Harley Davidson 2011 Touring Models. Service Manual

sm02881

1. Horizontal brace - thick (rear)
2. Horizontal brace - thin (front)
3. Vertical brace (right side)
4. Vertical brace (left side)
5. Stepped ends

Figure 2-144. Windshield Braces

Apply one drop of Loctite Medium Strength Threadlocker
243 (blue) to threads of three short screws. Install screws
through the middle and outer holes of the horizontal
braces. Loosely install acorn nuts on rear side.

See

Figure 2-144

. Remove paper backing from adhesive

strip on vertical brace. With the stepped end overlapping
the horizontal brace and the end with the slight bend
angled outward, align holes in brace with holes in wind-
shield. Press into position.

Position mounting bracket on rear side of windshield with
the wireform facing inboard.

Apply one drop of Loctite Medium Strength Threadlocker
243 (blue) to the threads of two short screws and one long
screw. Install the longer screw at the stepped end where
the vertical brace overlaps the horizontal brace, and short
screws in the remaining holes. Loosely install acorn nuts.

10. Install second vertical brace and mounting bracket in a

similar manner.

11. See

Figure 2-145

. Following the sequence shown, tighten

all screws to 20-25

in-lbs

(2.3-2.8 Nm).

12. Install windshield. See

2.43 WINDSHIELD: ROAD KING

MODELS

sm02882

Figure 2-145. Windshield Torque Sequence

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2-118 2011 Touring Service: Chassis

2.44

HEADLAMP NACELLE: ROAD KING MODELS

REMOVAL

Remove windshield. See

2.43 WINDSHIELD: ROAD KING

MODELS

Remove the screw securing the bottom of the headlamp
door (chrome ring). Remove the headlamp door.

Remove seven screws to free the headlamp housing from
the headlamp nacelle.

Remove headlamp connector [38] from back of headlamp
bulb. Remove the headlamp housing assembly from the
motorcycle.

See

Figure 2-146

. Remove flange nut (3) and remove

chrome strip (4).

Carefully pry off the fork lock plate (5). Remove two screws
(7).

Loosen screw (8) but do not remove nut (10) and flat
washer (9).

Remove acorn nuts from the left side and right side fork
bracket studs.

Cover the front fender to protect the fender paint. Remove
the auxiliary lamp bracket from the fork bracket studs and
carefully set on front fender.

10. Remove the grommets and clutch cable clamp from the

fork bracket studs.

11. See

Figure 2-147

. Separate the halves of the headlamp

nacelle slightly and slide the handlebar clamp shroud for-
ward running the shaft of the screw down the gap.

12. See

Figure 2-148

. Disconnect the accessory switch con-

nector (1) and auxiliary lamp switch connector (2).

13. Carefully separate the halves of the headlamp nacelle and

remove from motorcycle.

sm02883

1. Headlamp nacelle (left side
2. Trim strip
3. Flange nut
4. Chrome strip
5. Fork lock plate
6. Handlebar clamp shroud
7. Phillips screw (2)
8. Phillips screw
9. Flat washer
10. Keps nut

Figure 2-146. Headlamp Nacelle Assembly

sm02884

Figure 2-147. Handlebar Clamp Shroud and Screw

Assembly

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2011 Touring Service: Chassis 2-119

INSTALLATION

Fit halves of the headlamp nacelle together engaging the
holes in the nacelle with the left side and right side fork
bracket studs.

See

Figure 2-148

. Connect accessory switch connector

(1) and auxiliary lamp switch connector (2).

See

Figure 2-147

. If disassembled, install screw, flat

washer and nut on the handlebar clamp shroud.

Part the halves of the headlamp nacelle slightly. Slide the
handlebar clamp shroud rearward running the shaft of the
screw down the gap. Position the shroud over the flange
at the top of the nacelle.

Mate the halves of the headlamp nacelle and tighten the
screws to 10-20

in-lbs

(1.1-2.3 Nm).

See

Figure 2-146

. Install screws (7) and tighten to 10-20

in-lbs

(1.1-2.3 Nm). Install fork lock plate (5).

NOTE

To avoid possible damage to the brake hose and/or handlebar
switch wires, verify that trim strips are installed on inside edges
of the headlamp nacelle. Install new trim strips if cracked,
damaged or missing. Cutting or severe chafing of the brake
hose and/or handlebar switch wires could cause loss of function
while riding.

Install chrome strip (4) and secure with flange nut (3).
Tighten flange nut to 15-20

in-lbs

(1.7-2.3 Nm).

Install the grommets on the left and right side fork bracket
studs.

Slide the auxiliary lamp bracket onto the fork bracket studs.
Verify that the four grommets are in place on the inboard
side of the auxiliary lamp brackets.

sm02918

1. Accessory switch [67]
2. Auxiliary lamps switch [109]

Figure 2-148. Headlamp Nacelle (FLHRC)

10. Install the acorn nuts on the fork bracket studs and tighten

to 72-108

in-lbs

(8.1-12.2 Nm). Be sure to capture the

clutch cable clamp on the upper left stud before installing
the acorn nut.

11. Install headlamp connector [38] to back of headlamp bulb.

12. Install headlamp housing and secure with seven screws.

Tighten to 9-18

in-lbs

(1.0-2.0 Nm).

13. Fit the square-shaped portion of the headlamp door spring

into the slot at the top of the headlamp housing and then
snap the headlamp door (chrome ring) into place. Install
screw at the bottom of the headlamp door and tighten to
9-18

in-lbs

(1.0-2.0 Nm).

14. Install windshield. See

2.43 WINDSHIELD: ROAD KING

MODELS

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2-120 2011 Touring Service: Chassis

Harley Davidson 2011 Touring Models. Service Manual - page 1