Harley Davidson 2018 softail models. Service manual - page 23
1. Install exhaust shields as necessary. See Prepare.
1. Remove main fuse. See Main Fuse.
2. If necessary remove right foot support bracket. See
Remove and Install: Forward Foot Controls.
3. Disconnect front and rear HO2S (Heated oxygen sensor)
connectors. See Prepare.
1. See Exhaust System (Typical) or Exhaust System
(Two Into One). Remove exhaust system.
a. Remove flange nuts (5).
b. FLDE,FLHC,FLHCS: Remove support clamp screw
(4).
c. Remove muffler screws (1).
d. Remove exhaust system.
2. Remove and discard gaskets (6).
3. If necessary remove exhaust bracket.
a. Remove exhaust bracket screws (3).
b. Remove exhaust bracket (2).
Consumables
Description
Part Number
Size
LOCTITE 243 MEDIUM STRENGTH
99642-97
6 ml (¼ fl oz)
THREADLOCKER AND SEALANT
(BLUE)
1.
See Figure 1 or Figure 2. If removed install exhaust
bracket.
a. Install exhaust bracket (2).
b. Apply thread-locker to exhaust bracket screws (3).
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-97)
c. Install exhaust bracket screws (3). Tighten.
Torque: 54.2-67.8 N·m (40-50 ft-lbs) Exhaust bracket
screws
2.
Install new gaskets (6).
3.
Install exhaust system.
a. Install and align exhaust system.
b. Apply thread-locker to muffler screws (1).
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-97)
c. Install muffler screws. Hand tighten.
d. FLDE,FLHC,FLHCS: Install support clamp screw (4).
Hand tighten.
e. Install flange nuts (5). Hand tighten.
f. Tighten flange nuts.
Torque: 11.3-13.6 N·m (100-120 in-lbs) Exhaust to
engine flange nuts
g. Tighten muffler screws.
Torque: 13.6-16.3 N·m (120-144 in-lbs) Muffler screws
h. FLDE,FLHC,FLHCS: Tighten support clamp screw.
Torque: 54.2-67.8 N·m (40-50 ft-lbs) Exhaust support
clamp screw
1
Muffler screw (4)
2
Exhaust bracket
3
Exhaust bracket screw (2)
4
Support clamp screw
5
Flange nut (4)
6
Gasket (2)
Figure 1. Exhaust System (Typical)
1
Muffler screw (2)
2
Exhaust bracket
3
Exhaust bracket screw (2)
5
Flange nut (4)
6
Gasket (2)
Figure 2. Exhaust System (Two Into One)
Disassemble
1. See Figure 1. Remove HO2S (Heated oxygen sensor) (6). See Prepare.
2. Remove exhaust and muffler shields.
a. Remove exhaust and muffler shield clamps (1, 8).
b. Remove exhaust and muffler shields (3, 7, 9, 10).
3. Remove muffler (2). See Prepare.
4. Remove exhaust flange.
a. Remove retaining ring (4).
b. Remove exhaust flange (5).
Assemble
1.
NOTE
Recess in exhaust flange should face engine.
See Figure 1. Install exhaust flange.
a.
Install exhaust flange (5).
b.
Install Retaining ring (4).
2. Install muffler (2). See Prepare.
3. Install exhaust and muffler shields.
a. Install and position exhaust and muffler shields (3,
7, 9, 10).
b. Install exhaust shield clamps (8). Tighten. Torque:
2.3-4.5 N·m (20-40 in-lbs) Exhaust shield clamps
c. Install muffler shield clamps (1). Tighten.
Torque: 2.3-4.5 N·m (20-40 in-lbs) Muffler shield
clamps
4. Install HO2S (6). See Prepare.
1
Muffler shield clamp (4)
2
Muffler (2)
3
Rear exhaust shield
4
Retaining ring (2)
5
Exhaust flange (2)
6
HO2S (Heated oxygen sensor) (2)
7
Front exhaust shield
8
Exhaust shield clamp (6)
9
Intermediate exhaust shield (FXBB, FLSL, FXLR)
10
Muffler shield (2)
Figure 1. Exhaust System (Typical)
Consumables
Description
Part Number
Size
ANTI-SEIZE LUBRICANT
98960-97
29.6 ml (1 fl oz)
Disassemble
1. See Figure 1. Remove HO2S (Heated oxygen sensor) (4). See Prepare.
2. Remove intermediate exhaust shield.
a. Remove screws (7).
b. Remove intermediate exhaust shield (8).
3. Remove front exhaust shield, rear exhaust shield, and muffler shields.
a. Remove exhaust and muffler shield clamps (6, 11).
b. Remove exhaust shields (5, 9, 10).
4. Remove muffler (1). See Prepare.
5. Remove exhaust flange.
a. Remove retaining ring (2).
b. Remove exhaust flange (3).
Assemble
1.
See Figure 1. Install exhaust flange.
NOTE
Recess in exhaust flange should face engine.
a.
Install exhaust flange (3).
b.
Install Retaining ring (2).
2.
Install muffler (1). See Prepare.
3.
Install front exhaust shield, rear exhaust shield, and
muffler shields.
a. Install and position muffler and exhaust shields (5,
9, 10).
b. Install muffler and exhaust shield clamps (6, 11).
Hand tighten.
4.
Install intermediate exhaust shield.
a. Apply anti-seize lubricant to screws (7).
ANTI-SEIZE LUBRICANT (98960-97)
b. Install intermediate exhaust shield (8).
c. Install screws (7). Tighten.
Torque: 8.8-10.8 N·m (78-96 in-lbs) Exhaust
shield screws
5.
Tighten muffler and exhaust shield clamps.
Torque: 2.3-4.5 N·m (20-40 in-lbs) Exhaust shield
clamps
6. Install HO2S (4). See Prepare.
1
Muffler (2)
2
Retaining ring (2)
3
Exhaust flange (2)
4
HO2S (Heated oxygen sensor) (2)
5
Front exhaust shield
6
Exhaust shield clamp (4)
7
Screw (6)
8
Intermediate exhaust shield
9
Muffler shield (2)
10
Rear exhaust shield
11
Muffler shield clamp (2)
Figure 1. Exhaust System: FXFB, FXFBS
Consumables
Description
Part Number
Size
ANTI-SEIZE LUBRICANT
98960-97
29.6 ml (1 fl oz)
Disassemble
1. See Figure 1. Remove HO2S (Heated oxygen sensor)
(Heated oxygen sensor) (2). See Prepare.
2. Remove intermediate exhaust shield.
a. Remove exhaust shield rear clamp (11) and
exhaust shield front clamps (10).
b. Remove intermediate exhaust shield (9).
3. Remove front exhaust shield, rear exhaust shield, and
muffler shield.
a. Remove exhaust and muffler shield clamps (3, 12).
b. Remove shields (2, 8, 13).
4. Remove muffler (1). See Prepare
5. Remove exhaust flanges.
a.
Remove retaining rings (5).
b.
Remove exhaust flanges (4).
Assemble
1.
NOTE
Recess in exhaust flange should face engine.
See Figure 1. Install exhaust flanges.
a.
Install exhaust flanges (4).
b.
Install Retaining rings (5).
2. Install muffler (1). See Prepare.
3. Install front exhaust shield, rear exhaust shield, and
muffler shields.
a. Install and position muffler and exhaust shields (2,
8, 13).
b. Install muffler and exhaust shield clamps (3, 12).
Hand tighten.
4. Install intermediate exhaust shield.
a. Apply anti-seize lubricant to screws (7).
ANTI-SEIZE LUBRICANT (98960-97)
b. Install intermediate exhaust shield (9).
c. Install exhaust shield rear clamp (11) and exhaust
shield front clamps (10).
5. Tighten muffler and exhaust shield clamps. Torque:
8.8-10.8 N·m (78-96 in-lbs) Exhaust shield clamps
6. Install HO2S (6). See Prepare.
1
Muffler
2
Rear exhaust Shield
3
Exhaust shield clamp (4)
4
Exhaust flange (2)
5
Retaining ring (2)
6
HO2S (Heated oxygen sensor) (2)
7
Header assembly
8
Front exhaust shield
9
Intermediate exhaust shield
10
Intermediate exhaust shield front clamp (2)
11
Intermediate exhaust shield rear clamp
12
Muffler shield clamp (2)
13
Muffler shield
Figure 1. Exhaust System (Two Into One)
1. Connect front and rear HO2S (Heated oxygen sensor)
connectors. See Prepare.
2. If removed install right foot support bracket. See Remove
and Install: Forward Foot Controls.
3. Install main fuse. See Main Fuse.
1. Remove main fuse. See Main Fuse.
2. Remove right side cover. See Remove.
3. Remove battery. See Prepare.
4. Remove battery tray. See Prepare.
1. See Purge Solenoid. Remove purge solenoid.
a. Disconnect purge solenoid connector (2).
b. Remove solenoid-to-induction module and canister-to-solenoid lines (3, 4) from purge solenoid (1).
c. Remove purge solenoid.
1. See Figure 1. Install purge solenoid.
a. Install purge solenoid (1).
b. Install solenoid-to-induction module and canister-to-solenoid lines (3, 4).
c. Connect purge solenoid connector (2).
1
Purge solenoid
2
Purge solenoid connector
3
Solenoid-to-induction module line
4
Canister-to-solenoid line
5
BCM caddy
Figure 1. Purge Solenoid
1. Install battery tray. See Prepare.
2. Install battery. See Prepare.
3. Install right side cover. See Remove.
4. Install main fuse. See Main Fuse.
1. See Charcoal Canister. Remove charcoal canister and bracket assembly.
a. Remove lines (4, 5) from charcoal canister.
b. Remove screws (3).
c. Remove charcoal canister (1) and bracket (2).
NOTE
If charcoal canister is removed from bracket, a new charcoal canister and screws are required for installation.
2. If necessary, remove charcoal canister from bracket.
a. Remove and discard screws (6).
b. Discard charcoal canister.
1. See Figure 1. If removed, install charcoal canister to
bracket.
a. Install new charcoal canister (1) onto bracket (2).
b. Install new screws (6). Tighten.
Torque: 3.4-4.1 N·m (30-36 in-lbs) Charcoal canister
to bracket screws
2. Install charcoal canister and bracket assembly.
a. Install charcoal canister and bracket assembly
b. Install screws (3). Tighten.
Torque: 8.1-10.8 N·m (72-96 in-lbs) Charcoal
canister bracket to engine case screws
c. Install lines (4,5).
1
Charcoal canister
2
Bracket
3
Screw (2)
4
Canister-to-solenoid line
5
Vapor valve-to-canister line
6
screw (2)
Figure 1. Charcoal Canister
1. Remove right side cover. See Remove.
2. Remove main fuse. See Main Fuse.
3. Remove battery. See Prepare.
4. Remove battery tray. See Prepare.
NOTE
Air cleaner removal and lifting rear of fuel tank is only necessary for replacing purge solenoid to induction module line.
5. Remove air cleaner. See Remove.
6. Remove air cleaner backplate assembly. See Prepare.
7. Lift rear of fuel tank. See Prepare.
1. Remove vapor valve-to-canister line.
a. See Purge Lines. Disconnect vapor valve-to-canister line (4) from vapor valve (5).
b. See Purge Lines at Canister. Disconnect vapor valve-to-canister line (2) from charcoal canister (3).
c. Remove vapor valve-to-canister line.
2. Remove canister-to-solenoid line.
a. Disconnect canister-to-solenoid line (1) from charcoal canister (3).
b. See Purge Lines. Disconnect canister-to-solenoid line (1) from purge solenoid (2).
3. Remove solenoid-to-induction module line.
a. Remove solenoid-to-induction module line (3) from purge solenoid (2).
b. Remove solenoid-to-induction module line from induction module.
1. Install vapor valve-to-canister line.
a. See Figure 1. Install vapor valve-to-canister line (4) to charcoal canister (3).
b. See Figure 2. Install valve-to-canister line to vapor valve (5).
2. Install canister to solenoid line.
a. See Figure 1. Install canister-to-solenoid line (1) to charcoal canister (3).
b. See Figure 2. Install canister-to-solenoid line to purge solenoid (2).
3. Install solenoid-to-induction module line.
a. Install solenoid-to-induction module line (3) to induction module.
b. Install solenoid-to-induction module line to purge solenoid (2).
1
Canister-to-solenoid line
2
Vapor valve-to-canister line
3
Charcoal canister
Figure 1. Purge Lines at Canister
1
Canister-to-solenoid line
2
Purge solenoid
3
Solenoid-to-induction module line
4
Vapor valve-to-canister line
5
Vapor valve
Figure 2. Purge Lines
1. Secure fuel tank. See Prepare.
2. Install air cleaner backplate assembly. See Prepare.
3. Install air cleaner. See Remove.
4. Install battery tray. See Prepare.
5. Install battery. See Prepare.
6. Install right side cover. See Remove.
7. Install main fuse. See Main Fuse.
FASTENER
TORQUE VALUE
NOTES
ACR
23-26.4 N·m
7.38 AUTOMATIC COMPRESSION
(17-19 ft-lbs)
RELEASE (ACR), Install
Auxiliary lamp bezel nut
0.67-1.12 N·m
7.21 AUXILIARY LAMPS, Bulb
(6-10 in-lbs)
Replacement
Auxiliary lamp nut
20.3-24.4 N·m
7.21 AUXILIARY LAMPS, Remove
(15-18 ft-lbs)
and Install: Standard Lighting
Auxiliary lamp nut
20.3-24.4 N·m
7.21 AUXILIARY LAMPS, Remove
(15-18 ft-lbs)
and Install: Integrated LED Lighting
Auxiliary lamp nut (FLDE)
20.3-24.4 N·m
7.21 AUXILIARY LAMPS, Adjust
(15-18 ft-lbs)
Auxiliary lamp nut (FLHC)
25.7-31.1 N·m
7.21 AUXILIARY LAMPS, Adjust
(19-23 ft-lbs)
Battery tray screw
8.1-12.2 N·m
7.48 BATTERY TRAY, Install
(6-9 ft-lbs)
Battery, negative cable, screw
8-12 N·m
7.4 POWER DISCONNECT,
(6-9 ft-lbs)
Negative Battery Cable
Brake line clamp screw
4.1-5.4 N·m
7.11 LEFT HAND CONTROL
(36-48 in-lbs)
MODULE (LHCM), Install
Brake line clamp screw
4.1-5.4 N·m
7.12 RIGHT HAND CONTROL
(36-48 in-lbs)
MODULE (RHCM), Install
Brake line clamp screw
4.1-5.4 N·m
7.43 FRONT ELECTRICAL CADDY,
(36-48 in-lbs)
Install
Brake line clamp screw
4.1-5.4 N·m
7.51 BACKBONE WIRE HARNESS,
(36-48 in-lbs)
Install
Cover, under seat frame, large screw
10.9-13.6 N·m
7.51 BACKBONE WIRE HARNESS,
(96-120 in-lbs)
Install
Cover, under seat frame, small screw
2.3-3.4 N·m
7.51 BACKBONE WIRE HARNESS,
(20-30 in-lbs)
Install
ECM caddy large screw
4.1-6.8 N·m
7.45 ECM CADDY, Install
(36-60 in-lbs)
ECM caddy small screw
6.2-6.8 N·m
7.45 ECM CADDY, Install
(55-60 in-lbs)
ET sensor
14.9-21.2 N·m
7.36 ENGINE TEMPERATURE (ET)
(11-16 ft-lbs)
SENSOR, Install
Fender Support, Screw
57-62 N·m
7.23 REAR TURN SIGNAL LAMPS,
(42-46 ft-lbs)
Remove and Install: Fender Mount
Fender Support, Screw
57-62.3 N·m
7.26 LICENSE PLATE LAMP,
(42-46 ft-lbs)
Remove and Install: Side Mount
Fender Support, Screw
28-37 N·m
7.26 LICENSE PLATE LAMP,
(21-27 ft-lbs)
Remove and Install: Side Mount
Frame ground stud nut
5.7-10.2 N·m
7.45 ECM CADDY, Install
(50-90 in-lbs)
Frame ground stud nut
5.6-10.2 N·m
7.49 ENGINE GROUND CABLE,
(50-90 in-lbs)
Install
Frame ground stud nut
5.6-10.2 N·m
7.52 MAIN WIRE HARNESS, Install
(50-90 in-lbs)
Front light bar mounting screw
27.1-33.9 N·m
7.20 FRONT LIGHT BAR, Remove
(20-25 ft-lbs)
and Install: Standard Lighting
Front light bar mounting screw
27.1-33.9 N·m
7.20 FRONT LIGHT BAR, Remove
(20-25 ft-lbs)
and Install: Integrated LED Lighting
Front light bar, bracket screw
21.7-27.1 N·m
7.20 FRONT LIGHT BAR, Remove
(16-20 ft-lbs)
and Install: Standard Lighting
Front light bar, clamp screw
0.67-1.1 N·m
7.20 FRONT LIGHT BAR, Remove
(6-10 in-lbs)
and Install: Standard Lighting
Handlebar switch assembly retainer
0.9-1.1 N·m
7.11 LEFT HAND CONTROL
screws
(8-10 in-lbs)
MODULE (LHCM), Install
Handlebar switch assembly retainer
0.9-1.1 N·m
7.11 LEFT HAND CONTROL
screws
(8-10 in-lbs)
MODULE (LHCM), Clutch Switch
Replacement
Handlebar switch assembly retainer
0.9-1.1 N·m
7.12 RIGHT HAND CONTROL
screws
(8-10 in-lbs)
MODULE (RHCM), Install
Handlebar switch assembly retainer
0.9-1.1 N·m
7.12 RIGHT HAND CONTROL
screws
(8-10 in-lbs)
MODULE (RHCM), Front Brake
Switch Replacement
Handlebar switch housing screws
4-5.1 N·m
7.11 LEFT HAND CONTROL
(35-45 in-lbs)
MODULE (LHCM), Install
Handlebar switch housing screws
4-5.1 N·m
7.12 RIGHT HAND CONTROL
(35-45 in-lbs)
MODULE (RHCM), Install
Handlebar-mounted turn signal, ball
5.6-7.9 N·m
7.22 FRONT TURN SIGNAL LAMPS,
stud locknut
(50-70 in-lbs)
Remove and Install: Handlebar
Mount
Handlebar-mounted turn signal, ball
4-6.7 N·m
7.22 FRONT TURN SIGNAL LAMPS,
stud set screw
(3-5 ft-lbs)
Remove and Install: Handlebar
Mount
Headlamp (Oblong) mounting screw
13.5-17.6 N·m
7.19 HEADLAMP, Bulb Replacement:
(10-13 ft-lbs)
Oblong
Headlamp FLDE, FLHC, FLSB
25-40.6 N·m
7.19 HEADLAMP, Adjust
horizontal adjustment screw
(18-30 ft-lbs)
Headlamp FLDE, FLHC, FLSL,
36.6-43.3 N·m
7.19 HEADLAMP, Adjust
FXBB, FXLR, FLSB vertical
(27-32 ft-lbs)
adjustment screw
Headlamp FXBB, FXLR horizontal
29.8-37.9 N·m
7.19 HEADLAMP, Adjust
adjustment screw
(22-28 ft-lbs)
Headlamp FXBR/S vertical
13.5-17.6 N·m
7.19 HEADLAMP, Adjust
adjustment screw
(10-13 ft-lbs)
Headlamp FXFB/S vertical
14.9-19 N·m
7.19 HEADLAMP, Adjust
adjustment screw
(11-14 ft-lbs)
Headlamp bezel screw
1-1.6 N·m
7.19 HEADLAMP, Bulb Replacement:
(9-14 in-lbs)
Standard Round
Headlamp ground strap screw
8.8-10.8 N·m
7.19 HEADLAMP, Bulb Replacement:
(6.5-8.0 ft-lbs)
Nacelle Mounted
Headlamp isolator bracket screw
8.8-10.8 N·m
7.19 HEADLAMP, Bulb Replacement:
(6.5-8.0 ft-lbs)
Standard Round
Headlamp mounting ring screw
21.6-27.1 N·m
7.19 HEADLAMP, Remove and
(16-20 ft-lbs)
Install: Nacelle Mounted
Headlamp nacelle, screw
21.6-27.1 N·m
7.19 HEADLAMP, Remove and
(16-20 ft-lbs)
Install: Horizontal
Headlamp retainer screw
2-2.5 N·m
7.19 HEADLAMP, Bulb Replacement:
(18-22 in-lbs)
Standard Round
Headlamp, nacelle mounted, bezel
2.8-3.6 N·m
7.19 HEADLAMP, Bulb Replacement:
screw
(25-32 in-lbs)
Nacelle Mounted
Headlamp, nacelle mounted, retainer
1.9-2.8 N·m
7.19 HEADLAMP, Bulb Replacement:
screw
(17-25 in-lbs)
Nacelle Mounted
Headlamp, round, locknut
36.6-43.3 N·m
7.19 HEADLAMP, Remove and
(27-32 ft-lbs)
Install: Standard Round
Headlamp, upper triple clamp
21.6-27.1 N·m
7.19 HEADLAMP, Remove and
mounted, screw
(16-20 ft-lbs)
Install: Oblong
Headlamp, upper triple clamp
15-19 N·m
7.19 HEADLAMP, Remove and
mounted, screw
(11-14 ft-lbs)
Install: Horizontal
Horn, Bracket Screw
7-8 N·m
7.18 HORN, Assemble
(5-6 ft-lbs)
Horn, Narrow Mounting Screw
3-3.7 N·m
7.18 HORN, Install
(27-33 in-lbs)
Horn, Wide Mounting Screw
9.4-12 N·m
7.18 HORN, Install
(7-9 ft-lbs)
Housing to IM screw
2.3-2.8 N·m
7.13 INSTRUMENT MODULE (IM),
(20-25 in-lbs)
Remove and Install: Console Without
Panel
IM screw
1.1-2.3 N·m
7.13 INSTRUMENT MODULE (IM),
(10-20 in-lbs)
Remove and Install: Dual Instrument
IM to upper clamp screw
1.4-1.9 N·m
7.13 INSTRUMENT MODULE (IM),
(12-17 in-lbs)
Remove and Install: Handlebar
Mount
Ignition coil, screw
15-19 N·m
7.9 IGNITION COIL, Install
(11-14 ft-lbs)
Indicator lamp, screw
2.26-3.39 N·m
7.15 INDICATOR LAMPS, Install
(20-30 in-lbs)
JSS screw
2.3-2.8 N·m
7.42 JIFFY STAND SENSOR (JSS),
(20-25 in-lbs)
Install
Knock sensor screw
17.6-23 N·m
7.37 KNOCK SENSOR (KS), Install
(13-17 ft-lbs)
LED signal screw
2.25-3.2 N·m
7.22 FRONT TURN SIGNAL LAMPS,
(20-28 in-lbs)
Bulb Replacement
LED signal screw
2.5-2.9 N·m
7.23 REAR TURN SIGNAL LAMPS,
(22-26 in-lbs)
Bulb Replacement
LED signal screw
4.3-4.7 N·m
7.23 REAR TURN SIGNAL LAMPS,
(38-42 in-lbs)
Bulb Replacement
License Plate Lamp Cover, Screw
0.9-1.8 N·m
7.26 LICENSE PLATE LAMP,
(8-16 in-lbs)
Remove and Install: Side Mount
License plate holder, screw
6.8-9 N·m
7.24 TAIL LAMP, Remove and Install:
(60-80 in-lbs)
License Plate Bracket Mount
License plate holder, screw
9.5-15 N·m
7.26 LICENSE PLATE LAMP,
(84-133 in-lbs)
Remove and Install: License Plate
Bracket Mount
License plate, LED housing, screw
1.1-2.3 N·m
7.26 LICENSE PLATE LAMP,
(10-20 in-lbs)
Remove and Install: License Plate
Bracket Mount
License plate, center mount, lamp
1.1-2.25 N·m
7.26 LICENSE PLATE LAMP, Bulb
housing screw
(10-20 in-lbs)
Replacement
License plate, center mount, lamp
1.1-2.25 N·m
7.26 LICENSE PLATE LAMP,
housing screw
(10-20 in-lbs)
Remove and Install: Center Mount
License plate, center mount, tail lamp
1.1-2.25 N·m
7.24 TAIL LAMP, Remove and Install:
screw
(10-20 in-lbs)
Center Mount
License plate, tail lamp, screw
1.1-2.3 N·m
7.24 TAIL LAMP, Remove and Install:
(10-20 in-lbs)
License Plate Bracket Mount
Lightbar, front, cover screw
2.25-3.2 N·m
7.22 FRONT TURN SIGNAL LAMPS,
(20-28 in-lbs)
Bulb Replacement
Lightbar, front, screw
27.1-33.9 N·m
7.22 FRONT TURN SIGNAL LAMPS,
(20-25 ft-lbs)
Bulb Replacement
Oblong headlamp isolator screw
3.7-4.8 N·m
7.19 HEADLAMP, Remove and
(3-4 ft-lbs)
Install: Oblong
Oblong headlamp wireform screw
13.5-16.2 N·m
7.19 HEADLAMP, Remove and
(10-12 ft-lbs)
Install: Oblong
Rear Turn Signal, Center Mount,
20-24 N·m
7.23 REAR TURN SIGNAL LAMPS,
Screw
(15-18 ft-lbs)
Remove and Install: Center Mount
Rear Turn Signal, Fender Mount,
20-24 N·m
7.23 REAR TURN SIGNAL LAMPS,
Screw
(15-18 ft-lbs)
Remove and Install: Fender Mount
Rear Turn Signal, Fender Mount,
20-24 N·m
7.23 REAR TURN SIGNAL LAMPS,
Screw
(15-18 ft-lbs)
Remove and Install: Fender Mount
Rear Turn Signal, Fender Mount,
20-24 N·m
7.26 LICENSE PLATE LAMP,
Screw
(15-18 ft-lbs)
Remove and Install: Side Mount
Rear Turn Signal, Fender Support,
28-37 N·m
7.23 REAR TURN SIGNAL LAMPS,
Screw
(21-27 ft-lbs)
Remove and Install: Fender Mount
Rear Turn Signal, Light Bar Mount,
22-27 N·m
7.23 REAR TURN SIGNAL LAMPS,
Screw
(16-20 ft-lbs)
Remove and Install: Light Bar Mount
Rear fork clamp screw
2.71-4.07 N·m
7.41 REAR WHEEL SPEED
(24-36 in-lbs)
SENSOR (WSS), Install
Rear lightbar bottom cover screw
5.4-5.9 N·m
7.23 REAR TURN SIGNAL LAMPS,
(48-52 in-lbs)
Bulb Replacement
Rear lightbar bottom cover screw
4.3-4.7 N·m
7.23 REAR TURN SIGNAL LAMPS,
(38-42 in-lbs)
Bulb Replacement
Rear stoplamp switch
16.3-20.3 N·m
7.25 REAR STOPLAMP SWITCH,
(12-15 ft-lbs)
Install
Sensor, CKP, screw
10.2-13.6 N·m
7.35 CRANKSHAFT POSITION
(90-120 in-lbs)
SENSOR (CKP), Install
Sensor, vehicle speed, screw
11.3-13.6 N·m
7.39 VEHICLE SPEED SENSOR
(100-120 in-lbs)
(VSS), Install
Solenoid nut
7.9-11.8 N·m
7.5 STARTER, Install
(70-104 in-lbs)
Starter, mounting screw
29.8-32.5 N·m
7.5 STARTER, Install
(22-24 ft-lbs)
Stator mounting screws
6.2-8.5 N·m
7.6 ALTERNATOR, Install
(55-75 in-lbs)
Always use new screws
Sub caddy screw
4.1-6.8 N·m
7.28 ELECTRONIC CONTROL
(36-60 in-lbs)
MODULE (ECM), Install
Switch, Neutral Indicator
13.6-20.3 N·m
7.17 NEUTRAL INDICATOR
(120-180 in-lbs)
SWITCH, Install
Switch, Oil Pressure
17-23 N·m
7.16 OIL PRESSURE SWITCH,
(13-17 ft-lbs)
Install
Tail Lamp Lens Screw
2.3-2.7 N·m
7.24 TAIL LAMP, Bulb Replacement
(20-24 in-lbs)
Tail Lamp, Standard, Base Screw
4.5-5.4 N·m
7.24 TAIL LAMP, Remove and Install:
(40-48 in-lbs)
Standard
Tail Lamp, Standard, Lens Screw
2.3-2.7 N·m
7.24 TAIL LAMP, Remove and Install:
(20-24 in-lbs)
Standard
Tail Lamp, Tombstone, Screw
11-14 N·m
7.24 TAIL LAMP, Remove and Install:
(8-10 ft-lbs)
Tombstone
Tail lamp lens screw
2.3-2.7 N·m
7.24 TAIL LAMP, Remove and Install:
(20-24 in-lbs)
Standard
Tail lamp, circuit board screw
4.5-5.4 N·m
7.24 TAIL LAMP, Remove and Install:
(40-48 in-lbs)
Standard
Transmission ground stud nut
8.1-10.9 N·m
7.49 ENGINE GROUND CABLE,
(72-96 in-lbs)
Install
USB caddy screw
1.6-1.9 N·m
7.44 USB CADDY, Assemble
(14-17 in-lbs)
Voltage regulator, screw
12-14 N·m
7.7 VOLTAGE REGULATOR, Install
(106-124 in-lbs)
Wide mounting screw
12-15 N·m
7.44 USB CADDY, Install
(106-133 in-lbs)
tachometer screw
1.1-2.3 N·m
7.14 TACHOMETER, Install
(10-20 in-lbs)
Table 1. Battery Specifications
BATTERY
SPECIFICATIONS
Size
12 V/ 17.5 Ah/315 CCA
Type
Sealed, AGM (Absorbed glass mat) battery
Table 2. Starter Specifications
STARTER
SPECIFICATIONS
Cranking current
250 A maximum
Free current
90 A maximum
Table 3. Alternator Specifications
ALTERNATOR
VALUE
Three phase
42 A system
AC voltage output
16-28 VAC per 1,000 rpm
Stator coil resistance
0.1-0.3 Ω
Table 4. Spark Plug Cables
LOCATION
LENGTH
RESISTANCE
Left front and rear
187-194 mm (7.36-7.64 in)
1,840-5,085 Ω
Right front and rear
381-387 mm (15.00-15.24 in)
3,750-10,070 Ω
Table 5. Regulator Specifications
REGULATOR
VALUE
Amperes @ 3,600 rpm
40-44 A
Voltage @ 3,600 rpm
14.1-14.5 V @ 24 °C (75.2 °F)
Table 6. Fuse Specifications
ITEM
RATING
Main
40 A
Battery
5 A
Battery tender
7.5 A
System
7.5 A
Table 7. Ignition Coil Specifications
WINDING
RESISTANCE
Primary resistance
0.2-0.5 Ω
Secondary resistance
5,500-8,000 Ω
Table 8. Spark Plug Cables
LOCATION
LENGTH
RESISTANCE
Left front and rear
187-194 mm (7.36-7.64 in)
1,840-5,085 Ω
Right front and rear
381-387 mm (15.00-15.24 in)
3,750-10,070 Ω
1. Remove left side cover. See Remove.
Fuses
1. Remove fuse block from ECM (Electronic control module) sub caddy.
2. See Fuses. Remove fuse cover (4).
3. Remove fuse (1, 2 or 3).
Fuses
1. See Figure 1 and Figure 2. Install fuse (1, 2 or 3).
2. Install fuse cover (4).
3. Install fuse block onto ECM (Electronic control module) sub caddy.
1
Fuse, battery tender
2
Fuse, battery
3
Fuse, main
4
Fuse cover
Figure 1. Fuses
1
Battery tender
2
Battery
3
Main
Figure 2. Fuse Block
1. Install left side cover. See Remove.
WARNING
Be sure that all lights and switches operate properly
before operating motorcycle. Low visibility of rider
can result in death or serious injury. (00316a)
2. Test affected circuit for proper operation.
Remove main fuse when there is a possibility of injury caused by accidental vehicle start-up or electrical equipment
damage.
Remove Main Fuse
1. Models with security:
a. Verify that fob is present.
b. Turn OFF/RUN switch to RUN.
2. Remove left side cover. See Remove.
WARNING
To prevent accidental vehicle start-up, which
could cause death or serious injury, remove main
fuse before proceeding. (00251b)
3. See Figure 1. Remove fuse cover (2).
a. Remove fuse block from ECM (Electronic control
module) sub caddy.
b. Remove fuse cover.
4. Remove main fuse (1).
5. Models with security: Turn ignition switch OFF.
Install Main Fuse
1. See Figure 1. Install main fuse (1).
2. Install fuse cover (2).
3. Install fuse block onto ECM sub caddy.
4. Install left side cover. See Remove.
WARNING
Be sure that all lights and switches operate
properly before operating motorcycle. Low
visibility of rider can result in death or serious
injury. (00316a)
5. Test affected circuits for proper operation.
1
Fuse
2
Fuse cover
Figure 1. Main Fuse
Disconnect negative battery cable when there is a possibility of injury caused by starter engagement (engine rotation).
Disconnect Negative Battery Cable
1. Models with security:
a. Verify that fob is present.
b. Turn OFF/RUN switch to RUN.
2. Remove right side cover. See Remove.
WARNING
To prevent accidental vehicle start-up, which
could cause death or serious injury, disconnect
negative (-) battery cable before proceeding.
(00048a)
3. See Figure 1. Remove screw (1).
4. Disconnect negative battery cable (2).
5. Models with security: Turn ignition switch OFF.
Connect Negative Battery Cable
1. See Figure 1. Connect negative battery cable (2).
2. Install screw (1). Tighten
Torque: 8.1-10.8 N·m (72-96 in-lbs) Battery, negative
cable, screw
3. Install right side cover. See Remove.
WARNING
Be sure that all lights and switches operate
properly before operating motorcycle. Low
visibility of rider can result in death or serious
injury. (00316a)
4. Test affected circuits for proper operation.