2013 Harley Davidson Touring Models Service Manual – PDF DOWNLOAD
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2013 Harley Davidson Touring Models Service Manual – PDF DOWNLOAD
ABOUT THIS MANUAL
GENERAL
This service manual has been prepared with the following purposes in mind:
• To acquaint the user with the construction of the Harley- Davidson product and assist in the performance of basic maintenance and repair.
• To introduce the professional Harley-Davidson technician to the latest field-tested and factory-approved major repair methods.
We sincerely believe that this service manual will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL :
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Maintenance
2 Chassis
3 Engine
4 Fuel System
5 Drive
6 Transmission
7 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C ABS
D Appendix D Conversions
E Appendix E Glossary
- Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation.
- For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS.
- For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.
- A number of acronyms and abbreviations are used in this document. See the D.1 GLOSSARY for a list of acronyms, abbreviations and definitions.
TABLE OF CONTENTS:
2013 Harley Davidson Touring Models Service Manual – PDF DOWNLOAD
FOREWORD........................................................................................ 7 TABLE OF CONTENTS............................................................................... 9 1. MAINTENANCE.................................................................................. 25 1.1 FASTENER TORQUE VALUES.................................................................. 27 Fastener Torque Values in this Chapter.................................................. 27 1.2 GENERAL................................................................................. 29 Servicing a New Motorcycle.............................................................. 29 Safe Operating Maintenance.............................................................. 29 Shop Practices.......................................................................... 29 Repair and Replacement Procedures....................................................... 30 Cleaning................................................................................ 31 Tool Safety............................................................................. 31 1.3 FUEL AND OIL............................................................................ 33 Fuel.................................................................................... 33 Gasoline Blends......................................................................... 33 Engine Lubrication...................................................................... 33 Winter Lubrication...................................................................... 34 1.4 BULB REQUIREMENTS....................................................................... 35 General................................................................................. 35 1.5 MAINTENANCE SCHEDULE.................................................................... 37 General................................................................................. 37 1.6 ENGINE OIL AND FILTER................................................................... 42 Engine Oil Level........................................................................ 42 Changing Oil and Oil Filter............................................................. 43 1.7 AIR CLEANER AND EXHAUST SYSTEM.......................................................... 45 Removal................................................................................. 45 Installation............................................................................ 45 Exhaust System Leak Check............................................................... 46 1.8 TIRES AND WHEELS........................................................................ 47 General................................................................................. 47 Tires................................................................................... 47 Tire Replacement........................................................................ 48 Wheel Bearings.......................................................................... 48 Wheel Spokes............................................................................ 48 1.9 PRIMARY CHAINCASE LUBRICANT............................................................. 50 General................................................................................. 50 Changing Primary Chaincase Lubricant.................................................... 50 1.10 TRANSMISSION LUBRICANT................................................................. 52 Checking Transmission Lubricant......................................................... 52 Changing Transmission Lubricant......................................................... 52 1.11 CLUTCH................................................................................. 54 Adjustment.............................................................................. 54 1.12 DRIVE BELT AND SPROCKETS............................................................... 55 General................................................................................. 55 Cleaning................................................................................ 55 Inspection.............................................................................. 55 Checking Drive Belt Deflection.......................................................... 57 Setting Belt Deflection................................................................. 57 1.13 REAR SPROCKET ISOLATOR................................................................. 60 Inspection.............................................................................. 60 1.14 CABLE AND CHASSIS LUBRICATION.......................................................... 61 General................................................................................. 61 Steering Head Bearings.................................................................. 61 Jiffy Stand............................................................................. 61 Miscellaneous Lubrication............................................................... 61 1.15 BRAKES................................................................................. 62 Fluid Inspection........................................................................ 62 Brake Lines............................................................................. 62 1.16 BRAKE PADS AND DISCS................................................................... 63 Inspection.............................................................................. 63 Brake Pad Replacement................................................................... 63 1.17 SPARK PLUGS............................................................................ 67 Removal................................................................................. 67 Inspection.............................................................................. 67 Cleaning................................................................................ 67 Installation............................................................................ 67 Spark Plug Cable Inspection............................................................. 68 1.18 STEERING HEAD BEARINGS................................................................. 69 Lubrication............................................................................. 69 Checking................................................................................ 69 Adjustment.............................................................................. 70 1.19 REAR SUSPENSION ADJUSTMENTS............................................................ 72 Air Suspension.......................................................................... 72 Manual Suspension Preload............................................................... 73 1.20 CRITICAL FASTENERS..................................................................... 75 Inspection.............................................................................. 75 1.21 BATTERY MAINTENANCE.................................................................... 76 General................................................................................. 76 Cleaning and Inspection................................................................. 77 Battery................................................................................. 77 Voltmeter Test.......................................................................... 78 Charging Battery........................................................................ 78 Storage................................................................................. 79 1.22 HEADLAMP ALIGNMENT..................................................................... 81 Headlamp Alignment...................................................................... 81 Headlamp Adjustment: Single Headlamp Models............................................. 81 Headlamp Adjustment: Dual Headlamp Models............................................... 82 Auxiliary/Fog Lamp Alignment............................................................ 83 1.23 ENGINE MOUNTS.......................................................................... 84 Inspection.............................................................................. 84 1.24 STORAGE................................................................................ 85 General................................................................................. 85 Placing in Storage...................................................................... 85 Removal from Storage.................................................................... 85 1.25 TROUBLESHOOTING........................................................................ 86 General................................................................................. 86 Engine.................................................................................. 86 Lubrication System...................................................................... 87 Electrical System....................................................................... 88 Transmission............................................................................ 88 Handling................................................................................ 88 Brakes.................................................................................. 89 2. CHASSIS...................................................................................... 91 2.1 FASTENER TORQUE VALUES.................................................................. 93 Fastener Torque Values in this Chapter.................................................. 93 2.2 SPECIFICATIONS.......................................................................... 99 Specifications.......................................................................... 99 2.3 VEHICLE IDENTIFICATION NUMBER (V.I.N.)..................................................103 Vehicle Identification Number: Touring Models...........................................103 2.4 FRONT WHEEL.............................................................................105 Removal.................................................................................105 Cleaning and Inspection.................................................................106 Installation............................................................................107 2.5 REAR WHEEL..............................................................................108 Removal.................................................................................108 Cleaning and Inspection.................................................................109 Installation............................................................................110 2.6 REAR WHEEL COMPENSATOR..................................................................112 Isolator Replacement....................................................................112 Sprocket Bearing Replacement............................................................112 2.7 WHEEL LACING: FRONT RIM.................................................................114 Wheel Lacing: Angle Flange Hub..........................................................114 2.8 WHEEL LACING: 16 INCH REAR RIM..........................................................116 Wheel Lacing: 16 In. Rear Wheel.........................................................116 2.9 CHECKING AND TRUING WHEELS..............................................................119 General.................................................................................119 Checking Wheel Runout...................................................................119 Laced Wheel Rim Offset..................................................................120 Truing Laced Wheels.....................................................................122 2.10 SEALED WHEEL BEARINGS..................................................................124 Inspection..............................................................................124 Removal.................................................................................124 Installation............................................................................125 2.11 TIRES..................................................................................127 General.................................................................................127 Removal.................................................................................127 Cleaning, Inspection and Repair.........................................................127 Installation............................................................................128 Checking Tire Runout....................................................................130 Wheel Balancing.........................................................................131 2.12 FRONT BRAKE MASTER CYLINDER............................................................132 General.................................................................................132 Removal and Disassembly.................................................................132 Cleaning and Inspection.................................................................134 Assembly and Installation...............................................................134 Front Brake Line: Non-ABS Equipped......................................................134 2.13 FRONT BRAKE CALIPER....................................................................137 Removal.................................................................................137 Installation............................................................................137 2.14 REAR BRAKE MASTER CYLINDER.............................................................138 General.................................................................................138 Removal and Disassembly.................................................................138 Cleaning and Inspection.................................................................140 Assembly and Installation...............................................................140 Rear Brake Line: Non-ABS Equipped.......................................................140 2.15 REAR BRAKE CALIPER.....................................................................144 Removal.................................................................................144 Installation............................................................................144 2.16 BLEEDING BRAKES........................................................................145 General.................................................................................145 Procedure...............................................................................145 2.17 FRONT FORK.............................................................................147 Removal.................................................................................147 Disassembly.............................................................................147 Cleaning and Inspection.................................................................149 Assembly................................................................................150 Installation............................................................................151 2.18 STEERING HEAD BEARINGS.................................................................152 Removal.................................................................................152 Inspection..............................................................................153 Installation............................................................................154 2.19 REAR AIR SUSPENSION....................................................................155 Check for Air Leaks.....................................................................155 Shock Absorber Removal..................................................................156 Cleaning and Inspection.................................................................156 Disassembly and Assembly................................................................156 Shock Absorber Installation.............................................................156 2.20 REAR SHOCK ABSORBERS: MANUAL ADJUST....................................................157 Repair..................................................................................157 2.21 REAR FORK..............................................................................158 Removal.................................................................................158 Disassembly and Assembly................................................................158 Installation............................................................................160 2.22 CLUTCH CABLE...........................................................................161 Removal.................................................................................161 Installation............................................................................161 2.23 HANDLEBARS.............................................................................163 Adjustment..............................................................................163 Removal.................................................................................163 Installation............................................................................164 Left Handgrip...........................................................................165 Right Handgrip..........................................................................165 Heated Handgrips........................................................................165 Rubber Mounts...........................................................................167 2.24 MIRRORS................................................................................168 All Models Except FLHX..................................................................168 FLHX....................................................................................168 2.25 SEAT...................................................................................169 Seat: Models without Tour-Pak...........................................................169 Seat: Models with Tour-Pak..............................................................170 Seat: Road King Models..................................................................170 Seat Retention Nut Replacement..........................................................171 Seat Bumper.............................................................................171 2.26 SADDLEBAGS.............................................................................172 Removal.................................................................................172 Installation............................................................................172 2.27 SADDLEBAG SERVICE......................................................................173 Saddlebag Hardware......................................................................173 Saddlebag Guard/Support Rail............................................................174 2.28 TOUR-PAK...............................................................................176 Removal/Installation....................................................................176 Adjustment..............................................................................177 Luggage Rack/Tour-Pak Support...........................................................177 2.29 TOUR-PAK SERVICE.......................................................................178 Lockset.................................................................................178 Hinges..................................................................................178 Latches/Lockset Catch...................................................................179 Catches.................................................................................179 Tether..................................................................................180 Tether Brackets.........................................................................180 Luggage Rack............................................................................180 2.30 TOUR-PAK LIGHTS........................................................................182 General.................................................................................182 Side Marker Lights (if equipped)........................................................182 Tour-Pak Lights Harness.................................................................182 Wrap-Around Lights (if equipped)........................................................183 2.31 TOUR-PAK BACKREST......................................................................185 Passenger Backrest......................................................................185 Rubber Isolators........................................................................185 Passenger Backrest Flap.................................................................186 2.32 TOUR-PAK SPEAKER BOX...................................................................187 Speaker Box.............................................................................187 2.33 LOWER FAIRING AND ENGINE GUARD.........................................................188 Lower Fairing...........................................................................188 Serrated Washer Replacement.............................................................190 Engine Guard............................................................................190 2.34 UPPER FAIRING AND WINDSHIELD: FORK MOUNTED FAIRING MODELS..............................192 Outer Fairing and Windshield............................................................192 2.35 FAIRING CAP: FORK MOUNTED FAIRING MODELS...............................................193 Fairing Cap.............................................................................193 2.36 INNER FAIRING: FORK MOUNTED FAIRING MODELS.............................................194 Removal.................................................................................194 Installation............................................................................196 2.37 AIR DEFLECTORS.........................................................................198 Fairing Air Deflectors..................................................................198 Mid-Frame Air Deflectors................................................................198 2.38 UPPER FAIRING AND WINDSHIELD: FRAME MOUNTED FAIRING MODELS.............................200 Windshield..............................................................................200 Outer Fairing...........................................................................200 2.39 INSTRUMENT BEZEL: FRAME MOUNTED FAIRING MODELS.........................................203 Bezel...................................................................................203 2.40 INSTRUMENT NACELLE: FRAME MOUNTED FAIRING MODELS.......................................204 Instrument Nacelle......................................................................204 2.41 INNER FAIRING: FRAME MOUNTED FAIRING MODELS............................................206 Removal.................................................................................206 Installation............................................................................208 2.42 GLOVE BOX DOOR AND HINGE: FRAME MOUNTED FAIRING MODELS.................................210 Glove Box Door and Hinge................................................................210 2.43 WINDSHIELD: ROAD KING MODELS...........................................................211 Windshield..............................................................................211 Windshield Window.......................................................................211 2.44 HEADLAMP NACELLE: ROAD KING MODELS.....................................................214 Removal.................................................................................214 Installation............................................................................215 2.45 FRONT FENDER...........................................................................216 Removal.................................................................................216 Installation............................................................................217 2.46 REAR FENDER............................................................................218 Removal.................................................................................218 Fender Repair...........................................................................219 Installation............................................................................220 2.47 REAR FASCIA............................................................................221 Removal.................................................................................221 Installation............................................................................221 Stud Plate..............................................................................221 Rear Fascia Lamp........................................................................221 2.48 REAR FRAME.............................................................................222 Rear Frame..............................................................................222 2.49 FOOTBOARDS AND FOOTRESTS...............................................................224 Rider Footboards........................................................................224 Passenger Footboard.....................................................................225 Passenger Footrest: FLHX, FLTRX.........................................................226 2.50 JIFFY STAND............................................................................227 General.................................................................................227 Leg Removal.............................................................................227 Leg Installation........................................................................227 Jiffy Stand Bracket.....................................................................228 Jiffy Stand Interlock Sensor............................................................228 2.51 FRONT ENGINE MOUNT.....................................................................230 Removal.................................................................................230 Installation............................................................................230 2.52 MEDALLIONS, SERIALIZED BADGES AND TANK EMBLEMS.........................................232 Removal.................................................................................232 Installation............................................................................232 3. ENGINE.......................................................................................233 3.1 FASTENER TORQUE VALUES..................................................................235 Fastener Torque Values in this Chapter..................................................235 3.2 SPECIFICATIONS..........................................................................237 Specifications..........................................................................237 3.3 SERVICE WEAR LIMITS.....................................................................239 General.................................................................................239 3.4 ENGINE OIL FLOW.........................................................................241 Oil Feed................................................................................241 Top End.................................................................................241 Bottom End..............................................................................243 Oil Return..............................................................................245 Oil Cooler Operation....................................................................246 3.5 OIL PUMP OPERATION......................................................................247 General.................................................................................247 Operation...............................................................................247 3.6 BREATHER OPERATION......................................................................249 General.................................................................................249 3.7 OIL PRESSURE............................................................................250 Oil Pressure Indicator Lamp.............................................................250 Checking Oil Pressure...................................................................250 3.8 TROUBLESHOOTING.........................................................................252 Diagnosing Valve Train Noise............................................................252 Compression Test........................................................................252 Cylinder Leakdown Test..................................................................253 Diagnosing Smoking Engine or High Oil Consumption.......................................253 3.9 OIL COOLER..............................................................................254 Removal.................................................................................254 Installation............................................................................254 3.10 OIL COOLER ADAPTER.....................................................................255 Removal.................................................................................255 Disassembly.............................................................................255 Assembly................................................................................255 Installation............................................................................255 3.11 HOW TO USE THIS SECTION................................................................257 Top End Repair..........................................................................257 Bottom End Repair.......................................................................257 Typical Symptoms........................................................................257 3.12 TOP END SERVICE........................................................................258 Engine in Chassis.......................................................................258 Engine Removed from Chassis.............................................................259 3.13 CAM COMPARTMENT SERVICE................................................................260 Engine in Chassis.......................................................................260 Engine Removed From Chassis.............................................................261 3.14 STRIPPING MOTORCYCLE FOR SERVICE.......................................................262 Procedure...............................................................................262 3.15 ASSEMBLING MOTORCYCLE AFTER SERVICE....................................................263 Procedure...............................................................................263 3.16 REMOVING ENGINE FROM CHASSIS...........................................................264 Procedure...............................................................................264 3.17 INSTALLING ENGINE IN CHASSIS...........................................................265 Procedure...............................................................................265 3.18 TOP END OVERHAUL: DISASSEMBLY..........................................................266 General.................................................................................266 Rocker Covers...........................................................................266 Rocker Arm Support Plate................................................................266 Pushrods, Lifters and Covers............................................................268 Cylinder Head...........................................................................268 Cylinder................................................................................269 Piston..................................................................................270 3.19 BREATHER ASSEMBLY......................................................................272 Disassembly.............................................................................272 Cleaning and Inspection.................................................................272 Assembly................................................................................272 3.20 ROCKER ARM SUPPORT PLATE...............................................................273 Disassembly.............................................................................273 Cleaning and Inspection.................................................................273 Assembly................................................................................275 3.21 PUSHRODS, LIFTERS AND COVERS...........................................................276 Disassembly.............................................................................276 Cleaning and General Inspection.........................................................276 Lifter Inspection.......................................................................277 Assembly................................................................................277 3.22 CYLINDER HEAD..........................................................................278 Disassembly.............................................................................278 Cleaning................................................................................279 Inspection..............................................................................279 Valve Guide Replacement.................................................................280 Valve and Seat Refacing.................................................................284 Assembly................................................................................286 3.23 CYLINDER...............................................................................288 Cleaning................................................................................288 Inspection..............................................................................288 Deglazing Cylinder......................................................................290 Boring and Honing Cylinder..............................................................290 3.24 PISTON.................................................................................292 Disassembly.............................................................................292 Cleaning................................................................................292 Inspection..............................................................................292 Assembly................................................................................294 3.25 TOP END OVERHAUL: ASSEMBLY.............................................................296 General.................................................................................296 Piston..................................................................................296 Cylinder................................................................................297 Cylinder Head...........................................................................299 Push Rods, Lifters and Covers...........................................................303 Rocker Arm Support Plate................................................................304 Breather and Rocker Cover...............................................................305 3.26 CAM COMPARTMENT AND COMPONENTS.........................................................306 Cam Support Plate and Cover Removal.....................................................306 Cam Support Plate Cleaning and Inspection...............................................308 Camshafts...............................................................................309 Oil Pressure Relief Valve...............................................................311 Cam Needle Bearings.....................................................................311 Cam Support Plate and Cover Installation................................................314 3.27 OIL PUMP...............................................................................318 Removal.................................................................................318 Cleaning and Inspection.................................................................318 Installation............................................................................319 3.28 CRANKCASE DISASSEMBLY AND REPAIR.......................................................320 Crankcase Disassembly...................................................................320 Cleaning and Inspection.................................................................320 Right Crankcase Half....................................................................321 Left Crankcase Half.....................................................................322 Sprocket Shaft Bearing Inner Race.......................................................324 Cylinder Studs..........................................................................327 Pipe Plug and Oil Fittings..............................................................328 3.29 FLYWHEEL AND CONNECTING RODS...........................................................329 General.................................................................................329 Inspection..............................................................................329 Measuring Crankshaft Runout.............................................................329 3.30 CRANKCASE ASSEMBLY.....................................................................332 Crankcase Assembly......................................................................332 3.31 OIL PAN................................................................................334 Removal.................................................................................334 Installation............................................................................334 4. FUEL SYSTEM..................................................................................337 4.1 FASTENER TORQUE VALUES..................................................................339 Fastener Torque Values in this Chapter..................................................339 4.2 SPECIFICATIONS: FUEL SYSTEM.............................................................340 Specifications..........................................................................340 4.3 AIR CLEANER ASSEMBLY....................................................................341 Removal.................................................................................341 Installation............................................................................341 4.4 FUEL TANK...............................................................................343 Console.................................................................................343 Removal.................................................................................343 Installation............................................................................344 Vent Tube: Models Without EVAP System...................................................344 Fuel Supply Check Valve/Tube............................................................345 4.5 FUEL TANK TOP PLATE.....................................................................346 Removal.................................................................................346 Installation............................................................................347 4.6 FUEL FILTER.............................................................................348 Removal.................................................................................348 Installation............................................................................348 4.7 FUEL PRESSURE REGULATOR.................................................................349 Removal.................................................................................349 Installation............................................................................349 4.8 FUEL LEVEL SENDER.......................................................................350 Removal.................................................................................350 Installation............................................................................350 4.9 TWIST GRIP SENSOR.......................................................................351 Removal.................................................................................351 Installation............................................................................352 Twist Grip Sensor Jumper Harness........................................................353 4.10 THROTTLE CONTROL ACTUATOR (TCA)........................................................354 General.................................................................................354 4.11 INDUCTION MODULE.......................................................................355 Removal.................................................................................355 Installation............................................................................356 4.12 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP)...................................357 General.................................................................................357 Removal.................................................................................357 Installation............................................................................357 4.13 OXYGEN SENSORS (O2)....................................................................358 General.................................................................................358 Removal.................................................................................358 Installation............................................................................359 4.14 FUEL INJECTORS.........................................................................360 General.................................................................................360 Removal.................................................................................360 Installation............................................................................360 4.15 FUEL PUMP..............................................................................362 General.................................................................................362 Removal.................................................................................362 Installation............................................................................362 Fuel Pump and Fuel Level Sender Wire Harness............................................363 4.16 FUEL PRESSURE TEST.....................................................................364 General.................................................................................364 Testing.................................................................................364 4.17 EXHAUST SYSTEM.........................................................................366 Mufflers................................................................................366 System Removal..........................................................................366 System Installation.....................................................................368 4.18 ACTIVE EXHAUST (HDI)...................................................................369 Exhaust Valve Actuator..................................................................369 Exhaust Valve Actuator Cable............................................................369 Active Exhaust Valve....................................................................369 4.19 INTAKE LEAK TEST.......................................................................370 General.................................................................................370 Leak Tester.............................................................................370 Procedure...............................................................................370 4.20 EVAPORATIVE EMISSIONS CONTROL SYSTEM...................................................372 General.................................................................................372 Vapor Valve.............................................................................372 Fuel Vapor Vent Tube....................................................................373 Canister-to-Solenoid Tube...............................................................373 Solenoid-to-Induction Module Tube.......................................................373 Purge Solenoid..........................................................................373 Charcoal Canister.......................................................................374 5. DRIVE........................................................................................377 5.1 FASTENER TORQUE VALUES..................................................................379 Fastener Torque Values in this Chapter..................................................379 5.2 SPECIFICATIONS: DRIVE...................................................................380 Specifications..........................................................................380 5.3 PRIMARY CHAINCASE COVER.................................................................381 General.................................................................................381 Removal.................................................................................381 Installation............................................................................381 5.4 DRIVE COMPONENTS........................................................................383 Removal.................................................................................383 Installation............................................................................385 5.5 PRIMARY CHAINCASE HOUSING...............................................................388 Removal.................................................................................388 Inspection..............................................................................388 Mainshaft Bearing and Seal..............................................................388 Mainshaft Bearing Inner Race............................................................389 Shifter Shaft Bushings..................................................................390 Installation............................................................................390 5.6 CLUTCH..................................................................................392 Removal and Installation................................................................392 Clutch Pack Only........................................................................392 Clutch Pack and Bearing.................................................................394 5.7 TRANSMISSION SPROCKET...................................................................397 Removal.................................................................................397 Cleaning and Inspection.................................................................397 Installation............................................................................397 5.8 DRIVE BELT..............................................................................399 Removal and Adjustment..................................................................399 Installation............................................................................399 6. TRANSMISSION.................................................................................401 6.1 FASTENER TORQUE VALUES..................................................................403 Fastener Torque Values in this Chapter..................................................403 6.2 SPECIFICATIONS: TRANSMISSION............................................................404 Specifications..........................................................................404 Service Wear Limits.....................................................................404 6.3 TRANSMISSION............................................................................406 Power Flow..............................................................................406 6.4 SHIFTER LINKAGE.........................................................................408 Shifter Rod Adjustment..................................................................408 Heel-Toe Shift Levers...................................................................408 Shifter Rod Lever, Front................................................................408 6.5 CLUTCH RELEASE COVER....................................................................410 Removal and Disassembly.................................................................410 Cleaning and Inspection.................................................................410 Assembly and Installation...............................................................411 6.6 TRANSMISSION ASSEMBLY...................................................................412 Removal.................................................................................412 Disassembly.............................................................................413 Cleaning and Inspection.................................................................419 Assembly................................................................................419 Installation............................................................................422 6.7 MAIN DRIVE GEAR AND BEARING.............................................................424 Removal.................................................................................424 Cleaning and Inspection.................................................................425 Mainshaft Seal Replacement..............................................................427 Installation............................................................................428 6.8 TRANSMISSION CASE.......................................................................431 Removal.................................................................................431 Installation............................................................................431 Disassembly.............................................................................432 Cleaning and Inspection.................................................................432 Assembly................................................................................433 7. ELECTRICAL...................................................................................435 7.1 FASTENER TORQUE VALUES..................................................................437 Fastener Torque Values in this Chapter..................................................437 7.2 SPECIFICATIONS: ELECTRICAL..............................................................440 Specifications..........................................................................440 7.3 ELECTRONIC CONTROL MODULE (ECM).........................................................441 ECM.....................................................................................441 7.4 TURN SIGNAL AND SECURITY MODULE (TSM/TSSM/HFSM).........................................442 General.................................................................................442 Removal.................................................................................442 Installation............................................................................442 HFSM Antenna............................................................................443 7.5 IGNITION COIL...........................................................................444 Removal.................................................................................444 Installation............................................................................444 7.6 SYSTEM FUSES AND RELAYS.................................................................445 Main Fuse...............................................................................445 System Fuses and Relays.................................................................445 Main Fuse Holder........................................................................445 Fuse Blocks.............................................................................446 7.7 ELECTRICAL CADDIES......................................................................447 Top Caddy...............................................................................447 Left Side Caddy.........................................................................447 Battery Tray............................................................................450 7.8 SECURITY SIREN..........................................................................451 Removal.................................................................................451 Installation............................................................................451 7.9 STARTER.................................................................................452 General.................................................................................452 Removal.................................................................................452 Drive Assembly..........................................................................452 Solenoid................................................................................453 Installation............................................................................454 7.10 HEADLAMP: ALL EXCEPT ROAD GLIDE........................................................456 Headlamp: Single Headlamp Models........................................................456 7.11 HEADLAMP: ROAD GLIDE...................................................................458 Headlamp Adjuster Assembly..............................................................458 Headlamp Bulb Replacement: Dual Headlamp Models.........................................458 7.12 AUXILIARY/FOG LAMPS AND BRACKETS.......................................................460 Auxiliary/Fog Lamp Bulb Replacement.....................................................460 Auxiliary/Fog Lamp Housing..............................................................461 Auxiliary/Fog Lamp Bracket..............................................................463 Adjustment..............................................................................463 7.13 TAIL LAMP..............................................................................464 Tail Lamp Bulb Replacement..............................................................464 Circuit Board/Chrome Base...............................................................464 Rear Fender Lights Harness: all except FLHX, FLTRX......................................465 Rear Fascia Lamp........................................................................467 Rear Fender Lights Harness: FLHX, FLTRX.................................................467 7.14 FENDER TIP LAMPS.......................................................................469 Front Fender Tip Lamp...................................................................469 Front Fender Tip Lamp Jumper Harness....................................................469 Rear Fender Tip Lamp....................................................................471 7.15 TURN SIGNAL LAMPS......................................................................473 Turn Signal Bulb Replacement: Bullet Style..............................................473 Turn Signal Bulb Replacement: Flat Lens Style...........................................473 Front Turn Signal Lamp..................................................................473 Rear Turn Signal Lamp...................................................................477 Rear Turn Signal Lamps Bracket..........................................................480 7.16 IGNITION/LIGHT KEY SWITCH AND FORK LOCK................................................482 Fairing Models..........................................................................482 Road King Models........................................................................485 7.17 FAIRING CAP SWITCHES: FORK MOUNTED FAIRING MODELS......................................487 Removal.................................................................................487 Installation............................................................................487 7.18 INSTRUMENT NACELLE SWITCHES: FRAME MOUNTED FAIRING MODELS..............................489 Removal.................................................................................489 Installation............................................................................490 7.19 CRANKSHAFT POSITION SENSOR (CKP).......................................................491 General.................................................................................491 Removal.................................................................................491 Installation............................................................................491 7.20 ENGINE TEMPERATURE SENSOR (ET).........................................................492 Removal.................................................................................492 Installation............................................................................492 7.21 AUTOMATIC COMPRESSION RELEASE (ACR)....................................................493 General.................................................................................493 Removal.................................................................................493 Installation............................................................................493 7.22 VOLTAGE REGULATOR......................................................................495 Removal.................................................................................495 Installation............................................................................495 7.23 ALTERNATOR.............................................................................496 Removal.................................................................................496 Cleaning and Inspection.................................................................496 Installation............................................................................497 7.24 VEHICLE SPEED SENSOR (VSS).............................................................498 VSS.....................................................................................498 7.25 NEUTRAL SWITCH.........................................................................499 Removal.................................................................................499 Installation............................................................................499 7.26 OIL PRESSURE SWITCH AND SENDER.........................................................500 Removal.................................................................................500 Installation............................................................................500 7.27 STOP LAMP SWITCHES.....................................................................501 Front Stop Lamp Switch..................................................................501 Rear Stop Lamp Switch...................................................................501 7.28 HORN...................................................................................502 Inspection..............................................................................502 Removal.................................................................................502 Installation............................................................................502 7.29 CIGARETTE LIGHTER: FAIRING MODELS......................................................504 Troubleshooting.........................................................................504 Removal.................................................................................504 Installation............................................................................504 7.30 GAUGES AND INSTRUMENTS: FAIRING MODELS.................................................505 2 Inch Diameter Gauges: Fuel Level, Ambient Air Temperature, Voltmeter, Oil Pressure....505 Tachometer..............................................................................505 Speedometer.............................................................................506 7.31 INDICATOR LAMPS: FAIRING MODELS........................................................507 Indicator Lamps.........................................................................507 7.32 GAUGES AND INSTRUMENTS: ROAD KING MODELS...............................................508 Fuel Gauge..............................................................................508 Speedometer.............................................................................508 7.33 INDICATOR LAMPS: ROAD KING MODELS......................................................510 Indicator Lamps.........................................................................510 7.34 ADVANCED AUDIO SYSTEM..................................................................511 Radio...................................................................................511 Front Fairing Speakers..................................................................512 Front Headset Receptacle................................................................512 Rear Headset Receptacle.................................................................513 Rear Passenger Switches.................................................................513 Rear Speakers...........................................................................514 CB Module...............................................................................515 7.35 WIRE TROUGH............................................................................516 Removal.................................................................................516 Installation............................................................................517 7.36 MAIN WIRING HARNESS....................................................................518 Removal: All Models (Part 1)............................................................518 Removal: Road King Models (Part 2)......................................................518 Removal: Fork Mounted Fairing Models (Part 2)...........................................519 Removal: Frame Mounted Fairing Models (Part 2)..........................................520 Removal: All Models (Part 3)............................................................520 Installation: All Models (Part 1).......................................................522 Installation: Road King Models (Part 2).................................................524 Installation: Fork Mounted Fairing Models (Part 2)......................................525 Installation: Frame Mounted Fairing Models (Part 2).....................................525 Installation: All Models (Part 3).......................................................525 7.37 INTERCONNECT HARNESS...................................................................526 Fork Mounted Fairing Models.............................................................526 Frame Mounted Fairing Models............................................................529 7.38 RADIO ANTENNA CABLE....................................................................532 Models Equipped with Tour-Pak...........................................................532 Models without Tour-Pak.................................................................533 7.39 REAR AUDIO HARNESS: ULTRA MODELS.......................................................535 Removal.................................................................................535 Installation............................................................................535 7.40 CB ANTENNA CABLE: ULTRA MODELS.........................................................537 Removal.................................................................................537 Installation............................................................................537 7.41 HANDLEBAR SWITCH ASSEMBLIES............................................................539 Removal.................................................................................539 Specific Repair Procedures: Upper Switch Housings.......................................539 Specific Repair Procedures: Right Side Lower Switch Housings............................542 Specific Repair Procedures: Left Side Lower Switch Housings.............................545 General Repair Procedures...............................................................548 Installation............................................................................550 7.42 TSSM/HFSM MAINTENANCE..................................................................554 General.................................................................................554 Fob Battery.............................................................................554 Smart Siren (If Installed)..............................................................554 7.43 PERSONAL IDENTIFICATION NUMBER (PIN)...................................................555 General.................................................................................555 Initial PIN Entry.......................................................................555 Changing the PIN........................................................................555 7.44 H-DSSS ACTUATION.......................................................................557 General.................................................................................557 Actuation...............................................................................557 Fob Assignment..........................................................................557 Power Disruption and Configuring........................................................557 7.45 TSM/HFSM: PASSWORD LEARN...............................................................558 General.................................................................................558 Password Learn..........................................................................558 A. APPENDIX A CONNECTOR REPAIR..................................................................561 A.1 AUTOFUSE UNSEALED ELECTRICAL CONNECTORS.................................................563 Autofuse Unsealed Connector Repair......................................................563 A.2 BOSCH COMPACT 1.1M CONNECTOR............................................................564 Bosch Compact 1.1M Connector............................................................564 A.3 DELPHI 100W MICRO-PACK SEALED CONNECTOR.................................................565 Delphi 100W Micro-Pack Sealed Connector Repair..........................................565 Crimping Terminals......................................................................566 A.4 DELPHI 150 METRI-PACK SEALED CONNECTORS.................................................567 Delphi 150 Metri-Pack Sealed Connector Repair...........................................567 A.5 DELPHI 280 METRI-PACK UNSEALED CONNECTORS...............................................569 Fuse Block Repair.......................................................................569 A.6 DELPHI 480 METRI-PACK UNSEALED CONNECTORS...............................................570 Delphi 480 Metri-Pack Unsealed Connector Repair.........................................570 A.7 DELPHI 630 METRI-PACK UNSEALED CONNECTORS...............................................571 Delphi 630 Metri-Pack Unsealed Connector Repair.........................................571 A.8 DELPHI 800 METRI-PACK SEALED MAIN FUSE HOUSING..........................................572 Delphi 800 Metri-Pack Sealed Main Fuse Housing Repair...................................572 A.9 DELPHI METRI-PACK TERMINAL REPAIR.......................................................573 Metri-Pack Terminal Crimps..............................................................573 A.10 DELPHI MICRO 64 SEALED CONNECTORS......................................................575 Delphi Micro 64 Sealed Connector Repair.................................................575 A.11 DELPHI GT 150 SEALED CONNECTORS........................................................578 Delphi GT 150 Sealed Connector Repair...................................................578 A.12 DELPHI GT 280 SEALED 73-TERMINAL ECM CONNECTOR.........................................580 Delphi GT 280 Sealed 73-Terminal ECM Connector..........................................580 A.13 DEUTSCH DT SEALED CONNECTORS...........................................................582 Deutsch DT Sealed Connector Repair......................................................582 A.14 DEUTSCH DT SEALED TERMINAL REPAIR......................................................586 Deutsch DT Sealed Terminal Crimps.......................................................586 A.15 DEUTSCH DTM SEALED MINI TERMINAL REPAIR................................................587 Deutsch DTM Sealed Mini Terminal Crimps.................................................587 A.16 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR...................................588 Deutsch DTM Sealed Solid Barrel Terminal Crimps.........................................588 A.17 JAE MX19 SEALED CONNECTORS.............................................................590 JAE MX19 Sealed Connectors..............................................................590 Crimping Terminals......................................................................590 A.18 MOLEX CMC SEALED CONNECTORS............................................................591 Molex CMC Sealed Connectors.............................................................591 Crimping Terminals......................................................................592 A.19 MOLEX MX 150 SEALED CONNECTORS.........................................................593 Molex MX 150 Sealed Connector Repair....................................................593 Crimp Terminal to Lead..................................................................594 A.20 TYCO 070 MULTILOCK UNSEALED CONNECTOR..................................................597 Tyco 070 Multilock Unsealed Connector Repair............................................597 A.21 TYCO GET 64 SEALED CONNECTOR...........................................................601 Tyco GET 64 Sealed Connector............................................................601 Crimping Terminals......................................................................602 A.22 TYCO MCP SEALED CONNECTOR..............................................................603 Tyco MCP Sealed Connector...............................................................603 Crimping Terminals......................................................................604 A.23 SEALED SPLICE CONNECTORS...............................................................605 Sealed Splice Connector Repair..........................................................605 B. APPENDIX B WIRING............................................................................607 B.1 CONNECTORS..............................................................................609 Connector Locations.....................................................................609 B.2 WIRING DIAGRAMS.........................................................................615 Wiring Diagram Information..............................................................615 2013 Touring Wiring Diagrams............................................................617 C. APPENDIX C ABS...............................................................................665 C.1 FASTENER TORQUE VALUES..................................................................667 Fastener Torque Values in this Chapter..................................................667 C.2 ABS MODULE..............................................................................668 Hydraulic Control Unit (HCU)............................................................668 Electronic Control Unit (ECU)...........................................................669 C.3 WHEEL SPEED SENSORS.....................................................................671 Front Wheel Speed Sensor (WSS)..........................................................671 Rear Wheel Speed Sensor.................................................................672 C.4 ABS BRAKE LINES.........................................................................673 Front Master Cylinder to ABS Module.....................................................673 ABS Module to Front Brake Calipers......................................................674 Rear Master Cylinder to ABS Module......................................................676 ABS Module to Rear Brake Caliper........................................................678 D. APPENDIX D CONVERSIONS.......................................................................679 D.1 METRIC CONVERSION.......................................................................681 Conversion Table........................................................................681 D.2 FLUID CONVERSIONS.......................................................................682 United States System....................................................................682 Metric System...........................................................................682 British Imperial System.................................................................682 D.3 TORQUE CONVERSIONS......................................................................683 United States System....................................................................683 Metric System...........................................................................683 E. APPENDIX E GLOSSARY..........................................................................685 E.1 GLOSSARY................................................................................687 Acronyms and Abbreviations..............................................................687 TOOLS...........................................................................................691 TORQUE VALUES...................................................................................699 INDEX...........................................................................................715
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