2013 Harley Davidson Touring Models Service Manual – PDF DOWNLOAD
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2013 Harley Davidson Touring Models Service Manual – PDF DOWNLOAD2013 Harley Davidson Touring Models Service Manual – PDF DOWNLOAD
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2013 Harley Davidson Touring Models Service Manual – PDF DOWNLOAD
ABOUT THIS MANUAL GENERAL
This service manual has been prepared with the following purposes in mind:
• To acquaint the user with the construction of the Harley- Davidson product and assist in the performance of basic maintenance and repair.
• To introduce the professional Harley-Davidson technician to the latest field-tested and factory-approved major repair methods.
We sincerely believe that this service manual will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL :
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Maintenance
2 Chassis
3 Engine
4 Fuel System
5 Drive
6 Transmission
7 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C ABS
D Appendix D Conversions
E Appendix E Glossary
Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation.
For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS.
For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.
A number of acronyms and abbreviations are used in this document. See the D.1 GLOSSARY for a list of acronyms, abbreviations and definitions.
TABLE OF CONTENTS:
2013 Harley Davidson Touring Models Service Manual – PDF DOWNLOAD
FOREWORD........................................................................................ 7
TABLE OF CONTENTS............................................................................... 9
1. MAINTENANCE.................................................................................. 25
1.1 FASTENER TORQUE VALUES.................................................................. 27
Fastener Torque Values in this Chapter.................................................. 27
1.2 GENERAL................................................................................. 29
Servicing a New Motorcycle.............................................................. 29
Safe Operating Maintenance.............................................................. 29
Shop Practices.......................................................................... 29
Repair and Replacement Procedures....................................................... 30
Cleaning................................................................................ 31
Tool Safety............................................................................. 31
1.3 FUEL AND OIL............................................................................ 33
Fuel.................................................................................... 33
Gasoline Blends......................................................................... 33
Engine Lubrication...................................................................... 33
Winter Lubrication...................................................................... 34
1.4 BULB REQUIREMENTS....................................................................... 35
General................................................................................. 35
1.5 MAINTENANCE SCHEDULE.................................................................... 37
General................................................................................. 37
1.6 ENGINE OIL AND FILTER................................................................... 42
Engine Oil Level........................................................................ 42
Changing Oil and Oil Filter............................................................. 43
1.7 AIR CLEANER AND EXHAUST SYSTEM.......................................................... 45
Removal................................................................................. 45
Installation............................................................................ 45
Exhaust System Leak Check............................................................... 46
1.8 TIRES AND WHEELS........................................................................ 47
General................................................................................. 47
Tires................................................................................... 47
Tire Replacement........................................................................ 48
Wheel Bearings.......................................................................... 48
Wheel Spokes............................................................................ 48
1.9 PRIMARY CHAINCASE LUBRICANT............................................................. 50
General................................................................................. 50
Changing Primary Chaincase Lubricant.................................................... 50
1.10 TRANSMISSION LUBRICANT................................................................. 52
Checking Transmission Lubricant......................................................... 52
Changing Transmission Lubricant......................................................... 52
1.11 CLUTCH................................................................................. 54
Adjustment.............................................................................. 54
1.12 DRIVE BELT AND SPROCKETS............................................................... 55
General................................................................................. 55
Cleaning................................................................................ 55
Inspection.............................................................................. 55
Checking Drive Belt Deflection.......................................................... 57
Setting Belt Deflection................................................................. 57
1.13 REAR SPROCKET ISOLATOR................................................................. 60
Inspection.............................................................................. 60
1.14 CABLE AND CHASSIS LUBRICATION.......................................................... 61
General................................................................................. 61
Steering Head Bearings.................................................................. 61
Jiffy Stand............................................................................. 61
Miscellaneous Lubrication............................................................... 61
1.15 BRAKES................................................................................. 62
Fluid Inspection........................................................................ 62
Brake Lines............................................................................. 62
1.16 BRAKE PADS AND DISCS................................................................... 63
Inspection.............................................................................. 63
Brake Pad Replacement................................................................... 63
1.17 SPARK PLUGS............................................................................ 67
Removal................................................................................. 67
Inspection.............................................................................. 67
Cleaning................................................................................ 67
Installation............................................................................ 67
Spark Plug Cable Inspection............................................................. 68
1.18 STEERING HEAD BEARINGS................................................................. 69
Lubrication............................................................................. 69
Checking................................................................................ 69
Adjustment.............................................................................. 70
1.19 REAR SUSPENSION ADJUSTMENTS............................................................ 72
Air Suspension.......................................................................... 72
Manual Suspension Preload............................................................... 73
1.20 CRITICAL FASTENERS..................................................................... 75
Inspection.............................................................................. 75
1.21 BATTERY MAINTENANCE.................................................................... 76
General................................................................................. 76
Cleaning and Inspection................................................................. 77
Battery................................................................................. 77
Voltmeter Test.......................................................................... 78
Charging Battery........................................................................ 78
Storage................................................................................. 79
1.22 HEADLAMP ALIGNMENT..................................................................... 81
Headlamp Alignment...................................................................... 81
Headlamp Adjustment: Single Headlamp Models............................................. 81
Headlamp Adjustment: Dual Headlamp Models............................................... 82
Auxiliary/Fog Lamp Alignment............................................................ 83
1.23 ENGINE MOUNTS.......................................................................... 84
Inspection.............................................................................. 84
1.24 STORAGE................................................................................ 85
General................................................................................. 85
Placing in Storage...................................................................... 85
Removal from Storage.................................................................... 85
1.25 TROUBLESHOOTING........................................................................ 86
General................................................................................. 86
Engine.................................................................................. 86
Lubrication System...................................................................... 87
Electrical System....................................................................... 88
Transmission............................................................................ 88
Handling................................................................................ 88
Brakes.................................................................................. 89
2. CHASSIS...................................................................................... 91
2.1 FASTENER TORQUE VALUES.................................................................. 93
Fastener Torque Values in this Chapter.................................................. 93
2.2 SPECIFICATIONS.......................................................................... 99
Specifications.......................................................................... 99
2.3 VEHICLE IDENTIFICATION NUMBER (V.I.N.)..................................................103
Vehicle Identification Number: Touring Models...........................................103
2.4 FRONT WHEEL.............................................................................105
Removal.................................................................................105
Cleaning and Inspection.................................................................106
Installation............................................................................107
2.5 REAR WHEEL..............................................................................108
Removal.................................................................................108
Cleaning and Inspection.................................................................109
Installation............................................................................110
2.6 REAR WHEEL COMPENSATOR..................................................................112
Isolator Replacement....................................................................112
Sprocket Bearing Replacement............................................................112
2.7 WHEEL LACING: FRONT RIM.................................................................114
Wheel Lacing: Angle Flange Hub..........................................................114
2.8 WHEEL LACING: 16 INCH REAR RIM..........................................................116
Wheel Lacing: 16 In. Rear Wheel.........................................................116
2.9 CHECKING AND TRUING WHEELS..............................................................119
General.................................................................................119
Checking Wheel Runout...................................................................119
Laced Wheel Rim Offset..................................................................120
Truing Laced Wheels.....................................................................122
2.10 SEALED WHEEL BEARINGS..................................................................124
Inspection..............................................................................124
Removal.................................................................................124
Installation............................................................................125
2.11 TIRES..................................................................................127
General.................................................................................127
Removal.................................................................................127
Cleaning, Inspection and Repair.........................................................127
Installation............................................................................128
Checking Tire Runout....................................................................130
Wheel Balancing.........................................................................131
2.12 FRONT BRAKE MASTER CYLINDER............................................................132
General.................................................................................132
Removal and Disassembly.................................................................132
Cleaning and Inspection.................................................................134
Assembly and Installation...............................................................134
Front Brake Line: Non-ABS Equipped......................................................134
2.13 FRONT BRAKE CALIPER....................................................................137
Removal.................................................................................137
Installation............................................................................137
2.14 REAR BRAKE MASTER CYLINDER.............................................................138
General.................................................................................138
Removal and Disassembly.................................................................138
Cleaning and Inspection.................................................................140
Assembly and Installation...............................................................140
Rear Brake Line: Non-ABS Equipped.......................................................140
2.15 REAR BRAKE CALIPER.....................................................................144
Removal.................................................................................144
Installation............................................................................144
2.16 BLEEDING BRAKES........................................................................145
General.................................................................................145
Procedure...............................................................................145
2.17 FRONT FORK.............................................................................147
Removal.................................................................................147
Disassembly.............................................................................147
Cleaning and Inspection.................................................................149
Assembly................................................................................150
Installation............................................................................151
2.18 STEERING HEAD BEARINGS.................................................................152
Removal.................................................................................152
Inspection..............................................................................153
Installation............................................................................154
2.19 REAR AIR SUSPENSION....................................................................155
Check for Air Leaks.....................................................................155
Shock Absorber Removal..................................................................156
Cleaning and Inspection.................................................................156
Disassembly and Assembly................................................................156
Shock Absorber Installation.............................................................156
2.20 REAR SHOCK ABSORBERS: MANUAL ADJUST....................................................157
Repair..................................................................................157
2.21 REAR FORK..............................................................................158
Removal.................................................................................158
Disassembly and Assembly................................................................158
Installation............................................................................160
2.22 CLUTCH CABLE...........................................................................161
Removal.................................................................................161
Installation............................................................................161
2.23 HANDLEBARS.............................................................................163
Adjustment..............................................................................163
Removal.................................................................................163
Installation............................................................................164
Left Handgrip...........................................................................165
Right Handgrip..........................................................................165
Heated Handgrips........................................................................165
Rubber Mounts...........................................................................167
2.24 MIRRORS................................................................................168
All Models Except FLHX..................................................................168
FLHX....................................................................................168
2.25 SEAT...................................................................................169
Seat: Models without Tour-Pak...........................................................169
Seat: Models with Tour-Pak..............................................................170
Seat: Road King Models..................................................................170
Seat Retention Nut Replacement..........................................................171
Seat Bumper.............................................................................171
2.26 SADDLEBAGS.............................................................................172
Removal.................................................................................172
Installation............................................................................172
2.27 SADDLEBAG SERVICE......................................................................173
Saddlebag Hardware......................................................................173
Saddlebag Guard/Support Rail............................................................174
2.28 TOUR-PAK...............................................................................176
Removal/Installation....................................................................176
Adjustment..............................................................................177
Luggage Rack/Tour-Pak Support...........................................................177
2.29 TOUR-PAK SERVICE.......................................................................178
Lockset.................................................................................178
Hinges..................................................................................178
Latches/Lockset Catch...................................................................179
Catches.................................................................................179
Tether..................................................................................180
Tether Brackets.........................................................................180
Luggage Rack............................................................................180
2.30 TOUR-PAK LIGHTS........................................................................182
General.................................................................................182
Side Marker Lights (if equipped)........................................................182
Tour-Pak Lights Harness.................................................................182
Wrap-Around Lights (if equipped)........................................................183
2.31 TOUR-PAK BACKREST......................................................................185
Passenger Backrest......................................................................185
Rubber Isolators........................................................................185
Passenger Backrest Flap.................................................................186
2.32 TOUR-PAK SPEAKER BOX...................................................................187
Speaker Box.............................................................................187
2.33 LOWER FAIRING AND ENGINE GUARD.........................................................188
Lower Fairing...........................................................................188
Serrated Washer Replacement.............................................................190
Engine Guard............................................................................190
2.34 UPPER FAIRING AND WINDSHIELD: FORK MOUNTED FAIRING MODELS..............................192
Outer Fairing and Windshield............................................................192
2.35 FAIRING CAP: FORK MOUNTED FAIRING MODELS...............................................193
Fairing Cap.............................................................................193
2.36 INNER FAIRING: FORK MOUNTED FAIRING MODELS.............................................194
Removal.................................................................................194
Installation............................................................................196
2.37 AIR DEFLECTORS.........................................................................198
Fairing Air Deflectors..................................................................198
Mid-Frame Air Deflectors................................................................198
2.38 UPPER FAIRING AND WINDSHIELD: FRAME MOUNTED FAIRING MODELS.............................200
Windshield..............................................................................200
Outer Fairing...........................................................................200
2.39 INSTRUMENT BEZEL: FRAME MOUNTED FAIRING MODELS.........................................203
Bezel...................................................................................203
2.40 INSTRUMENT NACELLE: FRAME MOUNTED FAIRING MODELS.......................................204
Instrument Nacelle......................................................................204
2.41 INNER FAIRING: FRAME MOUNTED FAIRING MODELS............................................206
Removal.................................................................................206
Installation............................................................................208
2.42 GLOVE BOX DOOR AND HINGE: FRAME MOUNTED FAIRING MODELS.................................210
Glove Box Door and Hinge................................................................210
2.43 WINDSHIELD: ROAD KING MODELS...........................................................211
Windshield..............................................................................211
Windshield Window.......................................................................211
2.44 HEADLAMP NACELLE: ROAD KING MODELS.....................................................214
Removal.................................................................................214
Installation............................................................................215
2.45 FRONT FENDER...........................................................................216
Removal.................................................................................216
Installation............................................................................217
2.46 REAR FENDER............................................................................218
Removal.................................................................................218
Fender Repair...........................................................................219
Installation............................................................................220
2.47 REAR FASCIA............................................................................221
Removal.................................................................................221
Installation............................................................................221
Stud Plate..............................................................................221
Rear Fascia Lamp........................................................................221
2.48 REAR FRAME.............................................................................222
Rear Frame..............................................................................222
2.49 FOOTBOARDS AND FOOTRESTS...............................................................224
Rider Footboards........................................................................224
Passenger Footboard.....................................................................225
Passenger Footrest: FLHX, FLTRX.........................................................226
2.50 JIFFY STAND............................................................................227
General.................................................................................227
Leg Removal.............................................................................227
Leg Installation........................................................................227
Jiffy Stand Bracket.....................................................................228
Jiffy Stand Interlock Sensor............................................................228
2.51 FRONT ENGINE MOUNT.....................................................................230
Removal.................................................................................230
Installation............................................................................230
2.52 MEDALLIONS, SERIALIZED BADGES AND TANK EMBLEMS.........................................232
Removal.................................................................................232
Installation............................................................................232
3. ENGINE.......................................................................................233
3.1 FASTENER TORQUE VALUES..................................................................235
Fastener Torque Values in this Chapter..................................................235
3.2 SPECIFICATIONS..........................................................................237
Specifications..........................................................................237
3.3 SERVICE WEAR LIMITS.....................................................................239
General.................................................................................239
3.4 ENGINE OIL FLOW.........................................................................241
Oil Feed................................................................................241
Top End.................................................................................241
Bottom End..............................................................................243
Oil Return..............................................................................245
Oil Cooler Operation....................................................................246
3.5 OIL PUMP OPERATION......................................................................247
General.................................................................................247
Operation...............................................................................247
3.6 BREATHER OPERATION......................................................................249
General.................................................................................249
3.7 OIL PRESSURE............................................................................250
Oil Pressure Indicator Lamp.............................................................250
Checking Oil Pressure...................................................................250
3.8 TROUBLESHOOTING.........................................................................252
Diagnosing Valve Train Noise............................................................252
Compression Test........................................................................252
Cylinder Leakdown Test..................................................................253
Diagnosing Smoking Engine or High Oil Consumption.......................................253
3.9 OIL COOLER..............................................................................254
Removal.................................................................................254
Installation............................................................................254
3.10 OIL COOLER ADAPTER.....................................................................255
Removal.................................................................................255
Disassembly.............................................................................255
Assembly................................................................................255
Installation............................................................................255
3.11 HOW TO USE THIS SECTION................................................................257
Top End Repair..........................................................................257
Bottom End Repair.......................................................................257
Typical Symptoms........................................................................257
3.12 TOP END SERVICE........................................................................258
Engine in Chassis.......................................................................258
Engine Removed from Chassis.............................................................259
3.13 CAM COMPARTMENT SERVICE................................................................260
Engine in Chassis.......................................................................260
Engine Removed From Chassis.............................................................261
3.14 STRIPPING MOTORCYCLE FOR SERVICE.......................................................262
Procedure...............................................................................262
3.15 ASSEMBLING MOTORCYCLE AFTER SERVICE....................................................263
Procedure...............................................................................263
3.16 REMOVING ENGINE FROM CHASSIS...........................................................264
Procedure...............................................................................264
3.17 INSTALLING ENGINE IN CHASSIS...........................................................265
Procedure...............................................................................265
3.18 TOP END OVERHAUL: DISASSEMBLY..........................................................266
General.................................................................................266
Rocker Covers...........................................................................266
Rocker Arm Support Plate................................................................266
Pushrods, Lifters and Covers............................................................268
Cylinder Head...........................................................................268
Cylinder................................................................................269
Piston..................................................................................270
3.19 BREATHER ASSEMBLY......................................................................272
Disassembly.............................................................................272
Cleaning and Inspection.................................................................272
Assembly................................................................................272
3.20 ROCKER ARM SUPPORT PLATE...............................................................273
Disassembly.............................................................................273
Cleaning and Inspection.................................................................273
Assembly................................................................................275
3.21 PUSHRODS, LIFTERS AND COVERS...........................................................276
Disassembly.............................................................................276
Cleaning and General Inspection.........................................................276
Lifter Inspection.......................................................................277
Assembly................................................................................277
3.22 CYLINDER HEAD..........................................................................278
Disassembly.............................................................................278
Cleaning................................................................................279
Inspection..............................................................................279
Valve Guide Replacement.................................................................280
Valve and Seat Refacing.................................................................284
Assembly................................................................................286
3.23 CYLINDER...............................................................................288
Cleaning................................................................................288
Inspection..............................................................................288
Deglazing Cylinder......................................................................290
Boring and Honing Cylinder..............................................................290
3.24 PISTON.................................................................................292
Disassembly.............................................................................292
Cleaning................................................................................292
Inspection..............................................................................292
Assembly................................................................................294
3.25 TOP END OVERHAUL: ASSEMBLY.............................................................296
General.................................................................................296
Piston..................................................................................296
Cylinder................................................................................297
Cylinder Head...........................................................................299
Push Rods, Lifters and Covers...........................................................303
Rocker Arm Support Plate................................................................304
Breather and Rocker Cover...............................................................305
3.26 CAM COMPARTMENT AND COMPONENTS.........................................................306
Cam Support Plate and Cover Removal.....................................................306
Cam Support Plate Cleaning and Inspection...............................................308
Camshafts...............................................................................309
Oil Pressure Relief Valve...............................................................311
Cam Needle Bearings.....................................................................311
Cam Support Plate and Cover Installation................................................314
3.27 OIL PUMP...............................................................................318
Removal.................................................................................318
Cleaning and Inspection.................................................................318
Installation............................................................................319
3.28 CRANKCASE DISASSEMBLY AND REPAIR.......................................................320
Crankcase Disassembly...................................................................320
Cleaning and Inspection.................................................................320
Right Crankcase Half....................................................................321
Left Crankcase Half.....................................................................322
Sprocket Shaft Bearing Inner Race.......................................................324
Cylinder Studs..........................................................................327
Pipe Plug and Oil Fittings..............................................................328
3.29 FLYWHEEL AND CONNECTING RODS...........................................................329
General.................................................................................329
Inspection..............................................................................329
Measuring Crankshaft Runout.............................................................329
3.30 CRANKCASE ASSEMBLY.....................................................................332
Crankcase Assembly......................................................................332
3.31 OIL PAN................................................................................334
Removal.................................................................................334
Installation............................................................................334
4. FUEL SYSTEM..................................................................................337
4.1 FASTENER TORQUE VALUES..................................................................339
Fastener Torque Values in this Chapter..................................................339
4.2 SPECIFICATIONS: FUEL SYSTEM.............................................................340
Specifications..........................................................................340
4.3 AIR CLEANER ASSEMBLY....................................................................341
Removal.................................................................................341
Installation............................................................................341
4.4 FUEL TANK...............................................................................343
Console.................................................................................343
Removal.................................................................................343
Installation............................................................................344
Vent Tube: Models Without EVAP System...................................................344
Fuel Supply Check Valve/Tube............................................................345
4.5 FUEL TANK TOP PLATE.....................................................................346
Removal.................................................................................346
Installation............................................................................347
4.6 FUEL FILTER.............................................................................348
Removal.................................................................................348
Installation............................................................................348
4.7 FUEL PRESSURE REGULATOR.................................................................349
Removal.................................................................................349
Installation............................................................................349
4.8 FUEL LEVEL SENDER.......................................................................350
Removal.................................................................................350
Installation............................................................................350
4.9 TWIST GRIP SENSOR.......................................................................351
Removal.................................................................................351
Installation............................................................................352
Twist Grip Sensor Jumper Harness........................................................353
4.10 THROTTLE CONTROL ACTUATOR (TCA)........................................................354
General.................................................................................354
4.11 INDUCTION MODULE.......................................................................355
Removal.................................................................................355
Installation............................................................................356
4.12 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP)...................................357
General.................................................................................357
Removal.................................................................................357
Installation............................................................................357
4.13 OXYGEN SENSORS (O2)....................................................................358
General.................................................................................358
Removal.................................................................................358
Installation............................................................................359
4.14 FUEL INJECTORS.........................................................................360
General.................................................................................360
Removal.................................................................................360
Installation............................................................................360
4.15 FUEL PUMP..............................................................................362
General.................................................................................362
Removal.................................................................................362
Installation............................................................................362
Fuel Pump and Fuel Level Sender Wire Harness............................................363
4.16 FUEL PRESSURE TEST.....................................................................364
General.................................................................................364
Testing.................................................................................364
4.17 EXHAUST SYSTEM.........................................................................366
Mufflers................................................................................366
System Removal..........................................................................366
System Installation.....................................................................368
4.18 ACTIVE EXHAUST (HDI)...................................................................369
Exhaust Valve Actuator..................................................................369
Exhaust Valve Actuator Cable............................................................369
Active Exhaust Valve....................................................................369
4.19 INTAKE LEAK TEST.......................................................................370
General.................................................................................370
Leak Tester.............................................................................370
Procedure...............................................................................370
4.20 EVAPORATIVE EMISSIONS CONTROL SYSTEM...................................................372
General.................................................................................372
Vapor Valve.............................................................................372
Fuel Vapor Vent Tube....................................................................373
Canister-to-Solenoid Tube...............................................................373
Solenoid-to-Induction Module Tube.......................................................373
Purge Solenoid..........................................................................373
Charcoal Canister.......................................................................374
5. DRIVE........................................................................................377
5.1 FASTENER TORQUE VALUES..................................................................379
Fastener Torque Values in this Chapter..................................................379
5.2 SPECIFICATIONS: DRIVE...................................................................380
Specifications..........................................................................380
5.3 PRIMARY CHAINCASE COVER.................................................................381
General.................................................................................381
Removal.................................................................................381
Installation............................................................................381
5.4 DRIVE COMPONENTS........................................................................383
Removal.................................................................................383
Installation............................................................................385
5.5 PRIMARY CHAINCASE HOUSING...............................................................388
Removal.................................................................................388
Inspection..............................................................................388
Mainshaft Bearing and Seal..............................................................388
Mainshaft Bearing Inner Race............................................................389
Shifter Shaft Bushings..................................................................390
Installation............................................................................390
5.6 CLUTCH..................................................................................392
Removal and Installation................................................................392
Clutch Pack Only........................................................................392
Clutch Pack and Bearing.................................................................394
5.7 TRANSMISSION SPROCKET...................................................................397
Removal.................................................................................397
Cleaning and Inspection.................................................................397
Installation............................................................................397
5.8 DRIVE BELT..............................................................................399
Removal and Adjustment..................................................................399
Installation............................................................................399
6. TRANSMISSION.................................................................................401
6.1 FASTENER TORQUE VALUES..................................................................403
Fastener Torque Values in this Chapter..................................................403
6.2 SPECIFICATIONS: TRANSMISSION............................................................404
Specifications..........................................................................404
Service Wear Limits.....................................................................404
6.3 TRANSMISSION............................................................................406
Power Flow..............................................................................406
6.4 SHIFTER LINKAGE.........................................................................408
Shifter Rod Adjustment..................................................................408
Heel-Toe Shift Levers...................................................................408
Shifter Rod Lever, Front................................................................408
6.5 CLUTCH RELEASE COVER....................................................................410
Removal and Disassembly.................................................................410
Cleaning and Inspection.................................................................410
Assembly and Installation...............................................................411
6.6 TRANSMISSION ASSEMBLY...................................................................412
Removal.................................................................................412
Disassembly.............................................................................413
Cleaning and Inspection.................................................................419
Assembly................................................................................419
Installation............................................................................422
6.7 MAIN DRIVE GEAR AND BEARING.............................................................424
Removal.................................................................................424
Cleaning and Inspection.................................................................425
Mainshaft Seal Replacement..............................................................427
Installation............................................................................428
6.8 TRANSMISSION CASE.......................................................................431
Removal.................................................................................431
Installation............................................................................431
Disassembly.............................................................................432
Cleaning and Inspection.................................................................432
Assembly................................................................................433
7. ELECTRICAL...................................................................................435
7.1 FASTENER TORQUE VALUES..................................................................437
Fastener Torque Values in this Chapter..................................................437
7.2 SPECIFICATIONS: ELECTRICAL..............................................................440
Specifications..........................................................................440
7.3 ELECTRONIC CONTROL MODULE (ECM).........................................................441
ECM.....................................................................................441
7.4 TURN SIGNAL AND SECURITY MODULE (TSM/TSSM/HFSM).........................................442
General.................................................................................442
Removal.................................................................................442
Installation............................................................................442
HFSM Antenna............................................................................443
7.5 IGNITION COIL...........................................................................444
Removal.................................................................................444
Installation............................................................................444
7.6 SYSTEM FUSES AND RELAYS.................................................................445
Main Fuse...............................................................................445
System Fuses and Relays.................................................................445
Main Fuse Holder........................................................................445
Fuse Blocks.............................................................................446
7.7 ELECTRICAL CADDIES......................................................................447
Top Caddy...............................................................................447
Left Side Caddy.........................................................................447
Battery Tray............................................................................450
7.8 SECURITY SIREN..........................................................................451
Removal.................................................................................451
Installation............................................................................451
7.9 STARTER.................................................................................452
General.................................................................................452
Removal.................................................................................452
Drive Assembly..........................................................................452
Solenoid................................................................................453
Installation............................................................................454
7.10 HEADLAMP: ALL EXCEPT ROAD GLIDE........................................................456
Headlamp: Single Headlamp Models........................................................456
7.11 HEADLAMP: ROAD GLIDE...................................................................458
Headlamp Adjuster Assembly..............................................................458
Headlamp Bulb Replacement: Dual Headlamp Models.........................................458
7.12 AUXILIARY/FOG LAMPS AND BRACKETS.......................................................460
Auxiliary/Fog Lamp Bulb Replacement.....................................................460
Auxiliary/Fog Lamp Housing..............................................................461
Auxiliary/Fog Lamp Bracket..............................................................463
Adjustment..............................................................................463
7.13 TAIL LAMP..............................................................................464
Tail Lamp Bulb Replacement..............................................................464
Circuit Board/Chrome Base...............................................................464
Rear Fender Lights Harness: all except FLHX, FLTRX......................................465
Rear Fascia Lamp........................................................................467
Rear Fender Lights Harness: FLHX, FLTRX.................................................467
7.14 FENDER TIP LAMPS.......................................................................469
Front Fender Tip Lamp...................................................................469
Front Fender Tip Lamp Jumper Harness....................................................469
Rear Fender Tip Lamp....................................................................471
7.15 TURN SIGNAL LAMPS......................................................................473
Turn Signal Bulb Replacement: Bullet Style..............................................473
Turn Signal Bulb Replacement: Flat Lens Style...........................................473
Front Turn Signal Lamp..................................................................473
Rear Turn Signal Lamp...................................................................477
Rear Turn Signal Lamps Bracket..........................................................480
7.16 IGNITION/LIGHT KEY SWITCH AND FORK LOCK................................................482
Fairing Models..........................................................................482
Road King Models........................................................................485
7.17 FAIRING CAP SWITCHES: FORK MOUNTED FAIRING MODELS......................................487
Removal.................................................................................487
Installation............................................................................487
7.18 INSTRUMENT NACELLE SWITCHES: FRAME MOUNTED FAIRING MODELS..............................489
Removal.................................................................................489
Installation............................................................................490
7.19 CRANKSHAFT POSITION SENSOR (CKP).......................................................491
General.................................................................................491
Removal.................................................................................491
Installation............................................................................491
7.20 ENGINE TEMPERATURE SENSOR (ET).........................................................492
Removal.................................................................................492
Installation............................................................................492
7.21 AUTOMATIC COMPRESSION RELEASE (ACR)....................................................493
General.................................................................................493
Removal.................................................................................493
Installation............................................................................493
7.22 VOLTAGE REGULATOR......................................................................495
Removal.................................................................................495
Installation............................................................................495
7.23 ALTERNATOR.............................................................................496
Removal.................................................................................496
Cleaning and Inspection.................................................................496
Installation............................................................................497
7.24 VEHICLE SPEED SENSOR (VSS).............................................................498
VSS.....................................................................................498
7.25 NEUTRAL SWITCH.........................................................................499
Removal.................................................................................499
Installation............................................................................499
7.26 OIL PRESSURE SWITCH AND SENDER.........................................................500
Removal.................................................................................500
Installation............................................................................500
7.27 STOP LAMP SWITCHES.....................................................................501
Front Stop Lamp Switch..................................................................501
Rear Stop Lamp Switch...................................................................501
7.28 HORN...................................................................................502
Inspection..............................................................................502
Removal.................................................................................502
Installation............................................................................502
7.29 CIGARETTE LIGHTER: FAIRING MODELS......................................................504
Troubleshooting.........................................................................504
Removal.................................................................................504
Installation............................................................................504
7.30 GAUGES AND INSTRUMENTS: FAIRING MODELS.................................................505
2 Inch Diameter Gauges: Fuel Level, Ambient Air Temperature, Voltmeter, Oil Pressure....505
Tachometer..............................................................................505
Speedometer.............................................................................506
7.31 INDICATOR LAMPS: FAIRING MODELS........................................................507
Indicator Lamps.........................................................................507
7.32 GAUGES AND INSTRUMENTS: ROAD KING MODELS...............................................508
Fuel Gauge..............................................................................508
Speedometer.............................................................................508
7.33 INDICATOR LAMPS: ROAD KING MODELS......................................................510
Indicator Lamps.........................................................................510
7.34 ADVANCED AUDIO SYSTEM..................................................................511
Radio...................................................................................511
Front Fairing Speakers..................................................................512
Front Headset Receptacle................................................................512
Rear Headset Receptacle.................................................................513
Rear Passenger Switches.................................................................513
Rear Speakers...........................................................................514
CB Module...............................................................................515
7.35 WIRE TROUGH............................................................................516
Removal.................................................................................516
Installation............................................................................517
7.36 MAIN WIRING HARNESS....................................................................518
Removal: All Models (Part 1)............................................................518
Removal: Road King Models (Part 2)......................................................518
Removal: Fork Mounted Fairing Models (Part 2)...........................................519
Removal: Frame Mounted Fairing Models (Part 2)..........................................520
Removal: All Models (Part 3)............................................................520
Installation: All Models (Part 1).......................................................522
Installation: Road King Models (Part 2).................................................524
Installation: Fork Mounted Fairing Models (Part 2)......................................525
Installation: Frame Mounted Fairing Models (Part 2).....................................525
Installation: All Models (Part 3).......................................................525
7.37 INTERCONNECT HARNESS...................................................................526
Fork Mounted Fairing Models.............................................................526
Frame Mounted Fairing Models............................................................529
7.38 RADIO ANTENNA CABLE....................................................................532
Models Equipped with Tour-Pak...........................................................532
Models without Tour-Pak.................................................................533
7.39 REAR AUDIO HARNESS: ULTRA MODELS.......................................................535
Removal.................................................................................535
Installation............................................................................535
7.40 CB ANTENNA CABLE: ULTRA MODELS.........................................................537
Removal.................................................................................537
Installation............................................................................537
7.41 HANDLEBAR SWITCH ASSEMBLIES............................................................539
Removal.................................................................................539
Specific Repair Procedures: Upper Switch Housings.......................................539
Specific Repair Procedures: Right Side Lower Switch Housings............................542
Specific Repair Procedures: Left Side Lower Switch Housings.............................545
General Repair Procedures...............................................................548
Installation............................................................................550
7.42 TSSM/HFSM MAINTENANCE..................................................................554
General.................................................................................554
Fob Battery.............................................................................554
Smart Siren (If Installed)..............................................................554
7.43 PERSONAL IDENTIFICATION NUMBER (PIN)...................................................555
General.................................................................................555
Initial PIN Entry.......................................................................555
Changing the PIN........................................................................555
7.44 H-DSSS ACTUATION.......................................................................557
General.................................................................................557
Actuation...............................................................................557
Fob Assignment..........................................................................557
Power Disruption and Configuring........................................................557
7.45 TSM/HFSM: PASSWORD LEARN...............................................................558
General.................................................................................558
Password Learn..........................................................................558
A. APPENDIX A CONNECTOR REPAIR..................................................................561
A.1 AUTOFUSE UNSEALED ELECTRICAL CONNECTORS.................................................563
Autofuse Unsealed Connector Repair......................................................563
A.2 BOSCH COMPACT 1.1M CONNECTOR............................................................564
Bosch Compact 1.1M Connector............................................................564
A.3 DELPHI 100W MICRO-PACK SEALED CONNECTOR.................................................565
Delphi 100W Micro-Pack Sealed Connector Repair..........................................565
Crimping Terminals......................................................................566
A.4 DELPHI 150 METRI-PACK SEALED CONNECTORS.................................................567
Delphi 150 Metri-Pack Sealed Connector Repair...........................................567
A.5 DELPHI 280 METRI-PACK UNSEALED CONNECTORS...............................................569
Fuse Block Repair.......................................................................569
A.6 DELPHI 480 METRI-PACK UNSEALED CONNECTORS...............................................570
Delphi 480 Metri-Pack Unsealed Connector Repair.........................................570
A.7 DELPHI 630 METRI-PACK UNSEALED CONNECTORS...............................................571
Delphi 630 Metri-Pack Unsealed Connector Repair.........................................571
A.8 DELPHI 800 METRI-PACK SEALED MAIN FUSE HOUSING..........................................572
Delphi 800 Metri-Pack Sealed Main Fuse Housing Repair...................................572
A.9 DELPHI METRI-PACK TERMINAL REPAIR.......................................................573
Metri-Pack Terminal Crimps..............................................................573
A.10 DELPHI MICRO 64 SEALED CONNECTORS......................................................575
Delphi Micro 64 Sealed Connector Repair.................................................575
A.11 DELPHI GT 150 SEALED CONNECTORS........................................................578
Delphi GT 150 Sealed Connector Repair...................................................578
A.12 DELPHI GT 280 SEALED 73-TERMINAL ECM CONNECTOR.........................................580
Delphi GT 280 Sealed 73-Terminal ECM Connector..........................................580
A.13 DEUTSCH DT SEALED CONNECTORS...........................................................582
Deutsch DT Sealed Connector Repair......................................................582
A.14 DEUTSCH DT SEALED TERMINAL REPAIR......................................................586
Deutsch DT Sealed Terminal Crimps.......................................................586
A.15 DEUTSCH DTM SEALED MINI TERMINAL REPAIR................................................587
Deutsch DTM Sealed Mini Terminal Crimps.................................................587
A.16 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR...................................588
Deutsch DTM Sealed Solid Barrel Terminal Crimps.........................................588
A.17 JAE MX19 SEALED CONNECTORS.............................................................590
JAE MX19 Sealed Connectors..............................................................590
Crimping Terminals......................................................................590
A.18 MOLEX CMC SEALED CONNECTORS............................................................591
Molex CMC Sealed Connectors.............................................................591
Crimping Terminals......................................................................592
A.19 MOLEX MX 150 SEALED CONNECTORS.........................................................593
Molex MX 150 Sealed Connector Repair....................................................593
Crimp Terminal to Lead..................................................................594
A.20 TYCO 070 MULTILOCK UNSEALED CONNECTOR..................................................597
Tyco 070 Multilock Unsealed Connector Repair............................................597
A.21 TYCO GET 64 SEALED CONNECTOR...........................................................601
Tyco GET 64 Sealed Connector............................................................601
Crimping Terminals......................................................................602
A.22 TYCO MCP SEALED CONNECTOR..............................................................603
Tyco MCP Sealed Connector...............................................................603
Crimping Terminals......................................................................604
A.23 SEALED SPLICE CONNECTORS...............................................................605
Sealed Splice Connector Repair..........................................................605
B. APPENDIX B WIRING............................................................................607
B.1 CONNECTORS..............................................................................609
Connector Locations.....................................................................609
B.2 WIRING DIAGRAMS.........................................................................615
Wiring Diagram Information..............................................................615
2013 Touring Wiring Diagrams............................................................617
C. APPENDIX C ABS...............................................................................665
C.1 FASTENER TORQUE VALUES..................................................................667
Fastener Torque Values in this Chapter..................................................667
C.2 ABS MODULE..............................................................................668
Hydraulic Control Unit (HCU)............................................................668
Electronic Control Unit (ECU)...........................................................669
C.3 WHEEL SPEED SENSORS.....................................................................671
Front Wheel Speed Sensor (WSS)..........................................................671
Rear Wheel Speed Sensor.................................................................672
C.4 ABS BRAKE LINES.........................................................................673
Front Master Cylinder to ABS Module.....................................................673
ABS Module to Front Brake Calipers......................................................674
Rear Master Cylinder to ABS Module......................................................676
ABS Module to Rear Brake Caliper........................................................678
D. APPENDIX D CONVERSIONS.......................................................................679
D.1 METRIC CONVERSION.......................................................................681
Conversion Table........................................................................681
D.2 FLUID CONVERSIONS.......................................................................682
United States System....................................................................682
Metric System...........................................................................682
British Imperial System.................................................................682
D.3 TORQUE CONVERSIONS......................................................................683
United States System....................................................................683
Metric System...........................................................................683
E. APPENDIX E GLOSSARY..........................................................................685
E.1 GLOSSARY................................................................................687
Acronyms and Abbreviations..............................................................687
TOOLS...........................................................................................691
TORQUE VALUES...................................................................................699
INDEX...........................................................................................715
2013 HARLEY DAVIDSON TOURING MODELS SERVICE MANUAL – PDF DOWNLOAD:
PLEASE NOTE:
This is the SAME exact manual used by your dealers to fix your vehicle.
The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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