Harley Davidson 2011 Touring Models. Service Manual - page 2

2.36 INNER FAIRING: FORK MOUNTED
FAIRING MODELS

Removal............................................................................2-99
Installation.......................................................................2-101

2.37 AIR DEFLECTORS

Air Deflectors..................................................................2-103

Removal..................................................................2-103
Installation...............................................................2-103

Mid-Frame Air Deflectors................................................2-103

Removal..................................................................2-103
Installation...............................................................2-103

2.38 UPPER FAIRING AND WINDSHIELD:
FRAME MOUNTED FAIRING MODELS

Windshield......................................................................2-104

Removal..................................................................2-104
Installation...............................................................2-104

Outer Fairing...................................................................2-104

Removal..................................................................2-104
Installation...............................................................2-105

2.39 INSTRUMENT BEZEL: FRAME
MOUNTED FAIRING MODELS

Bezel...............................................................................2-107

Removal..................................................................2-107
Installation...............................................................2-108

2.40 INSTRUMENT NACELLE: FRAME
MOUNTED FAIRING MODELS

Instrument Nacelle..........................................................2-109

Removal..................................................................2-109
Installation...............................................................2-110

2.41 INNER FAIRING: FRAME MOUNTED
FAIRING MODELS

Removal..........................................................................2-111

Disassembly............................................................2-112

Installation.......................................................................2-113

Outer Fairing............................................................2-113
Inner Fairing............................................................2-113

2.42 GLOVE BOX DOOR AND HINGE:
FRAME MOUNTED FAIRING MODELS

Glove Box Door and Hinge.............................................2-115

Removal..................................................................2-115
Installation...............................................................2-115

2.43 WINDSHIELD: ROAD KING MODELS

Windshield......................................................................2-116

Removal..................................................................2-116
Installation...............................................................2-116

Windshield Window........................................................2-116

Removal..................................................................2-116
Installation...............................................................2-117

2.44 HEADLAMP NACELLE: ROAD KING
MODELS

Removal..........................................................................2-119
Installation.......................................................................2-120

2.45 FRONT FENDER

Removal..........................................................................2-121
Installation.......................................................................2-121

2.46 REAR FENDER

Removal..........................................................................2-122
Fender Repair.................................................................2-123

Mounting Hardware.................................................2-123
Lights and Harnesses..............................................2-123

Installation.......................................................................2-123

2.47 REAR FASCIA

Removal..........................................................................2-125
Installation.......................................................................2-125
Stud Plate.......................................................................2-125

Removal..................................................................2-125
Installation...............................................................2-125

Rear Fascia Lamp..........................................................2-125

Removal..................................................................2-125
Installation...............................................................2-125

2.48 REAR FRAME

Rear Frame.....................................................................2-126

Removal..................................................................2-126
Installation...............................................................2-127
Thread Repair..........................................................2-127

2.49 FOOTBOARDS AND FOOTRESTS

Rider Footboards............................................................2-128

Removal..................................................................2-128
Installation...............................................................2-128
Disassembly............................................................2-128
Assembly.................................................................2-128

Passenger Footboard.....................................................2-129

Removal..................................................................2-129
Disassembly............................................................2-129
Assembly.................................................................2-129
Installation...............................................................2-129

Passenger Footrest: FLHX, FLTRX................................2-129

Removal..................................................................2-129
Disassembly............................................................2-129
Assembly.................................................................2-130
Installation...............................................................2-130

2.50 JIFFY STAND

General...........................................................................2-131
Leg Removal...................................................................2-131
Leg Installation................................................................2-131
Jiffy Stand Bracket..........................................................2-132

Removal..................................................................2-132
Installation...............................................................2-132

Jiffy Stand Interlock Sensor............................................2-132

Removal..................................................................2-132
Installation...............................................................2-133

TABLE OF CONTENTS VII

TABLE OF CONTENTS

2.51 FRONT ENGINE MOUNT

Removal..........................................................................2-134
Installation.......................................................................2-134

ENGINE

3.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................3-1

3.2 SPECIFICATIONS

Specifications......................................................................3-3

3.3 SERVICE WEAR LIMITS

General...............................................................................3-5

3.4 ENGINE OIL FLOW

Oil Feed..............................................................................3-7
Top End...............................................................................3-7
Bottom End.........................................................................3-9
Oil Return..........................................................................3-11
Oil Cooler Operation.........................................................3-12

3.5 OIL PUMP OPERATION

General.............................................................................3-13
Operation..........................................................................3-13

3.6 BREATHER OPERATION

General.............................................................................3-15

3.7 OIL PRESSURE

Oil Pressure Indicator Lamp.............................................3-16
Checking Oil Pressure......................................................3-16

3.8 TROUBLESHOOTING

Diagnosing Valve Train Noise...........................................3-18
Compression Test.............................................................3-18
Cylinder Leakdown Test...................................................3-19
Diagnosing Smoking Engine or High Oil Consumption.....3-19

Check Prior To Cylinder Head Removal....................3-19
Check After Cylinder Head Removal.........................3-19

3.9 OIL COOLER

Removal............................................................................3-20
Installation.........................................................................3-20

3.10 OIL COOLER ADAPTER

Removal............................................................................3-21
Disassembly.....................................................................3-21
Assembly..........................................................................3-21
Installation.........................................................................3-21

3.11 HOW TO USE THIS SECTION

Top End Repair.................................................................3-23
Bottom End Repair...........................................................3-23
Typical Symptoms.............................................................3-23

3.12 TOP END SERVICE

Engine in Chassis.............................................................3-24
Engine Removed from Chassis........................................3-25

3.13 CAM COMPARTMENT SERVICE

Engine in Chassis.............................................................3-26
Engine Removed From Chassis.......................................3-27

3.14 STRIPPING MOTORCYCLE FOR
SERVICE

Procedure.........................................................................3-28

Cam Compartment Service Only...............................3-28
Top End Service........................................................3-28

3.15 ASSEMBLING MOTORCYCLE AFTER
SERVICE

Procedure.........................................................................3-29

After Top End Service................................................3-29
After Cam Compartment Service..............................3-29

3.16 REMOVING ENGINE FROM CHASSIS

Procedure.........................................................................3-30

3.17 INSTALLING ENGINE IN CHASSIS

Procedure.........................................................................3-31

3.18 TOP END OVERHAUL: DISASSEMBLY

General.............................................................................3-32
Rocker Covers..................................................................3-32
Rocker Arm Support Plate................................................3-32
Push Rods, Lifters and Covers.........................................3-34
Cylinder Head...................................................................3-35
Cylinder.............................................................................3-36
Piston................................................................................3-36

3.19 BREATHER ASSEMBLY

Disassembly.....................................................................3-38

Early Production........................................................3-38
Late Production.........................................................3-38

Cleaning and Inspection...................................................3-38
Assembly..........................................................................3-38

Early Production........................................................3-38
Late Production.........................................................3-38

3.20 ROCKER ARM SUPPORT PLATE

Disassembly.....................................................................3-40
Cleaning and Inspection...................................................3-40

Inspection..................................................................3-40
Rocker Shaft Fit.........................................................3-40
Rocker Arm Shaft to Bushing....................................3-41
Replace Rocker Arm Bushings.................................3-41

Assembly..........................................................................3-42

3.21 PUSH RODS, LIFTERS AND COVERS

Disassembly.....................................................................3-43
Cleaning and Inspection...................................................3-43
Lifter Inspection................................................................3-44
Assembly..........................................................................3-44

3.22 CYLINDER HEAD

Disassembly.....................................................................3-45
Cleaning............................................................................3-46
Inspection.........................................................................3-46

VIII TABLE OF CONTENTS

TABLE OF CONTENTS

Cylinder Head............................................................3-46
Valve Guides.............................................................3-47
Valves........................................................................3-47
Valve Springs.............................................................3-47
Tapered Keepers.......................................................3-47
Valve Seats................................................................3-47

Valve Guide Replacement................................................3-47

Removal....................................................................3-47
Installation.................................................................3-48

Valve and Seat Refacing..................................................3-51
Assembly..........................................................................3-53

3.23 CYLINDER

Cleaning............................................................................3-56
Inspection.........................................................................3-56
Deglazing Cylinder............................................................3-58
Boring and Honing Cylinder..............................................3-58

3.24 PISTON

Disassembly.....................................................................3-60

Piston Rings..............................................................3-60

Cleaning............................................................................3-60
Inspection.........................................................................3-60
Assembly..........................................................................3-62

Checking Piston Ring Gap........................................3-62
Installing Piston Rings...............................................3-62

3.25 TOP END OVERHAUL: ASSEMBLY

General.............................................................................3-64
Piston................................................................................3-64
Cylinder.............................................................................3-65
Cylinder Head...................................................................3-67
Push Rods, Lifters and Covers.........................................3-71
Rocker Arm Support Plate................................................3-72
Breather and Rocker Cover..............................................3-73

3.26 CAM COMPARTMENT AND
COMPONENTS

Cam Support Plate and Cover Removal..........................3-75

Prepare Engine..........................................................3-75
Cam Chain and Sprockets Removal.........................3-75
Cam Support Plate Removal.....................................3-76

Cam Support Plate Cleaning and Inspection....................3-77

Oil Pressure Valve.....................................................3-77
Cam Support Plate....................................................3-77

Camshafts.........................................................................3-77

Removal....................................................................3-77
Installation.................................................................3-78

Oil Pressure Relief Valve..................................................3-79

Removal....................................................................3-79
Inspection..................................................................3-79
Installation.................................................................3-79

Cam Needle Bearings.......................................................3-80

Removal....................................................................3-80
Installation.................................................................3-81

Cam Support Plate and Cover Installation.......................3-83

3.27 OIL PUMP

Removal............................................................................3-87
Cleaning and Inspection...................................................3-87
Installation.........................................................................3-88

3.28 CRANKCASE DISASSEMBLY AND
REPAIR

Crankcase Disassembly...................................................3-90
Cleaning and Inspection...................................................3-90
Right Crankcase Half........................................................3-91

Main Bearing Removal..............................................3-91
Main Bearing Installation...........................................3-91
Piston Jets Removal..................................................3-92
Piston Jets Installation...............................................3-92

Left Crankcase Half..........................................................3-92

Main Bearing Removal..............................................3-92
Main Bearing Installation...........................................3-94

Sprocket Shaft Bearing Inner Race..................................3-94

Removal....................................................................3-94
Installation.................................................................3-95

Cylinder Studs..................................................................3-97

Removal....................................................................3-97
Installation.................................................................3-97

Pipe Plug and Oil Fittings.................................................3-98

Removal....................................................................3-98
Installation.................................................................3-98

3.29 FLYWHEEL AND CONNECTING RODS

Inspection.........................................................................3-99
Measuring Crankshaft Runout..........................................3-99

Crankshaft Removed.................................................3-99

3.30 CRANKCASE ASSEMBLY

Crankcase Assembly......................................................3-101

3.31 OIL PAN

Removal..........................................................................3-103
Installation.......................................................................3-103

FUEL SYSTEM

4.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................4-1

4.2 SPECIFICATIONS: FUEL SYSTEM

Specifications......................................................................4-3

4.3 ELECTRONIC FUEL INJECTION (EFI)

Troubleshooting..................................................................4-4

4.4 AIR CLEANER ASSEMBLY

Removal..............................................................................4-5
Installation...........................................................................4-6

4.5 FUEL TANK

Removal..............................................................................4-8

Purge and Disconnect Fuel Line.................................4-8
Remove Tank...............................................................4-8

Installation...........................................................................4-8
Evaporative Emissions Tube: Non-CA Models...................4-9

Removal......................................................................4-9
Installation...................................................................4-9

Fuel Supply Check Valve/Tube...........................................4-9

Removal......................................................................4-9
Installation.................................................................4-10

TABLE OF CONTENTS IX

TABLE OF CONTENTS

4.6 FUEL TANK TOP PLATE

Removal............................................................................4-11
Installation.........................................................................4-12

4.7 FUEL FILTER

Removal............................................................................4-13
Installation.........................................................................4-13

4.8 FUEL PRESSURE REGULATOR

Removal............................................................................4-14
Installation.........................................................................4-14

4.9 FUEL LEVEL SENDER

Removal............................................................................4-15
Installation.........................................................................4-15

4.10 TWIST GRIP SENSOR

Removal............................................................................4-16
Installation.........................................................................4-17
Twist Grip Sensor Jumper Harness..................................4-18

Removal....................................................................4-18
Installation.................................................................4-18

4.11 THROTTLE CONTROL ACTUATOR
(TCA)

General.............................................................................4-19

4.12 ENGINE TEMPERATURE SENSOR (ET)

Removal............................................................................4-20
Installation.........................................................................4-20

4.13 INDUCTION MODULE

Removal............................................................................4-21
Installation.........................................................................4-22

4.14 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE SENSOR (TMAP)

General.............................................................................4-23
Removal............................................................................4-23
Installation.........................................................................4-23

4.15 OXYGEN SENSORS (O2)

General.............................................................................4-24
Removal............................................................................4-24
Installation.........................................................................4-25

4.16 FUEL INJECTORS

General.............................................................................4-26
Removal............................................................................4-26
Installation.........................................................................4-26

4.17 FUEL PUMP

General.............................................................................4-28
Removal............................................................................4-28
Installation.........................................................................4-28
Fuel Pump and Fuel Level Sender Wire Harness............4-29

Removal....................................................................4-29
Installation.................................................................4-29

4.18 FUEL PRESSURE TEST

General.............................................................................4-30
Testing..............................................................................4-30

4.19 EXHAUST SYSTEM

Mufflers.............................................................................4-32

Removal....................................................................4-32
Installation.................................................................4-32

System Removal...............................................................4-32
System Installation............................................................4-33

4.20 ACTIVE EXHAUST (HDI)

Exhaust Valve Actuator.....................................................4-35

Removal....................................................................4-35
Installation.................................................................4-35

Exhaust Valve Actuator Cable..........................................4-35

Removal....................................................................4-35
Installation.................................................................4-35

Active Exhaust Valve........................................................4-35

General......................................................................4-35

4.21 INTAKE LEAK TEST

General.............................................................................4-36
Leak Tester.......................................................................4-36

Parts List....................................................................4-36
Tester Assembly........................................................4-36
Tester Adjustment......................................................4-36

Procedure.........................................................................4-36

4.22 EVAPORATIVE EMISSIONS CONTROL
SYSTEM

General.............................................................................4-38
Vapor Valve.......................................................................4-38
Fuel Vapor Vent Tube.......................................................4-39

Removal....................................................................4-39
Installation.................................................................4-39

Canister-to-Solenoid Tube................................................4-39

Removal....................................................................4-39
Installation.................................................................4-39

Solenoid-to-Induction Module Tube..................................4-39

Removal....................................................................4-39
Installation.................................................................4-39

Purge Solenoid.................................................................4-40

Removal....................................................................4-40
Installation.................................................................4-40

Charcoal Canister.............................................................4-40

Removal....................................................................4-40
Installation.................................................................4-40

DRIVE

5.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................5-1

5.2 SPECIFICATIONS: DRIVE

Specifications......................................................................5-2

5.3 PRIMARY CHAINCASE COVER

General...............................................................................5-3
Removal..............................................................................5-3

X TABLE OF CONTENTS

TABLE OF CONTENTS

2.46

REAR FENDER

REMOVAL

1.

Remove seat. See

2.25 SEAT

.

2.

All except FLHX, FLTRX:

See

Figure 2-151

. Disconnect

rear lighting connector from front of fender. Release con-
nector from fender.

3.

FLHX, FLTRX:

See

Figure 2-152

. Remove shield and

disconnect lights harness from rear fascia lamp. Release
lights harness from retainers on left fascia.

4.

See

Figure 2-153

. Remove saddlebag support fastener

(4) from each side.

5.

Remove fastener (10), seat strap (9) and saddlebag
bracket (8) from each side.

6.

Remove fastener (11) on each side. Remove frame covers
(1).

sm04825

Figure 2-151. Rear Fender Lights Connector (models with

under fender wiring)

sm06606

Figure 2-152. Rear Fender Lights Connector (FLHX, FLTRX)

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2-122 2011 Touring Service: Chassis

11

10

9

8

1

7

5

2

4

3

2

6

sm05829

7.

1.

Fastener, fender to saddlebag support (2)

Cover (2)

2.

8.

Fastener, fender support to fender support (2)

Forward saddlebag bracket (2)

9.

3.

Seat strap

Fastener, luggage rack to fender support (4)

4.

10.

Fastener, saddlebag support to fender support

Cover fastener, front (2)

11.

5.

Cover fastener, rear (2)

Tail lamp connector anchor location

6. Nut, fender to saddlebag support (2)

Figure 2-153. Rear Fender

7.

See

Figure 2-153

. Remove fasteners (7) and flange nuts

(6) to release fender support bracket from saddlebag
support.

8.

If equipped with a luggage rack or Tour-Pak, back out
screws (3) 2-3 turns.

9.

Remove fender mounting screws (2) from both sides. Be
aware that rear fender will drop when screws are removed.

10. See

Figure 2-155

. Carefully roll the fender back and out

of the frame.

FENDER REPAIR

Mounting Hardware

1.

See

Figure 2-154

. Remove nut (1), washer (2) and

mounting boss (3).

2.

Install

new

components as necessary. Tighten nut (1) to

15-20 ft-lbs (20.3-27.1 Nm)

1

2

3

sm06643

1. Nut (4)
2. Washer (4)
3. Mounting boss (4)

Figure 2-154. Rear Fender Mounting Hardware

Lights and Harnesses

All except FLHX, FLTRX:

For service of the tail lights or har-

ness, see

7.14 TAIL LAMP

.

FLHX, FLTRX:

For service of the rear fascia or fascia lamp

see

2.47 REAR FASCIA

. For service of the tail lights or har-

ness, see

7.14 TAIL LAMP

.

INSTALLATION

1.

See

Figure 2-155

. Carefully roll the fender into position.

NOTE

FLHX, FLTRX: The rear fender lights harness is routed below
the front left fender mounting nut.

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2011 Touring Service: Chassis 2-123

2.

See

Figure 2-153

. Verify the rear fender lights harness is

routed below the front left fender mounting nut. Install four
fasteners (2) and tighten to 15-20 ft-lbs (20.3-27.1 Nm).

3.

Tighten four luggage rack fasteners (3) to 15-20 ft-lbs
(20.3-27.1 Nm).

sm04756

Figure 2-155. Carefully Roll Out Rear Fender

4.

See

Figure 2-153

. Install rear fender support-to-saddlebag

support fastener (7) and nut (6). Tighten to 15-20 ft-lbs
(20.3-27.1 Nm).

5.

Install cover (1) on each side and start fastener (11). Verify
all electrical harnesses are above the cover flange and
not pinched.

6.

Install forward cover fastener (10) along with flat washer,
seat strap (9) and saddlebag bracket (8) on each side but
do not tighten at this time.

7.

Install saddlebag support fastener (4) on each side. The
air suspension fitting bracket is also retained by this
fastener on the left side. Tighten fasteners (4) to 15-20 ft-
lbs (20.3-27.1 Nm).

8.

Tighten cover fasteners (11) to 15-20 ft-lbs (20.3-27.1
Nm).

9.

All except FLHX, FLTRX:

See

Figure 2-151

. Connect

rear fender lights connector and secure anchor in rear
fender hole.

10.

FLHX, FLTRX:

See

Figure 2-152

. Connect rear fender

lights connector and install shield. Secure harness in
retainers on left fascia.

11. Install seat. See

2.25 SEAT

.

12. Install saddlebags. The front bracket (8) may need to be

rotated to align with attachment stud. Once saddlebags
are secured, tighten fasteners (10) to 12-15 ft-lbs (16.3-
20.3 Nm).

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2-124 2011 Touring Service: Chassis