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Harley Davidson 2011 Touring Models. Service Manual - page 4

Table 1-2. Recommended Engine Oils

COLD WEATHER

STARTS BELOW 50 °F

(10 °C)

LOWEST AMBIENT

TEMPERATURE

H-D RATING

VISCOSITY

H-D TYPE

Excellent

Below 40 °F (4 °C)

HD 360

SAE 10W40

H-D Multi-grade

Excellent

Above 40 °F (4 °C)

HD 360

SAE 20W50

Screamin' Eagle SYN3
Synthetic Motorcycle
Lubricant

Good

Above 40 °F (4 °C)

HD 360

SAE 20W50

Screamin' Eagle Syn-
thetic Blend Motorcycle
Engine Oil

Good

Above 40 °F (4 °C)

HD 360

SAE 20W50

H-D Multi-grade

Poor

Above 60 °F (16 °C)

HD 360

SAE 50

H-D Regular Heavy

Poor

Above 80 °F (27 °C)

HD 360

SAE 60

H-D Extra Heavy

WINTER LUBRICATION

In colder climates, the engine oil should be changed often. If
motorcycle is used frequently for short trips, less than 15 mi
(24 km), in ambient temperatures below 60 °F (16 °C), oil
change intervals should be reduced to 1500 mi (2400 km).
Motorcycles used only for short runs must have a thorough
tank flush-out before

new

oil is put in. The tank flush-out should

be performed by an authorized dealer or qualified technician.

NOTE

The further below freezing the temperature drops, the shorter
the oil change interval should be.

Water vapor is a normal by-product of combustion in any
engine. During cold weather operation, some of the water vapor
condenses to liquid form on the cool metal surfaces inside the
engine. In freezing weather this water will become slush or ice
and, if allowed to accumulate too long, may block the oil lines
and cause damage to the engine.

If the engine is run frequently and allowed to thoroughly warm
up, most of this water will become vapor again and will be
blown out through the crankcase breather.

If the engine is not run frequently and allowed to thoroughly
warm up, this water will accumulate, mix with the engine oil
and form a sludge that is harmful to the engine.

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1-8 2011 Touring Service: Maintenance

1.4

BULB REQUIREMENTS

GENERAL

Use the table to identify the bulb location and part number.
Refer to

Table 1-3

NOTE

The speedometer, tachometer, odometer and indicator lamps
are illuminated with LEDs. LEDs are non-repairable. The entire
assembly must be replaced if an LED fails.

Table 1-3. Bulb Chart

HARLEY-DAVIDSON

PART NUMBER

CURRENT

DRAW

AMPERAGE

BULBS

REQUIRED

DESCRIPTION
(ALL LAMPS 12 VOLT)

LAMP

68329-03

4.58/5.0

FLHTC/U, FLHR/C, FLHX, FLHTK

Headlamp

68329-03

4.58/5.0

FLTRX, FLTRU

53436-97

0.32

Position lamp, international

68167-04

0.59/2.10

Tail/stop lamp, FLHX, FLTRX

Tail and stop
lamp

68168-89A

2.25/0.59

Front/running

Turn signal lamp

68572-64B

1.75

Front international

68163-84

1.75

Front, FLHX (HDI)

68572-64B

2.25

Rear, FLHR, FLHRC, FLHTC,
FLHTCU, FLHTK, FLTRU (all)

68168-89A

2.25/0.59

Rear, FLHX, FLTRX (domestic)

N/A

LED

Rear, FLHX, FLTRX (international)*

68163-84

1.75

Rear, FLHX, FLTRX (Canadian)

53788-06 (right side)

0.14

N/A

Tour-Pak side lamps*

Additional lighting

53789-06 (left side)

0.14

FLHTCU, FLHTK, FLTRU

68165-64

0.59/2.10

Tour-Pak tail/stop lamps

68193-95

0.30

Fender tip lamps, front

69375-06 (FLHX, FLTRX)

N/A

Fender tip lamps, rear*

59672-09 (all but FLHX, FLTRX)

53436-97

0.37

License plate lamp international

52441-95

0.35

License plate lamp FLHX, FLTRX
domestic

68453-05

2.1

Auxiliary lamps

68851-98

2.7

Fog lamps international

Instrument panel is illuminated with LEDs. Replace entire assembly upon
failure.

High beam indicator

Instrument panel
lamps

Oil pressure indicator

Neutral indicator

Turn signal indicator

N/A

Speedometer

Gauge lamps
FLHR/C

N/A

Odometer

Illuminated with LEDs. Replace assembly upon failure.

Fuel gauge*

N/A

Engine

HOME

2011 Touring Service: Maintenance 1-9

Table 1-3. Bulb Chart

HARLEY-DAVIDSON

PART NUMBER

CURRENT

DRAW

AMPERAGE

BULBS

REQUIRED

DESCRIPTION
(ALL LAMPS 12 VOLT)

LAMP

N/A

Speedometer

Gauge lamps
FLHTC/U

N/A

Tachometer

FLTRX

67445-00

0.24

Voltmeter

FLTRU
FLHX

67445-00

0.24

Oil pressure gauge

FLHTK

FLHTC/U, FLHTK, FLHX, FLTRX,
FLTRU

67445-00

0.24

Air temperature gauge
FLHTC/U, FLHTK, FLHX, FLTRX,
FLTRU

67445-00

0.24

Fuel gauge

Illuminated with LEDs. Replace entire assembly upon failure.

Items with *

HOME

1-10 2011 Touring Service: Maintenance

1.5

MAINTENANCE SCHEDULE

GENERAL

The table below lists the periodic maintenance requirements
for Touring model motorcycles. If you are familiar with the
procedures, just refer to the table for the recommended service
interval. If necessary, see the quick reference table (

Table 1-5

for the required specifications.

If more detailed information is needed, turn to the sections
which follow for step-by-step instructions.

Also, throughout this manual, you will be instructed to use
various lubricants, greases and sealants. Refer to

Table 1-6

for the correct part numbers of these items.

Table 1-4. Regular Service Intervals: 2011 Touring Models

NOTES

50000 MI

80000 KM

45000 MI

72000 KM

40000 MI

64000 KM

35000 MI

56000 KM

30000 MI

48000 KM

25000 MI

40000 KM

20000 MI

32000 KM

15000 MI

24000 KM

10000 MI

16000 KM

5000 MI

8000 KM

1000 MI

1600 KM

PROCEDURE

ITEM SERVICED

Replace

Engine oil and filter

1, 3

Inspect for leaks,
contact or abrasion

Oil lines and brake
system

Inspect, service as
required

Air cleaner

Check pressure,
inspect tread

Tires

1, 5

Check torque

Wheel spokes (if
equipped)

Replace

Primary chaincase
lubricant

Replace

Transmission lub-
ricant

Check adjustment

Clutch

Inspect, adjust belt

Drive belt and
sprockets

Inspect for wear

Compensator
sprocket isolators

Check and lub-
ricate

Brake and clutch
controls

Inspect and lub-
ricate

Jiffy stand

1, 3

Inspect for leaks,
contact or abrasion

Fuel lines and fit-
tings

Replace

Fuel tank filter

Inspect sight glass

Brake fluid

Inspect for wear

Brake pads and
discs

Inspect

Spark plugs

Replace

Check operation

Electrical equip-
ment and switches

1, 6

Replace

Front fork oil

Lubricate

Steering head
bearings

1, 2

Adjust

Check pressure,
operation and
leakage

Air suspension

Inspect

Windshield bush-
ings (if applicable)

Lubricate hinges
and latches

Fuel door, Tour-
Pak, saddlebags (if
equipped)

Check tightness

Critical fasteners

Check battery and
clean connections

Battery

Inspect for leaks,
cracks, and loose
or missing
fasteners or heat
shields

Exhaust system

HOME

2011 Touring Service: Maintenance 1-11

Table 1-4. Regular Service Intervals: 2011 Touring Models

NOTES

50000 MI

80000 KM

45000 MI

72000 KM

40000 MI

64000 KM

35000 MI

56000 KM

30000 MI

48000 KM

25000 MI

40000 KM

20000 MI

32000 KM

15000 MI

24000 KM

10000 MI

16000 KM

5000 MI

8000 KM

1000 MI

1600 KM

PROCEDURE

ITEM SERVICED

Verify component
and system func-
tions

Road test

1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified.

NOTES:

2. Disassemble, lubricate and inspect every 50,000 miles (80,000 kilometers).
3. Perform annually or at specified intervals, whichever comes first.
4. Change D.O.T. 4 brake fluid and flush system every two years.
5. Perform spoke tension check at the 1000, 5000, 20,000 mile (1600, 8000, 32000 kilometer) services and every 15,000 mile (24000 kilometer)
interval thereafter. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service manual.
6. Replace fork oil and inspect every 50,000 miles (80,000 kilometers).
7. Perform at each rear tire change.

Table 1-5. Quick Reference Maintenance Chart

DATA

SPECIFICATION

ITEM SERVICED

14-21 ft-lbs (19.0-28.5 Nm)

Drain plug torque

Engine oil and filter

4 qt. (3.8 L)

Oil capacity *

Hand tighten 1/2-3/4 turn after gasket contact

Filter

63798-99A

Chrome filter part number

63731-99A

Black filter part number

FORMULA+ TRANSMISSION AND PRIMARY
CHAIN LUBRICANT (Part No. 99851-05)

Lubricant type and capacity

Primary chain lubricant

or
SYN3 20W50 OIL (Part No. 99824-03/00QT)
Wet: 38 oz. (1124 ml)
Dry: 45 oz. (1331 ml)

14-21 ft-lbs (19.0-28.5 Nm)

Primary chaincase drain plug torque

1/2-1 turn

Adjuster screw free play

Clutch adjustment

72-120

in-lbs

(8.1-13.6 Nm)

Adjuster screw locknut torque

1/16-1/8 in. (1.6-3.2 mm)

Free play at hand lever

84-108

in-lbs

(9.5-12.2 Nm)

Clutch inspection cover torque

Dipstick at FULL with motorcycle on jiffy stand and
filler plug resting on threads.

Lubricant level

Transmission lubricant

FORMULA+ TRANSMISSION AND PRIMARY
CHAIN LUBRICATION (Part No. 99851-05)

Lubricant type and capacity

or
SYN3 20W50 OIL (Part No. 99824-03/00QT)
32 oz (0.95 liters)

14-21 ft-lbs (19.0-28.5 Nm)

Transmission drain plug torque

25-75

in-lbs

(2.8-8.5 Nm)

Transmission filler plug/dipstick torque

Front: 36 psi (248 kPA)

Pressure: solo rider or with passenger

Tire pressure and wear

Rear: 40 psi (276 kPA)

Replace if less than 1/32 in. (0.8 mm) of tread
pattern

Wear

in-lbs

(6.2 Nm) minimum

Spoke nipple torque

Wheel spokes

99953-99A (12 oz.)

D.O.T. 4 hydraulic brake fluid part number

Brake fluid level (Check
sight glass. If fluid is low,
remove reservoir cover
and re-check.)

Front: 0.20 in. (5.0 mm)
Rear: 0.26 in. (6.5 mm)

Fluid level (from top of master cylinder reservoir)

Front: 10-12

in-lbs

(1.1-1.4 Nm)

Master cylinder reservoir cover screw torque

Rear: 12-15

in-lbs

(1.4-1.7 Nm)

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1-12 2011 Touring Service: Maintenance

Table 1-5. Quick Reference Maintenance Chart

DATA

SPECIFICATION

ITEM SERVICED

0.016 in. (0.4 mm)

Minimum brake pad thickness

Brake pads and discs

75-102

in-lbs

(8.5.-11.5 Nm)

Brake caliper pad pin torque

Front: 0.18 in. (4.5 mm)

Minimum brake disc thickness

Rear: 0.25 in. (6.3 mm)

0.008 in. (0.20 mm)

Maximum brake disc lateral runout (warpage)

10 lb. (4.5 kg)

Upward force applied at midpoint of bottom belt
strand

Drive belt deflection

3/8-7/16 in. (9.5-11.1 mm)

FLHR/C, FLHTC/U, FLHTK, FLTRU

1/4-5/16 in. (6.4-7.9 mm)

FLHX, FLTRX

108-132

in-lbs

(12.2-14.9 Nm)

Air cleaner cover bracket screw torque

Air cleaner

36-60

in-lbs

(4.1-6.8 Nm)

Air cleaner cover screw torque

LOCTITE MEDIUM STRENGTH THREADLOCKER
243 (BLUE)

Air cleaner cover screw Threadlocker

Part No. 99642-97 (6 ml)

Harley® Lube Part No. 94968-09

Lubricant part number

Clutch cable

35-45

in-lbs

(4.0-5.1 Nm)

Handlebar switch housing screw torque

HD-6R12

Type

Spark plugs

0.038-0.043 in. (0.97-1.09 mm)

Gap

12-18 ft-lbs (16.3-24.4 Nm)

Torque

See

2.17 FRONT FORK

Amount

Front fork oil

HYDRAULIC FORK OIL (TYPE E)

Type and part number

Part No. 99884-80 (16 oz.)

60-70

in-lbs

(6.8-7.9 Nm)

Terminal bolt torque

Battery

72-96

in-lbs

(8.1-10.9 Nm)

Top caddy screw torque

* Capacity is approximate. When changing oil, initially add 3.5 qt. (3.3 L). Run engine until warm. Check and fill as necessary.

Table 1-6. Lubricants, Greases, Sealants

PACKAGE

PART NUMBER

ITEM

1 oz squeeze tube

98960-97

SILVER GRADE ANTI-SEIZE

squeeze packet

42830-05 (included in master cylinder
rebuild kit)

CCI #20 Brake Grease

12 oz. bottle

99953-99A

D.O.T. 4 Brake Fluid

1 oz squeeze tube

99861-02

Electrical Contact Lubricant

1 qt bottle

99851-05

Genuine Harley-Davidson Formula+
Transmission and Primary Chaincase
Lubricant

1 qt bottle

99816-2050/00QT

Genuine Harley-Davidson
H-D 360 20W50 Oil

1 qt bottle

99813-09

Screamin' Eagle 20W50 Synthetic Blend
Motorcycle Engine Oil

1 qt bottle

99824-03/00QT

SYN3 20W50 Full Synthetic Oil

squeeze packet

42820-04

G40M Brake Grease

1.9 oz squeeze tube

99650-02

Gray High Performance Sealant

3.5 oz tube

99653-85

HYLOMAR Gasket and Thread Sealant

HOME

2011 Touring Service: Maintenance 1-13

Table 1-6. Lubricants, Greases, Sealants

PACKAGE

PART NUMBER

ITEM

6 ml squeeze tube

99818-97

Loctite Pipe Sealant With Teflon 565

Loctite Prism Primer (770)

Loctite Prism Superbonder (411)

Loctite Superbonder 420 Adhesive

6 ml squeeze tube

99642-97

Loctite Threadlocker 243 (blue)

6 ml squeeze tube

94759-99

Loctite Threadlocker 262 (red)

10 ml bottle

98618-03

Loctite Threadlocker 272

4 oz. bottle

94971-09

Screamin' Eagle Assembly Lube

14 oz. cartridge

99857-97

Special Purpose Grease

1/4 fl. oz

94968-09

Harley® Lube

16 oz bottle

99884-80

Type "E" Hydraulic Fork Oil

HOME

1-14 2011 Touring Service: Maintenance

1.6

ENGINE OIL AND FILTER

CHECKING OIL LEVEL

Check engine oil level at each complete fuel refill.

Do not allow hot oil level to fall below Add/Fill mark on
dipstick. Doing so can result in equipment damage and/or
equipment malfunction. (00189a)

Oil level cannot be accurately measured on a cold engine.
For pre-ride inspection, with motorcycle leaning on jiffy
stand on level ground, oil should register on dipstick
between arrows when engine is cold. Do not add oil to
bring the level to the FULL mark on a COLD engine.
(00185a)

Do not overfill oil tank. Doing so can result in oil carryover
to the air cleaner leading to equipment damage and/or
equipment malfunction. (00190a)

Oil Level Cold Check

For pre-ride inspection, place vehicle on level ground and
rest the vehicle on its jiffy stand (unless sidecar is
attached).

See

Figure 1-1

. Remove filler plug/dipstick and wipe off

the dipstick. Insert the dipstick and tighten into the fill
spout.

NOTE

The oil level marks for checking with motorcycle upright or on
jiffy stand are on the same side of the dipstick. Be sure to use
the correct portion of dipstick when checking oil level.

See

Figure 1-2

. Remove the dipstick and verify the level

of the oil. The correct oil level should register midway (2)
between the FULL and ADD marks on the dipstick.

NOTE

If oil level is at or below the ADD mark, add only enough oil to
bring the level to the middle of the two marks on the dipstick.

Oil Level Hot Check

NOTES

•

The engine will require a longer warm up period in colder
weather.

•

Engine oil level hot check should be performed only when
engine is at normal operating temperature.

Ride motorcycle until engine is at normal operating tem-
perature.

Place vehicle on level ground and rest the vehicle on its
jiffy stand (unless sidecar is attached). Allow engine to
idle for 1-2 minutes. Turn engine off.

See

Figure 1-1

. Remove filler plug/dipstick and wipe off

the dipstick. Insert the dipstick and tighten into the fill
spout.

NOTE

The oil level marks for checking with motorcycle upright or on
jiffy stand are on the same side of the dipstick. Be sure to use
the correct portion of dipstick when checking oil level.

See

Figure 1-2

. Remove the dipstick and note the level

of the oil. The level should be between the ADD (1) and
FULL (3) marks. Add oil as necessary to bring the level
to the FULL mark on the dipstick. Do not overfill.

NOTE

Refer to

Table 1-2

. Use only recommended oil specified in

1.3 FUEL AND OIL, Engine Lubrication

Start engine and carefully check for oil leaks around drain
plug and oil filter.

sm05693

Figure 1-1. Engine Oil Filler Cap

sm05900

1. ADD QT (lower) mark
2. Cold check level
3. FULL (hot check) mark

Figure 1-2. Engine Oil Dipstick

HOME

2011 Touring Service: Maintenance 1-15

sm00068a

1. First gear
2. Second gear
3. Third gear
4. Fourth gear
5. Fifth gear
6. Sixth gear
7. Mainshaft
8. Countershaft

Figure 6-1. Transmission Power Flow

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6-4 2011 Touring Service: Transmission

6.4

SHIFTER LINKAGE

SHIFTER ROD

The shifter rod is set at the factory and should not need
adjustment under normal circumstances. However, if full
engagement or full lever travel is not achieved, adjust the shifter
rod.

NOTE

To ensure proper gear engagement and avoid possible damage
to transmission, the shift levers should not contact the footboard
when shifting.

See

Figure 6-2

. Remove locknut, lockwasher and flat

washer to free front end of shifter rod from inner shift arm.

Loosen locknuts (1) and adjust rod (2) as necessary.

Install flat washer, lockwasher and locknut to fasten front
end of shifter rod to inner shift arm.

Tighten locknuts (1) to 80-120

in-lbs

(9.0-13.6 Nm).

sm03667

1. Locknut (2)
2. Shifter rod

Figure 6-2. Shifter Rod

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2011 Touring Service: Transmission 6-5

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