Harley Davidson FLHRC 2006. Maintenance & Repair Manual

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TRANSMISSION LUBRICANT

1.9

GENERAL

8496

See Section

1.2 MAINTENANCE SCHEDULE for the

required service interval.

PROCEDURE

Remove the filler plug from the clutch release cover on

the right side of the transmission case. See Figure 1-11.

Check the O-ring for tears, cuts or general deterioration.

Replace as necessary. See Figure 1-12.

Locate transmission drain plug on the right side of the oil

pan. Remove the magnetic plug and drain the transmis-

sion lubricant into a suitable container.

Figure 1-11. Clutch Release Cover

Remove any foreign material from the drain plug. Check

the O-ring on the drain plug for tears, cuts or general

deterioration. Replace as necessary.

OMF50

Install the transmission lubricant drain plug and tighten

to 14-21 ft-lbs (19-28 Nm).

1WARNING

When adding lubricant, do not allow dirt, debris or other

contaminants to enter the transmission case. Exercise

O-Ring

caution so that lubricant does not contact rear wheel,

tire and brake components. Such contact can adversely

affect traction and may lead to loss of vehicle control,

which could result in death or serious injury.

Figure 1-12. Transmission Lubricant Filler Plug/Dipstick

Fill the transmission with

20-24 oz. (590-710 ml) of

transmission lubricant or until the lubricant level on the

dipstick of the filler plug is at the F(ULL) mark with the

motorcycle in a level, upright position and the filler plug

resting on the threads.

Use only Harley-Davidson FORMULA+ TRANSMIS-

SION AND PRIMARY CHAINCASE LUBRICANT, Part

No. 99851-05 (quart).

Install the transmission filler plug/dipstick in the clutch

release cover. Tighten the plug to 25-75 in-lbs (2.8-8.5

Nm).

2006 Touring: Maintenance

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DRIVE BELT

1.10

GENERAL

See Section

1.2 MAINTENANCE SCHEDULE for the

required service interval.

PROCEDURE

Remove left side saddlebag. See Section 2.26 SAD-

DLEBAG, REMOVAL.

Obtain BELT TENSION GAUGE (HD-35381A), or install

Belt Tension Gauge (Part No. HD-35381A)

adapter (HD-35381-3) on old style gauge. See Figure 1-

Belt Tension Gauge Adapter (Part No. HD-35381-3)

13.

Apply 10 lbs. (4.5 kg) of force at the midpoint of the bot-

Figure 1-13. Obtain Belt Tension Gauge

tom belt strand. See Figure 1-14. Check deflection at the

loosest spot in the belt with the transmission in neutral

and the motorcycle cold. Belt deflection should be as fol-

f1652x6x

lows:

Table 1-6. Belt Deflection

Orientation

Inches

Millimeters

On Jiffy Stand

Without Rider or Luggage

1/4 - 5/16

6.4

- 7.9

10 psi (69 kPa) in Rear Shocks

Motorcycle Upright

3/16 - 1/4

4.8

- 6.4

Transmission Sprocket

With Rear Wheel in the Air

Rear Wheel Sprocket

10 lbs. (4.5 kg) of Force

If belt deflection is within specification, install left side

Refer toTable 1-6.

saddlebag. If adjustment is necessary, move to step 4.

Remove right side saddlebag. See Section 2.26 SAD-

Figure 1-14. Check and Adjust Belt Deflection

DLEBAG, REMOVAL.

Standing on right side of motorcycle, remove E-clip from

groove at end of axle.

CAUTION

Obtain torque wrench with 1/2 inch drive head and AXLE

Since any extension can act as a torque multiplier, the

NUT TORQUE ADAPTER (HD-47925). Proceed as fol-

torque wrench must be perpendicular to the torque

lows:

adapter when the cone nut is tightened. The 90 degree

NOTE

orientation between the tools cancels the multiplier

effect and prevents the cone nut from being over-tight-

The Axle Nut Torque Adapter simplifies the belt adjustment

ened. If the torque adapter is kept inline with the torque

procedure by allowing the cone nut to be properly tightened

wrench, the multiplier effect is in force and parts damage

without having to remove the right side muffler. The tool also

will occur.

can be used to loosen the cone nut, as well as rotate the

weld nut on the left side.

c. Loosen cone nut, and then snug to 15-20 ft-lbs (20-

27 Nm). See Figure 1-16.

a. Install torque adapter perpendicular to torque

wrench as shown in Figure 1-15.

If belt is too tight, move to step 8 to increase belt deflec-

tion. If belt is too loose, reduce belt deflection as follows:

b. Insert tool up between rear wheel and muffler to

capture cone nut. For best clearance with muffler,

a. Rotate weld nut on left side of axle in a clockwise

be sure torque adapter is on the outboard side.

direction.

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2006 Touring: Maintenance

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b. Check belt deflection. Apply 10 lbs. (4.5 kg) of force

Torque Wrench

at the midpoint of the bottom belt strand. Belt

Axle Nut Torque Adapter

deflection should be within the range specified in

(HD-47925)

Table 1-6.

c. If belt is still too loose, repeat steps 7(a) through

7(b). If belt is now too tight, move to step 8.

90°

If belt is too tight, increase belt deflection as follows:

a. Using a hydraulic center stand, raise motorcycle so

that the rear wheel is off the ground.

b. Rotate weld nut on left side of axle in a counter-

clockwise direction.

c. Push wheel forward slightly so that adjuster cam

f2369x2x

just contacts weld nub on both sides of rear swing-

arm. See Figure 1-16.

d. Check belt deflection. Apply 10 lbs. (4.5 kg) of force

at the midpoint of the bottom belt strand. Belt

deflection should be within the range specified in

Table 1-6.

e. If belt is still too tight, repeat steps 8(b) through 8(d).

If belt is now too loose, move to step 7.

Holding weld nut on left side of axle, tighten cone nut on

right side to 95-105 ft-lbs (128.8-142.4 Nm).

NOTE

9292

If the axle moves during tightening of the cone nut, then the

Figure 1-15.

Install Tool Perpendicular to Torque Wrench

belt deflection procedure must be restarted.

LEFT SIDE

RIGHT SIDE

Increase

Reduce

Belt

Deflection

8398

8407

Weld Nut

Cone Nut

Weld Nub

E-Clip

Adjuster Cam

Figure 1-16. Move Rear Wheel Forward Until Adjuster Cams Just Contact Weld Nubs

2006 Touring: Maintenance

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THROTTLE CABLES

1.11

GENERAL

f1225x2x

See Section

1.2 MAINTENANCE SCHEDULE for the

required service interval.

PROCEDURE

LUBRICATION

CAUTION

Do not remove the switch housing assembly without first

placing the 5/32 inch (4.0 mm) cardboard insert between

the brake lever and lever bracket. Removal without the

insert may result in damage to the rubber boot and

plunger of the Front Stoplight Switch.

NOTE

Figure 1-17. Install Cardboard Insert

Use the eyelet of an ordinary cable strap if the cardboard

insert is not available.

Place the cardboard insert between the brake lever and

lever bracket. See Figure 1-17.

Using a T25 TORX drive head, remove the upper and

lower switch housing screws.

Using a T27 TORX drive head, loosen the upper screw

securing the handlebar clamp to the master cylinder

housing. Remove the lower clamp screw with flat

washer.

Remove the brass ferrules from the notches on the

inboard side of the throttle grip. Remove the ferrules

from the cable end fittings. See Figure 1-18.

NOTE

f1474x2x

On non cruise equipped models, remove the friction shoe

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

Throttle Grip

Groove

is a loose fit and may fall out or become dislodged if the lower

Idle Cable

Notch

switch housing is turned upside down or shaken.

Throttle Cable

Ferrule

Remove the throttle grip from the end of the handlebar.

Figure 1-18. Remove Throttle/Idle Cables

Move upper switch housing to the side in order to access

lower housing.

Obtain tube of Lubit-8 Tufoil Chain and Cable Lube (HD

Part No. 94968-85TV- 1/4 fl. oz.). Insert pin of tube

1CAUTION

between throttle cable and cable housing inside lower

switch housing. Squeeze tube to squirt a quantity of

Lubit-8 Tufoil Chain and Cable Lube contains detergents.

lubricant into cable housing moving pin around cable

Avoid contact with eyes. Keep out of reach of children.

OD. See Figure 1-19.

2006 Touring: Maintenance

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16. Using a T25 TORX drive head, tighten the lower and

upper switch housing screws to 35-45 in-lbs (4-5 Nm).

NOTE

Always tighten the lower switch housing screw first so that

Insert

any gap between the upper and lower housings is at the front

Lubricant

of the switch assembly.

Here

17. Remove the cardboard insert between the brake lever

and lever bracket.

18. Turn the Ignition/Light Key Switch to IGNITION and

apply brake lever to test operation of brake lamp.

ADJUSTMENT

7958

NOTE

For throttle and idle cable adjustment on cruise equipped

Figure 1-19. Lubricate Throttle/Idle Cables

models, see Section

8.31 CRUISE CONTROL (FLHRC,

FLHTCU, FLTR).

Slide rubber boot off throttle cable adjuster mechanism.

Repeat the procedure squirting a quantity of lubricant

See Figure 1-20. Holding cable adjuster with a 3/8 inch

between the idle cable and cable housing.

wrench, loosen jam nut turning in a clockwise direction.

Back jam nut away from cable adjuster until it stops. Turn

NOTE

cable adjuster clockwise until it contacts jam nut. Repeat

On non cruise equipped models, install the friction shoe with

procedure on idle cable adjuster.

the concave side up so that the pin hole is over the point of

Point the front wheel straight ahead. Gently turn the

the adjuster screw. The friction shoe is a loose fit and may fall

throttle grip so that the throttle is wide open (fully coun-

out or become dislodged if the lower switch housing is turned

terclockwise) and then hold in position. Now turn the

upside down or shaken.

cable adjuster counterclockwise until the throttle cam

stop just touches the stop plate on the carburetor/induc-

Apply a light coating of graphite to the handlebar.

tion module. See Figure 1-21. Release the throttle grip,

10.

Slide the throttle grip over the end of the right handlebar

turn cable adjuster counterclockwise an additional 1/2-1

until it bottoms against the closed end. Rotate the grip

full turn, and then tighten the jam nut against the cable

so that the ferrule notches are at the top. To prevent

adjuster. Cover cable adjuster mechanism with rubber

binding, pull the grip back about 1/8 inch (3.2 mm).

boot.

11.

Position the lower switch housing beneath the throttle

grip. Install the brass ferrules onto the cables so that the

end fittings seat in the ferrule recess. Seat the ferrules in

f1376b2x

their respective notches on the throttle grip. Verify that

the cables are captured in the grooves molded into the

grip. See Figure 1-18.

12.

Position the upper switch housing over the handlebar

and lower switch housing. Verify that the wire harness

conduit runs in the depression at the bottom of the han-

dlebar.

13.

Start the upper and lower switch housing screws, but do

not tighten.

14.

Position the brake lever/master cylinder assembly

inboard of the switch housing assembly engaging the

tab on the lower switch housing in the groove at the top

Throttle Cable Adjuster

Idle Cable Adjuster

of the brake lever bracket.

Jam Nut

15.

Align the holes in the handlebar clamp with those in the

Throttle Grip

master cylinder housing and start the lower screw (with

Tension Adjuster Screw

flat washer). Position for rider comfort. Beginning with

the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0

Figure 1-20. Throttle Cable Assembly - Throttle Side

Nm) torque using a T27 TORX drive head.

(FLHR/S)

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2006 Touring: Maintenance

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Throttle Cable Guide

Throttle Cam Stop

Stop Plate

Idle Cable Guide

Cable Housing

Spring

Cable Barrel End

Throttle Wheel

f1381a2x

Figure 1-21. Throttle Cable Assembly - Carburetor Side

Turn the front wheel full right. Turn the idle cable adjuster

Verify that the throttle control operates freely without

counterclockwise until the cable housing just touches

binding. With the tension adjuster screw backed off, the

the spring in the cable guide (as seen through slot).

throttle grip must freely return to the closed (idle) posi-

Work the throttle grip to verify that the throttle cable

tion. The throttle control also must open and close freely

returns to the idle position when released. If the cable

when the front wheel is turned to both the right and left

does not return to idle, turn the cable adjuster clockwise

fork stops. If the throttle grip does not return to the idle

slightly until the correct response is achieved. Tighten

position freely, check the adjuster screw tension

(if

jam nut against the cable adjuster and cover cable

present). If the adjuster screw is backed off, inspect the

adjuster mechanism with rubber boot.

cables for short bends.

2006 Touring: Maintenance

1-25

HOME

ENRICHENER CONTROL

1.12

GENERAL

f1438x4x

See Section

1.2 MAINTENANCE SCHEDULE for the

required service interval.

PROCEDURE

NOTE

The fuel enrichener knob should open, remain open and then

close without binding. The knurled plastic nut next to the

enrichener knob controls the ease at which the cable slides

within the conduit.

Enrichener Knob

Lockwasher

Knurled Nut

Hex Nut

If adjustment is needed, proceed as follows:

Mounting Bracket

Enrichener Cable

Flat

See Figure 1-22. Loosen hex nut at backside of mount-

ing bracket.

Figure 1-22. Enrichener Control

Move cable assembly free of slot in mounting bracket.

Hold cable assembly at flat with adjustable wrench.

Hand turn knurled nut counterclockwise to reduce sliding

resistance until knob slides inward unaided.

Turn knurled nut clockwise to increase sliding resistance

until knob remains fully out without holding and then

closes with relative ease.

Slide enrichener cable into slot of mounting bracket. Flat

on threads must face rear of motorcycle for script on

enrichener knob to be right side up. With external tooth

lockwasher and hex nut positioned on the inboard side

of the mounting bracket, tighten hex nut to 20-35 in-lbs

(2.3-4.0 Nm).

CAUTION

Do not lubricate the cable or inside of conduit. The cable

must have sliding resistance to work properly.

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2006 Touring: Maintenance

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FUEL SYSTEM

1.13

GENERAL

f1723x4x

See Section

1.2 MAINTENANCE SCHEDULE for the

required service interval.

PROCEDURE

LINES AND FITTINGS

Carefully inspect fuel system lines and fittings for leaks or

damage.

FUEL FILTER (CARBURETED)

1WARNING

When servicing the fuel system, do not smoke or allow

open flame or sparks in the vicinity. Gasoline is

extremely flammable and highly explosive, which could

result in death or serious injury. (00330a)

Turn handle of fuel valve to OFF.

1WARNING

Gasoline can drain from the carburetor fuel line when

disconnected from fuel valve fitting. Gasoline is

extremely flammable and highly explosive, which could

result in death or serious injury. Wipe up spilled fuel

immediately and dispose of rags in a suitable manner.

Valve Handle

Vacuum Fitting

(00256a)

Fuel Outlet Fitting

Jam Nut

Hose Clamp

Filter Strainer

Using a side cutters, cut clamp and remove hose from

Carburetor Fuel

Gasket

fuel outlet fitting at front of fuel valve. See Figure 1-23.

Inlet Hose

10.

Atmospheric

Drain free end of hose into a suitable container.

Convoluted Tubing

Pressure Port

Remove elbow of intake manifold vacuum tube from fit-

ting on inboard side of fuel valve.

Figure 1-23. Vacuum Operated Fuel Valve

Attach a length of fuel hose to the fuel outlet fitting. The

hose must be long enough to reach a suitable gasoline

Gently apply a vacuum of 1-10 inches of Mercury (Hg) to

container.

vacuum fitting to get a good flow of gasoline through the

Turn handle of fuel valve to RES(ERVE).

valve.

Using the correct hose adapter, connect the Mity-Vac®

When fuel tank is completely drained, remove Mity-Vac®

Hand Pump (HD-23738A) to vacuum fitting.

Hand Pump from the vacuum fitting.

Holding fuel tank adapter, turn the hex jam nut in a

CAUTION

clockwise direction to remove fuel valve assembly.

To avoid damage to the diaphragm of the fuel valve, do

not apply a vacuum greater than 25 inches of Mercury

10. Remove fuel filter strainer from the valve head. Clean or

replace.

(Hg) to vacuum fitting.

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HOME

11. Remove hex jam nut from the fuel valve.

CAUTION

12. Remove gasket from the valve head. Discard the gasket.

Do not allow dirt or fluids to get into the vacuum tube

13. Install a new gasket on the valve head.

that connects the fuel valve to the intake manifold. Con-

taminants can block the vacuum signal which could

14. Install the fuel filter strainer fitting the internal tube into

cause the fuel valve to malfunction.

the larger hole in the valve head.

19. Connect elbow of intake manifold vacuum tube to fitting

on inboard side of fuel valve.

15. Clean threads and sealing surface of fuel tank adapter

and inspect for damage. Replace if necessary.

20. Slide new clamp onto free end of carburetor fuel inlet

hose. Install hose onto fuel outlet fitting at front of fuel

16. With hex side down, turn jam nut two full turns in a coun-

valve. Crimp clamp using HOSE CLAMP PLIERS (HD-

terclockwise direction to thread onto fuel tank adapter.

97087-65B).

17. Insert fuel filter strainer into fuel tank. Holding hex jam

21. Turn handle of fuel valve to OFF and fill the fuel tank.

nut to prevent rotation, turn fuel valve two full turns in a

Carefully inspect for leaks at fitting.

clockwise direction to thread onto hex jam nut.

22. Turn valve handle to ON and start engine. No priming or

special procedures are required to start fuel flow. Care-

1WARNING

fully inspect for leaks at fitting.

Do not thread fuel valve onto hex jam nut more than two

23. Stop engine and return valve to the OFF position.

turns or nut may “bottom” on valve, a condition which

may result in a gasoline leak. Any gasoline leak is a

potential fire hazard that could result in death or serious

FUEL FILTER CANISTER

injury.

(FUEL INJECTED)

18. Holding fuel valve to prevent rotation, turn hex jam nut in

See Section 9.4 FUEL TANK (FUEL INJECTED), FUEL FIL-

a counterclockwise direction until snug. Tighten hex jam

TER CANISTER, for replacement procedure.

nut to 15-20 ft-lbs (20.3-27.1 Nm).

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2006 Touring: Maintenance

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BRAKES

1.14

NOTE

GENERAL

Use only Harley-Davidson DOT 4 BRAKE FLUID, Part No.

See Section

1.2 MAINTENANCE SCHEDULE for the

99953-99A (12 ounce bottle), from a sealed container.

required service interval.

Install cover (with gasket) on the master cylinder reser-

voir. Install two Phillips screws and tighten to 6-8 in-lbs

PROCEDURE

(0.7-0.9 Nm).

1WARNING

BRAKE FLUID

After repairing the brake system, test brakes at low

Inspect the brake fluid condition and level. Proceed as fol-

speed. If brakes are not operating properly, testing at

lows:

high speeds can cause loss of control, which could

result in death or serious injury. (00289a)

CAUTION

DOT 4 brake fluid will damage painted and molded-in

color surfaces it comes in contact with. Always use cau-

BRAKE PADS AND DISCS

tion and protect surfaces from spills whenever brake

work is performed. Failure to comply can result in cos-

Inspect the brake pads and discs as follows:

metic damage. (00239a)

Brake Pads

IMPORTANT NOTE

If brake pad friction material is worn to 0.04 inch (1.02 mm) or

Immediately wipe up any brake fluid spillage with a

less, replace the entire set of pads.

clean, dry, soft cloth. Follow up by thoroughly wiping

affected area with a clean, damp, soft cloth (small spills)

or washing with a large quantity of soapy water (large

1WARNING

spills).

Always replace brake pads in complete sets for correct

and safe brake operation. Improper brake operation

CAUTION

could result in death or serious injury. (00111a)

To prevent dirt and other contaminants from entering the

Brake Discs

master cylinder reservoir, thoroughly clean the cover

before removal.

The minimum brake disc thickness is stamped on the side of

the disc.

Remove two Phillips screws from cover of master cylin-

der reservoir. Remove cover (with gasket).

When checking the brake pads and discs, inspect the brake

lines and hoses for damage or leaks.

1WARNING

Use only fresh, uncontaminated DOT 4 brake fluid. Fluid

containers that have been opened may have been con-

taminated by dirt or moisture. Use of contaminated

brake fluid may adversely affect braking ability and lead

to brake failure which could result in death or serious

injury.

IMPORTANT NOTE

The shelf life of a bottle of unopened DOT 4 brake fluid is

one year. The shelf life of an uncontaminated bottle that

has been opened and then resealed is one week.

Stand the motorcycle upright so that the master cylinder

reservoir is in a level position. Fluid level should be 1/4

inch (6.4 mm) from the top. Add fluid as necessary.

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SPARK PLUGS

1.15

Before installing spark plugs, check condition of threads

GENERAL

in cylinder head and on plug. If necessary soften depos-

its with penetrating oil and clean out with a thread

See Section

1.2 MAINTENANCE SCHEDULE for the

chaser.

required service interval.

Apply a very light coating of ANTISEIZE LUBRICANT to

spark plug threads.

PROCEDURE

Install spark plug finger tight and then torque to 12-18 ft-

lbs (16-24 Nm).

NOTE

1WARNING

If a torque wrench is not available, finger tighten spark plug

Never disconnect a spark plug cable with the engine run-

and then using a spark plug wrench, tighten plug an addi-

ning. Doing so will result in an electric shock from the

tional 1/4 turn.

ignition system that could result in death or serious

injury.

Table 1-7. Spark Plug Data

Disconnect spark plug cables from spark plug terminals.

SIZE

12 mm

Remove spark plug using a 5/8 inch spark plug socket.

Examine plugs as soon as they have been removed. The

GAP

0.038-0.043 in. (0.97-1.09 mm)

deposits on the plug base are an indication of the plug

efficiency and are a guide to the general condition of

TYPE

HD-6R12 (No Substitute)

rings, valves, carburetor and ignition system.

a. A wet black and shiny deposit on plug base, elec-

NOTE

trodes and ceramic insulator tip indicate an oil

fouled plug. The condition may be caused by worn

The number 6R12 plug is supplied as original equipment and

rings and pistons, loose valves or seals, weak bat-

is the only plug that should be used. The resistor plug

tery or faulty ignition.

reduces radio interference created by the ignition system and

will not adversely affect performance or fuel economy.

b. A dry fluffy or sooty black deposit indicates a too

rich carburetor air-fuel mixture or long periods of

Install spark plug cable from left side coil tower onto front

engine idling. Excessive use of the enrichener may

cylinder spark plug. Install spark plug cable from right

also cause this condition.

side coil tower onto rear cylinder spark plug.

c. An overheated plug can be identified by a light

brown, glassy deposit. This condition may be

accompanied by cracks in the insulator or by ero-

sion of the electrodes. This condition is caused by

too lean an air-fuel mixture, a hot running engine,

valves not seating or improper ignition timing. The

glassy deposit on the spark plug is a conductor

when hot and may cause high speed misfiring. A

plug with eroded electrodes, heavy deposits or a

cracked insulator should be replaced.

d. A plug with white, yellow or light tan to rusty brown

powdery deposit indicates balanced combustion.

The deposits may be cleaned off at regular intervals

if desired.

Set the spark plug gap using a wire-type gauge. Bend

the outside electrode so only a slight drag on the gauge

is felt when passing it between electrodes. Never make

adjustments by bending the center electrode. Set gap on

all plugs at 0.038-0.043 in. (0.97-1.09 mm)

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2006 Touring: Maintenance

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ENGINE IDLE SPEED

1.16

GENERAL

Throttle

Stop Screw

See Section

1.2 MAINTENANCE SCHEDULE for the

required service interval.

PROCEDURE

Inspect the engine idle speed as follows:

NOTES

● The C.V. carburetor has an enrichener circuit that will

cause the engine to idle at approximately 1500 rpm with

the engine at normal operating temperature and the

enrichener knob pulled fully out.

● The increase in idle speed is intended to alert the rider

that the engine is warmed up to normal operating tem-

perature and the enrichener knob should be pushed all

the way in.

f1381d2x

● Continuing to use the enrichener when the engine is at

full operating temperature WILL CAUSE FOULED

PLUGS.

Figure 1-24. Idle Speed Adjustment

● TECHNICIAN - Be sure the engine is warmed up to nor-

mal operating temperature and the enrichener knob is

pushed all the way in BEFORE adjusting engine idle

NOTE

speed. Be aware that because there are variations in

To measure engine rpm on models without tachometers, use

individual components, it is possible for a properly

a test tachometer connected to the negative ignition coil ter-

warmed up engine to idle at

2000 rpm with the

minal.

enrichener knob pulled PARTIALLY OUT.

See Figure 1-24. With the engine at normal operating

temperature and the enrichener all the way in

(enrichener valve closed) adjust the throttle stop screw

so the engine idles at 950-1050 rpm.

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STEERING HEAD BEARINGS

1.18

GENERAL

f2108x2x

See Section

1.2 MAINTENANCE SCHEDULE for the

required service interval.

PROCEDURE

GREASING

Turn handlebar full right to access the grease fitting at

the left side of the steering head. See Figure 1-25.

Using SPECIAL PURPOSE GREASE (Part No. 99857-97),

connect grease gun to fitting and inject grease until it

exudes from top and bottom of steering head.

Figure 1-25. Steering Head Bearing Grease Fitting

CHECKING

Check the swing-by and adjust as necessary. See Section

2.17 STEERING HEAD BEARINGS for more information.

INSPECTING/REPLACING

Disassemble the steering head and inspect the bearings for

brinelling, scoring, or other damage. Replace and/or repack

the bearings as required. See Section

2.17 STEERING

HEAD BEARINGS for more information.

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CRITICAL FASTENERS

1.19

●

Tighten four engine to transmission bolts to 30-35 ft-lbs

GENERAL

(41-48 Nm).

See Section

1.2 MAINTENANCE SCHEDULE for the

NOTE

required service interval.

Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER

PROCEDURE

PARTIAL REMOVAL), INSTALLATION (AFTER PARTIAL

REMOVAL), or FLHR/S. For fuel injected models, see Sec-

tion

9.4 FUEL TANK (FUEL INJECTED), INSTALLATION

ENGINE MOUNTS

(AFTER PARTIAL REMOVAL), FLHXI, FLHT/C/U/I, FLTRI, or

FLHR/C/S/I.

Inspect the condition and tightness of the stabilizer links and

engine mounts. Replace fastener if damaged. Proceed as fol-

lows:

OTHER FASTENERS

NOTE

Inspect the condition and tightness of other critical fasteners.

Raise fuel tank to access top engine stabilizer bolts and jam

Replace fastener if damaged. Proceed as follows:

nuts. For carbureted models, see Section 4.7 FUEL TANK

(CARBURETED), PARTIAL REMOVAL, FLHX, FLHT, or

FLHR/S. For fuel injected models, see Section 9.4 FUEL

Table 1-8. Critical Fastener Torque

TANK (FUEL INJECTED), PARTIAL REMOVAL, FLHXI,

FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

Fastener

ft/in-lbs

Axle

Top

Front axle nut

50-55 ft-lbs

68-75 Nm

● On left side of motorcycle, tighten top engine mounting

Rear axle cone nut

95-105 ft-lbs

129-142 Nm

bracket bolts to front and rear cylinder heads to 35-40 ft-

Brakes

lbs (48-54 Nm). See A of Figure 1-26.

Banjo Bolts

17-22 ft-lbs

23-30 Nm

● Top stabilizer link - tighten eyelet bolt to top engine

Front Brake Disc Mounting

16-24 ft-lbs

22-33 Nm

mounting bracket to 18-22 ft-lbs (24-30 Nm). See B of

Screws

Figure 1-26.

Front Brake Caliper Mounting

28-38 ft-lbs

38-52 Nm

● Moving to right side of motorcycle, tighten eyelet bolt to

Bolts

frame weldment to 18-22 ft-lbs (24-30 Nm). See C of Fig-

Brake Caliper Pad Pins

180-200 in-lbs

20-23 Nm

ure 1-26.

Rear Brake Disc Mounting

30-45 ft-lbs

41-61 Nm

Screws

● Verify tightness of jam nuts on top stabilizer link.

Rear Master Cylinder Mounting

30-40 ft-lbs

41-54 Nm

Nut

Bottom

Reservoir Cover Screws

6-8 in-lbs

0.7-0.9 Nm

● Front stabilizer link - on left side of motorcycle, tighten

Front Forks

eyelet bolt to frame weldment to 18-22 ft-lbs (24-30 Nm).

See D of Figure 1-26.

Axle Holder Nuts

132-180 in-lbs

14.9-20.3 Nm

● Moving to right side of motorcycle, tighten eyelet bolt to

Hand Controls

block on front engine mounting bracket to 18-22 ft-lbs

Clutch Lever/Handlebar Clamp

60-80 in-lbs

6.8-9.0 Nm

(24-30 Nm). See E of Figure 1-26.

Master Cylinder/Handlebar

60-80 in-lbs

6.8-9.0 Nm

● Verify tightness of jam nuts on front stabilizer link.

Clamp Screws

● Tighten center front engine mounting bracket to rubber

Upper/Lower Switch Housing

35-45 in-lbs

4-5 Nm

Screws

mount bolt to 15-20 ft-lbs (20-27 Nm). See F of Figure 1-

26.

Handlebars

● Tighten the two front engine mount to frame crossmem-

Lower Clamp (Riser) Bolts

30-40 ft-lbs

40.7-54.2 Nm

ber bolts to 15-20 ft-lbs (20-27 Nm). See G of Figure 1-

Pivot Shaft

26.

Locknuts

40-45 ft-lbs

54-61 Nm

● Tighten two engine to front engine mounting bracket

Swingarm Bracket Bolts

34-42 ft-lbs

46-57 Nm

bolts to 33-38 ft-lbs (45-52 Nm). See H of Figure 1-26.

1-34

2006 Touring: Maintenance

HOME

BATTERY

1.20

Inspect battery for discoloration, raised top, or warped

GENERAL

case, which may indicate that battery has been over-

heated or overcharged. Inspect battery case for cracks

See Section

1.2 MAINTENANCE SCHEDULE for the

or leaks. Replace battery if any of these conditions are

required service interval.

found.

NOTE

For testing or charging information, see Section 8.10 BAT-

PROCEDURE

TERY.

Coat battery terminals with ELECTRICAL CONTACT

Verify that battery top is clean and dry. Dirt on top of bat-

LUBRICANT, Part No. 99861-02 (1 oz tube).

tery may cause it to self-discharge at a faster than nor-

mal rate.

Inspect battery clamp, screws and cables for breakage,

loose connections and corrosion. Clean or replace as

necessary.

1-36

2006 Touring: Maintenance

HOME

TROUBLESHOOTING

1.21

10. Ignition timing incorrect due to faulty ignition coil, ignition

GENERAL

module or sensors (MAP, CKP and/or TSM/TSSM).

The following check list of possible operating troubles and

11. Engine lubricant too heavy (winter operation).

their probable causes will be helpful in keeping your motorcy-

NOTE

cle in good operating condition. More than one of these con-

Always disengage clutch for cold weather starts.

ditions may be causing the trouble and all should be carefully

checked.

12. Sticking or damaged valve or push rod wrong length.

13. Primary cam sprocket spline sheared or missing spacer.

1WARNING

The troubleshooting section of this manual is a guide to

Starts Hard

diagnose problems. Read the appropriate sections of

Spark plugs in bad condition, have improper gap or are

this manual before performing any work. Improper repair

partially fouled.

and/or maintenance could result in death or serious

injury.

Spark plug cables in bad condition.

Battery nearly discharged.

ENGINE

Loose wire connection at one of the battery terminals,

ignition coil or plug between ignition sensor and module.

Carburetor controls not adjusted correctly.

Starter Motor Does Not Operate or Does

Water or dirt in fuel system and carburetor.

Not Turn Engine Over

Intake air leak.

Ignition/Light Key Switch not in IGNITION position.

Fuel tank vent hose and vapor valve plugged, or carbu-

Engine Stop switch in the OFF position.

retor fuel line closed off and restricting fuel flow.

Discharged battery, loose or corroded connections

Enrichener valve inoperative.

(solenoid chatters).

10. Engine lubricant too heavy (winter operation).

TSM/TSSM BAS tripped and Ignition/Light Key Switch

NOTE

not cycled to OFF and then back to IGNITION.

Always disengage clutch for cold weather starts.

Starter control circuit, relay or solenoid faulty.

11. Ignition not functioning properly (possible sensor failure).

Electric starter shaft pinion gear not engaging or over-

running clutch slipping.

12. Faulty ignition coil.

13. Valves sticking.

Engine Turns Over But Does Not Start

Starts But Runs Irregularly or Misses

Fuel tank empty.

Fuel supply valve turned to OFF.

Spark plugs in bad condition or partially fouled.

Fouled spark plugs.

Spark plug cables in bad condition and leaking.

Engine flooded with gasoline as a result of over use of

Spark plug gap too close or too wide.

enrichener.

Faulty ignition coil, module and/or sensor.

Fuel valve or filter clogged.

Battery nearly discharged.

Vacuum hose to automatic fuel supply valve discon-

Damaged wire or loose connection at battery terminals,

nected, leaking or pinched.

ignition coil, or plug between ignition sensor and module.

Discharged battery, loose or broken battery terminal

Intermittent short circuit due to damaged wire insulation.

connections.

Water or dirt in fuel system, carburetor or filter.

Loose wire connection at coil, battery or plug between

Fuel tank vent system plugged or carburetor vent line

ignition sensor and module.

closed off.

Spark plug cables in bad condition and shorting, cable

10. Carburetor controls misadjusted.

connections loose, or cables connected to wrong cylin-

ders.

11. Damaged carburetor.

2006 Touring: Maintenance

1-37

HOME

12. Loose or dirty ignition module connector at crankcase.

Engine to transmission mounting bolts loose.

13. Faulty MAP and/or CKP Sensor.

Upper engine mounting bracket loose.

14. Incorrect valve timing.

Ignition timing incorrect/poorly tuned engine.

15. Weak or broken valve springs.

Internal engine problem.

16. Damaged intake or exhaust valve.

Broken frame.

Stabilizer links worn or loose.

A Spark Plug Fouls Repeatedly

10. Rubber mounts loose or worn.

11. Rear fork pivot shaft nuts loose.

Fuel mixture too rich or enrichener left out too long.

12. Front engine mounting bolts loose.

Incorrect spark plug for the kind of service.

Piston rings badly worn or broken.

Check Engine Lamp Illuminates During

Valve guides or seals badly worn.

Operation

Fault detected. Check for trouble codes.

Pre-Ignition or Detonation (Knocks or

Pings)

Fuel octane rating too low.

LUBRICATION SYSTEM

Faulty spark plugs.

Incorrect spark plug for the kind of service.

Oil Does Not Return To Oil Pan

Excessive carbon deposit on piston head or in combus-

tion chamber.

Oil pan empty.

Ignition timing advanced due to faulty sensor inputs

Oil pump not functioning.

(MAP, CKP).

Restricted oil lines or fittings.

Restricted oil filter.

Overheating

Oil pump misaligned or in poor condition.

Insufficient oil supply or oil not circulating.

O-ring damaged or missing from oil pump/crankcase

Insufficient air flow over engine.

junction (also results in poor engine performance).

Heavy carbon deposit.

Ignition timing retarded due to faulty MAP and/or CKP

Engine Uses Too Much Oil Or Smokes

Sensor.

Excessively

Leaking valve.

Oil pan overfilled.

Restricted oil return line to pan.

Valve Train Noise

Restricted breather operation.

Low oil pressure caused by oil feed pump not functioning

Restricted oil filter.

properly or oil passages obstructed.

Oil pump misaligned or in poor condition.

Faulty hydraulic lifters.

Piston rings badly worn or broken.

Bent push rod.

Valve guides or seals worn.

Incorrect push rod length.

O-ring damaged or missing from oil pump/crankcase

Rocker arm binding on shaft.

junction (also results in poor engine performance).

Valve sticking in guide.

Chain tensioner spring or shoe worn.

Engine Leaks Oil From Case, Push Rods,

Hoses, Etc.

Excessive Vibration

Loose parts.

Wheels and/or tires worn or damaged.

Imperfect seal at gaskets, push rod cover, washers, etc.

Restricted oil return line to pan.

Engine/transmission/motorcycle not aligned properly.

Restricted breather hose to air cleaner.

Primary chain badly worn or links tight as a result of

insufficient lubrication or misalignment.

Restricted oil filter.

1-38

2006 Touring: Maintenance

Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 2