2015 Harley Davidson Softail Models Service Manual – PDF DOWNLOAD

ABOUT THIS MANUAL
GENERAL:

This service manual has been prepared with the following purposes in mind:

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 Reference

1 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 1 -1
1 2 GENERAL
Servicing а New Motorcycle 1-3
Safe Operating Maintenance 1-3
Disposal and Recycling 1 -3
Shop Practices 1 -3
Repair Notes 1 -3
Safety 1 -3
Removing Parts 1 -3
Cleaning 1-3
DisassemЫy and AssemЫy 1 -4
Checking Torques оп Fasteners 1-4
Magnetic Parts Trays 1 -4
Repair and Replacement Procedures 1 -4
Hardware and Threaded Parts 1 -4
Threadlocking Agents 1 -4
Wiring, Hoses and Lines 1-4
lnstruments and Gauges 1-4
Bearings 1-4
Bushings 1 -4
Gaskets 1-4
Lip-Type Seals 1 -4
O-Rings 1 -5
Gears 1 -5
Shafts 1 -5
Part Replacement 1 -5
Cleaning 1 -5
Protecting Rubber Parts 1 -5
Cleaning Process 1-5
Rust ог Corrosion Removal 1-5
Bearings 1 -5
Tool Safety 1 -5
Air Tools 1 -5
Wrenches 1-5
Pliers/Cutters/Pry Bars 1 -5
Hammers 1 -6
Punches/Chisels 1-6
Screwdrivers 1 -6
Ratchets and Handles 1 -6
Sockets 1 -6
Storage Units 1 -6
1 3 FUEL AND OIL
Fuel 1-7
Gasoline Blends 1 -7
Engine Lubrication 1 -7
Winter Lubrication 1 -8
1 4 BULB REQUIREMENTS
General 1 -9
1 5 MAINTENANCE SCHEDULE
General 1 -10
1 6 ENGINE OIL AND FILTER
Checking and Adding Oil 1 -15
Changing Oil and Filter 1 -15
1 7 AIR CLEANER AND EXHAUST SYSTEM
Removal 1 -17
Cleaning and lnspection 1 -17
lnstallation 1 -18
Exhaust System Leak Check 1-19
Exhaust System Leakage 1-19
1 8 TIRES AND WHEELS
General 1 -20
Tires 1 -20
Tire Replacement 1 -21
1 nspection 1-21
When То Replace Tires 1 -21
Wheel Bearings 1 -21
Wheel Spokes 1 -21
ldentify Wheel Spoke Groups 1 -22
Wheel Spoke Adjustment 1 -22
1 9 PRIMARY CHAINCASE LUBRICANT
General 1 -23
Changing Primary Chaincase Lubricant 1 -23
1 1 О TRANSMISSION LUBRICANT
Checking Transmission Lubricant 1 -25
Changing Transmission Lubricant 1 -25
1 11 CLUTCH
Adjustment 1 -27
1 12 DRIVE BELT AND SPROCKETS
и,
General 1 -29 t-
Cleaning 1 -29 z
lnspection 1 -29 W
Sprockets 1 -29 t-
Drive Belt 1 -29 Z
Checking Drive Belt Deflection 1-30 О
Adjusting Belt Deflection 1 -32 U
1 13 THROTTLE CABLES
LL
о
СаЫе lnspection, Lubrication and Adjustment 1-33 W
lnspection and Lubrication 1 -33 J
Adjustment 1-33 [Q
1 14 CABLE AND CHASSIS LUBRICATION !
General 1 -35
СаЫеs and Hand Levers 1 -35
Jiffy Stand 1 -35
Steering Head Bearings 1 -35
1 15 BRAKES
Fluid lnspection 1 -36
Rear Brake Pedal 1 -36
Pedal Height 1 -36
Pedal Lubrication 1-36
Pedal Pad 1 -36
Brake Lines lnspection 1 -37
1 1 б BRAKE PADS AND DISCS
1 nspection 1 -38
Brake Pads 1 -38
Brake Disc 1 -38
Brake Pad Replacement 1-38
Rear Brake Caliper 1 -38
Front Brake Caliper 1 -40
1 17 SPARK PLUGS
Removal 1 -42
1 nspection 1 -42
111
TABLE OF CONTENTS
Cleaning 1-42
lnstallation 1-42
Spark Plug СаЫе lnspection 1-43
1 18 STEERING HEAD BEARINGS
Adjustment: FLSTC, FLSTF/B, FLSTN, FLS 1-44
Bearing Adjustment (Fall-away) 1-44
Adjustment: FXST 1-45
Bearing Adjustment (Fall-away) 1-45
Adjustment: FXSB 1-46
Bearing Adjustment (Fall-away) 1-46
Lu brication 1-4 7
1 19 BATTERY MAINTENANCE
General 1-48
Cleaning and lnspection 1-49
Voltmeter Test 1-49
Charging Battery 1-49
Safety Precautions 1-49
Using а Battery Charger 1-49
Battery Disconnection and Removal 1-50
Storage 1-50
Battery I nstallation and Connection 1-51
1 20 HEADLAMP ALIGNMENT
Headlamp Alignment 1-53
Headlamp Adjustment 1-53
1 21 SUSPENSION ADJUSTMENTS
Shock Absorbers 1-55
Calculate Number of Turns 1-55
Adjustment 1-55
1 22 STORAGE
General 1-56
Placing in Storage 1-56
Removal from Storage 1-56
1 23 TROUBLESHOOTING
General 1-58
Engine 1-58
Starter Motor Does Not Operate ог Does Not Turn Engine
Over 1-58
Engine Turns Over But Does Not Start 1-58
Starts Hard 1-58
Starts But Runs lrregularly ог Misses 1-58
А Spark Plug Fouls Repeatedly 1-59
Pre-lgnition ог Detonation (Knocks ог Pings ) 1-59
Overheating 1-59
Valve Train Noise 1-59
Excessive Vibration 1-59
Check Engine Light llluminates During Operation 1-59
Lubrication System 1-59
Oil Does Not Return То Oil Tank 1-59
Engine Uses Тоо Much Oil Ог Smokes Excessively 1-59
Engine Leaks Oil From Cases, Pushrods, Hoses,
Etc 1-59
Low Oil Pressure 1-60
High Oil Pressure 1-60
Electrical System 1-60
Alternator Does Not Charge 1-60
IV TABLE OF CONTENTS
Alternator Charge Rate Is Below Normal 1-60
Speedometer Operates Erratically 1 -60
Transmission 1-60
Shifts Hard 1-60
Jumps Out Of Gear 1-60
Clutch Slips 1-60
Clutch Drags Ог Does Not Release 1-60
Clutch Chatters 1-60
Handling 1-60
lrregularities 1-60
Brakes 1-60
Brake Does Not Hold Normally 1-60
CHASSIS
2 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 2-1
2 2 SPECIFICATIONS
Specifications 2-5
Chassis Specifications 2-5
Тiге Specifications 2-6
2 3 VEHICLE IDENTI FICATION NUMBER
(V I N )
Vehicle ldentification Number 2-9
2 4 FRONT WHEEL
Removal 2-11
DisassemЫy 2-11
Disc Wheel 2-11
Laced Wheel 2-11
Cleaning and lnspection 2-13
AssemЫy 2-13
Disc Wheel 2-13
Laced Wheel 2-14
lnstallation 2-14
2 5 REAR WHEEL
Removal 2-15
DisassemЫy 2-15
Cleaning and lnspection 2-16
AssemЫy 2-16
lnstallation 2-17
2 6 WHEEL LACING
Wheel Lacing: Angle Flange Hub 2-18
2 7 CHECКING AND TRUING WHEELS
General 2-20
Checking Wheel Runout 2-20
Checking Radial Runout 2-20
Checking Lateral Runout 2-20
Laced Wheel Rim Offset 2-21
Truing Laced Wheels 2-23
Radial Runout 2-23
Lateral Runout 2-23
2 8 SEALED WHEEL BEARINGS
lnspection 2-25
Removal 2-25
lnstallation 2-27
2 9 TIRES
General 2-29
Removal 2-29
Cleaning, lnspection and Repair 2-29
lnstallation 2-30
Tube Туре Tires 2-30
Tubeless Tires: Cast Wheels 2-30
Checking Tire Runout 2-31
Lateral Runout 2-31
Radial Runout 2-31
Wheel Balancing 2-31
Static vs Dynamic 2-31
Weights 2-31
2 1 О VEHICLE ALIGNMENT
Axle Alignment 2-33
Checking Axle Alignment 2-33
Adjusting Axle Alignment 2-34
2 11 FRONT BRAKE MASTER CYLINDER
General 2-35
Removal and DisassemЫy 2-35
Cleaning and lnspection 2-36
AssemЫy and lnstallation 2-36
2 12 FRONT BRAKE CALIPER
Removal 2-38
DisassemЬly 2-38
Cleaning, lnspection and Repair 2-39
AssemЬly 2-40
lnstallation 2-40
2 13 REAR BRAKE MASTER CYLINDER
General 2-41
Removal 2-41
DisassemЬly 2-41
Cleaning and lnspection 2-42
AssemЫy 2-42
lnstallation 2-43
2 14 REAR BRAKE CALIPER
Removal 2-47
DisassemЫy 2-4 7
Cleaning, lnspection and Repair 2-49
AssemЫy 2-49
Rear Brake Line Routing 2-50
lnstallation 2-50
2 15 BRAKE LINES
Front Master Cylinder to Front HCU 2-52
Removal 2-52
lnstallation 2-52
HCU to Front Brake Caliper 2-53
Removal 2-53
lnstallation 2-53
Rear Master Cylinder to Rear HCU 2-54
Removal 2-54
lnstallation 2-55
TABLE OF CONTENTS
Rear HCU to Rear Brake Caliper 2-56
Removal 2-56
lnstallation 2-56
2 16 ABS: ELECTRONIC CONTROL UNIT
(ECU)
Removal: AII But FXSB 2-58
lnstallation: AII But FXSB 2-58
Removal: FXSB 2-59
lnstallation: FXSB 2-59
2 17 ABS: HYDRAULIC CONTROL UNIT
(HCU)
Front Hydraulic Control Unit (HCU) 2-60
Removal 2-60
lnstallation 2-60
Rear Hydraulic Control Unit (HCU) 2-61
Removal 2-61
lnstallation 2-61
2 18 BLEEDING BRAKES
General 2-63
Procedure 2-63
2 19 FRONT FORK
General 2-65
Fork Oil Leak Check 2-65
Fork Oil Seals 2-65
Oil Leak Check 2-65
Replacing Fork Oil 2-65
Removal 2-66
DisassemЫy 2-66
Cleaning and lnspection 2-71
AssemЫy 2-71
lnstallation 2-71
2 20 STEERING HEAD
Removal 2-73
FLSTC, FLSTF/B, FLSTN, FLS Models 2-73
FXST Model 2-73
FXSB Models 2-73
lnspection 2-74
AII Models 2-74
DisassemЫy 2-74
Removing Lower Bearings From Fork Stem 2-74
Steering Head Bearing Race Removal 2-74
AssemЫy 2-75
lnstallation 2-75
FLSTC, FLSTF/B, FLSTN, FLS Models 2-75
FXST Models 2-75
FXSB Model 2-76
2 21 BELT GUARD AND DEBRIS
DEFLECTOR
Removal 2-77
Belt Guard 2-77
Debris Deflector 2-77
lnstallation 2-77
Belt Guard 2-77
Debris Deflector 2-77
TABLE OF CONTENTS V
TABLE OF CONTENTS
2 22 REAR SHOCK ABSORBERS
General 2-78
Removal 2-78
lnstallation 2-78
Shock Disposal 2-79
2 23 REAR FORK
Removal 2-81
Cleaning and lnspection 2-82
Pivot Bearing Replacement 2-82
lnstallation 2-83
2 24 THROTTLE CONTROL
Removal/DisassemЫy 2-84
Cleaning and lnspection 2-84
AssemЫy/lnstallation 2-84
2 25 CLUTCH CONTROL
Removal 2-86
1 nstallation 2-86
2 26 LE FT HAND GRIP
Removal and lnstallation 2-88
Removal 2-88
lnstallation 2-88
2 27 HANDLEBAR: FLSTC, FLSTN, FLS,
FXST
Removal 2-89
lnstallation 2-90
2 28 HANDLEBAR: FLSTF/8
Removal 2-91
lnstallation 2-92
2 29 HANDLEBAR: FXSB
2 34 REAR FENDER: FLS
Removal 2-105
lnstallation 2-105
License Plate Bracket AssemЫy and lnstallation: FLS (all
but Domestic and California models) 2-105
License Plate Bracket AssemЫy and lnstallation: FLS
(Domestic and California models ) 2-106
Fender lnstallation 2-106
2 35 REAR FENDER: FXSB
Removal 2-108
lnstallation 2-109
2 36 REAR FENDER: FLSTN
Removal 2-110
DisassemЬly 2-11 О
AssemЫy 2-111
lnstallation 2-112
2 37 REAR FENDER WIRE CONDUIT
lnstallation 2-113
2 38 FOOTBOARDS AND FOOTRESTS
Rider Footboards 2-114
Removal 2-114
lnstallation 2-114
Rider Footrest 2-114
Removal 2-114
lnstallation 2-114
Passenger Footrest 2-114
Removal 2-114
lnstallation 2-115
2 39 JI F FY STAND
Cleaning 2-116
Sensor: HDI Models 2-116
Removal 2-117
Removal 2-95 lnstallation 2-117
Handlebars 2-95
Lower Handlebar Clamps 2-95 2 40 FORK LOCK
lnstallation 2-95
Lower Clamp 2-95
Handlebars 2-96
Removal 2-118
lnstallation 2-118
Return to Service 2-96 2 41 SEAT AND STRAP RETENTION NUT
2 30 FRONT FENDER Replacement 2-119
Removal 2-98
1 nsta l lation 2-99
2 42 SEAT: FLS, FXST, FXSB
Replacement 2-120
2 31 REAR FENDER: FLSTC Removal 2-120
Removal 2-100
lnstallation 2-120
lnstallation 2-100 2 43 SEAT: FLSTN, FLSTF, FLSTFB, FLSTC
2 32 REAR FENDER: FLSTF/8 Removal and lnstallation 2-121
Removal 2-102 2 44 LUGGAGE RACK: FLSTN
lnstallation 2-102
Removal and lnstallation 2-122
2 33 REAR FENDER: FXST
2 45 SADDLEBAGS: FLSTC
Removal 2-103
lnstallation 2-103 Removal 2-123
lnstallation 2-123
VI TABLE OF CONTENTS
2 46 WINDSHIELD: FLSTC
Removal 2-125
lnstallation 2-125
2 47 SAREE GUARD: INDIA MODELS
Upper Saree Guards: AII but FXSB 2-126
Removal 2-126
lnstall ation 2-126
Upper Saree Guards: FXSB 2-126
Removal 2-126
lnstallation 2-126
Lower Saree Guard 2-126
Removal 2-126
lnstallation 2-126
2 48 FRONT LICENSE PLATE BRACKET
Removal and lnstallation 2-127
2 49 MEDALLIONS, BADGES AND TANK
EMBLEMS
Removal 2-128
lnstallation 2-128
ENGINE
3 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 3-1
3 2 SPECIFICATIONS
Specifications 3-3
3 3 SERVICE WEAR LIMITS
General 3-5
3 4 ENGINE OIL FLOW
Oil Feed 3-7
Тор End 3-8
Bottom End 3-9
Chain Guide Bracket 3-11
Oil Return 3-11
3 5 OIL PUMP OPERATION
General 3-12
Operation 3-12
3 6 BREATHER OPERATION
General 3-14
3 7 OIL PRESSURE
Oil Pressure lndicator Lamp 3-15
Checking Oil Pressure 3-15
3 8 TROUBLESHOOTING
Diagnosing Valve Train Noise 3-17
Compression Test 3-17
Cylinder Leakdown Test 3-17
Diagnosing Smoking Engine ог High Oil Consumption 3-18
Check Prior to Cylinder Head Removal 3-18
Check After Cylinder Head Removal 3-18
TABLE OF CONTENTS
3 9 HOW ТО USE THIS SECTION
Тор End Repair 3-19
Bottom End Repair 3-19
Typical Symptoms 3-19
3 10 ТОР END SERVICE
Engine in Chassis 3-20
Engine Removed from Chassis 3-21
3 11 САМ COMPARTMENT SERVICE
Engine in Chassis 3-22
Engine Removed From Chassis 3-23
3 12 STRIPPING MOTORCYCLE FOR
SERVICE
Procedure 3-24
3 13 ASSEMBLING MOTORCYCLE AFTER
SERVICE
Procedure 3-25
3 14 REMOVING ENGINE FROM CHASSIS
Procedure 3-26
3 15 INSTALLING ENGINE IN CHASSIS
Procedure 3-27
3 16 ТОР END OVERHAUL: DISASSEMBLY
General 3-29
Rocker Covers 3-29
Rocker Arm Support Plate 3-29
Pushrods, Lifters and Covers 3-31
Cylinder Head 3-31
Cylinder 3-32
Piston 3-33
3 17 BREATHER ASSEMBLY
DisassemЫy 3-35
Cleaning and lnspection 3-35
Assem Ыу 3-35
3 18 ROCKER ARM SUPPORT PLATE
DisassemЫy 3-36
Cleaning and lnspection 3-36
lnspection 3-36
Rocker Shaft Fit 3-36
Rocker Arm Shaft to Bushing 3-37
Replace Rocker Arm Bushings 3-37
AssemЫy 3-38
3 19 PUSHRODS, LI FTERS AND COVERS
DisassemЫy 3-39
Cleaning and General l nspection 3-39
Lifter lnspection 3-39
AssemЫy 3-40
3 20 CYLINDER HEAD
DisassemЫy 3-41
Cleaning 3-42
TABLE OF CONTENTS VII
TABLE OF CONTENTS
lnspection 3-42
Cylinder Head 3-42
Valve Guides 3-43
Valves 3-43
Valve Springs 3-43
Tapered Keepers 3-43
Valve Seats 3-43
Valve Guide Replacement 3-43
Removal 3-43
l nstallation 3-44
Valve and Seat Refacing 3-47
AssemЫy 3-49
3 21 CYLINDER
Cleaning 3-51
1 nspection 3-51
Deglazing Cylinder 3-53
Boring and Honing Cylinder 3-53
3 22 PISTON
DisassemЫy 3-55
Piston Rings 3-55
Cl eaning 3-55
l nspection 3-55
AssemЫy 3-57
Checking Piston Ring Gap 3-57
l nstalling Piston Rings 3-57
3 23 ТОР END OVERHAUL: ASSEMBLY
General 3-59
Piston 3-59
Cylinder 3-60
Cylinder Head 3-62
Pushrods, Lifters and Covers 3-66
Rocker Arm Support Plate 3-67
Breather and Rocker Cover 3-68
3 24 САМ COMPARTMENT AND
COMPONENTS
Cam Support Plate and Cover Removal 3-69
Ргераге Engine 3-69
Cam Chain and Sprockets Removal 3-69
Cam Support Plate Removal 3-70
Cam Support Plate Cleaning and lnspection 3-71
Oil Pressure Valve 3-71
Cam Support Plate 3-71
Camshafts 3-71
R emoval 3-71
1 nstallation 3 -72
Oil Pressure Relief Valve 3-73
R emoval 3-73
1 nspection 3-73
l nstallation 3-74
Cam Needle Bearings 3 -74
R emoval 3-74
lnstallation 3-75
Cam Support Plate and Cover l nstallation 3-77
3 25 OIL PUMP
Removal 3-81
Cleaning and l nspection 3-81
VIII TABLE OF CONTENTS
lnstallation 3-82
3 26 CRANKCASE DISASSEMBLY AND
REPAIR
Crankcase DisassemЫy 3-83
Counterbalancer AssemЫy 3-83
Cleaning and lnspection 3-85
Right Crankcase Half 3-86
Chain Guide Screen 3-86
Main Bearing Removal 3-86
Main Bearing lnstallation 3-87
Piston Jets Removal 3-87
Piston Jets l nstallation 3-87
Left Crankcase H alf 3-88
Main Bearing Removal 3-88
Main Bearing lnstallation 3-89
Sprocket Shaft Bearing l nner Race 3-89
R emoval 3-89
1 nstallation 3-90
Cylinder Studs 3-92
Removal 3-92
lnstallation 3-92
Pipe Plugs and Oil Fittings 3-92
Removal/lnstall ation 3-92
3 27 F LYWHEEL AND CONNECTING RODS
General 3-93
Symptoms 3-93
No Oil Pressure 3-93
Vibration 3-93
1 nspection 3-93
Measuring Crankshaft Runout 3-93
Crankshaft lnstalled 3-93
Crankshaft Removed 3-94
3 28 COUNTERBALANCER ASSEMBLY
REPAIR
Cleaning, l nspection, and Repair 3-95
General 3-95
Balance Shaft Removal 3-95
Bearing Removal 3-96
Balance Shaft lnstallation 3-96
Balance Shaft Support Bearings Removal 3-97
Balance Shaft Su pport Bearings lnstallation 3-97
Front and Rear Balance Sprockets 3-98
Hydraulic Tensioners 3-98
Chain Tensioner Guides 3 -98
Balance Shaft Support 3-98
Balance Chain 3-99
3 29 CRANKCASE ASSEMBLY
Counterbalancer AssemЫy lnstallation 3-100
Crankcase 3-103
3 30 OIL TANK: ALL BUT FXSB
Removal and DisassemЫy 3-106
Oil Tank 3-106
Oil Line Fittings/Retainers 3-108
lnstallation 3-109
3 31 OIL TANK: FXSB
Removal and DisassemЫy 3-110
Oil Tank 3 -110
Oil Line Fittings/Retainers 3-112
lnstallation 3 -113
FUEL SYSTEM
4 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 4-1
4 2 SPECI FICATIONS: FUEL SYSTEM
Specifications 4-3
4 3 AIR CLEANER ASSEMBLY
Removal 4-4
lnstallation 4 -4
Backplate AssemЫy: HDI Models 4 -5
4 4 FUEL SUPPLY LINE
Purging Fuel Supply Line 4 -6
Disconnecting Fuel Supply Line 4 -6
4 5 FUEL PRESSURE TEST
General 4-7
Testing 4-7
4 6 FUEL TANK
General 4-9
Removal 4-9
Cleaning and lnspection 4-1 О
lnstallation 4 -11
4 7 CONSOLE: FXSB
Removal 4-12
1 nstallation 4-12
4 8 THROTTLE POSITION SENSOR (TPS)
General 4-13
Removal 4-13
lnstallation 4-13
4 9 INTAKE AIR TEMPERATURE SENSOR
(IAT)
General 4-14
Removal 4-14
lnstallation 4-14
4 10 ENGINE TEMPERATURE SENSOR (ЕТ)
General 4 -15
Removal 4-15
lnstallation 4-15
4 11 INDUCTION MODULE
Removal 4 -16
lnstallation 4 -17
4 12 IDLE AIR CONTROL (IAC)
General 4-18
TABLE OF CONTENTS
Removal 4-18
lnstallation 4-18
4 13 MANIFOLD ABSOLUTE PRESSURE
SENSOR (МАР)
Removal 4-19
lnstallation 4-19
4 14 OXYGEN (02) SENSOR
General 4-20
Removal 4 -20
Front 02 Sensor 4-20
Rear 02 Sensor 4-20
lnstallation 4-20
Front 02 Sensor 4-20
Rear 02 Sensor 4-20
4 15 FUEL INJECTORS
General 4-22
Removal 4-22
lnstallation 4 -22
4 16 FUEL PUMP AND FUEL GAUGE
SENDING UNIT
General 4-24
Removal 4-24
Vapor Valve 4-25
DisassemЫy and AssemЫy 4-26
Fuel Filter 4 -26
Regulator 4-26
lnlet sock 4-27
Fuel Pump 4-27
lnstallation 4-28
4 17 EXHAUST SYSTEM
Mufflers: FLSTC, FXST, FXSB 4-29
Removal 4-29
AssemЫy 4-29
System: FLSTC, FXST, FXSB 4-29
Removal 4-29
lnstallation 4-29
Mufflers: FLSTN, FLSTF/B, FLS 4-31
Removal 4 -31
AssemЫy 4-31
System: FLST N , FLSTF/B, FLS 4-31
Removal 4-31
1 nstallation 4 -31
4 18 INTAKE LEAK TEST
General 4-33
Leak Tester 4-33
Parts List 4-33
Tester AssemЫy 4-33
Tester Adjustment 4 -33
Procedure 4-33
4 19 EVAPORATIVE EMISSIONS CONTROL
SYSTEM
General 4-35
Charcoal Canister 4-36
TABLE OF CONTENTS IX
TABLE OF CONTENTS
Removal 4-36
l nstallation 4-36
TRANSM ISSION
Purg e Solenoid 4-36
Removal 4-36 6 1 FASTENER TORQUE VALUES
l nstallation 4-36 Fastener Torque Values in this Chapter 6-1
Hose Routing /Replacement 4-36
Fuel Tank Vent Hose 4-36 6 2 SPECI FICATIONS: TRANSMISSION
Purge Solenoid-to-lnduction Modul e Tube 4-36
Charcoal Canister-to-Purg e Solenoid Tube 4-37
Specifications 6-2
Service Wеаг Limits 6-2
Vent Tube-to-Charcoal Canister Tube 4-37
DRIVE
6 3 TRANSMISSION
Power Flow 6-3
5 1 FASTENER TORQUE VALUES
Neutral 6-3
First Gear 6-3
Fastener Torque Values in this Chapter 5-1 Second Gear 6-3
Third Gear 6-3
5 2 SPECI FICATIONS: DRIVE Fourth Gear 6-3
Specifications 5-2 Fifth Gear 6-3
Sixth Gear 6-3
5 3 PRIMARY CHAINCASE COVER
6 4 SHIFTER
General 5-3
Removal 5-3 Adjustment 6-5
1 nstallation 5-3 Shifter Rod Adjustment 6-5
Shift Lever Replacement 6-5
5 4 DRIVE COMPONENTS
6 5 CLUTCH RELEASE COVER
Removal 5-4
l nstallation 5-6 Removal and DisassemЫy 6-7
Cleaning and lnspection 6-7
5 5 PRIMARY CHAINCASE HOUSING AssemЫy and lnstallation 6-8
Removal 5-9 6 6 TRANSMISSION ASSEMBLY
1 nspection 5-9
Mainshaft Bearing and Seal 5-9
Removal 5-9
Removal 6-9
DisassemЫy 6-1 О
l nstallation 5-9 Shifter Cam/Shifter Forks 6-1 О
Mainshaft Bearing l nner Race 5-10
Removal 5-1 О
Mainshaft 6-12
Countershaft 6-15
l nstallation 5-1 О Removing Bearing Housing Bearings 6-16
l nstallation 5-11 Cl eaning and l nspection 6-17
AssemЫy 6-17
5 6 CLUTCH l nstalling Bearing Housing Bearings 6-17
Removal and l nstallation 5-13
Clutch Pack Only 5-13
Partial DisassemЫ y 5-13
Cleaning And lnspection 5-13
Countershaft 6-18
Mainshaft 6-18
Shifter Cam/Shifter Forks 6-19
1 nstallation 6-21
AssemЫy 5-14 6 7 MAIN DRIVE GEAR AND BEARING
Clutch Pack and Bearing 5-15
Complete DisassemЫy 5-15
AssemЫy 5-16
Removal 6-22
Cleaning and l nspection 6-23
Needle Bearing Replacement 6-24
5 7 TRANSMISSION SPROCKET l nstallation 6-25
Removal 5-18
Cleaning and l nspection 5-19
l nstallation 5-19
l nstalling Main Drive Gear Bearing 6-25
l nstalling Main Drive Gear 6-26
lnstalling Main Drive Gear Large Seal 6-26
5 8 DRIVE BEL Т
6 8 TRANSMISSION CASE
Removal 5-21
l nspection 5-21
1 nstallation 5-21
Removal 6-29
l nstallation 6-29
DisassemЫy 6-30
Shifter Arm AssemЫ y 6-30
Cleaning and lnspection 6-30
AssemЫy 6-31
Х TABLE OF CONTENTS
Countershaft Needle Bearing Replacement 6-31
Shifter Pawl Lever AssemЫy 6-31
ELECTRIC AL
7 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 7-1
7 2 SPECIFICATIONS: ELECTRICAL
Specifications 7-4
7 3 ELECTRICAL PANEL
General 7-5
Removal : AII But FXSB 7-5
l nstallation: AII But FXSB 7-6
Removal : FXSB 7-6
l nstallation: FXSB 7-6
7 4 ELECTRONIC CONTROL MODULE (ЕСМ)
General 7-8
Removal: AII But FXSB 7-8
l nstallation: AII But FXSB 7-8
Removal : FXSB 7-8
l nstallation: FXSB 7-8
7 5 BODY CONTROL MODULE ( ВСМ)
General 7-9
ВСМ Configuration 7 -9
Removal: AII But FXSB 7-9
l nstallation: AII But FXSB 7-9
Removal: FXSB 7-10
l nstallation: FXSB 7-1 О
7 6 H-D555 ACTUATION
Sidecar Configu ration 7-11
Actuation 7 -11
Fob Assignment 7-11
7 7 PERSONAL IDENTI FICATION NUMBER
(PIN)
General 7-12
Changing The PIN 7-12
Modifying ап E xisting PIN 7-12
7 8 HD-555 MAINTENANCE
Fob Battery 7-14
Battery Replacement Schedule 7-14
Battery Replacement 7-14
Smart Siren (lf l nstalled) 7-14
Battery Replacement Schedule 7-14
Battery Replacement 7-14
7 9 SECURITY SIREN
Removal: AII But FXSB 7-15
l nstallation: AII But FXSB 7-15
Removal: FXSB 7-15
l nstallation: FXSB 7-16
7 10 FUSES
Removal 7-17
TABLE OF CONTENTS
l nstallation 7-17
7 11 IGNITION AND LIGHT SWITCH
General 7-18
Removal and l nstallation: AII But FXSB 7-18
Removal and l nstallation: FXSB 7-19
7 12 BATTERY CABLES
Routing Procedure 7-20
7 13 STARTER
General 7-22
Removal 7 -22
Drive AssemЫy 7-22
DisassemЫy 7-22
l nspection 7-22
AssemЫy 7-23
Solenoid 7-23
Cover and Plunger Removal 7-23
Short Post Contact: Starter 7-23
Long Post Contact: Battery Positive 7-24
Plunger and Cover l nstallation 7-24
l nstallation 7-24
7 14 HEADLAMP
General 7-26
Headlamp AssemЫy Removal and l nstallation 7-26
Removal 7-26
l nstallation 7-26
Bulb Removal and l nstallation 7-26
FXST, FXSB Models 7-27
FLSTC, FLSTF/B, FLSTN and FLS Models 7-27
7 15 TAIL LAMP: ALL BUT FLSTN
General 7-29
Bulb Replacement 7-29
Base Replacement 7-29
7 16 TAIL LAMP: FLSTN
Bulb Replacement 7-31
Tail Lamp Replacement 7-31
7 17 AUXILIARY LAMPS: FLSTC, FLSTN
Auxiliary Lamp Bulb 7-33
Removal 7-33
l nstallation 7-33
FLSTC Models 7-33
Auxiliary Lamp Bracket Removal 7-33
Auxiliary Lamp Bracket l nstallation 7-34
Auxiliary Lamp Hou sing Removal 7-34
Auxiliary Lamp Hou sing l nstallation 7-34
FLSTN Models 7-36
Auxiliary Lamp Bracket Removal 7-36
Auxiliary Lamp Bracket l nstallation 7-36
Auxiliary Lamp Housing Removal 7-37
Auxiliary Lamp Housing l nstall ation 7-37
Adjustment: FLSTC/FLSTN Models 7-38
7 18 TURN SIGNALS AND RUNNING LIGHTS
Bulb Replacement: Bullet Style 7-40
Bulb Replacement: Flat Lens Style 7-40
TABLE OF CONTENTS XI
TABLE OF CONTENTS
Lamp Replacement 7-40
AII Models 7-40
Front Turn Signals 7-41
Front Turn Signals: FLSTC, FLSTN 7-42
Rear Turn Signals: AII But FLSTN, FLS, FXSB 7-42
Rear Turn Signals: FLS 7-42
Rear Turn Signals: FXSB 7-44
Rear Turn Signals: FLSTN 7-45
7 1 9 CRANK POSITION SENSOR (СКР)
General 7-47
Removal 7-47
lnstallation 7-4 7
7 20 AUTOMATIC COMPRESSION RELEASE
(ACR)
General 7 -48
Removal 7-48
lnstallation 7-48
7 21 IGNITION COIL
Removal 7-50
AII But FXSB 7-50
FXSB 7-50
lnstallation 7-50
AII But FXSB 7-50
FXSB 7-50
7 22 SPARK PLUG CABLES
General 7-52
Removal 7-52
1 nsta l lation 7 -52
7 23 VOLTAGE REGULATOR
DisassemЫy 7-53
7 28 WHEEL SPEED SENSORS
Front Wheel Speed Sensor 7-60
Removal 7-60
lnstallation 7-61
Rear Wheel Speed Sensor 7-61
Removal 7-61
lnstallation 7-62
7 29 INDICATOR LAMPS
General 7-64
Removal: AII But FXSB 7-64
lnstallation: AII But FXSB 7-64
Removal: FXSB 7-65
lnstallation: FXSB 7-65
7 30 NEUTRAL SWITCH
General 7-66
Removal 7-66
lnstallation 7-66
7 31 OIL PRESSURE SWITCH
General 7-67
Removal 7-67
lnstallation 7-67
7 32 REAR STOP LAMP SWITCH
General 7-68
Removal 7-68
lnstallation 7-68
7 33 HORN
lnspection 7-69
Removal and lnstallation: AII But FXSB 7-69
Removal апd lnstallation: FXSB 7-70
lnstallatioп 7-53 7 34 ACTIVE EXHAUST
7 24 дLTERNATOR General 7-71
Removal 7-71
Removal 7-54
Cleaning апd lnspection 7-54
Repair 7-71
lnstallation 7-71
lnstallation 7-54
7 25 FUEL GAUGE
7 35 MAIN WIRING HARNESS
Removal 7-72
General 7-55

installation 7-73
Removal 7-55
lnstallation 7-55
7 26 SPEEDOMETER
General 7-57
Removal: AII But FXSB 7-57
lnstallation: AII But FXSB 7-57
Removal: FXSB 7-57
lnstallation: FXSB 7-58
7 27 VEHICLE SPEED SENSOR (VSS)
General 7-59
Removal 7-59
lnstallation 7-59
XII TABLE OF CONTENTS
7 36 HANDLEBAR CONTROL MODULES
General 7-75
Repair Procedures 7-75
7 37 RIGHT HANDLEBAR CONTROL
MODULE
Removal 7-76
1 nstallation 7-77
Front Brake Switch Replacement 7-78
7 38 LEFT HANDLEBAR CONTROL MODULE
Removal 7-79
lnstallation 7-79
Clutch Switch Replacement 7-80
AP PENDIX А CONNECTOR REPAIR
д 1 AUTOFUSE UNSEALED ELECTRICAL
CONNECTORS
Autofuse Unsealed Connector Repair A-1
General A-1
OisassemЫy A-1
AssemЫy A -1
д 2 BOSCH СОМ РАСТ 1 1 М CONNECTOR
Bosch Compact 1 1 М Conn ector А-2
General A -2
Housings А-2
Removing Socket Terminal A -2
lnstalling Socket Terminal A -2
д З BOSCH ВТС SEALED CONNECTOR
Bosch ВТС Sealed Connector Repair А-3
Plugging and Unplugging Connector А-3
Removin g and l n stalling Connector Cover A-3
Removin g and l nstalling Wire Terminals А-4
Crimping Terminals to Leads А-5
д 4 DELPHI 1 OOW MICRO-PACK SEALED
CONNECTOR
Oelphi 1 OOW Micro-Pack Sealed Conn ector Repair А-6
General A-6
Separating Socket Housing From ЕСМ А-6
Mating Socket Housing То ЕСМ А -6
Removin g Socket Terminal A-6
lnstalling Socket Terminal А -6
Crimping Terminals A -7
д 5 DELPHI 150 METRI-PACK SEALED
CONNECTORS
Oelphi 150 Metri-Pack Seal ed Conn ector Repair А-8
General A -8
Separating Pin and Socket Housings А-8
Mating Pin and Socket Housings А-8
Removing Socket Terminal A-8
ln serting Socket Terminal A-8
д 6 DELPHI 280 METRI-PACK UNSEALED
CONNECTORS
Fuse Block Repair A-10
Removin g Socket Terminals А-1 О
l nstalling Socket Terminals A-10
Crimping Terminals А-1 О
д 7 DELPHI 480 METRI-PACK UNSEALED
CONNECTORS
O elphi 480 Metri-Pack Unsealed Connector Repair A-11
General A -11
Separating Pin and Socket Housings A -11
Mating Pin and Socket Housings A-11
Removing Socket Terminals A-11
lnstalling Socket Terminals A -11
TABLE OF CONTENTS
д 8 DELPHI 630 METRI-PACK UNSEALED
CONNECTORS
Oelphi 630 Metri-Pack Unsealed Connector Repair A-12
Separating Pin and Socket Housings A-12
Mating Pin and Socket Housings А-12
Removing Socket Terminal A-12
l n stalling Socket Terminal A-12
д 9 DELPHI 800 METRI-PACK SEALED MAIN
FUSE HOUSING
O elphi 800 Metri-Pack Sealed Main Fuse Housing
Repair А-13
Removing Socket Terminals А-13
l n stalling Socket Terminals А-13
д 1 О DELPHI METRI-PACK TERMINAL
REPAIR
Metri-Pack Terminal Crimps A-14
Matching Terminal То Crimper A -14
Preparing Wire Lead A-14
Crimping Wire Core A-14
Crimping ln sulation/Seal A-15
ln spectin g Crimps А-15
д 11 DELPHI MICRO 64 SEALED
CONNECTORS
O elphi Micro 64 Sealed Connector Repair А-16
General A -16
Separating Pin and Socket Housings A-16
Mating Pin and Socket Housings A-16
Removing Terminal A-16
l n stalling Terminal A-17
Preparing Wire Leads for Crimping A-17
Crimpin g Terminals А-17
ln spectin g Crimps А-17
д 12 DELPHI GT 150 SEALED
CONNECTORS
Oelphi GT 150 Sealed Conn ector Repair А-19
General A -19
Separating Pin and Socket Housings A -19
Mating Pin and Socket Housings A-19
Removing Socket Terminals А -19
lnstall ing Socket Terminals A -19
д 13 DEUTSCH DT SEALED CONNECTORS
O eutsch ОТ Sealed Conn ector Repair A-21
General А -21
Separating Pin and Socket Housings A-21
Matin g Pin and Socket Housings A-21
Removing Socket Terminals A-21
l n stalling Socket Terminals A-21
Removing Pin Terminals А-22
ln stall ing Pin Terminals A-23
Crimping Terminals А -23
А 14 DEUTSCH DT SEALED TERMINAL
REPAIR
O eutsch ОТ Sealed Terminal Crimps А-25
TABLE OF CONTENTS X I I I
TABLE OF CONTENTS
Preparing Wire Leads for Crimpin g A-25
Crimping Terminal to Lead A-25
lnspectin g Crimps А-25
д 15 DEUTSCH DTM SEALED MINI
TERMINAL REPAIR
Deutsch DTM Sealed Mini Terminal Crimps А-26
P reparing Wire Leads for Crimping A-26
Crimpin g а Mini Terminal to Wire Lead А-26
l nspecting Crimps А-26
А 16 DEUTSCH DTM SEALED SOLID
8ARREL MINI TERMINAL REPAIR
Deutsch DTM Sealed Solid Barrel Terminal Crimps А-27
Preparing Wire Leads For Crimpin g A-27
Adjustin g Crimper Tool А-27
Crimping а Barrel Contact То Wire Lead A -27
lnspecting Crimps А-27
д 17 JAE МХ19 SEALED CONNECTORS
JAE МХ19 Sealed Conn ectors A-29
Connector Housings А-29
Removing Terminals А-29
lnstalling Terminals А-29
Crimping Termin als А-29
д 18 MOLEX СМС SEALED CONNECTORS
Molex СМС Sealed Conn ectors А-30
Separating the Conn ector А-30
Removing Terminals А -30
l nstalling Terminals А-30
Crimping Terminals A -31
А 19 MOLEX МХ 150 SEALED
CONNECTORS
Molex МХ 150 Sealed Conn ector Repair А-32
Separating Pin and Socket Housings А-32
Matin g Pin and Socket Housings А-32
Removing Terminals А-32
l nstalling Terminals A-32
Crimp Terminal to Lead A -33
Prepare Lead A-33
Prepare Tool A-33
Position Terminal in the Pun ch/Die А-34
l nsert Stripped Lead A-34
Crimp Terminal to Lead A-34
lnspect Crimp А-35
д 20 ТУСО 040 MULTILOCK UNSEALED
CONNECTOR
Тусо 040 Multilock Unsealed Conn ector Repair А-36
General A -36
Separating Pin and Socket Housings А-36
Matin g Pin and Socket Housings А-36
Removing Terminals from Housing А -36
lnserting Terminals into Housing A-37
Crimping Terminals to Leads А-37
l nspecting Crimped Terminals A-37
XIV TABLE OF CONTENTS
А 21 ТУСО 070 MULTILOCK UNSEALED
CONNECTOR
Тусо 070 Multilock Unsealed Connector Repair А-38
General A-38
Separating Pin and Socket Housings А-38
Mating Pin and Socket Housings А-38
Removing Terminals from Housing А-38
lnserting Terminals into Housing A-39
Crimpin g Terminals to Leads А-40
lnspecting Crimped Terminals А-40
А 22 ТУСО GET 64 SEALED CONNECTOR
Тус о GET 64 Sealed Conn ector Repair А-41
General А-41
Housings A -41
Removing Socket Termin als А-41
lnstalling Socket Termin als А-42
Crimpin g Terminals А-42
А 23 ТУСО МСР SEALED CONNECTOR
Тусо МСР Sealed Connector А-43
General A -43
Housing A -43
Removing the Large Terminals А-43
Removing the Small Terminals А-43
lnstalling Terminals А -44
Crimpin g Terminals А-44
д 24 SEALED SPLICE CONNECTORS
Sealed Splice Connector Repair А-45
General A -45
Preparin g Wire Leads А-45
Splicing Wire Leads А-45
lnspecting Seals A -45
APPEND I X В WIRING
8 1 CONNECTORS
Connector Locations 8-1
Function /Location В-1
Pl ace and Color 8-1
Conn ector N umber 8-1
Repair l nstructions 8-1
8 2 WIRING DIAGRAMS
Wiring Diagram l n formation 8-5
Wire Color Codes В-5
Wiring Diagram Symbols В-5
2015 Softail Wiring Diagrams В-7
APPEND I X С REFERENCE
С 1 LENGTH CONVERSION
Conversion ТаЫе С-1
С 2 FLUID CONVERSION
Un ited States System C-2
Metric System C-2
British lmperial System C-2
TABLE O F CONTENTS
С З TORQUE CONVERSION REFERENCE MATERIAL
United States System С-3
Metric System C-3 TOOLS I
С 4 GLOSSARY TORQUE VALUES IX
Acronyms and Abbreviations С-4
INDEX XXI