Harley Davidson 2011 Touring Models. Service Manual

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

See

Figure 6-38

. Install

new

retaining rings (1).

Install

new

O-ring (4) into groove in main drive gear.

sm03044

Figure 6-41. Pressing in Seal

sm02302

Figure 6-42. Installing Transmission Side Needle Bearing

in Main Driver Gear

MAINSHAFT SEAL REPLACEMENT

TOOL NAME

PART NUMBER

MAIN DRIVE GEAR SEAL INSTALLER

HD-47933

See

Figure 6-43

. If the mainshaft seal was not installed with

the main drive gear needle bearings (or if a faulty seal is dis-
covered with the main drive gear installed in the transmission
case), the seal can be installed using the MAIN DRIVE GEAR
SEAL INSTALLER (Part No. HD-47933).

sm03045

1. Driver
2. Seal protector sleeve

Figure 6-43. Main Drive Gear Seal Installer (Part No.

HD-47933)

Remove the damaged seal using a seal remover or rolling
head pry bar.

Inspect bore to be sure it is clean and smooth.

See

Figure 6-44

. Place the seal protector sleeve (1) over

the end of the mainshaft. Lightly lubricate the protector
sleeve and seal ID with clean transmission oil.

Verify that the garter spring is in place on the lip of the

new

oil seal. Apply a light coat of H-D 20W-50 engine oil

to the seal lip.

Squarely seat the mainshaft seal (2) on the seal protector
sleeve with the garter spring facing the bearing.

See

Figure 6-45

. Using MAIN DRIVE GEAR SEAL

INSTALLER (Part No. HD-47933), hand press seal onto
mainshaft and into end of main drive gear. A rubber mallet
may be used to lightly tap driver, if necessary. Seal is
properly installed when seal driver contacts end of main
drive gear.

sm03048

1. Seal protector sleeve
2. Seal

Figure 6-44. Seal Protector Sleeve

HOME

6-24 2011 Touring Service: Transmission

sm03049

Figure 6-45. Seal Driver

INSTALLATION

TOOL NAME

PART NUMBER

INSTALLER CUP

HD-35316-12

CROSS PLATE

HD-35316-3A

8 IN. BOLT

HD-35316-4A

12 IN. BOLT

HD-35316-5

WASHER

HD-35316-7

BEARING DRIVER

HD-35316-8

INSTALLER

HD-47856-1

PILOT

HD-47856-2

ADAPTER

HD-47856-3

NUT

HD-47856-6

CROW'S FOOT WRENCH

HD-47856-7

Improper tightening of sprocket nut can cause drive
component damage. (00541b)

Installing Main Drive Gear Bearing

NOTE

CROSS PLATE (Part No. HD-35316-3A) will retrofit to earlier
transmissions. Note that one end of cross plate is stamped,
"UP 6 SPEED". Mount cross plate with this end pointing up for
6 speed transmissions.

See

Figure 6-46

. Place CROSS PLATE (Part No. HD-

35316-3A) (2) on right side of transmission case as shown,
and secure with two screws (3). Position cross plate so
that large bolt hole in cross plate is lined up with center of
main drive gear bearing bore in left side of transmission
case.

Apply a light coat of graphite lubricant to the threads of 12
IN. BOLT (Part No. HD-35316-5) (1) and install through
cross plate and main drive gear bearing bore.

At left side of case, place main drive gear bearing (4),
BEARING DRIVER (Part No. HD-35316-8) (5), BEARING
(6), FLAT WASHER (7) and NUT (8) over end of bolt.

Tighten nut until main drive gear bearing bottoms against
lip cast into transmission case bearing bore.

sm03051

1. 12 in. bolt
2. Cross plate
3. Screw (2)
4. Main drive gear bearing
5. Bearing driver
6. Bearing
7. Flat washer
8. Nut

Figure 6-46. Installing Main Drive Gear Bearing (Typical)

Installing Main Drive Gear

NOTE

See

Figure 6-47

. Make sure new O-ring (4) is installed onto

main drive gear (3). Lubricate O-ring with clean engine oil
before installing drive gear into transmission case.

See

Figure 6-47

. Apply a light coat of graphite lubricant

to the threads of 8 IN. BOLT (Part No. HD-35316-4A) (1)
and insert through WASHER (Part No. HD-35316-7) (2)
and main drive gear (3). Insert assembly into transmission
case, through main drive gear bearing.

At outside of case, place INSTALLER CUP (Part No. HD-
35316-12) (5), BEARING (6), FLAT WASHER (7) and NUT
(8) over end of bolt.

Tighten nut until main drive gear contacts main drive gear
bearing.

NOTE

See

Figure 6-48

. In next step, bearing retaining ring must be

installed with the flat side facing the bearing and the opening
in the ninety degree range shown.

HOME

2011 Touring Service: Transmission 6-25

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

See

Figure 6-49

. Install

new

retaining ring (2).

sm03052

1. 8 in. bolt
2. Washer
3. Main drive gear
4. O-ring
5. Installer cup
6. Bearing
7. Flat washer
8. Nut

Figure 6-47. Installing Main Drive Gear (Typical)

sm03053

Figure 6-48. Retaining Ring Opening

Installing Main Drive Gear Large Seal

See

Figure 6-49

. From outside of crankcase, install

PILOT (Part No. HD-47856-2) over end of main drive gear
bearing inner race.

Coat lips of

new

main drive gear seal with transmission

lubricant.

See

Figure 6-50

. Place seal over pilot with garter spring

facing bearing, and position seal squarely in end of
crankcase bore.

NOTE

ADAPTER (Part No. HD-47856-3) and main drive gear have
right-hand threads.

See

Figure 6-51

. Thread ADAPTER (Part No. HD-47856-

3) onto end of main drive gear until it contacts main drive
gear.

sm03057

1. Pilot
2. Retaining Ring

Figure 6-49. Install Pilot

sm03058

Figure 6-50. Place Main Drive Gear Seal Over Pilot

HOME

6-26 2011 Touring Service: Transmission

sm03059

Figure 6-51. Install Adapter

See

Figure 6-52

. Slide INSTALLER (Part No. HD-47856-

1) (1) over adapter until cupped end of installer is flat
against seal.

Thread NUT (Part No. HD-47856-6) (2) onto end of
adapter, until it tightens against installer.

See

Figure 6-53

. Place CROW'S FOOT WRENCH (Part

No. HD-47856-7) (1) with 1/2 inch drive breaker bar (2)
on large nut. Place an adjustable wrench (3) on flats of
hex head cast into end of adapter.

Holding adjustable wrench, tighten large nut with crow's
foot wrench until outer face of seal is flush with outer edge
of transmission bore.

NOTE

It is acceptable to recess seal as much as 0.030 in. (0.762 mm)
below outer edge of bore. Seal depth will be controlled by tool.

Remove nut, installer, adapter and pilot.

10. Install side door and transmission components. See

6.6 TRANSMISSION ASSEMBLY, Installation

11. Install sprocket and drive belt. See

5.7 TRANSMISSION

SPROCKET

. Do not adjust belt at this time.

12. Install the bearing inner race on the transmission main-

shaft. See

6.6 TRANSMISSION ASSEMBLY, Assembly

13. Install the primary chaincase housing. See

5.5 PRIMARY

CHAINCASE HOUSING, Installation

14. Install the clutch assembly, primary chain, chain tensioner

assembly and compensating sprocket components. See

5.4 DRIVE COMPONENTS, Installation

15. Install the primary chaincase cover. See

5.3 PRIMARY

CHAINCASE COVER, Installation

16. Adjust the drive belt. See

1.12 DRIVE BELT AND

SPROCKETS, Setting Belt Deflection

17. Install exhaust system. See

4.19 EXHAUST SYSTEM,

System Installation

sm03061

1. Installer
2. Nut

Figure 6-52. Installer and Nut

sm03062

1. Crow's foot wrench
2. 1/2 inch breaker bar
3. Adjustable wrench

Figure 6-53. Press Seal Into Crankcase

HOME

2011 Touring Service: Transmission 6-27

6.8

TRANSMISSION CASE

REMOVAL

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)

Disconnect battery, negative (-) cable first.

Drain engine oil. See

1.6 ENGINE OIL AND FILTER,

Changing Oil and Oil Filter

Drain transmission lubricant. See

1.10 TRANSMISSION

LUBRICANT, Transmission Lubrication

Remove starter. See

7.10 STARTER, Removal

Remove transmission assembly. See

6.6 TRANSMISSION

ASSEMBLY, Removal

Remove oil pan. See

3.31 OIL PAN

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)

Position jack across lower frame to support rear of
motorcycle. Slide wooden blocks beneath the crankcase
to support the weight of the engine and transmission
assembly.

Remove rear fork. See

2.21 REAR FORK, Removal

Disconnect

vehicle

speed

sensor

(VSS).

See

7.23 VEHICLE SPEED SENSOR (VSS), VSS

10. Disconnect neutral switch. See

7.24 NEUTRAL SWITCH,

Removal

11. Remove fastener from ground post at top of transmission

case and remove battery negative ring terminal.

12. Move O2 sensor, starter solenoid, neutral switch and VSS

harness out of the way.

13. Mark splines on shift arm and shift shaft to assist in

assembly. Remove shift arm from shift shaft.

14. In a crosswise pattern, remove four fasteners that connect

transmission to engine.

NOTE

See

Figure 6-54

. Do not use a hammer to remove transmission.

If the transmission sticks or binds on the ring dowels, gently
pry away from crankcase using the indent.

15. Move transmission rearward until two ring dowels in lower

flange are free of crankcase. Remove transmission case
from left side of the motorcycle.

sm03566

Figure 6-54. Transmission Case Pry Point

INSTALLATION

Install

new

ground post at top of transmission case.

Tighten ground post until snug.

NOTE

A new transmission case comes with the shifter shaft sleeve
and seal, centering screw, countershaft needle bearing and
main drive gear bearing and seal installed.

Thoroughly wipe all engine oil from pockets in crankcase
flange.

Install

new

engine-to-transmission gasket engaging two

index pins in holes of transmission flange.

Verify that transmission dowels are seated. Place trans-
mission case into position behind crankcase. Mate engine
and transmission flanges.

Install and tighten fasteners.

Shorter bolts are installed at the top, longer fasteners
are installed at the bottom. Using a crosswise pattern,

hand tighten

fasteners.

See

Figure 6-55

. Tighten bolts in the sequence shown

to 15 ft-lbs (20.3 Nm) in the same crosswise pattern.

Final tighten bolts to 34-39 ft-lbs (46.1-52.9 Nm).

Install oil pan. See

3.31 OIL PAN

Install rear fork. See

2.21 REAR FORK, Installation

Install shift arm on shift shaft. Align marks made during
disassembly.

Install transmission and side door assembly. See

6.6 TRANSMISSION ASSEMBLY, Installation

10. Connect battery ground (-) cable to ground post at top of

transmission case. Tighten securely.

11. Adjust drive belt tension. See

1.12 DRIVE BELT AND

SPROCKETS

12. Install primary chaincase. See

5.5 PRIMARY CHAINCASE

HOUSING

HOME

6-28 2011 Touring Service: Transmission

13. Install drive components. See

5.4 DRIVE COMPONENTS

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.

14. Install primary chaincase cover. See

5.3 PRIMARY

CHAINCASE COVER

15. Install neutral switch and tighten to 120-180

in-lbs

(13.6-

20.3 Nm).

16. Install VSS and tighten screw to 84-132

in-lbs

(9.5-14.9

Nm).

17. Mate VSS, O2 sensors, starter solenoid and neutral switch

connectors to main harness.

18. Install starter. See

7.10 STARTER, Installation

19. Install the exhaust system. See

4.19 EXHAUST SYSTEM

20. Clean transmission drain plug and install. Tighten to 14-

21 ft-lbs (19.0-28.5 Nm). Place motorcycle in an upright
position. Fill transmission to proper level with fresh trans-
mission fluid. See

1.10 TRANSMISSION LUBRICANT

Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incomplete
disengagement, clutch drag and/or difficulty in finding
neutral at engine idle. (00199b)

21. Fill primary. See

1.9 PRIMARY CHAINCASE LUBRICANT,

Changing Primary Chaincase Lubricant

22. Fill engine oil. See

1.6 ENGINE OIL AND FILTER, Chan-

ging Oil and Oil Filter

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)

23. Connect battery cables.

sm02180

Figure 6-55. Transmission Housing to Crankcase Torque

Sequence

DISASSEMBLY

Shifter Arm Assembly

See

Figure 6-56

. After removing door assembly, remove

screw (8) and shifter rod lever (9) from the shifter pawl
lever assembly (1).

Remove retaining ring (7), washer (6) and seal (5). Discard
retaining ring and seal. Pull shifter pawl lever assembly
out of the transmission case.

Inspect sleeve (2) inside transmission case.

CLEANING AND INSPECTION

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)

Clean all parts in solvent except the case and main drive
gear needle bearings. Blow parts dry with low pressure
compressed air.

NOTE

Never wash the transmission case and needle bearings with
solvent. Normal cleaning methods will wash dirt or other con-
taminants into the bearing case (behind the needles) leading
to bearing failure.

See

Figure 6-56

. Inspect the shifter pawl lever assembly

(1) for wear. Replace assembly if pawl ends are damaged.
Replace centering spring (3) if elongated.

HOME

2011 Touring Service: Transmission 6-29

Inspect the shifter spring (4). Replace if the spring fails to
hold the pawl on the cam pins.

Thoroughly clean the oil pan with solvent.

Inspect preformed transmission top cover vent hose for
nicks, cuts or general deterioration. Replace as necessary.
Use low-pressure compressed air to verify that hose and
fitting are unobstructed.

sm03066

1. Shifter pawl lever assembly
2. Sleeve (inside transmission case)
3. Shift lever centering spring
4. Shifter shaft lever spring
5. Seal
6. Washer
7. Retaining ring
8. Screw
9. Shifter rod lever
10. Washer
11. Screw

Figure 6-56. Shifter Arm Assembly

ASSEMBLY

Countershaft Needle Bearing Replacement

Find a suitable bearing driver 1.25 in. (31.75 mm) in dia-
meter.

From the outside of the transmission case place the needle
bearing open end first next to the bearing bore. Hold the
driver squarely against the closed end of the bearing and
tap the bearing into place. The bearing is properly posi-
tioned when it is driven inward flush with the outside sur-
face of the case or to a maximum depth of 0.030 in. (0.76
mm).

Lubricate the bearing with Screamin' Eagle Assembly Lube
(Part No. 94971-09.)

Shifter Pawl Lever Assembly

See

Figure 6-56

. Verify that sleeve (2) is inside transmis-

sion case.

See

Figure 6-57

. Slide shifter lever centering spring (3)

over shaft of shifter pawl lever assembly (2). Align opening
on spring with tab on lever.

Place shifter shaft lever spring (4) on shifter pawl lever
assembly.

NOTE

Do not bend shifter shaft lever spring more than necessary for
assembly.

See

Figure 6-58

. Insert the assembly into the transmission

case.

See

Figure 6-59

. Verify that pin sits inside shifter shaft

lever spring.

See

Figure 6-58

. Install a

new

seal. Install washer (1) and

new

retaining ring (2).

NOTE

In next step, shifter rod lever must be installed so angle of lever
is toward front of vehicle, one spline from vertical.

See

Figure 6-56

. Install shifter rod lever (9) on the shifter

pawl lever assembly shaft end using screw (8). Tighten
to 18-22 ft-lbs (24.4-29.8 Nm).

sm03067

1. Pawl (part of shifter pawl lever assembly)
2. Shifter pawl lever assembly
3. Shifter lever centering spring
4. Shifter shaft lever spring

Figure 6-57. Shifter Pawl Lever Assembly

HOME

6-30 2011 Touring Service: Transmission

7.1

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

7.29 GAUGES AND INSTRUMENTS: FAIRING
MODELS, 2 Inch Diameter Gauges: Fuel Level,
Ambient Air Temperature, Voltmeter, Oil Pressure

1.1-2.3 Nm

10-20

in-lbs

2 inch diameter gauge nuts

7.21 AUTOMATIC COMPRESSION RELEASE
(ACR), Installation/Apply three equally spaced dots
of LOCTITE 246 THREADLOCKER MEDIUM
STRENGTH/HIGH TEMPERATURE around lower
third of threads

14.9-20.3 Nm

11-15 ft-lbs

Automatic compression release (ACR)

7.13 AUXILIARY LAMPS AND BRACKETS, Auxil-
iary Lamp Bracket

20-27 Nm

15-20 ft-lbs

Auxiliary lamp bracket to fork bracket
screws (FLHTC/U, FLHTK)

7.13 AUXILIARY LAMPS AND BRACKETS, Auxil-
iary Lamp Bracket

8.1-12.2 Nm

72-108

in-lbs

Auxiliary lamp bracket to fork bracket
stud acorn nuts (FLHR/C)

7.10 STARTER, Installation

6.8-7.9 Nm

60-70

in-lbs

Battery terminal bolt

7.22 ALTERNATOR, Installation

6.8-7.9 Nm

60-70

in-lbs

Battery terminal bolt

7.8 ELECTRICAL CADDIES, Battery Tray

8.1-10.9 Nm

72-96

in-lbs

Battery tray screws

7.40 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation

8.1-12.2 Nm

72-108

in-lbs

Brake clamp fasteners

7.33 ADVANCED AUDIO SYSTEM, Radio

4.0-5.1 Nm

35-45

in-lbs

CB module to radio screw

7.33 ADVANCED AUDIO SYSTEM, CB Module

4.0-5.1 Nm

35-45

in-lbs

CB module to radio screw

7.20 CRANKSHAFT POSITION SENSOR
(CKP), Installation

10.2-13.6 Nm

90-120

in-lbs

CKP sensor mount screw

7.31 GAUGES AND INSTRUMENTS: ROAD KING
MODELS, Speedometer

4.1-6.8 Nm

36-60

in-lbs

Console-to-tank screw

7.32 INDICATOR LAMPS: ROAD KING
MODELS, Indicator Lamps

4.1-6.8 Nm

36-60

in-lbs

Console-to-tank screw

7.18 FAIRING CAP SWITCHES: FORK MOUNTED
FAIRING MODELS, Installation

2.8-3.4 Nm

25-30

in-lbs

Fairing cap screws

7.33 ADVANCED AUDIO SYSTEM, Front Fairing
Speakers

2.5-3.2 Nm

22-28

in-lbs

Fairing speaker lower screw (FLHX,
FLHTC/U)

7.33 ADVANCED AUDIO SYSTEM, Front Fairing
Speakers

4.0-5.7 Nm

35-50

in-lbs

Fairing speaker upper screws (FLHX,
FLHTC/U)

7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Road King Models

4.1-6.8 Nm

36-60

in-lbs

Fork lock screws (Road King)

7.15 FENDER TIP LAMPS, Front Fender Tip Lamp

2.3-2.8 Nm

20-25

in-lbs

Front fender tip lamp bracket screws

7.15 FENDER TIP LAMPS, Front Fender Tip Lamp
Jumper Harness

2.3-2.8 Nm

20-25

in-lbs

Front fender tip lamp bracket screws

7.15 FENDER TIP LAMPS, Front Fender Tip Lamp
Jumper Harness

1.1-1.7 Nm

10-15

in-lbs

Front fender tip lamp trim strip tee bolt
nuts

7.16 TURN SIGNAL LAMPS, Front Turn Signal
Lamp

20-27 Nm

15-20 ft-lbs

Front turn signal lamp mounting bracket
screws (Bullet Style; fork mounted)

7.16 TURN SIGNAL LAMPS, Front Turn Signal
Lamp

4.1-6.8 Nm

30-60

in-lbs

Front turn signal lamp mounting bracket
screws (FLHR/C, FLHT/C/U)

7.16 TURN SIGNAL LAMPS, Front Turn Signal
Lamp

20-27 Nm

15-20 ft-lbs

Front turn signal lamp-to-bracket
fastener: Bullet Style; fork mounted

HOME

2011 Touring Service: Electrical 7-1

NOTES

TORQUE VALUE

FASTENER

7.33 ADVANCED AUDIO SYSTEM, Front Headset
Receptacle

4.1-6.8 Nm

36-60

in-lbs

Fuel tank console screws

7.6 IGNITION COIL, Installation

5.7-10.2 Nm

50-90

in-lbs

Ground terminal nut

7.40 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Left Side Handlebar Switches

8.1-12.2 Nm

72-108

in-lbs

Handlebar clamp to clutch lever bracket
screws

7.40 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation

8.1-12.2 Nm

72-108

in-lbs

Handlebar clamp to clutch lever bracket
screws

7.40 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Right Side Handlebar Switches

8.1-12.2 Nm

72-108

in-lbs

Handlebar clamp to master cylinder
screws

7.40 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Right Side Handlebar Switches

4.0-5.0 Nm

35-45

in-lbs

Handlebar switch housing screws

7.40 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Left Side Handlebar Switches

4.0-5.0 Nm

35-45

in-lbs

Handlebar switch housing screws

7.40 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation

4.0-5.0 Nm

35-45

in-lbs

Handlebar switch housing screws

7.40 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation

4.0-5.0 Nm

35-45

in-lbs

Handlebar switch housing screws

7.35 MAIN WIRING HARNESS, Installation: All
Models (Part 1)/(10 mm)

5.7-10.2 Nm

50-90

in-lbs

Harness ground stud flange nuts

7.35 MAIN WIRING HARNESS, Installation: All
Models (Part 1)/(10 mm)

5.7-10.2 Nm

50-90

in-lbs

Harness ground stud flange nuts

7.12 HEADLAMP: ROAD GLIDE, Headlamp
Adjuster Assembly

4.0-5.1 Nm

35-45

in-lbs

Headlamp adjuster mounting screw (dual
headlamp models)

7.11 HEADLAMP: ALL EXCEPT ROAD
GLIDE, Headlamp: Single Headlamp Models

1.0-2.0 Nm

9-18

in-lbs

Headlamp door screw

7.12 HEADLAMP: ROAD GLIDE, Headlamp
Adjuster Assembly

1.7-2.8 Nm

15-25

in-lbs

Headlamp mounting screw (dual head-
lamp models)

7.12 HEADLAMP: ROAD GLIDE, Headlamp Bulb
Replacement: Dual Headlamp Models

1.7-2.8 Nm

15-25

in-lbs

Headlamp mounting screw (dual head-
lamp models)

7.11 HEADLAMP: ALL EXCEPT ROAD
GLIDE, Headlamp: Single Headlamp Models

2.5-3.6 Nm

22-32

in-lbs

Headlamp retaining screws (Fairing
equipped)

7.11 HEADLAMP: ALL EXCEPT ROAD
GLIDE, Headlamp: Single Headlamp Models

1.0-2.0 Nm

9-18

in-lbs

Headlamp retaining screws (Non-fairing
equipped)

7.27 HORN, Installation

9.0-13.6 Nm

80-120

in-lbs

Horn bracket acorn nut

7.27 HORN, Installation

9.0-11.3 Nm

80-100

in-lbs

Horn stud flange nut

7.6 IGNITION COIL, Installation

3.6-4.5 Nm

32-40

in-lbs

Ignition coil screws

7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Fairing Models

9.6-13.0 Nm

85-115

in-lbs

Ignition switch housing nut

7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Fairing Models

4.1-6.8 Nm

36-60

in-lbs

Ignition switch housing screws

7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Road King Models

2.3-3.4 Nm

20-30

in-lbs

Ignition switch screws (Road King)

7.19 INSTRUMENT NACELLE SWITCHES:
FRAME MOUNTED FAIRING MODELS, Installation

2.8-4.0 Nm

25-35

in-lbs

Instrument bezel screws

7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Road King Models

4.1-6.8 Nm

36-60

in-lbs

Instrument console screws

7.19 INSTRUMENT NACELLE SWITCHES:
FRAME MOUNTED FAIRING MODELS, Installation

20-27 Nm

15-20 ft-lbs

Instrument nacelle to fork bracket screws

7.19 INSTRUMENT NACELLE SWITCHES:
FRAME MOUNTED FAIRING MODELS, Installation

20-27 Nm

15-20 ft-lbs

Instrument nacelle to fork bracket screws

7.8 ELECTRICAL CADDIES, Left Side Caddy

8.1-10.9 Nm

72-96

in-lbs

Left electrical caddy fastener

HOME

7-2 2011 Touring Service: Electrical

NOTES

TORQUE VALUE

FASTENER

7.16 TURN SIGNAL LAMPS, Rear Turn Signal
Lamps Bracket

6.8-9.0 Nm

60-80

in-lbs

License plate bracket screws

7.16 TURN SIGNAL LAMPS, Rear Turn Signal
Lamps Bracket

6.8-9.0 Nm

60-80

in-lbs

License plate bracket screws

7.24 NEUTRAL SWITCH, Installation

13.6-20.3 Nm

120-180

in-lbs

Neutral switch

7.25 OIL PRESSURE SWITCH AND
SENDER, Installation

10.8-16.3 Nm

96-144

in-lbs

Oil pressure sender

7.25 OIL PRESSURE SWITCH AND
SENDER, Installation

10.8-16.3 Nm

96-144

in-lbs

Oil pressure switch

7.33 ADVANCED AUDIO SYSTEM, Radio

4.0-5.1 Nm

35-45

in-lbs

Radio (storage box) to support bracket
screws

7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Fairing Models

4.0-5.1 Nm

35-45

in-lbs

Radio support bracket screws

7.14 TAIL LAMP, Rear Fender Lights Harness: all
except FLHX, FLTRX

6.8-10.9 Nm

60-96

in-lbs

Rear fender lights harness stud plate
flange nuts

7.15 FENDER TIP LAMPS, Rear Fender Tip Lamp

2.3-2.8 Nm

20-25

in-lbs

Rear fender tip lamp screws

7.26 STOPLIGHT SWITCHES, Rear Stoplight
Switch/Use Loctite Pipe Sealant with Teflon 565

16.3-20.3 Nm

12-15 ft-lbs

Rear stoplight switch

7.16 TURN SIGNAL LAMPS, Rear Turn Signal
Lamps Bracket/Use LOCTITE High Strength
Threadlocker 271 (red)

9.5-16.3 Nm

84-144

in-lbs

Rear turn signal lamps bracket screws

7.16 TURN SIGNAL LAMPS, Rear Turn Signal
Lamps Bracket/Use LOCTITE High Strength
Threadlocker 271 (red)

9.5-16.3 Nm

84-144

in-lbs

Rear turn signal lamps bracket screws

7.16 TURN SIGNAL LAMPS, Rear Turn Signal
Lamp

3.4-5.6 Nm

30-50

in-lbs

Rear turn signal lamp-to-rear turn signal
lamps bracket screws

7.10 STARTER, Solenoid

7.3-9.0 Nm

65-80

in-lbs

Solenoid contact post jamnut

7.10 STARTER, Drive Assembly

7.9-10.2 Nm

70-90

in-lbs

Solenoid ring terminal nut

7.29 GAUGES AND INSTRUMENTS: FAIRING
MODELS, Speedometer

1.1-2.3 Nm

10-20

in-lbs

Speedometer bracket screws

7.10 STARTER, Drive Assembly

10.2-12.4 Nm

90-110

in-lbs

Starter end cover screw

7.10 STARTER, Installation/Apply a drop of Loctite
Threadlocker 243 (blue) to the threads.

33.9-36.6 Nm

25-27 ft-lbs

Starter mounting screw

7.10 STARTER, Solenoid

7.9-10.2 Nm

70-90

in-lbs

Starter ring terminal hex nut

7.10 STARTER, Installation

7.9-10.2 Nm

70-90

in-lbs

Starter terminal post nut

7.10 STARTER, Drive Assembly

4.4-7.3 Nm

39-65

in-lbs

Starter through bolts

7.22 ALTERNATOR, Installation/Always use new
screws

6.2-8.5 Nm

55-75

in-lbs

Stator mounting screws

7.29 GAUGES AND INSTRUMENTS: FAIRING
MODELS, Tachometer

1.1-2.3 Nm

10-20

in-lbs

Tachometer bracket screws

7.14 TAIL LAMP, Circuit Board/Chrome Base

4.5-5.4 Nm

40-48

in-lbs

Tail lamp circuit board/chrome base
screw

7.14 TAIL LAMP, Tail Lamp Bulb Replacement

2.3-2.7 Nm

20-24

in-lbs

Tail lamp screws

7.14 TAIL LAMP, Circuit Board/Chrome Base

2.3-2.7 Nm

20-24

in-lbs

Tail lamp screws

7.14 TAIL LAMP, Rear Fender Lights Harness: all
except FLHX, FLTRX

2.3-2.7 Nm

20-24

in-lbs

Tail lamp screws

7.14 TAIL LAMP, Rear Fender Lights Harness:
FLHX, FLTRX

2.3-2.7 Nm

20-24

in-lbs

Tail lamp screws

7.15 FENDER TIP LAMPS, Rear Fender Tip Lamp

2.3-2.7 Nm

20-24

in-lbs

Tail lamp screws

7.16 TURN SIGNAL LAMPS, Rear Turn Signal
Lamp

2.3-2.7 Nm

20-24

in-lbs

Tail lamp screws

HOME

2011 Touring Service: Electrical 7-3

7.2

SPECIFICATIONS: ELECTRICAL

SPECIFICATIONS

Table 7-1. Ignition

DATA

IGNITION

1000 ± 50 RPM

Idle speed

12 mm

Spark plug size

0.038-0.043 in.

Spark plug gap

0.97-1.09 mm

Harley-Davidson

No. 6R12

(no substitute)

Spark plug type

0.5-0.7 ohms

Ignition coil primary resistance

5500-7500 ohms

Ignition coil secondary resistance

Table 7-2. Fuses

AMPS

FUSE

Main fuse

Brakes

Accessory

P&A

Radio power/siren

ECM power

Ignition

Engine control: active exhaust (HDI only)

Lighting

Instruments

Headlamp

ABS

P&A ignition

Fuel pump

Battery

Power outlet (if equipped)

Radio memory

Table 7-3. Charging System

DATA

CHARGING SYSTEM

28 amp hour/405 CCA

Battery

16-23 VAC per 1000 RPM

Alternator AC voltage output

0.1-0.2 ohms

Alternator stator coil resistance

14.3-14.7

75 °F (24 °C)

Regulator voltage output @ 3600
RPM

35-50 amps

Regulator amperes @ 3000 RPM

Table 7-4. Starter Specifications

STARTER DATA

3000 rpm (min) @ 11.5 V

Free speed

90 A (max) @ 11.5 V

Free current

200 A (max) @ 68 °F

Cranking current

8.0 ft-lbs (10.8 Nm) @ 2.4 V

Stall torque

Table 7-5. Starter Service Wear Limits

ITEM

11.0

0.443

Brush length (minimum)

0.41

0.016

Commutator runout

28.98

1.141

Commutator diameter (minimum)

0.203

0.008

Commutator mica depth (minimum)

HOME

2011 Touring Service: Electrical 7-5

7.3

VOLTAGE REGULATOR

REMOVAL

Remove main fuse. See

7.7 SYSTEM FUSES AND

RELAYS

Remove locknuts from studs on lower frame crossmember.
Lift voltage regulator off studs. Allow voltage regulator to
hang upside down at front of lower frame crossmember.

See

Figure 7-2

. Pull away locking latch and remove socket

of voltage regulator connector [77] (2).

Pull away locking latch and remove socket of stator con-
nector [46] (1).

INSTALLATION

See

Figure 7-2

. Install stator connector [46] (1). Secure

connector with locking latch (3).

Install voltage regulator connector [77] (2). Secure con-
nector with locking latch (3).

See

Figure 7-1

. Install voltage regulator with locknuts on

studs and tighten to 70-100

in-lbs

(7.9-11.3 Nm).

Make sure wires are properly secured.

Install main fuse. See

7.7 SYSTEM FUSES AND RELAYS

Test charging system.

sm03470a

1. Stator connector [46]
2. Voltage regulator output connector [77]

Figure 7-1. Voltage Regulator (Left Side View)

sm03471

1. Stator [46A]
2. Voltage regulator [77A]
3. Locking latch

Figure 7-2. Voltage Regulator (Bottom View)

HOME

7-6 2011 Touring Service: Electrical

7.4

ELECTRONIC CONTROL MODULE (ECM)

ECM

Removal

Remove seat. See

2.25 SEAT

Free ECM from top caddy.

Disconnect ECM connector. See

A.11 DELPHI GT 280

SEALED 73-TERMINAL ECM CONNECTOR

NOTE

Internal latches are not fully disengaged until locking bar is in
the fully released position. Forcing socket housing with latches
partially engaged will result in connector damage.

Installation

Connect ECM connector. See

A.11 DELPHI GT 280

SEALED 73-TERMINAL ECM CONNECTOR

NOTE

Pin and socket housings must be fully engaged before locking
bar is rotated to the latched position. Forcing locking bar without
full engagement will result in connector damage.

Secure ECM in top caddy. Verify holes engage two index
pins on right side of top caddy.

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)

Install seat. See

2.25 SEAT

NOTE

After installing ECM, the password learn procedure must be
performed.

Perform password learn procedure. See

7.44 TSM/HFSM:

PASSWORD LEARN

HOME

2011 Touring Service: Electrical 7-7

Harley Davidson 2011 Touring Models. Service Manual - page 24