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2007 Harley Davidson Softail Service Repair Manual Instant Download

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2007 Harley Davidson Softail Service Repair Manual Instant Download

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  1. 11 21 31 41 IMAINTENANCE ICHASSIS 2007 SOFTAIL SERVICE MANUAL IENGINE IFUEL SYSTEM I ELECTRIC STARTER 51 IDRIVE The information in this Service Manual applies to all 2007 Softail@models. 61 71 sl I I ITRANSMISSION © 2006 HARLEY-DAVIDSON MOTORCOMPANY All RIGHTS RESERVED PART NO.99482-07 Printed in the U.S.A. IELECTRICAL IAPPENDIX VISITTHE HARLEY-DAVIDSON WEB SITE http://www.harley-davidson.com IINDEX CMI- 5M - 03107 1 fl't1i;r • l1E:. ••

  2. FOREWORD GENERAL PREPARATION FOR SERVICE This Service Manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair. Secondly, it will introduce to the professional Harley-Davidson Technician the latest field- tested and factory-approved major repair methods. We sin- cerely believe that this Service Manual will make your associ- ation with Harley-Davidson products more pleasant and profitable. AWARNING Stop the engine when refueling or servicing the fuel sys- tem. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) Good preparation is very important for efficient service work. A clean work area at the start of each job will allow you to per- form the repair as easily and quickly as possible, and will reduce the incidence of misplaced tools and parts. A motorcy- cle that is excessively dirty should be cleaned before work starts. Cleaning will occasionally uncover sources of trouble. Tools, instruments and any parts needed for the job should be gathered before work is started. Interrupting a job to locate tools or parts is a distraction and causes needless delay.See APPENDIX A-TOOLS for equipment required for special ser- vice work. HOWTO USE YOUR SERVICE MANUAL Information is arranged as follows: • Section 1-Maintenance NOTE • Section 2-Ghassis • Toavoid unnecessary disassembly, carefully read all rel- ative service information before repair work is started. • Section 3-Engine • In figure legends, the number which follows the name of a part indicates the quantity necessary for one complete assembly. • Section 4-Fuel System • Section 5-Electric Starter SERVICE BULLETINS • Section 6-Drive • Section 7-Transmission In addition to the information presented in this Service Manual, Harley-Davidson Motor Company will periodically issue Service Bulletins to Harley dealers. Service Bulletins cover interim engineering changes and supplementary infor- mation. • Section 8-Electrical • Appendix A-Tools • Appendix B-Wiring USE GENUINE REPLACEMENT PARTS • Appendix G-Metric Conversions • Appendix D-Glossary Use the TABLE OF CONTENTS following this FOREWORD or the INDEX at the back of the book to find the desired sub- ject. AWARNING When replacement parts are required, use only genuine Harley-Davidson parts or parts with equivalent character- istics (which include type, strength and material). Failure to do so may result in product malfunction. This could result in death or serious injury. Note that each manual section contains sequentially num- bered topics.The numbering system allows quick cross refer- ences throughout the document. To ensure satisfactory and lasting repairs, carefully follow the Service Manual instructions and use only genuine Harley- Davidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSONstand more than 100 years of design, research, manufacturing, testing inspecting experience. This is your assurance that the parts you are using will fit right, operate properly and last longer For example, the sixth topic (BRAKES) in section one (MAIN- TENANCE) could be referred to as: 1.6 BRAKES and This cross reference directs the reader to section 1 (MAINTENANCE) and topic 6 (BRAKES). i.

  3. WARNINGS AND CAUTIONS PRODUCT REFERENCES Statements in this service manual preceded by the following words are of special significance. AWARNING ADANGER Follow the directions listed on all products. Carefully read all labels, warnings and cautions before use. Inade- quate safety precautions could result in death or serious injury. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. When reference is made in this Service Manual to a specific brand name product, tool or instrument, an equivalent product, tool or instrument may be substituted. AWARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (00119a) Kent-Moore Products ACAUTION All tools mentioned in this manual with an "HD", "J" or "8" preface must be ordered through: CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (00139a) Kent-Moore SPX Corporation 28635 Mound Road Warren, Michigan USA 48092-3499 CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage (00140a) Sealing and Threadlocking Products LOCTITE PRODUCTS AWARNING • Proper service and repair is important for the safe, reliable operation of all mechanical products. The service procedures recommended and described in this Service Manual are effective methods for per- forming service operations. Some of these service operations require the designed for the purpose.These special tools should be used when and as recommended. It is important to note that some warnings against the use of spe- cific service methods, which could damage the motorcycle or render it unsafe, are stated in this Ser- vice Manual. However, please remember that these warnings are not all-inclusive. Inadequate safety pre- cautions could result in death or serious injury. Some procedures in this Service Manual call for the use of Loctite®products. If you have any questions regarding Loctite product usage or retailer/wholesaler locations, please contact Loctite Corp. at www.loctite.com. use of tools specially CONTENTS All photographs, illustrations and procedures may not neces- sarily depict the most current model or component, but are based on the latest production information available at the time of publication. • Since Harley-Davidson could not possibly know, evaluate or advise the service trade of all possible ways in which service might be performed, or of the possible hazardous consequences of each method, we have not undertaken any such broad evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by Harley-David- son must first thoroughly satisfy himself that neither his nor the operator's safety will be jeopardized as a result. This could result in death or serious injury. Since product improvement is our continual goal, Harley- Davidson reserves the right to change specifications, equip- ment or designs at any time without notice and without incur- ring obligation. • Wear eye protection when using hammers, arbor or hydraulic presses, gear pullers, spring compressors, slide hammers and similar tools. Be especially cau- tious when using pulling, pressing or compressing equipment. The forces involved can cause parts to fly outward with considerable force, possibly result- ing in death or serious injury. ii.

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  5. TABLE OF CONTENTS Page No. 1-13 Page No. SECTION 1-MAINTENANCE 1.5 Battery Maintenance General Battery Electrolyte Antidotes (table) Disconnection and Removal. Installation and Connection Inspection Storage . 1-13 1-13 1-14 1-14 1-15 1-15 . . . . 1-1 1-1 1-1 1-1 1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-4 1-4 1-4 1-4 1-4 1-4 1-4 1.1 General Servicing a New Motorcycle Safe Operating Maintenance Shop Practices Repair Notes Safety Removing Parts Cleaning Disassembly and Assembly Repair and Replacement Procedures Hardware and Threaded Parts Threadlocking Agents Wiring, Hoses and Lines Instruments and Gauges Bearings Bushings Exhaust System Leakage Gaskets Lip Type Seals O-Rings (Preformed Packings) Gears Shafts Part Replacement Cleaning Part Protection Cleaning Process Rust or Corrosion Removal Tool Safety Air Tools Wrenches Pliers/Cutters/Prybars Hammers Punches/Chisels Screwdrivers Ratchets and Handles Sockets Storage Units . . .. .. .. . . . . . 1-16 1-16 1-17 1-17 1-17 1-17 1.6 Brakes Fluid Inspection Rear Brake Pedal Pedal Height Pedal Lubrication Pedal Pad . . . . . . .. .. .. .. .. .. 1-18 1-18 1-18 1.7 Bleeding Brakes General Procedure .. . . . . 1-19 1-19 1-19 1-19 1-19 1-20 1-20 1-22 1.8 Brake Pads and Discs Inspection Brake Pads Brake Disc Thickness Brake Disc Lateral Runout and Warpage Brake Pad Replacement Rear Brake Caliper Front Brake Caliper: All But FLSTSC .. .. . . . . .. .. . . . . . . : . .. .. 1-23 1-23 1-23 1-24 1-24 1-24 1.9 Tires and Wheels Tires Tire Pressures (table) Tire Replacement Wheel Bearings Wheel Spokes .. . . . . . . . .. .. . . . . 1-25 1-25 1.10 Primary Chain General . . 1-26 1-26 1.11 Primary Chaincase Lubricant . Changing Lubricant .. . . . 1-28 1-28 1.12 CIutch Adjustment . 1.2 Fuel and Oil Fuel Gasoline Blends Engine Oil Winter Lubrication . 1-5 1-5 1-5 1-5 1-5 . . . . . 1-30 1-30 1.13 Transmission Lubricant Changing Lubricant . . 1-31 1-31 1-31 1-32 1.14 Rear Belt Deflection Inspection Rear Belt Deflection (Table) Adjustment . 1-6 1-6 1.3 Maintenance Schedule First Scheduled Maintenance . .. . .. .. 1-11 1-11 1-11 1-11 1-11 1-12 1.4 Engine Oil and Filter Checking and Adding Oil Type of Oil Checking Oil Level Recommended Oil Grades (table) Changing Oil and Filter .. .. .. 1-33 1-33 1-33 1-33 1-33 1-33 1-34 1.15 Rear Belt and Sprockets General Cleaning Inspection Sprockets Rear Belt Drive Belt Wear Analysis (table) . .. . . . . . .. . .. 1.16 Suspension Adjustments Rear Shock Preload 1-35 1-35 iii

  6. Page No. Page No. 1-55 1-55 1-55 1.17 Steering Head Bearings: All But FLSTSC Adjustment Bearing Adjustment (Fall-away) Lubrication 1.29 Troubleshooting General Engine Starter Motor Does Not Operate or Does Not Turn Engine Over Engine Turns Over But Does Not Start Starts Hard Starts But Runs Irregularly or Misses A Spark Plug Fouls Repeatedly Pre-Ignition or Detonation (Knocks or Pings) Overheating Valve Train Noise Excessive Vibration Check Engine Light Illuminates During Operation Lubrication System Oil Does Not Return To Oil Tank Engine Uses Too Much Oil Or Smokes Excessively Engine Leaks Oil From Cases, Push Rods, Hoses Low Oil Pressure High Oil Pressure Electrical System Alternator Does Not Charge Alternator Charge Rate Is Below Normal. Speedometer Operates Erratically Transmission Shifts Hard Jumps Out Of Gear Clutch Slips Clutch Drags Or Does Not Release Clutch Chatters Handling Irregularities Brakes Brake Does Not Hold Normally . . 1-36 1-36 1-36 1-36 .. . . .. .. .. .. .. .. . .. .. . 1-55 1-55 1-55 1-55 1-56 1-56 1-56 1-56 1-56 1-56 1-56 1-56 1-56 1-56 1-57 1-57 1-57 1-57 1-57 1-57 1-57 1-57 1-57 1-57 1-57 1-57 1-58 1-58 1-58 1-58 . 1.18 Steering Head Bearings: FLSTSC General Lubrication Adjustment Adjustment 1-37 1-37 1-37 1-37 1-38 . .. . . . 1.19 Rocker Bearings: FLSTSC Inspection . 1-39 1-39 . . .. 1.20 Front Fork Oil Replacing Fork Oil. . 1-41 1-41 . . 1-43 1-43 1.21 Spark Plugs Inspection . .. . .. . .. .. .. . . . . . .. . . . 1-44 1-44 1-45 1.22 Air Cleaner Filter Removal Installation . . .. .- 1.23 Cable and Chassis Lubrication General Cables and Hand Levers Jiffy Stand 1-46 1-46 1-46 1-46 . . . 1.24 Throttle Cables Cable Inspection, Lubrication and Adjustment.. Inspection and Lubrication Adjustment . .. 1-47 1-47 1-47 1-48 . .. 1.25 Engine Mounts Inspection . 1-49 1-49 SECTION 2-CHASSIS . 1.26 Headlamp Alignment Inspection.................................................................. Adjustment.. .................. FLSTSC Models FLSTC/FLSTF/FLSTN/FXST/FXSTB/FXSTC Models 1-51 FXSTD Models...................................................... 1-50 1-50 1-51 1-51 2-1 2-2 2-2 2-2 2-3 2.1 Specifications Tires Tire Fitment, Tubeless Cast Wheels (table) Tire Fitment, Laced Wheels (table) Tire Pressure, All Models (table) . .. . .. . 1-51 2-4 2.2 Torque Values . 1.27 Critical Fasteners Inspection Critical Fasteners (table) . 1-52 1-52 1-52 2.3 Vehicle Identification Number (V.I.N.) General . . 2-7 2-7 . .. 1-53 1-53 1-54 1.28 Storage General Removal From Storage . .. 2.4 Front Wheel: All But FLSTSCIFXSTD Removal Disassembly Disc Wheel. Laced Wheel Cleaning and Inspection Assembly Disc Wheel Laced Wheel Installation . . . . 2-9 2-9 2-9 2-9 2-9 2-11 2-11 2-11 2-11 2-11 .. . . . . . . iv

  7. Page No. Page No. 2.5 Front Wheel: FXSTD Removal Disassembly Cleaning and Inspection Assembly Installation . 2-12 2-12 2-12 2-12 2-13 2-13 2.16 Rear Brake Master Cylinder/Reservoir Removal Installation Disassembly Cleaning and Inspection Assembly 2-42 2-42 2-42 2-45 2-46 2-46 . .. . . .. . . . . . . 2-14 2-14 2-14 2-14 2-14 2-16 2.6 Front Wheel: FLSTSC Removal Disassembly Cleaning and Inspection Assembly Installation . 2.17 Front Brake Caliper: All But FLSTSC Removal Disassembly Cleaning, Inspection and Repair Assembly Installation . .. 2-48 2-48 2-48 2-51 2-52 2-53 . . . . . . . 2-17 2-17 2-17 2-19 2-19 2-19 2.7 Rear Wheel Removal. Disassembly Cleaning and Inspection Assembly Installation . .. . . . 2-54 2-54 2-54 2-54 2-55 2-56 2-56 2-58 2-58 2-58 2.18 Front Brake Caliper: FLSTSC . Front Brake Caliper Removal Disassembly Cleaning and Inspection Assembly Installation Brake Reaction Link Removal Installation .. .. . .. . . . 2.8 Sealed Wheel Bearings Inspection Removal. Installation . 2-20 2-20 2-20 2-21 .. . . . . . . . 2-22 2-22 2-23 2.9 Wheel Lacing: 16 In. Rim General Procedure . . . 2.19 Rear Brake Caliper: All But FXSTIFXSTBIFXSTCIFLSTF Removal : Disassembly Cleaning, Inspection and Repair Assembly Installation 2-60 2-60 2-60 2-63 2-63 2-64 . 2.10 Wheel Lacing: 21 In. Rim Procedure . .. 2-25 2-25 . .. .. .. . 2-28 2-28 2-28 2-29 2-31 2.11 Truing Laced Wheel General Lateral Truing Wheel Offset Dimensions (table) Radial Truing . . . 2.20 Rear Brake Caliper: FXSTIFXSTBIFXSTCIFLSTF Removal · Disassembly Cleaning, Inspection and Repair Assembly Installation .. . 2-65 2-65 2-65 2-68 2-69 2-70 . . . 2-32 2-32 2-32 2-32 2.12 Disc Rim Runout General Lateral Runout Radial Runout .. . . . .. . . 2.13 Tires General Removal Cleaning, Inspection and Repair Installation Tube Type Tires Tubeless Tires . 2-33 2-33 2-34 2-34 2-35 2-35 2-35 2-71 2-71 2-71 2-71 2-71 2-75 2-75 2.21 Front Forks: All But FLSTSC General Removal Disassembly Cleaning and Inspection Assembly Installation . . . . . . . . . .. . . .. 2.14 Vehicle Alignment...................... Inspection 2-36 2-36 2.15 Front Brake Master Cylinder General............. Removal/Disassembly ...... Cleaning and Inspection Assembly/Installation 2-37 2-37 2-37 2-38 2-40 v

  8. Page No. Page No. 2.22 Springer Fork: FLSTSC General Handlebar and Risers Removal Installation Front Shock Absorber Removal Installation Rigid Fork Removal Installation Spring Fork Disassembly Assembly Fork Rockers Removal Installation Fork Stem Bearings Removaillnstallation . 2-76 2-76 2-76 2-76 2·76 2-78 2·78 2-78 2-79 2-79 2-79 2-80 2-80 2-82 2-84 2-84 2-84 2-85 2-85 2.28 Handlebars: FLSTF Removal........................ Installation................................................. FXSTD 2-99 2-99 2-100 2-102 . . . . 2.29 Clutch Hand Control Removal.................................................................... Installation 2-102 2-102 2-102 .. . . . . . . . . . . . . . ;... 2.30 Front Fender: All But FLSTSC .. 2-103 FXST, FXSTB, FXSTC Models................................. Removal..... Installation............................................................. FLSTC, FLSTN Models Removal................................................................ Installation............................................................. FLSTF Models .......................................................... Removal................................................................ Installation............................................. FXSTD Models........................ Removal.......................................... Installation....... 2-103 2-103 2-103 2·103 2-103 2-103 2-104 2-104 2-104 2-104 2-104 2-104 2.23 Steering Head Removal FLSTC, FLSTF, FLSTN Models FXSTD, FXST, FXSTC, FXSTB Models FLSTSC Models Cleaning and Inspection All Models Disassembly Removing Lower Bearings From Fork Stem Steering Head Bearing Race Removal Assembly Installation FLSTC, FLSTF, FLSTN Models FXSTD, FXST, FXSTC, FXSTB Models FLSTSC Models .. 2-86 2-86 2·86 2-86 2-87 2-87 2-87 2-87 2-87 2-88 2-88 2-89 2-89 2-89 2-89 . . 2.31 Front Fender: FLSTSC Removal.. Front Fender.. Front Fender Bearing Replacement Installation............................................ 2-105 2-105 2-105 2-105 2-106 .. . . . . . .. . . .. . . 2.32 Rear Fender: FLSTC................... 2-107 Removal.................................................................... Installation... 2-107 2-108 2.33 Rear Fender: FLSTF Removal.................................................................... Installation.... 2-109 2-109 2-110 2.24 Rear Fork Removal Cleaning and Inspection Installation .. 2-90 2-90 2-90 2-91 2.34 Rear Fender: FXSTIFXSTBIFXSTC Removal.................................................................... Installation................... . . . 2-111 2-111 2-112 2.25 Rear Shock Absorbers General Removal Installation . 2-92 2-92 2-92 2-92 2.35 Rear Fender: FXSTD Removal.................................................................... Disassembly ............................................................. Assembly.................................................................. Installation................................................................. 2-113 2-113 2-113 2-114 2-114 . . . 2.26 Throttle ControL RemovallDisassembly Cleaning and Inspection Assembly/Installation Cable Routing All Models Except FLSTSC/FXSTD FLSTSC Models FXSTD Models . 2-93 2·93 2-93 2-93 2-94 2-94 2-94 2-94 . 2.36 Rear Fender: FLSTSC Removal.................................................................... Disassembly............................................................. Assembly................................ Installation........................ 2-115 2-115 2-115 2-116 2-116 .. . . . . . 2.37 Rear Fender: FLSTN Removal........... Disassembly ............................................................. Assembly.... Installation........................................................... 2-117 2-117 2-117 2-119 2-119 2.27 Handlebars: All but FLSTFIFLSTSC Removal FXSTD Installation FXSTD . 2-95 2-95 2-96 2-97 2-97 . . . . 2.38 Rear Fender Wire Conduit: All But FXSTD Installation................................................................. 2-120 2-120 vi

  9. Page No. Page No. 3.5 Oil Pump Operation General. Operation 3.6 Breather Operation General. 3.7 Oil Pressure Oil Pressure Indicator Lamp Checking Oil Pressure 3.8 How To Use This Section Top End Repair Bottom End Repair Typical Symptoms 3.9 Top End Service Engine In Chassis Engine Removed From Chassis 3.10 Bottom End Service Engine In Chassis: Cam Compartment Service Engine Removed: Flywheel Compartment Service or Complete Engine Overhaul 3.11 Troubleshooting Diagnosing Valve Train Noise Compression Test Compression Test Results (table) Cylinder Leakage Test Diagnosing Smoking Engine or High Oil Consumption Check Prior To Cylinder Head Removal.............. Check After Cylinder Head Removal.................... 3.12 Stripping Motorcycle For Service 3-22 Procedure................................................................. 3.13 Assembling Motorcycle After Service Procedure................................................................. 3.14 Removing Engine From Chassis 3-24 Procedure......................................................... 3.15 Installing Engine In Chassis Procedure 3.16 Top End Overhaul: Disassembly General. Breather Assembly Rocker Arm Support Plate Push Rods, Lifters and Covers Cylinder Head Cylinder Piston 3.17 Top End Overhaul: Assembly .. General Piston Cylinder Cylinder Head Push rods, Lifters and Covers Rocker Arm Support Plate Breather Assembly . 3-12 3-12 3-12 3-13 3-13 3-14 3-14 3-14 3-15 3-15 3-15 3-15 3-16 3-16 3-17 3-18 3-18 2.39 Belt Guard/Debris Deflector Removal. Belt Guard Debris Deflector Installation Belt Guard Debris Deflector . 2-122 2-122 2-122 2-122 2-122 2-122 2-122 . . . . .. . . . . . . . . . .. .. . . .. 2.40 Jiffy Stand................................... 2-123 Cleaning.................................................................... Removal.................................................................... Installation...... 2-123 2-124 2-124 2.41 Fork Lock.................................... 2-125 Removal................... Installation........ .. 2-125 2-125 2.42 SeaVStrap Retention NuL......... 2-126 Replacement............................................................. 2.43 Seat: FXSTIFXSTB Removal/Installation Seat Strap....................... Seat 2.44 Seat: FXSTC Removal/Installation Seat Strap............................................................. Seat 2.45 Seat: FXSTD Removal/Installation 2.46 Seat: FLSTSCIFLSTNI FLSTFIFLSTC Removal/Installation 2.47 Luggage Rack: FLSTN............... 2-131 Removaillnstallation 2.48 Saddlebags: FLSTC Removal........ Installation............ 2.49 Windshield: FLSTC Removal................................................................ Installation....................... . 2-126 2-127 2-127 2-127 2-127 2-128 2-128 2-128 2-128 2-129 2-129 . . 3-19 3-20 3-20 3-20 3-20 3-21 3-21 3-21 3-21 .. 2-130 2-130 3-22 3-23 3-23 2-131 2-132 2-132 2-132 2-133 2-133 2-133 3-24 3-25 3-25 3-27 3-27 3-27 3-28 3-29 3·30 3-31 3-33 3-34 3-34 3-34 3-35 3-38 3-41 3-42 3-43 . . SECTION 3-ENGINE . . .. . 3.1 Specifications 3.2 Engine Torque Values (table) 3.3 Service Wear Limits General..................................................................... 3.4 Engine Oil Flow............................ Oil Feed Top End Bottom End............................................................... Chain Guide Bracket................................................. Oil Return.................................................................. 3-1 3-3 3-4 3-4 3-6 3-6 3-7 3-7 3-11 3-11 . . . . . . . .. . . vii

  10. Page No. Page No. 3.18 Bottom End Overhaul: Disassembly....................................... General.... Cover and Cam Support Plate Crankcase ................................................................. Counterbalancer Assembly .. 3.24 Cylinder Removal Overview Cleaning Inspection Deglazing Cylinder Boring and Honing Cylinder Installation Overview Oversize Pistons/Cylinder Bores (table) . . . . . . . 3-88 3-88 3-88 3-89 3-90 3-92 3-92 3-92 3-45 3-45 3·45 3-49 3-50 3.19 Bottom End Overhaul: Assembly 3-53 General ............................... Counterbalancer Assembly ............ Balance Sprocket Spacers (table)......................... Crankcase ..... Cover and Cam Support Plate Rear Cam Sprocket Spacers (Table) .. 3-53 3-53 3-54 3·56 3-60 3-62 3.25 Piston Removal Overview Disassembly Piston Rings Cleaning Inspection Assembly Piston Rings Installation Overview . . 3-93 3-93 3-93 3-93 3-93 3-94 3-96 3-96 3-97 .. . . .. .. . . 3.20 Breather Assembly Removal Overview Disassembly Cleaning and Inspection Assembly Installation Overview .. 3-65 3-65 3-65 3-65 3-65 3-65 3-66 3-66 3-66 3-66 3-69 3-69 . . . . . 3.26 Cover and Cam Support Plate . Removal Overview Camshafts Removal Assembly Oil Pressure Relief Valve Removal Installation Cam Needle Bearings Removal Installation Cleaning and Inspection Oil Pressure Valve Cam Support Plate Installation Overview 3-99 3-99 3-100 3-100 3-101 3-103 3·103 3-103 3-104 3-104 3-105 3-106 3-106 3-106 3-106 . . . . 3.21 Rocker Arm Support Plate Removal Overview Disassembly Cleaning and Inspection Assembly Installation Overview .. . . . . . .. . . . . . .. . .. . 3.22 Push Rods, Lifters and Covers Removal Overview Disassembly Cleaning and Inspection Lifter Inspection Assembly Installation Overview 3-70 3-70 3-70 3-70 3-71 3-72 3·72 3-73 3-73 3-73 3-75 3-75 3-75 3-76 . . .. .. . . 3.27 Oil Pump Removal Overview.................................................... Cleaning and Inspection Installation and Overview.......................................... 3-107 3-107 3-107 3-108 3.23 Cylinder Head Removal Overview Disassembly Cleaning Inspection Cylinder Head Valve Guides Valve Stem To Guide Clearance Service Wear Limits (table) Valves Valve Springs Tapered Keepers Valve Seats Valve Guide Replacement Removal Installation Valve Stem To Guide Clearance (table) Valve and Seat Refacing Assembly Installation Overview . . . 3.28 Crankcase Removal Overview.................................................... Right Crankcase Half........ Chain Guide Screen Crankshaft Bearing.... ..... Piston Jets Left Crankcase Half .. Crankshaft (Roller) Bearing Cylinder Studs................. Removal................................................................ Installation............................................................. Pipe Plug and Oil Fittings ............. Removaillnstallation Cleaning and Inspection Installation Overview................................................. 3-109 3-109 3-109 3-109 3-109 3-110 3-111 3-111 3-113 3-113 3-113 3-113 3-113 3-114 3-114 .. . . .. . . 3-76 3-76 3-76 3-76 3-76 3-77 3-77 3-78 3-81 3-82 3-85 3-87 .. . . .. .. . . .. . . viii

  11. Page No. Page No. 4-16 4-16 4-16 4-17 4.8 Engine Temperature Sensor (ET) GeneraL Removal Installation 3.29 Counterbalancer Assembly Removal Overview Cleaning, Inspection and Repair General Balance Shaft Removal Balance Shaft Installation Balance Shaft Support Bearings Front and Rear Balance Sprockets Hydraulic Tensioners Chain Tensioner Guides Chain Guide Bracket. Balance Chain Installation Overview . 3-115 3-115 3-115 3-115 3-115 3-116 3-117 3-118 3-118 3-118 3-118 3-118 3-118 . . . . . . . . .. . . 4-18 4-18 4-20 . 4.9 Induction Module Removal Installation . . 4-21 4-21 4-21 4-21 . 4.10 Idle Air Control (lAC) GeneraL Removal Installation .. . .. . . . . 4.11 Manifold Absolute Pressure Sensor (MAP) General..................................................................... Removal.......................... Installation 3.30 FlywheeVConnecting Rod Removal Overview.................................................... Inspection Installation Overview............ ..................................... 3.31 Oil Tank....................................... 3-120 Removal/Disassembly .............................................. Oil Tank Oil Line Fittings/Retainers..................................... Installation................................................................. 3-119 3-119 3-119 3-119 4-22 4-22 4-22 4-22 4.12 Oxygen Sensor GeneraL.................................................................... Removal................................................................... Installation 4-23 4-23 4-23 4-23 4-25 4-25 4-25 4-26 3-120 3-120 3-122 3-123 . 4.13 Fuel Injectors General Removal Installation SECTION 4-FUEL SYSTEM . . . 4-1 4-1 . .. 4.1 Specifications Torque Values (table) 4.14 Fuel'PumpIFuel Gauge Sending Unit GeneraL Removal Disassembly/Assembly Installation 4-27 4-27 4-27 4-30 4-34 .. 4.2 Electronic Fuel Injection (EFI) System General Troubleshooting . . 4-3 4-3 4-3 .. .. .. . . . 4.3 Idle Speed General 4-5 4-5 4-35 4-35 4-35 . 4.15 Fuel Pressure Test GeneraL Testing . . . . . .. .. 4.4 Air Cleaner Removal Installation Backplate Assembly: HDI Models 4-6 4-6 4-6 4-7 4.16 Exhaust System: FXSTIFLSTCI FXSTBIFXSTC Mufflers Removal Assembly System Removal Installation 4-38 4-38 4-38 4-38 4-38 4-38 4-39 . . . 4.5 Fuel Tank General Removal Cleaning and Inspection Installation All But FXSTDL 4-8 4-8 4-8 4-12 4-12 4-12 .. .. . . . . . . . . 4-41 4-41 4-41 4-41 4-42 4-42 4-42 4.17 Exhaust System: FXSTDIFLSTF Mufflers Removal Assembly System Removal Installation 4-14 4-14 4-14 4-14 . 4.6 Throttle Position Sensor (TP) General RemovaL Installation . . . . . . . .. . 4.7 Intake Air Temperature Sensor (IAT) General RemovaL Installation . 4-15 4-15 4-15 4-15 4-44 4-44 4-44 4-44 4-45 4-45 4-45 . 4.18 Exhaust System: FLSTN Mufflers Removal Assembly System Removal Installation . . . . .. . .. .. . ix

  12. Page No. Page No. 4.19 Exhaust System: FLSTSC......... Removal.................................................................... Installation.. 4-47 4-47 4-48 6.3 Drive Components Primary Chain and Compensating Sprocket... Removal Installation . . . . 6-8 6-8 6-8 6-10 4.20 Intake Leak Test......................... General ..................................................................... Leak Tester ............................................................... Parts List.. ............................................................. Tester Assembly................................................... Tester Adjustment................................................. Procedure.................................................................. 4-50 4-50 4-50 4-50 4-50 4-50 4-51 6-14 6-14 6-14 6-14 6-14 6-16 6-17 6-17 6-18 6.4 Clutch Removal/Installation Clutch Pack Only Partial Disassembly Assembly Cleaning and Inspection Clutch Pack and Bearing Complete Disassembly Assembly . . .. . . .. .. . . 4.21 Evaporative Emissions Control: CA Models General..................................................................... Charcoal Canister..................................................... Removal................................................................ Installation. Hose Routing/Replacement.. 4-52 4-52 4-53 4-53 4-53 4-54 6-20 6-20 6-21 6-21 6.5 Transmission Sprocket Removal. Cleaning and Inspection Installation . . . .. 6.6 Drive Belt Removal Inspection Installation . . . . 6-23 6-23 6-23 6-24 SECTION 5-ELECTRIC STARTER 5.1 Specifications Torque Values........................................................... 5-1 5-1 SECTION 7-TRANSMISSION 5.2 Electric Starter System General ..................................................................... Starter Relay......................................................... Operation.................................................................. 5-2 5-2 5-2 5-2 7-1 7-2 7.1 Specifications Torque Values . .. 7-3 7-3 7-3 7-3 7-3 7-3 7-3 7-3 7-3 7-5 7.2 Transmission General Neutral 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear Shifter Linkage Adjustment . 5.3 Starter Relay Removal Installation . 5-5 5-5 5-5 .. .. . . . . . . . . . 5.4 Starter Removal Installation Disassembly, Inspection and Repair Assembly . 5-6 5-6 5-6 5-7 5-10 : . . .. . 5.5 Starter Solenoid General Disassembly Assembly . 5-12 5-12 5-12 5-12 7-6 7-6 7.3 Shifter Forks Cleaning and Inspection . . . . .. 7.4 Transmission Clutch Release Cover Removal/Disassembly Cleaning and Inspection Assembly/Installation 7-7 7-7 7-8 7-8 . . SECTION 6-DRIVE .. 6.1 Specifications Torque Values (Table) . .. 6-1 6-1 . 7-9 7-9 7-11 7-17 7-19 7-19 7-20 7-22 7.5 Transmission Assembly Removal Disassembly Countershaft Cleaning and Inspection Replacing Side Door Bearings Assembly Installation . 6.2 Primary Chaincase General Primary Chaincase Cover Removal Installation Primary Chaincase Housing Removal Inspection Installation Mainshaft Bearing and Lip Seal Removal Shifter Shaft Bushing . 6-2 6-2 6-2 6-2 6-3 6-4 6-4 6-4 6-4 6-6 6-6 6-7 .. . . .. .. . .. . . . . . . . . . . . x

  13. Page No. Page No. 8.10 Main Fuse Removal Installation . 8-15 8-15 8-15 7.6 Main Drive Gear And Bearing RemovaL Cleaning and Inspection Needle Bearing Replacement... Installation Installing Main Drive Gear Installing Main Drive Gear Seal . 7-24 7-24 7-26 7-27 7-30 7-31 7-32 . . . . .. . . .. 8.11 Ignition/Light Switch General Replacement Key Switch Functions and Positions (table) . 8-16 8-16 8-16 8-16 . .. . 7.7 Transmission Case RemovaL General Disassembly Shifter Arm Assembly Cleaning and Inspection Assembly Countershaft Needle Bearing Replacement Shifter Pawl Lever Assembly . 7-34 7-34 7-34 7-34 7-34 7-36 7-37 7-37 7-37 8-17 8-17 8-17 8-17 8.12 Alternator Removal/Disassembly Cleaning/Inspection Assembly/Installation . . . . . . . . .. .. . .. 8-18 8-18 8.13 Voltage Regulator GeneraL . .. 8-20 8-20 8-20 8-22 8.14 Front Electrical Caddy General Disassembly Assembly . . . . SECTION a-ELECTRICAL 8.1 Specifications Torque Values (table) .. .. 8-1 8-1 8.15 Battery....... Battery Testing General................................................................. Voltmeter Test Voltmeter Test For Battery Charge Conditions (table) 8-24 Conductance Test Load Test Battery Load Test (table)...................................... Charging Battery Safety Precautions....... Using a Battery Charger.. .................. Battery Charging RateslTimes (Approximate) (table) 8-26 8-24 8-24 8-24 8-24 8.2 Bulb Requirements General Softail Bulb Chart (table) . 8-3 8-3 8-3 . .. 8-24 8-25 8-25 8-26 8-26 8-26 8.3 Electrical Panel General Removal Installation . 8-4 8-4 8-4 8-5 . . . 8.4 Electronic Control Module (ECM) General RemovaL Installation 8-6 8-6 8-6 8-7 . . . 8.16 Battery Cables Routing Procedure 8-28 8-28 8-30 8-30 8-30 8-30 8-31 8-31 8.17 Headlamp GeneraL Removal/Installation FXSTD, FXSTS and FLSTSC Models FXST and FXSTB Models FLSTC, FLSTF and FLSTN Models .. 8.5 Crank Position Sensor (CKP) General Removal Installation . .. . . 8-8 8-8 8-8 8-9 . . .. . .. 8.6 Spark Plug Cables General RemovaL Inspection Installation . 8-10 8-10 8-10 8-11 8-11 . . . 8.18 Tail Lamp: All But FXSTDI FLSTSCIFLSTN General Bulb Replacement Base Replacement Tail Lamp Wires (table) . 8-33 8-33 8-33 8-33 8-34 . . .. 8.7 Ignition Coil Removal Installation . 8-12 8-12 8-12 .. . . . 8-35 8-35 8-36 8.19 Tail Lamp: FXSTD Removal Installation . 8.8 Fuses General Removal Installation . 8-13 8-13 8-13 8-13 . . . . . 8.20 Tail Lamp: FLSTSCIFLSTN Bulb Replacement Tail Lamp Replacement . 8-37 8-37 8-37 . 8.9 Relays General RemovaL Installation . 8-14 8-14 8-14 8-14 .. : . . . xi

  14. 8.21 Auxiliary Lamps: FLSTCIFLSTN Auxiliary Lamp Bulb Removal Installation FLSTC Models Auxiliary Lamp Bracket Removal Auxiliary Lamp Bracket Installation Auxiliary Lamp Housing Removal Auxiliary Lamp Housing Installation FLSTN Models Auxiliary Lamp Bracket Removal Auxiliary Lamp Bracket Installation Auxiliary Lamp Housing Removal Auxiliary Lamp Housing Installation Adjustment: FLSTC/FLSTN Models 8-60 8-60 8-60 8-60 8-60 8-60 8-39 8-39 8-39 8-39 8-40 8-40 8-40 8-40 8-40 8-42 8-42 8-42 8-44 8-44 8-45 8.30 Indicator Lamps: All But FXSTD General Removal. Installation Connector [21] Pins (table) Indicator Lamp Assembly Wiring (table) . . . .. .. . . . .. .. . .. .. 8-61 8-61 8-61 8-61 8.31 Indicator Lamps: FXSTD General Removal Installation . .. . .. . .. .. .. . . 8-62 8-62 8-62 8-62 8.32 Neutral Switch General Removal Installation . .. . .. 8.22 Front Fender Lamp: FLSTSC.... Removal. ................................................................... Installation................................................................. 8-46 8-46 8-46 8-63 8-63 8-63 8-63 8.33 Oil Pressure Switch General Removal Installation . .. . . 8.23 Turn Signals/Running Lights.... Bulb Replacement: All But FLSTC Bulb Replacement: FLSTC Lamp Replacement................................................... Front Turn Signals: All But FLSTC, FLSTN, FLSTSC, FXSTS................................................................... Front Turn Signals: FLSTSC, FXSTC Rear Turn Signals: All But FXSTD, FLSTSC, FLSTN 8-50 Rear Turn Signals: FXSTD Rear Turn Signals: FLSTSC Rear Turn Signals: FLSTN.................................... 8-47 8-47 8-47 8-47 8-64 8-64 8-64 8-64 8.34 Rear Stop Light Switch General Removal Installation . . . .. 8-48 8-49 8.35 Horn Inspection Replacement. . . . 8-65 8-65 8-65 8-50 8-51 8-51 8-66 8-66 8-66 8-67 8-67 8.36 Active Exhaust Module General Removal Repair Installation . .. . . . 8.24 TSMlTSSMlHFSM General..................................................................... Removal............... Installation TSMITSSM Configuration........................ 8-52 8-52 8-52 8-52 8-53 8.37 Main Wiring Harness Removal Installation . . . 8-68 8-68 8-70 8.25 Fuel Gauge General ..................................................................... Removal .................................................................... Installation 8-54 8-54 8-54 8-55 8-72 8-72 8-72 8.38 Handlebar Switch Assemblies .. General Repair Procedures . . 8.26 Instrument Console: FXSTD Removal........ ............................. Installation................................................................. 8-56 8-56 8-56 8-73 8-73 8-73 8-75 8-76 8-76 8-77 8-78 8.39 Right Handlebar Switch Removal Installation Disassembly Switch Repair/Replacement Upper Housing Repair Lower Housing Repair Assembly . . . . 8.27 Speedometer: All But FXSTD ... Removal.......... .......................................................... Installation 8-57 8-57 8-57 .. . .. 8.28 Speedometer: FXSTD Removal. ................................................................... Installation 8-58 8-58 8-58 . 8-79 8-79 8-79 8-80 8-80 8-80 8-82 8-83 8.40 Left Handlebar Switch Removal. Installation Disassembly Switch Repair/Replacement Upper Housing Repair Lower Housing Repair Assembly . . 8.29 Vehicle Speed Sensor: VSS...... General ..................................................................... Removal.. .................................................................. Installation 8-59 8 ~ 5 9 8-59 8-59 .. . . .. .. .

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  16. Page No. Page No. APPENDIX A-TOOLS 8-16 8-16 8-16 8-16 8-16 8.7 Deutsch Mini Terminal Crimps .. Terminal Crimps Prepare Wire Lead Crimp a Mini Terminal to a Wire Lead Inspect Crimp . .. .. A.1 Tools . A-1 . APPENDIX B-WIRING 8.8 Deutsch Solid 8arrel Terminal Crimps Wire Terminals Prepare Wire Lead Adjust Crimper Tool, Crimp 8arrel Contact to Wire Lead Inspect Crimp 8-17 8-17 8-17 8-17 8-18 8-18 . .. . . . . 8-1 8-1 8-1 8-1 8-1 8-1 8-2 8-2 8-2 8.1 Amp 1-Place Connector Pin and Socket Housings To Separate Housings To Mate Housings Wire Terminals Remove Socket Terminals Install Socket Terminal Remove Pin Terminals Install Pin Terminals . . .. . . . . 8-19 8-19 8-19 8-19 8-20 8.9 Fuse 810cks Fuse Wire Leads Remove Socket Terminals Install Socket Terminals Terminal Crimps .. . . . .. .. 8.2 Amp Multilock Pin and Socket Housings Separate Housings Mate Housings Wire Terminals Remove Terminals from Housing Insert Terminals into Housings Terminal Crimps Prepare Wire Leads Crimp Terminals to Leads Inspect Crimp . .. 8-3 8-3 8-3 8-3 8-4 8-4 8-5 8-6 8-6 8-6 8-7 .. 8-21 8-21 8-21 8-21 8-21 8-21 8.10 150 Metri-Pack Pin and Socket Housings Wire Terminals Remove Terminals Insert Terminals Terminal Crimps . . . . .. . . . . . . .. . . 8-23 8-23 8-23 8-23 8-23 8-23 8-23 8-24 8.11 280 Metri-Pack Pin and Socket Housings To Separate Housings To Mate Housings Wire Terminals Remove Socket Terminals Install Socket Terminals Terminal Crimps . .. . . . . . 8.3 Delphi Connectors Pin and Socket Housings To Separate Housings To Mate Housings Wire Terminals Remove Socket Terminals Install Socket Terminals Housing To Separate Housings To Mate Housings Wire Terminals Remove Terminal Installation . .. .. . .. . . . .. .. 8-8 8-8 8-8 8-8 8-8 8-8 8-9 8-10 8-10 8-10 8-10 8-10 8-10 .. . . : 8-25 8-25 8-25 8-25 8-25 8-25 8-26 8.12 480 Metri-Pack Pin and Socket Housings To Separate Housings To Mate Housings Wire Terminals Remove Socket Terminal . Install Socket Terminal . . . .. . .. .. . .. . 8-27 8-27 8-27 8-27 8-27 8-27 8-27 8.13 630 Metri-Pack Pin and Socket Housings Separate Housings Mate Housings Wire Terminals Remove Socket Terminals Install Socket Terminals . 8-11 8-11 8-11 8-11 8-12 8-12 8-12 8-13 8-14 8-14 8.5 Deutsch Pin and Socket Housings Separate Housings Mate Housings Wire Terminals Remove Socket Terminals Install Socket Terminals Remove Pin Terminals install Pin Terminals Terminal Crimps .. . . . . . . . . .. .. .. . .. . . 8.14 800 Metri-Pack Fuse and Socket Housing Remove the Maxi-Fuse Install Maxi-Fuse Wire Terminals Remove Socket Terminals Install Socket Terminals Terminal Crimps . .. .. .. .. .. 8-28 8-28 8-28 8-28 8-28 8-28 8-29 8-29 8.6 Standard Deutsch Terminal Crimps Terminal Crimps Prepare Wire Lead Crimp Terminal to Lead Inspect Crimp . 8-15 8-15 8-15 8-15 8-15 . . .. . . .. xiii

  17. Page No. Page No. 8.15 Metri-Pack Terminal Crimps .... Match Terminal to Crimper........................................ Terminal Crimps........................................................ Prepare Wire Lead............................... Crimp Wire Core Crimp Insulation/Seal............................................ Inspect Crimp 8.16 Packard 1OOW Socket Housing..... Separate Socket Housing from ECM Mate Socket Housing to ECM Wire Terminals Remove Socket Terminals Install Socket Terminals........................................ 8.17 Molex Pin and Socket Housings.......................................... Separate the Housings..................................... Mate the Housings................................. Wire Terminals.......................................................... Remove Terminals................................................ Install Terminal...................................................... 8.18 Packard Micro 64 Pin and Socket Housings.......................................... Separate the Housings......................................... Mate the Housings Wire Terminals Remove Terminals................................................ Install Terminals.................................................... Terminal Crimps........................................................ Prepare Wire Lead Crimp Terminal...................................................... Inspect Crimp............................................. 8.19 Sealed Splice Prepare Wire Leads................................ Splicing Wire Leads............. Inspect Seal .............................................................. 8.20 Connector Locations 8-30 8-30 8-31 8-31 8-31 8-31 8-31 8-32 8-32 8-32 8-32 8-32 8-32 8-32 8-34 8-34 8-34 8-34 8-34 8-34 8-35 8-36 8-36 8-36 8-36 8-36 8-36 8-37 8-38 8-38 8-38 8-38 8-39 8-39 8-40 8-40 8-41 8.21 Index to Wiring Diagrams......... Wire Color Codes...................................................... Wiring Diagram Symbols............ 8-43 8-43 8-43 APPENDIX C-METRIC CONVERSIONS C.1 Metric Conversions C-1 C.2 Fluid Conversions....................... United States System............................ Metric System........................................................... 8ritish Imperial System C-2 C-2 C-2 C-2 APPENDIX D-GLOSSARY D.1 Glossary D-I INDEX xiv

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