Harley Davidson 2011 Touring Models. Service Manual

18. Install brake caliper as follows:

Install caliper with bleeder at top (and cable
clip/bracket if ABS equipped and secure with two
mounting screws).

NOTE

Be sure that tab (stamped ABS) on clip is installed in slot
of bracket from inboard side. Clip cannot be installed once
mounting screws are started.

Tighten mounting screws to 28-38 ft-lbs (37.9-51.5
Nm).

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. Install

new

cable straps to secure brake hose and wheel

speed sensor if equipped.

20. If ABS equipped, install front wheel speed sensor cable

in clip. See

C.3 WHEEL SPEED SENSORS

21. Operate brake lever several times to set brake pads to

proper operating position.

22. 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 step (marked MAX) cast at rear of
reservoir.

23. Verify gasket and sealing surfaces are free of debris and

install master cylinder reservoir cover. Orient the cover

with the vent holes facing the rear. Install cover screws
and tighten to 10-12

in-lbs

(1.1-1.4 Nm).

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)

24. Test brake system.

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

Test ride motorcycle. Bleed 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.

sm04727

1. Front master cylinder reservoir
2. Rear master cylinder reservoir

Figure 1-27. Brake Fluid Level

HOME

1-40 2011 Touring Service: Maintenance

1.17

SPARK PLUGS

INSPECTION

Disconnecting spark plug cable with engine running can
result in electric shock and death or serious injury.
(00464b)

NOTE

Allow the engine to cool to room temperature before servicing
spark plugs.

Disconnect spark plug cables and remove spark plugs.

See

Figure 1-28

. Inspect the spark plug and compare your

observations with the descriptions provided below.

If a spark plug has eroded electrodes, heavy deposits
or a cracked insulator, discard it.

A wet, black and shiny deposit on base, electrodes
and ceramic insulator tip indicates an oil fouled spark
plug. The condition may be caused by one or more
of the following: worn pistons, worn piston rings, worn
valves, worn valve guides, worn valve seals, a weak
battery or a faulty ignition system.

A dry, fluffy or sooty black deposit indicates an air-
fuel mixture that is too rich.

A light brown, glassy deposit indicates an overheated
spark plug. This condition may be accompanied by
cracks in the insulator or by erosion of the electrodes
and is caused by an air-fuel mixture that is too lean,
an overheated engine, valves not seating or improper
ignition timing. The glassy deposit on the spark plug
is a conductor when hot and may cause high-speed
misfiring. A spark plug with eroded electrodes, heavy
deposits or a cracked insulator must be replaced.

A spark plug with a white, yellow, tan or rusty brown
powdery deposit indicates balanced combustion.
Clean off spark plug deposits at regular intervals.

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

If the spark plugs require cleaning between tune-ups,
proceed as follows:

Degrease firing end of spark plug using electrical
contact cleaner. Dry with compressed air.

Use a thin file to flatten the electrodes. A spark plug
with sharp edges on its electrodes requires 25-40%
less firing voltage than one with rounded edges.

If the spark plugs cannot be cleaned, replace with

new

spark plugs.

Check electrode gap with a wire-type feeler gauge. Bend
the outside of the electrode so only a slight drag on the
gauge is felt when passing it between electrodes. Proper
gap measurement is 0.038-0.043 in. (0.97-1.09 mm).

Check condition of threads on cylinder head and spark
plug. If necessary to remove deposits, apply penetrating
oil and clean out with a thread chaser.

Apply a light coat of SILVER GRADE ANTI-SEIZE (Part
No. 98960-97) to the spark plug threads. Install and tighten
to 12-18 ft-lbs (16.3-24.4 Nm).

Connect spark plug cables. The rear cylinder spark plug
cable attaches to the right coil terminal. Verify that the
cables are securely connected to the coil and spark plugs,
and secured to any anchor clips.

sm01640

Figure 1-28. Typical Spark Plug Deposits

SPARK PLUG CABLE INSPECTION

Inspect spark plug cables. Replace cables that are worn
or damaged.

Check for cracks or loose terminals.

Check for loose fit on ignition coil and spark plugs.

Check cable boots/caps for cracks or tears. Replace
boots/caps that are worn or damaged.

See

Figure 1-29

. Check spark plug cable resistance with

an ohmmeter. Replace cables not meeting resistance
specifications. Refer to

Table 1-13

HOME

2011 Touring Service: Maintenance 1-41

1.19

SUSPENSION ADJUSTMENTS

GENERAL

TOOL NAME

PART NUMBER

AIR SUSPENSION PUMP AND GAUGE

HD-34633A

See

Figure 1-30

. Adjust the rear air suspension pressure by

adding or removing air from the air valve located near the left
upper shock absorber mount. Always adjust pressures with
the motorcycle on the jiffy stand.

Do not exceed the motorcycle's Gross Vehicle Weight
Rating (GVWR) or Gross Axle Weight Rating (GAWR).
Exceeding these weight ratings can affect stability and
handling, which could result in death or serious injury.
(00016e)

Air pressure may be varied to suit load conditions, riding style
and personal comfort. Less initial pressure does not necessarily
result in a softer ride. Use

Table 1-14

Table 1-15

as a

starting point in determining suitable rear air suspension pres-
sures. Do not exceed maximum GVWR when loading vehicle
and do not pressurize system in excess of 50 psi (345 kPa).

Do not exceed maximum air pressure for rear suspension.
Air components fill rapidly. Therefore, use low air line
pressure. Failure to do so may result in possible damage
to components. (00165a)

NOTES

•

Use AIR SUSPENSION PUMP AND GAUGE (Part
No. HD-34633A) to adjust suspension air pressure.

•

Use a no-loss air gauge to check air pressure. Check
pressure in shock absorbers weekly if used daily or before
each trip if used occasionally.

•

Improper inflation of rear air suspension components can
result in a reduction of available suspension travel,
reduced rider comfort and possible damage to shock
absorbers.

Use caution when bleeding air from the suspension.
Moisture combined with lubricant may leak onto the rear
wheel, tire and/or brake components and adversely affect
traction, which could result in death or serious injury.
(00084a)

sm05722

Figure 1-30. Rear Air Suspension Air Valve

HOME

1-44 2011 Touring Service: Maintenance

Table 1-14. Recommended Suspension Air Pressure: FLHX, FLTRX, FLHR/C

PRESSURE

TOTAL WEIGHT

SHOCK LOAD

kPa

PSI

LB.

up to 68

up to 150

Solo rider

0-69

0-10

68-91

150-200

69-138

10-20

91-113

200-250

138-206

20-30

113-136

250-300

206-345

30-50

over 136

over 300

69-138

10-20

up to 68

up to 150

Solo rider with capacity luggage of 40 lbs (18 kg)

138-206

20-30

68-91

150-200

206-276

30-40

91-113

200-250

276-345

40-50

113-136

250-300

345

over 136

over 300

276-345

40-50

ALL

Rider plus passenger

345

ALL

Maximum GVWR

If Tour-Pak is installed, add 5-10 psi (34-69 kPa) to shock pressure. Do

not

exceed 50 psi (345 kPa) suspension pressure.

Table 1-15. Recommended Suspension Air Pressure: FLHTC, FLHTCU, FLHTK, FLTRU

PRESSURE

TOTAL WEIGHT

SHOCK LOAD

kPa

PSI

LB.

34-69

5-10

up to 68

up to 150

Solo rider

69-138

10-20

68-91

150-200

138-206

20-30

91-113

200-250

206-276

30-40

113-136

250-300

276-345

40-50

over 136

over 300

172-206

25-30

up to 68

up to 150

Solo rider with capacity luggage of 70 lbs (32 kg)

206-276

30-40

68-91

150-200

276-345

40-50

91-113

200-250

345

over 113

over 250

345

ALL

Rider plus passenger

345

ALL

Maximum GVWR

not

exceed 50 psi (345 kPa) suspension pressure.

HOME

2011 Touring Service: Maintenance 1-45

1.20

STEERING HEAD BEARINGS

LUBRICATION

See

Figure 1-31

.Turn handlebar to the right fork stop to

access grease fitting at the left side of the steering head.

Inject Special Purpose Grease, (Part No. 99857-97) until
it exits from the top and bottom of the steering head.

sm05702

Figure 1-31. Steering Head Bearing Grease Fitting

CHECKING

When lifting a motorcycle using a jack, be sure jack con-
tacts both lower frame tubes where down tubes and lower
frame tubes converge. Never lift by jacking on cross-
members, oil pan or other housings. Failure to comply can
cause serious damage resulting in the need to perform
major repair work. (00586c)

Raise the motorcycle so that the front and rear tires are
the same distance from the floor.

Verify that motorcycle is in stock configuration. Remove
all non-factory accessories, since they can influence front
end swing momentum (and lead to improper adjustment).

See

Figure 1-32

. Turn the front wheel to the left fork stop

and then let go. The wheel should swing from side to side,
finally stopping in the swing specified in

Table 1-16

. If it

stops in the lesser number swing, it should be at or after
the straight-forward position.

If the clutch cable or main harness appears to be influen-
cing swing momentum, proceed as follows and repeat the
previous step:

Clutch cable:

Disconnect clutch cable from hand

lever. Release cable from P-clamp, remove from inner
fairing, or release from cable clip on instrument
nacelle depending on model. See

2.22 CLUTCH

CABLE

Main harness:

Remove the rivet and P-clamp to

release main harness from steering head. Secure P-
clamp with a

new

rivet when procedure is complete.

NOTE

A steering head that is too tight can interfere with the vehicle's
ability to absorb a weave. A steering head that is too loose can
interfere with the vehicle's ability to absorb a wobble.

To correct a swing pattern, see

1.20 STEERING HEAD

BEARINGS, Adjustment

sm04908

Figure 1-32. Steering Head Bearing Swing Count

Table 1-16. Steering Head Bearing Swing Count

Art Reference

Maximum

Minimum

Model

(A)

FLTRX, FLTRU

(A-B)

FLHR, FLHRC

(B-C)

FLHX, FLHTC, FLHTCU, FLHTK

(D)

More than 4

TOO LOOSE

HOME

1-46 2011 Touring Service: Maintenance

ADJUSTMENT

Disassemble motorcycle as follows:

Road Glide models:

Remove headlamp nacelle. See

2.44 HEADLAMP NACELLE: ROAD KING MODELS

Fork mounted fairing models:

Remove outer fairing

and radio or storage box as equipped. See

2.34 UPPER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS

and

7.33 ADVANCED

AUDIO SYSTEM

, respectively.

Frame mounted fairing models:

Remove instrument

bezel. See

2.39 INSTRUMENT BEZEL: FRAME

MOUNTED FAIRING MODELS

See

Figure 1-33

. Loosen pinch bolts (3) on lower fork

bracket.

sm05704

1. Fork stem nut
2. Adjuster nut
3. Pinch bolt

Figure 1-33. Fork Stem and Brackets

Loosen the fork stem nut (1).

See

Figure 1-34

. Fashion a bearing adjuster tool using a

drill rod 1/4 in. (6.4 mm) in diameter and 16 in. (406.4 mm)
long.

NOTES

•

See

Figure 1-33

. Turning the bearing adjuster nut (2) as

little as one notch will make a noticeable difference in the
swing pattern.

•

Tap forks with a rubber hammer while turning adjuster nut
to prevent forks from binding in lower bracket bores.

Turn bearing adjuster nut (2) as follows:

To decrease the number of swings, rotate nut

clock-

wise

To increase the number of swings, rotate nut

coun-

terclockwise

NOTE

Original equipment fork stem nut has a blue dye coating. If a
replacement nut is being installed, the replacement nut will not
have the blue coating.

Tighten stem nut to 70-80 ft-lbs (94.9-108.4 Nm).

NOTE

Torque of the stem nut will affect the swing pattern.

Recheck the swing pattern and adjust as necessary.

Tighten pinch bolts to 53-57 ft-lbs (71.9-77.3 Nm).

Verify that the fork stem nut is tightened to 70-80 ft-lbs
(94.9-108.4 Nm).

10. Recheck the swing pattern and adjust if necessary.

11. Assemble motorcycle as follows:

Road Glide models:

Install headlamp nacelle. See

2.44 HEADLAMP NACELLE: ROAD KING MODELS

Fork mounted fairing models:

Install radio or

storage box (as equipped) and outer fairing. See

7.33 ADVANCED AUDIO SYSTEM

and

2.34 UPPER

FAIRING AND WINDSHIELD: FORK MOUNTED
FAIRING MODELS

, respectively.

Frame mounted fairing models:

Install instrument

bezel. See

2.39 INSTRUMENT BEZEL: FRAME

MOUNTED FAIRING MODELS

12. Install any accessories that were removed during the

checking procedure.

sm03579

1. All models except FLTRX
2. FLTRX
3. 1/8 in (3.2 mm)
4. 5/32 in (4.0 mm)
5. 5/32 in (4.0 mm) goes back for 1-1/4 in (31.8 mm)
6. 2 in (50.8 mm) to start of bend

Figure 1-34. Fashion Bearing Adjuster Tool

HOME

2011 Touring Service: Maintenance 1-47

1.21

HEADLAMP ALIGNMENT

The automatic-on headlamp feature provides increased
visibility of the rider to other motorists. Be sure headlamp
is on at all times. Poor visibility of rider to other motorists
can result in death or serious injury. (00030b)

NOTE

Vehicles with multiple beam headlamps that are individually
aimed should be adjusted so both lamps converge into one
pattern.

Verify that front and rear tire inflation pressures are correct
and that suspension is adjusted to the weight of the prin-
cipal rider. See

1.8 TIRES AND WHEELS

Fill fuel tank or add ballast to equal the weight of the fuel
needed.

NOTE

See

Figure 1-35

. To aid in properly placing the motorcycle, a

perpendicular line (1) can be drawn on the floor. For best res-
ults, choose an area with minimum light.

Draw a vertical line (2) on the wall.

Position motorcycle so that front axle is 25 ft (7.6 m) from
wall.

NOTE

As the weight of the rider will compress the suspension slightly,
have a person whose weight is approximately the same as that
of the principal rider sit on the motorcycle.

With the vehicle laden and upright, point the front wheel
straight forward at wall and measure the distance (4) from
the floor to the center of the HIGH BEAM bulb.

Draw a horizontal line (5) through the vertical line on the
wall that is 2.1 in (53.3 mm) lower than the measured bulb
centerline.

Verify headlamp alignment. With the motorcycle on, set
the headlamp switch to HIGH beam.

The center of the hot spot (brightest area of light
beam) should be centered where the two lines inter-
sect.

Adjust headlamp alignment if necessary.

sm05861

1. Perpendicular line
2. Vertical line
3. 25 feet (7.6 meters)
4. High beam bulb centerline
5. Horizontal line 2.1 in. (53.3 mm) lower than bulb

centerline

Figure 1-35. Check Headlamp Alignment

HEADLAMP ADJUSTMENT: SINGLE
HEADLAMP MODELS

NOTE

Headlamp adjustment can be performed without removing the
headlamp trim ring.

See

Figure 1-36

. Using adjuster slots in trim ring, insert

Phillips screwdriver between headlamp trim ring and
rubber gasket.

Horizontal:

Turn the horizontal adjusting screw to

adjust light beam left and right.

Vertical:

Turn the vertical adjusting screw to adjust

light beam up and down.

Adjust the light beam until it is centered as shown in

Figure 1-35

HOME

1-48 2011 Touring Service: Maintenance

om01372

1. Horizontal adjuster
2. Vertical adjuster

Figure 1-36. Headlamp Adjusters (typical)

HEADLAMP ADJUSTMENT: DUAL
HEADLAMP MODELS

See

Figure 1-37

. Rotate the hex adjusters (metric) located

near the bottom edge of the inner fairing. Refer to

Table 1-17

for adjuster rotation.

Horizontal:

Turn either the left or right adjuster to

adjust the light beam left and right.

Vertical:

Turn both adjusters equally to adjust the

light beam up and down.

Adjust the light beam until it is centered as shown in

Figure 1-35

Table 1-17. Adjuster Rotation, Dual Headlamp Models

Beam Movement

Rotation

Hex Adjuster

To the right

Left Only

CCW

Right Only

To the left

CCW

Left Only

Right Only

Upward

Left and Right
Equally

Downward

CCW

Left and Right
Equally

CW = Clockwise
CCW = Counter-clockwise

om00394

1. Left side adjuster
2. Right side adjuster

Figure 1-37. Headlamp Adjusters: Dual Headlamp Models

AUXILIARY LAMP ALIGNMENT

TOOL NAME

PART NUMBER

FLARE NUT SOCKET

SNAP-ON® FRX181

Place the vehicle facing a target wall as described in

1.21 HEADLAMP ALIGNMENT, Headlamp Alignment

NOTE

As the weight of the rider will compress the suspension slightly,
have a person whose weight is roughly the same as that of the
principal rider sit on the motorcycle.

With the vehicle upright and a rider seated on the motor-
cycle, measure the distance from the floor to the centerline
of each auxiliary lamp.

Measure the distance from the headlamp vertical centerline
to the vertical centerline of each auxiliary lamp.

HOME

2011 Touring Service: Maintenance 1-49

See

Figure 1-38

. Mark the auxiliary lamp horizontal and

vertical centerlines (2, 3) on the wall.

Remove two screws to release the turn signal lamp from
the mounting bracket.

Using FLARE NUT SOCKET (Part No. Snap-on®
FRX181), loosen the auxiliary lamp flange nut only enough
to allow movement of the lamp.

NOTE

Figure 1-38

depicts the light pattern for vehicles driven on the

right side of the road. In countries where travel is on the left
side of the road, shift the auxiliary lamp high intensity patterns
(4, 5) to the left of center.

Turn on the headlamp low beam and cover both the
headlamp and the right side auxiliary lamp. Adjust the left

side auxiliary lamp as necessary so that the entire high
intensity zone (4) is below and to the right of the left side
auxiliary lamp centerlines as shown in

Figure 1-38

Cover the headlamp and left side auxiliary lamp. Adjust
the right side auxiliary lamp as necessary so that the entire
high intensity zone (5) is both below and to the right of the
right side auxiliary lamp centerlines as shown in

Figure 1-38

Tighten auxiliary lamp flange nut to 15-18 ft-lbs (20.3-24.4
Nm).

10. Start two screws to secure turn signal lamp to mounting

bracket. Verify that conduit fits in slot at back of bracket
and is not pinched. Tighten screws to 36-60

in-lbs

(4.1-

6.8 Nm).

sm03622

1. Headlamp high beam area
2. Left side auxiliary lamp centerlines
3. Right side auxiliary lamp centerlines
4. Left side auxiliary high intensity beam area
5. Right side auxiliary high intensity beam area

Figure 1-38. Properly Aim Auxiliary Lamps

HOME

1-50 2011 Touring Service: Maintenance

1.22

CRITICAL FASTENERS

INSPECTION

Inspect critical fasteners at the scheduled service intervals.
Replace any fasteners that are damaged or missing.

Checking Torques on Fasteners

Refer to

Table 1-18

. Attempt to turn the fastener using a

torque wrench set to the minimum torque specification for
that fastener.

If the fastener does not rotate, the fastener torque
has been maintained. No further attention is neces-
sary at this time.

If the fastener rotates, remove it to determine if it has
a locking agent.

If it has a locking agent, clean all locking material from
the threaded hole. Replace the fastener with a

new

one or clean the original fastener threads and apply
the appropriate locking agent (see appropriate pro-
cedure).

Install and tighten the fastener to specification.

If the fastener does not have a locking agent, install and
tighten to specification.

Table 1-18. Critical Fasteners

TORQUE

FASTENER

SYSTEM

4.0-5.1 Nm

35-45

in-lbs

Switch housing screws

Hand controls

8.1-12.2 Nm

72-108

in-lbs

Clutch lever bracket handlebar
clamp screws

8.1-12.2 Nm

72-108

in-lbs

Master cylinder reservoir
handlebar clamp screws

23.0-25.8 Nm

17-19 ft-lbs

Brake caliper banjo bolts

Brakes

17.0-19.7 Nm

12.5-14.5 ft-lbs

Master cylinder banjo bolts

17.0-19.7 Nm

12.5-14.5 ft-lbs

ABS module banjo bolts

21.7-32.5 Nm

16-24 ft-lbs

Front brake disc screws

40.7-61.0 Nm

30-45 ft-lbs

Rear brake disc screws

1.1-1.4 Nm

10-12

in-lbs

Front master cylinder reservoir
cover screws

1.4-1.7 Nm

12-15

in-lbs

Rear master cylinder reservoir
cover screws

14.2-16.9 Nm

126-150

in-lbs

Rear master cylinder to frame
screws

38.0-51.5 Nm

28-38 ft-lbs

Front brake caliper mounting
screws

58.3-65.1 Nm

43-48 ft-lbs

Rear brake caliper to caliper
bracket screws

8.5-11.5 Nm

75-102

in-lbs

Brake caliper pad pin

81.3-88.1 Nm

60-65 ft-lbs

Front

Axle nuts

129.0-142.0 Nm

95-105 ft-lbs

Rear

14.9-20.3 Nm

132-180

in-lbs

Front axle holder nuts

Front forks

74.6-88.1 Nm

55-65 ft-lbs

Fasteners

Pivot shaft

74.6-88.1 Nm

55-65 ft-lbs

Rear fork bracket bolts

HOME

2011 Touring Service: Maintenance 1-51

1.23

BATTERY MAINTENANCE

GENERAL

Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHILDREN.
(00063a)

Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)

Batteries, battery posts, terminals and related accessories
contain lead and lead compounds, and other chemicals
known to the State of California to cause cancer, and birth
defects or other reproductive harm. Wash hands after
handling. (00019e)

All AGM batteries are permanently sealed, maintenance-free,
valve-regulated, lead/calcium and sulfuric acid batteries. The
batteries are shipped pre-charged and ready to be put into
service. Do not attempt to open these batteries for any reason.

NOTE

For charging information, see

1.23 BATTERY MAINTENANCE,

Charging Battery

. For testing information, see the electrical

diagnostic manual.

is00249

Figure 1-39. AGM Battery with Warning Label

sm02241

Keep flames away

Contents are corrosive

Wear safety glasses

Read instructions

Keep away from children

Contents are explosive

Figure 1-40. Battery Warning label

HOME

2011 Touring Service: Maintenance 1-53

Table 1-19. Antidotes for Battery Acid

TREATMENT

CONTACT

Flush with water.

External

Drink large quantities of milk or water, followed
by milk of magnesia, vegetable oil or beaten
eggs. Get immediate medical attention.

Internal

Flush with water. Get immediate medical
attention.

Eyes

CLEANING AND INSPECTION

Battery top must be clean and dry. Dirt and electrolyte on
top of the battery can cause battery to self-discharge.
Clean battery top with a solution of baking soda (sodium
bicarbonate) and water (5 teaspoons baking soda per
quart or liter of water). When the solution stops bubbling,
rinse off the battery with clean water.

Clean cable connectors and battery terminals using a wire
brush or sandpaper. Remove any oxidation.

Inspect the battery screws, clamps and cables for
breakage, loose connections and corrosion. Clean clamps.

Check the battery posts for melting or damage caused by
overtightening.

Inspect the battery for discoloration, raised top or a warped
or distorted case, which might indicate that the battery has
been frozen, overheated or overcharged.

Inspect the battery case for cracks or leaks.

BATTERY

Disconnection and Removal

Remove seat.

See

Figure 1-41

. If present, move purge solenoid (1) for-

ward to release from top caddy. Release HFSM antenna
(2) from top caddy and move out of the way.

Remove fasteners (4).

Cut cable ties (3) and move harnesses to allow more
clearance for the top caddy.

See

Figure 1-42

. Release top caddy from front hold-down

bracket and rotate top caddy (1) out of the way.

If equipped with security system siren, turn the ignition
switch ON with the hands-free fob present to disarm the
security system.

Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)

Remove battery negative cable (black) from the battery
negative (-) terminal.

Remove battery positive cable (red) from the battery pos-
itive (+) terminal.

Grasp lifting strap (2) and pull up to raise battery. When
battery is extracted far enough to get a good grip, grasp
battery and remove the rest of the way.

sm05698

1. Purge solenoid
2. HFSM antenna
3. Cable ties
4. Fastener
5. Hold-down (not visible)

Figure 1-41. Top Caddy

sm05699

1. Top caddy
2. Lifting strap

Figure 1-42. Move Top Caddy Aside

Installation and Connection

Run lifting strap rearward, first down the center of the
battery tray, then up and across the frame crossmember.

Place the battery into the battery tray, terminal side for-
ward.

HOME

1-54 2011 Touring Service: Maintenance

Connect the cables to the correct battery terminals. Failure
to do so could result in damage to the motorcycle electrical
system. (00215a)

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

Do not over-tighten bolts on battery terminals. Use
recommended torque values. Over-tightening battery ter-
minal bolts could result in damage to battery terminals.
(00216a)

Connect battery positive cable (red) to battery positive (+)
terminal. Tighten bolt to 60-70

in-lbs

(6.8-7.9 Nm).

Connect battery negative cable (black) to battery negative
(-) terminal. Tighten bolt to 60-70

in-lbs

(6.8-7.9 Nm).

Keep battery clean and lightly coat terminals with petro-
leum jelly to prevent corrosion. Failure to do so could
result in damage to battery terminals. (00217a)

Apply a light coat of petroleum jelly or ELECTRICAL
CONTACT LUBRICANT, (Part No. 99861-02) (1 oz tube),
to both battery terminals.

See

Figure 1-42

. Fold lifting strap (2) forward over top of

battery.

See

Figure 1-41

. Rotate top caddy into position above

battery and engage latch on hold-down bracket.

If equipped, engage HFSM antenna (2) and purge solenoid
(1) on top caddy. Verify all other connectors and harnesses
are routed below the purge solenoid mounting tongue.

Fasten top caddy to frame crossmember. Tighten screws
(4) to 72-96

in-lbs

(8.1-10.9 Nm).

10. Secure harnesses to frame with cable ties (3).

After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)

11. Install seat.

VOLTMETER TEST

Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)

Voltmeter Test

The voltmeter test provides a general indicator of battery con-
dition. Check the voltage of the battery to verify that it is fully
charged. If the open circuit (disconnected) voltage reading is
below 12.6V, charge the battery and check the voltage after
the battery has set for one to two hours. If the voltage reading
is 12.7V or above, perform a load test. See the electrical dia-
gnostic manual for the load test procedure. Refer to

Table 1-20

Table 1-20. Voltmeter Test For Battery Charge Conditions

STATE OF CHARGE

VOLTAGE (OCV)

100%

12.7 V

75%

12.6 V

50%

12.3 V

25%

12.0 V

11.8 V

CHARGING BATTERY

Safety Precautions

Never charge a battery without first reviewing the instructions
for the charger being used. In addition to the manufacturer's
instructions, follow these general safety precautions:

•

Always wear eye, face and hand protection.

•

Always charge batteries in a well-ventilated area.

•

Turn the charger off before connecting or disconnecting
the leads to the battery to avoid dangerous sparks.

•

Never try to charge a visibly damaged or frozen battery.

•

Connect the charger leads to the battery; red positive (+)
lead to the positive (+) terminal and black negative (-) lead
to the negative (-) terminal. If the battery is still in the
vehicle, connect the negative lead to the chassis ground.
Be sure that the ignition and all electrical accessories are
turned off.

•

Make sure that the charger leads to the battery are not
separated, frayed or loose.

•

If the battery temperature exceeds 110 °F (43 °C) during
charging, discontinue charger and allow the battery to
cool.

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2011 Touring Service: Maintenance 1-55

Harley Davidson 2011 Touring Models. Service Manual - page 9