Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual - page 40

6-6 2013 Softail Service: Transmission

sm02280a

Washer (FXS/B)

Pinch bolt, front (all but FXS/B)

Shifter peg, rear (all but FXS/B)

Shift lever (FXS/B)

10.

Shifter peg (FXS/B)

Shift lever, rear (all but FXS/B)

11.

Pinch bolt, rear (all but FXS/B)

Spacer

12.

Bushing (2)

Shifter peg, front (all but FXS/B)

13.

Shift lever, front (all but FXS/B)

O-ring (2)

14.

Pivot lever

Pinch bolt (FXS/B)

Figure 6-3. Shift Lever Assembly

RICANT, Changing Transmission Lubricant

2013 Softail Service: Transmission 6-7

6.5

CLUTCH RELEASE COVER

REMOVAL AND DISASSEMBLY

Remove main fuse.

Remove exhaust system if needed. See

4.17 EXHAUST

SYSTEM

Drain transmission. See

1.10 TRANSMISSION LUB-

NOTE

Actuating the clutch hand lever after removing the six screws
will help break the cover free.

See

Figure 6-4

. Remove the six screws that hold the clutch

release cover in place. Remove the clutch release cover
and discard the gasket.

Add freeplay to clutch cable. See

1.11 CLUTCH, Adjust-

ment

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

See

Figure 6-5

. Remove retaining ring (4). Lift inner ramp

(5) and ramp coupling (3) out of clutch release cover.
Disconnect clutch cable end (2) from the ball and ramp
coupling.

See

Figure 6-6

. Remove balls (4) and outer ramp (2).

Unscrew clutch cable fitting from clutch release cover.

sm03675

Figure 6-4. Cover Screws

sm03008

1. Cable fitting
2. Clutch cable end
3. Ramp coupling
4. Retaining ring
5. Inner ramp
6. Retaining ring opening

Figure 6-5. Clutch Cable Connection

sm03009

1. Inner ramp
2. Outer ramp
3. Outer ramp tab
4. Balls (3)
5. Ramp coupling

Figure 6-6. Coupling and Ramp Assembly

CLEANING AND INSPECTION

See

Figure 6-7

. Wash the ball and ramp mechanism

components in cleaning solvent.

1.10 TRANSMISSION LUBRICANT

6-8 2013 Softail Service: Transmission

Inspect the three balls (2) and ball socket surfaces on
ramps (1, 3) for wear, pitting, surface breakdown and other
damage. Replace as necessary.

Check fit of the ramp coupling (4) on inner ramp (1).
Replace both parts if there is excessive wear.

Inspect the retaining ring (6) for damage or distortion.

Check clutch cable end for frayed or worn ends. Replace
cable if damaged or worn. Check cable fitting O-ring for
damage.

Check the bore in the clutch release cover (5) where the
ramps (1, 3) are retained. There should be no wear that
would cause the ramps to tilt, causing improper clutch
adjustment.

sm03010

1. Inner ramp
2. Balls (3)
3. Outer ramp
4. Ramp coupling
5. Clutch release cover
6. Retaining ring
7. Gasket
8. Tab

Figure 6-7. Release Mechanism Assembly

ASSEMBLY AND INSTALLATION

TORQUE VALUE

FASTENER

14.9-17.6 Nm

132-156

in-lbs

Clutch release cover screws

10.2-13.6 Nm

90-120

in-lbs

Clutch cable fitting

NOTE

Replace cable fitting O-ring if damaged or deformed.

See

Figure 6-5

. Apply a drop of LOCTITE 243 MEDIUM

STRENGTH THREADLOCKER AND SEALANT (blue) to
clutch cable fitting (1) and screw fitting into clutch release
cover. Do not tighten at this time.

See

Figure 6-7

. Place outer ramp (3) with ball socket side

up in clutch release cover. Be sure tab (8) is in clutch
release cover slot.

Apply a multi-purpose grease to the balls (2) and outer
ramp sockets. Place a ball in each of the outer ramp
sockets.

Connect cable end to ramp coupling (4). Install coupling
on inner ramp (1) and place inner ramp and coupling in
position in clutch release cover (5).

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

NOTE

See

Figure 6-5

. Center retaining ring opening above the break

in the ribbing at bottom of the clutch release cover.

Figure 6-7

. Install retaining ring (6).

Verify that two dowel pins are in place on transmission
bearing housing flange. Place a

new

gasket (7) on dowel

pins.

NOTE

See

Figure 6-4

. Clutch release cover screws in positions (1)

and (6) are shorter than the others.

See

Figure 6-4

. Install clutch release cover. Tighten all six

screws to 132-156

in-lbs

(14.9-17.6 Nm) in sequence

shown.

Tighten clutch cable fitting to 90-120

in-lbs

(10.2-13.6

Nm).

Fill transmission to proper level with fresh transmission
fluid. See

10. Adjust clutch cable. See

1.11 CLUTCH

11. Install exhaust system if removed. See

4.17 EXHAUST

SYSTEM

12. Install main fuse.

3.30 OIL TANK: ALL BUT FXSB

2013 Softail Service: Transmission 6-9

6.6

TRANSMISSION ASSEMBLY

REMOVAL

NOTE

Leave the transmission case in the frame unless the case itself
requires replacement. For illustration purposes, some photo-
graphs may show the case removed. For information on case
removal see

6.8 TRANSMISSION CASE

Remove exhaust system. See

4.17 EXHAUST SYSTEM

Remove oil tank. See

Relieve drive belt tension. See

1.12 DRIVE BELT AND

SPROCKETS

Remove primary chaincase cover, clutch assembly,
primary chain, compensating sprocket assembly and
primary chaincase. See

5.5 PRIMARY CHAINCASE

HOUSING, Removal

Remove the bearing inner race from the transmission
mainshaft. See

5.5 PRIMARY CHAINCASE HOUSING,

Mainshaft Bearing Inner Race

Remove the clutch release cover from the transmission
bearing housing. See

6.5 CLUTCH RELEASE COVER,

Removal and Disassembly

See

Figure 6-8

. Remove oil slinger assembly from main-

shaft. Remove pushrod.

Remove transmission top cover, leaving the cover gasket
in place.

See

Figure 6-9

. Place shifter cam pawl on top cover

gasket.

sm03013

1. Retaining ring
2. Thrust washer (2)
3. Throw out bearing
4. Oil slinger
5. Pushrod
6. Pushrod end, left side

Figure 6-8. Pushrod Assembly: Cable Clutch

sm03011

1. Shifter pawl
2. Top cover gasket surface

Figure 6-9. Set Shifter Pawl on Gasket

NOTE

Remove and install sprocket nut only while transmission is in
vehicle frame. Trying to remove and install sprocket nut with
transmission in transmission stand may cause damage to
transmission or stand.

10. If main drive gear is to be removed, see

6.7 MAIN DRIVE

GEAR AND BEARING, Removal

NOTES

•

Replace the main drive gear bearing and retainer if the
main drive gear is removed. The bearing will be damaged
during the removal procedure.

•

Never attempt to remove bearing housing by tapping on
shafts from opposite side. Tapping them with a hammer
will damage the bearing housing bearings. If the bearing
housing sticks or binds on the ring dowels, pry loose using
indents at each side of bearing housing.

11. Cover mainshaft clutch hub splines with tape to prevent

the splines from damaging the main drive gear bearings.

12. See

Figure 6-11

. Remove the transmission bearing

housing:

Remove the transmission bearing housing mounting
hardware.

Remove exhaust bracket, if equipped.

Pry the bearing housing loose.

Remove bearing housing, mainshaft, countershaft
and shifter cam from transmission case as an
assembly.

Discard gasket.

6-10 2013 Softail Service: Transmission

sm02582

1. Locknut (2)
2. Retaining ring (2)
3. Bearing (2)
4. Bearing housing
5. Bearing housing gasket
6. O-ring
7. Transmission dipstick
8. Transmission case

Figure 6-10. Bearing Housing Bearings

sm02595

1. Bolt (8)
2. Bearing housing

Figure 6-11. Bearing Housing Hardware

DISASSEMBLY

TOOL NAME

PART NUMBER

TRANSMISSION SHAFT RETAINING
RING PLIERS

J-5586A

Shifter Cam/Shifter Forks

See

Figure 6-12

. Disassemble bearing housing assembly:

Place bearing housing on end (shafts pointing
upward).

Remove shift fork shafts using easy-out screw
extractor (14) (non-flute design) or vise grips. Shafts
have slight interference fit. Shafts can be reused; do
not damage end of shaft.

Mark end of shaft to aid during assembly.

Remove shift forks from dog rings.

See

Figure 6-13

. Remove lock plate fasteners (3) from

lock plate (2). Discard fasteners.

See

Figure 6-14

. Insert screwdriver and gently pry back

detent arm (4) to remove detent spring (3) tension from
shift cam (5). Remove shift cam.

If servicing detent assembly, remove detent screw (2),
detent arm (4), sleeve and detent spring (3). Discard detent
screw.

NOTE

Many transmission parts can be installed in either direction.
To prolong usable life, install used parts in same direction as
when removed.

See

Figure 6-15

. Using dog rings, lock two gears in place.

Temporarily place transmission assembly into transmission
case.

Remove mainshaft and countershaft locknuts.

Remove transmission assembly from transmission case.

2013 Softail Service: Transmission 6-11

sm05070a

1. Mainshaft
2. Countershaft
3. Mainshaft 1st gear
4. Mainshaft 2nd gear
5. Mainshaft 3rd gear
6. Mainshaft 4th gear
7. Mainshaft 5th gear
8. Countershaft 1st gear
9. Countershaft 2nd gear
10. Countershaft 3rd gear
11. Countershaft 4th gear
12. Countershaft 5th gear
13. Countershaft 6th gear
14. Screw extractor

Figure 6-12. Gear Set

sm03600a

1. Bearing housing
2. Lock plate
3. Lock plate fastener (2)
4. Shift cam

Figure 6-13. Shift Drum

6-12 2013 Softail Service: Transmission

7.36

RIGHT HANDLEBAR CONTROL MODULE

REMOVAL

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

NOTE

Fuel tank crossover hose does not need to be disconnected.
Once all other connections to fuel tank have been removed,
fuel tank can be slid back enough to reveal handlebar switch
assembly connectors.

Remove fuel tank. See

See

Figure 7-108

. Disconnect right hand control con-

nectors (1, 2).

Loosen the upper handlebar clamp-to-master cylinder
housing screw. Remove the lower handlebar clamp-to-
master cylinder housing screw.

Remove the upper and lower switch housing screws.

Remove the friction shoe from the end of the tension
adjuster screw.

NOTE

The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.

Loosen cable adjusters. See

1.13 THROTTLE CABLES

See

Figure 7-109

. Remove the brass ferrules (4) from the

notches on the inboard side of the throttle control grip.
Remove the ferrules from the cable end fittings.

Remove the throttle control grip from the end of the
handlebar.

10. See

Figure 7-110

. If replacing lower switch housing, pull

inserts (1, 2) from lower switch housing. Use a rocking
motion while pulling. Place a drop of light oil on the
retaining rings, if necessary. Remove the cables from the
switch housing.

11. See

. Remove screws (3) and retainer (1).

NOTE

Record wire routing before removal.

12. Carefully remove brake switch (2) and switch assembly

from lower switch housing. Remove switch assembly.

sm07233

1. Right hand controls [22-1]
2. Right hand controls [22-2]
3. Front turn signals [31]

Figure 7-108. Under Fuel Tank Right Side

sm01084a

1. Throttle cable (silver insert, front hole)
2. Groove in throttle grip
3. Notch
4. Brass ferrule
5. Idle cable (gold insert, rear hole)

Figure 7-109. Throttle Cable Attachment

7-76 2013 Softail Service: Electrical

sm02636a

1. Idle cable insert (gold insert, rear hole)
2. Throttle cable insert (silver insert, front hole)
3. Tension adjuster screw

Figure 7-110. Right Lower Module Housing

sm07031

1. Retainer
2. Brake switch
3. Screw (2)

Figure 7-111. Right Control Module and Brake Switch

Retainer

INSTALLATION

TORQUE VALUE

FASTENER

0.9-1.1 Nm

8-10

in-lbs

Handlebar switch assembly
retainer screws

6.8-9.0 Nm

60-80

in-lbs

Handlebar clamp to master
cylinder screws

4.0-5.1 Nm

35-45

in-lbs

Handlebar switch housing
screws

NOTE

When installing switch assembly and retainer, make sure wires
do not get pinched and that the rubber grommet on the wire
harness is properly placed on the switch housing.

See

. Place switch assembly into position on

lower switch housing and carefully install brake switch (2).

Install retainer (1) with screws (3). Tighten screws to 8-10

in-lbs

(0.9-1.1 Nm).

See

Figure 7-110

. If previously removed from lower switch

housing, push the throttle and idle control cables into the
lower switch housing until they snap in place. Note the
different diameter inserts crimped into the end of the
throttle and idle cable housings.

Push the silver insert (2) of throttle cable housing into
the hole in front of tension adjuster screw (3).

Push the gold insert (1) of idle cable housing into the
hole at the rear of tension adjuster screw (3).

NOTE

To aid assembly, place a drop of light oil on the retaining rings
of the crimped inserts. Always replace the retaining rings if
damaged or distorted.

Slide the throttle control grip over the end of the right
handlebar until it bottoms against the closed end. Rotate
the grip so that the ferrule notches are at the top. To pre-
vent binding, pull the grip back about 1/8 in (3.2 mm).

With the concave side facing upward, install the friction
shoe so that the pin hole is over the point of the adjuster
screw.

NOTE

The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.

See

Figure 7-109

. Position lower switch housing beneath

the throttle control grip. Install the brass ferrules (4) onto
the cable so that the end fittings seat in the ferrule recess.
Seat the ferrules in their respective notches (3) on the
throttle control grip. Verify that the cables are captured in
the grooves (2) molded into the grip.

2013 Softail Service: Electrical 7-77

sm04496a

1. Clamping surface
2. Range marks

Figure 7-112. Right Hand Control Assembly to Handlebar

Alignment

NOTE

See

Figure 7-112

. When installing right handlebar switch

assembly for motorcycles with internally wired handlebars,
make sure the clamping surface (1) stays within the range
marks (2) or damage to the wires will occur.

Position the upper switch housing over the handlebar and
lower switch housing.

Start the upper and lower switch housing screws, but do
not tighten.

See

Figure 7-113

. Position the brake lever/master cylinder

assembly inboard of the switch housing assembly, enga-
ging the tab (2) on the lower switch housing in the groove
(3) at the top of the brake lever bracket.

10. Install the lower handlebar clamp-to-master cylinder

housing screw (with flat washer). Position for rider comfort.
Beginning with the top screw, tighten to 60-80

in-lbs

(6.8-

9.0 Nm).

11. Tighten lower and upper switch housing screws to 35-45

in-lbs

(4.0-5.1 Nm).

NOTE

Always tighten the lower switch housing screw first so that any
gap between the upper and lower housings is at the front of
the switch.

12. Adjust throttle cables. See

1.13 THROTTLE CABLES

13. See

Figure 7-108

. Connect right hand control connectors

(1, 2).

14. Secure harness with clamps and cable strap as noted

during removal.

15. Install fuel tank. See

HANDLEBAR CONTROL MODULE, Removal

16. Install main fuse. See

7.10 FUSES

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

17. Test the switches for proper operation.

sm07068

1. Module housing assembly
2. Tab
3. Groove
4. Brake lever bracket

Figure 7-113. Module Housing Alignment

FRONT BRAKE SWITCH REPLACEMENT

TORQUE VALUE

FASTENER

0.9-1.1 Nm

8-10

in-lbs

Handlebar switch assembly
retainer screws

Remove upper switch housing cover. See

7.36 RIGHT

See

7.35 HANDLEBAR CONTROL MODULES, Repair

. From inside the switch housing, remove

screws (3) and retainer (1). Remove brake switch (2) from
housing.

Cut wires flush at inoperative brake switch.

new

brake switch wires have terminals installed, cut

wires at terminal end.

Remove 0.25-0.3125 in. (6.4-7.9 mm) of insulation from
each wire end.

Cut two pieces of dual wall heat-shrink tubing to a length
of 0.5 in. (12.7 mm).

Solder wires together and cover with heat-shrink tubing.
See

Procedures

See

HANDLEBAR CONTROL MODULE, Installation

. Install brake switch (2) into housing.

Install retainer (1) and screws (3). Tighten screws to 8-10

in-lbs

(0.9-1.1 Nm).

Assemble right handlebar switch housing. See

7.36 RIGHT

7-78 2013 Softail Service: Electrical

7.37

LEFT HANDLEBAR CONTROL MODULE

REMOVAL

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

NOTE

Fuel tank crossover hose does not need to be disconnected.
Once all other connections to fuel tank have been removed,
fuel tank can be slid back enough to reveal handlebar switch
assembly connectors.

Remove fuel tank. See

See

Figure 7-114

. Disconnect left hand control connector

(2).

Loosen the upper handlebar clamp-to-clutch lever screw.
Remove the lower handlebar clamp-to-clutch lever screw.

Remove the upper and lower switch housing screws.
Remove upper switch housing.

See

. Remove screws (3) and retainer (1).

Carefully remove clutch switch (2) and switch assembly
from lower switch housing.

NOTE

Make note of wire routing along with clamp and cable strap
locations before removal.

Remove switch assembly from motorcycle.

sm07179a

1. Instruments [20]
2. Left hand control [24]
3. Fuel gauge [117]
4. Front wheel speed sensor [167]
5. Headlamp [38]
6. Front fender tip lamp [32]: FLSTC

Figure 7-114. Under Fuel Tank Left Side

sm07034

1. Retainer
2. Clutch switch
3. Screw (2)

Figure 7-115. Left Handlebar Control Module and Clutch

Switch Retainer

INSTALLATION

TORQUE VALUE

FASTENER

0.9-1.1 Nm

8-10

in-lbs

Handlebar switch assembly
retainer screws

6.8-9.0 Nm

60-80

in-lbs

Handlebar clamp to clutch
lever bracket screws

4.0-5.1 Nm

35-45

in-lbs

Handlebar switch housing
screws

NOTE

When installing switch assembly and retainer, make sure wires
do not get pinched and that the rubber grommet on the wire
harness is properly placed on the switch housing.

See

. Place switch assembly into position on

lower switch housing and carefully install clutch switch (2).

2013 Softail Service: Electrical 7-79

sm03982b

1. Clamping surface
2. Range marks

Figure 7-116. Left Hand Control Assembly to Handlebar

Alignment

NOTE

See

Figure 7-116

. When installing left handlebar switch

assembly for motorcycles with internally wired handlebars,
make sure the clamping surface (1) stays within the range
marks (2) or damage to the wires will occur.

Install retainer (1) with screws (3). Tighten to 8-10

in-lbs

(0.9-1.1 Nm).

Position the upper switch housing over the handlebar and
lower switch housing.

Start the upper and lower switch housing screws, but do
not tighten.

See

Figure 7-117

. Position the clutch hand lever assembly

inboard of the switch housing assembly, engaging the tab
(3) on the lower switch housing in the groove (2) at the
bottom of the clutch lever bracket.

Secure the handlebar switch clamp to the clutch lever
bracket with two screws (with flat washers). Position for
rider comfort. Beginning with the top screw, tighten to
60-80

in-lbs

(6.8-9.0 Nm).

Tighten switch housing screws to 35-45

in-lbs

(4.0-5.1

Nm).

NOTE

Always tighten the lower switch housing screw first so that any
gap between the upper and lower housings is at the front of
the switch.

See

Figure 7-114

. Connect left hand control connector

(2).

Secure harness with clamps and cable strap as noted
during removal.

10. Install fuel tank. See

HANDLEBAR CONTROL MODULE, Removal

11. Install main fuse. See

7.10 FUSES

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

12. Test the switches for proper operation.

sm02631

1. Clutch lever bracket
2. Groove
3. Tab
4. Switch housing assembly

Figure 7-117. Clutch Lever Bracket

CLUTCH SWITCH REPLACEMENT

TORQUE VALUE

FASTENER

0.9-1.1 Nm

8-10

in-lbs

Handlebar switch assembly
retainer screws

Remove upper switch housing cover. See

7.37 LEFT

See

7.35 HANDLEBAR CONTROL MODULES, Repair

. From inside the switch housing, remove

screws (3) and retainer (1). Remove clutch switch (2) from
housing.

Cut wires flush at inoperative clutch switch.

new

clutch switch wires have terminals installed, cut

wires at terminal end.

Remove 0.25-0.3125 in. (6.4-7.9 mm) of insulation from
each wire end.

Cut two pieces of dual wall heat-shrink tubing to a length
of 0.5 in. (12.7 mm).

Solder wires together and cover with heat-shrink tubing.
See

Procedures

See

HANDLEBAR CONTROL MODULE, Installation

. Install clutch switch (2) into housing.

Install retainer (1) and screws (3). Tighten screws to 8-10

in-lbs

(0.9-1.1 Nm).

Assemble left handlebar switch housing. See

7.37 LEFT

7-80 2013 Softail Service: Electrical

A.1

AUTOFUSE UNSEALED ELECTRICAL
CONNECTORS

AUTOFUSE UNSEALED CONNECTOR
REPAIR

TOOL NAME

PART NUMBER

SNAP-ON TERMINAL PICK

GA500A

General

Autofuse Unsealed connector terminals are found in ignition
switches and some fuse blocks.

Disassembly

See

Figure A-1

Figure A-2

. Insert smallest pair of pins

on the SNAP-ON TERMINAL PICK (Part No. GA500A)
into chamber on mating end of socket housing to press
tangs on each side of terminal simultaneously.

Gently pull on wire to remove terminal from wire end of
socket housing.

If necessary, crimp

new

terminals on wires.

Assembly

Carefully bend tang on each side of terminal outward away
from terminal body. Use the thin flat blade from a hobby
knife.

With the open side of the terminal facing rib on wire end
of socket housing, insert terminal into chamber until it locks
in place.

sm02849a

Figure A-1. Removing Autofuse Unsealed Terminal from

Ignition Switch

sm03480a

Figure A-2. Removing Autofuse Unsealed Terminal from

Fuse Block

2013 Softail Service: Appendix A Connector Repair A-1

A.2

BOSCH COMPACT 1.1M CONNECTOR

TOOL NAME

PART NUMBER

SNAP-ON TERMINAL PICK

GA500A

General

See

Figure A-3

. The Bosch Compact 1.1M connector is found

on MAP and TMAP sensors.

Housings

Separate:

Snap back the secondary lock. Press on the latch

while pulling the socket connector from the sensor.

Join:

Align the sockets and press the housings together until

the latch snaps. Snap in the secondary lock.

sm07374

Figure A-3. Bosch Compact 1.1M Connector

Removing Socket Terminal

See

Figure A-4

. Slide the locking bar off the terminal

housing.

Insert the smallest pins of the SNAP-ON TERMINAL PICK
(Part No. GA500A) into the gaps on each side of the
socket to compress the tangs on each side of the terminal.

Gently pull on the wire to remove the terminal.

sm07337

Figure A-4. Terminal Removal: Bosch Compact 1.1M

Connector

Installing Socket Terminal

See

Figure A-5

. Use a hobby knife to bend the tangs on

each side of the terminal outward.

Align terminal to socket housing. Press terminal into
housing until it snaps.

NOTE

The teeth on the locking bar face down.

Slide the locking bar onto the connector.

sm07352

Figure A-5. Tangs: Bosch Compact 1.1M Socket Terminal