Harley Davidson 2018 softail models. Service manual — page 9
1. FLDE, FLHC, FLHCS, FLHCS ANV: Remove front light
bar. SeePrepare
2. Remove headlamp. See Bulb Replacement: Standard
Round
3. Remove handlebar. See Prepare.
4. Support front of motorcycle enough to take weight off of
front tire without lifting. See Secure the Motorcycle for
Service.
Upper Fork Bracket
1. See Fork Clamp Components (Typical). Remove
upper fork bracket assembly.
a. Loosen fork stem pinch bolt (4).
b. Remove fork stem screw (1) and washer (2).
c. Remove upper fork bracket (3).
Lower Fork Bracket
1. Secure lower fork bracket to frame.
2. Remove upper fork bracket.
3. Remove front fork. See Check For Oil Leak.
4. Remove fork stem and lower fork bracket assembly (10)
from steering head.
Special Tools
Description
Part Number
Qty.
UNIVERSAL DRIVER HANDLE
HD-33416
1
STEERING HEAD BEARING RACE
HD-39301-A
1
REMOVER
1. Clean all parts.
2. Inspect fork stem and upper and lower brackets. Replace
as necessary.
NOTICE
Replace both bearing assemblies even if one
assembly appears to be good. Mismatched
bearings can lead to excessive wear and premature
replacement. (00532c)
3. Inspect bearings for the following conditions:
Pitting
Wear
Scoring
Replace as necessary.
4. Inspect bearing cups. Replace as necessary
a. Remove bearing cups from steering head using STEERING HEAD BEARING RACE REMOVER (Part
Number:HD-39301-A) and UNIVERSAL DRIVER HANDLE (Part Number:HD-33416).
b. Install new steering head bearing cups.
Consumables
Description
Part Number
Size
SPECIAL PURPOSE GREASE
99857-97A
414 ml (14 fl oz)
WARNING
Properly seat bearing cups in steering head bore. Improper seating can loosen fork stem bearings adversely affecting
stability and handling, which could result in death or serious injury. (00302a)
WARNING
Properly adjust fork stem bearings. Improper adjustments can adversely affect stability and handling, which could
result in death or serious injury. (00301c)
Lower Fork Bracket
1. See Figure 1. Install front fork stem and lower fork bracket assembly.
a. Install new dust seal (6) over fork stem and lower fork bracket assembly (10).
b. Apply SPECIAL PURPOSE GREASE (99857-97A) to lower steering head bearing (7).
c. Install lower steering head bearing.
d. Install fork stem through steering head.
e. Apply SPECIAL PURPOSE GREASE (99857-97A) to upper steering head bearing.
f. Install upper steering head bearing and new dust seal (6).
2. Install upper fork bracket (3).
Upper Fork Bracket
1. See Figure 1. Install upper fork bracket (3) assembly.
a. Install washer (2) and fork stem screw (1). Tighten.
Torque: 18.1-19 N·m (160-168 in-lbs) Fork stem
screw, first torque
b. Loosen fork stem screw.
Angle: 45°
c. Final tighten fork stem screw. Tighten.
Torque: 7-7.6 N·m (62-67 in-lbs) Fork stem screw,
final torque
d. Tighten fork stem pinch bolt (4).
Torque: 21.7-27.1 N·m (16-20 ft-lbs) Fork stem
pinch bolt
1
Fork stem screw
2
Washer
3
Upper fork bracket
4
Fork Stem Pinch Bolt
5
Upper fork clamp pinch bolt (2)
6
Dust seal (2)
7
Steering head bearing (2)
8
Bearing cup (2)
9
Lower fork bracket pinch bolt (2) [FLSL, FXBR,
FXBRS, FXFB, FXFBS (4)]
10
Fork stem and lower fork bracket assembly
11
Fork stem retaining ring
Figure 1. Fork Clamp Components (Typical)
1. Install front fork. See Check For Oil Leak.
2. Install handlebar. See Prepare.
3. Install headlamp. See Bulb Replacement: Standard
Round
4. FLDE, FLHC, FLHCS, FLHCS ANV: Install front light bar.
See Prepare
5. Adjust steering head bearings. See Prepare.
1. Remove left side cover. See Remove.
2. Remove main fuse. See Main Fuse.
3. Remove seat. See Remove.
4. Remove fuel tank. See Prepare.
5. Remove frame plug and front electrical caddy. See
Prepare.
1. Turn forks to full right position.
2.
NOTE
Fork lock mounting screw has left handed threads.
Remove fork lock mounting screw through hole in lower
fork clamp.
3. See Fork Lock Location. Remove fork lock (1) and
gasket (2).
1. Turn handlebars to full right position, aligning hole in lower
fork clamp with mounting hole for fork lock fastener.
2.
NOTE
Fork lock needs to be in the retracted/unlocked
position for installation.
See Figure 1. Place fork lock and gasket in position.
3. Install fork lock mounting screw. Tighten.
Torque: 6.1-8.9 N·m (54-79 in-lbs)
1
Fork lock
2
Gasket
Figure 1. Fork Lock Location
1. Verify proper operation of fork lock.
2. Install electrical caddy and frame plug. See Prepare.
3. Install fuel tank. See Prepare.
4. Install seat. See Remove.
5. Install main fuse. See Main Fuse.
6. Install left side cover. See Remove.
1. Remove main fuse. See Main Fuse.
2. Remove saddlebags, if equipped. See Remove and
Install: Standard.
3. Remove mufflers and exhaust bracket. See Prepare.
4. Remove rear wheel. See Prepare.
5. Remove lower shock screw. See Prepare.
6. Remove belt guards. See Prepare.
7. See Rear Fork. Remove splash guard.
a. Remove screw (1).
b. Pull the bottom of splash guard (2) out and down and
remove.
8. Remove brake line P-clip (8).
9. Remove screws (5) and belt slot spacer (4).
1. See Rear Fork Assembly. Remove rear fork.
a. Support rear of transmission and frame.
b. Support rear fork (3).
c. Loosen pinch bolt (8).
d. Remove nut (7).
e. Remove pivot shaft (9) and spacer (6).
f.
Remove rear fork.
1.
See Rear Fork Assembly. Install splash guard.
a. Place the bottom tabs on splash guard (2) into the
slots on rear fork (3).
b. Slightly bend the splash guard top mounting tabs and
push the top onto the stubs (14) protruding from the
fork.
c. Install washer (13) and screw (1). Tighten.
Torque: 4-5 N·m (35-44 in-lbs) Splash guard screw
2.
Install rear fork.
a.
Align rear fork (3) with frame.
b.
See Rear Fork. Lift top of drive belt (9). Install pivot
shaft through right side of frame, rear fork (3),
transmission fork mount, drive belt, spacer (6) and
left side of frame.
c.
Install pivot shaft nut (7). Tighten.
Torque: 34-41 N·m (25-30 ft-lbs) Rear fork pivot
shaft nut, first torque
d.
Back off pivot shaft nut.
Angle: 90°
e.
Tighten pivot shaft nut.
Torque: 0.1-5.4 N·m (1-48 in-lbs) Rear fork pivot
shaft nut, second torque
f.
Install lower shock bolt. See Prepare.
NOTE
Verify spacer (6) does not have lateral play.
g.
Position belt slot spacer (4) in the center of the drive
belt and between frame and fork.
h.
Install drive belt slot spacer screws (5). Tighten.
Torque: 68-75 N·m (50-55 ft-lbs) Drive belt slot
spacer screw, first torque
i.
Loosen drive belt slot spacer screws.
Angle: 90°
j.
Tighten drive belt slot spacer screws.
Torque: 88-95 N·m (65-70 ft-lbs) Drive belt slot
spacer screw, final torque
k.
Place drive belt on sprocket and install rear wheel.
See Prepare.
NOTE
Adjust the belt tension after the drive belt slot
spacer screws have been torqued to final
specifications and before the pivot shaft nut has
been torqued to final specifications.
l.
Tighten pivot shaft nut (7).
Torque: 209-230 N·m (154-170 ft-lbs) Rear fork
pivot shaft nut, third torque
m. Back off pivot shaft nut.
Angle: 90°
n. Tighten pivot shaft nut.
Torque: 209-230 N·m (154-170 ft-lbs) Rear fork
pivot shaft nut, final torque
NOTE
After final torque of pivot shaft nut there will still
be a slight gap between the right side bearing
and rear fork.
o. See Rear Fork Assembly. Tighten pivot shaft pinch
bolt (8).
Torque: 24-27 N·m (18-20 ft-lbs) Rear fork pivot
shaft pinch bolt
NOTE
Verify spacer (6) does not have lateral play.
Rear Fork1Splash guard screw2Splash guard3Rear fork4Belt slot spacer5Belt slot spacer screw (2)6Spacer7Pivot shaft
nut8P-clip9Drive beltRear Fork Assembly1Splash guard screw2Splash guard3Rear fork4Belt slot spacer5Belt slot spacer
screw (2)6Spacer7Pivot shaft nut8Pivot shaft pinch bolt9Pivot shaft10Retaining ring (2)11Bearing (2)12Adjusting screw
(2)13Washer14Splash guard stubs (2)
Special Tools
Description
Part Number
Qty.
BEARING REMOVER/INSTALLER
HD-46281
1
TOOL
1. See Removing Rear Fork Bearings. Remove bearings
from rear fork using.
Special Tool: BEARING REMOVER/INSTALLER TOOL
(HD-46281)
NOTE
Remove bearings only if replacement is required.
2. See Rear Fork Bearings. Remove adjusting screws (1).
1. See Rear Fork Bearings. Clean all components in
solvent.
2. Dry parts with low-pressure, compressed air.
3. Carefully inspect bearings (2) for wear and/or corrosion.
Replace or repair as necessary.
4. Verify that the bearing retaining rings (3) are not bent or
damaged. Replace or repair as necessary.
5. If the bearings were removed, clean the bearing bores (4)
with a clean shop towel, removing any dirt or grit adhering
to the bearing surface.
6. Rough check rear fork (5) for correct alignment or
damage. Replace if bent or damaged.
7. Clean threads on adjustment screws (1) and adjusting
screw holes.
1. See Rear Fork Bearings. Install adjusting screw.
a. Inspect condition of adjusting screws (1) and replace
if necessary.
b. Install adjusting screws.
2. See Rear Fork Bearings. Install bearings.
a. Install new retaining rings (3) onto grooves on new
bearings (2) if removed.
b. See Installing Rear Fork Bearings. Position left
bearing squarely on left bearing bore.
c. Press left bearing into fork bearing bore until retaining
ring bottoms out.
d. Position right bearing on right bearing bore.
e. See Rear Fork Bearing Gap. Press right bearing into
fork bearing bore leaving a gap.
Length: 1.47-3.2 mm (0.06-0.13 in)
1
Rear fork
2
Bearing boss
3
Press
4
Handle
5
Pilot
6
Receiver cup
Figure 1. Removing Rear Fork Bearings
1
Adjusting screw (2)
2
Bearing (2)
3
Retainer ring (2)
4
Bearing bore (2)
5
Rear fork
Figure 2. Rear Fork Bearings
1
Rear fork
2
Bearing boss
3
Press
4
Handle
5
Pilot
6
Bearing
7
Receiver cup
Figure 3. Installing Rear Fork Bearings
1
Right side bearing
2
Left side bearing
3
Gap
Figure 4. Rear Fork Bearing Gap
1. See Rear Fork. Install brake line P-clip (8).
2. Install belt guards. See Prepare.
3. Install mufflers and exhaust bracket. See Prepare.
4. Install saddlebags if equipped. SeeRemove and Install:
Standard.
5. Install main fuse. See Main Fuse.
1. Remove main fuse. See Main Fuse.
2. Remove saddlebag, if equipped. See Remove and
Install: Standard.
1. See Belt Guards. Remove upper guard.
a.
Remove screw (5) and nut.
b.
Remove screw (4).
c.
Remove upper guard (6).
2. Remove lower guard.
a. Remove screw (1) and docking bracket (2) if
equipped.
b. Remove screws (3).
c. Remove lower belt guard (7) through opening in rear
fork.
Consumables
Description
Part Number
Size
LOCTITE 243 MEDIUM STRENGTH
99642-97
6 ml (¼ fl oz)
THREADLOCKER AND SEALANT
(BLUE)
1.
See Belt Guards. Install lower belt guard.
a. Guide lower guard (7) through rear fork.
b. Place lower guard in position.
c. Apply threadlock to screw (3).
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
(99642-97)
d. Install screws. Tighten.
Torque: 8-9 N·m (71-80 in-lbs) Lower belt guard
screw
2.
Install upper guard.
a. Place upper guard (6) in position.
b. Apply threadlock to screw (4).
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
(99642-97)
c. Install screw. Tighten.
Torque: 8-9 N·m (71-80 in-lbs) Upper belt guard
screw
d. Apply threadlock to screw (5).
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
(99642-97)
e. Install screw and nut. Tighten.
Torque: 8-9 N·m (71-80 in-lbs) Upper belt guard
screw
3.
Install docking bracket, if equipped.
a. Apply threadlock to screw (1).
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
(99642-97)
b. Position docking bracket (2) on frame and install
screw. Tighten.
Torque: 52-64 N·m (38-47 ft-lbs) Saddle bag docking
bracket screw
1
Screw
2
Docking bracket
3
Screw (2)
4
Screw
5
Screw
6
Upper guard
7
Lower guard
Figure 1. Belt Guards
1. Install saddlebag, if equipped. SeeRemove and Install:
Standard.
1. Install main fuse. See Main Fuse.
1. Disconnect negative battery cable. See Main Fuse.
2. Remove seat. See Remove.
3. Remove fender if needed. See Prepare.
4. Models with top mounted shock adjuster under the seat.
See Top Mounted Shock Adjuster. Remove cable tie
(2) from shock adjuster hose to fender harness.
5. Remove frame crossmember. See Prepare.
6. Models with side mounted shock adjuster.
a. Remove right side cover. See Remove.
b. Remove battery strap. See Prepare.
7. Using a suitable lift, support frame and raise slightly to
relieve pressure on the shock screw.
1. See Side Mounted Shock Adjuster. Remove shock
adjuster from bracket on models equipped with side
mounted shock adjuster.
a. Remove clip from ABS bracket (4).
b. Remove screw (2) and washer (1).
c. Set side mounted shock adjuster (3) to the side, being
careful not to damage oil line.
2. See Rear Shocks. Remove rear shock.
a. Remove screw (6).
b. Loosen pinch bolt (4).
c. Remove screw (5).
d. Remove rear shock (1, 2 or 3), depending on the
model.
1. Inspect shock absorber for signs of leakage. Replace shock absorber if a leak is found.
2. Inspect bushings for cracks and wear. Replace as necessary.
Consumables
Description
Part Number
Size
LOCTITE 243 MEDIUM STRENGTH
99642-97
6 ml (¼ fl oz)
THREADLOCKER AND SEALANT
(BLUE)
1.
See Side Mounted Shock Adjuster. Install shock
adjuster on bracket on models equipped with side
mounted adjuster.
a. Route side mounted shock adjuster (3) in front of the
battery tray.
b. Position side mounted shock adjuster on mounting
bracket.
c. Install washer (1) and screw (2). Tighten.
Torque: 6.1-8.27 N·m (54-73 in-lbs) Side mounted
shock adjuster screw
d. Insert shock adjuster hose clip onto the ABS bracket
(4).
2.
See Rear Shocks. Install rear shock.
a. Place rear shock (1, 2 or 3) in position.
b. Apply threadlocker to screws (5, 6) and bolt (4).
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
(99642-97)
c. Install screw (5).
Torque: 94.9-101.68 N·m (70-75 ft-lbs) Lower shock
screw
d. Tighten bolt (4).
Torque: 16.26-20.33 N·m (12-15 ft-lbs) Shock pinch
bolt
e. Raise or lower frame until eyelet of the shock aligns
with the hole in frame (8).
f. Install screw (6). Tighten.
Torque: 108.4-122 N·m (80-90 ft-lbs) Upper shock
screw
Top Mounted Shock Adjuster1Top mounted shock adjuster2Cable tie
1
Washer
2
Screw
3
Side mounted shock adjuster
4
ABS bracket
Figure 2. Side Mounted Shock Adjuster
1
Shock, side mounted adjuster
2
Shock, top mounted adjuster
3
Shock, cam adjustable
4
Pinch bolt
5
Lower shock screw
6
Upper shock screw
7
Rear fork
8
Frame
Figure 3. Rear Shocks
Consumables
Description
Part Number
Size
ANTI-SEIZE LUBRICANT
98960-97
29.6 ml (1 fl oz)
The rear shock absorbers contain no serviceable parts except an adjustment knob and hardware kit.
Remove shock adjuster knob.
1. See Rear Shock Adjuster Knob. Remove shock
adjuster knob (1).
a. Remove screw (3) and washer (2).
b. Hold a rag wrapped around the adjuster housing
and knob to prevent loss of the detent ball (4) and
spring (5). Carefully remove the knob.
c. Remove detent ball and spring.
Install shock adjuster knob.
1. See Rear Shock Adjuster Knob. Install shock adjuster
knob (1).
a. Press and hold detent ball (4) onto end of spring
(5). Install knob on adjuster housing.
NOTE
Before mounting the knob apply a light coat of
ANTI-SEIZE LUBRICANT to the knob mount
shaft. ANTI-SEIZE LUBRICANT (98960-97)
b. Install washer (2) and screw (3). Tighten securely.
c. Rotate knob to verify that the detent is properly
assembled. Clicks are heard every half rotation.
1
Knob
2
Washer
3
Screw
4
Detent ball
5
Spring
Figure 1. Rear Shock Adjuster Knob
1. Lower lift.
2. See Side Mounted Shock Adjuster. Models with side
mounted shock adjuster.
a. Install battery strap. See Prepare.
b. Install right side cover. See Remove.
3. See Top Mounted Shock Adjuster. Models with top
mounted shock adjuster (1). Install cable tie (2).
4. Install frame crossmember. See Prepare.
5. Install seat. See Remove.
6. Install main fuse. SeeMain Fuse.
7. Adjust shock absorber. See Adjust Shock Absorber.
1. Remove main fuse. See Main Fuse.
Clutch Cable Disconnect
NOTE
The two cable halves should only be taken apart if replacing the upper clutch cable or housing. Otherwise
disconnect at clutch lever and leave two halves assembled.
1.
See Figure 1. Access two piece clutch cable.
a.
Remove spring clips (1).
b.
Slide cover (2) up.
2.
See Figure 2. Identify upper clutch cable (1) and red
lock button (2).
3.
NOTE
Inspect lock button (2). Replace if damaged.
See Figure 3. Unlock upper clutch cable (1).
a. Place flat side of screwdriver (3) on tab of lock
button (2).
b. Push tab slightly inboard and then down to
disengage.
4.
Fully collapse cable (spring compressed) and push
button in.
5.
See Figure 4. Lift locking tab (1) from swaged ball end
(2).
6.
See Figure 5. Push swaged ball end (2) out from
coupler from opposite side and slightly pull clutch lever
in until locking tab is at top of window. Remove swaged
ball end from coupler (1).
7.
See Figure 6. Pry flex fingers (3) open and slide lower
clutch cable (2) from housing (1).
1
Clip
2
Cover
Figure 1. Clutch Cover and Clip
1
Upper clutch cable
2
Lock button
Figure 2. Lock Button
1
Upper clutch cable
2
Lock button
3
Screwdriver
Figure 3. Compressed Upper Clutch Cable
1
Locking tab (2)
2
Swaged ball end
Figure 4. Retaining Clips
1
Coupler
2
Swaged ball end
Figure 5. Coupler Disengagement
1
Housing
2
Lower clutch cable
3
Flex fingers
Figure 6. Lower Clutch Cable
Clutch Cable: Lower End
1. Remove clutch cable.
a. Disconnect clutch cable at release cover. See
Prepare.
b. Disconnect clutch cable. See Clutch Cable
Disconnect in this section.
Clutch Cable: Upper End
1. See Figure 7. Remove clutch cable.
a. Remove retaining ring (7).
b. Remove pivot pin (3).
c. Remove clutch hand lever (6).
d. Remove pin (5).
e. Remove clutch cable (8).
f. Disconnect clutch cable. See Clutch Cable
Disconnect in this section.
Clutch Hand Control
1. See Figure 7. Remove clutch hand control assembly.
a. Remove screws (1) and washers (2).
b. Remove lever bracket clamp (9).
c. Remove hand lever bracket (4).
1
Screw (2)
2
Washer (2)
3
Pivot pin
Большое спасибо!
Ваше мнение очень важно для нас.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст