2016 Harley Davidson Softail Models Service Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2016 Harley Davidson Softail Models Service Manual – PDF DOWNLOAD
GENERAL:
- 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.
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 Wiring
B Appendix B Reference
- 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:
2016 Harley Davidson Softail Models Service Manual – PDF DOWNLOAD
1 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 1-1
1 2 GENERAL
Servicing а New Motorcycle 1-3
Safe Operating Maintenance 1-3
Disposal and Recycling 1-3
Shop Practices 1-3
Repair Notes 1-3
Safety 1-3
Removing Parts 1-3
Cleaning 1-3
DisassemЫy and AssemЫy 1-4
Checking Torques оп Fasteners 1-4
Magnetic Parts Trays 1-4
Repair and Replacement Procedures 1-4
Hardware and Threaded Parts 1-4
Threadlocking Agents 1-4
Wiring, Hoses and Lines 1 -4
lnstruments and Gauges 1 -4
Bearings 1-4
Bushings 1-4
LGipa-sTkyeptes S e a l s 11 –44
O-Rings 1-5
Gears 1 -5
Shafts 1-5
Part Replacement 1-5
Cleaning 1 -5
Protecting Rubber Parts 1-5
Cleaning Process 1-5
Rust or Corrosion Removal 1-5
Tool BSeaaferitnyg s 11 –55
Air Tools 1-5
Wrenches 1 -5
Pliers/Cutters/Pry Bars 1-6
Hammers 1-6
Punches/Chisels 1-6
Screwdrivers 1-6
Ratchets and Handles 1-6
Sockets 1-6
Storage Units 1-6
1 3 FUEL AND OIL
Fuel 1-7
GEnagsionlein eL uBblreicnadtsio n : T w i n C a m 1 0 3 11 –77
Engine Lubrication: Twin Cam 110 1-8
Winter Lubrication 1-8
1 4 MAINTENANCE SCHEDULE
General 1-9
1 5 ENGINE OIL AND FILTER
Checking and Adding Oil 1-14
Changing Oil and Oil Filter 1-14
1 6 AIR CLEANER AND EXHAUST SYSTEM
Air Cleaner: AII except FLSS, FLSTFBS 1-16
Removal 1-16
lnstallation 1-16
Air Cleaner: FLSTFBS 1 -17
Rain Sock 1 -17
Removal 1-17
lnstallation 1-17
Air Cleaner: FLSS 1-17
Removal 1-17
lnstallation 1-17
Cleaning Filter Element 1-18
Check Exhaust System Leakage 1-18
Exhaust System Leakage 1-18
1 7 TIRES AND WHEELS
TGierense r a l 11 –1199
Tire Replacement 1-20
lnspection 1-20
When То Replace Tires 1-20
Wheel Bearings 1-20
Wheel Spokes 1-20
ldentify Wheel Spoke Groups 1-20
Adjust Wheel Spokes 1-21
1 8 PRIMARY CHAINCASE LUBRICANT
CGheannegrael P r i m a r y C h a i n c a s e L u b r i c a n t 11 –2222
1 9 TRANSMISSION LUBRICANT
Check Transmission Lubricant 1-24
Change Transmission Lubricant 1-24
1 10 CLUTCH: MECHANICAL CLUTCH
Adjustment 1-26
1 11 HYDRAULIC CLUTCH FLUID:
HYDRAULIC CLUTCH
z
w
1-
z
о
u
General 1-28
0
u lnspect Fluid 1-28
1 12 DRIVE BELT AND SPROCKETS
CGleenaenrinalg 11 –2299 m lnspection 1 -29 t-,;
Sprockets 1-29
Drive Belt 1-29
Check Drive Belt Deflection 1-30
Adjusting Drive Belt Deflection 1 -32
1 13 CABLE AND CHASSIS LUBRICATION
General 1-33
СаЫеs and Hand Levers 1-33
Jiffy Stand 1 -33
Steering Head Bearings 1-33
1 14 BRAKES
Fluid lnspection 1-34
lnspect Brake Lines 1-35
1 15 BRAKE PADS AND DISCS
1 nspection 1-36
Brake Pads 1-36
Brake Disc 1-36
Brake Pad Replacement 1-36
Rear Brake Caliper 1-36
Front Brake Caliper 1-38
V
TABLE OF CONTENTS
1 16 SPARK PLUGS
Removal 1-40
lnspection 1-40
Cleaning 1-40
lnstallation 1-41
1 17 STEERING HEAD BEARINGS
Adjustment: FLSTC, FLSTF, FLSTFB, FLSTFBS, FLSTN, FLS,
FLSS 1-42
Bearing Adjustment (Fall-Away) 1-42
Adjustment: FXSB 1-43
Bearing Adjustment (Fall-away) 1-43
Lubrication 1 -44
1 18 BATTERY MAINTENANCE
General 1-45
Cleaning and lnspection 1-46
Voltage Test 1-46
CharSgainfge tyB aPttreercya u t i o n s 11 –4466
Using а Battery Charger 1-46
SBtaottreargye D i s c o n n e c t i o n a n d R e m o v a l 11 –447 7
Battery lnstallation and Connection 1-48
1 19 HEADLAMP ALIGNMENT
Headlamp Alignment 1-50
Headlamp Adjustment 1-50
1 20 ·SUSPENSION ADJUSTMENTS
Shock Absorbers 1-51
Calculate Number of Preload Turns 1-51
Adjustment 1-51
1 21 STORAGE
General 1-52
Placing in Storage 1-52
Removal from Storage 1-52
1 22 TROUBLESHOOTING
EGnegnienrea l 11 –5544
Starter Motor Does Not Operate ог Does Not Turn Engine
Over 1-54
Engine Turns Over But Does Not Start 1-54
SSttaarrttss BHuatr Rd u n s l r e g u l a r l y о г M i s s e s 11 –5544 А Spark Plug Fouls Repeatedly 1-55
Pre-lgnition ог Detonation (Knocks ог Pings ) 1-55
Overheating 1-55
Valve Train Noise 1-55
Excessive Vibration 1-55
Check Engine Light llluminates During Operation 1-55
LubriOcail tiDoone Ss yNsotet mR e t u r n Т о O i l T a n k 1 1–5555
Engine Uses Тоо Much Oil Or Smokes Excessively”1-55
Engine Leaks Oil From Cases, Pushrods, Hoses,
LEotcw O il P r e s s u r e 1 1 –5556
High Oil Pressure 1-56
Electrical System 1-56
VI TABLE OF CONTENTS
Alternator Does Not Charge 1-56
Alternator Charge Rate Is Below Normal 1-56
Speedometer Operates Erratically 1-56
Transmission 1-56
Shifts Hard 1-56
Jumps Out Of Gear 1-56
Clutch Slips 1-56
Clutch Drags Ог Does Not Release 1-56
Clutch Chatters 1-56
Handling 1 -56
lrregularities 1-56
Brakes 1-56
Brake Does Not Hold Normally 1-56
CHASSIS
2 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 2-1
2 2 SPECIFICATIONS
SpecCifhicaastisoisn sS p e c if i c a t i o n s 22 –66
Tire Specifications 2-7
2 3 VEHICLE IDENTIFICATION NUMBER
(V I N )
Vehicle ldentification Number 2-1 О
2 4 FRONT WHEEL
Removal 2-12
DisassemЫy 2-12
Disc Wheel 2-12
CleaLnaincge da nWdh leneslp e c t io n 22 –1142 AssemЫy 2-14
Disc Wheel 2-15
lnstaLllaactieodn W h e e l 22 –1155
2 5 REAR WHEEL
Removal 2-16
DisassemЫy 2-16
CAslesaenminЬgly a n d l n s p e c t i o n 2 2 –1177
lnstallation 2-18
2 6 WHEEL LACING
Wheel Lacing: Angle Flange Hub 2-19
2 7 CHECKING AND TRUING WHEELS
General 2-21
Checking Wheel Runout 2-21
Checking Radial Runout 2-21
Checking Lateral Runout 2-21
Laced Wheel Rim Offset 2-22
True Laced Wheels 2-24
Adjust Radial Runout 2-24
Adjust Lateral Runout 2-24
2 8 SEALED WHEEL BEARINGS
lnspect 2-26
Removal 2-26
lnstallation 2-27
2 9 TIRES
General 2-29
Removal 2-29
Clean, lnspect and Repair 2-30
lnstall 2-30
Tube-Type Tires 2-30
Tubeless Tires: Cast Wheels 2-31
ChecLka tTeirrael RRuunnoouut t 22 –3311
Radial Runout 2-31
Balance Wheel 2-32
Static vs Dynamic 2-32
Weights 2-32
2 1 О VEHICLE ALIGNMENT
Axle Alignment 2-33
Checking Axle Alignment 2-33
Adjusting Axle Alignment 2 -34
2 11 FRONT BRAKE MASTER CYLINDER
General 2-35
Removal and DisassemЫy 2-35
Cleaning and lnspection 2-36
AssemЫy and lnstallation 2-36
2 12 FRONT BRAKE CALIPER
Removal 2-38
DisassemЫy 2-38
Cleaning, lnspection and Repair 2-39
AssemЫy 2-40
lnstallation 2-40
2 13 REAR BRAKE MASTER CYLINDER
General 2-41
Rear Brake Pedal 2-41
Pedal Height 2-41
Pedal Replacement 2-41
Pedal Pad 2-41
Removal 2-41
DisassemЫy 2-41
Cleaning and lnspection 2-42
AssemЫy 2-43
lnstallation 2-44
2 14 REAR BRAKE CALIPER
Removal 2-47
DisassemЬly 2-47
Cleaning, lnspection and Repair 2-49
AssemЫy 2-49
Rear Вгаkе Line Routing 2-50
1 nstallation 2-50
2 15 BRAKE LINES
Front Master Cylinder to Front HCU 2-52
Removal 2-52
lnstallation 2-52
TABLE OF CONTENTS
HCU to Front Brake Caliper 2-52
Removal 2-52
lnstallation 2-53
Rear Master Cylinder to Rear HCU 2-53
Removal 2-53
lnstallation 2-54
Rear HCU to Rear Brake Caliper 2-55
Removal 2-55
lnstallation 2-56
2 16 ABS: ELECTRONIC CONTROL UNIT
(ECU)
Removal: AII But FXSB 2-57
lnstallation: AII But FXSB 2-57
Removal: FXSB 2-58
lnstallation: FXSB 2-58
2 17 ABS: HYDRAULIC CONTROL UNIT
(HCU)
Front Hydraulic Control Unit (HCU) 2-59
Removal 2-59
lnstallation 2-59
RearR Heymdoravualli c C o n t r o l U n i t ( H C U ) 2 2 –6600
lnstallation 2-60
2 18 BLEEDING BRAKES
General 2-62
Procedure 2-62
2 19 FRONT FORK
CGheencekra Fl o r O i l L e a k 2 2–6644
Fork Oil Seals 2-64
Check Oil Leak 2-64
Replacing Fork Oil 2-64
Removal 2-65
DisassemЫy 2-65
Clean and lnspect 2-69
lAnssstaelmlaЫtioyn 22 –6699
2 20 STEERING HEAD
RemFoLvaSlT C , F L S T F L S T F B , F L S T F B S , F L S T N , F L S , F 2L-S7S1
Models 2-71
lnspFecXtSioBn M o d e l s 22 –7712
AII Models 2-72
DisassemЫy 2-72
Removing Lower Bearings From Fork Stem 2-72
AsseSmteЫeyri n g H e a d B e a r i n g R a c e R e m o v a l 2 2–7722
lnstallation 2-73
FLSTC, FLSTF, FLSTFB, FLSTFBS, FLSTN, FLS, FLSS
Models 2-73
FXSB Model 2-73
TABLE OF CONTENTS VII
TABLE OF CONTENTS
2 21 BELT GUARD AND DEBRIS
DEFLECTOR
Removal 2-7 4
Belt Guard 2-74
Debris Deflector 2-74
lnstallation 2-74
Belt Guard 2-74
Debris Deflector 2-74
2 22 REAR SHOCK ABSORBERS
General 2-75
Removal 2-75
lSnhsotaclkla tDioisnp o s a l 22 –7756
2 23 REAR FORK
Removal 2-78
Cleaning and lnspection 2-79
Plnisvtoatl lBateioanri n g R e p l a c e m e n t 22–7890
2 24 CLUTCH CONTROL: MECHANICAL
CLUTCH
Rlnesmtaollavtaiol n 22–8811
2 25 CLUTCH MASTER CYLINDER AND
RESERVOIR: HYDRAULIC CLUTCH
RDiesmasosveem Ы e 2 2 –8833
Cleaning and lnspection 2-84
AssemЬle 2-84
lnstall 2-85
2 26 CLUTCH HAND LEVER: HYDRAULIC
CLUTCH
Rlnesmtaollavtaiol n 22 –8866
2 27 CLUTCH FLUID LINE: HYDRAULIC
CLUTCH
Replacement 2-87
Removal 2-87
lnstallation 2-87
2 28 BLEEDING CLUTCH FLUID LINE:
HYDRAULIC CLUTCH
DrainD aranidn F i l l 22 –8899
Fill 2-89
Bleed Fluid Line and Secondary Clutch Actuator 2-90
2 29 LEFT HANDLEBAR GRIP
Removal and lnstallation 2 -91
Removal 2-91
1 nstallation 2-91
VIII TABLE OF CONTENTS
2 30 HANDLEBAR: FLSTC, FLSTN, FLS,
FLSS
Removal 2-92
lnstallation 2-93
2 31 HANDLEBAR: FLSTF, FLSTFB,
FLSTFBS
Removal 2-94
lnstallation 2-95
2 32 HANDLEBAR: FXSB
Removal 2-96
lnstallation 2-96
2 33 FRONT FENDER
Removal 2-98
lnstallation 2-98
2 34 REAR FENDER: FLSTC
Removal 2-99
lnstallation 2-99
2 35 REAR FENDER: FLSTF, FLSTFB,
FLSTFBS
Rlnesmtaollavtaiol n 22 –110011
2 36 REAR FENDER: FLS, FLSS
Rlnesmtaollavtaiol n 22–110022
License Plate Bracket AssemЫy and lnstallation: FLS,
FLSS {all but Domestic and California models) 2-102
FLiLcSenSs (eD Polmatees Bticra acnkde tC AaslsifeomrnЫiay m aondde llnss) t a l a t i o n : F L 2S-1, 03
Fender lnstallation 2-103
2 37 REAR FENDER: FXSB
Removal 2-105
lnstallation 2-106
2 38 REAR FENDER: FLSTN
RDeismasosveaml Ы y 2 2 –110077
AssemЫy 2-108
lnstallation 2-109
2 39 REAR FENDER WIRE CONDUIT
lnstallation 2-11 О
2 40 FOOTBOARDS AND FOOTRESTS
Rider Footboards 2-111
Removal 2-111
lnstallation 2-111
Rider Footrests 2 -111
Removal 2-111
lnstallation 2-111
Passenger Footrests 2-111
Removal 2-111
lnstallation 2-112
2 41 JIFFY STAND
Cleaning 2-113
Sensor: HDI Models 2-113
Removal 2-113
lnstallation 2-113
2 42 FORK LOCK
Removal 2-115
lnstallation 2-115
2 43 SEAT AND STRAP RETENTION NUT
Replacement 2-116
2 44 SEAT: FLS, FLSS, FXSB
Replacement 2-117
Removal 2-117
lnstallation 2-117
2 45 SEAT: FLSTN, FLSTF, FLSTFB,
FLSTFBS,FLSTC
Removal and lnstallation 2-118
2 46 LUGGAGE RACK: FLSTN
Removal and lnstallation 2-119
2 47 SADDLEBAGS: FLSTC
Removal 2-120
lnstallation 2-120
2 48 WINDSHIELD: FLSTC
Removal 2-122
lnstallation 2-122
2 49 SAREE GUARD: INDIA MODELS
Upper Saree Guards: AII Models Except FXSB 2-123
Removal 2-123
lnstallation 2-123
Upper Saree Guards: FXSB 2-123
Removal 2-123
lnstallation 2-123
Lower Saree Guard 2-123
Removal 2-123
lnstallation 2-123
2 50 FRONT LICENSE PLATE BRACKET
Removal and lnstallation 2-124
2 51 MEDALLIONS, BADGES AND TANK
EMBLEMS
Removal 2-125
lnstallation 2-125
ENGINE
3 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 3-1
TABLE OF CONTENTS
3 2 SPECIFICATIONS
Specifications 3-4
3 3 SERVICE WEAR LIMITS
General 3-7
3 4 ENGINE OIL FLOW
Oil Feed 3-10
Тор End 3-11
Bottom End 3-12
Chain Guide Bracket 3-14
Oil Return 3-14
3 5 OIL PUMP OPERATION
General 3-15
Operation 3-15
3 6 BREATHER OPERATION
General 3-17
3 7 OIL PRESSURE
Oil Pressure lndicator Lamp 3-18
Checking Oil Pressure 3-18
3 8 TROUBLESHOOTING
Diagnosing Valve Train Noise 3-20
Compression Test 3-20
Cylinder Leakdown Test 3-21
Diagnosing Smoking Engine ог High Oil Consumption 3-21
Check Before Cylinder Head Removal: 3-21
Check After Cylinder Head Removal: 3-21
3 9 HOW ТО USE THIS SECTION
Тор End Repair 3-22
Bottom End Repair 3-22
Typical Symptoms 3-22
3 1 О ТОР END SERVICE
Engine in Chassis 3-23
Engine Removed from Chassis 3-24
3 11 САМ COMPARTMENT SERVICE
Replace Camshaft 3-25
Engine Removed From Chassis 3-26
3 12 STRIPPING MOTORCYCLE FOR
SERVICE
Procedure 3-27
Cam Compartment Service Only 3-27
Complete Тор End Service 3-27
3 13 ASSEMBLING MOTORCYCLE AFTER
SERVICE
Procedure 3-28
After Complete Тор End Service 3-28
After Cam Compartment Service Only 3-28
3 14 REMOVING ENGINE FROM CHASSIS
Procedure 3-29
TABLE OF CONTENTS IX
TABLE OF CONTENTS
3 15 INSTALLING ENGINE IN CHASSIS
Р roced u re 3-30
3 16 ТОР END OVERHAUL: DISASSEMBLY
General 3-32
Rocker Covers 3-32
Rocker Arm Support Plate 3-32
Pushrods, Lifters and Covers 3-34
Cylinder Head 3-34
Cylinder 3-35
Piston 3-36
3 17 BREATHER ASSEMBLY
DisassemЫy 3-38
ACslesaenminЫg ya n d l n s p e c t i o n 3 3 –3388
3 18 ROCKER ARM SUPPORT PLATE
DisassemЫy 3-39
Cleaning, lnspection and Repair 3-39
R1 noscpkeecrt iSonh a f t F i t 33 –3399
Rocker Arm Shaft to Bushing 3-40
Replace Rocker Arm Bushings 3-40
AssemЫy 3-41
3 19 PUSHRODS, LIFTERS AND COVERS
DisassemЫy 3-42
Clean and lnspect 3-42
AlnssspeemctЫ Lei f t e r s 33 –4422
3 20 CYLINDER HEAD: TWIN САМ 103
DDeistaesrmseinminЫgy S e r v i c e 3 3 –4444
Cleaning 3-45
lnspection 3-45
Cylinder Head 3-45
Valve Guides 3-46
Valves 3-46
Valve Springs 3-46
VTaaplveer eSde aKtes e p e r s 33 –4466
Valve Guide Replacement 3-46
R1 nesmtaollavatiol n 33 –44 67
Valve and Seat Refacing 3-50
AssemЫy 3-52
3 21 CYLINDER HEAD: ТWIN САМ 110
Cylinder Head Repair 3-54
3 22 CYLINDER: TWIN САМ 103
Cleaning 3-55
lnspection 3-55
Deglazing Cylinder 3-57
Boring and Honing Cylinder 3-57
3 23 CYLINDER: ТWIN САМ 110
lnspection 3-58
Х TABLE OF CONTENTS
Cylinder Ваге Finished Size 3-58
3 24 PISTON: TWIN САМ 103
DisassemЬly 3-59
Piston Rings 3-59
Cleaning 3-59
lnspection 3-59
AssemЫy 3-61
Checking Piston Ring Gap 3-61
lnstalling Piston Rings 3-61
3 25 PISTON: TWIN САМ 110
Checking Piston Clearance 3-63
3 26 ТОР END OVERHAUL: ASSEMBLY
General 3-64
Piston 3-64
Cylinder 3 -65
Cylinder Head 3-67
Pushrods, Lifters and Covers 3-70
RBroecaktehre Ar armnd S Rupopckoertr PCloatvee r 33 –7712
3 27 САМ COMPARTMENT AND
COMPONENTS
Cam Support Plate and Cover Removal 3-74
PCraemp aCreh aEinn gainned S p r o c k e t s R e m o v a l 33 –7744
Cam Support Plate Removal 3-75
Cam Support Plate Cleaning and lnspection 3-76
COail mP rSesuspuproer tR Pellaietef V a l v e 33 –7766
Camshafts 3-76
Rlnesmtaollavtaiol n ‘ 3 3 –7767
Oil Pressure Relief Valve 3-78
Rlnesmpeocvtaiol n 3 3 –7789
Caml nNsetaeldlalet ioBne a r i n g s 3 3–7799
Removal 3-79
lnstallation 3-81
Cam Support Plate and Cover lnstallation 3-82
3 28 OIL PUMP
RCleemanoivnagl a n d l n s p e c t i o n 33 –8877
lnstallation 3-88
3 29 CRANKCASE DISASSEMBLY AND
REPAIR: TWIN САМ 103
Crankcase DisassemЫy 3-89
Counterbalancer AssemЫy 3-89
Cleaning and lnspection 3-91
Right Crankcase Half 3-92
Chain Guide Screen 3-92
Main Bearing Removal 3-92
Main Bearing lnstallation 3 -93
Piston Jets Removal 3-93
Piston Jets lnstallation 3-93
Left Crankcase Half 3-94
Main Bearing Removal 3-94
Main Bearing lnstallation 3-95
Sprocket Shaft Bearing lnner Race 3-95
Removal 3-95
lnstallation 3-96
Cylinder Studs 3-98
Removal 3-98
lnstallation 3-98
Pipe Plugs and Oil Fittings 3-98
Removal/lnstallation 3-98
3 30 CRANKCASE DISASSEMBLY AND
REPAIR: ТWIN САМ 110
General 3-99
3 31 FLY WHEEL AND CONNECTING RODS
Symptoms 3-100
Overview 3-100
VNiob rOatili oPnr e s s u r e 3 3–110000
1 nspection 3-100
Measuring Crankshaft Runout 3-100
Crankshaft lnstalled 3-100
Crankshaft Removed 3-101
3 32 COUNTERBALANCER ASSEMBLY
REPAIR
Cleaning, lnspection and Repair 3-102
General 3-102
Balance Shaft Removal 3-102
Bearing Removal 3-103
BBaallaannccee SShhaafftt Slnusptaplolartt ioBne a r in g s R e m o v a l 33 –110043
Balance Shaft Support Bearings lnstallation 3-104
Front and Rear Balance Sprockets 3-105
Hydraulic Tensioners 3-105
Chain Tensioner Guides 3-105
Balance Shaft Support 3-105
Balance Chain 3-106
3 33 CRANKCASE ASSEMBLY
Counterbalancer AssemЫy lnstallation 3-107
Crankcase AssemЫy 3-110
3 34 OIL TANK: ALL BUT FXSB
Removal and DisassemЫy 3-113
OOiill TLainnek F it t i n g s / R e ta i n e r s 33 –111135
lnstallation 3-116
3 35 OIL TANK: FXSB
Removal and DisassemЫy 3-117
OOiill TLainnek F it t i n g s / R e t a in e r s 33 –111179
lnstallation 3-120
FUEL SYSTEM
4 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 4-1
TABLE OF CONTENTS
4 2 SPECIFICATIONS: FUEL SYSTEM
Specifications 4-3
4 3 FUEL PRESSURE TEST
General 4-4
Testing 4-4
4 4 INTAKE LEAK TEST
General 4-6
Leak Tester 4-6
Parts List 4-6
AssemЫe Tester 4-6
Adjust Tester 4-6
Procedure 4-6
4 5 AIR CLEANER
Air Cleaner: AII But FLSTFBS, FLSS 4-8
Removal 4-8
lnstallation 4-8
Replace lnsert: With Screw Access 4-8
Replace lnsert: Without Screw Access 4-8
Snorkel 4-8
Air Cleaner: FLSTFBS 4-9
Removal 4-9
lnstallation 4-9
Air Cleaner: FLSS 4-10
Removal 4-1 О
1 nstallation 4-1 О
4 6 FUEL SUPPLY LINE
PDuisrcgoen Fnuecetl FSuueplp Slyu Lpipnley L i n e 44 –1111
4 7 CONSOLE: FXSB
Removal 4-12
lnstallation 4-12
4 8 FUEL TANK
General 4-13
RCelemanoivnagl a n d l n s p e c t i o n 44–1143
lnstallation 4-15
Fuel RSeumppolvya Cl h e c k V a l v e / Т u b e 44–1155
lnstallation 4-15
4 9 TWIST GRIP SENSOR (TGS)
Remove 4-17
lnstall 4-17
4 1 О THROTTLE CONTROL ACTUATOR
(ТСА)
General 4-19
4 11 INDUCTION MODULE
Removal 4-20
lnstallation 4-21
TABLE OF CONTENTS XI
TABLE OF CONTENTS
4 12 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE SENSOR (ТМАР)
Removal 4-22
lnstallation 4-22
4 13 HEATED OXYGEN SENSORS (НО2)
General 4-23
Removal 4-23
Front НО2 Sensor 4-23
Rear НО2 Sensor 4-23
lnstaFl/raotinotn Н О 2 S e n s o r 44–2233
Rear НО2 Sensor 4-23
4 14 FUEL INJECTORS
General 4-25
lRnesmtaollavtaiol n 44 –2255
4 15 ENGINE TEMPERATURE SENSOR (ЕТ)
General 4-27
Removal 4-27
lnstallation 4-27
4 16 FUEL PUMP AND FUEL GAUGE
SENDING UNIT
GReemneorvaal l 44–2288
VDaispaosrs VeamlvЬe/y a n d A s s e m Ь / y 44–3209
Fuel Filter 4-30
Regulator 4-30
lnlet sock 4-31
Fuel Pump 4-31
lnstal/ation 4-32
4 17 EXHAUST SYSTEM
Mufflers: FLSTC, FXSB 4-33
ARsesmeomvЬa/ly 44–3333
System: FLSTC, FXSB 4-33
Removal 4-33
1 nstal/ation 4-33
FMLuSffSle r s : F L S T N , F L S T F , F L S T F B , F L S T F B S , F L S , 4-35
Removal 4-35
SysteAmss: eFmLSЬ/TyN , F L S T F , F L S T F B , F L S T F B S , F L S , 4-35
FLSS 4-35
lRnesmtaollvaatiol n 44–3355
4 18 EVAPORATIVE EMISSIONS CONTROL
SYSTEM
General 4-37
Charcoal Canister 4-38
Removal 4-38
lnstallation 4-38
Purge Solenoid 4-38
Remova/ 4-38
XII TABLE OF CONTENTS
lnstallation 4-38
Hose Routing and Rep/acement 4-38
Fuel Tank Vent Hose 4-38
Purge Solenoid-to-lnduction Module Tube 4-38
Charcoal Canister-to-Purge Solenoid Tube 4-39
Vent Tube-to-Charcoal Canister Tube 4-39
DRIVE
5 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 5-1
5 2 SPECIFICATIONS: DRIVE
Specifications 5-2
5 3 PRIMARY CHAINCASE COVER
lRnesmtaol/avtaiol n 55 –33
5 4 DRIVE COMPONENTS
Removal 5-4
lnstallation 5-6
5 5 CLUTCH RELEASE BEARING AND PUSH
ROD: HYDRAULIC CLUTCH
Removal 5-9
lnstal/ation 5-9
lMnsetaasllu Crelu Rtcehle lnassep ePcltaioten CMoovveemr e n t 55–99
5 6 PRIMARY CHAINCASE HOUSING
Removal 5-11
Mlnasipneschtaioftn B e a r i n g a n d S e a / 5 5 –1111
Removal 5-11
Mainlsnhsataft/ lBateioanri n g l n n e r R a c e 5 5 –1121
Removal 5-12
lnstallnlasttioanl/a t io n 5 5 –1132
5 7 MECHANICAL CLUTCH
Removal and lnstallation 5-15
Clutch Pack Оп/у 5-15
PCaleratinalin Dg isAansds elmnsЬp/ye c t io n 5 5–1155
AssemЬ/y 5-16
ClutcCho Pmapclke tean Ddi sBaesasreinmgЬ / y 55 –1177
AssemЬ/y 5-18
5 8 HYDRAULIC CLUTCH
C/utch Pack Only 5-19
Partial DisassemЬ/y 5-19
C/eaning And lnspection 5-19
AssemЫy 5-19
5 9 TRANSMISSION SPROCKET
Removal 5-21
Cleaning and lnspection 5-22
1 nstallation 5-22
5 10 DRIVE BELT
Removal 5-24
1 nspection 5-24
1 nstallation 5-24
TRANSMISSION
6 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 6-1
6 2 SPECIFICATIONS: TRANSMISSION
Specifications 6-2
Service Wear Limits 6-2
6 3 TRANSMISSION
Power Flow 6-4
Neutral 6-4
First Gear 6-4
Second Gear 6-4
Third Gear 6-4
Fourth Gear 6-4
FSiifxtthh GGeeaarr 66 –44
6 4 SHIFTER
Adjustment 6-6
Shifter Rod Adjustment 6-6
Shift Lever Replacement 6-6
6 5 CLUTCH RELEASE COVER:
MECHANICAL CLUTCH
Removal and DisassemЫy 6-8
Cleaning and lnspection 6-8
AssemЫy and lnstallation 6-9
6 6 TRANSMISSION SIDE COVERS:
HYDRAULIC CLUTCH
Removal 6-1 О
lnstallation 6-1 О
6 7 SECONDARY CLUTCH ACTUATOR:
HYDRAULIC CLUTCH
Replacement 6-12
Validate Repair 6-12
6 8 TRANSMISSION ASSEMBLY
Removal 6-14
DisassemЫy 6-15
SMhaiifntesrh Cafta m / S h i f t e r F o r k s 66 –1175
Countershaft 6-19
Removing Bearing Housing Bearings 6-20
Cleaning and lnspection 6-21
AssemЫy 6-21
lnstalling Bearing Housing Bearings 6-21
Countershaft 6-22
Mainshaft 6-22
TABLE OF CONTENTS
Shifter Cam/Shifter Forks 6-23
lnstallation 6-25
6 9 MAIN DRIVE GEAR AND BEARING
Removal 6-27
Cleaning and lnspection 6-28
Needle Bearing Replacement 6-29
Mainshaft Seal Replacement 6-30
1 nstallation 6-31
lnstalling Main Drive Gear Bearing 6-31
lnstalling Main Drive Gear 6-31
lnstalling Main Drive Gear Large Seal 6-32
6 1 О TRANSMISSION CASE
Removal 6-34
lnstallation 6-34
DisaSssheifmteЫr Ay r m A s s e m Ь l y 66 –3355
Cleaning and lnspection 6 -35
AssemЫy 6-36
Countershaft Needle Bearing Replacement 6-36
Shifter Pawl Lever AssemЬly 6-36
ELECTRICAL
7 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 7-1
7 2 SPECIFICATIONS: ELECTRICAL
Specifications 7-4
7 3 ELECTRICAL PANEL
General 7 -5
Removal: AII But FXSB 7-5
lnstallation: AII Except FXSB 7-6
Removal: FXSB 7-6
lnstallation: FXSB 7-6
7 4 ELECTRONIC CONTROL MODULE (ЕСМ)
General 7-8
Removal: AII But FXSB 7-8
lnstallation: AII But FXSB 7-8
Removal: FXSB 7-8
lnstallation: FXSB 7-8
7 5 BODY CONTROL MODULE (ВСМ)
General 7-9
ВСМ Configuration 7-9
Removal: AII Except FXSB 7-9
lnstallation: AII Except FXSB 7-9
Removal: FXSB 7-9
lnstallation: FXSB 7-10
7 6 H-D555 ACTIVATION
Activation 7-11
Fob Assignment 7-11
7 7 PERSONAL IDENTIFICATION NUMBER
(PIN)
General 7-12
TABLE OF CONTENTS XIII
TABLE OF CONTENTS
Changing The PIN 7 -12
Modifying an Existing PIN 7-12
7 8 HD-SSS MAINTENANCE
Fob Battery 7-14
Battery Replacement Schedule 7-14
Battery Replacement 7-14
Smart Siren (lf lnstalled) 7-14
Battery Replacement Schedule 7-14
Battery Replacement 7-14
7 9 SECURITY SIREN
Removal: AII But FXSB 7-15
Rlnesmtaollavatiol: nF: XASII BB u t F X S B 77 –1155
lnstallation: FXSB 7-16
7 10 FUSES
Rlnesmtaollavatiol n 77 –1177
7 11 IGNITION AND LIGHT SWITCH
RGeemneorvaal l a n d l n s t a l la t i o n : A II E x c e p t F X S B 7 7 –1188
Removal and lnstallation: FXSB 7-19
7 12 BATTERY CABLES
Routing Procedure 7-20
7 13 STARTER
General 7-22
Removal 7-22
DriveD AissassesmemЫЬy l y 7 7 –2222
lnspection 7-22
AssemЫy 7-23
Solenoid 7 -23
Remove Cover and Plunger 7-23
SLohnogrt PPoosstt C Coonntatacctt: :B Sattatertreyr P o s i t i v e 7 7–2234
lnstall Plunger and Cover 7-24
lnstallation 7-24
7 14 HEADLAMP
General 7-26
Headlamp AssemЫy Removal and lnstallation 7-26
Removal 7-26
Bulbl nRsetmalolavtaiol na n d l n s t a l a t i o n 7 7 –2266
FXSB Models 7-27
FLSTC, FLSTFLSTFB, FLSTFBS, FLSTN, FLS, FLSS
Models 7-27
7 15 TAIL LAMP: ALL BUT FLSTN
General 7-29
BBualsbe RReepplalacceemmeennt t 77 –2299
7 16 TAIL LAMP: FLSTN
Bulb Replacement 7-31
Tail Lamp Replacement 7-31
XIV TABLE OF CONTENTS
7 17 AUXILIARY LAMPS: FLSTC, FLSTN
Auxiliary Lamp Bulb 7-33
Removal 7-33
lnstallation 7-33
FLSTC Models 7-33
Auxiliary Lamp Bracket Removal 7 -33
Auxiliary Lamp Bracket lnstallation 7-34
Auxiliary Lamp Housing Removal 7-34
Auxiliary Lamp Housing lnstallation 7-34
FLSTN Models 7-36
Auxiliary Lamp Bracket Removal 7-36
Auxiliary Lamp Bracket lnstallation 7-36
Auxiliary Lamp Housing Removal 7-37
Auxiliary Lamp Housing lnstallation 7-37
Adjustment: FLSTC/FLSTN Models 7-38
7 18 TURN SIGNALS AND RUNNING LIGHTS
BBuullbb RReeppllaacceemmeenntt:: FBlualtle Lt eSntsy lSe t y l e 77 –4400
LampA IRI eMpoladceelsm e n t 77 –4400
FFrroonntt TTuurrnn SSiiggnnaallss:: FFLLSSTTFC, ,F FLLSSTTFNB , F L S T F B S , F L S 7, -40
FLSS, FXSB 7-40
FRXeaSrB T u r n S i g n a l s : A I B u t F L S T N , F L S , F L S S , 7 -41
Rear Turn Signals: FLS, FLSS 7-42
RReeaarr TTuurrnn SSiiggnnaallss:: FFXLSSTBN 77 –4443
7 19 CRANK POSITION SENSOR (СКР)
General 7-46
Removal 7-46
lnstallation 7-46
7 20 AUTOMATIC COMPRESSION RELEASE
(ACR)
General 7 -4 7
Rlnesmtaollavatiol n 77 –4477
7 21 IGNITION COIL
lnspect Spark Plug СаЫеs 7-49
RemAovII aBl u t F X S B 77 –4499
FXSB 7-49
lnstaAllaII tiEoxnc e p t F X S B 77 –4499
FXSB 7-50
7 22 SPARK PLUG CABLES
RGeemneorvaal l 77 –5522
lnstallation 7-52
7 23 VOLTAGE REGULATOR
DisassemЫy 7-53
lnstallation 7 -53
TABLE OF CONTENTS
7 24 ALTERNATOR Repair 7-71
Removal 7 -54 lnstallation 7 -71
Cleaning and lnspection 7-54 7 35 MAIN WIRING HARNESS lnstallation 7-54 Removal 7-72
7 25 FUEL GAUGE lnstallation 7-73
General 7 -56 7 36 HANDLE8AR CONTROL MODULES Removal 7-56
lnstallation 7-56 General 7-75
Repair Procedures 7-75
7 26 SPEEDOMETER 7 37 RIGHT HAND CONTROL MODULE General 7-58
Removal: AII 8ut FXS8 7-58 Removal 7-76
lnstallation: AII Except FXS8 7-58
Removal: FXS8 7-58
lnstallation 7-76
Front 8rake Switch Replacement 7-78
lnstallation: FXS8 7-59 7 38 LEFT HAND CONTROL MODULE
7 27 VEHICLE SPEED SENSOR (VSS) Removal 7-79
General 7-60 lnstallation 7-80
Removal 7-60 Clutch Switch Replacement 7-81
lnstallation 7-60 APPEN D I X А WIRING
7 28 WHEEL SPEED SENSORS
Front Wheel Speed Sensor 7-61 А 1 CONNECTORS
Removal 7 -61 Connector Locations A -1 lnstallation 7 -61 Function/Location А -1 Rear Wheel Speed Sensor 7-62 Place and Color A -1 Removal 7 -62 Connector Number A -1 lnstallation 7-63 Repair lnstructions A-1
7 29 INDICATOR LAMPS д 2 WIRING DIAGRAMS
General 7 -64 Wiring Diagram lnformation A -5 Rlnesmtaollavtaiol: nA: IAI 8II u8tu Ft XFSX8S 8 77 –6644 Wire Color Codes А -5 Removal: FXS8 7 -65 Wiring Diagram Symbols А-5 lnstallation: FXS8 7 -65 2016 Softail Wiring Diagrams A -7
APPEN D I X В REFERENCE 7 30 NEUTRAL SWITCH
General 7 -66 8 1 LENGTH CONVERSION Rlnesmtaollavtaiol n 77 –6666 Conversion ТаЫе 8 -1
7 31 OIL PRESSURE SWITCH 8 2 FLUID CONVERSION
General 7-67
Removal 7-67
lnstallation 7-67
United States System 8-2
Metric System 8-2
British lmperial System 8-2
7 32 REAR STOP LAMP SWITCH 8 3 TORQUE CONVERSION
General 7-68
Removal 7-68
United States System 8-3
Metric System 8-3
lnstallation 7-68 8 4 GLOSSARY
7 33 HORN Acronyms and Abbreviations 8-4
lnspection 7-69
Removal and lnstallation: AII 8ut FXS8 7-69 REFERENCE MATERIAL
Removal and lnstallation: FXS8 7-70 TOOLS I
7 34 ACTIVE EXHAUST
General 7-71 TORQUE VALUES VII
Removal 7-71
TABLE OF CONTENTS XV
TABLE OF CONTENTS
INDEX XXI
XVI TABLE
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