Harley Davidson 2011 Touring Models. Service Manual

Using a Battery Charger

Charge the battery if any of the following conditions exist:

•

Vehicle lights appear dim.

•

Electric starter sounds weak.

•

Battery has not been used for an extended period of time.

Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

If battery releases an excessive amount of gas during
charging, decrease the charging rate. Overheating can
result in plate distortion, internal shorting, drying out or
damage. (00413b)

Perform a voltmeter test to determine the state of charge.
See the electrical diagnostic manual. If battery needs to
be charged, proceed to the next step.

NOTE

The figures listed in the table below show typical charging
times. Charge times may vary. When using an appropriate
automatic charger, allow the charger to determine when char-
ging is complete.

Table 1-21. 28 Amp-Hour Battery Charging Rate/Times (Approximate)

0.75 AMP

CHARGER

1.5 AMP

CHARGER

2 AMP

CHARGER

5 AMP

CHARGER

PERCENT

OF CHARGE

READING

(VOLTS)

100

12.7

10 hours 18 minutes

5 hours 42 minutes

4 hours 30 minutes

2 hours 24 minutes

12.6

19 hours 42 minutes

10 hours 18 minutes

8 hours

3 hours 48 minutes

12.3

29 hours

15 hours

11 hours 30 minutes

5 hours 12 minutes

12.0

38 hours 18 minutes

19 hours 42 minutes

15 hours

6 hours 36 minutes

11.8

NOTE

Do not use battery chargers that produce excessively high
voltage designed for flooded batteries or excessively high
current designed for much larger batteries. Charging should
be limited to no more than 5 amps at no more than 14.6 volts.

Unplug or turn OFF battery charger before connecting
charger cables to battery. Connecting cables with charger
ON can cause a spark and battery explosion, which could
result in death or serious injury. (00066a)

Do not reverse the charger connections described in the
following steps or the charging system of the motorcycle
could be damaged. (00214a)

Connect red battery charger lead to the positive (+) ter-
minal and black battery charger lead to the negative (-)
terminal of the battery.

NOTE

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.

Step away from the battery and turn on the charger. Refer
to

Table 1-21

Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion, which
could result in death or serious injury. (00067a)

After the battery is fully charged, turn the charger OFF
and disconnect the black battery charger lead to the neg-
ative (-) terminal of the battery.

Disconnect the red battery charger lead to the positive (+)
terminal of the battery.

Mark the charging date on the battery.

Perform either a conductance test or load test to determine
the condition of the battery. See the electrical diagnostic
manual.

If charging a battery because voltmeter test reading was
below 12.6 V, perform voltmeter test. See the electrical
diagnostic manual.

HOME

1-56 2011 Touring Service: Maintenance

STORAGE

TOOL NAME

PART NUMBER

GLOBAL BATTERY CHARGER

99863-01A

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)

If the motorcycle is to be stored with the security system armed,
connect a GLOBAL BATTERY CHARGER (Part No. 99863-
01A) to maintain battery charge.

If the motorcycle is to be stored with the battery installed,
without a GLOBAL BATTERY CHARGER, and with the security
system

not

armed, remove the main fuse.

If the motorcycle will not be operated for several months, such
as during the winter season, remove the battery from the
motorcycle and fully charge.

See

Figure 1-43

. A battery that is removed from the vehicle is

affected by self-discharge. A battery that is stored in the vehicle
is affected by self-discharge and, more significantly, by parasitic
loads. A parasitic load is generated by such things as diode
leakage or maintaining computer memory with the vehicle
turned off. Batteries self-discharge at a faster rate at higher
ambient temperatures. To reduce the self-discharge rate, store
battery in a cool, dry place.

Charge the battery once per month if stored in the vehicle.
Charge the battery every three months if stored out of the
vehicle.

NOTES

•

The GLOBAL BATTERY CHARGER (Part No. 99863-01A)
may be used to maintain battery charge for extended
periods of time without risk of overcharging or boiling.

•

When returning a battery to service after storage, see the
electrical diagnostic manual.

50 %

75 %

100 %

105 °F (40.5 °C)

77 °F (25 °C)

sm02838

1. Capacity
2. Months of non-use

Figure 1-43. Battery Self-Discharge Rate

HOME

2011 Touring Service: Maintenance 1-57

1.24

ENGINE MOUNTS

INSPECTION

General

Inspect the condition and tightness of the stabilizer links and
engine mounts. Replace fasteners if damaged. To properly
check fastener torque, see information in

1.22 CRITICAL

FASTENERS

Stabilizer Link

See

Figure 1-44

. Check top stabilizer link eyelet to frame

weldment bolt (1): 18-22 ft-lbs (24.4-29.9 Nm).

Check top stabilizer link eyelet to top engine mounting
bracket bolt (2): 18-22 ft-lbs (24.4-29.9 Nm).

Check for lateral movement at each end of the stabilizer
link. Any lateral movement indicates the need to replace
the stabilizer link. Rotational movement does not indicate
excess wear.

Front Engine Mount

See

Figure 1-44

. Check two engine to front engine

mounting bracket bolts (3): 36-40 ft-lbs (49-54 Nm).

Check three front engine mount end cap bolts (4): 42-48
ft-lbs (56.9-65.0 Nm).

Rear Frame Fasteners

See

Figure 1-45

. Check three fasteners on each side that

attach the rear frame to the main frame. The correct torque is
40-50 ft-lbs (54.2-67.8 Nm).

sm05710

1. Link-to-frame weldment fastener
2. Link-to-engine mounting bracket fastener
3. Engine mount fastener (2)
4. Engine mount end cap fastener

Figure 1-44. Front Mount and Stabilizer

sm05739

Figure 1-45. Rear Frame Fasteners

HOME

1-58 2011 Touring Service: Maintenance

1.25

STORAGE

GENERAL

If the motorcycle will not be operated for several months, such
as during the winter season, there are several things which
should be done to protect parts against corrosion, to preserve
the battery and to prevent the buildup of gum and varnish in
the fuel system.

This work should be performed following service manual pro-
cedures.

PLACING IN STORAGE

TOOL NAME

PART NUMBER

STORAGE COVER

98716-87A

Do not store motorcycle with gasoline in tank within the
home or garage where open flames, pilot lights, sparks or
electric motors are present. Gasoline is extremely flam-
mable and highly explosive, which could result in death
or serious injury. (00003a)

Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)

Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)

Prepare the fuel system by filling fuel tank and adding a
gasoline stabilizer. Use one of the commercially available
gasoline stabilizers following the manufacturer's instruc-
tions.

Run motorcycle until engine is at normal operating temper-
ature. Stop the engine and change the engine oil and filter.
Check the transmission lubricant level.

Remove the spark plugs, inject a few squirts of engine oil
into each cylinder and crank the engine 5-6 revolutions.
Install spark plugs.

Inspect drive belt deflection. See

1.12 DRIVE BELT AND

SPROCKETS

Inspect drive belt and sprockets.

Inspect air cleaner filter. See

1.7 AIR CLEANER AND

EXHAUST SYSTEM

Lubricate controls. See

1.14 CABLE AND CHASSIS

LUBRICATION

Inspect operation of all electrical equipment and switches.

Check tire inflation and inspect tires for wear and/or
damage. See

1.8 TIRES AND WHEELS

. If the motorcycle

will be stored for an extended period of time, securely
support the motorcycle under the frame so that all weight
is off the tires.

10. Wash painted and chrome-plated surfaces. Apply a light

film of oil to exposed unpainted surfaces.

11. Remove the battery from the vehicle. Charge the battery

until the correct voltage is obtained. Charge the battery
every other month if it is stored at temperatures below 60
°F (16 °C). Charge battery once a month if it is stored at
temperatures above 60 °F (16 °C). See

1.23 BATTERY

MAINTENANCE

12. If the motorcycle is to be covered, use a material that will

breathe, such as STORAGE COVER (Part No. 98716-
87A) or light canvas. Plastic materials that do not breathe
promote the formation of condensation, which leads to
corrosion.

REMOVAL FROM STORAGE

The clutch failing to disengage can cause loss of control,
which could result in death or serious injury. Prior to
starting after extended periods of storage, place transmis-
sion in gear and push vehicle back and forth several times
to assure proper clutch disengagement. (00075a)

Charge and install the battery.

Remove and inspect the spark plugs. Replace if neces-
sary.

Clean the air cleaner element.

If fuel tank was drained, fill fuel tank with fresh gasoline.

Start the engine and run until it reaches normal operating
temperature.

HOME

2011 Touring Service: Maintenance 1-59

1.26

TROUBLESHOOTING

GENERAL

The Troubleshooting section of this manual is a guide to
diagnose problems. Read the appropriate sections of this
manual before performing any work. Improper repair and/or
maintenance could result in death or serious injury.
(00528b)

The following check list of possible operating troubles and their
probable causes will be helpful in keeping a motorcycle in good
operating condition. More than one of these conditions may
be causing the trouble and all should be carefully checked.

NOTE

For further troubleshooting information, see the electrical dia-
gnostic manual.

ENGINE

Starter Motor Does Not Operate or Does Not
Turn Engine Over

Ignition switch not in IGNITION position.

Engine run switch in OFF position.

Discharged battery, loose or corroded connections
(solenoid chatters).

Starter control circuit, relay, or solenoid faulty.

Electric starter shaft pinion gear not engaging or overrun-
ning clutch slipping.

TSM/TSSM/HFSM Bank Angle Sensor tripped and igni-
tion/light key switch not cycled OFF then back to IGNI-
TION.

Security system activated.

Motorcycle in gear and clutch not pulled in.

Jiffy stand down and transmission in gear (HDI models
only).

10. Main fuse not in place.

Engine Turns Over But Does Not Start

Fuel tank empty.

Fouled spark plugs.

Discharged battery, loose or damaged battery terminal
connections.

Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

Spark plug cables in bad condition and shorting, cable
connections loose or cables connected to incorrect cylin-
ders.

Damaged wire or loose wire connection at ignition coil,
battery, or ECM connector.

Ignition timing incorrect due to faulty ignition coil, ECM or
sensors.

Bank Angle Sensor tripped and ignition switch not cycled
OFF then back to IGNITION.

Fuel filter clogged.

10. Sticking or damaged valve(s) or wrong length push rod(s).

11. Plugged fuel injectors.

Starts Hard

Spark plugs in bad condition or have improper gap or are
partially fouled.

Spark plug cables in poor condition.

Battery nearly discharged.

Damaged wire or loose wire connection at one of the bat-
tery terminals, ignition coil or ECM connector.

Water or dirt in fuel system.

Intake air leak.

Fuel tank vent hose, filler cap vent or vapor valve plugged,
or fuel line closed off, restricting fuel flow.

Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

Ignition not functioning properly (possible sensor failure).

10. Faulty ignition coil.

11. Valves sticking.

12. Partially plugged fuel injector(s).

Starts But Runs Irregularly or Misses

Spark plugs in poor condition or partially fouled.

Spark plug cables in poor condition and shorting or leaking.

Spark plug gap too close or too wide.

Faulty ignition coil, ECM, or sensor.

Battery nearly discharged.

Damaged wire or loose connection at battery terminals,
ignition coil or ECM connector.

Intermittent short circuit due to damaged wire insulation.

Water or dirt in fuel system.

Fuel tank vent system plugged.

10. Air leak at intake manifold or air cleaner.

11. Loose or dirty ECM connector.

12. Faulty Sensor(s): Temperature Manifold Absolute Pressure

(TMAP), Crank Position (CKP) or Oxygen (O2).

13. Incorrect valve timing.

14. Weak or damaged valve springs.

HOME

2011 Touring Service: Maintenance 1-61

15. Damaged intake or exhaust valve.

16. Partially plugged fuel injector(s).

A Spark Plug Fouls Repeatedly

Fuel mixture too rich.

Incorrect spark plug for the kind of service.

Piston rings badly worn or damaged.

Valve guides or seals badly worn.

Pre-Ignition or Detonation (Knocks or Pings)

Fuel octane rating too low.

Faulty spark plugs.

Incorrect spark plug for the kind of service.

Excessive carbon deposit on piston head or in combustion
chamber.

Ignition timing advanced due to faulty sensor inputs (TMAP
and/or CKP).

Ignition timing advanced due to ECM or sensors (CKP,
ET or TMAP) defective.

Intake manifold vacuum leak.

Overheating

Insufficient oil supply or oil not circulating.

Insufficient air flow over engine.

Heavy carbon deposits.

Ignition timing retarded due to defective ECM or faulty
sensor(s) (TMAP and/or CKP).

Leaking valve(s).

Valve Train Noise

Low oil pressure caused by oil feed pump not functioning
properly or oil passages obstructed.

Faulty hydraulic lifter(s).

Bent push rod(s).

Incorrect push rod length.

Rocker arm binding on shaft.

Valve sticking in guide.

Chain tensioning spring or shoe worn.

Cam(s), cam gear(s) or cam bushing(s) worn.

Cam timing incorrect.

Excessive Vibration

Wheels bent or damaged and/or tires worn or damaged.

Engine/Transmission/Rear Wheel not aligned properly.

Primary chain badly worn or links tight as a result of
insufficient lubrication or misalignment.

Engine to transmission mounting bolts loose.

Upper engine mounting bracket loose/damaged or
mounting bracket pre-loaded.

Ignition timing advanced due to faulty sensor inputs (TMAP
and/or CKP)/poorly tuned engine.

Internal engine problem.

Damaged frame.

Stabilizer links worn or loose, or stabilizer link brackets
loose or damaged.

10. Rubber mount (front) snubbers not centered and con-

tacting side of mount.

11. Rubber mounts (front or rear) loose or worn.

12. Rear fork pivot shaft fasteners loose.

13. Front engine mount bracket bolts loose.

14. Exhaust system binding and causing unnecessary side

loads.

Check Engine Light Illuminates During
Operation

Fault detected. See the electrical diagnostic manual for more
information.

LUBRICATION SYSTEM

Oil Does Not Return To Oil Reservoir

Oil reservoir empty.

Oil pump not functioning.

Restricted oil lines or fittings.

Restricted oil filter.

O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).

Engine Uses Too Much Oil Or Smokes
Excessively

Oil reservoir overfilled.

Restricted oil return line to oil reservoir.

Restricted breather operation.

Restricted oil filter.

Oil pump misaligned or in poor condition.

Piston rings badly worn or broken.

Valve guides or seals worn or damaged.

O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).

Plugged crankcase scavenge port.

10. Oil diluted with gasoline.

Engine Leaks Oil From Cases, Push Rods,
Hoses, Etc.

Loose parts.

Imperfect seal at gaskets, push rod covers, washers, etc.

HOME

1-62 2011 Touring Service: Maintenance

Restricted breather passages or hose to air cleaner.

Restricted oil filter.

Oil reservoir overfilled.

Lower rocker housing gasket installed incorrectly (upside
down).

Restricted oil return line to oil reservoir.

Porosity.

Low Oil Pressure

Oil reservoir underfilled.

Faulty low oil pressure switch.

Oil pump O-ring damaged or missing.

Bypass valve stuck in open position.

Ball missing or leaking in cam support plate.

Worn oil pump gerotor(s).

Oil diluted with gasoline.

High Oil Pressure

Oil reservoir overfilled.

Bypass valve stuck in closed position.

ELECTRICAL SYSTEM

NOTE

For diagnostic information see the electrical diagnostic manual.

Alternator Does Not Charge

Voltage regulator module not grounded.

Engine ground wire loose or damaged.

Faulty voltage regulator module.

Loose or damaged wires in charging circuit.

Faulty stator and/or rotor.

Alternator Charge Rate Is Below Normal

Weak or damaged battery.

Loose connections.

Faulty voltage regulator module.

Faulty stator and/or rotor.

Speedometer Operates Erratically

Contaminated vehicle speed sensor (remove sensor and
clean off metal particles).

Loose connections.

TRANSMISSION

Shifts Hard

Primary chaincase overfilled with lubricant.

Clutch not fully disengaging.

Transmission lubricant too heavy (winter operation).

Shifter return spring (inside transmission) bent or broken.

Bent shifter rod.

Shifter forks (inside transmission) sprung.

Corners worn off shifter clutch dog rings (inside transmis-
sion).

Jumps Out Of Gear

Shifter rod improperly adjusted.

Shifter drum (inside transmission) improperly adjusted or
damaged/worn.

Shifter engaging parts (inside transmission) badly worn
and rounded.

Shifter forks bent.

Damaged gears.

Clutch Slips

Clutch controls improperly adjusted.

Insufficient clutch spring tension.

Worn friction discs.

Clutch Drags Or Does Not Release

Lubricant level too high in primary chaincase.

Clutch controls improperly adjusted.

Primary chain badly misaligned or too tight.

Insufficient clutch spring tension.

Clutch discs warped.

Clutch Chatters

Friction discs or steel discs worn or warped.

HANDLING

Irregularities

Improperly loaded motorcycle. Non-standard equipment
on the front end such as heavy radio receivers, extra
lighting equipment or luggage tends to cause unstable
handling.

Damaged tire(s) or improper front-rear tire combination.

Irregular or peaked front tire tread wear.

Incorrect tire pressure.

Shock absorber not functioning normally.

Incorrect air suspension pressure.

Loose wheel axle nuts. Tighten to recommended torque
specification.

Excessive wheel hub bearing play.

Rear wheel out of alignment with frame and front wheel.

10. Steering head bearings improperly adjusted. Correct

adjustment and replace pitted or worn bearings and races.

11. Loose spokes (laced wheel vehicles only).

12. Tire and wheel unbalanced.

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2011 Touring Service: Maintenance 1-63

13. Rims and tires out-of-round or eccentric with hub.

14. Rims and tires out-of-true sideways.

15. Rear fork pivot assembly: improperly tightened or

assembled, or loose/pitted or damaged pivot bearings.

16. Engine mounts and/or stabilizer links loose, worn or

damaged.

BRAKES

Brake Does Not Hold Normally

Brake fluid reservoir low, system leaking or pads worn.

Brake system contains air bubbles.

Master cylinder/caliper piston seals worn or parts dam-
aged.

Brake pads contaminated with grease or oil.

Brake pads badly worn.

Brake disc badly worn or warped.

Brake drags - insufficient brake pedal or hand lever free-
play, caliper piston worn or damaged, or excessive brake
fluid in reservoir.

Brake fades due to heat build up - brake pads dragging
or excessive braking.

Brake fluid leak when under pressure.

HOME

1-64 2011 Touring Service: Maintenance

Carefully inspect the pistons for damage or excessive
wear.

Discard pistons with cracked, worn or bent ring lands.

Check the piston skirt for cracks, gouges, deep
scratches or heavy scoring.

Check the piston heads for evidence of burning,
etching or melting.

Look for marks or imprints caused by contact with
valves.

Run your index finger around the edge of the piston crown
to feel for dings, nicks or burrs. Lightly file the edge of the
crown to remove any defects.

NOTE

Worn ring grooves result in high oil consumption and blow-by
of exhaust gases. Blow-by of exhaust gases contaminates the
engine oil supply with acids and leaves sludge in the crankcase.
It also reduces engine efficiency by weakening the combustion
seal necessary for efficient transfer of energy to the piston.

See

Figure 3-64

. Measure piston ring side clearance.

Insert the edge of a

new

ring into the piston ring

groove. Insert a feeler gauge between the upper sur-
face of the ring and the ring land.

Since the grooves wear unevenly, repeat this check
at several locations around the piston groove circum-
ference.

Discard the piston if the side clearance of either
compression ring exceeds 0.0045 in. (0.11 mm).

Discard the piston if the oil control ring side clearance
exceeds 0.010 in. (0.25 mm).

NOTES

•

Check the piston clearance in the cylinder in which the
piston will run. The torque plates must be installed on the
cylinder and it must be deglazed and suitable for continued
service.

•

This inspection is very heat sensitive. Do not check piston
running clearance immediately after honing or deglazing
cylinder. Even holding the piston in your hand for too long
can cause measurements to vary by as much as 0.0002
in. (0.0051 mm). Both piston and cylinder must be at room
temperatures before proceeding.

•

Piston measurement is taken on the bare aluminum to
avoid measuring errors. An oval-shaped opening is present
on each side of the piston for proper placement of the
micrometer. See upper frame of

Figure 3-65

. The oval

openings are too small for a standard flat anvil micrometer
which would result in measuring errors. Use a 3-4 inch
blade or ball anvil style micrometer, or a 4-5 inch micro-
meter with spherical ball anvil adapters. See lower frame
of

Figure 3-65

See

Figure 3-65

. Measure running clearance of pistons

as follows:

Holding outside micrometer, measure piston skirt
diameter across the thrust faces (perpendicular to
piston pin bore). Start below the bottom ring land and
move micrometer towards bottom of skirt. Micrometer
will be loose, then tight, about 0.5 in. (12.7 mm), from
bottom and then loose again.

Measure the piston skirt at the tightest spot and then
transfer that measurement to dial bore gauge.

Using a grease pencil, mark the top, middle and
bottom of the piston ring travel zone in the cylinder
bore. Measure at markings in cylinder parallel and
perpendicular to crankshaft.

Replace piston and/or cylinder if running clearance
exceeds 0.003 in. (0.076 mm).

sm02534

Figure 3-63. Piston Pin Clearance

sm02535

Figure 3-64. Measure Piston Ring Side Clearance

HOME

2011 Touring Service: Engine 3-61

2.1

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

NOTES

TORQUE VALUE

FASTENER

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

1.1-2.3 Nm

10-20

in-lbs

2 inch diameter gauge nuts

2.37 AIR DEFLECTORS, Mid-Frame Air Deflectors

2.8-4.0 Nm

25-35

in-lbs

Air deflector bolts

2.37 AIR DEFLECTORS, Air Deflectors

2.8-3.4 Nm

25-30

in-lbs

Air deflector screws

2.19 REAR AIR SUSPENSION, Check for Air
Leaks

4.5-5.6 Nm

40-50

in-lbs

Air valve mount hex nut

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

20-27 Nm

15-20 ft-lbs

Auxiliary lamp bracket to fork bracket
screws (FLHT/C/U)

2.12 FRONT BRAKE MASTER CYLINDER, Front
Brake Line: Non-ABS Equipped

23.1-25.8 Nm

17-19 ft-lbs

Banjo bleeder bolt to front caliper

2.13 FRONT BRAKE CALIPER, Installation

23.1-25.8 Nm

17-19 ft-lbs

Banjo bleeder bolt to front caliper

2.12 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation

16.9-19.7 Nm

12.5-14.5 ft-lbs

Banjo bolt to front master cylinder

2.12 FRONT BRAKE MASTER CYLINDER, Front
Brake Line: Non-ABS Equipped

16.9-19.7 Nm

12.5-14.5 ft-lbs

Banjo bolt to front master cylinder

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

23.1-25.8 Nm

17-19 ft-lbs

Banjo bolt to rear caliper

2.15 REAR BRAKE CALIPER, Installation

23.1-25.8 Nm

17-19 ft-lbs

Banjo bolt to rear caliper

2.14 REAR BRAKE MASTER CYL-
INDER, Assembly and Installation

16.9-19.7 Nm

12.5-14.5 ft-lbs

Banjo bolt to rear master cylinder

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

16.9-19.7 Nm

12.5-14.5 ft-lbs

Banjo bolt to rear master cylinder

2.48 REAR FRAME, Rear Frame

8.1-10.8 Nm

72-96

in-lbs

Battery tray screws

2.13 FRONT BRAKE CALIPER, Installation/metric

37.9-51.5 Nm

28-38 ft-lbs

Brake caliper (front) mounting screws

2.5 REAR WHEEL, Installation/metric

58.3-65.1 Nm

43-48 ft-lbs

Brake caliper (rear) mounting screws

2.15 REAR BRAKE CALIPER, Installation/metric

58.3-65.1 Nm

43-48 ft-lbs

Brake caliper (rear) mounting screws

2.16 BLEEDING BRAKES, Procedure

9.0-11.3 Nm

80-100

in-lbs

Brake caliper bleeder valve

2.4 FRONT WHEEL, Installation/Always use new
screws

21.7-32.5 Nm

16-24 ft-lbs

Brake disc (front) screws

2.5 REAR WHEEL, Installation/Always use new
screws

41-61 Nm

30-45 ft-lbs

Brake disc (rear) screws

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

9.0-11.3 Nm

80-100

in-lbs

Brake light switch bracket fastener

2.12 FRONT BRAKE MASTER CYLINDER, Front
Brake Line: Non-ABS Equipped

13.6-20.3 Nm

120-180

in-lbs

Brake line bracket-to-lower fork bracket
screw

2.18 STEERING HEAD BEARINGS, Installation

13.6-20.3 Nm

120-180

in-lbs

Brake line bracket-to-lower fork bracket
screw

2.14 REAR BRAKE MASTER CYL-
INDER, Assembly and Installation

20.3-27.1 Nm

15-20 ft-lbs

Brake pedal shaft locknut

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

20.3-27.1 Nm

15-20 ft-lbs

Brake pedal shaft locknut

2.33 LOWER FAIRING AND ENGINE
GUARD, Engine Guard

20.3-27.1 Nm

15-20 ft-lbs

Engine guard screws

HOME

2011 Touring Service: Chassis 2-1

NOTES

TORQUE VALUE

FASTENER

2.51 FRONT ENGINE MOUNT, Installation

48.8-54.2 Nm

36-40 ft-lbs

Engine mount bracket fasteners

2.51 FRONT ENGINE MOUNT, Installation

56.9-65.0 Nm

42-48 ft-lbs

Engine mount end cap fasteners

2.41 INNER FAIRING: FRAME MOUNTED
FAIRING MODELS, Installation

27.1-40.7 Nm

20-30 ft-lbs

Fairing bracket-to-steering head locknuts
(frame mounted fairing)

2.35 FAIRING CAP: FORK MOUNTED FAIRING
MODELS, Fairing Cap

2.8-3.4 Nm

25-30

in-lbs

Fairing cap screws

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

2.5-3.2 Nm

22-28

in-lbs

Fairing speaker lower screw (FLHX,
FLHTC/U)

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

4.0-5.7 Nm

35-50

in-lbs

Fairing speaker upper screws (FLHX,
FLHTC/U)

2.17 FRONT FORK, Installation

71.9-77.3 Nm

53-57 ft-lbs

Fork bracket pinch bolt

2.17 FRONT FORK, Installation

81.4-94.9 Nm

60-70 ft-lbs

Fork cap bolt

2.17 FRONT FORK, Assembly

14.9-24.4 Nm

132-216

in-lbs

Fork damper tube screw (metric)

2.17 FRONT FORK, Changing Fork Oil

8-11 Nm

72-96

in-lbs

Fork oil drain plug

2.17 FRONT FORK, Changing Fork Oil

81.4-94.9 Nm

60-70 ft-lbs

Fork tube plug

2.28 TOUR-PAK, Luggage Rack/Tour-Pak Support

20.3-27.1 Nm

15-20 ft lbs

Frame cover fastener, rear

2.46 REAR FENDER, Installation

20.3-27.1 Nm

15-20 ft-lbs

Frame cover fastener, rear

2.4 FRONT WHEEL, Installation/metric

14.9-20.3 Nm

132-180

in-lbs

Front axle holder nuts

2.4 FRONT WHEEL, Installation/metric

81.4-88.1 Nm

60-65 ft-lbs

Front axle nut

2.51 FRONT ENGINE MOUNT, Installation

54.2-67.8 Nm

40-50 ft-lbs

Front engine mount fasteners

2.45 FRONT FENDER, Installation

22-27 Nm

16-20 ft-lbs

Front fender mount screws

2.16 BLEEDING BRAKES, Procedure

1.1-1.4 Nm

10-12

in-lbs

Front master cylinder reservoir cover
screws

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS, Outer Fairing

6.8-9.5 Nm

60-84

in-lbs

Front turn signal lamp acorn nuts, frame
mounted fairing

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

43.4-48.8 Nm

32-36 ft-lbs

Guard to frame screws

2.22 CLUTCH CABLE, Installation

8.1-12.0 Nm

72-108

in-lbs

Handlebar clamp to clutch lever bracket
screws

2.23 HANDLEBARS, Adjustment

8.1-12.0 Nm

72-108

in-lbs

Handlebar clamp to clutch lever bracket
screws

2.12 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation

8.1-12.2 Nm

72-108

in-lbs

Handlebar clamp to master cylinder
screws

2.23 HANDLEBARS, Rubber Mounts

40.7-54.2 Nm

30-40 ft-lbs

Handlebar lower clamp bolts (risers)

2.23 HANDLEBARS, Adjustment

21.7-27.1 Nm

16-20 ft-lbs

Handlebar upper clamp screws

2.23 HANDLEBARS, Installation

21.7-27.1 Nm

16-20 ft-lbs

Handlebar upper clamp screws

2.23 HANDLEBARS, Installation

21.7-27.1 Nm

16-20 ft-lbs

Handlebar upper clamp screws

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

1.0-2.0 Nm

9-18

in-lbs

Headlamp housing screws

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

1.0-2.0 Nm

9-18

in-lbs

Headlamp housing screws

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

1.7-2.3 Nm

15-20

in-lbs

Headlamp nacelle handlebar chrome
strip flange nut

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

1.1-2.3 Nm

10-20

in-lbs

Headlamp nacelle handlebar clamp
shroud screws

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

1.1-2.3 Nm

10-20

in-lbs

Headlamp nacelle handlebar clamp
shroud screws

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

8.1-12.2 Nm

72-108

in-lbs

Headlamp nacelle to fork bracket stud
acorn nuts

HOME

2-2 2011 Touring Service: Chassis

NOTES

TORQUE VALUE

FASTENER

2.39 INSTRUMENT BEZEL: FRAME MOUNTED
FAIRING MODELS, Bezel

2.8-4.0 Nm

25-35

in-lbs

Instrument bezel screws (frame mounted
fairing models)

2.40 INSTRUMENT NACELLE: FRAME MOUNTED
FAIRING MODELS, Instrument Nacelle

20.3-27.1 Nm

15-20 ft-lbs

Instrument nacelle to fork bracket screws
(frame mounted fairing models)

2.50 JIFFY STAND, Jiffy Stand Bracket

48.8-57.0 Nm

36-42 ft-lbs

Jiffy stand bracket fasteners

2.50 JIFFY STAND, Jiffy Stand Interlock
Sensor/Use Loctite Medium Strength Threadlocker
243 (blue) if reusing screw

10.8-13.6 Nm

96-120

in-lbs

Jiffy stand interlock sensor fastener

2.50 JIFFY STAND, Leg Installation

20.3-27.1 Nm

15-20 ft-lbs

Jiffy stand leg stop hex screw

2.48 REAR FRAME, Rear Frame

8.1-10.8 Nm

72-96

in-lbs

Left electrical caddy fastener

2.33 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing

4.0-4.5 Nm

35-40

in-lbs

Lower fairing clip stud flange nuts

2.33 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing

2.3-2.8 Nm

20-25

in-lbs

Lower fairing glove box tray screws

2.33 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing

2.3-2.8 Nm

20-25

in-lbs

Lower fairing glove box tray screws

2.33 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing

10.2-11.3 Nm

90-100

in-lbs

Lower fairing to engine guard clamp
screws

2.28 TOUR-PAK, Luggage Rack/Tour-Pak Support

20.3-27.1 Nm

15-20 ft lbs

Luggage rack screws

2.46 REAR FENDER, Installation

20.3-27.1 Nm

15-20 ft-lbs

Luggage rack screws

2.24 MIRRORS, FLHX/metric

3.4-4.5 Nm

30-40

in-lbs

Mirror flange nut (FLHX)

2.24 MIRRORS, All Models Except FLHX/metric

6.8-10.8 Nm

60-96

in-lbs

Mirror stem acorn nut

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS, Outer Fairing

1.1-1.7 Nm

10-15

in-lbs

Outer fairing long screws, frame
mounted fairing

2.34 UPPER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS, Outer Fairing and
Windshield

2.3-3.4 Nm

20-30

in-lbs

Outer fairing screws (fork mounted
fairing)

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS, Outer Fairing

0.7-1.4 Nm

6-12

in-lbs

Outer fairing short screws, frame
mounted fairing

2.49 FOOTBOARDS AND FOOTRESTS, Pas-
senger Footrest: FLHX, FLTRX

48.8-56.9 Nm

36-42 ft-lbs

Passenger footboard/footrest fastener

2.49 FOOTBOARDS AND FOOTRESTS, Pas-
senger Footboard

5.4-8.1 Nm

48-72

in lbs

Passenger footboard/footrest lower
fastener

2.49 FOOTBOARDS AND FOOTRESTS, Pas-
senger Footboard

48.8-56.9 Nm

36-42 ft-lbs

Passenger footboard/footrest upper
fastener

2.49 FOOTBOARDS AND FOOTRESTS, Pas-
senger Footrest: FLHX, FLTRX/Use Loctite Medium
Strength Threadlocker 243 (blue)

20-27 Nm

15-20 ft-lbs

Passenger footrest pad screw (FLHX,
FLTRX)

2.41 INNER FAIRING: FRAME MOUNTED
FAIRING MODELS, Installation

10.9-16.3 Nm

96-144

in-lbs

Radio bracket-to-fairing bracket locknuts
(frame mounted fairing)

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

3.4-5.6 Nm

30-50

in-lbs

Rail clamp screws

2.5 REAR WHEEL, Installation/metric

20-27 Nm

15-20 ft-lbs

Rear axle cone nut (preliminary)

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped/Use Loctite Pipe
Sealant with Teflon 565

16.3-20.3 Nm

12-15 ft-lbs

Rear brake light switch

2.47 REAR FASCIA, Installation

3.4-5.1 Nm

30-45

in-lbs

Rear fascia flange nuts

2.47 REAR FASCIA, Installation

2.0-2.5 Nm

18-22

in-lbs

Rear fascia lamp screws

2.47 REAR FASCIA, Rear Fascia Lamp

2.0-2.5 Nm

18-22

in-lbs

Rear fascia lamp screws

2.46 REAR FENDER, Fender Repair

20.3-27.1 Nm

15-20 ft-lbs

Rear fender mounting boss

2.46 REAR FENDER, Installation

20.3-27.1 Nm

15-20 ft-lbs

Rear fender mounting screws

HOME

2011 Touring Service: Chassis 2-3

NOTES

TORQUE VALUE

FASTENER

2.47 REAR FASCIA, Installation

5.1-9.6 Nm

45-85

in-lbs

Rear fender support-to-fender nut

2.47 REAR FASCIA, Stud Plate

5.1-9.6 Nm

45-85

in-lbs

Rear fender support-to-fender nut

2.46 REAR FENDER, Installation

20.3-27.1 Nm

15-20 ft-lbs

Rear fender support -to-saddlebag sup-
port fastener

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

20.3-27.1 Nm

15-20 ft-lbs

Rear fender support-to-saddlebag sup-
port fastener

2.47 REAR FASCIA, Stud Plate

20.3-27.1 Nm

15-20 ft-lbs

Rear fender support-to-saddlebag sup-
port fastener

2.21 REAR FORK, Installation/Apply two drops of
Loctite Medium Strength Threadlocker 243 (blue)
to threads

74.6-88.1 Nm

55-65 ft-lbs

Rear fork bracket screws

2.21 REAR FORK, Installation/Apply two drops of
Loctite Medium Strength Threadlocker 243 (blue)
to threads

74.6-88.2 Nm

55-65 ft-lbs

Rear fork pivot shaft fasteners

2.48 REAR FRAME, Rear Frame

54.2-61.0 Nm

40-45 ft-lbs

Rear frame-to-main frame fastener

2.16 BLEEDING BRAKES, Procedure

1.4-1.7 Nm

12-15

in-lbs

Rear master cylinder reservoir cover
screws

2.14 REAR BRAKE MASTER CYL-
INDER, Assembly and Installation

14.2-17.0 Nm

126-150

in-lbs

Rear master cylinder-to-frame screws

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

14.2-17.0 Nm

126-150

in-lbs

Rear master cylinder-to-frame screws

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

10.8-16.3 Nm

96-144

in-lbs

Rear muffler fastener

2.49 FOOTBOARDS AND FOOTRESTS, Rider
Footboards

48.8-57.0 Nm

36-42 ft-lbs

Rider footboard bracket screws

2.49 FOOTBOARDS AND FOOTRESTS, Rider
Footboards

6.8-9.0 Nm

60-80

in-lbs

Rider footboard pivot bolt nut

2.27 SADDLEBAG SERVICE, Saddlebag Hardware

2.3-2.8 Nm

20-25

in-lbs

Saddlebag latch/check strap screws

2.27 SADDLEBAG SERVICE, Saddlebag Hardware

2.3-2.8 Nm

20-25

in-lbs

Saddlebag latch/check strap screws

2.27 SADDLEBAG SERVICE, Saddlebag Hardware

2.0-2.3 Nm

18-20

in-lbs

Saddlebag lid check strap screws

2.25 SEAT, Seat: Road King Models

6.8-10.8 Nm

60-96

in-lbs

Saddlebag mounting bracket screw

2.26 SADDLEBAGS, Installation

16.3-20.3 Nm

12-15 ft-lbs

Saddlebag mounting bracket screw

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

16.3-20.3 Nm

12-15 ft-lbs

Saddlebag mounting bracket screw

2.28 TOUR-PAK, Luggage Rack/Tour-Pak Support

16.3-20.3 Nm

12-15 ft lbs

Saddlebag mounting bracket screw

2.46 REAR FENDER, Installation

16.3-20.3 Nm

12-15 ft-lbs

Saddlebag mounting bracket screw

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

8.1-13.6 Nm

72-120

in-lbs

Saddlebag side guard to front guard
screw

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

7.9-11.3 Nm

70-100

in-lbs

Saddlebag support rail to front guard
screw

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

20.3-27.1 Nm

15-20 ft-lbs

Saddlebag support to fender support
fastener

2.46 REAR FENDER, Installation

20.3-27.1 Nm

15-20 ft-lbs

Saddlebag support to fender support
fastener

2.25 SEAT, Seat Bumper

9.0-13.6 Nm

80-120

in-lbs

Seat bumper fastener

2.25 SEAT, Seat: Models without Tour-Pak

5.4-8.1 Nm

48-72

in-lbs

Seat mounting screw

2.25 SEAT, Seat: Models with Tour-Pak

5.4-8.1 Nm

48-72

in-lbs

Seat mounting screw

2.25 SEAT, Seat: Road King Models

5.4-8.1 Nm

48-72

in-lbs

Seat mounting screw

2.25 SEAT, Seat: Models without Tour-Pak

5.4-8.1 Nm

48-72

in-lbs

Seat strap screw

2.25 SEAT, Seat: Models with Tour-Pak

5.4-8.1 Nm

48-72

in-lbs

Seat strap screw

HOME

2-4 2011 Touring Service: Chassis

NOTES

TORQUE VALUE

FASTENER

2.19 REAR AIR SUSPENSION, Check for Air
Leaks

16.3-23.0 Nm

12-17 ft-lbs

Shock absorber compression fitting

2.20 REAR SHOCK ABSORBERS, Disassembly
and Assembly

16.3-23.0 Nm

12-17 ft-lbs

Shock absorber compression fitting

2.20 REAR SHOCK ABSORBERS, Installation/Use
LOCTITE MEDIUM STRENGTH THREADLOCKER
243 (blue)

47.5-54.2 Nm

35-40 ft-lbs

Shock lower mounting bolt

2.21 REAR FORK, Installation/Apply two or three
drops of Loctite Medium Strength Threadlocker
243 (blue) to threads

47.5-54.2 Nm

35-40 ft-lbs

Shock lower mounting bolt

2.20 REAR SHOCK ABSORBERS, Installation/Use
LOCTITE MEDIUM STRENGTH THREADLOCKER
243 (blue)

47.5-54.2 Nm

35-40 ft-lbs

Shock upper mounting bolt

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

20.3-27.1 Nm

15-20 ft-lbs

Side rail to saddlebag support screws

2.32 TOUR-PAK SPEAKER BOX, Speaker Box

2.8-4.0 Nm

25-35

in-lbs

Speaker box fasteners

2.28 TOUR-PAK, Removal/Installation

2.8-4.0 Nm

25-35

in-lbs

Speaker box mounting screws

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

1.1-2.3 Nm

10-20

in-lbs

Speedometer/tachometer bracket screws

2.9 CHECKING AND TRUING WHEELS, Truing
Laced Wheels

6.2 Nm

in-lbs

Spoke nipple

2.48 REAR FRAME, Rear Frame

8.1-10.8 Nm

72-96

in-lbs

Top caddy mounting screw

2.29 TOUR-PAK SERVICE, Latches/Lockset
Catch/Use Loctite Medium Strength Threadlocker
243 (blue)

2.3-2.8 Nm

20-25

in-lbs

Tour-Pak latch screw

2.29 TOUR-PAK SERVICE, Lockset

2.8-4.0 Nm

25-35

in-lbs

Tour-Pak lockset hex nut

2.29 TOUR-PAK SERVICE, Lockset

3.4-5.1 Nm

30-45

in-lbs

Tour-Pak lockset jam nut

2.29 TOUR-PAK SERVICE, Luggage Rack

6.8-9.5 Nm

60-84

in-lbs

Tour-Pak luggage rack fastener

2.30 TOUR-PAK LIGHTS, Tour-Pak Lights Harness

7.3-7.9 Nm

65-70

in-lbs

Tour-Pak metal plate flange nuts

2.30 TOUR-PAK LIGHTS, Tour-Pak Lights Harness

10.8-13.6 Nm

96-120

in-lbs

Tour-Pak mounting bolts

2.28 TOUR-PAK, Removal/Installation

10.8-13.6 Nm

96-120

in-lbs

Tour-Pak mounting screws

2.28 TOUR-PAK, Adjustment

10.8-13.6 Nm

96-120

in-lbs

Tour-Pak mounting screws

2.29 TOUR-PAK SERVICE, Tether Brackets

4.5-6.8 Nm

40-60

in-lbs

Tour-Pak passenger backrest flange nuts

2.31 TOUR-PAK BACKREST, Passenger Backrest

4.5-6.8 Nm

40-60

in-lbs

Tour-Pak passenger backrest flange nuts

2.31 TOUR-PAK BACKREST, Passenger Backrest
Flap

2.4-2.7 Nm

21-24

in-lbs

Tour-Pak passenger backrest flap
screws

2.30 TOUR-PAK LIGHTS, Side Marker Lights (if
equipped)

2.3-2.8 Nm

20-25

in-lbs

Tour-Pak side marker lights screws

2.29 TOUR-PAK SERVICE, Hinges/Use Loctite
High Strength Threadlocker 262 (red)

2.3-2.8 Nm

20-25

in-lbs

Tour-Pak tether screw

2.29 TOUR-PAK SERVICE, Tether/Use Loctite
High Strength Threadlocker 262 (red)

2.3-2.8 Nm

20-25

in-lbs

Tour-Pak tether screw

2.22 CLUTCH CABLE, Installation

19.0-28.5 Nm

14-21 ft-lbs

Transmission drain plug

2.11 TIRES, Installation

1.4-1.7 Nm

12-15

in-lbs

Valve stem nut

2.34 UPPER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS, Outer Fairing and
Windshield

2.8-3.4 Nm

25-30

in-lbs

Windshield screws (fork mounted fairing)

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS, Windshield

0.7-1.5 Nm

6-13

in-lbs

Windshield wellnut screws (frame
mounted fairing)

2.43 WINDSHIELD: ROAD KING
MODELS, Windshield Window

2.3-2.8 Nm

20-25

in-lbs

Windshield window screws (Road King
Models)

HOME

2011 Touring Service: Chassis 2-5

Harley Davidson 2011 Touring Models. Service Manual - page 10