Content .. 6 7 8 9 ..

Harley Davidson 2011 Touring Models. Service Manual - page 8

Table B-1. Connector Locations

LOCATION

TERMINAL

PROBE
COLOR

TYPE

DESCRIPTION

NO.

Inside of Tour-Pak

Radio antenna cable to mast

[52]

Rear of battery box (under seat)

Black

12-place Deutsch DTM Sealed
(BK)

Console pod

[53]

Under left side cover

Gray

Delphi PED 280 Unsealed

Fuse block/relays

[64]

Top of transmission case (under
starter)

Gray

3-place Delphi GT 150 Sealed
(BK)

VSS

[65]

Inside headlamp nacelle (FLHR/C)

Gray

4-place Tyco Mate-N-lok
Unsealed (BK)

Accessory switch

[67]

Inside headlamp nacelle (FLHR/C)

Gray

2-place Tyco 070 Multilock
Unsealed (W)

Auxiliary lamps

[73]

Below rear left speaker box

7-place DIN (BK)

Passenger headset

[76]

Bottom of voltage regulator (right
side)

Green

2-place Dekko (BK)

Voltage regulator

[77]

Under seat

Breakout Box

73-place Delphi Micro 64
Sealed (BK)

ECM

[78]

Rear of lower front frame cross-
member

Brown

2-place Deutsch DTM Sealed
(BK)

CKP sensor

[79]

Top of induction module

Gray

4-place Bosch Compact 1.1M
Sealed (BK)

TMAP sensor

[80]

Bottom front of battery tray

Gray

4-place Delphi GT 150 Sealed
(BK)

Ignition coil

[83]

Below fuel tank (left side)

Purple

2-place Molex BPT Sealed (BK)

Front fuel injector

[84]

Below fuel tank (left side)

Purple

2-place Molex BPT Sealed (BK)

Rear fuel injector

[85]

Back of front cylinder (left side)

Gray

2-place Delphi GT 150 Sealed
(BK)

ET sensor

[90]

Under left side cover

Black

4-place Deutsch DT Sealed
(GY)

DLC

[91]

Circuit board under tail lamp
assembly

Gray

4-place Tyco 070 Multilock
Unsealed (BK)

Tail lamp

[93]

Circuit board under tail lamp
assembly

Gray

6-place Tyco 070 Multilock
Unsealed (BK)

Rear fender lights harness in
circuit board

[94]

Under seat

Purple

2-place Delphi 150 Metripack
Sealed (BK)

Purge solenoid

[95]

Inner fairing - above upper fork
bracket (right side)

Gray

12-place Tyco 070 Multilock
Unsealed (BK)

Fairing cap switches

[105]

Inside instrument nacelle (under
bezel) (FLT models)

Gray

12-place Tyco 070 Multilock
Unsealed (BK)

Interconnect to nacelle switch
harness

[105A,

105B]

Inside instrument nacelle (under
bezel) (FLT models)

Gray

4-place Tyco 070 Multilock
Unsealed (BK)

Nacelle switch harness to
speaker switch

[105C,

105D]

Steering head, left side (FLHTC/U,
FLHTK)

Gray

3-place Tyco 070 Multilock
Unsealed (BK)

Ambient Air Temperature (AAT)
sensor

[107]

Inside instrument nacelle (under
bezel) (FLT models)

Inner fairing (back of tachometer)
(FLH models)

Breakout Box

Red

12-place Delphi Micro 64
Sealed (GY)

Tachometer

[108]

Instrument nacelle (back of tacho-
meter) (FLT models)

Inside headlamp nacelle (FLHR/C)

Gray

4-place Tyco Mate-N-Lok
Unsealed (BK)

Auxiliary lamps switch

[109]

HOME

2011 Touring Service: Appendix B Wiring B-3

Table B-1. Connector Locations

LOCATION

TERMINAL

PROBE
COLOR

TYPE

DESCRIPTION

NO.

Inner fairing (back of voltmeter)

Red

2-way Tyco Positive Lock
Spade Unsealed (BK)

Voltmeter lamp

[110]

Inner fairing (back of voltmeter)

Red

3-way Faston 250 Spade
Unsealed (BK)

Voltmeter

[111]

Inner fairing (back of oil pressure
gauge)

Red

2-way Tyco Positive Lock
Spade Unsealed (BK)

Oil pressure gauge lamp

[112]

Inner fairing (back of oil pressure
gauge)

Red

3-way Faston 250 Spade
Unsealed (BK)

Oil pressure gauge

[113]

Inner fairing (back of air temperature
gauge)

Red

2-way Tyco Positive Lock
Spade Unsealed (BK)

Air temperature gauge lamp

[114]

Inner fairing (back of air temperature
gauge)

Red

3-way Faston 250 Spade
Unsealed (BK)

Air temperature gauge

[115]

Inner fairing (back of fuel gauge)

Red

2-way Tyco Positive Lock
Spade Unsealed (BK)

Fuel gauge lamp

[116]

Inner fairing (back of fuel gauge) (All
except FLHR/C)

Red

3-way Faston 250 Spade
Unsealed (BK)

Fuel gauge

[117]

Bottom fuel tank left side (FLHR/C)

Front right crankcase (FLHR/C)

Black

Push On Right Angle Molded
terminal (BK)

Oil pressure switch

[120]

Mid-chassis, lower right side between
frame and exhaust pipe)

Red

Tyco Insulated Spade terminals
(BK)

Rear stop lamp switch

[121]

Between cylinders (left side)

Red

Flag terminals (BK)

Horn

[122]

Top of starter

Red

Delphi 56 Spade terminal (W)

Starter solenoid

[128]

Top of transmission (right side)

Push On Right Angle Molded
terminals (BK)

Neutral switch

[131]

Inner fairing

Red

Tyco Insulated Spade terminals

Cigar lighter

[132]

Rear of lower front frame cross-
member.

3-place Molex MX 150 Sealed
(BK)

Jiffy stand sensor (if equipped)

[133]

HDI: Rear of lower front frame
crossmember.

Gray

Under seat

Gray

3-place Delphi GT 150 Sealed

Sidecar BAS

[134]

Under right side cover

Gray

4-place Molex MX 150 Sealed
(BK)

HO2 sensor rear exhaust
header

[137]

Under right side cover

Gray

4-place Molex MX 150 Sealed
(GY)

HO2 sensor front exhaust
header

[138]

Front right crankcase (FLHX, FLHTK,
FLHTC/U, FLTR/U/X)

Gray

4-place Delphi 150 Metripack
Sealed (BK)

Oil pressure sender

[139]

Under console on top of fuel tank
canopy

Gray

4-place Delphi GT 280 Sealed
(BK)

Fuel pump and fuel level
sender

[141]

Under left side cover

Gray

3-place Delphi GT 150 Sealed
(BK)

Security siren (optional)

[142]

Under front fender tip lamp bracket

Gray

2-place Tyco 070 Multilock
Unsealed (BK)

Front fender tip lamp (if
equipped)

[143]

Under Tour-Pak

24-place Tyco Ampseal Sealed
(BK)

Audio amplifier

[149]

Inside headlamp nacelle (FLHR/C)

Gray

3-place Molex MX 150 Sealed
(BK)

Left handlebar switches (cruise
control)

[158]

Inside headlamp nacelle (FLHR/C)

Gray

3-place Molex MX 150 Sealed
(GY)

Right handlebar switches
(cruise control)

[159]

HOME

B-4 2011 Touring Service: Appendix B Wiring

See

Figure 1-20

. Push wheel forward and verify that cam

(5) contacts boss (4) on both sides of rear fork.

For purposes of adjustment only, snug the cone nut (6) to
15-20 ft-lbs (20-27 Nm).

Use BELT TENSION GAUGE (Part No. HD-35381A) to
check belt deflection as adjustment is made. See

1.12 DRIVE BELT AND SPROCKETS, Checking Drive
Belt Deflection

sm04528

1. Torque wrench
2. Axle nut torque adapter (HD-47925)

Figure 1-19. Install Tool Perpendicular to Torque Wrench

NOTE

It may be beneficial to use a second AXLE NUT TORQUE
ADAPTER (Part No. HD-47925) and breaker bar or ratchet to
rotate and hold the weld nut. The position of the breaker bar
or ratchet in relation to the tool is not important and can be
mated in any position that will make use easy.

10. See

Figure 1-20

. Adjust belt tension by rotating weld nut

(3) on left side of axle; clockwise to tighten the belt or
counterclockwise to loosen the belt. If loosening the belt
tension, push the wheel forward and verify both cams (5)
touch the bosses (4) on both sides after the weld nut is
rotated.

11. When correct tension is obtained, verify the cams touch

the bosses on both sides of the rear fork.

HOME

1-32 2011 Touring Service: Maintenance

sm05697

Adjuster cam

Increase belt deflection

Reduce belt deflection

Cone nut

E-clip

Weld nut

4. Boss

Figure 1-20. Rear Wheel Adjuster Cams

Assembly

NOTE

It is important that the weld nut does not rotate once belt ten-
sion is correct. If the axle moves during tightening of the cone
nut, the belt deflection procedure must be restarted.

Hold weld nut and tighten cone nut to 95-105 ft-lbs (128.8-
142.4 Nm).

Again, verify the cams touch the bosses on both sides of
the rear fork. Check belt deflection to verify that it is still
within specification.

With the flat side out, install

new

E-clip in groove on right

side of axle.

If removed, install fasteners that attach mufflers to the
saddlebag frames and tighten to 96-144

in-lbs

(10.9-16.3

Nm).

Install saddlebags.

HOME

2011 Touring Service: Maintenance 1-33

1.13

COMPENSATOR SPROCKET ISOLATOR

INSPECTION

Support the vehicle in an upright position in neutral, and
in a fashion that will not allow the rear wheel to rotate. Do
not lift the wheels off the ground.

Remove left saddlebag.

See

Figure 1-21

. Hang a weighted string (1) on the left

axle spacer as close as possible to, but not touching, the
rear sprocket.

NOTE

A piece of masking tape on the face of the sprocket will protect
the finish.

Place a piece of masking tape on the face of the sprocket
where the marks will be drawn.

NOTE

Do not allow the rear wheel to rotate when rotating the sprocket.
A false measurement will occur.

Rotate the rear sprocket by hand in one direction until it
stops. Hold in place.

While holding the sprocket, carefully mark the masking
tape along the edge of the sprocket in line with the string.

Rotate the rear sprocket in the opposite direction until it
stops and again hold it in place.

Make a second mark in line with the string.

Measure the distance (2) between the marks along the
edge of the sprocket. If the measurement exceeds 0.400
in (10.2 mm) the rubber isolator must be replaced.

NOTE

Components can be visually inspected when disassembled.
Excessive play in the compensator components are caused
by deteriorated, crumbling, or flaking of the rubber segments.
Wear on the raised "nubs" or small amounts of rubber debris
are normal and do not indicate a worn out isolator. See

2.6 REAR WHEEL COMPENSATOR

if the rear wheel com-

pensator needs to be serviced.

sm06800

1. Weighted string
2. Measured distance

Figure 1-21. Check Compensator Wear

HOME

1-34 2011 Touring Service: Maintenance

1.14

CABLE AND CHASSIS LUBRICATION

GENERAL

Inspect and lubricate the following at scheduled service inter-
vals as specified in

1.5 MAINTENANCE SCHEDULE

•

Front brake hand lever.

•

Clutch hand lever.

•

Clutch cable.

•

Foot shift lever pivot (if applicable).

•

Rear brake lever pivot.

•

Steering head bearings.

•

Jiffy stand.

If motorcycle is operated on muddy or dusty roads, clean and
lubricate more frequently.

Use Harley® Lube (Part no. HD-94968-09) for hand levers and
cables.

STEERING HEAD BEARINGS

Lubricate the steering head bearings with HARLEY-DAVIDSON
SPECIAL PURPOSE GREASE. See

1.20 STEERING HEAD

BEARINGS

for procedure.

JIFFY STAND

Clean and lubricate the jiffy stand. For more information, see

2.50 JIFFY STAND

MISCELLANEOUS LUBRICATION

Hinges, Latches, Etc.

Lubricate the rub points of latches and hinges using Harley®
Lube (Part No. 94968-09) as required.

Lubricate the fingers on the saddlebag latches where they
engage the hinge.

HOME

2011 Touring Service: Maintenance 1-35

1.15

BRAKES

FLUID INSPECTION

Position vehicle for inspection.

Front brake:

Position vehicle on a flat level surface.

Turn handlebar so front brake master cylinder is
approximately level.

Rear brake:

Have an assistant hold vehicle upright

on a level surface.

See

Figure 1-22

. View reservoir sight glass and verify fluid

presence.

If fluid is not visible through sight glass, check brake
system for fluid leaks. Check that brake pads are properly
installed and not worn beyond service wear limits. Perform
any necessary repairs. See

1.16 BRAKE PADS AND

DISCS

If fluid is still not visible through sight glass, remove cover
and verify fluid level. If necessary, add HARLEY-DAV-
IDSON D.O.T. 4 BRAKE FLUID (Part No. 99953-99A) to
reservoir. Replace cover. See

2.16 BLEEDING BRAKES

Front brake hand lever and rear brake foot pedal must
have a firm feel when applied. If not, bleed system using

only HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID (Part
No. 99953-99A). See

2.16 BLEEDING BRAKES

om01495

1. Sight glass, front master cylinder reservoir
2. Sight glass, rear master cylinder reservoir

Figure 1-22. Brake Fluid Sight Glass (typical)

HOME

1-36 2011 Touring Service: Maintenance

1.16

BRAKE PADS AND DISCS

INSPECTION

Check brake pads and discs:

•

At every scheduled service interval.

•

Whenever the components are removed during service
procedures.

Brake Pads

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

Replace both rear brake pads if the friction material of either
pad is worn to 0.016 in. (0.4 mm) or less above the backing
plate.

Replace all front brake pads (inner and outer pads of both the
left and right side calipers) if the friction material of any single
pad is worn to 0.016 in. (0.4 mm) or less above the backing
plate.

NOTE

Refer to the wear indicator lines for a general indication of pad
wear. See

Figure 1-24

Always install a

new

pad pin (provided in brake pad service

kit) whenever the brake pads are replaced.

Inspect the brake lines and hoses for damage or wear.

Brake Disc Thickness

The minimum front brake disc thickness is 0.18 in. (4.5 mm)
and is stamped on the side of the disc.

The minimum rear brake disc thickness is 0.25 in. (6.3 mm)
and is stamped on the side of the disc.

Replace any disc that is excessively worn or badly scored.

Brake Disc Lateral Runout

Measure brake disc runout using a dial caliper mounted to a
stationary surface. Maximum brake disc lateral runout or

warpage is 0.008 in. (0.2 mm) when measured near the outside
diameter of the disc.

BRAKE PAD REPLACEMENT

Rear Brake Caliper

Remove right side saddlebag. See

2.26 SADDLEBAGS,

Removal

If ABS equipped, release rear wheel speed sensor cable
from retainer clip on brake hose.

Remove two screws to release brake caliper from caliper
bracket.

Remove brake caliper from brake disc.

NOTE

Do not operate the brake pedal with the rear brake caliper
removed or the caliper pistons may be forced out. The caliper
contains no serviceable components and will require replace-
ment.

Stand motorcycle upright, so that rear master cylinder
reservoir is level. Wrap a clean shop cloth around the
outside of the reservoir to protect paint from brake fluid
spills.

Remove cover from master cylinder reservoir.

NOTE

Fluid level will rise as pistons are pushed into the caliper,
possibly overflowing the master cylinder reservoir. Remove
fluid from the reservoir if necessary.

Push each pad back until pistons are fully seated in the
bores.

See

Figure 1-26

. Pull retaining clip (3) from groove in pad

pin.

See

Figure 1-23

. Remove pad pin (metric).

10. Pull on pad pin side of brake pads to release from caliper.

11. See

Figure 1-26

. Remove pad spring (1) if damaged or

worn.

12. If removed, seat

new

pad spring on flat in caliper, so that

clips on spring engage indentations in caliper. Be sure
that forked end of pad spring is on the pad pin side of the
caliper.

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

HOME

2011 Touring Service: Maintenance 1-37

sm04684

1. Rear caliper
2. Front left caliper (screen removed)

Figure 1-23. Brake Caliper Pad Pin

13. Install

new

brake pads as follows:

See

Figure 1-24

and

Figure 1-25

. Insert brake pad

into caliper engaging square corner of pad in slot of
caliper.

Push pad pin tab of brake pad into caliper until seated.

Verify that brake pad friction material faces brake disc
gap in caliper.

Repeat step to install remaining brake pad.

14. Verify that pad pin tabs are centered under forks of pad

spring. Adjust pads if necessary.

15. Install

new

pad pin and tighten to 75-102

in-lbs

(8.5-11.5

Nm).

16. See

Figure 1-26

. Install retaining clip in groove of pad pin,

so that lip overhangs caliper housing.

17. Install brake caliper onto brake disc and install two screws.

Tighten screws to 43-48 ft-lbs (58.3-65.1 Nm).

18. If ABS equipped, secure sensor cable with clip on brake

hose.

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

19. Operate brake pedal several times to set brake pads to

proper operating position.

20. See

Figure 1-27

. Check brake fluid level in master cylinder

reservoir. If necessary, add D.O.T. 4 BRAKE FLUID until
level is flush with ledge cast at front of reservoir.

21. Install master cylinder reservoir cover and tighten to 12-15

in-lbs

(1.4-1.7 Nm).

22. Install right side saddlebag. See

2.26 SADDLEBAGS,

Installation

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

23. Test brake system.

Turn ignition switch ON. Depress brake pedal to verify
operation of brake lamp.

Test ride motorcycle. Bleed the system if brakes feel
spongy. See

2.16 BLEEDING BRAKES

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

sm04673

1. Square corner
2. Pad pin tab
3. Pad pin hole
4. Friction material
5. Wear indicator lines

Figure 1-24. Brake Pad

HOME

1-38 2011 Touring Service: Maintenance

sm04686

Figure 1-25. Brake Caliper (Bottom View)

sm04685

1. Pad spring (forked end)
2. Pad pin tab
3. Pad pin retaining clip

Figure 1-26. Brake Caliper (Top View)

Front Brake Calipers

If present, carefully cut cable straps to release front wheel
speed sensor cable and front fender tip lamp wires from
brake hose to left brake caliper.

On ABS equipped motorcycles, release front wheel speed
sensor cable from clip as follows:

Push on lip at rear of clip to disengage from bracket.

Rotate tab (stamped ABS) rearward until clip is per-
pendicular to bracket and remove cable.

Remove two brake caliper mounting screws. Slide brake
caliper straight down off from brake disc. Allow the brake
caliper to hang by the brake hose.

NOTE

Do not operate the brake lever with the front brake caliper
removed or the caliper pistons may be forced out. The caliper
contains no serviceable components and will require replace-
ment.

Turn front wheel to left until front master cylinder reservoir
is level. Wrap a clean shop cloth around the outside of the
reservoir to protect paint from brake fluid spills.

Remove cover from master cylinder reservoir.

NOTE

Fluid level will rise as pistons are pushed back into the caliper,
possibly overflowing the master cylinder reservoir. Remove
fluid from the reservoir if necessary.

Push each pad back until pistons are fully seated in the
bores.

Remove screen from caliper.

See

Figure 1-26

. Pull retaining clip from groove in pad pin.

See

Figure 1-23

. Remove pad pin (metric).

10. Pull on pad pin end of brake pads to release from caliper.

11. Remove pad spring if damaged or worn.

12. If removed, seat

new

pad spring on flat in caliper, so that

clips on spring engage indentations in caliper. Be sure
that forked end of pad spring is on the pad pin side of the
caliper.

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

13. Install

new

brake pads as follows:

See

Figure 1-24

and

Figure 1-25

. Insert brake pad

into caliper engaging square corner of pad in slot of
caliper.

Push pad pin tab of brake pad into caliper until seated.

Verify that brake pad friction material faces brake disc
gap in caliper.

Repeat step to install remaining brake pad.