Harley Davidson 2018 softail models. Service manual - page 20
1
Long shift shaft
2
Fifth and sixth gear shifter fork
3
Short shift shaft
4
Third and fourth gear shifter fork
5
First and second gear shifter fork
Figure 6. Shifter Forks and Shafts
1
Long shift shaft
2
Fifth and sixth gear shifter fork
3
Mainshaft fifth gear
4
Short shift shaft
5
Countershaft fifth gear
6
Third and fourth gear shifter fork
7
Third gear
8
Second gear
9
First and second gear shifter fork
10
First gear
Figure 7. Transmission Gears and Shifter Forks
1. Install transmission mainshaft bearing inner race. See Mainshaft Bearing Inner Race.
2. Install clutch release cover. See Prepare.
3. Fill transmission oil. See Check Transmission Lubricant.
4. Install engine oil fill spout. See Prepare.
5. Fill engine oil. See Check Engine Oil Level.
6. Install exhaust system. See Prepare.
7. Install primary chaincase housing. See Prepare.
8. Install the primary chain, clutch, compensating sprocket and chain tensioner. See Prepare.
9. Install starter. See Prepare.
10. Install primary chaincase cover. See Prepare.
11. Fill primary chaincase oil. See Change Primary Chaincase Lubricant.
12. Mid-mount controls: Install foot shift lever. See Shifter Rod.
13. Install rider left footboard and bracket, if removed. See Prepare.
14. Adjust drive belt deflection. See Inspect.
15. Verify rear fork pivot shaft torque. See Prepare.
16. Connect negative battery cable. See Main Fuse.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable
before proceeding. (00048a)
1. Disconnect negative battery cable. See Main Fuse.
2. Remove rider footboard and bracket, if needed. See Prepare.
3. Mid-mount controls: Remove foot shift lever. See Shifter Rod.
4. Drain primary chaincase oil. See Change Primary Chaincase Lubricant.
5. Remove primary chaincase cover. See Prepare.
6. Remove starter. See Prepare.
7. Remove primary chain, clutch and compensating sprocket. See Prepare.
8. Remove primary chaincase housing. See Prepare.
9. Remove bearing inner race from transmission mainshaft. See Mainshaft Bearing Inner Race.
10. Remove transmission sprocket. See Prepare.
11. Remove transmission bearing housing and gear assembly. See Prepare.
Special Tools
Description
Part Number
Qty.
MAIN DRIVE GEAR REMOVER
HD-35316-D
1
AND INSTALLER SET
NOTICE
Failure to use Main Drive Gear Remover and Installer can cause premature failure of bearing and related parts.
(00540b)
NOTE
Main drive gear and bearing can be removed with the transmission case in the frame after removing bearing housing.
1. See Figure 1. Remove gear using MAIN DRIVE GEAR REMOVER AND INSTALLER SET (Part
Number:HD-35316-D).
2. Remove tool.
3. Remove large main drive gear oil seal.
4. Remove retaining ring from bearing bore.
5. See Figure 2. Remove main drive gear bearing from transmission case using MAIN DRIVE GEAR REMOVER
AND INSTALLER SET (Part Number:HD-35316-D).
6. Discard main drive gear bearing.
1
Cross plate
2
Screw (2)
3
12-in bolt
4
Main drive gear
5
Washer
6
Bearing
7
Nut
Figure 1. Removing Main Drive Gear
1
8-in bolt
2
Bearing driver
3
Pilot
4
Main drive gear bearing
5
Receiver cup
6
Bearing
7
Nut
Figure 2. Removing Main Drive Gear Bearing
NOTE
Never wash the transmission case and needle bearings with solvent unless replacing the needle bearings. Normal
cleaning methods wash dirt or other contaminants into the bearing case (behind the needles) and leads to bearing
failure.
1. Clean all parts in solvent except the transmission case and needle bearings. Dry parts with low-pressure,
compressed air.
2. Inspect the main drive gear for pitting and wear.
3. Inspect the needle bearings inside the main drive gear.
4. Inspect mainshaft race. Replace the needle bearings if the mainshaft race is damaged.
Special Tools
Description
Part Number
Qty.
MAIN DRIVE GEAR REMOVER
HD-35316-D
1
AND INSTALLER SET
MAIN DRIVE GEAR SEAL
HD-47856
1
INSTALLER KIT
NOTICE
Improper tightening of sprocket nut can cause drive component damage. (00541b)
1. See Figure 1. Install main drive gear bearing using MAIN DRIVE GEAR REMOVER AND INSTALLER SET (Part
Number:HD-35316-D).
1
12-in bolt
2
Cross plate
3
Screw (2)
4
Main drive gear bearing
5
Bearing driver
6
Bearing
7
Nut
Figure 1. Installing Main Drive Gear Bearing (Typical)
2. See Figure 2. Install new O-ring (4) onto main drive gear (3). Lubricate O-ring with clean engine oil.
3. Install main drive gear using MAIN DRIVE GEAR REMOVER AND INSTALLER SET (Part Number:HD-35316-D).
NOTE
See Figure 3. Install retaining ring with the flat side facing the bearing and the opening within the range shown.
4. Install new retaining ring.
1
8-in bolt
2
Washer
3
Main drive gear
4
O-ring
5
Installer cup
6
Bearing
7
Nut
Figure 2. Installing Main Drive Gear (Typical)
Figure 3. Retaining Ring Opening
5. See Figure 4. Install new main drive gear large seal using MAIN DRIVE GEAR SEAL INSTALLER KIT (Part
Number:HD-47856).
1
Crow's foot wrench
2
Breaker bar
3
Adjustable wrench
Figure 4. Press Seal into Crankcase
Special Tools
Description
Part Number
Qty.
MAIN DRIVE GEAR BEARING AND
HD-47932
1
SEAL INSTALLATION TOOL
NOTE
See Figure 2. When replacing needle bearings, replace retaining rings (1) with new retaining rings (2).
1. See Figure 1. Remove mainshaft seal (7).
2. Remove retaining rings (1), needle bearings (2, 6) and spacer (5) from main drive gear (3). Discard retaining rings.
3. Discard O-ring (4).
1
Retaining ring (2)
2
Inner needle bearing
3
Main drive gear
4
O-ring
5
Spacer
6
Outer needle bearing
7
Mainshaft seal
Figure 1. Main Drive Gear Assembly
1
Original retaining ring
2
Replacement retaining ring
Figure 2. Main Drive Gear Retaining Rings
4. See Figure 3. Use MAIN DRIVE GEAR BEARING AND SEAL INSTALLATION TOOL (Part Number:HD-47932)
to install outer needle bearing. Press until tool contacts gear.
Figure 3. Installing Outer Needle Bearing in Main Drive Gear
NOTE
The mainshaft seal can also be installed after the main drive gear is installed. See Replace Mainshaft Seal.
5. See Figure 4. Install mainshaft seal with garter spring side down.
a. Use the 0.090-in step of MAIN DRIVE GEAR BEARING AND SEAL INSTALLATION TOOL (Part
Number:HD-47932).
b. Press until tool contacts gear.
6. See Figure 1. Turn over the main drive gear. Install spacer (5).
7. See Figure 5. Use MAIN DRIVE GEAR BEARING AND SEAL INSTALLATION TOOL (Part Number:HD-47932)
to press inner needle bearing until tool contacts gear.
8. See Figure 1. Install new retaining rings (1).
9. Install new O-ring (4).
Figure 4. Pressing in Seal
Figure 5. Installing Inner Needle Bearing in Main Drive Gear
Special Tools
Description
Part Number
Qty.
MAIN DRIVE GEAR SEAL
HD-47933
1
INSTALLER
See Figure 1. Use the MAIN DRIVE GEAR SEAL INSTALLER (Part Number:HD-47933) to replace the mainshaft seal
while the main drive gear is installed.
1
Driver
2
Seal protector sleeve
Figure 1. Main Drive Gear Seal Installer
1. Remove the seal using a seal remover or rolling head pry bar.
2. Verify that bore is clean and smooth.
3. See Figure 2. Place the seal protector sleeve (1) of MAIN DRIVE GEAR SEAL INSTALLER (Part
Number:HD-47933) over the end of the mainshaft.
4. Lightly lubricate the protector sleeve and seal ID with clean transmission oil.
5. Slide the seal (2) on the seal protector sleeve with the garter spring facing the bearing.
6. See Figure 3. Hand press seal onto place until seal driver contacts end of main drive gear using MAIN DRIVE
GEAR SEAL INSTALLER (Part Number:HD-47933). Lightly tap with a rubber mallet if necessary.
1
Seal protector sleeve
2
Seal
Figure 2. Seal Protector Sleeve
Figure 3. Seal Driver
1. Install bearing housing and gear assembly. See Prepare.
2. Install transmission sprocket. See Prepare.
3. Install bearing inner race to transmission mainshaft. See Mainshaft Bearing Inner Race.
4. Install primary chaincase housing. See Prepare.
5. Install the primary chain, clutch, compensating sprocket and chain tensioner. See Prepare.
6. Install starter. See Prepare.
7. Install primary chaincase cover and new gasket. See Prepare.
8. Fill primary chaincase oil. See Change Primary Chaincase Lubricant.
9. Mid-mount controls: Install foot shift lever. See Shifter Rod.
10. Install rider left footboard and bracket, if removed. See Prepare.
11. Adjust drive belt deflection. See Inspect.
12. Verify rear fork pivot shaft torque. See Prepare.
13. Connect negative battery cable. See Main Fuse.
WARNING
Disconnect negative (-) 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. (00049a)
1. Remove battery. See Prepare.
2. Remove battery tray. See Prepare.
3. Drain engine oil. See Check Engine Oil Level.
4. Drain transmission oil. See Check Transmission
Lubricant.
5. Drain primary chaincase oil. See Change Primary
Chaincase Lubricant.
6. See Oil Return Line. Disconnect oil return line (1).
7. Remove exhaust system. See Prepare.
8. Remove clutch release cover. See Prepare.
9. Remove screw securing jiffy stand sensor, if equipped.
See Prepare.
10. Remove rider footboard and bracket, if needed. See
Prepare.
11. Mid-mount controls: Remove foot shift lever. See
Shifter Rod.
12. Remove primary chaincase cover. See Prepare.
13. Remove starter. See Prepare.
14. Remove primary chain, clutch and compensating
sprocket. See Prepare.
15. Remove primary chaincase housing. See Prepare.
16. Loosen drive belt. See Inspect.
17. Remove transmission assembly. See Prepare.
18. Remove oil pan. See Prepare.
NOTICE
When lifting a motorcycle using a jack, be sure jack
contacts both lower frame tubes where down tubes
and lower frame tubes converge. Never lift by
jacking on cross-members, oil pan, mounting
brackets, components or housings. Failure to
comply can cause serious damage resulting in the
need to perform major repair work. (00586d)
19. 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.
20. Remove rear fork. See Prepare.
21. Disconnect vehicle speed sensor (VSS). See Prepare.
22. Disconnect neutral switch. See Prepare.
1. Remove battery negative cable from ground post at top of transmission case.
2. Move aside the harness that terminates at the O2 sensor, starter solenoid, neutral switch and VSS.
3. Remove transmission shift lever.
a. Mark splines on transmission shift lever and shift shaft to help with assembly.
b. Remove pinch screw.
c. Pull lever from shaft.
4. In a cross-wise pattern, remove four bolts securing transmission to engine.
NOTE
See Figure 2. 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 pry point.
5. Move transmission rearward until two ring dowels in lower flange are free of crankcase.
6. Remove transmission case from rear of the motorcycle.
1
Oil return line
2
Clamp
3
Oil return tube
Figure 1. Oil Return Line
Figure 2. Transmission Case Pry Point
1.
Install new ground post at top of transmission case.
Tighten ground post until snug.
NOTE
A new transmission case has the shifter shaft sleeve
and seal, centering screw, countershaft needle
bearing and main drive gear bearing and seal
installed.
2.
Wipe all engine oil from pockets in crankcase flange.
3.
Install new engine-to-transmission gasket.
4.
Verify that transmission dowels are seated. Place
transmission case into position.
5.
Secure transmission.
a. Install shorter bolts at the top, longer bolts at the
bottom. Hand-tighten bolts.
b. See Figure 1. Tighten bolts in the sequence shown
to.
Torque: 20.3 N·m (15 ft-lbs) Transmission mounting
bolts, initial torque
c. Tighten to the final torque in the same sequence.
Torque: 46.1-52.9 N·m (34-39 ft-lbs) Transmission
mounting bolts, final torque
6.
Secure battery ground cable to ground post at top of
transmission case. Tighten to.
Torque: 7.5-12.9 N·m (66-114 in-lbs) Battery ground
cable to transmission
Figure 1. Transmission Housing to Crankcase Tightening Sequence
Remove Shifter Pawl Lever
1. See Shifter Arm and Pawl Assembly (Typical). Remove shifter rod lever.
a. Remove pinch screw (8).
b. Remove shifter rod lever (9) from the shifter pawl lever assembly (1).
2. Remove shifter pawl assembly.
a. Remove retaining ring (7), washer (6) and seal (5).
b. Discard retaining ring and seal.
c. Remove shifter pawl lever assembly.
3. Inspect sleeve (2) in transmission case.
Remove Oil Return Tube
1. If transmission case is installed in vehicle:
a. Disconnect battery.
b. See Oil Return Line. Disconnect oil return hose (1) from return tube (3).
2. See Figure 1.. Remove screws (2, 4).
3. Remove oil return tube (1).
1
Oil return tube
2
Screw
3
Shift lever
4
Screw
Figure 1. Oil Return Tube/Cover
WARNING
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)
NOTE
Never wash the transmission case and needle bearings with solvent. Normal cleaning methods wash dirt or other
contaminants into the bearing case (behind the needles) leading to bearing failure.
1. Clean all parts in solvent except the case and main drive gear needle bearings. Dry parts with low-pressure,
compressed air.
2. See Figure 1. Inspect the shifter pawl lever assembly (1) for wear. Replace assembly if pawl ends are damaged.
Replace centering spring (3) if elongated.
3. Inspect the shifter shaft lever spring (4). Replace if the spring fails to hold the pawl on the cam pins.
4. Thoroughly clean the oil pan.
5. Inspect transmission top cover vent hose for damage. Verify that hose and fitting are unobstructed.
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
Screw
Figure 1. Shifter Arm and Pawl Assembly (Typical)
Special Tools
Description
Part Number
Qty.
SHIFTER SHAFT SEAL
HD-51337
1
INSTALLATION TOOL
Install Oil Return Tube
1. See Oil Return Tube/Cover. Install new O-ring on
lower oil tube adapter.
2. Install oil return tube (1).
a. Locate oil return tube between shift lever (3) and
transmission housing.
3. Install screws (2, 4).
a. Tighten.
Torque: 11.3-13.6 N·m (100-120 in-lbs) Oil return
tube screw
4. If transmission case is installed in vehicle:
a. See Oil Return Line. Connect oil return hose (1) to
return tube (3). Secure with clamp (2).
b. Connect battery.
5. Check engine oil level after running engine.
Replace Countershaft Needle Bearing
1. Press or drive out bearing using a bearing driver 31.75 mm (1.25 in) in diameter.
2. Install new bearing.
a. From the outside of the transmission case, place the bearing on the bearing bore.
b. Install the bearing flush or to a maximum depth of 0.76 mm (0.030 in) with the outside surface of the
case.
3. Lubricate the bearing with SCREAMIN' EAGLE ASSEMBLY LUBE.
Install Shifter Pawl Lever
1. See Shifter Arm and Pawl Assembly (Typical). Verify
that sleeve (3) is in transmission case bore.
2. Install screw (10) into side of transmission case.
Tighten.
Torque: 24.4-31.2 N·m (18-23 ft-lbs) Shifter pawl
centering screw
3. See Figure 1. Assemble shifter arm.
a. Slide shifter lever centering spring (2) over shaft of
shifter pawl lever assembly (3).
b. Align opening on spring with tab on lever.
c. Place shifter shaft lever spring (4) on shifter pawl
lever assembly. Flex spring only enough to
assemble.
4.
See Figure 2. Insert the shifter arm assembly into the
transmission case.
5.
See Figure 3. Verify that pin of screw sits inside shifter
shaft lever spring.
6.
Install new seal with garter spring facing the
transmission.
a. Drive the seal until the tool bottoms on the
transmission case.
Special Tool: SHIFTER SHAFT SEAL
INSTALLATION TOOL (HD-51337)
7.
See Figure 2. Install washer (1) and new retaining ring
(2).
NOTE
Install shifter rod lever one spline from vertical
toward front of vehicle.
8.
See Shifter Arm and Pawl Assembly (Typical). Install
shifter rod lever (9).
a. Install pinch screw (8).
b. Tighten to 24.4-29.8 N·m (18-22 ft-lbs).
1
Pawl (part of shifter pawl lever assembly)
2
Shifter pawl lever assembly
3
Shifter lever centering spring
4
Shifter shaft lever spring
Figure 1. Shifter Pawl Lever Assembly
1
Washer (with seal behind)
2
Retaining ring
3
Shifter shaft lever
4
Pin
Figure 2. Shifter Shaft Lever, Exterior View
Figure 3. Shifter Shaft Lever Spring
1. Install neutral switch. See Prepare.
2. Install VSS. See Prepare.
3. Install rear fork. See Prepare.
4. Install oil pan. See Prepare.
5. Install transmission. See Prepare.
6. Install primary chaincase housing. See Prepare.
7. Install primary chain, clutch and compensating sprocket.
See Prepare.
8. See Oil Return Line. Connect oil return line (1).
9. Install starter. See Prepare.
10. Install primary chaincase cover and new gasket. See
Prepare.
11. Mid-mount controls: Install foot shift lever. See Shifter
Rod.
12. Install rider footboard and bracket, if removed. See
Prepare.
13. Install transmission shift linkage. See Shifter Rod.
14. Install jiffy stand sensor, if removed. See Prepare.
15. Install clutch release cover. See Prepare.
16. Install exhaust system. See Prepare.
17. Fill primary chaincase. See Change Primary Chaincase
Lubricant.
18. Fill transmission. See Check Transmission Lubricant.
19. Fill engine oil. See Check Engine Oil Level.
20. Adjust drive belt deflection. See Inspect.
21. Install battery tray. See Prepare.
22. Install battery. See Prepare.
FASTENER
TORQUE VALUE
NOTES
Air filter element screws
5.4-8.1 N·m
6.3 AIR CLEANER BACKPLATE
(48-72 in-lbs)
ASSEMBLY, Remove and Install:
Round
Backplate screws
5.6-6.8 N·m
6.3 AIR CLEANER BACKPLATE
(50-60 in-lbs)
ASSEMBLY, Remove and Install:
Oval
Breather bolts
29.8-32.5 N·m
6.3 AIR CLEANER BACKPLATE
(22-24 ft-lbs)
ASSEMBLY, Remove and Install:
Round
Breather bolts
29.8-32.5 N·m
6.3 AIR CLEANER BACKPLATE
(22-24 ft-lbs)
ASSEMBLY, Remove and Install:
Oval
metric
Charcoal canister bracket to engine
8.1-10.8 N·m
6.22 CHARCOAL CANISTER:
case screws
(72-96 in-lbs)
CALIFORNIA EMISSIONS, Install
Charcoal canister to bracket screws
3.4-4.1 N·m
6.22 CHARCOAL CANISTER:
(30-36 in-lbs)
CALIFORNIA EMISSIONS, Install
Console screw (Front)
3.4-5.6 N·m
6.4 CONSOLE, Remove and Install:
(30-50 in-lbs)
Single Instrument with Panel
Console screw (Rear)
2.8-3.4 N·m
6.4 CONSOLE, Remove and Install:
(25-30 in-lbs)
Dual Instrument
Console screw (Rear)
2.8-3.4 N·m
6.4 CONSOLE, Remove and Install:
(25-30 in-lbs)
Single Instrument with Panel
Console screws
4.5-5.6 N·m
6.4 CONSOLE, Remove and Install:
(40-50 in-lbs)
Single Instrument without Panel
Console screws (Front)
3.4-5.6 N·m
6.4 CONSOLE, Remove and Install:
(30-50 in-lbs)
Dual Instrument
Exhaust bracket screws
54.2-67.8 N·m
6.20 EXHAUST SYSTEM, Install
(40-50 ft-lbs)
Exhaust shield clamps
2.3-4.5 N·m
6.20 EXHAUST SYSTEM,
(20-40 in-lbs)
Disassemble and Assemble:
Standard
Exhaust shield clamps
2.3-4.5 N·m
6.20 EXHAUST SYSTEM,
(20-40 in-lbs)
Disassemble and Assemble:
Upswept
Exhaust shield clamps
8.8-10.8 N·m
6.20 EXHAUST SYSTEM,
(78-96 in-lbs)
Disassemble and Assemble: Two
Into One
Exhaust shield screws
8.8-10.8 N·m
6.20 EXHAUST SYSTEM,
(78-96 in-lbs)
Disassemble and Assemble:
Upswept
Exhaust support clamp screw
54.2-67.8 N·m
6.20 EXHAUST SYSTEM, Install
(40-50 ft-lbs)
Exhaust to engine flange nuts
11.3-13.6 N·m
6.20 EXHAUST SYSTEM, Install
(100-120 in-lbs)
Fuel line to fuel rail screw
2.5-4.5 N·m
6.8 FUEL LINE, Install
(22-40 in-lbs)
Fuel line to fuel rail screw
2.5-4.5 N·m
6.16 INDUCTION MODULE, Install
(22-40 in-lbs)
Fuel pump assembly screws
4.5-5 N·m
6.10 FUEL PUMP, Install
(40-45 in-lbs)
Fuel rail screws
3.5-5.5 N·m
6.15 FUEL INJECTORS, Install
(31-49 in-lbs)
Fuel tank mounting screw
38-43.4 N·m
6.7 PURGE FUEL LINE, Secure Fuel
(28-32 ft-lbs)
Tank
Fuel tank mounting screw
38-43.4 N·m
6.7 PURGE FUEL LINE, Secure Fuel
(28-32 ft-lbs)
Tank
Fuel tank vent screws
9.5-12.2 N·m
6.9 FUEL TANK, Install
(84-108 in-lbs)
HO2S (Heated oxygen sensor)
16.3-19 N·m
6.18 HEATED OXYGEN SENSORS
(12-14 ft-lbs)
(HO2S), Install
Induction module bracket
7.5-9.5 N·m
6.16 INDUCTION MODULE,
(66-84 in-lbs)
Assemble
Induction module flange adapter
10.9-17.6 N·m
6.16 INDUCTION MODULE, Install
screws
(96-156 in-lbs)
metric
Induction module flange adapter
10.9-17.6 N·m
6.16 INDUCTION MODULE, Install
screws
(96-156 in-lbs)
metric
Muffler clamp
51.5-58.3 N·m
6.19 MUFFLERS, Install
(38-43 ft-lbs)
Muffler end cap screws
8.8-10.8 N·m
6.19 MUFFLERS, Install
(78-96 in-lbs)
Muffler screws
13.5-16.3 N·m
6.19 MUFFLERS, Install
(119-144 in-lbs)
Muffler screws
13.6-16.3 N·m
6.20 EXHAUST SYSTEM, Install
(120-144 in-lbs)
Muffler shield clamps
2.3-4.5 N·m
6.20 EXHAUST SYSTEM,
(20-40 in-lbs)
Disassemble and Assemble:
Standard
Temperature manifold absolute
2.5-4.5 N·m
6.13 TEMPERATURE MANIFOLD
pressure sensor (TMAP) screw
(23-39 in-lbs)
ABSOLUTE PRESSURE (TMAP)
SENSOR, Install
Throttle body to manifold screws
4-6 N·m
6.16 INDUCTION MODULE,
(35-53 in-lbs)
Assemble
Table 1. Capacities
ITEM
GALLONS
LITERS
Fuel tank
5
18.9
3.5
13.25
Low fuel warning light on
1
3.8
(approximate)
Table 2. Fuel Pump Specifications
MEASUREMENT
VALUE
Pressure
375-425 kPa (54-62 psi)
Current draw
7.5A or less
1. Remove air cleaner cover. See Remove.
Consumables
Description
Part Number
Size
LOCTITE 565 THREAD SEALANT
99818-97
6 ml (¼ fl oz)
Remove
1. See Figure 1. Remove breather tube assembly (5) from breather bolts (6).
2. Remove breather bolts.
3. Remove backplate (7).
4. Discard seal ring (8).
5. Verify that passages in breather bolts (6) are clear.
1
Cover screw (1 or 5)
2
Air cleaner cover
3
Filter screw (3)
4
Filter element
5
Breather tube assembly
6
Breather bolt (2)
7
Backplate
8
Seal ring
9
Rubber seal
Figure 1. Air Cleaner Assembly
Install
1. See Figure 1. Install new seal ring (8) on backplate (7).
2. Apply thread sealant to threads of breather bolts (6).
LOCTITE 565 THREAD SEALANT (99818-97)
3. Install backplate.
4. Install breather bolts. Hand tighten.
5. Install breather tube assembly (5) to filter element (4).
6. Install filter element.
7. Install filter element screws (3). Tighten.
Torque: 5.4-8.1 N·m (48-72 in-lbs) Air filter element
screws
8. Tighten breather bolts.
Torque: 29.8-32.5 N·m (22-24 ft-lbs) Breather bolts
9. Attach breather tube assembly (5) to breather bolts.
NOTE
Failure to connect the breather tubes allows
crankcase vapors to be vented into the atmosphere
in violation of legal emissions standards.
Consumables
Description
Part Number
Size
LOCTITE 565 THREAD SEALANT
99818-97
6 ml (¼ fl oz)
Remove
1. See Figure 1. Remove breather tubes (1) from breather bolts (2).
2. Remove breather bolts.
3. Remove backplate screws (5).
4. Remove backplate (4).
5. Discard gasket (3).
6. Verify that passages in breather bolts are clear.
1
Breather tube (2)
2
Breather bolt (2)
3
Gasket
4
Backplate
5
Backplate screw (3)
Figure 1. Air Cleaner Assembly
Install
1. See Figure 1. Install new gasket (3) on backplate (4).
2. Apply thread sealant to threads of breather bolts (2).
LOCTITE 565 THREAD SEALANT (99818-97)
3. Install backplate.
4. Install breather bolts. Hand tighten.
5. Install backplate screws (5). Tighten.
Torque: 5.6-6.8 N·m (50-60 in-lbs) Backplate screws
6. Tighten breather bolts.
Torque: 29.8-32.5 N·m (22-24 ft-lbs) Breather bolts
7. Install breather tubes (1) onto breather bolts.
NOTE
Failure to connect the breather tubes allows
crankcase vapors to be vented into the atmosphere
in violation of legal emissions standards.
1. Install air cleaner cover. See Remove.
1. Remove main fuse. See Main Fuse.
2. All but FXFB, FXFBS: Remove seat. See Remove.
Remove
1. See Figure 1. Detach console.
a. Remove front screws (1).
b. Remove rear screw (4)
c. Move console (2) rearward.
2. See Figure 2. Disconnect connector.
a. Remove grommet (4) from backbone (1).
b. Pull harness (2) from backbone.
NOTE
See the electrical diagnostic manual for the appropriate disassembly procedure for the connector.
c. Disconnect connector (3).
3. Remove console.
Install
1. See Figure 2. Connect connector.
a. Connect connector (3).
b. Feed harness (2) into backbone (1).
c. position grommet (4) into backbone.
2. See Figure 1. Install console.
a. Align console (2) with bracket (3).
b. Install front screws (1).
c. Install rear screw (4).
d. Tighten front screws.
Torque: 3.4-5.6 N·m (30-50 in-lbs) Console
screws (Front)
e. Tighten rear screw.
Torque: 2.8-3.4 N·m (25-30 in-lbs) Console screw
(Rear)
1
Front screw (2)
2
Console
3
Bracket
4
Rear screw
Figure 1. Console
1
Backbone
2
Harness
3
Connector
4
Grommet
Figure 2. Console Harness