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Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 6

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7.

Install pad pins, but do not fully tighten.

1

8.

Pump rear brake pedal to move inside pistons out until

they contact inside brake pad.

9.

Pry the outside pad back pushing the pistons into their

bores. Use a putty knife with a wide thin blade to avoid

scoring or scratching the brake disc.

10. Verify that inside pad is captured between brake disc

and pistons. Completely remove pad pins to free outside

brake pad. Note the orientation of the pad.

11. Install new outside brake pad using the same orienta-

tion. Curved portion of pad must face rear of motorcycle.

If the inside pad moved during the previous step, rein-

stall.

f2026x2x

2

3

NOTE

1.

Pad Pins

Replacing one pad at a time keeps the anti-rattle spring in

2.

Bridge Bolts

place. Remove both pads to remove or replace the spring.

3.

Anchor Weldment

12. Inspect pad pins. See CLEANING AND INSPECTION,

step 4.

Figure 2-65. Loosen Both Pad Pins

13. Install two pad pins and tighten to 180-200 in-lbs (20.3-

22.6 Nm).

IMPORTANT NOTE

Immediately wipe up any brake fluid spillage with a

1WARNING

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

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

After servicing brakes and before moving motorcycle,

or washing with a large quantity of soapy water (large

pump brakes to build brake system pressure. Insuffi-

spills).

cient pressure can adversely affect brake performance,

which could result in death or serious injury. (00279a)

CAUTION

14. Pump rear brake pedal to move pistons out until they

To prevent dirt and other contaminants from entering the

contact both brake pads. Verify piston location against

master cylinder reservoir, thoroughly clean the cover

pads.

before removal.

3.

Remove two Phillips screws to release cover from rear

master cylinder reservoir.

2

1

NOTE

As the pistons are pushed back into the caliper, fluid level

may rise more than 1/4 inch (6.4 mm) and overflow the reser-

voir. Watch the fluid level as the pistons are retracted and

remove fluid from the reservoir if necessary.

4.

Pry the inside pad back pushing the pistons into their

bores. Use a putty knife with a wide thin blade to avoid

scoring or scratching the brake disc.

NOTE

Do not completely pull pad pins from caliper during the next

step. Completely removing pad pins at this time will make

f2156x2x

3

assembly difficult.

5.

Once the pistons have been retracted, pull the pad pins

1.

Outboard Pad

part way out until the inside pad drops free. Note the ori-

2.

Inboard Pad

Right Side

entation of the pad.

3.

Faces Rear

6.

Install new inside brake pad using the same orientation.

Figure 2-66. Rear Brake Pad Locations

Curved portion of pad must face rear of motorcycle.

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2006 Touring: Chassis

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1.

Bridge Bolt (3)

12. Inner Brake Pad

15

2.

Pad Pin (2)

13. Anti-Rattle Spring

3.

Decal

14. Crossover O-Ring (2)

4.

Outside Caliper Housing

15. Inside Caliper Housing

5.

Rubber Damper

6.

Bleeder Valve

13

7.

Bleeder Valve Cap

8.

Square Seal (4)

9.

Wiper (4)

14

10. Piston (4)

10

11. Outer Brake Pad

6

8

7

10

9

8

12

11

9

2

3

1

4

5

f2072x2x

Figure 2-67. Rear Brake Caliper Assembly (Right Side)

15. Verify that brake fluid level is 1/4 inch (6.4 mm) below top

of reservoir with master cylinder in a level position. Add

1WARNING

DOT 4 BRAKE FLUID, if necessary.

After repairing the brake system, test brakes at low

16. Install the master cylinder reservoir cover, but first verify

speed. If brakes are not operating properly, testing at

high speeds can cause loss of control, which could

that the cover gasket bellows is not extended or brake

result in death or serious injury. (00289a)

fluid will be ejected from the reservoir. Install two Phillips

screws and alternately tighten to

6-8 in-lbs

(0.7-0.9

20. Test ride the motorcycle. If the brakes feel spongy, bleed

Nm).

the system again. See Section

2.14 BLEEDING

HYDRAULIC BRAKES.

17. Install master cylinder reservoir cover. Install two Phillips

screws to fasten cover to reservoir and tighten to 6-8 in-

NOTE

lbs (0.7-0.9 Nm).

To allow new brake pads to “wear in” properly with the brake

disc, avoid making hard stops for the first 100 miles (160 km).

18. Install right side saddlebag. See Section 2.26 SADDLE-

BAG, INSTALLATION.

19. Test operation of brake lamp with the rear brake applied

and the Ignition/Light Key Switch turned to IGNITION.

2006 Touring: Chassis

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5.

Remove caliper from anchor weldment on rear swing-

arm.

CALIPER DISASSEMBLY

1.

See Figure 2-65. Remove two pad pins. Remove brake

pads from caliper housings.

2.

Remove three bridge bolts and separate inside and out-

side caliper housings.

3.

Remove anti-rattle spring from channel around boss in

Figure 2-68. Brake Caliper Piston Remover

outside caliper housing.

(Part No. HD-43293A)

4.

If damaged, cut anchor of rubber damper and remove.

5.

Remove bleeder valve, if damaged.

f1781x2x

1WARNING

Compressed air can pierce the skin and flying debris

from compressed air could cause serious eye injury.

Wear safety glasses when working with compressed air.

Never use your hand to check for air leaks or to deter-

mine air flow rates. (00061a)

6.

Remove four pistons as follows:

a. Obtain BRAKE CALIPER PISTON REMOVER (Part

No. HD-43293A). See inset of Figure 2-68.

Brake Caliper

Piston Remover

Bridge

b. Seat tool in outside caliper housing aligning holes in

Bolt

tool with three bridge bolt holes in housing. Place

inside caliper housing over tool aligning bridge bolt

Figure 2-69. Direct Compressed Air Into Banjo Bolt Hole

holes with three holes in tool.

c. Install bridge bolts and tighten securely.

d. If the bleeder valve was removed, reinstall finger

CALIPER REMOVAL

tight or place a gloved finger over the valve hole.

NOTE

CAUTION

If only replacing brake pads, see REAR BRAKE PAD

To prevent air from escaping through the banjo bolt hole,

REPLACEMENT in this section.

and to avoid scratching or nicking the banjo seating sur-

face, use only a tapered, rubber tipped nozzle on air

1.

Block motorcycle underneath frame so rear wheel is

hose. Loss of air pressure will keep the pistons from

raised off the ground.

moving, while any damage to the banjo seating surface

2.

Remove saddlebags. See Section 2.26 SADDLEBAG,

requires caliper replacement.

REMOVAL.

e. Using a tapered, rubber-tipped nozzle on the air

hose, apply low pressure compressed air into the

CAUTION

banjo bolt hole to force pistons into contact with

Damaged banjo bolt surfaces will leak when reassem-

cushion of tool. See Figure 2-69.

bled. Prevent damage to seating surfaces by carefully

f.

Remove bridge bolts and separate caliper housings.

removing brake line components.

g. Remove pistons from caliper piston bores. For best

3.

Remove banjo bolt and two steel/rubber washers to

results, wiggle pistons slightly while pulling.

detach rear brake line from caliper. Discard washers.

4.

Remove rear wheel. See Section 2.4 REAR WHEEL,

7.

Remove two crossover O-rings from inside caliper hous-

REMOVAL, steps 2-7.

ing. Discard O-rings.

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c. Check rubber damper for cuts, tears or signs of

f1779x2x

deterioration.

d. Always replace wipers, square seals and crossover

O-rings after caliper disassembly.

1WARNING

Always replace brake pads in complete sets for correct

and safe brake operation. Improper brake operation

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

3.

Inspect brake pads and discs. See INSPECTION at the

beginning of this section.

Wiper

4.

Inspect pad pins for wear and grooving. Replace both

Square

pins if wear of either pin exceeds 0.015 inch (0.38 mm).

Seal

Figure 2-70. Remove Wipers and Square Seals

CALIPER ASSEMBLY

From Piston Bores

1.

Install new square seals into caliper piston bores.

CAUTION

2.

Install new wipers into caliper piston bores.

Do not use metal objects to remove parts from caliper

piston bores or damage will occur. Damaged pistons or

CAUTION

bores will leak when reassembled. Use a wooden tooth-

pick to assist in the removal of parts, if necessary.

Do not use DOT 4 brake fluid for lubrication or in-

creased lever travel will result.

8.

Using a wooden toothpick, remove wiper and square

seal from each piston bore. Discard wipers and seals.

3.

Lubricate the following areas using a thin film of G.E.

See Figure 2-70.

VERSILUBE^® #G322L SILICONE GREASE (marked

“Piston Lube” in the service parts kit):

● Inside diameter of square seals and wipers.

CLEANING AND INSPECTION

● Caliper piston bores.

● Nose radius and outside diameter of piston.

1WARNING

Use denatured alcohol to clean brake system compo-

f1782x2x

nents. Do not use mineral-based solvents (such as gaso-

line or paint thinner), which will deteriorate rubber parts

even after assembly. Deterioration of these components

Rubber Damper

can cause brake failure, which could result in death or

Anchor Bead

serious injury. (00291a)

1.

Clean all parts with denatured alcohol or DOT 4 BRAKE

FLUID. Wipe parts dry with a clean, lint free cloth. Blow

Anti-Rattle

out drilled passages and bores with a clean air supply.

Spring

Do not use a wire or similar instrument to clean drilled

passages.

2.

Carefully inspect all components. Replace any parts that

appear damaged or worn.

a. Check pistons for pitting, scratching or corrosion on

face and also on ground surfaces.

b. Inspect caliper piston bore. Replace caliper if bore

shows signs of pitting or corrosion. Do not hone

bore for reuse.

Figure 2-71. Install Anti-Rattle Spring

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BLEEDING HYDRAULIC BRAKES

2.14

GENERAL

Bleed the hydraulic brake system any time a brake line, mas-

ter cylinder or brake caliper has been opened or disassem-

bled, or whenever the brake lever/pedal operation feels

“spongy.” Bleeding evacuates air from the system leaving

only incompressible hydraulic fluid.

NOTE

Harley-Davidson recommends that all brake service be per-

formed by a Harley-Davidson dealer or other qualified techni-

cian.

NOTE

Hydraulic brake fluid bladder-type pressure equipment can

be used to fill brake master cylinders through the bleeder

valve. Remove master cylinder reservoir cover so that sys-

tem cannot pressurize. Do not use pressure bleeding equip-

ment when the hydraulic system is sealed with master

cylinder reservoir cover and gasket in place.

f1994x2x

CAUTION

Figure 2-72. Bleeding Hydraulic System

DOT 4 brake fluid will damage painted and molded-in

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

tion and protect surfaces from spills whenever brake

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

CAUTION

metic damage. (00239a)

To prevent dirt and other contaminants from entering the

IMPORTANT NOTE

master cylinder reservoir, thoroughly clean the cover

before removal.

Immediately wipe up any brake fluid spillage with a

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

2.

Remove the two Phillips screws to release cover from

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

the master cylinder reservoir.

or washing with a large quantity of soapy water (large

3.

Add DOT 4 BRAKE FLUID to the master cylinder reser-

spills).

voir until the fluid level is 1/4 inch (6.4 mm) from the top.

Do not reuse old brake fluid. Use only DOT 4 fluid from a

1WARNING

sealed container.

4.

Depress and hold brake lever/pedal to build up hydraulic

Use only fresh, uncontaminated DOT 4 brake fluid. Fluid

pressure.

containers that have been opened may have been con-

taminated by dirt or moisture. Use of contaminated

5.

Open bleeder valve about 1/2 turn. Brake fluid will flow

brake fluid may adversely affect braking ability and lead

from bleeder valve through tubing. Close bleeder valve

to brake failure which could result in death or serious

when brake lever/pedal has moved 1/2 to 3/4 of its full

injury.

range of travel. Allow brake lever/pedal to return slowly

IMPORTANT NOTE

to its released position.

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

6.

Repeat steps 3-5 until all air bubbles are purged.

one year. The shelf life of an uncontaminated bottle that

7.

Final tighten the bleeder valve to

80-100 in-lbs

has been opened and then resealed is one week.

(9.0-11.3 Nm). Install the bleeder cap.

1.

Install end of a length of plastic tubing over caliper

8.

Add brake fluid to the master cylinder reservoir until the

bleeder valve. Place free end of tube in a clean con-

fluid level is about 1/4 inch (6.4 mm) from the top. Do not

tainer. See Figure 2-72. Stand motorcycle upright.

reuse brake fluid.

2-62

2006 Touring: Chassis

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FRONT FORKS

2.15

CHANGING FORK OIL

2

NOTE

If changing the fork oil at the 50,000 mile (80,000 km) service

interval, or if fork is leaking or fails visual inspection, see

REMOVAL and DISASSEMBLY, as complete disassembly

and inspection of the fork is required. However, if a decision

has been made to replace the fork oil before the recom-

mended service interval, and the fork passes visual inspec-

tion, see steps 1-5 below.

3

1.

Disassemble motorcycle and remove fork. See

REMOVAL.

2.

Partially disassemble fork. See DISASSEMBLY, steps 1-

8.

1

8312

3.

Position fork assembly upside down over drain pan.

Allow sufficient time for fork to thoroughly drain (about

1.

Pinch Bolt

10-15 minutes).

2.

Fork Cap Bolt

3.

Fork Stop

4.

Fill and assemble fork. See ASSEMBLY, steps 14-21.

Figure 2-73. Remove Fork Cap Bolt (FLHR/C/S Shown)

5.

Install fork and assemble motorcycle. See INSTALLA-

TION.

c. Remove two lower fork bracket screws to release

front turn signal lamp/auxiliary lamp bracket,

chrome skirt and inner fairing. If necessary, see

REMOVAL

Section

8.16 TURN SIGNAL LAMPS, FRONT

TURN SIGNAL LAMP, FLHX, REMOVAL, or Sec-

1.

Place suitable blocking under frame to raise front wheel

tion

8.13 AUXILIARY LAMPS, AUXILIARY LAMP

several inches off the floor. For best results, use an

BRACKET, REMOVAL.

hydraulic center stand on a level surface.

FLTR:

2.

Remove the front wheel and fender. See Section 2.33

a. Remove instrument nacelle. See Section

2.31

FRONT FENDER, REMOVAL.

UPPER FAIRING/WINDSHIELD (FLTR), INSTRU-

3.

Proceed as follows:

MENT NACELLE, REMOVAL.

FLHR/C/S:

4.

Standing at front of motorcycle, loosen fork cap bolt from

a. Remove headlamp nacelle. See Section

2.32

fork tube plug at top of fork tube, but do not remove.

WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S),

5.

Loosen pinch bolt (with lockwasher) on left side of lower

NACELLE REMOVAL

(FLHR/C) or NACELLE

fork bracket, but do not remove. See Figure 2-73.

REMOVAL (FLHRS).

6.

Spray glass cleaner on fork tube above the rubber fork

stop. After lubricating surfaces, move fork stop up fork

FLHX, FLHT/C/U:

tube until it contacts bottom of upper fork bracket.

a. Loosen two outer fairing screws outboard of the

7.

Holding fork slider to prevent fork from dropping, remove

speakers on the left and right side. Remove two

fork cap bolt from fork tube plug. Slide fork tube down

outer fairing screws reaching in below the left and

and out of upper fork bracket, fork stop, lower fork

right sides of the fairing cap. If necessary, see Sec-

bracket, and slider cover.

tion

2.30 UPPER FAIRING/WINDSHIELD (FLHX,

8.

Thread fork cap bolt back into fork tube plug to prevent

FLHT/C/U), OUTER FAIRING/WINDSHIELD,

loss of fork oil while handling.

REMOVAL.

9.

Move front fork to bench area. Place suitable drain pan

b. Remove fairing cap. See Section

2.30 UPPER

on floor beneath vise.

FAIRING/WINDSHIELD (FLHX, FLHT/C/U), FAIR-

ING CAP, REMOVAL.

10.

Repeat steps 4-9 to remove right fork.

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2006 Touring: Chassis

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4.

Remove fork cap bolt from fork tube plug. Remove and

discard quad ring seal.

Vise Grip

5.

Using flat, slowly unthread fork tube plug from fork tube.

Be aware that fork tube plug is under spring pressure, so

have a firm grasp on plug as the last thread is turned.

Remove O-ring from fork tube plug. Discard O-ring.

6.

Remove fork spring from fork tube.

7.

Remove fork assembly from fork tube holder.

8.

Turning fork upside down, drain fork oil into drain pan.

Rubber Pad

For best results, slowly pump fork tube and slider at least

ten times. Be aware that damper valve, if equipped, may

fall out of inverted fork tube while draining. With the wear

ring at the bottom (spring side up), slide damper valve

Figure 2-74. Fork Tube Holder (HD-41177)

back into fork tube when drained.

Flat

NOTE

f1898x2x

If just changing the fork oil, continue procedure at ASSEM-

BLY, step 14. If overhauling the fork assembly, continue with

Fork Tube

Plug

step below.

9.

Install fork spring back into fork tube.

10. Place a shop rag on the floor, and turning fork assembly

upside down, press end of spring against rag. While

compressing spring to prevent rotation of damper tube,

remove 6mm screw from end of fork slider. Use an air

impact wrench for best results. Discard 6mm screw and

copper crush washer.

11. Remove fork spring, damper valve (if equipped) and

damper tube from fork tube.

12. Remove wear ring and rebound spring from damper

Figure 2-75. Install Fork Tube Into Fork Holder

tube. Remove wear ring from damper valve, if equipped.

DISASSEMBLY

CAUTION

Do not expand or stretch retaining clip to remove from

1.

Remove the fork assembly. See REMOVAL in this sec-

fork tube or clip may become bent or distorted.

tion.

2.

On right side fork, remove nuts, lockwashers, flat wash-

13. Using pick tool, remove retaining clip between fork slider

and fork tube.

ers and axle holder from studs at end of fork slider.

14. Remove fork tube from fork slider.

CAUTION

NOTE

Exercise caution to avoid scratching or nicking fork

To overcome any resistance, use the fork tube as a slide

tube. Damaging tube can result in fork oil leaks after

hammer, that is, first push fork tube into fork slider and then

assembly.

pull it outward with a moderate amount of force. Repeat this

sequence until fork tube separates from fork slider.

3.

Obtain the FORK TUBE HOLDER (HD-41177). See Fig-

ure 2-74. Proceed as follows:

15. Slide fork oil seal, slider spacer and slider bushing off

a. Clamp end of tool in vise in a horizontal position

end of fork tube. Discard fork oil seal and slider bushing.

with plastic knobs facing toward you.

16. Gently pry at split line to expand fork leg bushing, and

b. With the fork cap bolt topside, clamp fork tube

then remove from groove at end of fork tube. Discard

between rubber pads on inboard side of tool.

fork leg bushing.

Tighten knobs until fork tube is securely held. See

Figure 2-75.

17. Remove lower stop from fork slider.

2006 Touring: Chassis

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HOME

3.

With the wear ring topside, slide damper tube into fork

tube, so that tube end drops through hole at bottom of

f2045x2x

fork tube. Install lower stop at end of damper tube.

4.

Install fork slider in fork tube holder. Slide fork tube into

fork slider.

5.

Coat slider bushing ID with clean fork oil. Slide slider

bushing down fork tube.

6.

Slide slider spacer down fork tube until it contacts slider

bushing.

7.

Obtain the FORK OIL SEAL INSTALLER (HD-34634).

See Figure 2-77. Proceed as follows:

Figure 2-76. Measure Fork Tube Runout

a. Slide the fork oil seal installer down the fork tube,

and using the tool like a slide hammer, drive slider

bushing into counterbore of fork slider. Remove tool.

CLEANING AND INSPECTION

NOTE

Place masking tape over edge of fork tube to avoid damaging

1.

Thoroughly clean and inspect all parts. Replace any

lip of fork oil seal during installation.

parts that are bent, broken or obviously damaged.

b. Coat new fork oil seal ID with clean fork oil. With the

2.

Inspect fork cap bolt quad ring seal and fork tube plug O-

lip garter spring side facing down (toward the fork

ring for cuts, tears or signs of deterioration. Replace if

slider), slide seal down fork tube until it contacts

necessary.

slider spacer. Remove masking tape from edge of

fork tube.

3.

Replace the retaining clip if bent or distorted.

4.

Check the slider and fork leg bushings for scratches or

excessive wear. Always replace bushings in a set if

f1901x2x

either bushing is damaged or worn.

5.

Check the fork tube and slider for scoring, scratches and

excessive or abnormal wear. Replace parts as neces-

sary. Set the fork tube on V-blocks and measure the

runout using a dial indicator gauge. Replace fork if

runout exceeds 0.008 inch (0.2 mm). See Figure 2-76.

6.

Inspect upper fork spring and rebound spring for dam-

age or distortion. Replace upper fork spring if free length

is less than 18.4 inches (467.3 mm). Replace rebound

Figure 2-77. Fork Oil Seal Installer (HD-34634)

spring if free length is less than 15/16 inches (23.8 mm)

or whenever the upper fork spring requires replacement.

f1902x2x

ASSEMBLY

CAUTION

Exercise caution to avoid scratching or nicking fork

tube. Damaging tubes can result in fork oil leaks after

assembly.

1.

Coat fork leg bushing ID with clean fork oil. Expand fork

leg bushing at split line only so far as required to slip

over end and into groove of fork tube.

2.

Install new wear ring in groove at top of damper tube.

Install rebound spring on opposite end.

Figure 2-78. Install Fork Oil Seal

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2006 Touring: Chassis

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c. Slide the fork oil seal installer down the fork tube

until it contacts the fork oil seal.

d. Using the tool like a slide hammer, drive fork oil seal

down fork tube until retaining clip groove is visible in

fork slider ID. See Figure 2-78. Remove tool.

CAUTION

Do not expand or stretch retaining clip to install on fork

tube or clip may become bent or distorted.

e. Slide the retaining clip down the fork tube until it

contacts the fork oil seal. Install retaining clip in the

fork slider groove.

Figure 2-79. Front Fork Oil Level Gauge (HD-59000B)

8.

Install fork spring into fork tube.

f2168x2x

9.

Remove fork assembly from fork tube holder.

10. Place a shop rag on the floor, and turning fork assembly

upside down, press end of spring against rag.

11. Install new 6mm screw with copper crush washer. Slide

screw through hole at bottom of fork slider and start into

end of damper tube.

12. While compressing spring to prevent rotation of damper

tube, tighten 6mm screw to 132-216 in-lbs (14.9-24.4

Nm).

13. Remove fork spring from fork tube.

14. With the fork tube topside, clamp fork slider (not the fork

tube) into fork tube holder.

15. Install the drain plug at the bottom of the fork slider, if

removed. Tighten plug to 72-96 in-lbs (8-11 Nm).

Figure 2-80. Remove Excess Fork Oil

NOTE

All touring models with the exception of Road King have the

damper valve type fork on both the left and right sides. Road

Table 2-5. Fork Oil Requirements

King uses the conventional type fork on both sides. See step

AMOUNT

16 to set fork oil level on a damper valve type fork; see step

FORK

MODEL

17 to set fork oil level on a conventional type fork.

TYPE

OZ.

ML

IN.

MM

16. Set fork oil level on damper valve type fork as follows:

All models except

Damper Valve

10.8

319

5.59

142

Road King

Damper Valve Type Fork: FLHX, FLHT/C/U, FLTR

Road King

Conventional

11.1

328

5.24

133

a. Pour slightly more than 10.8 ounces (319 ml) of

Harley-Davidson Type E Fork Oil directly into the

g. Loosen thumbscrew on metal ring of tool and move

fork tube.

it up or down the rod until bottom of ring is 5.59

b. Slowly pump fork tube until some resistance is felt

inches (142 mm) from end of rod. Tighten thumb-

and then pump a few more times.

screw.

c. Install new wear ring in groove of damper valve.

h. Push the plunger on the cylinder all the way in.

With the wear ring at the bottom (spring side up),

slide damper valve into fork tube.

i.

With the fork tube bottomed in the fork slider, insert

d. Install fork spring into fork tube. Use fork spring to

rod until metal ring rests flat on top of fork tube. See

push damper valve to bottom of fork tube. Remove

Figure 2-80.

fork spring from fork tube.

j.

Pull out plunger to suck fork oil from fork tube.

e. Slowly pump fork tube a few more times to dis-

Observe fork oil through transparent tube as it is

charge air from damper valve.

drawn into cylinder. If no oil is drawn through trans-

parent tube, add enough oil so that tool usage sets

f.

See Figure 2-79. Obtain the FRONT FORK OIL

fork oil level.

LEVEL GAUGE (HD-59000B).

2006 Touring: Chassis

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HOME

k. Remove rod from fork tube. Push plunger into cylin-

der to eject excess fork oil into suitable container.

1

f2394x2x

2

l.

If necessary, repeat steps 16(i) thru 16(k). Level is

correct when no fork oil is observed being drawn

through transparent tube.

3

4

* Fairing Equipped

Motorcycles Only

1WARNING

Be sure fork oil level is correct. The incorrect amount of

fork oil can adversely affect handling and may lead to

loss of vehicle control, which could result in death or

serious injury.

5

17.

Set fork oil level on conventional type fork as follows:

Conventional Type Fork: FLHR/C/S

a. Pour slightly more than 11.1 ounces (328 ml) of

6

12

Harley-Davidson Type E Fork Oil directly into the

7

fork tube.

13

b. Slowly pump fork tube until some resistance is felt

8

and then pump a few more times.

14

c. See Figure 2-79. Obtain the FRONT FORK OIL

15

LEVEL GAUGE (HD-59000B).

9

16

d. Loosen thumbscrew on metal ring of tool and move

it up or down the rod until the bottom of ring is 5.24

inches (133 mm) from end of rod. Tighten thumb-

10

17

screw.

e. Push the plunger on the cylinder all the way in.

f.

With the fork tube bottomed in the fork slider, insert

rod until metal ring rests flat on top of fork tube. See

18

Figure 2-80.

19

g. Pull out plunger to suck fork oil from fork tube.

Observe fork oil through transparent tube as it is

drawn into cylinder. If no oil is drawn through trans-

11

parent tube, add enough oil so that tool usage sets

fork oil level.

20

23

h. Remove rod from fork tube. Push plunger into cylin-

der to eject excess fork oil into suitable container.

i.

If necessary, repeat steps 17(f) thru 17(h). Level is

21

24

correct when no fork oil is observed being drawn

25

through transparent tube.

22

26

1WARNING

1.

Fork cap bolt

14.

Slider spacer

Be sure fork oil level is correct. The incorrect amount of

2.

Quad ring seal

15.

Slider bushing

fork oil can adversely affect handling and may lead to

3.

Fork tube plug

16.

Fork leg bushing

loss of vehicle control, which could result in death or

4.

O-Ring

17.

Lower stop

serious injury.

5.

Spring

18.

Fork slider

6.

Damper valve*

19.

Plug

18. With the closer spaced coils at the bottom, slide fork

7.

Wear ring*

20.

Flat Washer

spring into fork tube.

8.

Wear ring

21.

Copper washer

19. Remove fork slider from fork tube holder. Clamp fork

9.

Damper tube

22.

Screw (6mm)

tube into fork tube holder.

10. Rebound spring

23.

Axle holder

20. Install new O-ring onto fork tube plug. Compressing fork

11. Fork tube

24.

Flat washer (2)

spring with end of fork tube plug, thread fork tube plug

12. Retaining clip

25.

Lockwasher (2)

into fork tube. Tighten fork tube plug to 22-58 ft-lbs (30-

13. Lip seal

26.

Nut (2)

79 Nm).

Figure 2-81. Right Side Fork

2-68

2006 Touring: Chassis

HOME

LOWER FORK BRACKET COVER/AIR DAM

2.16

LOWER FORK BRACKET COVER

(FLHRS)

REMOVAL

1.

Moving to the back of the lower fork bracket, remove two

hex screws (with flat washers) to release cover flange.

2.

Holding cover to prevent from dropping, remove T40

TORX screw at bottom.

7590

INSTALLATION

Figure 2-82. Air Dam

1.

With the concave side up, align holes in cover flange

with holes at back of the lower fork bracket. Start two hex

screws (with flat washers).

AIR DAM (FLTR)

NOTE

REMOVAL

Plastic plug(s) at back of lower fork bracket will prevent

proper cover installation. Remove and discard plug(s), if

NOTE

present.

By allowing the flow of air to pass under the fuel tank and

over the cylinder heads, removing the air dam evacuates

3.

Start T40 TORX screw at bottom of cover engaging off-

heated air and provides some relief to the rider in warmer

set hole in front brake line bracket.

temperatures (70˚ F. or above).

4.

Alternately tighten two hex screws to 70-110 in-lbs (7.9-

1.

Moving to the back of the lower fork bracket, remove two

12.4 Nm).

hex screws (with flat washers) to release air dam. See

5.

Tighten T40 TORX screw to 120-180 in-lbs (13.6-20.3

Figure 2-82.

Nm).

2.

Reinstall two hex screws (with flat washers) to keep dirt

and debris out of holes in lower fork bracket. Tighten

6.

Verify that cover does not contact brake lines to front

screws to 120-144 in-lbs (13.6-16.3 Nm).

brake calipers or master cylinder reservoir. Adjust either

brake line bracket or cover if necessary.

INSTALLATION

NOTE

Reinstall air dam in colder weather.

1.

With the concave side down, align holes in air dam with

holes at back of the lower fork bracket. Start two hex

screws (with flat washers).

NOTE

Plastic plug(s) at back of lower fork bracket will prevent

proper cover installation. Remove and discard plug(s), if

present.

2.

Alternately tighten hex screws to 120-144 in-lbs (13.6-

16.3 Nm).

2-70

2006 Touring: Chassis

HOME

STEERING HEAD BEARINGS

2.17

LUBRICATION

f2108x2x

At the 1000 mile (1600 km) service interval, and at every

10,000 mile (16,000 km) service interval thereafter, grease

the steering head bearings using Special Purpose Grease,

Part No. 99857-97. Turn handlebar full right to access the

grease fitting at the left side of the steering head. Connect

grease gun to fitting and inject grease until it exudes from top

and bottom of steering head. See Figure 2-83.

At every 25,000 mile (40,000 km) service interval, check the

swing-by following the CHECKING procedure below.

At every 50,000 mile (80,000 km) service interval, disassem-

ble the steering head and inspect the bearings for brinelling,

scoring, or other damage. Replace and/or repack the bear-

ings as required.

Figure 2-83. Steering Head Bearing Grease Fitting

CHECKING

1.

Using an hydraulic center stand on a level surface, raise

ADJUSTMENT

the vehicle so that the front and rear tires are the same

distance from the floor.

1.

On FLHX, FLHT/C/U models, remove outer fairing and

2.

Verify that motorcycle is in stock configuration. Remove

radio (storage box on FLHT). On FLHR/C/S, remove

all non-factory accessories, since they can influence

headlamp nacelle. On FLTR models, remove the instru-

front end swing momentum (and lead to improper adjust-

ment bezel.

ment).

2.

Loosen the pinch bolts on the lower fork bracket and

3.

Turn the front wheel until contact is made with the left

slide the rubber fork stops up slightly on the fork tubes.

fork stop and then let go. The wheel should swing right,

This will prevent any binding of the front end when the

left, then right and stop. The wheel need not stop near

adjustment is made. See Figure 2-73.

the center or straight-forward position, but it must move

to the right making a partial third swing. See frame C of

3.

Bend tab on lock plate away from flat of fork stem nut.

Figure 2-84.

Loosen the fork stem nut. See Figure 2-85.

4.

To correct a swing pattern that is too short or too long,

4.

Fashion a bearing adjuster tool using a drill rod

16

see ADJUSTMENT below.

inches long. See lower frame of Figure 2-86.

A

B

C

D

Steering head is set up too

Steering head is still set up too

Steering head adjustment is

Steering head is set up too

tight. The wheel stops in its first

tight. The wheel stops in its

OK. The wheel need not stop

loose. The wheel begins its

swing.

second swing. A steering head

near the center, but it must

fourth swing. A steering head

that is too tight can interfere

move to the right making a

that is too loose can interfere

with the vehicle’s ability to

partial third swing.

with the vehicle’s ability to

absorb a weave.

absorb a wobble.

CORRECT

f1475x2x

Figure 2-84. Check Steering Head Bearing Swing-By

2006 Touring: Chassis

2-71

HOME

f1907x2x

Fork Stem

9441

Nut

Upper Fork Bracket

Bearing

Adjuster

Star Nut

Lock

Plate

Figure 2-85. Fork Stem Nut

f1792x2x

5/32 Inch goes back

for 1-1/4 Inches.

To decrease the number of swings, stand on the left side

5/32 Inch

A

of the vehicle and insert the rod to engage the notches

1/8 Inch

of the bearing adjuster (star) nut under the fork bracket.

NOTE

2 Inches

Each Rod is 1/4 Inch Diameter

Start of

Push forward to rotate the nut clockwise.

by 16 Inches Long.

Bend

A

End View

NOTE

Turning the bearing adjuster nut as little as one notch will

A

make a noticeable difference in the swing pattern.

To increase the number of swings, stand on the right

side of the vehicle and insert the rod to engage the

notches of the bearing adjuster nut. Push forward to

rotate the nut counterclockwise.

5.

Tighten the fork stem nut to 60-80 ft-lbs (81-109 Nm).

The tightness of the nut will affect the swing pattern.

6.

Recheck the swing pattern. See step 3 under CHECK-

ING. Repeat steps 4-6 above until swing pattern is cor-

rect.

7.

Tighten pinch bolts to 30-35 ft-lbs (41-48 Nm) and prop-

erly position the rubber fork stops.

8.

Verify that the fork stem nut is tightened to 60-80 ft-lbs

FLTR

(81-109 Nm). Bend tab on lockplate against flat of fork

All Others

Road Glide

stem nut.

9.

On FLHX, FLHT/C/U models, install radio (storage box

on FLHT) and outer fairing. On FLHR/C/S, install head-

lamp nacelle. On FLTR models, install the instrument

bezel.

Figure 2-86. Fashion Steering Head Bearing

10. Recheck the swing pattern. See step 3 under CHECK-

Adjustment Tool From Drill Rod

ING. Repeat ADJUSTMENT procedure if swing pattern

is not correct.

2.

Remove the front wheel and fork assemblies. Remove

brake line from lower fork bracket.

REMOVAL

3.

Bend tab away from flat of fork stem nut. Remove nut.

1.

On FLHX, FLHT/C/U models, remove the auxiliary lamp

4.

Remove the bearing adjuster and fork stem assembly.

bracket, outer fairing and radio (storage box on FLHT).

See upper frame of Figure 2-86. Remove dust shield

On FLHR/ C, remove headlamp nacelle. On FLTR mod-

and bearing from top of steering head.

els, remove the instrument nacelle.

2-72

2006 Touring: Chassis

HOME

f1279x2x

Remover

Collet

A

Figure 2-87. Steering Head Bearing Race Remover

(Part No. HD-39301A)

B

Figure 2-88. Universal Driver (Part No. HD-33416)

INSPECTION

1.

Check the bearing races in the steering head. If pitted or

C

grooved, replace both the bearings and races.

2.

Turn bearings in races. Replace the bearings if they do

not move freely and smoothly. Always replace both races

and bearings even if one race and bearing appears

good.

STEERING HEAD BEARING RACE REMOVAL

NOTE

To remove the upper and lower steering head bearing races,

use the Steering Head Bearing Race Remover (Part No. HD-

39301A) with the Universal Driver (Part No. HD-33416). See

D

Figure 2-87 and Figure 2-88.

Proceed as follows:

1.

With the tapered side down, seat the two-piece remover

tool on the upper bearing race leaving a gap in the mid-

dle. See Figure 2-89.

2.

Install the collet on the driver.

3.

Insert the driver at the bottom of the steering head tube,

and while holding the remover tool on the race, center

the collet in the gap. Tap the driver to remove the upper

A

Install Remover on Upper Race

race.

B

Install Collet on Driver

C

Install Driver in Remover and Remove Upper Race

4.

Reverse the tool and repeat the procedure to remove the

D

Remove Lower Race

lower bearing race.

Figure 2-89. Remove Upper and Lower

REMOVING BEARING FROM FORK STEM

Steering Head Bearing Races

1.

Chisel cage retaining rollers off bearing on fork stem.

2006 Touring: Chassis

2-73

HOME

REAR AIR SUSPENSION

2.18

GENERAL

Frame

All models feature air-adjustable rear suspension. Air pres-

Cover

sure may be varied to suit load conditions, riding style and

personal comfort. Less initial pressure does not necessarily

result in a softer ride. See the table below for the recom-

mended air suspension pressures.

Table 2-6. Rear Air Suspension Pressures

Recommended

Shock Loading

Pressures

PSI

kPa

All Models Except FLHRS, FLHX - Standard Shocks

Solo rider up to 150 lbs. (68 kg),

0

0

hereafter referred to as “Average”

Solo rider 150-200 lbs. (68-91 kg)

0-10

0-69

Solo rider 200-250 lbs. (91-113 kg)

5-15

35-103

Air Valve

Average rider with passenger

f2018x2x

10-15

69-103

up to 150 lbs. (68 kg)

Average rider with passenger

Figure 2-90. Rear Air Suspension Air Valve

20-25

138-172

up to 200 lbs. (91 kg)

(Under Protective Cap)

Maximum GVWR

20-35

138-241

(see Section 2.1 Specifications)

FLHRS, FLHX Only - Low Profile Shocks

CAUTION

Solo rider up to 160 lbs. (73 kg),

0-5

0-35

hereafter referred to as “Average”

Improper inflation of rear air suspension components

also can result in a reduction of available suspension

Solo rider 160-200 lbs. (73-91 kg)

0-10

0-69

travel, reduced rider comfort and possible damage to

Solo rider over 200 lbs. (91 kg)

5-10

35-69

shock absorbers.

Average rider with passenger

20-30

138-207

up to 150 lbs. (68 kg)

CAUTION

Average rider with passenger

25-35

172-241

All air components fill rapidly. Use low air line pressure

over 150 lbs. (68 kg)

to avoid possible damage. A small hand or foot operated

Maximum GVWR

air pump is the best way to add air to suspension com-

40-50

276-345

(see Section 2.1 Specifications)

ponents.

1WARNING

CAUTION

Use this table as a starting point in determining suit-

Use a no-loss air gauge to check air pressure. Check

able rear air suspension pressures. Do not exceed

pressure in shocks weekly if in daily use or before each

maximum GVWR when loading vehicle and do not

trip if only used occasionally.

pressurize system in excess of 50 psi (345 kPa) for

FLHRS, FLHX models and 35 psi (241 kPa) for all

others. Excessive load weight and/or air suspension

NOTE

pressure can adversely affect handling and lead to

An AIR SUSPENSION PUMP AND GAUGE (Part No. HD-

loss of vehicle control, which could result in death

34633A) is available at your Harley-Davidson dealer.

or serious injury.

2006 Touring: Chassis

2-75

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