Harley Davidson Softail 2000-2005. Service manual — page 42

e. Push the lens cap into the housing until is snaps into

place.

Passing Light Adjustment
(2005 FLSTN Domestic Models Only)

1. Check the headlight aim and adjust if necessary. Refer
to Chapter Eight.

2. Park the motorcycle on a level surface approximately
25 ft. (7.6 m) from the wall.

3. Check tire inflation pressure. Readjust it if necessary,
as described in Chapter Three.

4. Have an assistant (with the same approximate weight
as the vehicle’s owner) sit on the seat.

5. Draw a horizontal line on the wall the same height as
the center of the headlight (Figure 69).

6. Aim the headlight at the wall. Switch the headlight to
the HIGH beam. Point the front wheel straight ahead.

7. Check the headlight beam alignment. The broad, flat
pattern of light (main beam of light) must be centered on
the horizontal line with an equal area of light above and
below line. Mark this location on the wall (A, Figure 70).

8. Turn off the headlight.

9. Measure the distance from the horizontal centerline of
the headlight to the horizontal centerline of the left side
passing light. Note the dimension.

10. Measure the distance from the headlight vertical cen-
terline out to the vertical centerline of the passing light.
Note the dimension.

2004-2005 MODEL SERVICE INFORMATION

581

15

70

69

25 ft.

(7.6 m)

11. Repeat Steps 9 and 10 for the right side passing light.
Note both dimensions.
12. Refer to the dimensions take in Steps 9-11 and mark
these locations on the wall. Refer to B and C, Figure 69.
13. Have the same assistant used in Step 4, sit on the seat
and turn the headlight to HIGH beam. Verify that the
headlight beam is still correctly aligned with the vertical
and horizontal centerlines on the wall.
14. Turn the headlight to LOW beam.
15. Completely cover the headlight and the right side
passing light so their beam is not visible on the wall.
16. Observe the location of the left side passing light on
the wall. It should be within the area indicated in D, Fig-
ure 69. If the location is incorrect perform Step 20.
17. Remove the cover from the right side passing light
and place it over the left side passing light.
18. Leave the headlight on LOW beam and still covered
so their beam is not visible on the wall.
19. Observe the location of the right side passing light on
the wall. It should be within the area indicated in E, Fig-
ure 69. If the location is incorrect perform Step 20.
20. Adjust the passing lamp as follows:

a. Turn off the headlight and passing lights.
b. Loosen the screw at the base of the trim ring (13,

Figure 66) and remove the trim bezel from the pass-
ing light housing.

c. Carefully pull the sealed beam unit partially out of

the housing.

d. Loosen the nut securing the housing.
e. Move the housing in the desired direction to correct

the aim.

f. Reinstall the sealed beam unit and trim bezel. Se-

curely tighten the clamping screw.

g. Recheck alignment and repeat if necessary.

Front and Rear Turn Signal Bulb Replacement
(All Models Except FLSTC)

1. Locate the notch at the base of the lens, insert a coil and
carefully twist the coin until the lens pops off the base (A,
Figure 68).
2. Push in on the bulb (B, Figure 68), rotate it counter-
clockwise and remove it.
3. Install a new bulb and lens.
4. Push in on the lens and make sure it snaps into place
around the entire perimeter.

Front Turn Signal Replacement
(FLSTSC, FLSTFSE, FXSTS
and FXSTDSE2 Models)

Refer to Figure 71.

582

SUPPLEMENT

71

FRONT TURN SIGNAL

(FLSTSC, FLSTFSE, FXSTS AND FXSTDSE2 MODELS)

1. Set screw
2. Ball stud
3. Mounting bracket
4. Jam nut
5. Star lockwasher

6. Acorn nut
7. Housing
8. Socket assembly
9. Bulb

10. Lens

1. Support the motorcycle with the front wheel off the
ground. See

Motorcycle Stands

in Chapter Nine.

2. Remove the fuel tank as described in this Supplement.
3. Follow each front turn signal wiring harness to the
main wiring harness. Disconnect the two-pin electrical
connector for each front turn signal assembly.
4. Remove the mirror and front turn signal assembly as
follows:

a. Loosen the acorn nut securing the mirror and turn

signal mounting bracket.

b. Hold onto the turn signal assembly and remove the

Acorn nut, toothed lockwasher and washer.

c. Remove the mirror from the master cylinder and the

turn signal mounting bracket. Remove the mirror.

d. Remove the turn signal assembly.

5. Repeat Step 4 for the other mirror and turn signal as-
semblies.

Front Turn Signal Replacement
(All Models Except FLSTSC, FLSTFSE, FXSTS,
FXSTDSE2 and FLSTN)

Refer to Figure 72 and Figure 73.

1. Support the motorcycle with the front wheel off the
ground. See

Motorcycle Stands

in Chapter Nine.

2. Remove the fuel tank as described in this Supplement.
3. Follow each front turn signal wiring harness to the
main wiring harness. Disconnect the two-pin electrical
connector for each front turn signal assembly.
4A. On FXSTB models remove the mirror and front turn
signal assembly as follows:

a. Remove the screws securing the outer portion of the

mounting clamp. Remove the outer clamp and the
turn signal assembly from the front fork.

b. If necessary, secure the jam nut and remove the bolt

securing the inner clamp to the standoff.

c. If necessary, loosen the jam nut from the standoff

and remove the assembly from the case.

4B. On FXST, FXSTD, FXSTDSE2, FLSTF, FLSTFSE
models, remove the mirror and front turn signal assembly
as follows:

a. On the right side, secure the retainer and unscrew

the ball stud clamp. Remove the turn signal assem-
bly.

b. On the left side, remove the Acorn nut and washer

and remove the mirror.

2004-2005 MODEL SERVICE INFORMATION

583

15

72

FRONT TURN SIGNAL

(FXSTB MODELS)

1. Mounting clamp assembly
2. Bolt
3. Screw
4. Stand off
5. Jam nut
6. Housing
7. Socket assembly
8. Bulb
9. Lens

c. On the left side, secure the retainer and unscrew the

ball stud clamp.

d. Remove the turn signal assembly

5. Repeat Step 4 for the other mirror and turn signal as-
semblies.

Taillight/Brake Light Replacement
(2005 FLSTN and FLSTSC Models)

The bulb replacement procedure is identical to the

FLSTS Models

in Chapter Eight.

SWITCHES

Ignition/Light Switch Removal/Installation
(FLSTFSE Models)

Refer to Figure 74.

1. Remove the seat.

NOTE

Always disarm the optional TSSM security
system prior to disconnecting the battery or
the siren will sound.

2. Disconnect the negative battery cable as described in
Chapter Eight.

3. Remove the fuel tank console as described in this Sup-
plement.

4. Turn the fuel tank console over onto towels on the
workbench.

5. Remove the screws securing the ignition switch to the
bottom surface of the fuel tank console.

6. Remove the ignition switch noting the orientation
within the console.

7. Install the new ignition switch with the electrical con-
nector terminal facing toward the rear of the fuel console.
Tighten the screws securely.

8. Installation is the reverse of removal.

584

SUPPLEMENT

73

FRONT TURN SIGNAL

(FXST, FXSTD, FXSTDSE2, FLSTF AND FLSTFSE MODELS)

1. Mounting clamp assembly
2. Retainer (right side)
3. Ball stud clamp (left side)
4. Ball stud
5. Jam nut
6. Housing
7. Socket assembly
8. Bulb
9. Lens

SPEEDOMETER AND INDICATOR LIGHTS

(FLSTFSE MODELS)

Removal/Installation

Refer to Figure 74.

1. Remove the seat.

NOTE

Always disarm the optional TSSM security
system prior to disconnecting the battery or
the siren will sound.

2. Disconnect the negative battery cable as described in
Chapter Eight.

2004-2005 MODEL SERVICE INFORMATION

585

15

74

FUEL TANK CONSOLE

(FLSTFSE MODELS)

1. Trim bezel
2. Seal ring
3. Speedometer
4. Acorn nut
5. Washer
6. Rubber boot
7. Fuel tank console
8. Screw
9. Ignition switch

10. Bezel
11. Indicator lamp assembly
12. Mounting clamp
13. Trim panel
14. Bolt

3. Remove the fuel tank console as described in this Sup-
plement.
4. Turn the fuel tank console over onto towels on the
workbench.
5. If still in place, remove the rubber boot from the reset
switch, then remove the nut securing the reset switch from
the side of the fuel tank console.
6. Unhook the retaining clip securing the indicator lamp
wire to the backside of the speedometer.
7. Remove the screws securing the speedometer to the
console.
8. Remove the speedometer, seal ring and trim bezel from
the console.
9. To remove the indictor light assembly, remove the
screws and mounting bracket from the backside of the
console and remove it from the fuel tank console.
10. Installation is the reverse of removal.

TACHOMETER

(FXSTDSE2 AND FLSTFSE MODELS)

Removal/Installation and
Illumination Bulb Replacement

Refer to Figure 75.

1. Disconnect the negative battery cable as described in
Chapter Eight.
2. Remove the screw securing the cover to the base of the
tachometer.
3. Label each wire and terminal, then remove the nuts
and star washers securing the wiring terminals to the base
of the tachometer.
4. Carefully push tachometer out of the mounting bracket
on the handlebar upper clamp.
5. To replace the illumination bulb, use a flat bladed
screwdriver and carefully remove the bulb from the ta-
chometer base (Figure 76). Install a new bulb and press it
into place.
6. Install by reversing these removal steps. Make sure to
use the star washers when securing the wiring terminals to
the tachometer. Tighten the nuts securely.

586

SUPPLEMENT

Table 17 ELECTRICAL SYSTEM TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N•m

Starter jackshaft bolt (2005 models)

–

60-80

7-9

75

TACHOMETER

(FXSTDSE2 AND

FLSTFSE MODELS)

1. Tachometer
2. Wire guide
3. Cover
4. Screw

76

CHAPTER NINE

WHEEL, HUBS AND TIRES

FRONT WHEEL

Removal
(FLSTFSE Models)

Refer to Figure 77.

1. Support the motorcycle with the front wheel off the
ground. See

Motorcycle Stands

in Chapter Nine.

2. Remove the caliper mounting bolts and remove the
caliper from each side as described in Chapter Thirteen.

NOTE

Place a plastic or wooden spacer between
the brake pads in place of the disc. Then, if
the brake lever is inadvertently applied, the
pistons will not be forced out of the calipers.
If the pistons are forced out, disassemble the
calipers to reseat the pistons.

3. Remove the set screw securing the front axle cover and
remove the cover from each side.

4. On the left side, remove the axle nut, lockwasher and
washer.

5. On the right side, loosen the fork slider axle clamp
nuts.

6. Prior to removing the front axle, note the location of
the right side spacer and left side spacer. The spacers are
not symmetrical and must be reinstalled on the correct
sides during installation. The spacers are marked R or L.

7. On the right side, withdraw the front axle from the fork
sliders and front wheel.

8. Pull the wheel away from the fork sliders and remove
it.

9. Remove the spacers from the right side and the left side
of the wheel hub.

CAUTION

Do not set the wheel down on the brake disc
surface, as it may be damaged.

10. Inspect the front wheel assembly as described in
Chapter Nine.

Installation

1. Clean the axle in solvent and dry it thoroughly. Make
sure the axle bearing surfaces on both fork sliders and the
axle are free of burrs and nicks.
2. If removed, install the lockwasher and axle nut onto
the right side of the axle. Secure the axle in a vise with soft
jaws and tighten the axle nut to 50-55 ft.-lb. (68-75 N•m).
3. Apply an antiseize lubricant to the axle shaft prior to
installation.
4. If the oil seals or bearings were replaced, check the
front axle spacer alignment as described under

Front Hub

in Chapter Nine.
5. Install the right and the left side spacers onto the cor-
rect side of the wheel.
6. Install the wheel between the fork sliders and install
the axle from the right side. Push the front axle through
the right side fork, spacer, hub, left side spacer and left
side fork.
7. Make sure axle spacers are installed correctly.
8. Install the washer, lockwasher and the

left side

axle nut

finger-tight. Make sure axle spacers are installed cor-
rectly.
9. Secure the right side axle nut and tighten the left side
axle nut to 50-55 ft.-lb. (68-75 N•m).
10. Insert a flat feeler gauge between the right side spacer
and the inner surface of the right side fork slider. The
specified distance of 0.103-0.113 in. (2.62-2.87 mm)
must be maintained in order to center the brake discs with
the calipers.
11. Maintain the specified distance (Step 9) on the right
side fork slider, and tighten the bolts on the fork slider
clamp to 11-18 ft.-lb. (15-24 N•m).
12. Install the axle cover on each side with the set screw
located at the bottom. Apply a medium strength thread
lock to the set screws and tighten to 6-8 in.-lb. (0.7–0.9
N•m).
13. Install both front brake calipers as described in Chap-
ter Thirteen.
14. With the front wheel off the ground, rotate it several
times and apply the front brake to seat the brake pads
against the discs.

2004-2005 MODEL SERVICE INFORMATION

587

15

15. Remove the stand and lower the front wheel to the
ground.

Removal/Installation
(FLSTF Models)

Refer to

Front Wheel Removal and Installation

(Non-Springer Fork Models)

in Chapter Nine and to Fig-

ure 78.

REAR WHEEL

(FXSTDSE2 AND FLSTFSE MODELS)

Refer to Figure 79 and Figure 80.

Removal

1. Remove the right side passenger foot peg.
2. Remove both mufflers as described in Chapter Seven.
3. Remove the screws and washers and remove the rear
axle chrome cover from each side.

588

SUPPLEMENT

77

FRONT WHEEL

(FXSTDSE2 MODELS)

1. Cover
2. Nut
3. Lockwasher
4. Axle
5. Spacer
6. Bolt

7. Brake disc
8. Bearing
9. Spacer sleeve

10. Cast wheel
11. Valve stem
12. Valve stem cap

13. Balance weight
14. Bearing
15. Brake disc
16. Spacer
17. Lockwasher

4. On the left side, remove the spring clip and loosen the
axle castellated nut.
5. Support the motorcycle with an appropriate size jack
with the rear wheel off the ground.
6. Remove the bolts securing the drive belt guard and the
debris deflector. Remove the belt guard and the deflector.

NOTE

Prior to removing the castellated nut, mark
the wheel bearing spacers and adjustment
collars with R (right side) or L (left side).
The spacers are unique and must be rein-

stalled onto the correct side of the wheel
during installation. The adjustment collars
are symmetrical.

NOTE

The cover brackets are labeled with R (right
side) or L (left side). The left side bracket is
deeper and must be installed on the correct
side.

7. On the left side, remove the axle castellated nut,
washer, adjustment collar and cover bracket.

2004-2005 MODEL SERVICE INFORMATION

589

15

78

FRONT WHEEL

(FLSTFSE MODELS)

1. Cover
2. Set screw
3. Axle
4. Spacer
5. Bearing
6. Cover
7. Bolt
8. Spacer sleeve
9. Cast wheel

10. Balance weight

11. Valve stem cap
12. Valve stem nut
13. Valve stem
14. Bearing
15. Brake disc
16. Spacer
17. Washer
18. Lockwasher
19. Nut
20. Bolt

590

SUPPLEMENT

79

REAR WHEEL

(FXSTDSE2 MODELS)

1. Spacer sleeve
2. Bearing
3. Sprocket spacer
4. Driven sprocket
5. Spacer (left side)
6. Cover bracket
7. Adjustment collar
8. Washer
9. Castellated nut

10. Clip
11. Chrome cover
12. Washer
13. Bolt
14. Cap

15. Cover bracket
16. Spacer (right side)
17. Brake disc
18. Bolt
19. Cast wheel
20. Screw
21. Nut
22. Jam nut
23. Axle
24. Drive belt adjuster
25. Valve stem
26. Valve stem cap
27. Balance weight

2004-2005 MODEL SERVICE INFORMATION

591

15

80

REAR WHEEL

(FLSTFSE MODELS)

1. Spacer sleeve
2. Bearing
3. Driven sprocket
4. Spacer
5. Cover bracket
6. Adjustment collar
7. Washer
8. Castellated nut
9. Clip

10. Chrome cover
11. Washer
12. Bolt
13. Cap

14. Bolt
15. Brake disc
16. Cast wheel
17. Jam nut
18. Axle
19. Drive belt adjuster
20. Balance weight
21. Nut
22. Screw
23. Washer
24. Valve stem cap
25. Nut
26. Valve stem

8. Remove the rear brake pads as described in Chapter
Thirteen.
9. Loosen the jam nut and completely loosen the drive
belt adjuster on each side of the swing arm to allow maxi-
mum slack in the drive belt.
10. On the left side, use a soft-faced mallet and gently tap
the rear axle toward the right side. Remove the left side
spacer.

NOTE

The rear wheel is heavy and can be difficult
to remove. Check the tire-to-ground clear-
ance before removing the rear axle. If neces-
sary, have an assistant help in the removal.

11. From the right side, withdraw the rear axle while
holding onto the rear wheel. The right side spacer will
usually fall off at this time. Lower the wheel to the
wooden blocks or the ground.
12. Move the rear wheel forward and lift the drive belt off
the driven sprocket.
13. Lift the rear caliper and move it toward the front of
the motorcycle until the caliper notch clears the tab on the
swing arm. Move the caliper out of the way and secure it
with a Bungee cord.
14. Raise the motorcycle sufficiently to allow the rear
wheel to roll back and clear the rear fender.
15. Remove the rear wheel and lower the motorcycle to a
safe level. The right side cover bracket and adjustment
collar will fall off at this time.

NOTE

Place a plastic or wooden spacer between
the brake pads in place of the disc. Then, if
the brake pedal is inadvertently depressed,
the pistons will not be forced out of the cali-
per. If the pistons are forced out, disassem-
ble the caliper to reseat the pistons.

CAUTION

Do not set the wheel down on the brake disc
surface, as it may be damaged.

16. Install the wheel bearing spacers, adjustment collars
and castellated nut onto the axle in the same order of re-
moval.
17. Inspect the rear wheel as described in Chapter Nine.

Installation

CAUTION

The rear wheel bearing spacer must be in-
stalled onto the correct side of the rear
wheel. If installed incorrectly, the wheel will

be off-set to the wrong side within the swing
arm. This will result in the drive belt being
out of alignment with the driven sprocket re-
sulting in rapid drive belt wear.

1. Remove the wheel bearing spacers, adjustment collars
and nut from the rear axle and keep them in the same or-
der.
2. Clean the axle in solvent and dry it thoroughly. Make
sure the bearing surfaces on the axle are free of burrs and
nicks.
3. Apply an antiseize lubricant to the axle shaft prior to
installation.
4. Raise the motorcycle sufficiently to allow the rear
wheel to roll forward and clear the rear fender.
5. Move the rear caliper into position and onto the locat-
ing tab on the swing arm.
6. Move the rear wheel forward and install the drive belt
onto the driven sprocket.
7. Lower the motorcycle to a level where the rear axle can
be installed.
8. Install the right side adjustment collar and the cover
bracket onto the swing arm receptacle and hold into
place.
9. Move the rear wheel into position and align it with the
swing arm.
10. Move the rear caliper up into position and align it
with the rear axle receptacles in the swing arm.

NOTE

The right side spacer is smaller than the left
side spacer. Install the correct one at this
time.

11. Install the right side spacer onto the wheel and hold it
in place.
12. From the right side, carefully install the rear axle
through the adjustment collar, cover bracket, right side
of the swing arm, rear caliper, right side spacer and rear
hub.
13. Install the left side spacer onto the wheel and hold it
in place.
14. Continue to push the rear axle through the left side
spacer, swing arm, cover bracket and the adjustment col-
lar.
15. Install the washer and the castellated nut. Tighten the
axle nut finger-tight at this time.
16. After the rear axle is installed, make sure both spacers
and adjustment collars are in the correct location and are
still in place. The notch in the adjustment collar must align
with the tip of the drive belt adjuster. Reposition at this
time if incorrect.

592

SUPPLEMENT

17. Install the rear brake pads as described in Chapter
Thirteen.
18. Check drive belt tension and adjustment as described
in Chapter Three.
19. Have an assistant apply the rear brake and tighten the
rear axle nut 60-65 ft.-lb. (81-88 N•m). If necessary,
tighten the rear axle nut to align the nut slot with the axle
spring pin hole. Install the spring pin and snap it into
place.
20. Install the drive belt debris deflector and guard and
tighten the bolts securely.
21. Install the rear axle chrome covers, screws and wash-
ers and tighten the screws to 20-30 in.-lb. (2-3 N•m).
22. Install both mufflers as described in Chapter
Seven.
23. Rotate the wheel several times to make sure it rotates
freely. Then apply the rear brake pedal several times to
seat the pads against the disc.
24. Remove the jack or stand and lower the rear wheel to
the ground.
25. Install both mufflers as described in Chapter
Seven.
26. Install the right side passenger foot peg.

FRONT AND REAR HUBS

(FXSTDSE2 AND FLSTFSE MODELS)

Refer to

Front and Rear Hubs

in Chapter Nine and to

Figure 79 and 80.

DRIVEN SPROCKET ASSEMBLY

(FXSTDSE2 MODELS)

Removal/Installation

Refer to Figure 79.

1. Remove the rear wheel as described in this chapter.
2. Remove the bolts and washers securing the driven
sprocket to the hub
3. Remove the sprocket and the spacer from the rear hub.
4. Position the spacer and the driven sprocket onto the
rear hub.
5. Apply a medium strength thread locking compound to
the bolts prior to installation.
6. Install the bolts and washers and tighten the bolts to
55-60 ft.-lb. (75-81 N•m).
7. Install the rear wheel as described in this chapter.

2004-2005 MODEL SERVICE INFORMATION

593

15

Table 18 WHEEL TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N•m

Driven sprocket bolts

55-60

–

75-81

Front axle nut

50-55

–

68-75

Front axle cover

–

6-8

0.7-0.9

Fork slider clamp bolts

11-18

–

15-24

Rear axle cover

–

20-30

2-3

Rear axle nut

60-65

–

81-85

CHAPTER TEN

FRONT SUSPENSION AND STEERING

(TELESCOPIC FORK)

HANDLEBARS AND RISERS

(FXSTDSE2 AND FLSTFSE MODELS)

Removal/Installation

Refer to Figure 81 and Figure 82.

NOTE

Both switch assemblies will remain with the
handlebar since their wiring harnesses are
located within the handlebar tube.

1. Support the motorcycle with the front wheel off the
ground. See

Motorcycle Stands

in Chapter Nine.

2. Remove the fuel tank as described in this Supplement.
3. Follow each handlebar switch wiring harness, where
they exit the center of the handlebar, to the main wiring
harness. Disconnect the six-pin electrical connector for
each switch assembly.
4. Disconnect the two-pin electrical connector for each
front turn signal assembly.
5. Remove the mirror and front turn signal assembly as
follows:

a. Loosen the acorn nut securing the mirror and turn

signal mounting bracket.

b. Hold onto the turn signal assembly and remove the

acorn nut, toothed lockwasher and washer.

c. Remove the mirror from the master cylinder and the

turn signal mounting bracket. Remove the mirror.

d. Remove the turn signal assembly.

6. Repeat Step 5 for the other mirror and turn signal as-
semblies.

NOTE

Before removing the handlebar, make a
drawing of the throttle cable routing from
the handlebar through the frame. This infor-
mation will help when reinstalling the han-
dlebar and connecting the cables.

7. On the right side of the handlebar, remove the screws
securing the brake master cylinder and remove the master
cylinder. Do not disconnect the hydraulic brake line.

594

SUPPLEMENT

81

FRONT BRAKE HOSE

(FXSTDSE2 MODELS)

1. Bolt
2. Upper mount/

tachometer mount

3. Grommet
4. Handlebar
5. Riser
6. Rear trim panel
7. Rear trim panel

(chrome)

8. Washer
9. Lockwasher

10. Bolt

2004-2005 MODEL SERVICE INFORMATION

595

15

82

HANDLEBAR

(FLSTFSE MODELS)

1. Bolt
2. Upper mount/tachometer mount
3. Handlebar
4. Grommet
5. Riser
6. Washer
7. Rubber bushing
8. Collar
9. Ground strap

10. Bolt

8. On the left side of the handlebar, remove the screws se-
curing the clutch master cylinder and remove the master
cylinder. Do not disconnect the hydraulic brake line.
9. Remove the tachometer from the upper clamp as de-
scribed in this Supplement.
10. Carefully pull back and remove the rear trim panel
from the front chrome trim panel
11. Loosen the clamping bolts securing the upper
clamp/tachometer mount and allow the handlebar to
slowly pivot down until it stops.
12. Remove the two front clamp bolts, then the rear
clamp bolts.
13. Remove the upper clamp/tachometer mount and the
handlebar assembly along with the electrical harness for
both switch assemblies.
14. To remove the lower risers or clamps as an assembly,
remove the bolt, lockwasher and washer on each side se-
curing the assembly to the upper bracket.
15. Install the handlebar by reversing these steps. Note
the following:

a. Check the knurled rings on the handlebar for galling

and bits of aluminum. Clean the knurled section
with a wire brush.

b. Check the handlebar for cracks, bends or other

damage. Replace the handlebar if necessary. Do not
attempt to repair it.

c. Thoroughly clean the upper and lower clamp halves

of all residue.

d. After installing the handlebar, reposition the han-

dlebar while sitting on the motorcycle.

e. Tighten the front clamp bolts first and then the rear

bolts. Tighten to 144-180 in.-lb. (16-20 N•m).

f. If removed, tighten the riser mounting bolts to

30-40 ft.-lb. (41-54 N•m).

g. Adjust the mirrors while sitting on the motorcycle.

FRONT FORK

Removal/Installation
(FXSTDSE2 Models)

The removal and installation is the same as all other mod-

els with the exception of a trim cap on top of the fork tube.
1. Turn the trim cap

counterclockwise

and remove the

trim cap and washer from the fork tube.
2. Install the washer and trim cap and tighten securely.

CHAPTER ELEVEN

FRONT SUSPENSION AND STEERING

(SPRINGER FORK)

STEERING PLAY ADJUSTMENT

A special tool is available for adjusting the steering play. The

Springer Steering Head Bearing Tool (part No. HD-47255) takes the
place of having to fabricate a tool from the bearing retainer (part No.
48306-88) and three roll pins (part No. 614).

596

SUPPLEMENT

Table 19 FRONT FORK OIL CAPACITY AND OIL LEVEL DIMENSION

Model

Capacity (each fork leg)

Oil level dimension

FLSTF, FLSTC, FXST,

FLSTN, FLSTFSE

12.9 U.S. oz. (382 cc)

4.72 in. (119.9 mm)

FXSTB

12.0 U.S. oz. (356 cc)

7.28 in. (184.9 mm)

FXSTD, FXSTDSE2

11.6 U.S. oz. (343 cc)

7.48 in. (189.9 mm)

Table 20 FRONT SUSPENSION TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N•m

Handlebar clamp bolts

–

144-180

16-20

Riser mounting bolts

30-40

–

41-54