Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual - page 8

SUBJECT

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PAGE NO.

E.1 GLOSSARY...............................................................................................................................E-1

APPENDIX

GLOSSAR

E.1

GLOSSARY

ACRONYMS AND ABBREVIATIONS

Table E-1. Acronyms and Abbreviations

DESCRIPTION

ACRONYM OR ABBREVIATION

Amperes

Ambient air temperature

AAT

Anti-lock braking system

ABS

Alternating current

Accessory position on ignition switch

ACC

Automatic compression release

ACR

Absorbed glass mat (battery)

AGM

Ampere-hour

Active Intake Solenoid

AIS

American wire gauge

AWG

Battery voltage

B+

Bar

bar

Bank angle sensor

BAS

Body control module

BCM

Breakout box

BOB

Before top dead center

BTDC

Celsius (Centigrade)

°C

California

Calibration

CAL

Controller area network

CAN

Cubic centimeters

Cold cranking amps

CCA

Counterclockwise

CCW

Crankshaft position

CKP

Centimeters

Cubic centimeters

Clockwise

Direct current

Data link connector

DLC

Domestic

DOM

Department of Transportation

DOT

Diagnostic trouble code

DTC

Digital volt ohm meter

DVOM

Electronic control module

ECM

Engine coolant temperature

ECT

Electronic Control Unit

ECU

Electrically erasable programmable read only memory

EEPROM

Electronic fuel injection

EFI

Electro Hydraulic Control Unit

EHCU

Engine temperature

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2013 Softail Service: Appendix E Glossary E-1

sm02226

1. Throttle cable
2. Throttle cam
3. Idle cable
4. Idle cable housing
5. Cam stop
6. Spring

Figure 1-27. Induction Module Cable Connection

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2013 Softail Service: Maintenance 1-35

1.14

CABLE AND CHASSIS LUBRICATION

GENERAL

Inspect and lubricate the following items according to

1.5 MAINTENANCE SCHEDULE

•

Front brake hand lever

•

Clutch hand lever

•

Throttle control cables

•

Throttle control grip sleeve

•

Clutch cable

•

Steering head bearings

•

Jiffy stand

If service is on muddy or dusty roads, clean and lubricate at
shorter intervals.

CABLES AND HAND LEVERS

For throttle cables, see

1.13 THROTTLE CABLES

Use HARLEY® LUBE for clutch lever and cable.

Use G40M BRAKE GREASE on front brake lever pin pivot hole
and on the end of piston that contacts brake lever.

JIFFY STAND

Clean and lubricate the jiffy stand. For more information, see

2.36 JIFFY STAND

STEERING HEAD BEARINGS

Lubricate the steering head bearings with HARLEY-DAVIDSON
SPECIAL PURPOSE GREASE. See

1.18 STEERING HEAD

BEARINGS

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1-36 2013 Softail Service: Maintenance

1.15

BRAKES

FLUID INSPECTION

Position vehicle for inspection.

Front brake:

Position vehicle on a flat level surface.

Turn handlebar so front brake master cylinder is
approximately level.

Always check:

rear brake fluid level on the side

stand.

See

Figure 1-28

. View reservoir sight glass and verify fluid

presence. Sight glass should appear dark if fluid is present.

If sight glass is not dark, check brake system for fluid
leaks. Check that brake pads are properly installed and
not worn beyond service wear limits. Perform any neces-
sary repairs. See

1.16 BRAKE PADS AND DISCS

Remove cover and verify fluid level. If necessary, add
HARLEY-DAVIDSON DOT 4 BRAKE FLUID to reservoir.
Replace cover. See

2.15 BLEEDING BRAKES

Front brake hand lever and rear brake foot pedal must
have a firm feel when applied. If not, bleed system using
only HARLEY-DAVIDSON DOT 4 BRAKE FLUID. See

2.15 BLEEDING BRAKES

om01509

1. Sight glass, front master cylinder reservoir
2. Sight glass, rear master cylinder reservoir

Figure 1-28. Brake Fluid Sight Glass (typical)

REAR BRAKE PEDAL

TORQUE VALUE

FASTENER

16.3-21.7 Nm

12-16 ft-lbs

Brake pedal screw, rear

Pedal Height

The rear brake pedal is nonadjustable. When brake system
components are properly assembled, brake pedal is correctly
adjusted.

Pedal Lubrication

See

Figure 1-29

. Rear brake pedal contains greaseless bush-

ings (4, 5). Replace bushings if worn.

Tighten brake pedal screw (1) to 12-16 ft-lbs (16.3-21.7 Nm).

Pedal Pad

If replacing brake pedal pad (8), slide old pad off brake pedal
(7) then slide

new

pad on pedal.

sm03054

1. Screw
2. Washer
3. O-ring
4. Bushing
5. Bushing
6. O-ring
7. Brake pedal
8. Pad
9. Cotter pin
10. Washer
11. Master cylinder pushrod
12. Clevis pin

Figure 1-29. Rear Brake Pedal (typical)

BRAKE LINES INSPECTION

Inspect brake lines for leaks, contact or abrasion. Refer to

Table 1-13

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2013 Softail Service: Maintenance 1-37

Table 1-13. Brake Line Inspection

REMEDY

INSPECTION

LINE TYPE

OK/Monitor

No marks

Steel lines

Slight mark in paint or plating*

Copper colored-paint/plating worn off*

Silver colored base material-no noticeable feel of wear*

Replace

Silver colored base material-noticeable feel of wear*

Brake fluid leak or other damage

OK/Monitor

No marks

Rubber hose

Slight dent or flattening of ribs*

Replace

Worn to bottom of ribs

Brake fluid leak or other damage

OK/Monitor

No marks

Protective cover
(steel, rubber, plastic or braided)

Slight dent in covering*

Slight dent or flattening of plastic covering*

Replace

Worn or cut-through covering-exposed brake line material

Brake fluid leak or other damage

* If there is line contact, reposition the line. If base material is visible, prevent corrosion with touch-up paint.

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1-38 2013 Softail Service: Maintenance

1.16

BRAKE PADS AND DISCS

INSPECTION

Check brake pads and discs:

•

At every scheduled service interval.

•

Whenever the components are removed during service
procedures.

Brake Pads

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

See

Figure 1-30

. Replace brake pads (3) if brake pad friction

material on either the front or rear caliper is worn to 0.04 in.
(1.02 mm) or less above the backing plate (4). Always replace
both pads in a caliper as a set. See

1.16 BRAKE PADS AND

DISCS, Brake Pad Replacement

When checking the brake pads and discs, inspect the brake
hoses for correct routing and any signs of damage.

Brake Disc

•

The minimum brake disc (2) thickness is stamped on the
side of the disc.

•

Maximum brake disc lateral runout and warpage is 0.008
in. (0.2 mm) when measured near the outside diameter.

Replace disc if badly scored or warped. See

2.4 FRONT

WHEEL

2.5 REAR WHEEL

sm02217

1. Front brake caliper (viewed from below)
2. Brake disc
3. Brake pads
4. Backing plate
5. Rear brake caliper (viewed from above)

Figure 1-30. Brake Pad Inspection

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2013 Softail Service: Maintenance 1-39

BRAKE PAD REPLACEMENT

TORQUE VALUE

FASTENER

9.0-13.6 Nm

80-120

in-lbs

Brake caliper, rear, pad pin

21.7-27.1 Nm

16-20 ft-lbs

Brake caliper, rear, mounting
fasteners

0.7-0.9 Nm

6-8

in-lbs

Brake master cylinder, rear,
reservoir cover screws

38.0-51.5 Nm

28-38 ft-lbs

Brake caliper, front, lower
mounting bolt

38.0-51.5 Nm

28-38 ft-lbs

Brake caliper, Front, Upper
mounting bolt

20.4-21.7 Nm

15-16 ft-lbs

Brake caliper, front, pad pin

1.4-1.7 Nm

12-15

in-lbs

Brake master cylinder, front,
reservoir cover screws

Rear Brake Caliper

Remove right saddlebag, if present.

ABS models:

remove cable strap securing wheel speed

sensor cable to rear brake hose at caliper.

See

Figure 1-31

. Loosen, but do not remove pad pin

(metric) (2).

Remove mounting bolt (1) and slider pin (3). Pull rear
caliper away from brake disc.

Remove pad pin (2) and pads.

NOTE

Loosening the reservoir cap will allow air to escape and help
prevent contamination. It will also help prevent fluid from
squirting out of the reservoir if the pistons are retracted too
quickly.

Loosen rear master cylinder reservoir cap.

NOTE

As the pistons are pushed back into the caliper, fluid level may
rise above the recommended 1/4 ± 1/8 in. (6.35 ± 3.18 mm)
below the gasket surface. Fluid may have to be removed to
allow for this.

Using the old brake pad and a C-clamp, retract the pistons
fully into the caliper.

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

Inspect pad pin for grooving and wear. Measure the pad
pin diameter in an unworn area. Then in the area of any
grooving or wear. If wear exceeds 0.015 in. (0.38 mm),
replace pin.

See

Figure 1-32

. Inspect torque clip. Replace if worn or

damaged.

10. See

Figure 1-33

. Inspect anti-rattle spring. Replace if worn

or damaged.

11. See

Figure 1-34

. Install

new

brake pads and pad pin. Tab

(1) must engage clip (2) in caliper housing. Tighten pad
pin to 80-120

in-lbs

(9.0-13.6 Nm).

12. See

Figure 1-31

. Install caliper. Tighten mounting bolt (1)

and slider pin (3) to 16-20 ft-lbs (21.7-27.1 Nm).

13.

ABS models:

secure wheel speed sensor cable to rear

brake hose with a cable strap near the caliper.

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

SM03916a

1. Mounting bolt
2. Pad pin
3. Slider pin

Figure 1-31. Rear Brake Caliper

sm04639a

Figure 1-32. Torque Clip

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1-40 2013 Softail Service: Maintenance

sm04627a

1. Anti-rattle spring tabs
2. Inner brake pad tab

Figure 1-33. Anti-rattle Spring

sm04625a

1. Brake pad tab
2. Torque clip

Figure 1-34. Rear Brake Pad Installation

14. Pump brake pedal to move pistons out until both brake

pads contact rotor.

15. Check brake fluid level in master cylinder. Fill to proper

level if necessary using DOT 4 BRAKE FLUID. Install
master cylinder reservoir cap. Tighten reservoir cap screws
to 6-8

in-lbs

(0.7-0.9 Nm).

16. Install right saddlebag if necessary.

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

17. Test brake system.

Turn ignition switch ON. Pump brake pedal to verify
operation of the brake lamp.

Test ride the motorcycle. If the brakes feel spongy,
bleed the system. See

2.15 BLEEDING BRAKES

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

Front Brake Caliper

See

Figure 1-35

. Loosen, but do not remove bridge

bolt/pad pin (3) (metric).

Remove both caliper mounting bolts (1, 2) (metric). Detach
caliper from front forks and brake disc.

NOTE

The brake pads have tabs that are clipped onto the pad springs.
Disengage the tabs from the pad springs as you remove the
pads.

Remove the bridge bolt/pad pin. Remove brake pads.

NOTE

Loosening the reservoir cap will allow air to escape and help
prevent contamination. It will also help prevent fluid from
squirting out of the reservoir if the pistons are retracted too
quickly.

Loosen front master cylinder reservoir cap.

NOTE

As the pistons are pushed back into the caliper, fluid level may
rise above the recommended 1/4 ± 1/8 in. (6.35 ± 3.18 mm)
below the gasket surface. Remove fluid if necessary.

Using the old brake pad and a C-clamp, retract the pistons
fully into the caliper.

Inspect bridge bolt/pad pin for grooving and wear. Measure
the pad pin diameter in an unworn area, and then in the
area of any grooving or wear. If wear exceeds 0.015 in.
(0.38 mm), replace the pin.

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

NOTES

•

See

Figure 1-36

. Make sure the pad spring tabs (1) on

brake pad engage the pad springs in the pistons.

•

If the directional tab (2) does not face down when caliper
is installed, brake noise may develop.

•

See

Figure 1-37

. Front brake pads with a white marking

on each brake pad must be used. These brake pads have
an isolator pad installed on the back of the brake pad.

Install

new

pads into caliper. The directional tab (2) must

face down when caliper is installed.

Loosely install the center bridge bolt/pad pin.

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2013 Softail Service: Maintenance 1-41

Attach caliper to front fork.

See

Figure 1-35

. Place caliper over brake disc with

bleeder valve facing upward.

ABS models:

place wheel speed sensor cable

retainer in position.

Loosely install long mounting bolt (1) (metric) into
upper hole on fork leg.

Install short mounting bolt (2) (metric) into lower hole
on fork leg. Tighten bottom mounting bolt to 28-38 ft-
lbs (38.0-51.5 Nm).

Final tighten the top mounting bolt to 28-38 ft-lbs
(38.0-51.5 Nm).

Final tighten center bridge bolt/pad pin (3) to 15-16
ft-lbs (20.4-21.7 Nm).

10. Pump brake hand lever to move pistons out until they

contact both brake pads. Verify piston location against
pads. If the front wheel is off the ground, rotate wheel to
check for excessive brake pad drag.

11. Check brake fluid level in master cylinder. Fill to proper

level if necessary using DOT 4 BRAKE FLUID. Install
master cylinder reservoir cap. Tighten reservoir cap screws
to 12-15

in-lbs

(1.4-1.7 Nm).

12. Test brake system.

Turn ignition switch ON. Pump brake hand lever to
verify operation of the brake lamp.

Test ride the motorcycle. If the brakes feel spongy,
bleed the system. See

2.15 BLEEDING BRAKES

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

sm04574a

1. Long mounting bolt (metric)
2. Short mounting bolt (metric)
3. Pad pin (metric)

Figure 1-35. Front Brake Caliper (Left Side Shown)

sm04031b

1. Pad spring tabs
2. Directional tab
3. Front brake pad

Figure 1-36. Front Brake Pads

sm06990a

Figure 1-37. Softail Front Pad Indicator Markings

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