2013 Harley Davidson Softail Models Service Manual – PDF DOWNLOAD
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2013 Harley Davidson Softail Models Service Manual – PDF DOWNLOAD2013 Harley Davidson Softail Models Service Manual – PDF DOWNLOAD
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2013 Harley Davidson Softail Models Service Manual – PDF DOWNLOAD
ABOUT THIS MANUAL GENERAL:
This service manual has been prepared with the following purposes in mind:
To acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair.
To introduce the professional Harley-Davidson technician to the latest field-tested and factory-approved major repair methods.
We sincerely believe that this service manual will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL:
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Maintenance
2 Chassis
3 Engine
4 Fuel System
5 Drive
6 Transmission
7 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C ABS
D Appendix D Conversions
E Appendix E Glossary
Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation.
For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS.
For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.
A number of acronyms and abbreviations are used in this document. See the D.1 GLOSSARY for a list of acronyms, abbreviations and definitions.
TABLE OF CONTENTS:
2013 Harley Davidson Softail Models Service Manual – PDF DOWNLOAD
FOREWORD......................................................... 7
TABLE OF CONTENTS................................................ 9
1. MAINTENANCE................................................... 23
1.1 FASTENER TORQUE VALUES................................... 25
Fastener Torque Values in this Chapter................... 25
1.2 GENERAL.................................................. 28
Servicing a New Motorcycle............................... 28
Safe Operating Maintenance............................... 28
Disposal and Recycling................................... 28
Shop Practices........................................... 28
Repair and Replacement Procedures........................ 29
Cleaning................................................. 30
Tool Safety.............................................. 30
1.3 FUEL AND OIL............................................. 32
Fuel..................................................... 32
Gasoline Blends.......................................... 32
Engine Lubrication....................................... 32
Winter Lubrication....................................... 33
1.4 BULB REQUIREMENTS........................................ 34
General.................................................. 34
1.5 MAINTENANCE SCHEDULE..................................... 35
General.................................................. 35
1.6 ENGINE OIL AND FILTER.................................... 40
Checking and Adding Oil.................................. 40
Changing Oil and Filter.................................. 40
1.7 AIR CLEANER AND EXHAUST SYSTEM........................... 42
Removal.................................................. 42
Installation............................................. 43
Exhaust System Leak Check................................ 44
1.8 TIRES AND WHEELS......................................... 45
General.................................................. 45
Tires.................................................... 45
Tire Replacement......................................... 46
Wheel Bearings........................................... 46
Wheel Spokes............................................. 46
1.9 PRIMARY CHAINCASE LUBRICANT.............................. 48
General.................................................. 48
Changing Primary Chaincase Lubricant..................... 48
1.10 TRANSMISSION LUBRICANT.................................. 50
Transmission Lubricant................................... 50
Changing Transmission Lubricant.......................... 50
1.11 CLUTCH.................................................. 52
Adjustment............................................... 52
1.12 DRIVE BELT AND SPROCKETS................................ 54
General.................................................. 54
Cleaning................................................. 54
Inspection............................................... 54
Checking Belt Deflection................................. 55
Adjusting Belt Deflection................................ 56
1.13 THROTTLE CABLES......................................... 58
Cable Inspection, Lubrication and Adjustment............. 58
1.14 CABLE AND CHASSIS LUBRICATION........................... 60
General.................................................. 60
Cables and Hand Levers................................... 60
Jiffy Stand.............................................. 60
Steering Head Bearings................................... 60
1.15 BRAKES.................................................. 61
Fluid Inspection......................................... 61
Rear Brake Pedal......................................... 61
Brake Lines Inspection................................... 61
1.16 BRAKE PADS AND DISCS.................................... 63
Inspection............................................... 63
Brake Pad Replacement.................................... 64
1.17 SPARK PLUGS............................................. 67
Removal.................................................. 67
Inspection............................................... 67
Cleaning................................................. 67
Installation............................................. 67
Spark Plug Cable Inspection.............................. 68
1.18 STEERING HEAD BEARINGS.................................. 69
Adjustment: FLSTC, FLSTF/B, FLSTN, FLS................... 69
Adjustment: FXST, FXS.................................... 70
Adjustment: FXSB......................................... 72
Lubrication.............................................. 73
1.19 CRITICAL FASTENERS...................................... 74
Inspection............................................... 74
1.20 BATTERY MAINTENANCE..................................... 75
General.................................................. 75
Cleaning and Inspection.................................. 76
Voltmeter Test........................................... 76
Charging Battery......................................... 76
Disconnection and Removal................................ 77
Storage.................................................. 77
Installation and Connection.............................. 78
1.21 HEADLAMP ALIGNMENT...................................... 80
Headlamp Alignment....................................... 80
Headlamp Adjustment...................................... 80
1.22 SUSPENSION ADJUSTMENTS.................................. 82
Shock Absorbers.......................................... 82
1.23 STORAGE................................................. 83
General.................................................. 83
Placing in Storage....................................... 83
Removal from Storage..................................... 83
1.24 TROUBLESHOOTING......................................... 85
General.................................................. 85
Engine................................................... 85
Lubrication System....................................... 86
Electrical System........................................ 87
Transmission............................................. 87
Handling................................................. 87
Brakes................................................... 87
2. CHASSIS....................................................... 89
2.1 FASTENER TORQUE VALUES................................... 91
Fastener Torque Values in this Chapter................... 91
2.2 SPECIFICATIONS........................................... 95
Specifications........................................... 95
2.3 VEHICLE IDENTIFICATION NUMBER (V.I.N.)................... 99
Vehicle Identification Number............................ 99
2.4 FRONT WHEEL..............................................101
Removal..................................................101
Disassembly..............................................101
Cleaning and Inspection..................................103
Assembly.................................................103
Installation.............................................104
2.5 REAR WHEEL...............................................105
Removal..................................................105
Disassembly..............................................105
Cleaning and Inspection..................................106
Assembly.................................................106
Installation.............................................107
2.6 WHEEL LACING.............................................108
Wheel Lacing: Angle Flange Hub...........................108
2.7 CHECKING AND TRUING WHEELS...............................110
General..................................................110
Checking Wheel Runout....................................110
Laced Wheel Rim Offset...................................111
Truing Laced Wheels......................................113
2.8 SEALED WHEEL BEARINGS....................................115
Inspection...............................................115
Removal..................................................115
Installation.............................................117
2.9 TIRES....................................................119
General..................................................119
Removal..................................................119
Cleaning, Inspection and Repair..........................119
Installation.............................................120
Checking Tire Runout.....................................122
Wheel Balancing..........................................123
2.10 VEHICLE ALIGNMENT.......................................124
Axle Alignment...........................................124
2.11 FRONT BRAKE MASTER CYLINDER.............................126
General..................................................126
Removal and Disassembly..................................126
Cleaning and Inspection..................................128
Assembly and Installation................................128
2.12 FRONT BRAKE CALIPER.....................................130
Removal..................................................130
Disassembly..............................................130
Cleaning, Inspection and Repair..........................132
Assembly.................................................133
Installation.............................................134
2.13 REAR BRAKE MASTER CYLINDER..............................135
General..................................................135
Removal..................................................135
Disassembly..............................................135
Cleaning and Inspection..................................136
Assembly.................................................136
Installation.............................................137
2.14 REAR BRAKE CALIPER......................................141
Removal..................................................141
Disassembly..............................................141
Cleaning, Inspection and Repair..........................143
Assembly.................................................144
Rear Brake Line Routing..................................144
Installation.............................................144
2.15 BLEEDING BRAKES.........................................146
General..................................................146
Procedure................................................146
2.16 FRONT FORK: TELESCOPIC..................................148
General..................................................148
Replacing Fork Oil.......................................148
Removal..................................................149
Disassembly..............................................149
Cleaning and Inspection..................................149
Assembly.................................................154
Installation.............................................154
2.17 STEERING HEAD...........................................155
Removal..................................................155
Inspection...............................................156
Disassembly..............................................157
Assembly.................................................157
Installation.............................................158
2.18 BELT GUARD AND DEBRIS DEFLECTOR.........................159
Removal..................................................159
Installation.............................................159
2.19 REAR SHOCK ABSORBERS....................................160
General..................................................160
Removal..................................................160
Installation.............................................160
Shock Disposal...........................................161
2.20 REAR FORK...............................................163
Removal..................................................163
Cleaning and Inspection..................................164
Pivot Bearing Replacement................................164
Installation.............................................165
2.21 THROTTLE CONTROL........................................166
Removal/Disassembly......................................166
Cleaning and Inspection..................................166
Assembly/Installation....................................166
2.22 CLUTCH CONTROL..........................................168
Removal..................................................168
Installation.............................................168
2.23 HANDLEBARS: FLSTC, FLSTN, FLS, FXST.....................170
Removal..................................................170
Installation.............................................171
2.24 HANDLEBARS: FLSTF/B.....................................172
Removal..................................................172
Installation.............................................173
2.25 HANDLEBARS: FXS.........................................176
Removal..................................................176
Installation.............................................176
2.26 HANDLEBARS: FXSB........................................178
Removal..................................................178
Installation.............................................178
2.27 FRONT FENDER............................................181
Removal..................................................181
Installation.............................................182
2.28 REAR FENDER: FLSTC......................................183
Removal..................................................183
Installation.............................................183
2.29 REAR FENDER: FLSTF/B....................................185
Removal..................................................185
Installation.............................................185
2.30 REAR FENDER: FXST.......................................186
Removal..................................................186
Installation.............................................186
2.31 REAR FENDER: FLS, FXS...................................188
Removal..................................................188
Installation.............................................188
2.32 REAR FENDER: FXSB.......................................191
Removal..................................................191
Installation.............................................192
2.33 REAR FENDER: FLSTN......................................193
Removal..................................................193
Disassembly..............................................193
Assembly.................................................195
Installation.............................................195
2.34 REAR FENDER WIRE CONDUIT................................196
Installation.............................................196
2.35 FOOTBOARDS AND FOOTRESTS................................197
Rider Footboards.........................................197
Rider Footrest...........................................197
Passenger Footrest.......................................197
2.36 JIFFY STAND.............................................199
Cleaning.................................................199
Sensor: HDI Models.......................................199
Removal..................................................200
Installation.............................................200
2.37 FORK LOCK...............................................201
Removal..................................................201
Installation.............................................201
2.38 SEAT AND STRAP RETENTION NUT............................202
Replacement..............................................202
2.39 SEAT: FLS, FXS, FXST, FXSB..............................203
Replacement..............................................203
2.40 SEAT: FLSTN, FLSTF, FLSTFB, FLSTC.......................204
Removal and Installation.................................204
2.41 LUGGAGE RACK: FLSTN.....................................205
Removal and Installation.................................205
2.42 SADDLEBAGS: FLSTC.......................................206
Removal..................................................206
Installation.............................................206
2.43 WINDSHIELD: FLSTC.......................................208
Removal..................................................208
Installation.............................................208
2.44 SAREE GUARD: INDIA MODELS...............................209
Left Side Removal and Installation.......................209
Right Side Removal and Installation......................209
2.45 FRONT LICENSE PLATE BRACKET.............................211
Removal and Installation.................................211
2.46 MEDALLIONS, SERIALIZED BADGES AND TANK EMBLEMS..........212
Removal..................................................212
Installation.............................................212
3. ENGINE........................................................213
3.1 FASTENER TORQUE VALUES...................................215
Fastener Torque Values in this Chapter...................215
3.2 SPECIFICATIONS...........................................217
Specifications...........................................217
3.3 SERVICE WEAR LIMITS......................................219
General..................................................219
3.4 ENGINE OIL FLOW..........................................221
Oil Feed.................................................221
Top End..................................................222
Bottom End...............................................223
Chain Guide Bracket......................................225
Oil Return...............................................226
3.5 OIL PUMP OPERATION.......................................227
General..................................................227
Operation................................................227
3.6 BREATHER OPERATION.......................................229
General..................................................229
3.7 OIL PRESSURE.............................................230
Oil Pressure Indicator Lamp..............................230
Checking Oil Pressure....................................230
3.8 TROUBLESHOOTING..........................................232
Diagnosing Valve Train Noise.............................232
Compression Test.........................................232
Cylinder Leakdown Test...................................232
Diagnosing Smoking Engine or High Oil Consumption........233
3.9 HOW TO USE THIS SECTION..................................234
Top End Repair...........................................234
Bottom End Repair........................................234
Typical Symptoms.........................................234
3.10 TOP END SERVICE.........................................235
Engine in Chassis........................................235
Engine Removed from Chassis..............................236
3.11 CAM COMPARTMENT SERVICE.................................237
Engine in Chassis........................................237
Engine Removed From Chassis..............................238
3.12 STRIPPING MOTORCYCLE FOR SERVICE........................239
Procedure................................................239
3.13 ASSEMBLING MOTORCYCLE AFTER SERVICE.....................240
Procedure................................................240
3.14 REMOVING ENGINE FROM CHASSIS............................241
Procedure................................................241
3.15 INSTALLING ENGINE IN CHASSIS............................242
Procedure................................................242
3.16 TOP END OVERHAUL: DISASSEMBLY...........................244
General..................................................244
Rocker Covers............................................244
Rocker Arm Support Plate.................................244
Pushrods, Lifters and Covers.............................246
Cylinder Head............................................246
Cylinder.................................................247
Piston...................................................248
3.17 BREATHER ASSEMBLY.......................................250
Disassembly..............................................250
Cleaning and Inspection..................................250
Assembly.................................................250
3.18 ROCKER ARM SUPPORT PLATE................................251
Disassembly..............................................251
Cleaning and Inspection..................................251
Assembly.................................................253
3.19 PUSHRODS, LIFTERS AND COVERS............................254
Disassembly..............................................254
Cleaning and General Inspection..........................254
Lifter Inspection........................................255
Assembly.................................................255
3.20 CYLINDER HEAD...........................................256
Disassembly..............................................256
Cleaning.................................................257
Inspection...............................................257
Valve Guide Replacement..................................258
Valve and Seat Refacing..................................262
Assembly.................................................264
3.21 CYLINDER................................................266
Cleaning.................................................266
Inspection...............................................266
Deglazing Cylinder.......................................268
Boring and Honing Cylinder...............................268
3.22 PISTON..................................................270
Disassembly..............................................270
Cleaning.................................................270
Inspection...............................................270
Assembly.................................................272
3.23 TOP END OVERHAUL: ASSEMBLY..............................274
General..................................................274
Piston...................................................274
Cylinder.................................................275
Cylinder Head............................................277
Pushrods, Lifters and Covers.............................281
Rocker Arm Support Plate.................................282
Breather and Rocker Cover................................283
3.24 CAM COMPARTMENT AND COMPONENTS..........................284
Cam Support Plate and Cover Removal......................284
Cam Support Plate Cleaning and Inspection................286
Camshafts................................................287
Oil Pressure Relief Valve................................289
Cam Needle Bearings......................................289
Cam Support Plate and Cover Installation.................292
3.25 OIL PUMP................................................296
Removal..................................................296
Cleaning and Inspection..................................296
Installation.............................................297
3.26 CRANKCASE DISASSEMBLY AND REPAIR........................298
Crankcase Disassembly....................................298
Counterbalancer Assembly.................................298
Cleaning and Inspection..................................300
Right Crankcase Half.....................................301
Left Crankcase Half......................................303
Sprocket Shaft Bearing Inner Race........................304
Cylinder Studs...........................................307
Pipe Plugs and Oil Fittings..............................307
3.27 FLYWHEEL AND CONNECTING RODS............................308
General..................................................308
Inspection...............................................308
Measuring Crankshaft Runout..............................308
3.28 COUNTERBALANCER ASSEMBLY REPAIR.........................311
Cleaning, Inspection, and Repair.........................311
3.29 CRANKCASE ASSEMBLY......................................316
Counterbalancer Assembly Installation....................316
Crankcase................................................319
3.30 OIL TANK: ALL BUT FXSB..................................322
Removal and Disassembly..................................322
Installation.............................................325
3.31 OIL TANK: FXSB..........................................326
Removal and Disassembly..................................326
Installation.............................................329
4. FUEL SYSTEM...................................................331
4.1 FASTENER TORQUE VALUES...................................333
Fastener Torque Values in this Chapter...................333
4.2 SPECIFICATIONS: FUEL SYSTEM..............................335
Specifications...........................................335
4.3 AIR CLEANER ASSEMBLY.....................................336
Removal..................................................336
Installation.............................................336
Backplate Assembly: HDI Models...........................337
4.4 FUEL SUPPLY LINE.........................................338
Purging Fuel Supply Line.................................338
Disconnecting Fuel Supply Line...........................338
4.5 FUEL PRESSURE TEST.......................................339
General..................................................339
Testing..................................................339
4.6 FUEL TANK................................................341
General..................................................341
Removal..................................................341
Cleaning and Inspection..................................342
Installation.............................................343
4.7 CONSOLE: FXS, FXSB.......................................344
Removal..................................................344
Installation.............................................344
4.8 THROTTLE POSITION SENSOR (TPS)...........................345
General..................................................345
Removal..................................................345
Installation.............................................345
4.9 INTAKE AIR TEMPERATURE SENSOR (IAT)......................346
General..................................................346
Removal..................................................346
Installation.............................................346
4.10 ENGINE TEMPERATURE SENSOR (ET)..........................347
General..................................................347
Removal..................................................347
Installation.............................................347
4.11 INDUCTION MODULE........................................348
Removal..................................................348
Installation.............................................349
4.12 IDLE AIR CONTROL (IAC)..................................350
General..................................................350
Removal..................................................350
Installation.............................................350
4.13 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP).................351
Removal..................................................351
Installation.............................................351
4.14 OXYGEN (O2) SENSOR......................................352
General..................................................352
Removal..................................................352
Installation.............................................352
4.15 FUEL INJECTORS..........................................354
General..................................................354
Removal..................................................354
Installation.............................................354
4.16 FUEL PUMP AND FUEL GAUGE SENDING UNIT...................356
General..................................................356
Removal..................................................356
Vapor Valve..............................................357
Disassembly and Assembly.................................358
Installation.............................................360
4.17 EXHAUST SYSTEM..........................................362
Mufflers: FLSTC, FXST, FXSB..............................362
System: FLSTC, FXST, FXSB................................362
Mufflers: FLSTN, FLSTF/B, FLS, FXS.......................364
System: FLSTN, FLSTF/B, FLS, FXS.........................364
4.18 INTAKE LEAK TEST........................................366
General..................................................366
Leak Tester..............................................366
Procedure................................................366
4.19 EVAPORATIVE EMISSIONS CONTROL SYSTEM....................368
General..................................................368
Charcoal Canister........................................369
Purge Solenoid...........................................369
Hose Routing/Replacement.................................369
5. DRIVE.........................................................371
5.1 FASTENER TORQUE VALUES...................................373
Fastener Torque Values in this Chapter...................373
5.2 SPECIFICATIONS: DRIVE....................................374
Specifications...........................................374
5.3 PRIMARY CHAINCASE COVER..................................375
General..................................................375
Removal..................................................375
Installation.............................................375
5.4 DRIVE COMPONENTS.........................................376
Removal..................................................376
Installation.............................................378
5.5 PRIMARY CHAINCASE HOUSING................................381
Removal..................................................381
Inspection...............................................381
Mainshaft Bearing and Seal...............................381
Mainshaft Bearing Inner Race.............................382
Installation.............................................383
5.6 CLUTCH...................................................385
Removal and Installation.................................385
Clutch Pack Only.........................................385
Clutch Pack and Bearing..................................387
5.7 TRANSMISSION SPROCKET....................................390
Removal..................................................390
Cleaning and Inspection..................................391
Installation.............................................391
5.8 DRIVE BELT...............................................393
Removal..................................................393
Inspection...............................................393
Installation.............................................393
6. TRANSMISSION..................................................395
6.1 FASTENER TORQUE VALUES...................................397
Fastener Torque Values in this Chapter...................397
6.2 SPECIFICATIONS: TRANSMISSION.............................398
Specifications...........................................398
Service Wear Limits......................................398
6.3 TRANSMISSION.............................................400
Power Flow...............................................400
6.4 SHIFTER..................................................402
Adjustment...............................................402
Shifter Rod Adjustment...................................402
Shift Lever Replacement..................................402
6.5 CLUTCH RELEASE COVER.....................................404
Removal and Disassembly..................................404
Cleaning and Inspection..................................404
Assembly and Installation................................405
6.6 TRANSMISSION ASSEMBLY....................................406
Removal..................................................406
Disassembly..............................................407
Cleaning and Inspection..................................414
Assembly.................................................414
Installation.............................................418
6.7 MAIN DRIVE GEAR AND BEARING..............................419
Removal..................................................419
Cleaning and Inspection..................................420
Installation.............................................422
6.8 TRANSMISSION CASE........................................426
Removal..................................................426
Installation.............................................426
Disassembly..............................................427
Cleaning and Inspection..................................427
Assembly.................................................428
7. ELECTRICAL....................................................431
7.1 FASTENER TORQUE VALUES...................................433
Fastener Torque Values in this Chapter...................433
7.2 SPECIFICATIONS: ELECTRICAL...............................436
Specifications...........................................436
7.3 ELECTRICAL PANEL.........................................437
General..................................................437
Removal: All But FXSB....................................437
Installation: All But FXSB...............................438
Removal: FXSB............................................438
Installation: FXSB.......................................438
7.4 ELECTRONIC CONTROL MODULE (ECM)..........................440
General..................................................440
Removal: All But FXSB....................................440
Installation: All But FXSB...............................440
Removal: FXSB............................................440
Installation: FXSB.......................................440
7.5 BODY CONTROL MODULE (BCM)................................441
General..................................................441
BCM Configuration........................................441
Removal: All But FSXB....................................441
Installation: All But FXSB...............................441
Removal: FXSB............................................442
Installation: FXSB.......................................442
7.6 H-DSSS ACTUATION.........................................443
Sidecar Configuration....................................443
Actuation................................................443
Fob Assignment...........................................443
7.7 PERSONAL IDENTIFICATION NUMBER (PIN).....................444
General..................................................444
Changing the PIN.........................................444
7.8 HD-SSS MAINTENANCE.......................................446
Fob Battery..............................................446
Smart Siren (If Installed)...............................446
7.9 SECURITY SIREN...........................................447
Removal: All But FXSB....................................447
Installation: All But FXSB...............................447
Removal: FXSB............................................448
Installation: FXSB.......................................448
7.10 FUSES...................................................449
Removal..................................................449
Installation.............................................449
7.11 IGNITION AND LIGHT SWITCH...............................450
General..................................................450
Removal and Installation: All But FXS/B..................450
Removal and Installation: FXS/B..........................451
7.12 BATTERY CABLES..........................................452
Routing Procedure........................................452
7.13 STARTER.................................................454
General..................................................454
Removal..................................................454
Drive Assembly...........................................454
Solenoid.................................................455
Installation.............................................456
7.14 HEADLAMP................................................458
General..................................................458
Headlamp Assembly Removal and Installation...............458
Bulb Removal and Installation............................458
7.15 TAIL LAMP: ALL BUT FLSTN................................461
General..................................................461
Bulb Replacement.........................................461
Base Replacement.........................................461
7.16 TAIL LAMP: FLSTN........................................463
Bulb Replacement.........................................463
Tail Lamp Replacement....................................463
7.17 AUXILIARY LAMPS: FLSTC, FLSTN...........................465
Auxiliary Lamp Bulb......................................465
FLSTC Models.............................................465
FLSTN Models.............................................468
Adjustment: FLSTC/FLSTN Models...........................470
7.18 TURN SIGNALS AND RUNNING LIGHTS.........................472
Bulb Replacement: Bullet Style...........................472
Bulb Replacement: Flat Lens Style........................472
Lamp Replacement.........................................472
7.19 CRANK POSITION SENSOR (CKP).............................479
General..................................................479
Removal..................................................479
Installation.............................................479
7.20 AUTOMATIC COMPRESSION RELEASE (ACR).....................481
General..................................................481
Removal..................................................481
Installation.............................................481
7.21 IGNITION COIL...........................................483
Removal..................................................483
Installation.............................................483
7.22 SPARK PLUG CABLES.......................................485
General..................................................485
Removal..................................................485
Installation.............................................485
7.23 VOLTAGE REGULATOR.......................................486
Disassembly..............................................486
Installation.............................................486
7.24 ALTERNATOR..............................................487
Removal..................................................487
Cleaning and Inspection..................................487
Installation.............................................487
7.25 FUEL GAUGE..............................................488
General..................................................488
Removal..................................................488
Installation.............................................488
7.26 SPEEDOMETER.............................................490
General..................................................490
Removal: All But FXS/B...................................490
Installation: All But FXS/B..............................490
Removal: FXS.............................................490
Installation: FXS........................................491
Removal: FXSB............................................491
Installation: FXSB.......................................491
7.27 VEHICLE SPEED SENSOR (VSS)..............................493
General..................................................493
Removal..................................................493
Installation.............................................493
7.28 INDICATOR LAMPS.........................................494
General..................................................494
Removal: All But FXS/B...................................494
Installation: All But FXS/B..............................494
Removal: FXS.............................................495
Installation: FXS........................................496
Removal: FXSB............................................496
Installation: FXSB.......................................496
7.29 NEUTRAL SWITCH..........................................498
General..................................................498
Removal..................................................498
Installation.............................................498
7.30 OIL PRESSURE SWITCH.....................................499
General..................................................499
Removal..................................................499
Installation.............................................499
7.31 REAR STOP LAMP SWITCH...................................500
General..................................................500
Removal..................................................500
Installation.............................................500
7.32 HORN....................................................501
Inspection...............................................501
Removal and Installation: All But FXS/B..................501
Removal and Installation: FXS/B..........................502
7.33 ACTIVE EXHAUST..........................................503
General..................................................503
Removal..................................................503
Repair...................................................503
Installation.............................................503
7.34 MAIN WIRING HARNESS.....................................504
Removal..................................................504
Installation.............................................505
7.35 HANDLEBAR CONTROL MODULES...............................507
General..................................................507
Repair Procedures........................................507
7.36 RIGHT HANDLEBAR CONTROL MODULE..........................508
Removal..................................................508
Installation.............................................509
Front Brake Switch Replacement...........................510
7.37 LEFT HANDLEBAR CONTROL MODULE...........................511
Removal..................................................511
Installation.............................................511
Clutch Switch Replacement................................512
A. APPENDIX A CONNECTOR REPAIR...................................513
A.1 AUTOFUSE UNSEALED ELECTRICAL CONNECTORS..................515
Autofuse Unsealed Connector Repair.......................515
A.2 BOSCH COMPACT 1.1M CONNECTOR.............................516
Bosch Compact 1.1M Connector.............................516
A.3 DELPHI 100W MICRO-PACK SEALED CONNECTOR..................517
Delphi 100W Micro-Pack Sealed Connector Repair...........517
Crimping Terminals.......................................518
A.4 DELPHI 150 METRI-PACK SEALED CONNECTORS..................519
Delphi 150 Metri-Pack Sealed Connector Repair............519
A.5 DELPHI 280 METRI-PACK UNSEALED CONNECTORS................521
Fuse Block Repair........................................521
A.6 DELPHI 480 METRI-PACK UNSEALED CONNECTORS................522
Delphi 480 Metri-Pack Unsealed Connector Repair..........522
A.7 DELPHI 630 METRI-PACK UNSEALED CONNECTORS................523
Delphi 630 Metri-Pack Unsealed Connector Repair..........523
A.8 DELPHI 800 METRI-PACK SEALED MAIN FUSE HOUSING...........524
Delphi 800 Metri-Pack Sealed Main Fuse Housing Repair....524
A.9 DELPHI METRI-PACK TERMINAL REPAIR........................525
Metri-Pack Terminal Crimps...............................525
A.10 DELPHI MICRO 64 SEALED CONNECTORS.......................527
Delphi Micro 64 Sealed Connector Repair..................527
A.11 DELPHI GT 150 SEALED CONNECTORS.........................530
Delphi GT 150 Sealed Connector Repair....................530
A.12 DELPHI GT 280 SEALED 73-TERMINAL ECM CONNECTOR..........532
Delphi GT 280 Sealed 73-Terminal ECM Connector...........532
A.13 DEUTSCH DT SEALED CONNECTORS............................534
Deutsch DT Sealed Connector Repair.......................534
A.14 DEUTSCH DT SEALED TERMINAL REPAIR.......................538
Deutsch DT Sealed Terminal Crimps........................538
A.15 DEUTSCH DTM SEALED MINI TERMINAL REPAIR.................539
Deutsch DTM Sealed Mini Terminal Crimps..................539
A.16 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR....540
Deutsch DTM Sealed Solid Barrel Terminal Crimps..........540
A.17 JAE MX19 SEALED CONNECTORS..............................542
JAE MX19 Sealed Connectors...............................542
Crimping Terminals.......................................542
A.18 MOLEX CMC SEALED CONNECTORS.............................543
Molex CMC Sealed Connectors..............................543
Crimping Terminals.......................................544
A.19 MOLEX MX 150 SEALED CONNECTORS..........................545
Molex MX 150 Sealed Connector Repair.....................545
Crimp Terminal to Lead...................................546
A.20 TYCO 070 MULTILOCK UNSEALED CONNECTOR...................549
Tyco 070 Multilock Unsealed Connector Repair.............549
A.21 TYCO GET 64 SEALED CONNECTOR............................553
Tyco GET 64 Sealed Connector.............................553
Crimping Terminals.......................................554
A.22 TYCO MCP SEALED CONNECTOR...............................555
Tyco MCP Sealed Connector................................555
Crimping Terminals.......................................556
A.23 SEALED SPLICE CONNECTORS................................557
Sealed Splice Connector Repair...........................557
B. APPENDIX B WIRING.............................................559
B.1 CONNECTORS...............................................561
Connector Locations......................................561
B.2 WIRING DIAGRAMS..........................................565
Wiring Diagram Information...............................565
2013 Softail Wiring Diagrams.............................567
C. APPENDIX C ABS................................................589
C.1 FASTENER TORQUE VALUES...................................591
Fastener Torque Values in this Chapter...................591
C.2 ELECTRONIC CONTROL UNIT (ECU)............................592
Removal: All But FXSB....................................592
Installation: All But FXSB...............................592
Removal: FXSB............................................593
Installation: FXSB.......................................593
C.3 HYDRAULIC CONTROL UNIT (HCU).............................594
Front Hydraulic Control Unit (HCU).......................594
Rear Hydraulic Control Unit (HCU)........................595
C.4 WHEEL SPEED SENSORS......................................597
Front Wheel Speed Sensor.................................597
Rear Wheel Speed Sensor..................................598
C.5 ABS BRAKE LINES..........................................600
Front Master Cylinder to Front HCU.......................600
HCU to Front Brake Caliper...............................601
Rear Master Cylinder to Rear HCU.........................602
Rear HCU to Rear Brake Caliper...........................604
D. APPENDIX D CONVERSIONS........................................607
D.1 METRIC CONVERSION........................................609
Conversion Table.........................................609
D.2 FLUID CONVERSIONS........................................610
United States System.....................................610
Metric System............................................610
British Imperial System..................................610
D.3 TORQUE CONVERSIONS.......................................611
United States System.....................................611
Metric System............................................611
E. APPENDIX E GLOSSARY...........................................613
E.1 GLOSSARY.................................................615
Acronyms and Abbreviations...............................615
TOOLS............................................................619
TORQUE VALUES....................................................627
INDEX............................................................641
2013 HARLEY DAVIDSON SOFTAIL MODELS SERVICE MANUAL – PDF DOWNLOAD:
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