Harley Davidson Softail 2000-2005. Service manual — page 38

Inspection

It is not necessary to remove the disc from the wheel to

inspect it. Small nicks and marks on the disc are not im-
portant, but radial scratches deep enough to snag a finger-

nail reduce braking effectiveness and increase brake pad
wear. If these grooves are present, and the brake pads are
wearing rapidly, replace the disc.

The specifications for the standard and wear limits are

in Table 1. Each disc is also marked with the minimum
(MIN) thickness. If the specification marked on the disc
differs from the one in Table 1, use the specification on
the disc.

When servicing the brake discs, do not have the discs

surfaced to compensate for warp. The discs are thin, and
grinding will only reduce their thickness, causing them to
warp rapidly. A warped disc may be caused by the brake
pads dragging on the disc, due to a faulty caliper, and
overheating the disc. Overheating can also be caused by
unequal pad pressure on the disc.

Three main causes of unequal brake pad pressure are:

1. The brake caliper piston seals are worn or damaged.
2. The master cylinder’s small relief port is plugged.
3. The primary cup on the master cylinder piston is worn
or damaged.

NOTE

It is not necessary to remove the wheel to
measure the disc thickness. The measure-
ment can be performed with the wheel in-
stalled or removed from the motorcycle.

4. Measure the thickness of the disc at several locations
around the disc with a vernier caliper or a micrometer
(Figure 146). Replace the disc if the thickness in any area
is less than the MIN dimension on the disc (Figure 147).
5. Make sure the disc mounting bolts are tight prior to
running this check. Check the disc runout with a dial indi-
cator as shown in Figure 148.

NOTE

When checking the front disc, turn the han-
dlebar all the way to one side, then to the
other side.

6. Slowly rotate the wheel and watch the dial indicator. If
the runout exceeds the specification in Table 1, replace
the disc.
7. Clean the disc of any rust or corrosion and wipe it clean
with brake cleaner. Never use an oil-based solvent that
may leave an oil residue on the disc.

Removal/Installation

1. Remove the front or rear wheel as described in Chapter
Nine.
2. Remove the Torx bolts (Figure 149) securing the brake
disc to the hub and remove the disc.

BRAKES

517

13

146

147

148

3. Check the brake disc bolts for thread damage. Replace
worn or damaged fasteners.
4. Check the threaded bolt holes for the brake disc in the wheel
hub for thread damage. True them with a tap if necessary.
5. Clean the disc and the disc mounting surface thoroughly
with brake cleaner. Allow the surfaces to dry before installation.
6. Install the disc onto the wheel hub.
7. Apply a drop of ThreeBond TB1342 or an equivalent to
the threads of

new

Torx bolts prior to installation.

8. Install the bolts and tighten the specification in Table 2.

BLEEDING THE SYSTEM

If air enters the brake system, the brake will feel soft or

spongy and braking pressure will be reduced. Bleed the sys-
tem to remove the air. Air can enter the system if there is a
leak in the system, the brake fluid level in a master cylinder
runs low, a brake line is opened or the brake fluid is replaced.

The brakes can be bled with a brake bleeder or manually.

This section includes procedures for both.

Before bleeding the brake system:

1. Check the brake lines to make sure all fittings are tight.
2. Make sure the caliper piston does not stick or bind in its
bore.
3. Check piston movement in each master cylinder. Operate
the lever or brake pedal, making sure there is no binding or
other abnormal conditions.

Brake Bleeder Process

This procedure uses the Mityvac hydraulic brake bleeding

kit (Figure 150) available from motorcycle or automotive
supply stores and mail order outlets.

NOTE

This procedure is shown on the rear wheel and
relates to the front wheel as well.

1. Remove the dust cap from the caliper bleed valve.
2. Place a clean shop cloth over the caliper to protect it from
accidental brake fluid spills.
3. Open the bleed screw approximately a half turn.
4. Assemble the brake bleeder according to its manufac-
turer’s instructions. Secure it to the caliper bleed valve.
5. Clean the top of the master cylinder of all dirt and debris.
6. Remove the screws securing the master cylinder top
cover, and remove the cover and rubber diaphragm.
7. Fill the reservoir almost to the top with DOT 5 brake
fluid, and reinstall the diaphragm and cover. Leave the cover
in place during this procedure to prevent the entry of dirt.

WARNING

Do not intermix DOT 3, DOT 4, or DOT 5.1
brake fluids as they are not silicone-based.
Non-silicone brake fluid used in these mod-
els can cause brake failure.

8. Operate the pump several times to create a vacuum in the
line (Figure 151, typical). Brake fluid will quickly flow
from the caliper into the pump’s reservoir. Tighten the cali-
per bleed valve before the fluid stops flowing through the
hose. To prevent air from being drawn through the master
cylinder, add fluid to maintain the level at the top of the res-
ervoir.

NOTE

Do not allow the master cylinder reservoir to
empty during the bleeding operation or more
air will enter the system. If this occurs, the
procedure must be repeated.

9. Continue the bleeding process until the fluid drawn from
the caliper is bubble free. If bubbles are in the brake fluid,
more air is trapped in the line. Repeat Step 8, making sure to
refill the master cylinder to prevent air from being drawn
into the system.

518

CHAPTER THIRTEEN

149

150

10. When the brake fluid is free of bubbles, tighten the bleed
valve and remove the brake bleeder assembly. Reinstall the
bleed valve dust cap.

NOTE

Dispose of the brake fluid expelled during the
bleeding process. Do not reuse the brake fluid.

11. If necessary, add fluid to correct the level in the master
cylinder reservoir. When topping off the front master cylin-

der, turn the handlebar until the reservoir is level. Add fluid
until it is level with the reservoir gasket surface. The fluid
level in the rear master cylinder must be slightly below the
upper gasket surface.
12. Reinstall the reservoir diaphragm and cover. Install the
screws and tighten securely.
13. Test the feel of the brake lever or pedal. It should be firm
and offer the same resistance each time it is operated. If it
feels spongy, there is probably still air in the system. Bleed
the system again. After bleeding the system, check for leaks
and tighten all fittings and connections as necessary.

WARNING

Do not ride the motorcycle until the front
and/or rear brakes are operating correctly
with full hydraulic advantage.

14. Test ride the motorcycle slowly at first to make sure the
brakes are operating properly.

Without a Brake Bleeder

NOTE

Before bleeding the brakes, make sure all
brake hoses and lines are tight.

1. Connect a length of clear tubing to the bleed valve on the
caliper. Place the other end of the tube into a clean container.
Fill the container with enough clean DOT 5 brake fluid to
keep the end of the tube submerged. The tube must be long
enough so a loop can be made higher than the bleeder valve
to prevent air from being drawn into the caliper during
bleeding.
2. Clean the top of the master cylinder of all debris.
3. Remove the screws securing the master cylinder top
cover, and remove the cover and diaphragm.
4. Fill the reservoir almost to the top with DOT 5 brake
fluid, and reinstall the diaphragm and cover. Leave the cover
in place during this procedure to prevent the entry of dirt.

WARNING

Do not intermix DOT 3, DOT 4, or DOT 5.1
brake fluids as they are not silicone-based.
Non-silicone brake fluid used in these mod-
els can cause brake failure.

NOTE

During this procedure, check the fluid level in
the master cylinder reservoir often. If the res-
ervoir runs dry, air will enter the system.

5. Slowly apply the brake lever several times. Hold the lever
in the applied position and open the bleed valve about a half
turn (Figure 152, typical). Allow the lever to travel to its

BRAKES

519

13

152

Box-end wrench

Catch bottle

Catch hose

151

Vacuum brake bleeder

Bleed valve

limit. When the limit is reached, tighten the bleed valve, then
release the brake lever. As the brake fluid enters the system,
the level will drop in the master cylinder reservoir. Maintain
the level at the top of the reservoir to prevent air from being
drawn into the system.
6. Continue the bleeding process until the fluid emerging
from the hose is completely free of air bubbles. If the fluid is
being replaced, continue until the fluid emerging from the
hose is clean.

NOTE

If bleeding is difficult, allow the fluid to stabi-
lize for a few hours. Repeat the bleeding pro-
cedure when the bubbles in the system
dissipate.

7. Hold the lever in the applied position and tighten the
bleed valve. Remove the bleed tube and install the bleed
valve dust cap.

NOTE

Dispose of the brake fluid expelled during the
bleeding process. Do not reuse the brake fluid.

8. If necessary, add fluid to correct the level in the master
cylinder reservoir. When topping off the front master cylin-
der, turn the handlebar until the reservoir is level. Add fluid
until it is level with the reservoir gasket surface. The fluid
level in the rear master cylinder must be slightly below the
upper gasket surface.
9. Install the diaphragm and top cover, and tighten the
screws securely.
10. Test the feel of the brake lever or pedal. It should be firm
and offer the same resistance each time it is operated. If it
feels spongy, there is probably still air in the system and it
must be bled again. After bleeding the system, check for
leaks and tighten all fittings and connections as necessary.

WARNING

Do not ride the motorcycle until the front
and/or rear brakes are operating correctly
with full hydraulic advantage.

11. Test ride the motorcycle slowly at first to make sure the
brakes are operating properly.

REAR BRAKE PEDAL

Removal/Installation

1. Remove the exhaust system as described in Chapter
Seven.

2. On models so equipped, remove the right side floorboard
as described in Chapter Fourteen.
3. Remove the cotter pin and washer from the clevis pin (A,
Figure 153).
4. Withdraw the clevis pin and disconnect the master cylin-
der from the rear brake pedal assembly.
5. Remove the bolt and washer (B, Figure 153) securing
the rear brake pedal to the mounting post on the footrest.
6. Inspect the brake pedal bushings for fractures or dam-
age, and replace it if necessary.
7. Check the O-ring seal on each side of the bushings for
hardness or deterioration and replace if necessary.
8. Make sure the grease fitting is clear. Apply grease with
a gun and make sure it is passing through the fitting and
the brake pedal. Clean out if necessary.
9. Install the pedal by reversing these removal steps. Note
the following:

a. Apply waterproof grease to the bushings and O-rings

prior to installation.

b. Apply a medium strength threadlocking compound to

the mounting bolt threads, then tighten the bolt to
15-18 ft.-lb. (20-24 N•m).

c. Apply waterproof grease to the fitting (Figure 154).

520

CHAPTER THIRTEEN

153

154

Table 1 BRAKE SYSTEM SPECIFICATIONS

Brake fluid

DOT 5 silicone base

Brake pad minimum thickness

FLSTS & FXSTS

1/16 in. (1.6 mm)

All other models

0.04 in. (1.02 mm)

Brake disc runout (max.)

0.008 in. (0.2 mm )

Table 2 BRAKE SYSTEM TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N•m

Bleed valves

–

80-100

9-11

Brake disc bolts

Front wheel

16-24

–

22-32

Rear wheel

30-45

–

41-61

Brake pad pins (Non-Springer models)

Front and rear calipers

–

180-200

20-23

Brake reaction link (FLSTS)

Acorn locknut

35-40

–

48-54

Caliper body mounting bolts

Front and rear (Non-Springer models)

28-38

–

38-52

Front brake caliper (Springer models)

Inner brake pad retainer screw

–

40-50

5-6

Upper mounting bolt

28-30

–

38-41

Lower mounting bolt

25-30

–

34-41

Front brake caliper (Non-Springer models)

Upper mounting bolt

28-38

–

38-52

Lower mounting bolt

28-38

–

38-52

Front master cylinder

Clamp screw

–

70-80

8-9

Cover screws

–

6-8

1

Rear master cylinder

Cartridge mounting hex nut

50

–

68

Cover screws

–

6-8

1

Rear brake pedal locknut

15-18

–

20-24

Brake line banjo bolts

17-22

–

23-30

BRAKES

521

13

CHAPTER FOURTEEN

BODY

SEAT

Removal/Installation

1. Place the motorcycle on level ground on the jiffy
stand.
2A. On FXST, FXSTB and FXSTS models, remove the
bolt and washer (Figure 1) securing the seat. Remove the
seat from the slot in the frame backbone (Figure 2).
2B. On FLSTF and FLSTC models, remove the side
thumbscrews securing the rider’s seat and remove the
seat. Remove the rear thumbscrew securing the passenger
seat and remove the seat out from the seat strap.
2C. On FLSTS models, remove the rear thumbscrew se-
curing the passenger seat and remove the seat from the
rider’s seat mount. Remove the nuts securing the rider’s
seat and remove the seat.
3. Inspect the seat front mounting tab and bracket(s). Re-
place if necessary.
4. Installation is the reverse of removal. Note the follow-
ing:

a. Push the rider’s seat forward and engage the front

bracket into the slot in the frame backbone.

b. Tighten all thumb screws securely.

c. Pull up on the front of the seat (Figure 2) to ensure

the seat front hook is secured in the frame backbone
slot.

FRONT FENDER

Removal/Installation
(FLSTC and FLSTF Models)

1. Remove the front wheel as described in Chapter Nine.

2. On FLSTC models, disconnect the electrical connector
for the front fender lamp (under the fuel tank) as described
in Chapter Eight. Pull the electrical cable free from the
frame and secure it to the front fender.

3. Remove the screws, or nuts, securing the front fender
to the fork sliders.

4. Carefully remove the front fender from between the
fork sliders.

5. Installation is the reverse of removal. Tighten the
screws and nuts securely.

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Removal/Installation
(FXSTD, FXST and FXSTB Models)

1. Place the motorcycle on the jiffy stand on level ground.

2A. On FXSTD models, remove the four screws and
washers securing the front fender to the fork sliders.

2B. On FXST and FXSTB models, remove the acorn nut
and washers and screws securing the front fender to the
fork sliders (A, Figure 3).

3. Carefully remove the front fender (B, Figure 3) from
between the fork sliders.

4. Installation is the reverse of removal. Tighten the
screws and/or acorn nut securely.

Removal/Installation
(FXSTS Models)

Refer to Figure 4.

1. On the right side, remove cotter pin (Figure 5),
locknut (A, Figure 6), shaft nut (Figure 7), washers (B,
Figure 6) and screw securing the brake reaction link to the
front fender.
2. On the left side, repeat Step 2.

NOTE

The rubber spacers and washers may come
off with the shaft nuts or may stay with the
fender bracket bushing.

3. The brake reaction links (A, Figure 8) are now free
from the fender. Let them pivot down out of the way.
4A. On the right side, remove the locknut and shoulder
bolts (B, Figure 8) securing the pivot link and caliper
mounting bracket to the front fender. Remove the fender
insert and place it on the shoulder bolt and nut to avoid
misplacing them.
4B. On the left side, remove the locknut and shoulder
bolts securing the pivot link to the front fender. Remove
the fender insert and place it on the shoulder bolt and nut
to avoid misplacing them.
5. Very carefully, lift the fender out from the forks and the
pivot links.
6. Move the fender into place over the front wheel.
7. Install the fender insert and bearing (Figure 9) into the
receptacle in the front fender on both sides.
8. Move the pivot link into place. Install the shoulder
bolts (B, Figure 8) securing the pivot link to the front
fender. Tighten the shoulder bolts securely.
9. Move the pivot link (A, Figure 8) and the caliper
mounting bracket into position on the front fender.
10. Install the washer (Figure 10) in between the pivot
link and the fender.
11. Install the bolt (A, Figure 11) through the caliper
mounting bracket, washer and pivot link. Push the bolt in
until it bottoms.
12. Install the shaft nut, rubber spacer and washer (B,
Figure 11) onto the bolt.
13. Tighten the shaft nut onto the bolt (Figure 12) to
10-20 ft.-lbs. (14-27 N

•

m).

14. Install the washer (Figure 13) onto the bolt and the
nut (A, Figure 6). Tighten the nut to 10-20 ft.-lbs. (14-27
N

•

m).

BODY

523

14

1

2

3

15. Install a new cotter pin (Figure 5) and bend the ends
over completely.
16. Repeat Steps 8-15 for the other side.

Removal/Installation
(FLSTS Models)

Refer to Figure 14.
Read this procedure thoroughly prior to starting to re-

move the front fender. Each step must be taken slowly and
carefully and in the proper order to avoid damage to the
finish of the front fender and the springer fork assembly.

CAUTION

Removal of the front fender is very difficult
due its the close proximity of the spring fork
legs.

To protect the finish, cover the front fender and left side

fork assembly with a towel or large, heavy cloth. Tape the
towel or cloth onto the front fender and to the fork with
duct tape.
1. Remove the front wheel as described in Chapter Nine.
2. Remove the front brake caliper as described in Chapter
Thirteen.

524

CHAPTER FOURTEEN

4

FRONT FENDER (FXSTS)

1. Rigid fork
2. Pivot shaft
3. Rubber spacer
4. Washer
5. Bearing
6. Fender
7. Locknut
8. Shoulder bolt
9. Pivot link

10. Bushing
11. Fender insert
12. Bolt
13. Reaction link
14. Shaft nut
15. Locknut
16. Cotter pin

5

6

3. Disconnect the front fender lamp (under the fuel tank)
as described in Chapter Eight. Pull the electrical cable free
from the frame and secure it to the front fender.

4. On the left side, remove the spring clip and nut from
the screw securing the front fender to the bracket.

5. Insert the front axle through the front fender pivot area
to support the fender assembly.

6. Support the front fender and on the left side, remove
the screw and washer.

BODY

525

14

9

10

11

12

7

8

13

7. Working on the right side of the fork assembly, slide
the front fender down until the mounting bracket is just in
front of the left side rigid fork leg.
8. While holding onto the right side fender braces, care-
fully rotate the front fender down between both fork legs
and remove the fender.
9. Installation is the reverse of removal. Note the follow-
ing:

a. Install a

new

nut on the fender bracket.

b. Tighten the nut to 18-22 ft.-lbs. (24-30 N

•

m).

Front Fender Bearing Replacement (FLSTS Models)

CAUTION

As previously noted during fender removal,
protect the fender finish during this proce-
dure.

1. Remove the front fender as previously described.
2. Place the front fender in an arbor press with the out-
board side facing up.
3. Use a suitable size tool, or socket, that matches the
bearing outer race and is smaller in diameter than the
fender bore.
4. Carefully press the bearing out of the fender bore.
5. Repeat for the bearing on the other side.
6. Place the fender on its side on the workbench.
7. Install the

new

bearing into the fender bore from the in-

board surface.
8. Use the same tool setup used in Step 3 and carefully
drive the new bearing into the fender bore.
9. Tap the new bearing in until it is flush with the out-
board surface of the fender bore.
10. Repeat for the bearing on the other side.
11. Install the front fender as previously described.

526

CHAPTER FOURTEEN

14

FRONT FENDER (FLSTS)

1. Front fender
2. Grommet
3. Crimp nut
4. Washer
5. Screw
6. Spring pin
7. Locknut
8. Hub cap
9. Seal

10. Spacer (right side)
11. Nylon insert
12. O-ring
13. Bearing
14. Nut

To fender
light

REAR FENDER INNER PANEL

Removal/Installation

1. Remove the rear wheel as described in Chapter Nine.
2. Remove the two bolts (A, Figure 15) securing the in-
ner panel to the swing arm.
3. Lift the upper right side corner (B, Figure 15) and re-
move the inner panel from the swing arm and frame.
4. Inspect the inner panel (Figure 16) for cracks and de-
terioration. This component keeps out water and road de-
bris from the electrical components located behind it.
5. Installation is the reverse of removal.

REAR FENDER

Removal/Installation
(FLSTS Models)

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

Motorcycle Stands

in Chapter Nine.

2. Remove the seat as described in this chapter.
3. Remove both saddlebags as described in this chapter.
4. Disconnect the battery negative lead as described in
Chapter Eight.

5. Disconnect the rear wiring harness eight-pin electrical
connector under the seat.
6. Disconnect both rear turn signals two-pin electrical
connectors from the rear wiring harness.
7. Remove the ignition module and module tray as de-
scribed in Chapter Eight.
8. Remove the bolts and threaded studs securing the
fender mounting brackets on both sides. Remove the
mounting brackets located on the inner surface of the rear
fender.
9. Carefully lift the rear fender up and off the frame and
remove it.
10. Installation is the reverse of removal. Note the fol-
lowing:

a. Tighten the bolts and fender mounting bolts and

threaded studs to 21-27 ft.-lbs. (29-37 N

•

m).

b. Check the operation of the taillight/brake light and

rear turn signals for proper operation.

Removal/Installation
(FXSTD Models)

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

Motorcycle Stands

in Chapter Nine.

2. Remove the seat as described in this chapter.
3. Disconnect the battery negative lead as described in
Chapter Eight.
4. Working underneath the rear fender, remove the
screws and washers securing the fender support on both
sides.
5. At the front edge of the fender support, remove the
screw, spacer and nut securing the fender support. Repeat
for the fender support on the other side.
6. Remove the taillight/brake light assembly as described
in Chapter Eight.
7. Disconnect both rear turn signals two-pin electrical
connectors from the rear wiring harness.
8. Remove the ignition module and module tray as de-
scribed in Chapter Eight.
9. Working underneath the rear fender, remove the nuts
securing the fender to the fender mounting brackets on
both sides.
10. Carefully lift the rear fender up and off the frame and
remove it.
11. Installation is the reverse of removal. Note the fol-
lowing:

a. Tighten the bolts and fender mounting bolts and

threaded studs to 21-27 ft.-lbs. (29-37 N

•

m).

b. Check the operation of the taillight/brake light and

rear turn signals for proper operation.

BODY

527

14

15

16

Removal/Installation
(All Models Except FLSTS and FXSTD)

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

Motorcycle Stands

in Chapter Nine.

2. Remove the seat as described in this chapter.
3. On FLSTC models, remove the sissy bar as described
in this chapter.
4. On models so equipped, remove the saddlebags as de-
scribed in this chapter.
5. Disconnect the battery negative lead as described in
Chapter Eight.
6. Disconnect the rear wiring harness eight-pin electrical
connector under the seat.
7. Disconnect both rear turn signals two-pin electrical
connectors from the rear wiring harness.
8. Remove the ignition module and module tray as de-
scribed in Chapter Eight.
9A. On FLSTC models, perform the following:

a. Remove the bolts and saddlebag threaded studs se-

curing the fender mounting brackets on both sides.
Secure the sissy bar at this time

b. Remove the mounting brackets located on the inner

surface of the rear fender.

c. Carefully lift the rear fender and sissy bar up and off

the frame and remove it.

9B. On FLSTF models, perform the following:

a. Remove the screws securing the fender mounting

bracket to the mounting brackets and wiring re-
tainer plate underneath the rear fender.

b. Remove the mounting brackets and wiring retainer

plates.

c. Carefully lift the rear fender up and off the frame

and remove it.

9C. On all other models, perform the following:

a. At the front edge of the fender support, loosen but

do not remove the two screws.

b. Remove the remaining middle two fender support

screws from the mounting bracket underneath the
rear fender.

c. Remove the rear screw from the mounting bracket

underneath the rear fender.

d. Remove the two screws at the front edge of the

fender support.

e. Repeat these steps for the other side.
f. Remove both fender support brackets. Insert a long

screwdriver or long rod through the frame and front
fender holes to support the rear fender.

g. Remove the locknuts and washers securing the rear

fender to the fender mounting bracket.

h. Remove the long screwdriver or long rod and re-

move the rear fender from the frame.

528

CHAPTER FOURTEEN

17

SADDLEBAG (FLSTS)

1. Frame bracket
2. Threaded stud
3. Locknut
4. Saddlebag
5. Flange nut
6. Washer
7. Acorn nut
8. Washer
9. Isolator

10. Mounting bracket

10. Installation is the reverse of removal. Note the fol-
lowing:

a. Tighten the bolts and fender mounting bolts to

21-27 ft.-lbs. (29-37 N

•

m).

b. Check the operation of the taillight/brake light and

rear turn signals for proper operation.

WINDSHIELD

Removal/Installation

1. Place the motorcycle on level ground on the jiffy stand.

2. Use a finger to lift up on the wire form latch spring on
each side of the windshield at the mounting brackets.

3. Straddle the front wheel and hold onto the windshield.
Gently pull straight up on the top of the windshield until
the upper notches on the side brackets are free of the upper
grommets on the passing lamp support.

4. Continue to raise the windshield until the side brackets
lower notches are free from the lower grommets and re-
move the windshield.

5. Installation is the reverse of removal. Note the follow-
ing:

a. Lower the windshield down until the latches are

seated on the grommets.

b. Push down on the wire form latch springs until they

overhang the upper grommets.

c. Make sure the windshield is securely in place prior

to riding.

SADDLEBAGS

Removal/Installation

Refer to Figure 17 and Figure 18.

1. Place the motorcycle on level ground on the jiffy stand.

2. Remove the acorn nut and washer securing the
saddlebag mounting bracket to the front lower support
bracket.

3. Unhook the latches and open the saddlebag cover.

4. Within the saddlebag, remove the flange nuts and
washers securing the saddle bag to the threaded studs.

5. Remove the saddlebag from the threaded studs.

6. Inspect the threaded studs for damage.

7. Installation is the reverse of removal.

BODY

529

14

18

SADDLEBAG (FLSTC)

1. Frame bracket
2. Threaded stud
3. Locknut
4. Saddlebag
5. Flange nut
6. Washer
7. Self locking fastener
8. Concho kit
9. Buckle assembly

10. Acorn nut
11. Washer
12. Isolator
13. Mounting bracket

530

CHAPTER FOURTEEN

19

FOOTBOARDS AND FOOTRESTS

1. Footrest
2. Bolt
3. Locknut
4. Footrest bracket—passenger (right side)
5. Spring washer
6. Bolt
7. Bolt
8. Bolt
9. Footrest bracket—passenger (left side)

10. Floorboard and pad assembly
11. Screw

12. Washer
13. Mounting bracket (footboard and brake pedal

[FLST models])

14. Mounting bracket (footboard and shifter pedal

[FLST models])

15. Hinge bolt
16. Mounting bracket (footboard and brake pedal

[FXST models])

17. Mounting bracket (footboard and shifter pedal

[FXST models])

FOOTBOARDS AND FOOTRESTS

Footrboards
Removal/Installation

Refer to Figure 19.

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

Motorcycle Stands

in Chapter Nine.

2. Remove the bolt and nut securing the footboard to the
mounting bracket. Remove the footboard from the mount-
ing bracket.

3. On the right side, perform the following to remove the
mounting bracket:

a. Remove the front brake pedal as described in Chap-

ter Thirteen.

b. Remove the rear master cylinder from the mounting

bracket as described in Chapter Thirteen.

c. Remove the bolts and washers securing the mount-

ing bracket to the frame.

d. Remove the mounting bracket.

4. On the left side, perform the following to remove the
mounting bracket:

a. Disconnect the shift rod from the inner shift lever.
b. If necessary, remove the outer shift lever(s) from

the inner shift lever shaft.

c. Remove the bolts and washers securing the floor-

board mounting bracket, jiffy stand and shift lever
assembly to the frame.

d. Remove the mounting bracket assembly from the

frame.

5. If necessary, remove the rubber pad from the footboard
and install a new one. Push the locating pins all the way
through the footboard to secure the rubber pad in place.
6. Inspect the pivot bolts and nuts for damage. Replace
them if necessary.
7. Inspect the footboard and the mounting brackets for
damage and fractures. Replace as necessary.
8. Install the footboard(s) assembly onto the frame.
9. Apply a medium strength threadlocking compound to
the bolt threads prior to installation.
10. Tighten the bolts to 25-30 ft.-lbs. (34-41 N

•

m).

Driver’s Footrests
Removal/Installation

1. Place the motorcycle on level ground on the jiffy stand.
2. Remove the bolt, spring washer (models so equipped)
and nut (A, Figure 20) securing the footrest to the mount-
ing bracket. Remove the footrest (B, Figure 20).
3. Install by reversing these removal steps. Tighten the
bolt and nut securely.

Passenger Footrests
Removal/Installation

1. Place the motorcycle on level ground on the jiffy stand.
2. Remove the bolt, spring washer (models so equipped)
and nut (A, Figure 21) securing the footrest to the mount-
ing bracket. Remove the footrest (B, Figure 21).
3. If necessary, remove the footrest (A, Figure 22), then
remove the bolt securing the mounting bracket (B) to the
frame and remove it.

BODY

531

14

20

21

22

4. Install by reversing these removal steps. Tighten the
bolt and nut securely.

JIFFY STAND

Refer to Figure 23.

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

Motorcycle Stands

in Chapter Nine.

2. On models so equipped, remove the left side floor-
board as described in this chapter.

3. Disconnect the shift rod from the inner shift lever (Fig-
ure 24).
4. Use Vise grip pliers and disconnect the return spring
(A, Figure 25) from the frame tab.
5. Remove the bolt, lockwasher, washer and leg stop (B,
Figure 25) securing the jiffy stand to the mounting
bracket.
6. Remove the jiffy stand (C, Figure 25) from the mount-
ing bracket.
7. Clean and lubricate the jiffy stand prior to installation
as described in Chapter Three.
8. Installation is the reverse of removal. Note the follow-
ing:

a. Tighten the bolt securely.
b. Ensure that the jiffy stand operates correctly in both

positions prior to riding the motorcycle.

532

CHAPTER FOURTEEN

24

23

JIFFY STAND

1. Bolt
2. Lockwasher
3. Washer
4. Leg stop
5. Mounting bracket
6. Washer
7. Bolt
8. Spring
9. Bumper

10. Jiffy stand

25