Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual - page 1

MAINTENANCE

1.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................1-1

1.2 GENERAL

Servicing a New Motorcycle...............................................1-4
Safe Operating Maintenance..............................................1-4
Disposal and Recycling......................................................1-4
Shop Practices....................................................................1-4

Repair Notes................................................................1-4
Safety..........................................................................1-4
Removing Parts...........................................................1-4
Cleaning......................................................................1-4
Disassembly and Assembly........................................1-5
Checking Torques on Fasteners..................................1-5
Magnetic Parts Trays...................................................1-5

Repair and Replacement Procedures................................1-5

Hardware and Threaded Parts....................................1-5
Threadlocking Agents..................................................1-5
Wiring, Hoses and Lines.............................................1-5
Instruments and Gauges.............................................1-5
Bearings......................................................................1-5
Bushings......................................................................1-5
Gaskets.......................................................................1-5
Lip-Type Seals.............................................................1-6
O-Rings.......................................................................1-6
Gears...........................................................................1-6
Shafts..........................................................................1-6
Part Replacement........................................................1-6

Cleaning..............................................................................1-6

Part Protection.............................................................1-6
Cleaning Process........................................................1-6
Rust or Corrosion Removal.........................................1-6
Bearings......................................................................1-6

Tool Safety..........................................................................1-6

Air Tools.......................................................................1-6
Wrenches....................................................................1-6
Pliers/Cutters/Pry Bars................................................1-7
Hammers.....................................................................1-7
Punches/Chisels..........................................................1-7
Screwdrivers................................................................1-7
Ratchets and Handles.................................................1-7
Sockets........................................................................1-7
Storage Units...............................................................1-7

1.3 FUEL AND OIL

Fuel.....................................................................................1-8
Gasoline Blends..................................................................1-8
Engine Lubrication..............................................................1-8
Winter Lubrication...............................................................1-9

1.4 BULB REQUIREMENTS

General.............................................................................1-10

1.5 MAINTENANCE SCHEDULE

General.............................................................................1-11

Disposal and Recycling.............................................1-11

1.6 ENGINE OIL AND FILTER

Checking and Adding Oil..................................................1-16

Type of Oil.................................................................1-16
Checking Oil Level.....................................................1-16

Changing Oil and Filter.....................................................1-16

1.7 AIR CLEANER AND EXHAUST SYSTEM

Removal............................................................................1-18

Cleaning and Inspection............................................1-18

Installation.........................................................................1-19
Exhaust System Leak Check............................................1-20

Exhaust System Leakage..........................................1-20

1.8 TIRES AND WHEELS

General.............................................................................1-21
Tires..................................................................................1-21
Tire Replacement.............................................................1-22

Inspection..................................................................1-22
When To Replace Tires.............................................1-22

Wheel Bearings................................................................1-22
Wheel Spokes...................................................................1-22

Identify Wheel Spoke Groups....................................1-23
Wheel Spoke Adjustment..........................................1-23

1.9 PRIMARY CHAINCASE LUBRICANT

General.............................................................................1-24
Changing Primary Chaincase Lubricant...........................1-24

1.10 TRANSMISSION LUBRICANT

Transmission Lubricant.....................................................1-26
Changing Transmission Lubricant....................................1-26

1.11 CLUTCH

Adjustment........................................................................1-28

1.12 DRIVE BELT AND SPROCKETS

General.............................................................................1-30
Cleaning............................................................................1-30
Inspection.........................................................................1-30

Sprockets...................................................................1-30
Drive Belt...................................................................1-30

Checking Belt Deflection...................................................1-31
Adjusting Belt Deflection...................................................1-32

1.13 THROTTLE CABLES

Cable Inspection, Lubrication and Adjustment.................1-34

Inspection and Lubrication........................................1-34
Adjustment.................................................................1-34

1.14 CABLE AND CHASSIS LUBRICATION

General.............................................................................1-36
Cables and Hand Levers..................................................1-36
Jiffy Stand.........................................................................1-36
Steering Head Bearings....................................................1-36

1.15 BRAKES

Fluid Inspection.................................................................1-37
Rear Brake Pedal.............................................................1-37

Pedal Height..............................................................1-37
Pedal Lubrication.......................................................1-37
Pedal Pad..................................................................1-37

Brake Lines Inspection.....................................................1-37

1.16 BRAKE PADS AND DISCS

Inspection.........................................................................1-39

Brake Pads................................................................1-39
Brake Disc.................................................................1-39

Brake Pad Replacement...................................................1-40

Rear Brake Caliper....................................................1-40
Front Brake Caliper...................................................1-41

III

T

ABLE

OF

CONTENTS

1.17 SPARK PLUGS

Removal............................................................................1-43
Inspection.........................................................................1-43
Cleaning............................................................................1-43
Installation.........................................................................1-43
Spark Plug Cable Inspection............................................1-44

1.18 STEERING HEAD BEARINGS

Adjustment: FLSTC, FLSTF/B, FLSTN, FLS....................1-45

Bearing Adjustment (Fall-away)................................1-45

Adjustment: FXST, FXS....................................................1-46

Bearing Adjustment (Fall-away)................................1-46

Adjustment: FXSB............................................................1-48

Bearing Adjustment (Fall-away)................................1-48

Lubrication........................................................................1-49

1.19 CRITICAL FASTENERS

Inspection.........................................................................1-50

Checking Fastener Torque........................................1-50

1.20 BATTERY MAINTENANCE

General.............................................................................1-51
Cleaning and Inspection...................................................1-52
Voltmeter Test...................................................................1-52

Voltmeter Test............................................................1-52

Charging Battery...............................................................1-52

Safety Precautions....................................................1-52
Using a Battery Charger............................................1-52

Disconnection and Removal.............................................1-53
Storage.............................................................................1-53
Installation and Connection..............................................1-54

1.21 HEADLAMP ALIGNMENT

Headlamp Alignment........................................................1-56
Headlamp Adjustment......................................................1-56

1.22 SUSPENSION ADJUSTMENTS

Shock Absorbers..............................................................1-58

Calculate Number of Turns........................................1-58
Adjustment.................................................................1-58

1.23 STORAGE

General.............................................................................1-59
Placing in Storage.............................................................1-59
Removal from Storage......................................................1-59

1.24 TROUBLESHOOTING

General.............................................................................1-61
Engine...............................................................................1-61

Starter Motor Does Not Operate or Does Not Turn Engine
Over ..........................................................................1-61
Engine Turns Over But Does Not Start ....................1-61
Starts Hard................................................................1-61
Starts But Runs Irregularly or Misses .......................1-61
A Spark Plug Fouls Repeatedly................................1-62
Pre-Ignition or Detonation (Knocks or Pings)............1-62
Overheating...............................................................1-62
Valve Train Noise.......................................................1-62
Excessive Vibration...................................................1-62
Check Engine Light Illuminates During Operation.....1-62

Lubrication System...........................................................1-62

Oil Does Not Return To Oil Tank...............................1-62
Engine Uses Too Much Oil Or Smokes Excessively..1-62
Engine Leaks Oil From Cases, Pushrods, Hoses,
Etc.............................................................................1-62
Low Oil Pressure.......................................................1-63
High Oil Pressure......................................................1-63

Electrical System..............................................................1-63

Alternator Does Not Charge......................................1-63
Alternator Charge Rate Is Below Normal..................1-63
Speedometer Operates Erratically............................1-63

Transmission....................................................................1-63

Shifts Hard.................................................................1-63
Jumps Out Of Gear...................................................1-63
Clutch Slips................................................................1-63
Clutch Drags Or Does Not Release..........................1-63
Clutch Chatters..........................................................1-63

Handling............................................................................1-63

Irregularities...............................................................1-63

Brakes...............................................................................1-63

Brake Does Not Hold Normally.................................1-63

CHASSIS

2.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................2-1

2.2 SPECIFICATIONS

Specifications......................................................................2-5

Chassis Specifications................................................2-5
Tire Specifications.......................................................2-6

2.3 VEHICLE IDENTIFICATION NUMBER
(V.I.N.)

Vehicle Identification Number.............................................2-9

2.4 FRONT WHEEL

Removal............................................................................2-11
Disassembly.....................................................................2-11

Disc Wheel................................................................2-11
Laced Wheel..............................................................2-11

Cleaning and Inspection...................................................2-13
Assembly..........................................................................2-13

Disc Wheel................................................................2-13
Laced Wheel..............................................................2-14

Installation.........................................................................2-14

2.5 REAR WHEEL

Removal............................................................................2-15
Disassembly.....................................................................2-15
Cleaning and Inspection...................................................2-16
Assembly..........................................................................2-16
Installation.........................................................................2-17

2.6 WHEEL LACING

Wheel Lacing: Angle Flange Hub.....................................2-18

2.7 CHECKING AND TRUING WHEELS

General.............................................................................2-20
Checking Wheel Runout...................................................2-20

Checking Radial Runout............................................2-20

IV TABLE OF CONTENTS

TABLE OF CONTENTS

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

Inspection.........................................................................2-25
Removal............................................................................2-25
Installation.........................................................................2-27

2.9 TIRES

General.............................................................................2-29
Removal............................................................................2-29
Cleaning, Inspection and Repair......................................2-29
Installation.........................................................................2-30

Tube Type Tires.........................................................2-30
Tubeless Tires: Cast Wheels.....................................2-30
Tubeless Tires: Laced Wheels..................................2-31

Checking Tire Runout.......................................................2-32

Lateral Runout...........................................................2-32
Radial Runout............................................................2-32

Wheel Balancing...............................................................2-33

Static vs Dynamic......................................................2-33
Weights......................................................................2-33

2.10 VEHICLE ALIGNMENT

Axle Alignment..................................................................2-34

Checking Axle Alignment..........................................2-34
Adjusting Axle Alignment...........................................2-35

2.11 FRONT BRAKE MASTER CYLINDER

General.............................................................................2-36
Removal and Disassembly...............................................2-36
Cleaning and Inspection...................................................2-38
Assembly and Installation.................................................2-38

2.12 FRONT BRAKE CALIPER

Removal............................................................................2-40
Disassembly.....................................................................2-40
Cleaning, Inspection and Repair......................................2-42
Assembly..........................................................................2-43
Installation.........................................................................2-44

2.13 REAR BRAKE MASTER CYLINDER

General.............................................................................2-45
Removal............................................................................2-45
Disassembly.....................................................................2-45
Cleaning and Inspection...................................................2-46
Assembly..........................................................................2-46
Installation.........................................................................2-47

2.14 REAR BRAKE CALIPER

Removal............................................................................2-51
Disassembly.....................................................................2-51
Cleaning, Inspection and Repair......................................2-53
Assembly..........................................................................2-54
Rear Brake Line Routing..................................................2-54
Installation.........................................................................2-54

2.15 BLEEDING BRAKES

General.............................................................................2-56
Procedure.........................................................................2-56

2.16 FRONT FORK: TELESCOPIC

General.............................................................................2-58
Replacing Fork Oil............................................................2-58
Removal............................................................................2-59
Disassembly.....................................................................2-59
Cleaning and Inspection...................................................2-59
Assembly..........................................................................2-64
Installation.........................................................................2-64

2.17 STEERING HEAD

Removal............................................................................2-65

FLSTC, FLSTF/B, FLSTN, FLS Models....................2-65
FXST Model...............................................................2-65
FXS, FXSB Models....................................................2-65

Inspection.........................................................................2-66

All Models..................................................................2-66

Disassembly.....................................................................2-67

Removing Lower Bearings From Fork Stem.............2-67
Steering Head Bearing Race Removal.....................2-67

Assembly..........................................................................2-67
Installation.........................................................................2-68

FLSTC, FLSTF/B, FLSTN, FLS Models....................2-68
FXST Models.............................................................2-68
FXS, FXSB Models....................................................2-68

2.18 BELT GUARD AND DEBRIS
DEFLECTOR

Removal............................................................................2-69

Belt Guard.................................................................2-69
Debris Deflector.........................................................2-69

Installation.........................................................................2-69

Belt Guard.................................................................2-69
Debris Deflector.........................................................2-69

2.19 REAR SHOCK ABSORBERS

General.............................................................................2-70
Removal............................................................................2-70
Installation.........................................................................2-70
Shock Disposal.................................................................2-71

2.20 REAR FORK

Removal............................................................................2-73
Cleaning and Inspection...................................................2-74
Pivot Bearing Replacement..............................................2-74
Installation.........................................................................2-75

2.21 THROTTLE CONTROL

Removal/Disassembly......................................................2-76
Cleaning and Inspection...................................................2-76
Assembly/Installation........................................................2-76

2.22 CLUTCH CONTROL

Removal............................................................................2-78
Installation.........................................................................2-78

TABLE OF CONTENTS V

TABLE OF CONTENTS

2.23 HANDLEBARS: FLSTC, FLSTN, FLS,
FXST

Removal............................................................................2-80
Installation.........................................................................2-81

2.24 HANDLEBARS: FLSTF/B

Removal............................................................................2-82
Installation.........................................................................2-83

2.25 HANDLEBARS: FXS

Removal............................................................................2-86
Installation.........................................................................2-86

2.26 HANDLEBARS: FXSB

Removal............................................................................2-88

Handlebars................................................................2-88
Lower Handlebar Clamps..........................................2-88

Installation.........................................................................2-88

Lower Clamp.............................................................2-88
Handlebars................................................................2-89
Return to Service.......................................................2-90

2.27 FRONT FENDER

Removal............................................................................2-91
Installation.........................................................................2-92

2.28 REAR FENDER: FLSTC

Removal............................................................................2-93
Installation.........................................................................2-93

2.29 REAR FENDER: FLSTF/B

Removal............................................................................2-95
Installation.........................................................................2-95

2.30 REAR FENDER: FXST

Removal............................................................................2-96
Installation.........................................................................2-96

2.31 REAR FENDER: FLS, FXS

Removal............................................................................2-98
Installation.........................................................................2-98

License Plate Bracket Assembly and Installation: FXS,
FLS (all but Domestic and California models)...........2-98
License Plate Bracket Assembly and Installation: FLS
(Domestic and California models).............................2-99
Fender Installation.....................................................2-99

2.32 REAR FENDER: FXSB

Removal..........................................................................2-101
Installation.......................................................................2-102

2.33 REAR FENDER: FLSTN

Removal..........................................................................2-103
Disassembly...................................................................2-103
Assembly........................................................................2-105
Installation.......................................................................2-105

2.34 REAR FENDER WIRE CONDUIT

Installation.......................................................................2-106

2.35 FOOTBOARDS AND FOOTRESTS

Rider Footboards............................................................2-107

Removal..................................................................2-107
Installation...............................................................2-107

Rider Footrest.................................................................2-107

Removal..................................................................2-107
Installation...............................................................2-107

Passenger Footrest........................................................2-107

Removal..................................................................2-107
Installation...............................................................2-108

2.36 JIFFY STAND

Cleaning..........................................................................2-109
Sensor: HDI Models........................................................2-109
Removal..........................................................................2-110
Installation.......................................................................2-110

2.37 FORK LOCK

Removal..........................................................................2-111
Installation.......................................................................2-111

2.38 SEAT AND STRAP RETENTION NUT

Replacement...................................................................2-112

2.39 SEAT: FLS, FXS, FXST, FXSB

Replacement...................................................................2-113

Removal..................................................................2-113
Installation...............................................................2-113

2.40 SEAT: FLSTN, FLSTF, FLSTFB, FLSTC

Removal and Installation................................................2-114

2.41 LUGGAGE RACK: FLSTN

Removal and Installation................................................2-115

2.42 SADDLEBAGS: FLSTC

Removal..........................................................................2-116
Installation.......................................................................2-116

2.43 WINDSHIELD: FLSTC

Removal..........................................................................2-118
Installation.......................................................................2-118

2.44 SAREE GUARD: INDIA MODELS

Left Side Removal and Installation.................................2-119

Removal..................................................................2-119
Installation...............................................................2-119

Right Side Removal and Installation...............................2-119

Removal..................................................................2-119
Installation...............................................................2-119

2.45 FRONT LICENSE PLATE BRACKET

Removal and Installation................................................2-121

2.46 MEDALLIONS, SERIALIZED BADGES
AND TANK EMBLEMS

Removal..........................................................................2-122
Installation.......................................................................2-122

VI TABLE OF CONTENTS

TABLE OF CONTENTS

2.45

FRONT LICENSE PLATE BRACKET

REMOVAL AND INSTALLATION

1.

See

Figure 2-138

. Remove fastener securing front license

plate bracket.

2.

Install

new

license plate bracket and tighten fastener finger

tight.

3.

Adjust headlamp. See

1.21 HEADLAMP ALIGNMENT

.

sm07522

Figure 2-138. Front License Plate Bracket

HOME

2013 Softail Service: Chassis 2-121

2.46

MEDALLIONS, SERIALIZED BADGES AND TANK
EMBLEMS

REMOVAL

1.

Mark location of emblem with masking tape.

NOTE

Wear protective gloves.

2.

Saw behind emblem with mono-filament fishing line or
waxed dental floss to remove emblem.

3.

Use 3M GENERAL PURPOSE ADHESIVE REMOVER to
remove remaining foam backing tape and adhesive from
mounting surface.

NOTE

For maximum bond, the surface must be clean and dry.

4.

Clean with a mixture of 50 percent isopropyl alcohol and
50 percent distilled water.

NOTE

Apply medallion within minutes of cleaning.

5.

Allow surface to dry.

INSTALLATION

NOTES

•

Apply in ambient temperatures between 70-100 °F (21-38
°C).

•

Do not remove protective film from adhesive until ready
to apply.

•

Do not bend emblem to fit contour of mounting surface.

1.

Test fit medallion in intended location

a.

Check medallion against curve of mounting surface.

b.

Match left and right sides of fuel tank.

NOTES

•

Protect adhesive from grease, oil, dust, dirt and finger
prints.

•

Once applied, do not shift the medallion.

•

The adhesive bonds in 72 hours at room temperature.

2.

Remove protective film from back of medallion.

3.

Apply even pressure across the entire surface with palms
and fingers of both hands. Hold in place for 15 seconds.

4.

Wait 20 minutes before touching medallion.

5.

Wait 24 hours before washing.

HOME

2-122 2013 Softail Service: Chassis

TABLE OF CONTENTS

SUBJECT

............................................................................................................................

PAGE NO.

3.1 FASTENER TORQUE VALUES.................................................................................................3-1
3.2 SPECIFICATIONS.....................................................................................................................3-3
3.3 SERVICE WEAR LIMITS...........................................................................................................3-5
3.4 ENGINE OIL FLOW...................................................................................................................3-7
3.5 OIL PUMP OPERATION..........................................................................................................3-13
3.6 BREATHER OPERATION........................................................................................................3-15
3.7 OIL PRESSURE......................................................................................................................3-16
3.8 TROUBLESHOOTING.............................................................................................................3-18
3.9 HOW TO USE THIS SECTION................................................................................................3-20
3.10 TOP END SERVICE..............................................................................................................3-21
3.11 CAM COMPARTMENT SERVICE..........................................................................................3-23
3.12 STRIPPING MOTORCYCLE FOR SERVICE........................................................................3-25
3.13 ASSEMBLING MOTORCYCLE AFTER SERVICE................................................................3-26
3.14 REMOVING ENGINE FROM CHASSIS................................................................................3-27
3.15 INSTALLING ENGINE IN CHASSIS......................................................................................3-28
3.16 TOP END OVERHAUL: DISASSEMBLY...............................................................................3-30
3.17 BREATHER ASSEMBLY........................................................................................................3-36
3.18 ROCKER ARM SUPPORT PLATE........................................................................................3-37
3.19 PUSHRODS, LIFTERS AND COVERS.................................................................................3-40
3.20 CYLINDER HEAD..................................................................................................................3-42
3.21 CYLINDER.............................................................................................................................3-52
3.22 PISTON..................................................................................................................................3-56
3.23 TOP END OVERHAUL: ASSEMBLY.....................................................................................3-60
3.24 CAM COMPARTMENT AND COMPONENTS.......................................................................3-70
3.25 OIL PUMP..............................................................................................................................3-82
3.26 CRANKCASE DISASSEMBLY AND REPAIR........................................................................3-84
3.27 FLYWHEEL AND CONNECTING RODS...............................................................................3-94
3.28 COUNTERBALANCER ASSEMBLY REPAIR.......................................................................3-97
3.29 CRANKCASE ASSEMBLY..................................................................................................3-102
3.30 OIL TANK: ALL BUT FXSB..................................................................................................3-108
3.31 OIL TANK: FXSB..................................................................................................................3-112

ENGINE