2016 Harley-Davidson Softail Models Service Manual – PDF DOWNLOAD
DESCRIPTION:
2016 Harley-Davidson Softail Models Service Manual – PDF DOWNLOAD
ABOUT THIS MANUAL
GENERAL :
- The rider’s safety depends upon proper motorcycle service and maintenance. If a procedure in this manual is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the procedure. Improper service or maintenance could result in death or serious injury.
- 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 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. Chapters and topics in this manual are sequentially numbered for easy navigation. For example, a cross-reference shown as 2.2 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.2 SPECIFICATIONS. For quick and easy reference, all pages contain a chapter number followed by a page number. For example, page 3-5 refers to page 5 in Chapter 3. A number of acronyms and abbreviations are used in this document. See the BA GLOSSARY for a list of acronyms, abbreviations and definitions.
TABLE OF CONTENTS:
2016 Harley-Davidson Softail Models Service Manual – PDF DOWNLOAD
MAINTENANCE
1.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 1-1
1.2 GENERAL
Servicing a 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
Disassembly and Assembly 1-4
Checking Torques on 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
Instruments and Gauges 1-4
Bearings 1-4
Bushings 1-4
Gaskets 1-4
Lip-Type Seals 1-4
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
Bearings 1-5
Tool Safety 1-5
Air Tools 1-5
Wrenches 1-5
Pliers/Cutters/Pry Bars 1-6
Hammers 1-6
Punches/Chisels 1-6
Screwd rivers 1-6
Ratchets and Handles 1-6
Sockets 1-6
Storage Units 1-6
1.3 FUEL AND OIL
Fuel. 1-7
Gasoline Blends 1-7
Engine Lubrication: Twin Cam 103 1-7
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: All except FLSS, FLSTFBS 1-16
Removal. 1-16
Installation 1-16
Air Cleaner: FLSTFBS 1-17
Rain Sock 1-17
Removal. 1-17
Installation 1-17
Air Cleaner: FLSS 1-17
Removal. 1-17
Installation 1-17
Cleaning Filter Element. 1-18
Check Exhaust System Leakage 1-18
Exhaust System Leakage 1-18
1.7 TIRES AND WHEELS
General 1-19
Tires 1-19
Tire Replacement.. 1-20
Inspection 1-20
When To Replace Tires 1-20
Wheel Bearings 1-20
Wheel Spokes 1-20
Identify Wheel Spoke Groups 1-20
Adjust Wheel Spokes 1-21
1.8 PRIMARY CHAINCASE LUBRICANT
General. 1-22
Change Primary Chaincase Lubricant… 1-22
1.9 TRANSMISSION LUBRICANT
Check Transmission Lubricant.. 1-24
Change Transmission Lubricant… 1-24 ~
ZW
IZ
oo
1.10 CLUTCH: MECHANICAL CLUTCH
Adjustment… 1-26
1.11 HYDRAULIC CLUTCH FLUID:
HYDRAULIC CLUTCH
General 1-28 ~
Inspect Fluid 1-28
1.12 DRIVE BELT AND SPROCKETS ~
General. 1-29 I~n
Cleaning 1-29 ~
Inspection 1-29
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
Cables and Hand Levers 1-33
Jiffy Sta nd 1-33
Steering Head Bearings 1-33
1.14 BRAKES
Fluid Inspection 1-34
Inspect Brake Lines 1-35
1.15 BRAKE PADS AND DISCS
Inspection 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
Inspection 1-40
Cleaning 1-40
Installation 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 Inspection 1-46
Voltage Test… 1-46
Charging Battery 1-46
Safety Precautions 1-46
Using a Battery Charger 1-46
Battery Disconnection and Removal… 1-47
Storage 1-4 7
Battery Installation 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
General 1-54
Engine 1-54
Starter Motor Does Not Operate or Does Not Turn Engine
Over 1-54
Engine Turns Over But Does Not Start 1-54
Starts Hard 1-54
Starts But Runs Irregularly or Misses 1-54
A Spark Plug Fouls Repeatedly 1-55
Pre-Ignition or Detonation (Knocks or Pings ) 1-55
Overheating 1-55
Valve Train Noise 1-55
Excessive Vibration 1-55
Check Engine Light Illuminates During Operation 1-55
Lubrication System 1-55
Oil Does Not Return To Oil Tank 1-55
Engine Uses Too Much Oil Or Smokes Excessively ..1-55
Engine Leaks Oil From Cases, Push rods, Hoses,
Etc 1-55
Low Oil Pressure 1-56
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 Or Does Not Release 1-56
Clutch Chatters 1-56
Handling 1-56
Irregularities 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
Specifications .2-6
Chassis Specifications 2-6
Tire Specifications 2-7
2.3 VEHICLE IDENTIFICATION NUMBER
(V.I.N.)
Vehicle Identification Number .2-10
2.4 FRONT WHEEL
Removal. .2-12
Disassembly 2-12
Disc Wheel 2-12
Laced Wheel. 2-12
Cleaning and Inspection 2-14
Assembly 2-14
Disc Wheel 2-15
Laced Wheel. .2-15
Installation 2-15
2.5 REAR WHEEL
RemovaL .2-16
Disassembly .2-16
Cleaning and Inspection 2-17
Assembly .2-17
Installation .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
TABLE OF CONTENTS
Inspect. .2-26
Removal 2-26
Installation 2-27
2.9 TIRES
General 2-29
Removal. .2-29
Clean, Inspect and Repair 2-30
Install .2-30
Tube-Type Tires 2-30
Tubeless Tires: Cast Wheels .2-31
Check Tire Runout. .2-31
Lateral Runout.. 2-31
Radial Runout. 2-31
Balance Wheel. 2-32
Static vs Dynamic 2-32
Weights ‘” .2-32
2.10 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 Disassembly 2-35
Cleaning and Inspection 2-36
Assembly and Installation 2-36
2.12 FRONT BRAKE CALIPER
Removal. .2-38
Disassembly .2-38
Cleaning, Inspection and Repair .2-39
Assembly .2-40
Installation 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
Disassembly 2-41
Cleaning and Inspection 2-42
Assembly .2-43
Installation .2-44
2.14 REAR BRAKE CALIPER
Removal. .2-47
Disassembly .2-47
Cleaning, Inspection and Repair 2-49
Assembly 2-49
Rear Brake Line Routing 2-50
Installation 2-50
2.15 BRAKE LINES
Front Master Cylinder to Front HCU 2-52
Removal .2-52
Installation .2-52
HCU to Front Brake Caliper 2-52
Removal 2-52
Installation 2-53
Rear Master Cylinder to Rear HCU 2-53
Removal 2-53
Installation .2-54
Rear HCU to Rear Brake Caliper 2-55
Removal 2-55
Installation 2-56
2.16 ABS: ELECTRONIC CONTROL UNIT
(ECU)
Removal: All But FXSB 2-57
Installation: All But FXSB .2-57
Removal: FXSB .2-58
Installation: FXSB .2-58
2.17 ABS: HYDRAULIC CONTROL UNIT
(HCU)
Front Hydraulic Control Unit (HCU) 2-59
Removal .2-59
Installation .2-59
Rear Hydraulic Control Unit (HCU) 2-60
Removal .2-60
Installation 2-60
2.18 BLEEDING BRAKES
General 2-62
Procedure 2-62
2.19 FRONT FORK
General 2-64
Check For Oil Leak 2-64
Fork Oil Seals 2-64
Check Oil Leak 2-64
Replacing Fork OiL 2-64
Removal. 2-65
Disassembly 2-65
Clean and Inspect… 2-69
Assembly .2-69
Installation 2-69
2.20 STEERING HEAD
Removal 2-71
FLSTC,FLSTF,FLSTFB,FLSTFBS,FLSTN,FLS,FLSS
Models 2-71
FXSB Models .2-71
Inspection .2-72
All Models 2-72
Disassembly 2-72
Removing Lower Bearings From Fork Stem 2-72
Steering Head Bearing Race Removal. 2-72
Assembly .2-72
Installation 2-73
FLSTC, FLSTGFLSTFB, 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 .2-74
Belt Guard .2-74
Debris Deflector .2-74
Installation 2-74
Belt Guard 2-74
Debris Deflector 2-74
2.22 REAR SHOCK ABSORBERS
General 2-75
Removal .2-75
Installation 2-75
Shock Disposal. .2-76
2.23 REAR FORK
Removal .2-78
Cleaning and Inspection 2-79
Pivot Bearing Replacement.. 2-79
Installation .2-80
2.24 CLUTCH CONTROL: MECHANICAL
CLUTCH
Removal 2-81
Installation .2-81
2.25 CLUTCH MASTER CYLINDER AND
RESERVOIR: HYDRAULIC CLUTCH
Remove .2-83
Disassemble .2-83
Cleaning and Inspection 2-84
Assemble 2-84
Install 2-85
2.26 CLUTCH HAND LEVER: HYDRAULIC
CLUTCH
Removal 2-86
Installation .2-86
2.27 CLUTCH FLUID LINE: HYDRAULIC
CLUTCH
Replacement. .2-87
Removal 2-87
Installation 2-87
2.28 BLEEDING CLUTCH FLUID LINE:
HYDRAULIC CLUTCH
Drain and Fill. 2-89
Drain .2-89
Fill 2-89
Bleed Fluid Line and Secondary Clutch Actuator 2-90
2.29 LEFT HANDLEBAR GRIP
Removal and Installation 2-91
Removal 2-91
Installation 2-91
VIII TABLE OF CONTENTS
2.30 HANDLEBAR: FLSTC, FLSTN, FLS,
FLSS
Removal. .2-92
Installation 2-93
2.31 HANDLEBAR: FLSTF, FLSTFB,
FLSTFBS
Removal .2-94
Installation .2-95
2.32 HANDLEBAR: FXSB
Removal. 2-96
Installation .2-96
2.33 FRONT FENDER
Removal. .2-98
Installation .2-98
2.34 REAR FENDER: FLSTC
Removal. 2-99
Installation 2-99
2.35 REAR FENDER: FLSTF, FLSTFB,
FLSTFBS
Removal. .2-101
Installation 2-1 01
2.36 REAR FENDER: FLS, FLSS
Removal. 2-102
Installation 2-1 02
License Plate Bracket Assembly and Installation: FLS,
FLSS (all but Domestic and California models) 2-102
License Plate Bracket Assembly and Installation: FLS,
FLSS (Domestic and California models) 2-103
Fender Installation 2-1 03
2.37 REAR FENDER: FXSB
Removal. .2-105
Installation 2-106
2.38 REAR FENDER: FLSTN
Removal .2-107
Disassembly 2-107
Assembly .2-108
Installation .2-109
2.39 REAR FENDER WIRE CONDUIT
Installation 2-11 0
2.40 FOOTBOARDS AND FOOTRESTS
Rider Footboards 2-111
Removal 2-111
Installation .2-111
Rider Footrests 2-111
Removal. .2-111
Installation 2-111
Passenger Footrests .2-111
Removal. 2-111
Installation .2-112
TABLE OF CONTENTS
2.41 JIFFY STAND 3.2 SPECIFICATIONS
Cleaning 2-113
Sensor: HOI Models 2-113
RemovaL .2-113
Installation .2-113
2.42 FORK LOCK
Removal. 2-115
Installation 2-115
2.43 SEAT AND STRAP RETENTION NUT
Replacement. .2-116
2.44 SEAT: FLS, FLSS, FXSB
Replacement. .2-117
Removal .2-117
Installation 2-117
2.45 SEAT: FLSTN, FLSTF, FLSTFB,
FLSTFBS,FLSTC
Removal and Installation 2-118
2.46 LUGGAGE RACK: FLSTN
Removal and Installation .2-119
2.47 SADDLEBAGS: FLSTC
RemovaL .2-120
Installation .2-120
2.48 WINDSHIELD: FLSTC
Removal. 2-122
Installation 2-122
2.49 SAREE GUARD: INDIA MODELS
Upper Saree Guards: All Models Except FXSB 2-123
Removal 2-123
Installation .2-123
Upper Saree Guards: FXSB 2-123
Removal 2-123
Installation .2-123
Lower Saree Guard 2-123
Removal .2-123
Installation 2-123
2.50 FRONT LICENSE PLATE BRACKET
Removal and Installation 2-124
2.51 MEDALLIONS, BADGES AND TANK
EMBLEMS
Removal. .2-125
Installation 2-125
ENGINE
3.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 3-1
Specifications 3-4
3.3 SERVICE WEAR LIMITS
General 3-7
3.4 ENGINE OIL FLOW
Oil Feed 3-10
Top 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 Indicator 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 or High Oil Consumption 3-21
Check Before Cylinder Head Removal: 3-21
Check After Cylinder Head Removal: 3-21
3.9 HOW TO USE THIS SECTION
Top End Repair 3-22
Bottom End Repair 3-22
Typical Symptoms 3-22
3.10 TOP END SERVICE
Engine in Chassis 3-23
Engine Removed from Chassis 3-24
3.11 CAM 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 Top End Service 3-27
3.13 ASSEMBLING MOTORCYCLE AFTER
SERVICE
Procedure 3-28
After Complete Top 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 Cylinder Bore Finished Size 3-58
Procedure 3-30
3.16 TOP 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
Disassembly 3-38
Cleaning and Inspection 3-38
Assembly 3-38
3.18 ROCKER ARM SUPPORT PLATE
Disassembly 3-39
Cleaning, Inspection and Repair 3-39
Inspection 3-39
Rocker Shaft Fit. 3-39
Rocker Arm Shaft to Bushing 3-40
Replace Rocker Arm Bushings 3-40
Assembly 3-41
3.19 PUSHRODS, LIFTERS AND COVERS
Disassembly 3-42
Clean and Inspect.. 3-42
Inspect Lifters 3-42
Assemble 3-42
3.20 CYLINDER HEAD: TWIN CAM 103
Determining Service 3-44
Disassembly 3-44
Cleaning 3-45
Inspection 3-45
Cylinder Head 3-45
Valve Guides 3-46
Valves 3-46
Valve Springs 3-46
Tapered Keepers 3-46
Valve Seats 3-46
Valve Guide Replacement.. 3-46
Removal 3-46
Installation 3-47
Valve and Seat Refacing 3-50
Assembly 3-52
3.21 CYLINDER HEAD: TWIN CAM 110
Cylinder Head Repair 3-54
3.22 CYLINDER: TWIN CAM 103
Cleaning 3-55
Inspection 3-55
Deglazing Cylinder 3-57
Boring and Honing Cylinder 3-57
3.23 CYLINDER: TWIN CAM 110
Inspection 3-58
X TABLE OF CONTENTS
3.24 PISTON: TWIN CAM 103
Disassembly 3-59
Piston Rings 3-59
Cleaning 3-59
Inspection 3-59
Assembly 3-61
Checking Piston Ring Gap 3-61
Installing Piston Rings 3-61
3.25 PISTON: TWIN CAM 110
Checking Piston Clearance 3-63
3.26 TOP END OVERHAUL: ASSEMBLY
General 3-64
Piston 3-64
Cylinder 3-65
Cylinder Head 3-67
Pushrods, Lifters and Covers 3-70
Rocker Arm Support Plate 3-71
Breather and Rocker Cover 3-72
3.27 CAM COMPARTMENT AND
COMPONENTS
Cam Support Plate and Cover Removal. 3-74
Prepare Engine 3-74
Cam Chain and Sprockets Removal. 3-74
Cam Support Plate Removal. 3-75
Cam Support Plate Cleaning and Inspection 3-76
Oil Pressure Relief Valve 3-76
Cam Support Plate 3-76
Camshafts 3-76
Removal 3-76
Installation 3-77
Oil Pressure Relief Valve 3-78
Removal 3-78
Inspection 3-79
Installation 3-79
Cam Needle Bearings 3-79
Removal 3-79
Installation 3-81
Cam Support Plate and Cover Installation 3-82
3.28 OIL PUMP
Removal 3-87
Cleaning and Inspection 3-87
Installation 3-88
3.29 CRANKCASE DISASSEMBLY AND
REPAIR: TWIN CAM 103
Crankcase Disassembly 3-89
Counterbalancer Assembly 3-89
Cleaning and Inspection 3-91
Right Crankcase Half 3-92
Chain Guide Screen 3-92
Main Bearing Removal 3-92
Main Bearing Installation 3-93
Piston Jets Removal. 3-93
Piston Jets Installation 3-93
Left Crankcase Half… 3-94
TABLE OF CONTENTS
Main Bearing Removal. 3-94
Main Bearing Installation 3-95
Sprocket Shaft Bearing Inner Race 3-95
Removal 3-95
Installation 3-96
Cylinder Studs 3-98
Removal 3-98
Installation 3-98
Pipe Plugs and Oil Fittings 3-98
Removal/I nstallation 3-98
3.30 CRANKCASE DISASSEMBLY AND
REPAIR: TWIN CAM 110
General 3-99
3.31 FLYWHEEL AND CONNECTING RODS
Symptoms 3-1 00
Overview 3-1 00
No Oil Pressure 3-100
Vibration 3-100
Inspection 3-100
Measuring Crankshaft Runout.. 3-1 00
Crankshaft Installed 3-100
Crankshaft Removed 3-101
3.32 COUNTERBALANCER ASSEMBLY
REPAIR
Cleaning, Inspection and Repair 3-1 02
General 3-1 02
Balance Shaft Removal 3-102
Bearing Removal 3-103
Balance Shaft Installation 3-1 03
Balance Shaft Support Bearings Removal. 3-104
Balance Shaft Support Bearings Installation 3-104
Front and Rear Balance Sprockets 3-105
Hydraulic Tensioners 3-105
Chain Tensioner Guides 3-1 05
Balance Shaft Support 3-1 05
Balance Chain 3-106
3.33 CRANKCASE ASSEMBLY
Counterbalancer Assembly Installation 3-1 07
Crankcase Assembly 3-11 0
3.34 OIL TANK: ALL BUT FXSB
Removal and Disassembly 3-113
Oil Tank 3-113
Oil Line Fittings/Retainers 3-115
Installation 3-116
3.35 OIL TANK: FXSB
Removal and Disassembly 3-117
Oil Tank 3-117
Oil Line Fittings/Retainers 3-119
Installation 3-120
FUEL SYSTEM
4.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter .4-1
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
Assemble Tester .4-6
Adjust Tester .4-6
Procedure 4-6
4.5 AIR CLEANER
Air Cleaner: All But FLSTFBS, FLSS .4-8
Removal .4-8
Installation .4-8
Replace Insert: With Screw Access .4-8
Replace Insert: Without Screw Access .4-8
Snorkel .4-8
Air Cleaner: FLSTFBS .4-9
Removal .4-9
Installation 4-9
Air Cleaner: FLSS 4-10
Removal .4-1 0
Installation 4-10
4.6 FUEL SUPPLY LINE
Purge Fuel Supply Line .4-11
Disconnect Fuel Supply Line .4-11
4.7 CONSOLE: FXSB
Removal .4-12
Installation 4-12
4.8 FUEL TANK
General .4-13
Removal. .4-13
Cleaning and Inspection 4-14
Installation 4-15
Fuel Supply Check Valve/Tube 4-15
Removal. 4-15
Installation 4-15
4.9 TWIST GRIP SENSOR (TGS)
Remove .4-17
Install 4-17
4.10 THROTTLE CONTROL ACTUATOR
(TCA)
General. 4-19
4.11 INDUCTION MODULE
Removal 4-20
Installation 4-21
TABLE OF CONTENTS XI
TABLE OF CONTENTS
4.12 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE SENSOR (TMAP)
Removal .4-22
Installation .4-22
4.13 HEATED OXYGEN SENSORS (H02)
General .4-23
Removal .4-23
Front H02 Sensor .4-23
Rear H02 Sensor .4-23
Installation .4-23
Front H02 Sensor 4-23
Rear H02 Sensor 4-23
4.14 FUEL INJECTORS
General 4-25
Removal .4-25
Installation .4-25
4.15 ENGINE TEMPERATURE SENSOR (ET)
General .4-27
Removal .4-27
Installation .4-27
4.16 FUEL PUMP AND FUEL GAUGE
SENDING UNIT
General .4-28
Removal 4-28
Vapor Valve .4-29
Disassembly and Assembly .4-30
Fuel Filter .4-30
Regulator .4-30
Inlet sock 4-31
Fuel Pump .4-31
Installation .4-32
4.17 EXHAUST SYSTEM
Mufflers: FLSTC, FXSB .4-33
Removal .4-33
Assembly .4-33
System: FLSTC, FXSB .4-33
Removal 4-33
Installation .4-33
Mufflers: FLSTN, FLSTF, FLSTFB, FLSTFBS, FLS,
FLSS .4-35
Removal .4-35
Assembly .4-35
System: FLSTN, FLSTF, FLSTFB, FLSTFBS, FLS,
FLSS 4-35
Removal .4-35
Installation .4-35
4.18 EVAPORATIVE EMISSIONS CONTROL
SYSTEM
General .4-37
Charcoal Canister .4-38
Removal .4-38
Installation .4-38
Purge Solenoid .4-38
Removal .4-38
XII TABLE OF CONTENTS
Installation .4-38
Hose Routing and Replacement. .4-38
Fuel Tank Vent Hose 4-38
Purge Solenoid-to-Induction 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
Removal 5-3
Installation 5-3
5.4 DRIVE COMPONENTS
Removal. 5-4
Installation 5-6
5.5 CLUTCH RELEASE BEARING AND PUSH
ROD: HYDRAULIC CLUTCH
Removal 5-9
Installation 5-9
Measure Release Plate Movement… 5-9
Install Clutch Inspection Cover 5-9
5.6 PRIMARY CHAINCASE HOUSING
Removal. 5-11
Inspection 5-11
Mainshaft Bearing and Seal 5-11
Removal. 5-11
Installation 5-11
Mainshaft Bearing Inner Race 5-12
Removal. 5-12
Installation 5-12
Installation 5-13
5.7 MECHANICAL CLUTCH
Removal and Installation 5-15
Clutch Pack Only 5-15
Partial Disassembly 5-15
Cleaning And Inspection 5-15
Assembly 5-16
Clutch Pack and Bearing 5-17
Complete Disassembly 5-17
Assembly 5-18
5.8 HYDRAULIC CLUTCH
Clutch Pack Only 5-19
Partial Disassembly 5-19
Cleaning And Inspection 5-19
Assembly 5-19
5.9 TRANSMISSION SPROCKET
Removal. 5-21
Cleaning and Inspection 5-22
TABLE OF CONTENTS
Installation 5-22 Shifter Cam/Shifter Forks 6-23
Installation 6-25
5.10 DRIVE BELT
Removal 5-24
Inspection 5-24
Installation 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
Fifth Gear 6-4
Sixth Gear 6-4
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 Disassembly 6-8
Cleaning and Inspection 6-8
Assembly and Installation 6-9
6.6 TRANSMISSION SIDE COVERS:
HYDRAULIC CLUTCH
Removal 6-10
Installation 6-10
6.7 SECONDARY CLUTCH ACTUATOR:
HYDRAULIC CLUTCH
Replacement. 6-12
Validate Repair 6-12
6.8 TRANSMISSION ASSEMBLY
Removal 6-14
Disassembly 6-15
Shifter Cam/Shifter Forks 6-15
Mainshaft 6-17
Countershaft 6-19
Removing Bearing Housing Bearings 6-20
Cleaning and Inspection 6-21
Assembly 6-21
Installing Bearing Housing Bearings 6-21
Countershaft 6-22
Mainshaft 6-22
6.9 MAIN DRIVE GEAR AND BEARING
Removal. 6-27
Cleaning and Inspection 6-28
Needle Bearing Replacement.. 6-29
Mainshaft Seal Replacement. 6-30
Installation 6-31
Installing Main Drive Gear Bearing 6-31
Installing Main Drive Gear 6-31
Installing Main Drive Gear Large Seal 6-32
6.10 TRANSMISSION CASE
Removal. 6-34
Installation 6-34
Disassembly 6-35
Shifter Arm Assembly 6-35
Cleaning and Inspection 6-35
Assembly 6-36
Countershaft Needle Bearing Replacement.. 6-36
Shifter Pawl Lever Assembly 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: All But FXSB 7-5
Installation: All Except FXSB 7-6
Removal: FXSB 7-6
Installation: FXSB 7-6
7.4 ELECTRONIC CONTROL MODULE (ECM)
General 7-8
Removal: All But FXSB 7-8
Installation: All But FXSB 7-8
Removal: FXSB 7-8
Installation: FXSB 7-8
7.5 BODY CONTROL MODULE (BCM)
General 7-9
BCM Configuration 7-9
Removal: All Except FXSB 7-9
Installation: All Except FXSB 7-9
Removal: FXSB 7-9
Installation: FXSB 7-10
7.6 H-DSSS 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 (If Installed} 7-14
Battery Replacement Schedule 7-14
Battery Replacement… 7-14
7.9 SECURITY SIREN
Removal: All But FXSB 7-15
Installation: All But FXSB 7-15
Removal: FXSB 7-15
Installation: FXSB 7-16
7.10 FUSES
Removal. 7-17
Installation 7-17
7.11 IGNITION AND LIGHT SWITCH
General. 7-18
Removal and Installation: All Except FXSB 7-18
Removal and Installation: FXSB 7-19
7.12 BATTERY CABLES
Routing Procedure 7-20
7.13 STARTER
GeneraL 7-22
Removal 7-22
Drive Assembly 7-22
Disassembly 7-22
Inspection 7-22
Assembly 7-23
Solenoid 7-23
Remove Cover and Plunger 7-23
Short Post Contact: Starter 7-23
Long Post Contact: Battery Positive 7-24
Install Plunger and Cover 7-24
Installation 7-24
7.14 HEADLAMP
GeneraL 7-26
Headlamp Assembly Removal and Installation 7-26
Removal 7-26
Installation 7-26
Bulb Removal and Installation 7-26
FXSB Models 7-27
FLSTC,FLST~FLSTFB,FLSTFBS,FLSTN,FLS,FLSS
Models 7-27
7.15 TAIL LAMP: ALL BUT FLSTN
General 7-29
Bulb Replacement.. 7-29
Base Replacement. 7-29
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
Installation 7-33
FLSTC Models 7-33
Auxiliary Lamp Bracket Removal. 7-33
Auxiliary Lamp Bracket Installation 7-34
Auxiliary Lamp Housing Removal. 7-34
Auxiliary Lamp Housing Installation 7-34
FLSTN Models 7-36
Auxiliary Lamp Bracket Removal. 7-36
Auxiliary Lamp Bracket Installation 7-36
Auxiliary Lamp Housing Removal. 7-37
Auxiliary Lamp Housing Installation 7-37
Adjustment: FLSTC/FLSTN Models 7-38
7.18TURN SIGNALS AND RUNNING LIGHTS
Bulb Replacement: Bullet Style 7-40
Bulb Replacement: Flat Lens Style 7-40
Lamp Replacement.. 7-40
All Models 7-40
Front Turn Signals: FLSTC, FLSTN 7-40
Front Turn Signals: FLSTF, FLSTFB, FLSTFBS, FLS,
FLSS, FXSB 7-40
Rear Turn Signals: All But FLSTN, FLS, FLSS,
FXSB 7-41
Rear Turn Signals: FLS, FLSS 7-42
Rear Turn Signals: FXSB 7-43
Rear Turn Signals: FLSTN 7-44
7.19 CRANK POSITION SENSOR (CKP)
General 7-46
RemovaL 7-46
Installation 7-46
7.20 AUTOMATIC COMPRESSION RELEASE
(ACR)
General 7-47
Removal 7-47
Installation 7-47
7.21 IGNITION COIL
Inspect Spark Plug Cables 7-49
Removal. 7-49
All But FXSB 7-49
FXSB 7-49
Installation 7-49
All Except FXSB 7-49
FXSB 7-50
7.22 SPARK PLUG CABLES
General 7-52
Removal. 7-52
Installation 7-52
7.23 VOLTAGE REGULATOR
Disassembly 7-53
Installation 7-53
TABLE OF CONTENTS
7.24 ALTERNATOR Repair 7-71
Installation 7-71
Removal 7-54
Cleaning and Inspection 7-54
Installation 7-54
7.25 FUEL GAUGE
General 7-56
Removal 7-56
Installation 7-56
7.26 SPEEDOMETER
General 7-58
Removal: All But FXSB 7-58
Installation: All Except FXSB 7-58
Removal: FXSB 7-58
Installation: FXSB 7-59
7.27 VEHICLE SPEED SENSOR (VSS)
General 7-60
Removal. 7-60
Installation 7-60
7.28 WHEEL SPEED SENSORS
Front Wheel Speed Sensor 7-61
Removal 7-61
Installation 7-61
Rear Wheel Speed Sensor 7-62
Removal 7-62
Installation 7-63
7.29 INDICATOR LAMPS
General 7-64
Removal: All But FXSB 7-64
Installation: All But FXSB 7-64
Removal: FXSB 7-65
Installation: FXSB 7-65
7.30 NEUTRAL SWITCH
General 7-66
Removal 7-66
Installation 7-66
7.31 OIL PRESSURE SWITCH
General 7-67
Removal 7-67
Installation 7-67
7.32 REAR STOP LAMP SWITCH
General 7-68
Removal. 7-68
Installation 7-68
7.33 HORN
Inspection 7-69
Removal and Installation: All But FXSB 7-69
Removal and Installation: FXSB 7-70
7.34 ACTIVE EXHAUST
General. 7-71
Removal 7-71
7.35 MAIN WIRING HARNESS
Removal 7-72
Installation 7-73
7.36 HANDLEBAR CONTROL MODULES
General 7-75
Repair Procedures 7-75
7.37 RIGHT HAND CONTROL MODULE
Removal. 7-76
Installation 7-76
Front Brake Switch Replacement… 7-78
7.38 LEFT HAND CONTROL MODULE
Removal 7-79
Installation 7-80
Clutch Switch Replacement. 7-81
APPENDIX A WIRING
A.1 CONNECTORS
Connector Locations A-1
Function/Location A-1
Place and Color A-1
Connector Number A-1
Repair Instructions A-1
A.2 WIRING DIAGRAMS
Wiring Diagram Information A-5
Wire Color Codes A-5
Wiring Diagram Symbols A-5
2016 Softail Wiring Diagrams A-7
APPENDIX B REFERENCE
B.1 LENGTH CONVERSION
Conversion Table B-1
B.2 FLUID CONVERSION
United States System B-2
Metric System B-2
British Imperial System B-2
B.3 TORQUE CONVERSION
United States System B-3
Metric System B-3
B.4 GLOSSARY
Acronyms and Abbreviations B-4
REFERENCE MATERIAL
TOOLS .1
TORQUE VALUES VII
TABLE OF CONTENTS XV
TABLE OF CONTENTS
INDEX XXI
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V