2015 Harley-Davidson Touring Service Manual – PDF DOWNLOAD

Description

2015 Harley-Davidson Touring Service Manual – PDF DOWNLOAD

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DESCRIPTION:

2015 Harley-Davidson Touring Service Manual – PDF DOWNLOAD

GENERAL :

The rider’s safety depends щ:юп proper motorcycle service and maintenance. lf а procedure in this manual is not within your capaЫlities or you do not have the correct tools, have а Harley-Davidson dealer perform the procedure. lmproper service or maintenance could result in death or serious injury. (00627Ь) This service manual has been prepared with the following purposes in mind: То acquaint the user with the construction of the HarleyDavidson product and assist in the performance of basic maintenance and repair. То 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 profitaЫe.

TABLE OF CONTENTS:

2015 Harley-Davidson Touring Service Manual – PDF DOWNLOAD

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
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 on Fasteners 1-4
Magnetic Parts Тгауs 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
Disposal and Recycling 1-5
Cleaning 1-5
Protecting Rubber Parts 1-5
Cleaning Process 1-5
Rust or Corrosion Removal 1-5
Bearings 1-5
Tool Safety 1-5
Air Tools 1-5
Wrenches 1-5
Pliers/Cutters/Pry Bars 1-6
Hammers 1-6
Punches/Chisels 1-6
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 1-1 О
1 6 ENGINE OIL AND FILTER
Engine Oil Level 1-15
Oil Level Cold Check 1-15
Oil Level Hot Check 1-15
Changing Oil and Oil Filter 1-16
1 7 AIR CLEANER AND EXHAUST SYSTEM
Air Filter 1 -18
Removal 1 -18
lnstallation 1-18
Exhaust System Leak Check 1-18
Exhaust System Leakage 1-19
1 8 COOLANT
Cooling System 1-20
Checking Coolant Level 1-20
Clean Radiators 1-20
Drain and Fill Cooling System 1 -21
Drain System 1-21
Power Fill and Bleed 1-21
Manual Fill and Bleed 1-22
1 9 TIRES AND WHEELS
General 1-23
Tires 1-23
Tire Replacement 1-24
lnspection 1-24
When То Replace Tires 1-24
Wheel Bearings 1-24
Wheel Spokes 1-25
ldentify Wheel Spoke Groups 1-25
Wheel Spoke Adjustment 1-25
1 1 О PRIMARY CHAINCASE LUBRICANT
General 1-27
Changing Primary Chaincase Lubricant 1-27
1 11 TRANSMISSION LUBRICANT
Checking Transmission Lubricant 1-29
Changing Transmission Lubricant 1-29
1 12 CLUTCH CABLE: ROAD КING
Adjustment 1-31
1 1 З HYDRAULIC CLUTCH FLUID
General 1 -32
Fluid lnspection 1-32
1 14 DRIVE BELT AND SPROCKETS
General 1-33
Cleaning 1-33
lnspection 1-33
Sprockets 1-33
Drive Belt 1-33
Checking Drive Belt Deflection 1-34
Setting Belt Deflection 1-36
Adjustment 1-36
AssemЫy 1-37
1 15 REAR SPROCKET ISOLATOR
1 nspection 1 -38
1 16 CABLE AND CHASSIS LUBRICATION
Chassis Lubrication 1-39
1 17 BRAKES
Fluid lnspection 1-40
Brake Fluid Replacement 1-40
Brake Lines lnspection 1-41
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TABLE OF CONTENTS
1 18 BRAKE PADS AND DISCS
lnspection 1-42
Brake Pads 1-42
Brake Disc T hickness 1-42
Brake Disc Lateral Runout 1-42
Brake Pad Replacement 1-42
Rear Brake Caliper 1-42
Front Brake Calipers 1-44
1 19 SPARK PLUGS
Removal 1-46
lnspection 1-46
Cleaning 1-46
lnstallation 1-46
1 20 STEERING HEAD BEARINGS
Checking Swing-Back 1-48
Measure Swing-Back 1-48
Adjusting Swing-Back 1-49
lnspection and Lubrication 1-50
1 21 REAR SUSPENSION ADJUSTMENTS
Air Suspension 1-51
Manual Suspension Preload 1-52
1 22 BATTERY MAINTENANCE
General 1-54
Cleaning and lnspection 1-55
Battery 1-55
Disconnection and Removal 1-55
lnstallation and Connection 1-55
Voltmeter Test 1-56
Battery Tender Connector 1-56
Charging Battery 1-57
Safety Precautions 1-57
Using а Battery Charger 1-57
Storage 1-58
1 23 HEADLAMP ALIGNMENT
Checking Head\amp Alignment 1-59
Headlamp Adjustment 1-59
Auxiliary/Fog Lamp Adjustment 1-60
1 24 ENGINE MOUNTS
lnspection 1-62
General 1-62
Front Engine Mount 1-62
1 25 STORAGE
Genera\ 1-63
Placing in Storage 1-63
Remova\ from Storage 1-63
1 26 TROUBLESHOOTING
Genera\ 1-65
Engine 1-65
Starter Motor Does Not Operate ог Does Not Turn Engine
Over 1-65
Engine Turns Over But Does Not Start 1-65
Starts Hard 1-65
IV TABLE OF CONTENTS
Starts But Runs \rregularly ог Misses 1-65
А Spark Plug Fouls Repeated\y 1-66
Pre-lgnition ог Detonation (Knocks ог Pings ) 1-66
Overheating 1-66
Va\ve Train Noise 1-66
Excessive Vibration 1-66
Check Engine Light llluminates During Operation 1-66
Lubrication System 1-66
Oil Does Not Return То Oil Reservoir 1-66
Engine Uses Тоо Much Oil Or Smokes Excessively 1-66
Engine Leaks Oil From Cases, Pushrods, Hoses,
Etc 1-67
Low Oil Pressure 1-67
High Oil Pressure 1-67
Electrical System 1-67
Alternator Does Not Charge 1-67
Alternator Charge Rate Is Below Norma\ 1-67
Speedometer Operates Erratica\ly 1-67
Transmission 1-67
Shifts Hard 1-67
Jumps Out Of Gear 1-67
C\utch Slips 1-67
Clutch Drags Or Does Not Release 1-67
Clutch Chatters 1-67
Handling 1-67
lrregularities 1-67
Brakes 1-68
Brake Does Not Hold Normally 1-68
CHASSIS
2 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 2-1
2 2 SPECIFICATIONS
Specifications 2-1 О
Chassis Specifications 2-1 О
Tire Specifications 2-12
2 З VEHICLE IDENTIFICATION NUMBER
(VIN)
Vehicle \dentification Number (VIN) 2-14
Genera\ 2-14
Location 2-14
Abbreviated VIN 2-14
2 4 FRONT WHEEL
Removal 2-16
Brake Disc Removal 2-16
Cleaning and lnspection 2-16
lnstallation 2-17
Brake Disc lnstallation 2-17
Wheel lnstallation 2-17
2 5 REAR WHEEL
Removal 2-18
Cleaning and lnspection 2-19
lnstallation 2-19
2 6 REAR WHEEL COMPENSATOR
\solator Replacement 2-22
TABLE OF CONTENTS
Removal 2-22 AssemЫy and lnstallation 2-46
lnstallation 2-22 AssemЫy 2-46
Sprocket Bearing Replacement 2-22 lnstallation 2-46
Removal 2-22
lnstallation 2-22 2 15 REAR BRAKE CALIPER
2 7 WHEEL LACING: FRONT RIM
Removal 2-47
lnstallation 2-47
Wheel Lacing: Angle Flange Hub 2-24
2 16 BRAKE LINES
2 8 WHEEL LACING: 16 INCH REAR RIM Front Brake Line: Non-ABS Equipped 2-48
Wheel Lacing: 16 ln Rear Wheel 2-26 Removal 2-48
2 9 CHECКING AND TRUING WHEELS
lnstallation 2-49
Rear Brake Line: Non-ABS Equipped 2-49
General 2-29 Removal 2-49
Checking Wheel Runout 2-29
Checking Radial Runout 2-29
1 nstallation 2-50
Brake Line: Front Master Cylinder to ABS Module 2-52
Checking Lateral Runout 2-29
Laced Wheel Rim Offset 2-30
Removal 2-52
Front Line Routing 2-53
Truing Laced Wheels 2-31
Radial Runout 2-31
lnstallation 2-53
Brake Line: ABS Module to Front Caliper 2-54
Lateral Runout 2-32 Removal 2-54
lnstallation 2-55
2 1 О SEALED WHEEL BEARINGS Brake Line: Rear Master Cylinder to ABS Module 2-56
lnspection 2-33
Removal 2-33
lnstallation 2-35
Removal 2-56
lnstallation 2-56
Brake Line: ABS Module to Rear Caliper 2-59
Removal 2-59
2 11 TIRES lnstallation 2-59
General 2-36 2 17 A BS MODULE
Removal 2-36
Cleaning, lnspection and Repair 2-36
lnstallation 2-37
Tube Туре Тires 2-37
Tubeless Tires: Cast Wheels 2-37
Reflex ™ Linked Brakes with ABS Operation 2-60
ABS Module 2-60
Removal 2-60
lnstallation 2-61
Checking Tire Runout 2-38
Lateral Runout 2-38
2 18 BLEEDING BRAKES
Radial Runout 2-38 General 2-62
Wheel Balancing 2-38 Procedure 2-62
Static vs Dynamic 2-38
?ig№ 2? 2 19 FRONT FORK
Fork Oil Leak Check 2-64
2 12 FRONT BRAKE MASTER CYLINDER Fork Oil Seals 2-64
General 2-40 Oil Leak Check 2-64
Removal and DisassemЫy 2-40
Removal 2-40
Removal 2-64
1 nstallation 2-65
DisassemЫy 2-40
Cleaning and lnspection 2-41
AssemЫy and lnstallation 2-42
AssemЫy 2-42
DisassemЫy: AII Except Cartridge Fork (Low Models, Left
Side) 2-66
OisassemЫy: Cartridge Fork (Low Models, Left Side) 2-68
Cleaning and lnspection 2-70
lnstallation 2-42 AssemЫy: AII Except Low Models, Left Side 2-71
Filling and Final AssemЫy 2-71
2 1 З FRONT BRAKE CALIPER AssemЫy: Cartridge Fork (Low Models, Left Side) 2-72
Removal 2-43
Filling and Final AssemЫy 2-73
lnstallation 2-43 2 20 STEERING HEAD BEARINGS
2 14 REAR BRAKE MASTER CYLINDER Steering Stem Removal 2-75
General 2-44
Removal and DisassemЫy 2-44
Removal 2-44
DisassemЫy 2-44
Cleaning and lnspection 2-45
Removal 2-75
DisassemЫy 2-75
Steering Stem lnstallation 2-76
AssemЫy 2-76
lnstallation 2-76
TABLE OF CONTENTS V
TABLE OF CONTENTS
Upper Fork Bracket 2- 77
Removal 2- 77
lnstallation 2- 77
2 2 1 REAR SUSPENSION
Shock Absorber Removal 2- 79
Cleaning and lnspection 2- 79
Shock Absorber lnstallation 2-79
Air Shock Absorber Repair 2-80
Air Lines 2-80
Check for Leaks 2-80
Fittings 2- 80
Air Valve AssemЫy 2-80
Air Tubes 2- 80
Manual Adjust Shock Absorber Repair 2-81
2 22 REAR FORK
Removal 2-82
DisassemЫy and AssemЫy 2- 82
Bearing Removal 2- 82
Bearing lnstallation 2-83
Pivot Shaft/Mount DisassemЫy 2-83
1 nstallation 2-84
2 23 CLUTCH
Removal 2- 85
lnstallation 2-85
CLUTCH MASTER CYLINDER D
RESERVOIR
Removal 2- 87
DisassemЫy 2-87
Cleaning and lnspection 2-88
AssemЬly 2-88
lnstallation 2-89
2 25 HYDRAULIC CLUTCH HAND LEVER
Removal 2-90
lnstallation 2-90
2 26 CLUTCH FLUID LINE
Replacement 2- 91
Removal 2-91
lnstallation 2-91
Validate Repair 2-92
CLUTCH CONTROL
SYSTEM
Drain and Fill 2-94
Drain 2-94
Fill 2- 94
Bleed Fluid Line and Secondary Clutch Actuator 2- 95
2 2 8 HANDLEBAR
Adjustment 2 – 96
Removal 2- 97
lnstallation 2- 99
DisassemЫy, FLTR Models 2- 100
AssemЫy, FLTR Models 2-100
Pull Wire Leads 2-1 00
VI TABLE OF CONTENTS
Left Hand Grip 2-101
Removal 2-101
lnstallation 2- 1 01
Right Hand Grip 2- 1 01
Removal 2- 101
lnstallation 2-101
Rubber Mounts 2-101
Heated Hand Grips 2-102
Remove Left Hand Grip 2-102
lnstall Left Hand Grip 2- 102
Remove Right Hand Grip 2-103
lnstall Right Hand Grip 2-103
2 29 MIRRORS
AII Models Except FLHX/S 2-104
Removal 2- 104
lnstallation 2- 104
FLHX/S 2- 104
Removal 2-1 04
lnstallation 2-104
2 30 SEAT
Seat 2- 105
Removal 2- 105
lnstallation 2-105
Seat Retention Nut Replacement 2-106
Seat Bumper 2- 1 06
SADDLEBAGS
Removal 2- 107
lnstallation 2-107
SADDLEBAG SERVICE
Saddlebag Repair 2-108
Lock 2-108
Stri kes 2- 1 08
Cover 2-108
Cover Seal 2-109
Hinge 2-109
Latch AssemЫy 2-109
Saddlebag Support 2-110
Removal 2- 1 1 0
lnstallation 2- 1 1 О
2 ЗЗ TOUR-PAK
Removal and lnstallation 2-112
Removal 2- 1 12
lnstallation 2-112
Tour- Pak Support 2-112
Removal 2- 112
lnstallation 2-113
DisassemЫy/AssemЫy 2-11 З
2 34 TOUR-PAK SERVICE
Tour- Pak Liner 2-114
Removal 2- 1 14
lnstallation 2-114
Tour- Pak Seal 2- 1 14
lnspection 2-114
Replacement 2-114
Tour-Pak Lock 2- 1 1 4
Removal 2-1 1 4
lnstallation 2-1 1 4
Hinges 2-1 1 5
Removal 2-1 1 5
lnstallation 2-1 1 5
Latch Handle and Catch 2-1 1 5
Removal 2-1 1 5
lnstallation 2-1 1 5
Tether 2-1 1 5
Removal 2-1 1 5
l nstallation 2-1 1 5
Luggage Rack 2-1 1 6
Ground Plate 2 -1 1 6
Removal 2-1 1 6
lnstallation 2-1 1 6
2 35 TOUR-PAK BACKREST
Passenger Backrest 2-1 1 8
Removal 2-1 1 8
lnstallation 2-1 1 8
Rubber lsolators 2-1 1 8
Removal 2-1 1 8
lnstallation 2-1 1 8
Passenger Backrest Flap 2-1 1 8
Removal 2-1 1 8
l nstallation 2-1 1 8
2 36 FAIRING LOWERS AND ENGINE
GUARD
Fairing Lower: Air Cooled 2 -1 1 9
Removal 2-1 1 9
lnstallation 2-1 1 9
DisassemЫy 2-1 1 9
AssemЫy 2-1 21
Fairing Lower: Twin-Cooled 2-1 21
Removal 2-1 21
l nstallation 2-1 22
Repair 2-1 22
Engine Guard 2-1 23
Removal 2-1 23
lnstallation 2-1 23
2 37 OUTER FAIRING AND WINDSHIELD:
FORK MOUNTED FAIRING MODELS
Outer Fairing and Windshield 2-1 24
Removal 2-1 24
lnstallation 2-1 24
Fairing Seal 2-1 24
Headlamp Mount 2-1 24
Fairing Vent Bezel 2-1 25
2 3 8 DASH PANEL: FORK MOUNTED
FAIRING MODELS
Dash Panel 2-1 26
Removal 2-1 26
lnstallation 2 -1 26
2 39 INNER FAIRING: FORK MOUNTED
FAIRING MODELS
Rotate lnner Fairing 2-1 27
TAB L E OF CONTENTS
lnner Fairing AssemЫy Removal and lnstallation 2-1 27
Removal 2-1 27
lnstallation 2-1 28
lnner Fairing Shell Replacement 2-1 29
Removal 2-1 29
lnstallation 2-1 29
Fairing Vent 2-1 30
Cleaning 2-1 30
Removal 2-1 30
lnstallation 2-1 30
Vent Repair 2-1 31
Upper Support Bracket 2-1 31
Removal 2-1 31
1 nsta llation 2-1 32
Media Compartment 2-1 32
Removal 2-1 32
l nstallation 2-1 32
С аЫе Replacement 2-1 32
Cover Replacement 2-1 33
Latch Replacement 2-1 33
2 40 INSTRUMENT BEZEL: FRAME
MOUNTED FAIRING MODELS
lnstrument Bezel 2-1 34
Removal 2-1 34
lnstallation 2-1 34
2 41 INSTRUMENT NACELLE : FRAME
MOUNTED FAIRING MODELS
lnstrument Nacelle 2-1 35
Removal 2-1 35
lnstallation 2-1 35
2 42 OUTER FAIRING AND WINDSHIELD:
FRAME MOUNTED FAIRING MODELS
Windshield 2-1 36
Removal 2-1 36
lnstallation 2-1 36
Тор Air Duct 2-1 36
Removal 2-1 36
lnstallation 2-1 36
Cleaning Air Duct 2-1 36
Button Mechanism Repair 2-1 36
Outer Fairing 2-1 38
Removal 2-1 38
lnstallation 2-1 38
2 43 INNER FAIRING : FRAME MOUNTED
FAIRING MODELS
Removal 2-1 40
lnner Fairing AssemЫy 2-1 40
Fairing Mounting Bracket 2-1 41
lnstallation 2-1 42
Fairing Mounting Bracket 2-142
lnner Fairing AssemЫy 2-142
Fairing Air Duct 2-1 42
Removal 2-1 42
lnstallation 2-1 42
Air Duct Repair 2-1 43
lnner Fairing Shell Replacement 2-1 43
Removal 2-1 43
TABLE OF CONTENTS VII
TABLE OF CONTENTS
lnstallation 2- 144
Radio Support Bracket 2-144
Removal 2-144
l nstallation 2-145
2 44 STORAGE COMPARTMENTS: FRAME
MOUNTED FAIRING MODELS
Storage Compartment, Door and Hinge 2-147
Storage Compartment Door Replacement 2-147
Storage Compartment Removal 2-147
Storage Compartment lnstallation 2-147
Storage Compartment Door/Hinge Removal 2-147
Storage Compartment Door/Hinge lnstallation 2-147
Storage Compartment Media С аЫе 2- 148
2 45 AIR DEFLECTORS
Fairing Air Deflectors 2-149
Removal: Fork Mounted Fairing Models 2-149
lnstallation: Fork Mounted Fairing Models 2-149
Removal: Frame Mounted Fairing Models 2-149
lnstallation: Frame Mounted Fairing Models 2-149
Mid-Frame Air Deflectors 2-149
Removal 2- 149
lnstallation 2- 149
2 46 WINDSHIELD: ROAD IONG MODELS
Windshield 2-151
Removal 2-151
lnstallation 2-151
Windshield Window 2-151
Removal 2-151
lnstallation 2-152
2 47 HEADLAMP NACELLE: ROAD IONG
MODELS
Removal 2- 154
lnstallation 2- 155
2 48 FRONT FENDER
Removal 2-156
Repair 2-157
lnstallation 2- 157
2 49 REAR FENDER
Removal 2- 159
Fender Repair 2-160
Mounting Hardware 2- 160
Stud Plate 2- 160
Lights and Harnesses 2-160
lnstallation 2-160
2 50 REAR FASCIA
Removal 2-162
lnstallation 2- 162
Stud Plate 2-162
Removal 2- 162
lnstallation 2-162
Rear Fascia Lamp 2-162
VШ TABLE OF CONTENTS
2 51 REAR FRAME
Rear Frame 2-163
Removal 2-163
lnstallation 2-164
T hread Repair 2- 164
2 52 FOOTBOARDS AND FOOTRESTS
Rider Footboards 2-165
Removal 2-165
lnstallation 2-165
DisassemЫy 2-165
AssemЫy 2- 166
Passenger Footboard 2- 166
Removal 2-166
DisassemЫy 2-166
AssemЫy 2-166
1 nstallation 2-166
Passenger Footrest: FLHX/S and FLTRX/S 2-167
Removal 2- 167
DisassemЫy 2-167
AssemЫy 2- 167
1 nstallation 2-167
Passenger Footrest: Low Models 2-167
Removal 2-167
DisassemЫy 2-167
AssemЫy 2-168
lnstallation 2-168
Pad Replacement and Adjustment 2-168
2 53 JIFFY STAND
General 2-169
Leg Removal 2-169
Leg lnstallation 2-169
Jiffy Stand Bracket 2-170
Removal 2- 170
lnstallation 2- 170
Jiffy Stand lnterlock Sensor 2-170
Removal 2-170
lnstallation 2-171
2 54 FRONT ENGINE MOUNT
Removal 2- 172
lnstallation 2- 172
StaЬilizer Link 2- 173
Removal 2-173
lnstallation 2-173
StaЬilizer Link Bracket 2-173
2 55 MEDALLIONS, BADGES AND TANK
EMBLEMS
Removal 2-175
lnstallation 2-175
ENGINE
3 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 3- 1
З 2 SPECIFICATIONS
Specifications 3-3
3 3 SERVICE WEAR LIMITS
General 3 -5
3 4 ENGINE OIL FLOW
Oil Feed 3-7
Тор End 3-7
Bottom End 3-9
Oil Return 3 -11
Oil Cooler Operation 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 3-18
Diagnosing Smoking Engine or High Oil Consumption 3-18
Check Prior to Cylinder Head Removal 3-18
Check After Cylinder Head Removal 3-18
3 9 OIL COOLER
Removal 3-19
lnstallation 3 -1 9
3 1 О OIL COOLER ADAPTER
Removal 3-20
DisassemЫy 3 -20
AssemЫy 3 -20
lnstallation 3 -20
3 11 HOW ТО USE THIS SECTION
Тор End Repair 3-21
Bottom End Repair 3-21
Typical Symptoms 3 -21
3 12 ТОР END SERVICE
Engine in Chassis 3-22
Engine Removed from Chassis 3 -23
3 1 З САМ COMPARTMENT SERVICE
Engine in Chassis 3 -24
Engine Removed From Chassis 3-25
3 14 STRIPPING MOTORCYCLE FOR
SERVICE
Procedure 3-26
Cam Compartment Service Only 3-26
Тор End Service 3-26
TABLE O F CONTENTS
3 15 ASSEMBLING MOTORCYCLE AFTER
SERVICE
Procedure 3-27
After Тор End Service 3-27
After Cam Compartment Service 3-27
3 16 REMOVING ENGINE FROM CHASSIS
Procedure 3-28
3 17 INSTALLING ENGINE IN CHASSIS
Procedure 3-29
3 18 ТОР END OVERHAUL: DISASSEMBLY
General 3 -30
Rocker Covers 3-30
Rocker Arm Support Plate 3 -30
Pushrods, Lifters and Covers 3-32
Cylinder Head 3-32
Cylinder 3-33
Piston 3-34
3 19 BREATHER ASSEMBLY
DisassemЫy 3-36
Cleaning and lnspection 3-36
AssemЫy 3-36
3 20 ROCKER ARM SUPPORT PLATE
DisassemЫy 3-37
Cleaning and lnspection 3 -37
1 nspection 3-37
Rocker Shaft Fit 3-37
Rocker Arm Shaft to Bushing 3-38
Replace Rocker Arm Bushings 3-38
AssemЫy 3-39
3 21 PUSHRODS, LIFTERS AND COVERS
DisassemЫy 3 -40
Cleaning and General lnspection 3 -40
Lifter lnspection 3-40
AssemЫy 3 -41
3 22 CYLINDER HEAD
DisassemЫy 3-42
Cleaning 3-43
1 nspection 3-43
Cylinder Head 3-43
Valve Guides 3-44
Valves 3-44
Valve Springs 3-44
Tapered Keepers 3-44
Valve Seats 3-44
Valve Guide Replacement 3 -44
Removal 3 -44
lnstallation 3-45
Valve and Seat Refacing 3 -48
AssemЫy 3-50
3 23 CYLINDER
Cleaning 3 -52
1 nspection 3-52
TABLE OF CONTENTS IX
TABLE OF CONTENTS
Deglazing Cylinder 3-54
Boring and Honing Cylinder 3-54
З 24 PISTON
DisassemЫy 3-56
Piston Rings 3-56
Cleaning 3-56
1 nspection 3-56
AssemЫy 3-58
Checking Piston Ring Gap 3-58
lnstalling Piston Rings 3-58
3 25 ТОР END OVERHAUL: ASSEMBLY
General 3-60
Piston 3-60
Cylinder 3-61
Cylinder Head 3-63
Pushrods, Lifters and Covers 3-67
Rocker Arm Support Plate 3-68
Breather and Rocker Cover 3-69
Twin-Cooled Engine 3-69
3 26 САМ COMPARTMENT AND
COMPONENTS
Cam Support Plate and Cover Removal 3-70
Prepare Engine 3-70
Cam Chain and Sprockets Removal 3-70
Cam Support Plate Removal 3-71
Cam Support Plate Cleaning and lnspection 3-72
Oil Pressure Valve 3-72
Cam Support Plate 3-72
Camshafts 3-72
Removal 3-72
lnstallation 3-73
Oil Pressure Relief Valve 3-74
Removal 3-74
1 nspection 3-7 4
lnstallation 3-75
Cam Needle Bearings 3-75
Removal 3-75
lnstallation 3 -76
Cam Support Plate and Cover lnstallation 3-78
3 27 OIL PUMP
Removal 3-82
Cleaning and lnspection 3 -82
lnstallation 3-83
3 28 CRANKCASE DISASSEMBLY AND
REPAIR
Crankcase DisassemЫy 3-84
Cleaning and lnspection 3-84
Right Crankcase Half 3-85
Main Bearing Removal 3-85
Main Bearing lnstallation 3-85
Piston Jets Removal 3-86
Piston Jets lnstallation 3-86
Left Crankcase Half 3-86
Main Bearing Removal 3-86
Main Bearing lnstallation 3-87
Sprocket Shaft Bearing lnner Race 3-88
Х TABLE OF CONTENTS
Removal 3-88
lnstallation 3-89
Cylinder Studs 3-91
Removal 3-9 1
lnstallation 3-91
Pipe Plug and Oil Fittings 3-91
Removal 3-91
lnstallation 3-91
3 29 F LYWHEEL AND CONNECTING RODS
General 3-92
Symptoms 3-92
No Oil Pressure 3-92
Vibration 3-92
1 nspection 3-92
Measuring Crankshaft Runout 3-92
Crankshaft lnstalled 3-92
Crankshaft Removed 3-93
3 30 CRANKCASE ASSEMBLY
Crankcase AssemЫy 3-94
З 31 OIL PAN
Removal 3-96
lnstallation 3 -96
FUE L SYSTE M
4 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 4-1
4 2 SPECIFICATIONS: FUEL SYSTEM
Specifications 4-2
4 3 FUEL PRESSURE TEST
General 4-3
Testing 4-3
4 4 INTAKE LEAK TEST
General 4-5
Leak Tester 4-5
Parts List 4-5
Tester AssemЫy 4-5
Tester Adjustment 4-5
Procedure 4-5
4 5 AIR CLEANER ASSEMBLY
Removal 4-7
lnstallation 4-8
Air Cleaner Repair 4-8
lnsert: With Screw Access 4-8
lnsert: Without Screw Access 4-8
Snorkel 4-8
4 6 FUEL TANK
Console 4-9
Removal 4-9
lnstallation 4-9
Fuel Door 4-9
Door Replacement 4-9
Lock Replacement 4-9
Removal 4-9
Purge and Disconnect Fuel Line 4 -9
Remove Tank 4-9
1 nstallation 4-1 О
Vent Tube: Models Without EVAP System 4-10
Removal 4-10
lnstallation 4-11
Fuel Supply Check Valve/Тube 4-11
R emoval 4-11
lnstallation 4-11
4 7 FUEL TANK ТОР PLATE
Removal 4-13
lnstallation 4-14
4 8 FUEL FILTER
Removal 4-15
lnstallation 4-15
4 9 FUEL PRESSURE REGULATOR
Removal 4-16
1 nstallation 4-16
4 1 О FUEL LEVEL SENDER
Removal 4-17
1 nstallation 4-17
4 11 TWIST GRIP SENSOR (TGS)
Removal 4-18
lnstallation 4-19
Twist Grip Sensor Jumper Harness 4-20
Removal 4- 20
lnstallation 4-20
4 12 THROTTLE CONTROL ACTUATOR
(ТСА)
General 4-22
4 13 INDUCTION MODULE
Removal 4-23
lnstallation 4-24
4 14 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE SENSOR (ТМАР)
Removal 4-25
lnstallation 4-25
4 15 HEATED OXYGEN SENSORS (НО2)
Removal 4 -26
lnstallation 4- 27
4 16 FUEL INJECTORS
General 4 -28
Removal 4- 28
lnstallation 4-28
4 17 FUEL PUMP
General 4-30
Removal 4- 30
TABLE OF CONTENTS
1 пstallation 4-30
Fuel Pump and Fuel Level Sender Wire Harness 4-31
Removal 4-31
lnstallation 4-31
4 18 EXHAUST SYSTEM
Mufflers 4-32
Removal 4-32
lnstallation 4-32
System Removal 4-32
System lnstallation 4-34
4 19 ACTIVE EXHAUST: HDI
Exhaust Valve Actuator 4-35
Removal 4-35
lnstallation 4-35
Exhaust Valve Actuator С аЫе 4-35
Removal 4-35
lnstallation 4-35
Active Exhaust Valve 4-36
General 4-36
4 20 EVAPORATIVE EMISSIONS CONTROL
SYSTEM
General 4-37
Vapor Valve 4-37
Fuel Vapor Vent Tube 4-38
Removal 4-38
lnstallation 4-38
Canister-to-Solenoid Tube 4-38
Removal 4-38
lnstallation 4 -38
Solenoid-to-lnduction Module Tube 4-38
Removal 4-38
lnstallation 4-38
Purge Solenoid 4-38
Removal 4-38
1 nstallation 4-39
Charcoal Canister 4-39
Removal 4-39
lnstallation 4-39
DRI VE
5 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 5-1
5 2 SPECIFICATIONS: DRIVE
Specifications 5-2
5 3 PRIMARY CHAINCASE COVER
Removal 5-3
1 nstallation 5 -3
5 4 DRIVE COMPONENTS
Removal 5 -5
lnstallation 5 -7
5 5 PRIMARY CHAINCASE HOUSING
Removal 5-1 О
TABLE OF CONTENTS Х!
TABL E OF CONT ENTS
lnspection 5-1 О
Mainshaft Bearing and Seal 5-10
Removal 5-10
lnstallation 5-1 О
Mainshaft Bearing lnner Race 5-11
Removal 5-11
lnstallation 5-11
Shifter Shaft Bushings 5-12
lnstallation 5-12
5 6 CLUTCH: CONVENTIONAL
Clutch ldentification 5-14
Removal and lnstallation 5-14
Clutch Pack Only 5-14
Partial DisassemЫy 5-14
Cleaning And lnspection 5-14
AssemЫy 5-15
Clutch Pack and Bearing 5-16
Complete DisassemЬly 5-16
AssemЫy 5-17
5 7 CLUTCH: ASSIST AND SLIP
Clutch ldentification 5-19
Clutch Pack Only 5-19
Partial DisassemЫy 5-19
Cleaning And lnspection 5-19
AssemЫy 5-19
5 8 HYDRAULIC CLUTCH RELEASE
BEARING AND PUSHROD
Removal 5-22
lnstallation 5-22
Measure Release Plate Movement 5-22
lnstall Clutch lnspection Cover 5-22
5 9 TRANSMISSION SPROCKET
Removal 5-24
Cleaning and lnspection 5-24
lnstallation 5-24
5 1 О DRIVE BEL Т
Removal and Adjustment 5-26
Adjustment 5-26
Removal 5-26
lnstallation 5-26
T RANS MISSI ON
6 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 6-1
6 2 SPECIFICATIONS: TRANSMISSION
Specifications 6-3
Service Wear Limits 6-3
6 3 TRANSMISSION
Power Flow 6-4
Neutral 6-4
First Gear 6-4
Second Gear 6-4
XII TABLE OF CONTENTS
T hird Gear 6-4
Fourth Gear 6-4
Fifth Gear 6-4
Sixth Gear 6-4
6 4 SHIFTER LINKAGE
Shifter Rod Adjustment 6-6
Heel-Toe Shift Levers 6-6
Removal 6-6
Repair 6-6
lnstallation 6-6
Shifter Rod Lever, Front 6-6
Removal 6-6
1 nstallation 6-6
6 5 CLUTCH RELEASE COVER: CABLE
CLUTCH
Removal and DisassemЫy 6-8
Cleaning and lnspection 6-8
AssemЫy and lnstallation 6-9
6 6 TRANSMISSION SIOE COVERS:
HYDRAULIC CLUTCH
Removal 6-1 О
lnstallation 6-1 О
6 7 SECONDARY CLUTCH ACTUATOR
Replacement 6-11
Validate Repair 6-11
6 8 TRANSMISSION ASSEMBLY
Removal 6-13
DisassemЫy 6-14
Shifter Cam/Shifter Forks 6-14
Mainshaft 6-16
Countershaft 6-18
Removing Bearing Housing Bearings 6-19
Cleaning and lnspection 6-20
AssemЫy 6-20
lnstalling Bearing Housing Bearings 6-20
Cou ntershaft 6-20
Mainshaft 6-21
Shifter Cam/Shifter Forks 6-21
lnstallation 6-23
6 9 MAIN DRIVE GEAR AND BEARING
Removal 6-25
Cleaning and lnspection 6-26
Needle Bearing Replacement 6-27
Mainshaft Seal Replacement 6-28
1 nstallation 6-29
lnstalling Main Drive Gear Bearing 6-29
lnstalling Main Drive Gear 6-29
lnstalling Main Drive Gear Large Seal 6-30
6 1 О TRANSMISSION CASE
Removal 6-32
lnstallation 6-32
DisassemЫy 6-33
Shifter Arm AssemЬly 6-33
Cleaning and lnspection 6-33
AssemЫy 6-34
Countershaft Needle Bearing Replacement 6-34
Shifter Pawl Lever AssemЫy 6-34
E LECT RI CA L
7 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 7-1
7 2 SPECIFICATIONS: ELECTRICAL
Specifications 7-5
7 3 SYSTEM FUSES AND RELAYS
Main Fuse 7 -6
Removal 7 -6
lnstallation 7-6
System Fuses and Relays 7-6
Removal 7 -6
1 nstallation 7-6
Fuse Blocks 7-6
Main Fuse Holder 7-6
System Fuse Block 7-6
7 4 ELECTRONIC CONTROL MODULE (ЕСМ)
ЕСМ 7-7
Removal 7-7
lnstallation 7-7
7 5 BODY CONTROL MODULE (ВСМ)
Removal 7 -8
lnstallation 7-8
7 6 ELECTRICAL CADDIES
Fairing and Steering Head Caddies 7-9
Тор Caddy 7-9
Removal 7-9
lnstallation 7 -9
Left Side Caddy 7-9
Removal 7-9
lnstallation 7-1 О
Right Side Caddy 7-10
Removal 7-10
lnstallation 7-11
Battery Tray 7-11
Removal 7-11
lnstallation 7-11
7 7 IGNITION COIL
Spark Plug С аЫе lnspection 7-13
Removal 7-13
lnstallation 7 -13
7 8 STARTER
General 7-15
Removal 7-15
Drive AssemЫy 7-15
DisassemЫy 7-15
lnspection 7-15
AssemЫy 7-16
Solenoid 7-16
TABLE OF CONTENTS
Cover and Plunger Removal 7-16
Short Post Contact: Starter 7 -16
Long Post Contact: Battery Positive 7-17
Plunger and Cover lnstallation 7-17
lnstallation 7-17
7 9 HEADLAMP
Headlamp: AII But FLTR Models 7-19
Removal 7-19
lnstallation 7 -19
Bulb Replacement: Halogen Туре 7-19
Bulb Replacement: LED Туре 7-19
Headlamp: FLTR Models 7-19
Removal 7-19
lnstallation 7 -20
7 10 AUXILIARY/FOG LAMPS AND
BRACKETS
Auxiliary/Fog Lamp Bulb Replacement 7-21
Removal 7-21
lnstallation 7-21
Auxiliary/Fog Lamp Housing 7-21
Removal 7-21
lnstallation 7-22
Turn Signal/Auxiliary/Fog Lamp Bracket 7-22
Removal 7-22
lnstallation 7-23
Adjustment 7 -23
7 11 REAR LIGHTING
Tail Lamp Bulb Replacement 7-24
Removal 7-24
lnstallation 7-24
Tail Lamp Base 7 -24
Removal 7 -24
lnstallation 7-25
Rear Fender Lights Harness: all except FLHX/S,
FLTRX/S 7-25
Removal 7-25
lnstallation 7-26
Rear Fascia Lamp 7 -27
Removal 7 -27
lnstallation 7 -27
Rear Fender Lights Harness: FLHX/S, FLTRX/S 7-27
Removal 7-27
lnstallation 7 -27
7 12 FENDER TIP LAMPS
Front Fender Tip Lamp 7-29
Removal 7-29
lnstallation 7-29
Rear Fender Tip Lamp 7-30
Removal 7-30
lnstallation 7-30
7 13 TOUR-PAK LIGHTS
Tour-Pak Side Lamps/Trim Strips 7-31
Removal 7 -31
lnstallation 7-31
Tour-Pak Lights Harness 7 -31
Removal 7-31
TABLE OF CONTENTS ХШ
TABLE OF CONTENTS
lnstallation 7 -31
Wrap-Around Lamp (if equipped) 7-33
Removal 7-33
Repair 7-33
lnstallation 7-33
7 14 TURN SIGNAL LAMPS
Turn Signal Bulb Replacement: Bullet Style 7-34
Turn Signal Bulb Replacement: Flat Lens Style 7-34
Front Turn Signal Lamp 7-34
Removal: Flat Lens Style 7-34
lnstallation: Flat Lens Style 7-35
Removal: Bullet Style, Fork Mounted 7-35
lnstallation: Bullet Style, Fork Mounted 7-36
Removal: Bullet Style, Fairing Mounted 7-37
lnstallation: Bullet Style, Fairing Mounted 7-37
Rear Turn Signal Lamp 7 -38
Removal: AII but FLHX/S, FLTRX/S 7-38
lnstallation : AII but FLHX/S, FLTRX/S 7-38
Removal: FLHX/S, FLTRX/S 7-39
lnstallation: FLHX/S, FL TRX/S 7-39
Lamp Repair 7-40
Rear Turn Signal Lamps Bracket 7 -40
Removal: AII but FLHX/S, FLTRX/S 7-40
lnstallation : AII but FLHX/S, FLTRX/S 7-40
Removal: FLHX/S, FLTRX/S 7-41
lnstallation : FLHX/S, FLTRX/S 7-42
7 15 IGNITION SWITCH AND FORK LOCK
Fairing Models 7-43
Removal 7 -43
lnstallation 7-44
Road King Models 7-44
lgnition/Light Кеу Switch: Removal 7-44
lgnition/Light Кеу Switch: lnstallation 7-45
Fork Lock: Removal 7-45
Fork Lock: lnstallation 7 -45
7 16 ACCESSORY SWIТCHES
Fork Mounted Fairing Models 7-46
Removal 7-46
lnstallation 7-46
Frame Mounted Fairing Models 7 -46
Removal 7-46
lnstallation 7 -47
Nacelle Switches 7-47
Removal 7-47
lnstallation 7 -47
7 17 CRANKSHAFT POSITION SENSOR
(СКР)
General 7-48
Removal 7-48
lnstallation 7-48
7 18 ENGINE TEMPERATURE SENSOR (ЕТ)
Removal 7-49
lnstallation 7-49
XIV TABLE OF CONTENTS
7 19 AUTOMATIC COMPRESSION RELEASE
(ACR)
General 7-50
Removal 7 -50
lnstallation 7-51
7 20 VOLTAGE REGULATOR
Removal 7 -52
lnstallation 7-52
7 21 ALTERNATOR
Removal 7-54
Cleaning and lnspection 7 -54
lnstallation 7 -55
7 22 VEHICLE SPEED SENSOR (VSS)
VSS 7-56
Removal 7-56
lnstallation 7-56
7 23 WHEEL SPEED SENSORS
Front Wheel Speed Sensor (WSS) 7-57
Removal 7-57
lnstallation 7-57
Rear Wheel Speed Sensor 7 -58
Removal 7-58
lnstallation 7-58
7 24 NEUTRAL SWITCH
Removal 7-59
lnstallation 7-59
7 25 PRESSU SWITCH OR SENDER
Removal 7-60
lnstallation 7 -60
7 26 STOP LAMP SWITCHES
Front Stop Lamp Switch 7 -61
Removal/lnstallation 7-61
Rear Stop Lamp Switch 7-61
Removal 7-61
lnstallation 7-61
7 27 HORN
lnspection 7 -62
Removal 7 -62
lnstallation 7 -62
7 28 FAIRING POWER OUTLET
TrouЫeshooting 7-64
Removal 7-64
lnstallation 7-64
7 29 GAUGES AND INSTRUMENTS: FAIRING
MODELS
2-lnch Diameter Gauges 7-65
Removal 7 -65
lnstallation 7-65
Speedometer/Tachometer lnstrument Cluster: Fork Mounted
Fairing 7-65
Removal 7-65
lnstallation 7-65
Speedometer/Тachometer lnstrument Cluster: Frame Mounted
Fairing 7-66
Removal 7-66
1 nstallation 7-66
7 30 GAUGES AND INSTRUMENTS: ROAD
КING MODELS
Fuel Gauge 7-67
Removal 7-67
l nstallation 7-67
Speedometer 7 -67
Removal 7-67
lnstallation 7-68
7 31 INDICATOR LAMPS: ROAD КING
MODELS
lndicator Lamps 7-69
Removal 7-69
lnstallation 7 -69
7 32 ВООМ ! ВОХ INFOTAINMENT SYSTEM
Radio Face Protective Film 7-70
Replacement 7 -70
Radio: Fork Mounted Fairing 7-70
Removal 7-70
lnstallation 7-70
СВ Module: Fork Mounted Fairing 7-71
Removal 7-71
l nstallation 7-71
СВ Module Bracket 7-72
Front Fairing Speakers: Fork Mounted Fairing 7-72
Removal 7 -72
l nstallation 7-72
Speaker Grille 7-72
Radio: Frame Mounted Fairing 7-73
Removal 7-73
lnstallation 7-73
Front Fairing Speaker and Enclosure: Frame Mounted
Fairing 7-74
Speaker Grille 7-74
Speaker Only 7-74
Speaker Enclosure Removal 7-75
Speaker Enclosure lnstallation 7-75
Rear Speaker Enclosures 7-75
Removal 7-75
l nstallation 7-76
DisassemЫ y 7-76
AssemЫy 7-76
Passenger Audio Controls 7-77
Rider Headset Connector 7 -77
Removal 7-77
l nstallation 7-77
7 33 ANTENNA CABLES
Removal 7-78
Main С аЫе 7-78
С аЫе Extension: Models with Tour-Pak 7-78
TABLE O F CONTENTS
С а Ые Extension: FLHX/S, FLTRX/S 7-78
lnstallation 7-78
Main С а Ые 7-78
С аЫе Extension: Models with Tour-Pak 7-79
С аЫе Extension: FLHX/S, FLTRX/S 7-79
7 34 WIRE TROUGH
Removal 7-81
lnsta/lation 7-82
7 35 MAIN WIRING HARNESS
AmЬient Air Temperature Sensor 7-83
Remova/ : AII Models (Part 1) 7-83
Removal: Road King Models (Part 2) 7-83
Removal: Fork Mounted Fairing Models (Part 2) 7-84
Remova/: Frame Mounted Fairing Models (Part 2) 7-85
Removal: AII Models (Part 3) 7-86
lnstallation: AII Models (Part 1 ) 7-88
lnstallation: Road King Models (Part 2) 7-90
l nstallation: Fork Mounted Fairing Models (Part 2) 7-90
l nstallation: Frame Mounted Fairing Models (Part 2) 7-91
lnstallation: AII Models (Part 3) 7-91
7 36 FAIRING HARNESS
Harness Service: Fork Mounted Fairing 7-92
Removal 7 -92
Repair 7-92
1 nstallation 7-93
Harness Service: Frame Mounted Fairing 7-93
Removal 7-93
lnstallation 7-94
7 37 HANDLEBAR SWITCH PACKS
Removal 7-95
Handlebar Controls 7-95
lnstallation 7-96
Right Handlebar Controls 7-96
Left Handlebar Controls 7-97
Switch Pack Harness 7-98
Removal 7-98
lnstallation 7-99
Handlebar Switch Caps 7-99
7 38 HFSM MAINTENANCE
General 7-101
Fob Battery 7-101
Battery Replacement Schedule 7-101
Battery Replacement 7-1 О 1
Smart Siren (lf lnstalled) 7-101
Battery Replacement Schedule 7-101
Battery Replacement 7-1 О 1
HFSM Antenna 7-101
Removal 7-101
lnstallation 7 -102
7 39 PERSONAL IDENTIFICATION NUMBER
(PIN)
General 7-103
Changing The PIN 7-103
Modifying an Existing PIN 7-103
TABLE OF CONTE NTS XV
TABLE OF CONTENTS
7 40 H-DSSS ACTUATION
Sidecar Configuration 7-104
Actuation 7-104
Fob Assignment 7-104
7 41 SECURIТY SIREN
Removal 7-105
lnstallation 7-105
A PPEND IX А CONNECT O R RE PA I R
А 1 AUTOFUSE UNSEALED ELECTRICAL
CONNECTORS
Autofuse Unsealed Connector Repair A-1
General A -1
DisassemЫy A-1
AssemЫy A-1
А 2 BOSCH С О М РАСТ 1 1 М CONNECTOR
Bosch Compact 1 1 М Connector А-2
General A-2
Housings A-2
Removing Socket Terminal A-2
lnstalling Socket Terminal A-2
А З BOSCH ВТС SEALED CONNECTOR
Bosch ВТС Sealed Connector Repair А-3
Plugging and Unplugging Connector А-3
Removing and lnstalling Connector Cover A-3
Removing and lnstalling Wire Terminals A-4
Crimping Terminals to Leads А -5
А 4 DELPHI 1 OOW MICRO-PACK SEALED
CONNECTOR
Delphi 1 00W Micro-Pack Sealed Connector Repair А -6
General A-6
Separating Socket Housing From ЕСМ А-6
Mating Socket Housing То ЕСМ А -6
Removing Socket Terminal A -6
lnstalling Socket Terminal A -6
Crimping Terminals A-7
А 5 DELPHI 150 METRI-PACK SEALED
CONNECTORS
Delphi 150 Metri-Pack Sealed Connector Repair А-8
General A-8
Separating Pin and Socket Housings А-8
Mating Pin and Socket Housings А-8
Removing Socket Terminal А -8
lnserting Socket Terminal A-8
А 6 DELPHI 280 METRI-PACK UNSEALED
CONNECTORS
Fuse Block Repair А -1 О
Removing Socket Terminals А-1 О
lnstalling Socket Terminals A-10
Crimping Terminals А -1О
XVI TABLE O F CONTENTS
А 7 DELPHI 480 METRI-PACK UNSEALED
CONNECTORS
Delphi 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
А 8 DELPHI 630 METRI-PACK UNSEALED
CONNECTORS
Delphi 630 Metri-Pack Unsealed Connector Repair A-12
Separating Pin and Socket Housings A-12
Mating Pin and Socket Housings A-12
Removing Socket Terminal A -12
lnstalling Socket Terminal A -12
А 9 DELPHI 800 METRI-PACK SEALED MAIN
FUSE HOUSING
Delphi 800 Metri-Pack Sealed Main Fuse Housing
Repair A-13
Removing Socket Terminals А-13
lnstalling Socket Terminals A-13
А 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 lnsulation/Seal А-15
lnspecting Crimps А-15
А 11 DELPHI MICRO 64 SEALED
CONNECTORS
Delphi Micro 64 Sealed Connector Repair A-16
General A-16
Separating Pin and Socket Housings A-16
Mating Pin and Socket Housings A-16
Removing Terminal A -16
lnstalling Terminal A -17
Preparing Wire Leads for Crimping A-17
Crimping Terminals А -17
lnspecting Crimps А -17
12 DELPHI GT 150 SEALED
CONNECTORS
Delphi GT 150 Sealed Connector Repair А-19
General A-19
Separating Pin and Socket Housings A-19
Mating Pin and Socket Housings А-19
Removing Socket Terminals А-19
lnstalling Socket Terminals А-19
А 1 З DEUTSCH DT SEALED CONNECTORS
Deutsch DT Sealed Connector Repair A -21
General A-21
Separating Pin and Socket Housings A-21
Mating Pin and Socket Housings A-21
Removing Socket Terminals A -21
lnstalling Socket Terminals A -21
Removing Pin Terminals A-22
lnstalling Pin Terminals A-23
Crimping Terminals A -23
А 1 4 DEUTSCH DT SEALED TERMINAL
REPAIR
Deutsch DT Sealed Terminal Crimps А-25
Preparing Wire Leads for Crimping A-25
Crimping Terminal to Lead A-25
lnspecting Crimps A-25
А 15 DEUTSCH DTM SEALED MINI
TERMINAL REPAIR
Deutsch DTM Sealed Mini Terminal Crimps А-26
Preparing Wire Leads for Crimping A -26
Crimping а Mini Terminal to Wire Lead A-26
ln specting Crimps A- 26
А 16 DEUTSCH DTM SEALED SOLID
8ARREL MINI TERMINAL REPAIR
Deutsch DTM Sealed Solid Barrel Terminal Crimps А-27
Preparing Wire Leads For Crimping A -27
Adjusting Crimper Tool A-27
Crimping а Barrel Contact То Wire Lead A- 27
lnspecting Crimps A-27
А 17 JAE МХ19 SEALED CONNECTORS
JAE МХ19 Sealed Connectors A -29
Connector Housings A-29
Removing Terminals A-29
lnstalling Terminals A-29
Crimping Terminals A-29
А 18 MOLEX С М С SEALED CONNECTORS
Molex СМС Sealed Connectors А-30
Separating the Connector A-30
Removing Terminals A-30
l nstalling Terminals A-30
Crimping Terminals A -31
А 19 MOLEX МХ 150 SEALED
CONNECTORS
Molex МХ 150 Sealed Connector Repair А-32
Separating Pin and Socket Housings А-32
Mating Pin and Socket Housings А-32
Removing Terminals A-32
l nstalling Terminals A-32
Crimp Terminal to Lead A-33
Prepare Lead A -33
Prepare Tool A-33
Position Terminal in the Punch/Die А-34
l n sert Stripped Lead A-34
Crimp Terminal to Lead A-34
l nspect Crimp A-35
А 20 ТУС О 040 MULTILOCK UNSEALED
CONNECTOR
Тусо 040 Multilock Unsealed Connector Repair A-36
TABLE OF CONTENTS
General A-36
Separating Pin and Socket Housings А -36
Mating Pin and Socket Housings А-36
Removing Terminals from Housing A -36
lnserting Terminals into Housing A-37
Crimping Terminals to Leads А-37
lnspecting Crimped Terminals A-37
А 21 ТУСО 070 MULTILOCK UNSEALED
CONNECTOR
Тусо 070 Multilock Unsealed Connector Repair A -38
General A-38
Separating Pin and Socket Housings А -38
Mating Pin and Socket Housings А -38
Removing Terminals from Housing A-38
lnserting Terminals into Housing A-39
Crimping Terminals to Leads А -40
lnspecting Crimped Terminals A-40
А 22 ТУСО GET 64 SEALED CONNECTOR
Тусо GET 64 Sealed Connector Repair А -41
General А -41
Housings А -41
Removing Socket Terminals А-41
lnstalling Socket Terminals A-42
Crimping Terminals A-42
А 23 ТУСО М С Р SEALED CONNECTOR
Тусо МСР Sealed Connector A -43
General A-43
Housi ng А-43
Removing the Large Terminals А -43
Removing the Small Terminals А-43
lnstalling Terminals A -44
Crimping Terminals A -44
А 24 SEALED SPLICE CONNECTORS
Sealed Splice Connector Repair А-45
General A-45
Preparing Wire Leads A-45
Splicing Wire Leads A-45
lnspecting Seals A-45
A P PENDI X В WI RIN G
8 1 CONNECTORS
Connector Locations В-1
Function/Location B-1
Place and Color B-1
Connector Number B-1
Repair lnstructions В -1
8 2 WIRING DIAGRAMS
Wiring Diagram lnformation B-7
Wire Color Codes B-7
Wiring Diagram Symbols 8-7
2015 Touring Wiring Diagrams B-9
TABLE O F CONTENTS XVII
TABLE OF CONTENTS
A P PENDI X С CO O LING S YSTE M
С 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter C-1
С 2 SPECIFICATIONS: COOLING SYSTEM
General C- 2
С З COOLING SYSTEM OPERATION
Operation С-3
С 4 TESTING AND DIAGNOSTICS
TrouЫeshooting C-4
Low Engine Temperature С-4
High Engine Temperature С-4
Coolant Leaks С-4
Pressure Сар Test С-4
System Pressure Test C-4
Leak Detection Dye Test С-5
С 5 COOLING SYSTEM REPAIR
Crimp Clamps С-6
Removal C- 6
1 nstallation С-6
Coolant Bottle С-6
Removal С-6
1 nstallation С-6
Upper Coolant Line Removal C-7
Hose and Manifold Removal C-7
Cylinder Head Coolant Lines and Adapters C-7
Upper Coolant Line lnstallation C-8
Cylinder Head Coolant Lines and Adapters C- 8
Hose and Manifold lnstallation C-8
Coolant Down Tubes С-8
Removal С-8
lnstallation C-8
Horizontal Coolant Tube С-9
ХVШ TABLE OF CONTENTS
Removal С-9
lnstallation C-9
Radiator С-9
Removal С-9
lnstallation C-9
Coolant Distribution Components C-1 О
Coolant Pump/Thermostat Removal C- 1 0
Coolant Pump/Тhermostat lnstallation C- 1 О
Coolant Temperature Sensor C-12
Cooling Fan C-13
Removal С-13
1 nstallation С-13
A P PENDI X D REFE RENCE
D 1 METRIC CONVERSION
Conversion ТаЫе D-1
D 2 Ю CONVERSION
United States System D- 2
Metric System D- 2
British lmperial System D-2
D З TORQUE CONVERSION
United States System D-3
Metric System D-3
D 4 GLOSSARY
Acronyms and Abbreviations D-4
REFE RENCE MATE RIA L
TOOLS I
TORQUE VALUES IX
INDEX X XIX

2015 HARLEY-DAVIDSON TOURING SERVICE MANUAL – PDF DOWNLOAD:

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
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