)
6
Hex head short screw
7
Hex head long screw
8
Socket head screw
9
Spacer
Figure 1. License Plate Bracket
Remove side mounted bracket: See Bulb Replacement
Remove rear mounted bracket: See Bulb Replacement
Remove
1. See Standard License Plate Bracket. Remove license
plate bracket.
a. Reach up under the rear fender and remove nuts
(9).
b. Remove license plate bracket assembly.
Install
1. Install license plate bracket on fender.
a. Position license plate assembly on fender.
b. Install screws (8) and nuts (9). Tighten. Torque:
8-11 N·m (71-97 in-lbs) License plate
standard mount screws
Disassemble
1. Disassemble license plate bracket.
a. Remove nut (6), washer (5) and bolt (2).
b. Separate the bracket (3), clamp (4) and support (7).
2. Remove reflector if needed. See Remove
Assemble
1. Assemble the license plate bracket.
a. Position clamp (4) between the bracket (3) and the
support (7).
b. Install bolt (2), washer (5) and nut (6). Tighten.
Torque: 7-10 N·m (62-89 in-lbs) License plate
standard assembly bolt
c. Install reflector (1) if removed. See Remove
1
Reflector
2
Bolt
3
Bracket
4
Clamp
5
Washer
6
Nut
7
Support
8
Screw (3)
9
Nut (3)
Figure 1. Standard License Plate Bracket
Disassemble
1. See Center Mount License Plate Bracket. Remove
center mounted license plate bracket.
a. Remove license plate lamp housing. See Bulb
Replacement.
b. Remove screws (3,5) from rear fender support (4).
c. Separate license plate bracket (2) from rear fender
support.
Assemble
1. Install center mounted license plate bracket.
a. Align holes on center mounted licence plate bracket
(2) with rear fender support (4).
b. Install screws (5). Tighten.
Torque: 2.03-2.37 N·m (18-21 in-lbs) License
plate bracket inner mounting screws
c. Install screws (3). Tighten.
Torque: 7.11-8.69 N·m (63-77 in-lbs) License
plate bracket outer mounting screws
2. Install center mount lamp housing. See Bulb
Replacement
1
Reflector
2
License plate bracket
3
Screw (2)
4
Rear fender support
5
Screw (2)
Figure 1. Center Mount License Plate Bracket
Disassemble
1. Remove license plate lamp. See Bulb Replacement.
2. Remove turn signal lamps. See Bulb Replacement.
3. See Figure 1. Remove center mount licence plate
holder.
a. Remove screws (4).
b. Disassemble license plate holder (3), support
bracket assembly (1) and support bracket
reinforcement (2).
1
Support bracket assembly
2
Support bracket reinforcement
3
License plate holder
4
Screw (3)
Figure 1. License Plate Support Assembly
Assemble
1. See Figure 1. Install center mount licence plate holder.
a. Assemble license plate holder (3), support bracket
assembly (1) and support bracket reinforcement
(2).
b. Install screws (4). Tighten.
Torque: 7.11-8.69 N·m (63-77 in-lbs) License
plate holder screw
2. Install license plate lamp. See Bulb Replacement.
3. Install turn signal lamps. See Bulb Replacement.
1. Set motorcycle upright. See Secure the Motorcycle for
Service.
2. Remove shifter linkage. See Shifter Rod.
1. See Left Foot Support Bracket (Typical). Remove foot
support bracket.
a. Remove screws (2).
b. Remove foot support bracket (1).
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 foot support bracket.
a. Apply threadlocker to screws (2).
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-97)
b. Install foot support bracket (1).
c. Install screws. Tighten.
Torque: 54.2-61 N·m (40-45 ft-lbs) Foot support
bracket screws
1
Foot support bracket
2
Screw (2)
Figure 1. Left Foot Support Bracket (Typical)
Special Tools
Description
Part Number
Qty.
E-CLIP TOOL
HD-52369
1
Consumables
Description
Part Number
Size
LOCTITE 243 MEDIUM STRENGTH
99642-97
6 ml (¼ fl oz)
THREADLOCKER AND SEALANT
(BLUE)
Disassemble
1. See Figure 1. Remove shift lever bracket.
a. Remove screws (3).
b. Remove shift lever bracket (2).
c. Inspect O-rings (1) for damage, replace if
necessary.
2. See Figure 2. Remove wear peg (6), if equipped.
3. Remove footboard.
NOTE
Be careful when removing E-clip, use E-clip tool to
help prevent damage to painted surfaces.
a. Remove E-clip (5).
Special Tool: E-CLIP TOOL (HD-52369)
b. Remove clevis pin (2).
c. Remove torsion spring (4).
d. Remove footboard (3).
Assemble
1. See Figure 2. Install footboard.
a. Insert short leg of torsion spring (4) in hole in
footboard (3).
b. Position footboard and torsion spring on foot
support bracket (1).
c. Install clevis pin (2).
NOTE
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