Harley Davidson FLHRC 2006. Maintenance & Repair Manual

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REAR FACIA (FLHX)

2.35

REMOVAL

Remove saddlebags. See Section 2.26 SADDLEBAG,

REMOVAL.

Remove six flange nuts from studs at sides of rear

fender. See Figure 2-198.

On left side of motorcycle, loosen set screw and

unthread radio antenna mast.

Gently open adhesive conduit at split line to release rear

facia lamp wires.

At rear of motorcycle, spread top of facia to release from

top studs at sides of fender and then pull bottom in a

downward direction to release facia from fender. If nec-

essary, gently wiggle facia while pulling.

Remove two T20 TORX screws to release lamp assem-

bly from facia.

INSTALLATION

Install two T20 TORX screws to fasten lamp assembly to

9404

facia. Alternately tighten screws to 18-22 in-lbs (2.0-2.5

Nm).

Figure 2-198. Remove Flange Nuts

At rear of motorcycle, insert flange at top of facia

between flap and fender. Notch in flange engages loca-

tor bump on flap when facia is fully installed. Spread top

of facia to engage top studs at sides of fender.

Remove flange nuts from studs at sides of rear fender.

See Figure 2-198.

See Figure 2-198. Start six flange nuts on studs at sides

of fender. Apply a small dab of Loctite Medium Strength

Reaching into fender well, carefully pry stud plate away

Threadlocker 243 (blue) to threads of studs. Alternately

from rear fender.

tighten flange nuts to 20-30 in-lbs (2.3-3.4 Nm).

NOTE

Stud plates installed in production use adhesive strips as an

As it is necessary to overcome the resistance of the lock

assembly aid. Beginning at the edges, carefully work stud

patch on the stud threads, note that the flange nut torque

plate free using a small putty knife or gasket scraper.

specification is higher when using a new stud plate.

On left side of motorcycle, gently open adhesive conduit

at split line and insert rear facia lamp wires.

INSTALLATION

Install radio antenna mast and tighten set screw.

Install new stud plate.

Install saddlebags. See Section

2.26 SADDLEBAG,

INSTALLATION.

Install flange nuts on studs and alternately tighten to 80

in-lbs (9.0 Nm). See Figure 2-198.

NOTE

STUD PLATE

As it is necessary to overcome the resistance of the lock

patch on the stud threads, note that the flange nut torque

specification is higher when using a new stud plate.

REMOVAL

Install rear wheel. See Section

2.4 REAR WHEEL,

Lower rear wheel. See Section

2.4 REAR WHEEL,

INSTALLATION, steps 3-18.

REMOVAL, steps 1-6.

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REAR FACIA LAMP

9364

REMOVAL

Remove rear facia. See REMOVAL in this section.

On left side of motorcycle, remove bolt (with flat washer)

to remove passenger seat strap and saddlebag front

mounting bracket from chrome frame tube cover.

Remove Phillips screw and chrome frame tube cover.

Release rear facia lamp wires from cable clip at top of

radio antenna bracket. See Figure 2-199.

Cut cable strap to release rear facia lamp wires and

radio antenna cable from slotted hole in rear fender sup-

port.

Cut cable strap to release rear facia lamp wires and

radio antenna cable from shoulder of upper frame tube

(just in front of air valve mounting bracket).

Disconnect rear facia lamp connector [12], 3-place Mul-

tilock, inboard of upper frame tube.

Figure 2-199. Capture Rear Facia Lamp Wires

NOTE

Connector [12] serves as the Tour-Pak lights connector on

Install chrome frame tube cover on frame tube. Install

FLHTC/U models.

Phillips screw and tighten to 25-40 in-lbs (2.8-4.5 Nm).

Insert bolt

(with flat washer) through passenger seat

strap and slotted hole of saddlebag front mounting

INSTALLATION

bracket. Insert bolt into forward hole in chrome frame

tube cover. Snug saddlebag front mounting bracket bolt,

Route rear facia lamp wires forward through cable clip at

but do not tighten.

top of radio antenna bracket and then upward in front of

saddlebag rear mounting bracket to inboard side of

Install rear facia. See INSTALLATION in this section.

upper frame tube.

Using an open end/box wrench, tighten saddlebag front

On inboard side of upper frame tube, mate pin and

mounting bracket bolt to 60-96 in-lbs (6.8-10.8 Nm).

socket housings of rear facia lamp connector [12], 3-

place Multilock.

Using slotted hole, install new cable strap to secure rear

facia lamp wires and radio antenna cable to rear fender

support. See Figure 2-199.

Install new cable strap to secure rear facia lamp wires

and radio antenna cable to shoulder of upper frame tube

(just in front of air valve mounting bracket).

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JIFFY STAND

2.36

GENERAL

f1142a2x

The jiffy stand (or side stand) locks when placed in the full

forward position (down) with the full weight of the motorcycle

resting on it.

1WARNING

The jiffy stand locks when placed in the full forward

REAR

(down) position with vehicle weight on it. If the jiffy stand

is not in the full forward (down) position with vehicle

weight on it, the vehicle can fall over which could result

in death or serious injury. (00006a)

1WARNING

Always park motorcycle on a level, firm surface. An

unbalanced motorcycle can fall over, which could result

in death or serious injury. (00039a)

Flange Nut

Leg Stop (Longer Side Faces Rear)

Bracket

Figure 2-201. Leg Stop Orientation

(Full Forward Position)

1WARNING

Be sure jiffy stand is fully retracted before riding. If jiffy

stand is not fully retracted, it can contact the road sur-

face causing a loss of vehicle control, which could result

in death or serious injury. (00007a)

REMOVAL

f1852x2x

Jiffy Stand

Bolt

1WARNING

Rubber Stop

Lockwasher

Securely block motorcycle under frame to be sure that it

Flange Nut

Bracket

will not fall when jiffy stand is removed. Inadequate

Leg Stop

Frame Hole

safety precautions could result in death or serious

Spring

injury.

Figure 2-200. Jiffy Stand Assembly

Block motorcycle under frame, so that motorcycle is

securely upright and level. Jiffy stand should be able to

move through its full range of travel without the weight of

the motorcycle resting on it.

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Verify that the longer side of the leg stop faces the rear

7846

of the motorcycle. See Figure 2-201.

Extend and retract jiffy stand leg several times to verify

proper operation. Jiffy stand should swing freely to the

fully extended and fully retracted positions.

Move jiffy stand to the full forward position. Carefully

remove support blocking from beneath motorcycle frame

and rest motorcycle on jiffy stand.

CAUTION

Verify that rubber stop is in place on prong of jiffy stand.

Without the rubber stop, the stand will make hard con-

tact with the lower frame tube when retracted, possibly

resulting in chipping or nicking of the powder coat.

Replace rubber stop if torn or deteriorated. See Figure 2-

Figure 2-202.

Jiffy Stand Rubber Stop

202.

See Figure 2-200. Move jiffy stand to the retracted posi-

tion (up). Remove flange nut and leg stop from threaded

end of jiffy stand leg.

Move jiffy stand to the full forward position

(down).

Grasping end of spring as close to frame tube as possi-

ble, twist and turn end with needle nose pliers to unhook

from frame hole. Remove jiffy stand leg from bracket.

Inspect jiffy stand assembly for worn or damaged parts.

Replace parts as necessary.

INSTALLATION

Lubricate the jiffy stand leg with Loctite Aerosol Anti-

Seize Lubricant. Restrict the application to the area of

the jiffy stand leg that rotates within the bracket.

Insert threaded end of jiffy stand up through bottom of

bracket. With jiffy stand in the full forward position, par-

tially place spring end into frame hole. Rap spring with a

rubber mallet to fully seat in hole.

NOTE

Verify that opposite end of spring enters hole at front of leg

weldment. If end enters hole from rear, spring coil will rub on

leg when jiffy stand is exercised.

Holding jiffy stand at the full forward position, install leg

stop over threaded end with the stamped “side down.”

Install flange nut and tighten to 43-53 ft-lbs (58-72 Nm).

1WARNING

If leg stop is installed incorrectly, excess wear may

cause the motorcycle to fall over when rested on the jiffy

stand, which could result in death or serious injury.

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HOME

FOOTBOARDS/FOOTRESTS

2.37

c. Tighten front bracket socket screw to 30-35 ft-lbs

RIDER FOOTBOARD

(41-48 Nm).

d. Alternately tighten rear bracket hex bolts to 15-20 ft-

REMOVAL

lbs (20-27 Nm).

Remove right side footboard and bracket assembly as

follows:

a. Remove two allen head socket screws (with lock

DISASSEMBLY

washers and flat washers) to release footboard

brackets from frame weldment. See Figure 2-203.

NOTE

For best results, approach from left side of motorcy-

cle using a 3/8 inch ball allen with extension.

If only replacing the rubber pad, refer to step 1 below and

then see steps 4-5 under ASSEMBLY.

Remove left side footboard and bracket assembly as fol-

lows:

Tilt footboard upward. From bottom of footboard, use a

a. Raise the motorcycle on a hydraulic center stand so

large flat blade screwdriver to push four rubber anchors

that the weight of the motorcycle is not resting on

on pad up through holes in footboard.

the jiffy stand.

Remove nuts from pivot bolts at underside of footboard.

b. Remove socket screw (with lockwasher and flat

Remove pivot bolts to release footboard from brackets.

washer) to release footboard forward bracket from

frame weldment. See Figure 2-203. For best results,

Remove footboard brackets. See REMOVAL.

approach from opposite side of motorcycle using a

3/8 inch ball allen with extension.

c. To free footboard rear bracket from frame weldment

and jiffy stand bracket, remove lower hex bolt (with

ASSEMBLY

lockwasher) and upper hex bolt (with lockwasher

and locknut).

Install footboard brackets. See INSTALLATION.

Place footboard into position between brackets and

install pivot bolts so that the nuts will be on the inboard

INSTALLATION

side.

Install right side footboard and bracket assembly as fol-

NOTE

lows:

a. Insert two allen head socket screws (with lockwash-

The bottom of FLHRS footboards are stamped L(eft) or

ers and flat washers) through frame weldment into

R(ight) to ensure proper installation.

footboard brackets. See Figure

2-203. For best

Install nuts onto pivot bolts and alternately tighten to 84-

results, approach from left side of motorcycle using

108 in-lbs (9.5-12.2 Nm).

a 3/8 inch ball allen with extension.

b. Alternately tighten socket screws to 30-35 ft-lbs (41-

Moisten four rubber anchors on new pad with soapy

48 Nm).

water.

Install left side footboard and bracket assembly as fol-

Place pad into position on footboard. From bottom of

lows:

footboard, use pliers to pull rubber anchors down

through holes in footboard.

a. Insert allen head socket screw (with lockwasher and

flat washer) through frame weldment into footboard

forward bracket. See Figure 2-203. For best results,

approach from opposite side of motorcycle using a

PASSENGER FOOTBOARD

3/8 inch ball allen with extension.

b. At footboard rear bracket, slide upper hex bolt

through frame weldment, jiffy stand bracket and

footboard bracket thru hole. Install lockwasher and

REMOVAL

locknut. Slide lower hex bolt through frame weld-

Remove socket screw with lockwasher to remove foot-

ment and jiffy stand bracket into threaded hole of

board bracket from rear swingarm bracket.

footboard bracket.

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f2240x2x

ALL MODELS

Except FLHRS, FLHX

Left Side

Right Side

FLHRS, FLHX

Rubber Pad (2)

Nut

Footboard (2)

Left Front Bracket

Pivot Bolt (4)

10.

Socket Screw (3)

Pivot Bolt Nut (4)

11.

Lockwasher (3)

Left Rear Bracket

12.

Flat Washer (3)

Hex Bolt (2)

13.

Right Front Bracket

Lockwasher (2)

14.

Right Rear Bracket

Figure 2-203. Rider Footboards

INSTALLATION

NOTE

Passenger footboards can be adjusted to one of three posi-

Insert pin on footboard bracket into hole in rear swing-

tions. To move footboards to a new position, remove plastic

arm bracket.

plugs from holes in rear swingarm bracket as necessary.

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HOME

Place footboard into position on bracket and install pivot

pins from the outboard side. Using a brass drift and rub-

f2241x2x

ber mallet, tap pins until centered in lugs of bracket.

Moisten rubber beads on new pad with soapy water.

Place pad into position on footboard. From bottom of

footboard, use needle nose pliers to pull rubber beads

down through holes in footboard.

Engage nubs on inboard corners of pad with holes in

footboard.

PASSENGER FOOTREST

(FLHRS, FLHX)

REMOVAL

Rubber Pad

Steel Ball

Remove socket screw with lockwasher to remove foot-

Footboard

Spring

rest bracket from rear swingarm bracket.

Pivot Pin (2)

Socket Screw

Footboard Bracket

Lockwasher

INSTALLATION

Figure 2-204. Passenger Footboard

(All Models Except FLHRS, FLHX)

Insert pin on footrest bracket into hole in rear swingarm

bracket.

Install socket screw with lockwasher. Tighten

socket

NOTE

screw to 30-35 ft-lbs (40.7-47.5 Nm).

Passenger footrests can be adjusted to one of three posi-

tions. To move footrests to a new position, remove plastic

plugs from holes in rear swingarm bracket as necessary.

DISASSEMBLY

Install socket screw with lockwasher. Tighten socket

NOTE

screw to 30-35 ft-lbs (40.7-47.5 Nm).

If only replacing the rubber pad, refer to step 1 below and

then see steps 4-5 under ASSEMBLY.

Tilt footboard upward. From bottom of footboard, use a

DISASSEMBLY

small flat blade screwdriver to push rubber beads on pad

up through holes in footboard. Remove pad. See Figure

NOTE

2-204.

If only replacing the rubber pad, refer to step 1 below and

Using a brass drift and rubber mallet, tap two pivot pins

then see steps 7-9 under ASSEMBLY.

toward center of footboard and remove.

Remove socket screw from end of footrest. Remove rub-

Remove footboard from footboard bracket.

ber pad from footrest. See Figure 2-205.

Remove steel ball and spring from hole in footboard

bracket.

Remove footrest from footrest mount.

Remove footboard bracket from rear swingarm bracket.

Remove retaining ring from groove at end of pivot pin.

See REMOVAL.

Remove pivot pin.

Remove footrest mount and wave spring from footrest

bracket.

ASSEMBLY

Remove footrest bracket from rear swingarm bracket.

Install footboard bracket. See INSTALLATION.

See REMOVAL.

Place spring into hole in footboard bracket. Place ball on

top of spring. See Figure 2-204.

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Install pivot pin into top hole in footrest bracket. Top hole

is countersunk so that head of pivot pin is flush after

f2290x2x

installation.

NOTE

Verify operation of footrest mount before installing retaining

ring. The ease with which the footrest mount pivots is based

on the curvature of the wave spring. Flattening the wave

spring allows the footrest mount to move more easily, while

increasing the curvature makes movement more difficult.

Install new retaining ring in groove at end of pivot pin.

Slide footrest onto footrest mount.

Place rubber pad into footrest.

Apply a small dab of Loctite Medium Strength Thread-

Socket Screw

Footrest Mount

locker 243 (blue) to threads of socket screw.

Rubber Pad

Wave Spring

Start socket screw into end of footrest. Rotate footrest so

Footrest

Footrest Bracket

that the rubber pad is topside and tighten socket screw

Retaining Ring

Socket Screw

to 15-20 ft-lbs (20-27 Nm).

Pivot Pin

10. Lockwasher

Figure 2-205. Passenger Footrest (FLHRS, FLHX)

ASSEMBLY

Install footrest bracket. See INSTALLATION.

Align hole in wave spring with bottom hole in footrest

bracket. See Figure 2-205. Be sure that the concave

side is down and the flat edge is against the inboard side

of the footrest bracket.

Holding wave spring in place, install footrest mount

between arms of bracket with the rounded side of the

pivot pin end up.

2006 Touring: Chassis

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HOME

EXHAUST SYSTEM

2.38

Open worm drive clamps to release heat shield over

REMOVAL

front header pipe to rear header pipe connection

(outboard of transmission side door).

NOTE

Remove bolt (with flat washer and locknut) from

exhaust bracket clamp on front header pipe. Use a

To access engine and/or transmission components, use the

following procedure to remove the exhaust with minimal dis-

channel lock to open clamp and then remove from

assembly. To completely disassemble the exhaust system,

header pipe and transmission exhaust bracket.

see DISASSEMBLY in this section.

Remove two screws (with lockwashers) to detach

right side muffler from the lower saddlebag support

Remove saddlebags. See Section 2.26 SADDLEBAG,

rail.

REMOVAL.

Depressing rear brake pedal, remove right side

On Ultra models, remove fairing lowers. See Section

exhaust from motorcycle.

2.29 LOWER FAIRING/ENGINE GUARD, LOWER

m. Remove and discard gaskets from front and rear

FAIRING (FLHTCU), REMOVAL.

exhaust ports.

Remove two allen head socket screws (with lockwashers

and flat washers) to release right side front footboard

brackets from frame weldment. For best results,

approach from left side of motorcycle using a 3/8 inch

INSTALLATION

ball allen with extension.

Remove exhaust system in two sections as follows:

See Figure 2-206. Install exhaust system as follows:

Install new gaskets in both the front and rear cylin-

Open worm drive clamps to release heat shield over

der head exhaust ports (with the tapered side out).

rear header pipe to crossover pipe connection

(above starter). See Figure 2-206.

Place right side exhaust into position on motorcycle

and start two exhaust flange nuts to secure front

Loosen TORCA clamp

(special) between rear

header pipe to studs of front cylinder head.

header pipe and crossover pipe. Remove Keps nut

and pull bracket tab and stud from slots in TORCA

Start two screws (with lockwashers) to secure right

clamp and exhaust support bracket.

side muffler to the lower saddlebag support rail.

Start two exhaust flange nuts to secure rear header

Spray PB Blaster or other suitable penetrating oil in

pipe to studs of rear cylinder head.

and around joint between rear header pipe and

crossover pipe.

Engaging transmission exhaust bracket, capture

front header pipe in exhaust bracket clamp. Use a

Moving to left side of motorcycle, remove two

channel lock to close clamp, if necessary. Finger

screws (with lockwashers) to detach left side muffler

tighten clamp bolt (with flat washer and locknut).

from the lower saddlebag support rail.

Moving to left side of motorcycle, slide new TORCA

Pull and twist on crossover pipe to remove left side

clamp (special) onto crossover pipe.

exhaust from motorcycle. For best results, be sure

Twist and push crossover pipe onto right side

to allow sufficient time for the penetrating oil to

exhaust.

work.

Start two screws (with lockwashers) to secure left

Remove TORCA clamp from crossover pipe.

side muffler to the lower saddlebag support rail.

Discard TORCA clamp.

Position TORCA clamp

(special) between rear

Moving to right side of motorcycle, open worm drive

header pipe and crossover pipe. Fit bracket tab into

clamps and release heat shield from front header

slot of TORCA clamp engaging stud in slot of

pipe. Using an impact wrench with long 1/2 inch

exhaust support bracket. Start Keps nut on stud.

swivel socket, remove two exhaust flange nuts to

release front header pipe from studs of front cylin-

NOTE

der head. Slide exhaust flange down header pipe to

Verify that the exhaust pipes do not contact the motorcycle

improve clearance around exhaust port.

frame or any mounted components. Contact will cancel the

effect of the rubber isolation mounts and transmit vibration to

Open worm drive clamps and release heat shield

the rider.

from rear header pipe. Remove two exhaust flange

nuts to release rear header pipe from studs of rear

Tighten the exhaust system as follows:

cylinder head.

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f2386x2x

Worm Drive Clamp

Heat Shield, Crossover Pipe

Crossover Pipe

Rear Header Pipe

TORCA Clamp (Special)

Keps Nut

Bracket Tab

Exhaust Support Bracket

Left Muffler

10.

Screw

11.

Lockwasher

12.

Heat Shield, Front Header Pipe

13.

Front Header Pipe

19. Heat Shield, Front Header to Rear Header Pipe

14.

Flange Nut

20. Bolt

15.

Exhaust Flange

21. Flat Washer

16.

Circlip

22. Lock Nut

17.

Cylinder Head Gasket

23. Exhaust Bracket Clamp

18.

Heat Shield, Rear Header Pipe

24. Right Muffler

Figure 2-206. Remove/Install Exhaust System

● Using a long 1/2 inch swivel socket, tighten the top

● Tighten the exhaust bracket clamp bolt to 60-96 in-

nut of the front cylinder head exhaust flange to 9-18

lbs (6.8-10.8 Nm).

in-lbs (1-2 Nm). Tighten the bottom nut to 100-120

● Snug two screws (with lockwashers) holding the

in-lbs (11.3-13.6 Nm). Final tighten the top nut to

right side muffler to the lower saddlebag support

100-120 in-lbs (11.3-13.6 Nm).

rail. Alternately tighten screws to

96-144 in-lbs

● Tighten the bottom nut of the rear cylinder head

(10.8-16.3 Nm).

exhaust flange to 9-18 in-lbs (1-2 Nm). Tighten the

● Snug two screws (with lockwashers) holding the left

top nut to

100-120 in-lbs (11.3-13.6 Nm). Final

side muffler to the lower saddlebag support rail.

tighten the bottom nut to 100-120 in-lbs (11.3-13.6

Alternately tighten screws to 96-144 in-lbs (10.8-

Nm).

16.3 Nm).

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HOME

● Verify that all exhaust pipes are in alignment and do

Remove two allen head socket screws (with lockwashers

not contact the motorcycle frame or mounted com-

and flat washers) to release right side front footboard

ponents.

brackets from frame weldment. For best results,

approach from left side of motorcycle using a 3/8 inch

● Tighten the TORCA clamp (special) between the

rear header pipe and crossover pipe to 45-60 ft-lbs

ball allen with extension.

(61-81 Nm).

Open worm drive clamps and remove six heat shields

● Tighten Keps nut securing bracket tab to exhaust

from exhaust pipes. Mark the location of the heat shields

support bracket.

to ensure proper assembly. See Figure 2-207.

NOTE

Using a bungee cord, tie the muffler on the left side of

Verify that the heat shields do not contact the motorcycle

the motorcycle to the lower saddlebag support rail.

frame or any mounted components. Contact will cancel the

Remove the exhaust flange nuts to release the front and

effect of the rubber isolation mounts and transmit vibration to

rear header pipes from the cylinder head studs. For best

the rider.

results, use impact wrench with long 1/2 inch swivel

k. Open worm drive clamps and install heat shields as

socket.

follows:

Loosen the four TORCA clamps as follows:

● Over front header pipe (below exhaust port).

Right side of motorcycle

● Over rear header pipe (below exhaust port).

● Over front header pipe to rear header pipe connec-

● front header pipe to rear header pipe

tion (outboard of transmission side door).

● rear header pipe to right side muffler

● Over rear header pipe to crossover pipe connection

(above starter).

Position each worm drive clamp so that screw is on

Left side of motorcycle

the outboard side in the most accessible position

● rear header pipe to crossover pipe

and then tighten to 20-40 in-lbs (2.3-4.5 Nm).

● crossover pipe to left side muffer

Insert two allen head socket screws (with lockwashers

and flat washers) through frame weldment into right side

NOTE

front footboard brackets. For best results, approach from

To facilitate removal, spray PB Blaster or other suitable pene-

left side of motorcycle using a 3/8 inch ball allen with

trating oil in and around joints of exhaust pipes. For best

extension. Alternately tighten screws to 30-35 ft-lbs (41-

48 Nm).

results, be sure to allow sufficient time for the penetrating oil

to work.

On Ultra models, install fairing lowers. See Section 2.29

LOWER FAIRING/ENGINE GUARD, LOWER FAIRING

Remove four screws (with lockwashers) to detach left

(FLHTCU), INSTALLATION.

and right side mufflers from the lower saddlebag support

Install saddlebags. See Section

2.26 SADDLEBAG,

rails.

INSTALLATION.

Standing on right side of motorcycle, remove muffler

from rear header pipe.

10. Remove Keps nut and pull bracket tab and stud from

DISASSEMBLY

slots in TORCA clamp (special) and exhaust support

bracket.

NOTE

11. Remove rear header pipe from front header pipe, cross-

over pipe and rear cylinder head. Remove bracket tab

Use the following procedure to completely disassemble the

from slot in TORCA clamp (special).

exhaust system. If just removing the exhaust to access

engine and/or transmission components, see REMOVAL in

12. Remove bolt (with flat washer and locknut) from exhaust

this section.

bracket clamp on front header pipe. Use a channel lock

to open clamp and then remove from front header pipe

Remove saddlebags. See Section 2.26 SADDLEBAG,

and transmission exhaust bracket. Remove front header

REMOVAL.

pipe exhaust flange from front cylinder head.

On Ultra models, remove fairing lowers. See Section

13. Moving to left side of motorcycle, remove crossover pipe

2.29 LOWER FAIRING/ENGINE GUARD, LOWER

from left side muffler.

FAIRING (FLHTCU), REMOVAL.

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f2387x2x

Worm Drive Clamp (13)

Heat Shield (6)

Front Header Pipe

Rear Header Pipe

Crossover Pipe

Flange Nut

Exhaust Flange

13.

Screw

19. Exhaust Support Bracket

Circlip

14.

Lockwasher

20. Bolt

Cylinder Head Gasket

15.

Rubber Mount

21. Flat Washer

10.

TORCA Clamp (4)

16.

Saddlebag Support Rail Bracket

22. Lock Nut

11.

Left Muffler

17.

Keps Nut

23. Exhaust Bracket Clamp

12.

Right Muffler

18.

Bracket Tab

24. Transmisson Exhaust Bracket

Figure 2-207. Disassemble/Assemble Exhaust System

14.

Remove bungee cord to release left side muffler from

NOTE

lower saddlebag support rail.

TORCA clamps have eliminated the need for silicone

graphite tape during assembly. To ensure sealing integrity

15.

Remove and discard gaskets from front and rear

and prevent the possibility of leakage, always discard

exhaust ports. Discard TORCA clamps.

TORCA clamps whenever they are removed.

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HOME

Tighten the top nut of the front cylinder head

ASSEMBLY

exhaust flange to 9-18 in-lbs (1-2 Nm). Tighten the

bottom nut to 100-120 in-lbs (11.3-13.6 Nm). Final

NOTE

tighten the top nut to

100-120 in-lbs (11.3-13.6

Nm).

Always loosely assemble exhaust system on motorcycle

before following tightening procedure. Assemble as follows:

Tighten the bottom nut of the rear cylinder head

exhaust flange to 9-18 in-lbs (1-2 Nm). Tighten the

Install new gaskets in both the front and rear cylinder

top nut to

100-120 in-lbs (11.3-13.6 Nm). Final

head exhaust ports (with the tapered side out).

tighten the bottom nut to 100-120 in-lbs (11.3-13.6

Nm).

Install front header pipe exhaust flange onto front cylin-

der head. Start flange nuts on cylinder head studs.

Tighten the exhaust bracket clamp bolt to 60-96 in-

lbs (6.8-10.8 Nm).

Engaging transmission exhaust bracket, capture front

header pipe in exhaust bracket clamp. Use a channel

Snug two screws (with lockwashers) holding the

lock to close clamp, if necessary. Finger tighten clamp

right side muffler to the lower saddlebag support

bolt (with flat washer and locknut).

rail. Alternately tighten screws to

96-144 in-lbs

(10.8-16.3 Nm).

Slide a new TORCA clamp onto free end of front header

pipe.

Snug two screws (with lockwashers) holding the left

side muffler to the lower saddlebag support rail.

Install rear header pipe onto rear cylinder head and front

Alternately tighten screws to 96-144 in-lbs (10.8-

header pipe. Start flange nuts on cylinder head studs.

16.3 Nm).

Move TORCA clamp into position between front and rear

header pipes.

Verify that all exhaust pipes are in alignment and do

not contact the motorcycle frame or mounted com-

Slide new TORCA clamps onto free ends of rear header

ponents.

pipe. TORCA clamp to crossover pipe is special in that it

has slot for bracket tab to exhaust support bracket.

Tighten the four TORCA clamps to 45-60 ft-lbs (61-

81 Nm) in the following order:

Slide right side muffler onto rear header pipe. Finger

tighten two screws (with lockwashers) to attach muffler

●

crossover pipe to left side muffer

to lower saddlebag support rail. Place TORCA clamp

into position between rear header pipe and right side

●

rear header pipe to right side muffer

muffler.

●

front header pipe to rear header pipe

Moving to left side of motorcycle, install crossover pipe

●

rear header pipe to crossover pipe

onto remaining end of rear header pipe (above starter).

Place TORCA clamp into position between rear header

pipe and crossover pipe.

13.

Tighten Keps nut securing bracket tab to exhaust sup-

port bracket.

Fit bracket tab into slot of TORCA clamp engaging stud

in slot of exhaust support bracket. Start Keps nut on

14.

Open worm drive clamps and install six heat shields on

stud.

exhaust pipes as marked during removal. See Figure 2-

207. Position each clamp so that screw is on the out-

10.

Slide new TORCA clamp onto free end of crossover

board side in the most accessible position and then

pipe.

tighten to 20-40 in-lbs (2.3-4.5 Nm).

11.

Using a bungee cord, tie left side muffler to lower sad-

15.

Remove bungee cord from left side muffler.

dlebag support rail. Install left side muffler on crossover

pipe. Place TORCA clamp into position between cross-

16.

Insert two allen head socket screws (with lockwashers

over pipe and left side muffler. Finger tighten two screws

and flat washers) through frame weldment into right side

(with lockwashers) to attach muffler to saddlebag sup-

front footboard brackets. For best results, approach from

port rail.

left side of motorcycle using a 3/8 inch ball allen with

extension. Alternately tighten screws to 30-35 ft-lbs (41-

NOTE

48 Nm).

Verify that the exhaust pipes do not contact the motorcycle

17.

On Ultra models, install fairing lowers. See Section 2.29

frame or any mounted components. Contact will cancel the

LOWER FAIRING/ENGINE GUARD, LOWER FAIRING

effect of the rubber isolation mounts and transmit vibration to

(FLHTCU), INSTALLATION.

the rider.

18.

Install saddlebags. See Section

2.26 SADDLEBAG,

12. Tighten the exhaust system as follows:

INSTALLATION.

2-168

2006 Touring: Chassis

HOME

SPECIFICATIONS

3.1

MANUFACTURING TOLERANCES

Hydraulic Lifter

IN.

General

Fit in crankcase (loose)

0.0008-0.0020

0.02-0.05

Number of cylinders

Type

4-cycle, 45˚V², air-cooled

Cylinder Head

IN.

85 ft-lbs (115.2 Nm)

Valve guide in head (tight)

0.0020-0.0033

0.051-0.084

Torque

@ 3000 rpm

Valve seat in head (tight)

0.003-0.0045

0.076-0.114

Bore

3.75 in. (95.25 mm)

Head gasket surface

0-0.006

0-0.0152

Stroke

4.00 in. (101.6 mm)

(flatness)

Piston displacement (approx.)

88 cu. in. (1450 cc)

Compression ratio

9.0:1

Valve

IN.

Combustion chamber

5.187 cu. in. (85 cc) bathtub

Fit in guide: exhaust

0.001-0.003

0.0254-0.0762

Twin cams, chain driven with

Cam system

Fit in guide: intake

0.001-0.003

0.0254-0.0762

spring loaded tensioners

Seat width

0.040-0.062

1.02-1.58

Max. sustained engine speed

5500 rpm

Stem protrusion from

Idle speed

1000 rpm +/- 50

2.012-2.032

51.10-51.61

cylinder head boss

Weight

165 lbs (74.8 kg)

Valve Spring

IN.

Ignition System

135 lbs

61.2 kg

Sequential, non waste spark,

Closed

Type

@ 1.850 in.

@ 47.0 mm

MAP-N control

312 lbs

141.5 kg

Ignition timing:

Open

20^o-30^o

@ 1.300 in.

@ 33.0 mm

1050 rpm (Hot Idle)

Free length

2.325 in.

59.1 mm

Spark plug size

12 mm

Spark plug type

Harley-Davidson 6R12

Spark plug gap

0.038-0.043 in. (0.97-1.09 mm)

Piston

IN.

Spark plug torque

12-18 ft-lbs (16-24 Nm)

Fit in cylinder:

Early Style Piston

0.0006-0.0017

0.015-0.043

Late Style Piston

0.0014-0.0025

0.036-0.064

Oiling System

Ring end gap:

Twin gerotor, dual scavenge, crank mounted

Top compression ring

0.010-0.020

0.25-0.51

Pump

and driven, internal oil pump, dry sump

2nd compression ring

0.014-0.024

0.36-0.61

30-38 psi (207-262 kN/m²) at

Pressure

2000 rpm and normal operating temperature

Oil control ring

0.010-0.050

0.25-1.27

of 230^oF (110^oC)

Ring side clearance:

5 micron media,

Filtration

Top compression ring

0.0012-0.0037

0.030-0.094

filtered between pump and engine

2nd compression ring

0.0012-0.0037

0.030-0.094

Rocker Arm

IN.

Oil control ring

0.0031-0.0091

0.079-0.23

Shaft fit in bushing

0.0005-0.0020

0.013-0.051

Piston pin fit (loose)

0.0002-0.0005

0.005- 0.013

(loose)

End clearance

0.003-0.013

0.08-0.33

Connecting Rod

IN.

Bushing fit in rocker arm

0.002-0.004

0.051-0.102

(tight)

Piston pin fit (loose)

0.0007-0.0012

0.018-0.030

Side play between

0.005-0.015

0.13-0.38

Rocker Arm Shaft

IN.

flywheels

Shaft fit in rocker arm

Connecting rod to

0.0007-0.0022

0.018-0.056

0.0004-0.0017

0.0102-0.0432

support plate (loose)

crankpin (loose)

2006 Touring: Engine

3-1

HOME

MANUFACTURING TOLERANCES (CONT.)

TORQUE VALUES

Flywheel

IN.

Item

ft/in-lbs

Runout

Breather assembly bolts

90-120 in-lbs

10-14 Nm

0.000-0.010

0.000-0.254

(flywheels at rim)

Cam cover screws

125-155 in-lbs

14-18 Nm

Runout

Cam cover plate screws

20-30 in-lbs

2.3-3.4 Nm

0.000-0.002

0.000-0.051

(shaft at flywheel)

Cam support plate screws

90-120 in-lbs

10-14 Nm

End play

0.003-0.010

0.076-0.254

Bearing retainer plate

20-30 in-lbs

2-3 Nm

screws

Crankshaft/Sprocket

15 ft-lbs,

20.3 Nm,

IN.

Shaft Bearings

Crank sprocket flange bolt

loosen one full

turn, 24 ft-lbs

turn, 32.5 Nm

Bearing fit (loose)

0.0002-0.0015

0.005-0.038

15 ft-lbs,

20.3 Nm,

Crankshaft runout

0.0-0.003

0.0-0.076

Primary cam sprocket

loosen one full

loosen one

Bearing fit in

flange bolt

turn, 34 ft-lbs

full turn, 46.1

0.0038-0.0054

0.097-0.137

crankcase (tight)

Crank position sensor

Bearing inner race on

90-120 in-lbs

10.2-13.6 Nm

0.0004-0.0014

0.010-0.036

screw

crankshaft (tight)

Piston jet screws

25-35 in-lbs

2.8-4.0 Nm

Transmission housing to

15 ft-lbs,

20 Nm,

crankcase bolts

30-35 ft-lbs

41-48 Nm

Crankcase to front engine

33-38 ft-lbs

45-52 Nm

mounting bracket bolts

10 ft-lbs,

14 Nm,

Crankcase bolts

15-19 ft-lbs

20-26 Nm

120-144 in-lbs,

13.6-16.3 Nm,

Cylinder head bolts

15-17 ft-lbs

20.3-23.1 Nm

+ 90^o turn

Cylinder studs

10-20 ft-lbs

14-27 Nm

Engine oil drain plug

14-21 ft-lbs

19-28 Nm

Lifter cover screws

90-120 in-lbs

10-14 Nm

Oil pan screws

84-132 in-lbs

9.5-14.9 Nm

Oil filter

1/2-3/4 turn after gasket contact

Oil filter mount

12-16 ft-lbs

16-22 Nm

Crankcase oil fittings/plugs

120-168 in-lbs

13.6-18.9 Nm

Oil hose cover screws

84-108 in-lbs

10-12 Nm

Oil pressure switch/sender

96-120 in-lbs

11-14 Nm

Rocker arm support

18-22 ft-lbs

24-30 Nm

plate bolts

Rocker cover bolts

15-18 ft-lbs

20-24 Nm

Rocker housing bolts

120-168 in-lbs

13.6-18.9 Nm

Spark plugs

12-18 ft-lbs

16-24 Nm

Stator screws

55-75 in-lbs

6.2-8.5 Nm

Upper engine mounting

bracket:

To cylinder heads

35-40 ft-lbs

48-54 Nm

To top stabilizer link

18-22 ft-lbs

24-30 Nm

ET sensor

120-180 in-lbs

13.6-20.3 Nm

Intake flange adapter

96-144 in-lbs

10.9-16.3 Nm

screws

Exhaust flange adapter

100-120 in-lbs

11.3-13.6 Nm

nuts

3-2

2006 Touring: Engine

HOME

SERVICE WEAR LIMITS

3.2

GENERAL

REPLACE IF

Cylinder Bore

Wear limits can be used as a guide when deciding whether to

IN.

reuse engine parts. Replace used parts whenever the follow-

ing wear limits are exceeded.

Standard

More than 3.752

More than 95.301

0.005 in. oversize

More than 3.757

More than 95.428

REPLACE IF

Rocker Arm/

0.010 in. oversize

More than 3.762

More than 95.555

Rocker Arm Shaft

IN.

Shaft fit in bushing (loose)

More than 0.0035

More than 0.089

REPLACE IF

End clearance

More than 0.025

More than 0.635

Piston

IN.

Shaft fit in rocker arm

More than 0.0035

More than 0.089

support plate (loose)

Fit in cylinder (loose)

More than 0.003

More than 0.076

Piston pin fit (loose)

More than 0.0008

More than 0.020

Ring end gap

REPLACE IF

Top compression

More than 0.030

More than 0.76

Hydraulic Lifter

IN.

2nd compression

More than 0.034

More than 0.86

Fit in crankcase

More than 0.003

More than 0.08

Oil control ring rails

More than 0.050

More than 1.27

Roller fit

More than 0.0015

More than 0.038

Ring side clearance

Roller end clearance

More than 0.015

More than 0.38

Top compression

More than 0.0045

More than 0.11

2nd compression

More than 0.0045

More than 0.11

Oil control ring rails

More than 0.010

More than 0.25

REPLACE IF

Cam Support Plate

IN.

REPLACE IF

Connecting Rod

Cam chain

More than 0.090

More than 2.29

IN.

tensioner shoe wear

1/2 thickness of shoe

Piston pin fit (loose)

More than 0.002

More than 0.051

Crankshaft bushing fit

Less than 0.0008

Less than 0.0203

in cam support plate

Side play between

More than 0.020

More than 0.508

flywheels

Crankshaft bushing

More than 0.8545

More than 21.704

maximum ID

Fit on crankpin (loose)

More than 0.002

More than 0.051

REPLACE IF

Flywheel

Cylinder Head

IN.

Runout (flywheels at rim)

More than 0.015

More than 0.381

Valve guide in head (tight)

Less than 0.002

Less than 0.051

Runout (shaft at flywheel)

More than 0.005

More than 0.127

Valve seat in head (tight)

Less than 0.002

Less than 0.051

End play

More than 0.010

More than 0.254

Head warpage

More than 0.006

More than 0.152

REPLACE IF

Crankshaft/Sprocket

REPLACE IF

Shaft Bearings

Cylinder

IN.

Bearing to shaft

More than 0.0015

More than 0.038

Taper

More than 0.002

More than 0.051

clearance

Out of round

More than 0.002

More than 0.051

Shaft runout

More than 0.003

More than 0.076

Warpage of gasket or

Bearing fit in

More than 0.006

More than 0.152

Less than 0.0038

Less than 0.097

O-ring surfaces: top

crankcase (tight)

Warpage of gasket or

Bearing inner race

More than 0.004

More than 0.102

Less than 0.0004

Less than 0.010

O-ring surfaces: base

on shaft (tight)

2006 Touring: Engine

3-3

HOME

GENERAL INFORMATION

3.3

FUEL

LUBRICATION

Use a good quality leaded or unleaded gasoline (91 pump

octane or higher). Octane rating is usually posted on the

CHECKING ENGINE OIL LEVEL

pump.

CAUTION

Oil level cannot be accurately measured on a cold

Using gasolines with alcohol additives (such as metha-

engine. For preride inspection, with motorcycle leaning

nol) can cause rubber components within the fuel sys-

on jiffy stand on level ground, oil should register on dip-

tem to fail or result in engine damage.

stick between arrows when engine is cold. Do NOT add

oil to bring the level to the FULL mark on a COLD engine.

GASOLINE/ALCOHOL BLENDS

Perform engine oil level COLD CHECK as follows:

Harley-Davidson motorcycles were designed to give the best

a. With the vehicle resting on the jiffy stand on level

performance using unleaded gasoline. Some fuel suppliers

ground, wipe off the dipstick and insert it back into

sell gasoline/alcohol blends as a fuel. The type and amount

the oil pan with the plug pushed completely into the

of alcohol added to the fuel is important.

fill spout.

● DO NOT USE GASOLINES CONTAINING METHANOL.

b. Remove the dipstick and note the level of the oil. Oil

Using gasoline/methanol blends will result in starting

level should register between the two arrows on the

and driveablility deterioration and damage to critical fuel

dipstick. See Figure 3-1. If oil level is at or below the

system components.

lower arrow, add only enough oil to bring the level

● ETHANOL is a mixture of 10% ethanol (Grain alcohol)

between the two arrows on the dipstick.

and 90% unleaded gasoline. Gasoline/ethanol blends

Perform engine oil level HOT CHECK as follows:

can be used in your motorcycle if the ethanol content

a. Ride vehicle until engine is at normal operating tem-

does not exceed 10%.

perature.

● REFORMULATED OR OXYGENATED GASOLINES

b. With the vehicle resting on the jiffy stand on level

(RFG):

“Reformulated gasoline” is a term used to

ground, allow engine to idle for 1-2 minutes. Turn

describe gasoline blends that are specifically designed

engine off.

to burn cleaner than other types of gasoline. Your motor-

cycle will run normally using this type of gas.

c. Wipe off the dipstick and insert it back into the oil

pan with the plug pushed completely into the fill

You may find that some gasoline blends adversely affect the

spout.

starting, driveability or fuel efficiency of your bike. If you

experience one or more of these problems, we recommend

d. Remove the dipstick and note the level of the oil.

you try a different brand of gasoline or gasoline with a higher

Add only enough oil to bring the level to the FULL

octane rating.

mark on the dipstick. See Figure 3-1. Do not overfill.

COLD CHECK

HOT CHECK

f1254b3x

Figure 3-1. Engine Oil Dipstick

2006 Touring: Engine

3-5

HOME

Remove the oil filter as follows:

a. Obtain the OIL FILTER WRENCH (HD-42311). The

tool allows easy removal of the oil filter without risk

of damage to the CKP sensor or cable.

b. Place the jaws of the wrench over the oil filter with

the tool oriented vertically. See Figure 3-3.

c. Using a 3/8 inch drive with a 4 inch extension, turn

wrench in a counterclockwise direction. Do not use

with air tools.

NOTE

Figure 3-2. Oil Filter Wrench (Part No. HD-42311)

Use OIL FILTER WRENCH (HD-44067) if HD-42311 is not

available.

f1641x3x

Clean the oil filter mount flange of any old gasket mate-

rial.

Lubricate gasket with clean engine oil and install new oil

filter on filter mount. Hand tighten oil filter 1/2-3/4 turn

after gasket first contacts filter mounting surface. Do

NOT use OIL FILTER WRENCH for oil filter installation.

NOTE

Use of the Premium 5 micron synthetic media oil filter is

highly recommended, Part No.

63798-99A

(Chrome) or

63731-99A (Black).

Install engine oil drain plug with O-ring. Tighten plug to

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

With vehicle resting on jiffy stand, add 3-1/2 quarts (3.3

liters) engine oil as specified in Table 3-1. Use the proper

grade of oil for the lowest temperature expected before

the next oil change.

Figure 3-3. Remove Engine Oil Filter

Table 3-1. Recommended Engine Oils

Harley-

Lowest

Cold Weather

CHANGING ENGINE OIL AND FILTER

Harley-Davidson

Viscosity

Davidson

Ambient

Starts Below

Type

Rating

Temperature

50˚F (10˚C)

NOTE

SAE

Below 40˚F

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

HD Multi-grade

HD 360

Excellent

10W40

(4˚C)

5000 mile (8000 km) service interval thereafter, change the

SAE

Above 40˚F

HD Multi-grade

HD 360

Good

engine oil and engine oil filter. If motorcycle is ridden hard,

20W50

(4˚C)

under dusty conditions or in cold weather, change engine oil

SAE

Above 60˚F

HD Regular Heavy

HD 360

Poor

and filter more often.

(16˚C)

SAE

Above 80˚F

HD Extra Heavy

HD 360

Poor

Ride vehicle until engine is at normal operating tempera-

(27˚C)

ture.

Locate oil filler plug/dipstick on right side of vehicle at top

of transmission case. To remove the oil filler plug, pull

CAUTION

steadily while moving plug back and forth.

Oil level cannot be accurately measured on a cold

Locate oil drain plug at front left side of the oil pan.

engine. For preride inspection, with motorcycle leaning

Remove the oil drain plug and allow oil to drain com-

on jiffy stand on level ground, oil should register on dip-

pletely.

stick between arrows when engine is cold. Do NOT add

oil to bring the level to the FULL mark on a COLD engine.

Inspect the oil drain plug O-ring for cuts, tears or signs of

deterioration. Replace as necessary.

10. Perform engine oil level COLD CHECK as follows:

3-6

2006 Touring: Engine

Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 11