2013 HD Softail Service Manual

2013 Harley-Davidson Softail ModelsService Manual

99482-13A2013 H-D.

Harley-Davidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standardsand U.S.A. Environmental Protection Agency regulations effective on the date of manufacture.

To maintain the safety, dependability, and emission and noise control performance, it is essential thatthe procedures, specifications and service instructions in this manual are followed.

Any substitution, alteration or adjustment of emission system and noise control components outside offactory specifications may be prohibited by law.

IMPORTANT NOTICE

Harley-Davidson Motor Company

2013 Harley-Davidson SoftailModels Service Manual

2013 H-D.ALL RIGHTS RESERVED

99482-13A

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITEhttp://www.harley-davidson.com

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Please clip out and mail to:Service Communications DepartmentHarley-Davidson Motor CompanyP.O. Box 653Milwaukee, WI USA 53201

The Harley-Davidson Service Communications Department maintains a continuous effort to improve the qualityand usefulness of its publications. To do this effectively, we need user feedback - your critical evaluation ofthis manual.

2013 Harley-Davidson Softail Models Service Manual (99482-13A)

ABOUT THIS MANUALGENERALThis service manual has been prepared with the followingpurposes in mind:

To acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basicmaintenance and repair.

To introduce the professional Harley-Davidson technicianto the latest field-tested and factory-approved major repairmethods.

We sincerely believe that this service manual will make yourassociation with Harley-Davidson products more pleasant andprofitable.

HOW TO USE YOUR SERVICE MANUALRefer to the table below for the content layout of this manual.

CHAPTERNO.

Maintenance1

Chassis2

Engine3

Fuel System4

Drive5

Transmission6

Electrical7

Appendix A Connector RepairA

Appendix B WiringB

Appendix C ABSC

Appendix D ConversionsD

Appendix E GlossaryE

Use the TABLE OF CONTENTS (which follows this FORE-WORD) and the INDEX (at the back of this manual) to quicklylocate subjects. Chapters and topics in this manual aresequentially numbered for easy navigation.

For example, a cross-reference shown as 2.2SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.2SPECIFICATIONS.

For quick and easy reference, all pages contain a chapternumber followed by a page number. For example, page 3-5refers to page 5 in Chapter 3.

A number of acronyms and abbreviations are used in thisdocument. See the E.1 GLOSSARY for a list of acronyms,abbreviations and definitions.

PREPARATION FOR SERVICE

TOOL NAMEPART NUMBER

DIGITAL TECHNICIAN IIHD-48650

Stop the engine when refueling or servicing the fuelsystem. Do not smoke or allow open flame or sparks neargasoline. Gasoline is extremely flammable and highlyexplosive, which could result in death or serious injury.(00002a)

Good preparation is very important for efficient service work.Start each job with a clean work area. This will allow the repairto proceed as smoothly as possible. It will also reduce theincidence of misplaced tools and parts.

Clean a motorcycle that is excessively dirty before work starts.Cleaning will occasionally uncover sources of trouble. Gatherany tools, instruments and any parts needed for the job beforework begins. Interrupting a job to locate tools or parts is a dis-traction and causes needless delay.

NOTES

To avoid unnecessary disassembly, carefully read allrelated service information before repair work begins.

In figure legends, the number which follows the name ofa part indicates the quantity necessary for one completeassembly.

When servicing a vehicle equipped with the Harley-Dav-idson Smart Security System (H-DSSS), first disarm thesystem. Keep the fob close to the vehicle or use DIGITALTECHNICIAN II (Part No. HD-48650) to disable thesystem. Activate the system after service is completed.

SERVICE BULLETINSIn addition to the information presented in this manual, Harley-Davidson Motor Company will periodically issue service bul-letins to Harley-Davidson dealers. Service bulletins coverinterim engineering changes and supplementary information.Consult the service bulletins to keep your product knowledgecurrent and complete.

USE GENUINE REPLACEMENT PARTS

Harley-Davidson parts and accessories are designed forHarley-Davidsonmotorcycles. Using non-Harley-Davidsonparts or accessories can adversely affect performance,stability or handling, which could result in death or seriousinjury. (00001b)

To achieve satisfactory and lasting repairs, carefully follow theservice manual instructions and use only genuine Harley-Davidson replacement parts. Behind the emblem bearing thewords GENUINE HARLEY-DAVIDSON stand more than 100years of design, research, manufacturing, testing and inspectingexperience. This is your assurance that the parts you are usingwill fit right, operate properly and last longer.

I

FOREWORD

WARNINGS AND CAUTIONSStatements in this manual preceded by the following wordsare of special significance.

WARNING indicates a potentially hazardous situationwhich, if not avoided, could result in death or seriousinjury. (00119a)

CAUTION indicates a potentially hazardous situationwhich,if not avoided, may result in minor or moderate injury.(00139a)

NOTICE indicates a potentially hazardous situation which,if not avoided, may result in property damage. (00140b)

NOTE

Refers to important information, and is placed in italic type. Itis recommended that you take special notice of these items.

Proper service and repair is important for the safe, reliableoperation of all mechanical products. The service proceduresrecommended and described in this manual are effectivemethods for performing service operations.

Always wear proper eye protection when using hammers,arbor or hydraulic presses, gear pullers, spring com-pressors, slide hammers and similar tools. Flying partscould result in death or serious injury. (00496b)

Some of these service operations require the use of toolsspecially designed for the purpose. These special tools shouldbe used when and as recommended. It is important to notethat somewarnings against the use of specific servicemethods,which could damage the motorcycle or render it unsafe, arestated in this manual. However, remember that these warningsare not all-inclusive. Inadequate safety precautions could resultin death or serious injury.

Since Harley-Davidson could not possibly know, evaluate oradvise the service trade of all possible ways in which servicemight be performed, or of the possible hazardous con-sequences of each method, we have not undertaken any suchbroad evaluation. Accordingly, anyone who uses a serviceprocedure or tool which is not recommended by Harley-Dav-idson must first thoroughly satisfy himself that neither his northe operator's safety will be jeopardized as a result. Failure todo so could result in death or serious injury.

PRODUCT REFERENCES

Read and follow warnings and directions on all products.Failure to follow warnings and directions can result indeath or serious injury. (00470b)

When reference is made in this manual to a specific brandname product, tool or instrument, an equivalent product, toolor instrument may be substituted.

Kent-Moore ProductsAll tools mentioned in this manual with an "HD", "J" or "B"prefacemust be ordered through SPXKent-Moore. For orderinginformation or product returns, warranty or otherwise, visitwww.spx.com.

LOCTITE Sealing and THREADLOCKINGProductsSome procedures in this manual call for the use of LOCTITEproducts. If you have any questions regarding LOCTITE productusage or retailer/wholesaler locations, contact Loctite Corp. atwww.loctite.com.

PRODUCT REGISTERED MARKSApple, Alcantara S.p.A., Allen, Amp Multilock, Bluetooth,Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E.Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod,Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Magnaflux,Marson Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin,MPZ, Mulitilock, nano, NGK, Novus, Packard, Pirelli, Permatex,Philips, PJ1, Pozidriv, Robinair, S100, Sems, Snap-on, Teflon,Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch,Velcro, X-Acto, XM Satellite Radio, and zmo are among thetrademarks of their respective owners.

H-D MICHIGAN, INC. TRADEMARKINFORMATIONBar & Shield, Cross Bones, Digital Tech, Digital Technician,Digital Technician II, Dyna, Electra Glide, Evolution, Fat Bob,Fat Boy, Forty-Eight, Glaze, Gloss, H-D, H-Dnet.com, Harley,Harley-Davidson, HD, Heritage Softail, Iron 883, Low Rider,Night Rod, Nightster, Night Train, Profile, Revolution, RoadGlide, Road King, Road Tech, Rocker, Screamin' Eagle, Sev-enty-Two, Softail, Sportster, Street Glide, Street Rod, Sun Ray,Sunwash, Super Glide, SuperLow, Switchback, SYN3, Tech-Link, TechLink II, Tour-Pak, Twin Cam 88, Twin Cam 88B,Twin Cam 96, Twin Cam 96B, Twin Cam 103, Twin Cam 103B,Twin Cam 110, Twin Cam 110B, Ultra Classic, V-Rod, VRSCand Harley-Davidson Genuine Motor Parts and Genuine MotorAccessories are among the trademarks of H-D Michigan, Inc.

CONTENTSAll photographs, illustrations and procedures may not neces-sarily depict the most current model or component, but arebased on the latest production information available at the timeof publication.

Since product improvement is our continual goal, Harley-Dav-idson reserves the right to change specifications, equipmentor designs at any time without notice and without incurringobligation.

II FOREWORD

MAINTENANCE

1.1 FASTENER TORQUE VALUESFastener Torque Values in this Chapter..............................1-1

1.2 GENERALServicing a New Motorcycle...............................................1-4Safe Operating Maintenance..............................................1-4Disposal and Recycling......................................................1-4Shop Practices....................................................................1-4

Repair Notes................................................................1-4Safety..........................................................................1-4Removing Parts...........................................................1-4Cleaning......................................................................1-4Disassembly and Assembly........................................1-5Checking Torques on Fasteners..................................1-5Magnetic Parts Trays...................................................1-5

Repair and Replacement Procedures................................1-5Hardware and Threaded Parts....................................1-5Threadlocking Agents..................................................1-5Wiring, Hoses and Lines.............................................1-5Instruments and Gauges.............................................1-5Bearings......................................................................1-5Bushings......................................................................1-5Gaskets.......................................................................1-5Lip-Type Seals.............................................................1-6O-Rings.......................................................................1-6Gears...........................................................................1-6Shafts..........................................................................1-6Part Replacement........................................................1-6

Cleaning..............................................................................1-6Part Protection.............................................................1-6Cleaning Process........................................................1-6Rust or Corrosion Removal.........................................1-6Bearings......................................................................1-6

Tool Safety..........................................................................1-6Air Tools.......................................................................1-6Wrenches....................................................................1-6Pliers/Cutters/Pry Bars................................................1-7Hammers.....................................................................1-7Punches/Chisels..........................................................1-7Screwdrivers................................................................1-7Ratchets and Handles.................................................1-7Sockets........................................................................1-7Storage Units...............................................................1-7

1.3 FUEL AND OILFuel.....................................................................................1-8Gasoline Blends..................................................................1-8Engine Lubrication..............................................................1-8Winter Lubrication...............................................................1-9

1.4 BULB REQUIREMENTSGeneral.............................................................................1-10

1.5 MAINTENANCE SCHEDULEGeneral.............................................................................1-11

Disposal and Recycling.............................................1-11

1.6 ENGINE OIL AND FILTERChecking and Adding Oil..................................................1-16

Type of Oil.................................................................1-16Checking Oil Level.....................................................1-16

Changing Oil and Filter.....................................................1-16

1.7 AIR CLEANER AND EXHAUST SYSTEMRemoval............................................................................1-18

Cleaning and Inspection............................................1-18Installation.........................................................................1-19Exhaust System Leak Check............................................1-20

Exhaust System Leakage..........................................1-20

1.8 TIRES AND WHEELSGeneral.............................................................................1-21Tires..................................................................................1-21Tire Replacement.............................................................1-22

Inspection..................................................................1-22When To Replace Tires.............................................1-22

Wheel Bearings................................................................1-22Wheel Spokes...................................................................1-22

Identify Wheel Spoke Groups....................................1-23Wheel Spoke Adjustment..........................................1-23

1.9 PRIMARY CHAINCASE LUBRICANTGeneral.............................................................................1-24Changing Primary Chaincase Lubricant...........................1-24

1.10 TRANSMISSION LUBRICANTTransmission Lubricant.....................................................1-26Changing Transmission Lubricant....................................1-26

1.11 CLUTCHAdjustment........................................................................1-28

1.12 DRIVE BELT AND SPROCKETSGeneral.............................................................................1-30Cleaning............................................................................1-30Inspection.........................................................................1-30

Sprockets...................................................................1-30Drive Belt...................................................................1-30

Checking Belt Deflection...................................................1-31Adjusting Belt Deflection...................................................1-32

1.13 THROTTLE CABLESCable Inspection, Lubrication and Adjustment.................1-34

Inspection and Lubrication........................................1-34Adjustment.................................................................1-34

1.14 CABLE AND CHASSIS LUBRICATIONGeneral.............................................................................1-36Cables and Hand Levers..................................................1-36Jiffy Stand.........................................................................1-36Steering Head Bearings....................................................1-36

1.15 BRAKESFluid Inspection.................................................................1-37Rear Brake Pedal.............................................................1-37

Pedal Height..............................................................1-37Pedal Lubrication.......................................................1-37Pedal Pad..................................................................1-37

Brake Lines Inspection.....................................................1-37

1.16 BRAKE PADS AND DISCSInspection.........................................................................1-39

Brake Pads................................................................1-39Brake Disc.................................................................1-39

Brake Pad Replacement...................................................1-40Rear Brake Caliper....................................................1-40Front Brake Caliper...................................................1-41

III

TABLE

OFCONTE

NTS

1.17 SPARK PLUGSRemoval............................................................................1-43Inspection.........................................................................1-43Cleaning............................................................................1-43Installation.........................................................................1-43Spark Plug Cable Inspection............................................1-44

1.18 STEERING HEAD BEARINGSAdjustment: FLSTC, FLSTF/B, FLSTN, FLS....................1-45

Bearing Adjustment (Fall-away)................................1-45Adjustment: FXST, FXS....................................................1-46

Bearing Adjustment (Fall-away)................................1-46Adjustment: FXSB............................................................1-48

Bearing Adjustment (Fall-away)................................1-48Lubrication........................................................................1-49

1.19 CRITICAL FASTENERSInspection.........................................................................1-50

Checking Fastener Torque........................................1-50

1.20 BATTERY MAINTENANCEGeneral.............................................................................1-51Cleaning and Inspection...................................................1-52Voltmeter Test...................................................................1-52

Voltmeter Test............................................................1-52Charging Battery...............................................................1-52

Safety Precautions....................................................1-52Using a Battery Charger............................................1-52

Disconnection and Removal.............................................1-53Storage.............................................................................1-53Installation and Connection..............................................1-54

1.21 HEADLAMP ALIGNMENTHeadlamp Alignment........................................................1-56Headlamp Adjustment......................................................1-56

1.22 SUSPENSION ADJUSTMENTSShock Absorbers..............................................................1-58

Calculate Number of Turns........................................1-58Adjustment.................................................................1-58

1.23 STORAGEGeneral.............................................................................1-59Placing in Storage.............................................................1-59Removal from Storage......................................................1-59

1.24 TROUBLESHOOTINGGeneral.............................................................................1-61Engine...............................................................................1-61

Starter Motor Does Not Operate or Does Not Turn EngineOver ..........................................................................1-61Engine Turns Over But Does Not Start ....................1-61Starts Hard................................................................1-61Starts But Runs Irregularly or Misses .......................1-61A Spark Plug Fouls Repeatedly................................1-62Pre-Ignition or Detonation (Knocks or Pings)............1-62Overheating...............................................................1-62Valve Train Noise.......................................................1-62Excessive Vibration...................................................1-62Check Engine Light Illuminates During Operation.....1-62

Lubrication System...........................................................1-62

Oil Does Not Return To Oil Tank...............................1-62Engine Uses Too Much Oil Or Smokes Excessively..1-62Engine Leaks Oil From Cases, Pushrods, Hoses,Etc.............................................................................1-62Low Oil Pressure.......................................................1-63High Oil Pressure......................................................1-63

Electrical System..............................................................1-63Alternator Does Not Charge......................................1-63Alternator Charge Rate Is Below Normal..................1-63Speedometer Operates Erratically............................1-63

Transmission....................................................................1-63Shifts Hard.................................................................1-63Jumps Out Of Gear...................................................1-63Clutch Slips................................................................1-63Clutch Drags Or Does Not Release..........................1-63Clutch Chatters..........................................................1-63

Handling............................................................................1-63Irregularities...............................................................1-63

Brakes...............................................................................1-63Brake Does Not Hold Normally.................................1-63

CHASSIS


2.2 SPECIFICATIONSSpecifications......................................................................2-5

Chassis Specifications................................................2-5Tire Specifications.......................................................2-6

2.3 VEHICLE IDENTIFICATION NUMBER(V.I.N.)Vehicle Identification Number.............................................2-9

2.4 FRONT WHEELRemoval............................................................................2-11Disassembly.....................................................................2-11

Disc Wheel................................................................2-11Laced Wheel..............................................................2-11

Cleaning and Inspection...................................................2-13Assembly..........................................................................2-13

Disc Wheel................................................................2-13Laced Wheel..............................................................2-14

Installation.........................................................................2-14

2.5 REAR WHEELRemoval............................................................................2-15Disassembly.....................................................................2-15Cleaning and Inspection...................................................2-16Assembly..........................................................................2-16Installation.........................................................................2-17

2.6 WHEEL LACINGWheel Lacing: Angle Flange Hub.....................................2-18

2.7 CHECKING AND TRUING WHEELSGeneral.............................................................................2-20Checking Wheel Runout...................................................2-20

Checking Radial Runout............................................2-20

IV TABLE OF CONTENTS

TABLE OF CONTENTS

Checking Lateral Runout...........................................2-20Laced Wheel Rim Offset...................................................2-21Truing Laced Wheels........................................................2-23

Radial Runout............................................................2-23Lateral Runout...........................................................2-23

2.8 SEALED WHEEL BEARINGSInspection.........................................................................2-25Removal............................................................................2-25Installation.........................................................................2-27

2.9 TIRESGeneral.............................................................................2-29Removal............................................................................2-29Cleaning, Inspection and Repair......................................2-29Installation.........................................................................2-30

Tube Type Tires.........................................................2-30Tubeless Tires: Cast Wheels.....................................2-30Tubeless Tires: Laced Wheels..................................2-31

Checking Tire Runout.......................................................2-32Lateral Runout...........................................................2-32Radial Runout............................................................2-32

Wheel Balancing...............................................................2-33Static vs Dynamic......................................................2-33Weights......................................................................2-33

2.10 VEHICLE ALIGNMENTAxle Alignment..................................................................2-34

Checking Axle Alignment..........................................2-34Adjusting Axle Alignment...........................................2-35

2.11 FRONT BRAKE MASTER CYLINDERGeneral.............................................................................2-36Removal and Disassembly...............................................2-36Cleaning and Inspection...................................................2-38Assembly and Installation.................................................2-38

2.12 FRONT BRAKE CALIPERRemoval............................................................................2-40Disassembly.....................................................................2-40Cleaning, Inspection and Repair......................................2-42Assembly..........................................................................2-43Installation.........................................................................2-44

2.13 REAR BRAKE MASTER CYLINDERGeneral.............................................................................2-45Removal............................................................................2-45Disassembly.....................................................................2-45Cleaning and Inspection...................................................2-46Assembly..........................................................................2-46Installation.........................................................................2-47

2.14 REAR BRAKE CALIPERRemoval............................................................................2-51Disassembly.....................................................................2-51Cleaning, Inspection and Repair......................................2-53Assembly..........................................................................2-54Rear Brake Line Routing..................................................2-54Installation.........................................................................2-54

2.15 BLEEDING BRAKESGeneral.............................................................................2-56Procedure.........................................................................2-56

2.16 FRONT FORK: TELESCOPICGeneral.............................................................................2-58Replacing Fork Oil............................................................2-58Removal............................................................................2-59Disassembly.....................................................................2-59Cleaning and Inspection...................................................2-59Assembly..........................................................................2-64Installation.........................................................................2-64

2.17 STEERING HEADRemoval............................................................................2-65

FLSTC, FLSTF/B, FLSTN, FLS Models....................2-65FXST Model...............................................................2-65FXS, FXSB Models....................................................2-65

Inspection.........................................................................2-66All Models..................................................................2-66

Disassembly.....................................................................2-67Removing Lower Bearings From Fork Stem.............2-67Steering Head Bearing Race Removal.....................2-67

Assembly..........................................................................2-67Installation.........................................................................2-68

FLSTC, FLSTF/B, FLSTN, FLS Models....................2-68FXST Models.............................................................2-68FXS, FXSB Models....................................................2-68

2.18 BELT GUARD AND DEBRISDEFLECTORRemoval............................................................................2-69

Belt Guard.................................................................2-69Debris Deflector.........................................................2-69

Installation.........................................................................2-69Belt Guard.................................................................2-69Debris Deflector.........................................................2-69

2.19 REAR SHOCK ABSORBERSGeneral.............................................................................2-70Removal............................................................................2-70Installation.........................................................................2-70Shock Disposal.................................................................2-71

2.20 REAR FORKRemoval............................................................................2-73Cleaning and Inspection...................................................2-74Pivot Bearing Replacement..............................................2-74Installation.........................................................................2-75

2.21 THROTTLE CONTROLRemoval/Disassembly......................................................2-76Cleaning and Inspection...................................................2-76Assembly/Installation........................................................2-76

2.22 CLUTCH CONTROLRemoval............................................................................2-78Installation.........................................................................2-78

TABLE OF CONTENTS V

TABLE OF CONTENTS

2.23 HANDLEBARS: FLSTC, FLSTN, FLS,FXSTRemoval............................................................................2-80Installation.........................................................................2-81

2.24 HANDLEBARS: FLSTF/BRemoval............................................................................2-82Installation.........................................................................2-83

2.25 HANDLEBARS: FXSRemoval............................................................................2-86Installation.........................................................................2-86

2.26 HANDLEBARS: FXSBRemoval............................................................................2-88

Handlebars................................................................2-88Lower Handlebar Clamps..........................................2-88

Installation.........................................................................2-88Lower Clamp.............................................................2-88Handlebars................................................................2-89Return to Service.......................................................2-90

2.27 FRONT FENDERRemoval............................................................................2-91Installation.........................................................................2-92

2.28 REAR FENDER: FLSTCRemoval............................................................................2-93Installation.........................................................................2-93

2.29 REAR FENDER: FLSTF/BRemoval............................................................................2-95Installation.........................................................................2-95

2.30 REAR FENDER: FXSTRemoval............................................................................2-96Installation.........................................................................2-96

2.31 REAR FENDER: FLS, FXSRemoval............................................................................2-98Installation.........................................................................2-98

License Plate Bracket Assembly and Installation: FXS,FLS (all but Domestic and California models)...........2-98License Plate Bracket Assembly and Installation: FLS(Domestic and California models).............................2-99Fender Installation.....................................................2-99

2.32 REAR FENDER: FXSBRemoval..........................................................................2-101Installation.......................................................................2-102

2.33 REAR FENDER: FLSTNRemoval..........................................................................2-103Disassembly...................................................................2-103Assembly........................................................................2-105Installation.......................................................................2-105

2.34 REAR FENDER WIRE CONDUITInstallation.......................................................................2-106

2.35 FOOTBOARDS AND FOOTRESTSRider Footboards............................................................2-107

Removal..................................................................2-107Installation...............................................................2-107

Rider Footrest.................................................................2-107Removal..................................................................2-107Installation...............................................................2-107

Passenger Footrest........................................................2-107Removal..................................................................2-107Installation...............................................................2-108

2.36 JIFFY STANDCleaning..........................................................................2-109Sensor: HDI Models........................................................2-109Removal..........................................................................2-110Installation.......................................................................2-110

2.37 FORK LOCKRemoval..........................................................................2-111Installation.......................................................................2-111

2.38 SEAT AND STRAP RETENTION NUTReplacement...................................................................2-112

2.39 SEAT: FLS, FXS, FXST, FXSBReplacement...................................................................2-113


2.40 SEAT: FLSTN, FLSTF, FLSTFB, FLSTCRemoval and Installation................................................2-114

2.41 LUGGAGE RACK: FLSTNRemoval and Installation................................................2-115

2.42 SADDLEBAGS: FLSTCRemoval..........................................................................2-116Installation.......................................................................2-116

2.43 WINDSHIELD: FLSTCRemoval..........................................................................2-118Installation.......................................................................2-118

2.44 SAREE GUARD: INDIA MODELSLeft Side Removal and Installation.................................2-119


Right Side Removal and Installation...............................2-119Removal..................................................................2-119Installation...............................................................2-119

2.45 FRONT LICENSE PLATE BRACKETRemoval and Installation................................................2-121

2.46 MEDALLIONS, SERIALIZED BADGESAND TANK EMBLEMSRemoval..........................................................................2-122Installation.......................................................................2-122

VI TABLE OF CONTENTS

TABLE OF CONTENTS

ENGINE


3.2 SPECIFICATIONSSpecifications......................................................................3-3

3.3 SERVICE WEAR LIMITSGeneral...............................................................................3-5

3.4 ENGINE OIL FLOWOil Feed..............................................................................3-7Top End...............................................................................3-8Bottom End.........................................................................3-9Chain Guide Bracket.........................................................3-11Oil Return..........................................................................3-12

3.5 OIL PUMP OPERATIONGeneral.............................................................................3-13Operation..........................................................................3-13

3.6 BREATHER OPERATIONGeneral.............................................................................3-15

3.7 OIL PRESSUREOil Pressure Indicator Lamp.............................................3-16Checking Oil Pressure......................................................3-16

3.8 TROUBLESHOOTINGDiagnosing Valve Train Noise...........................................3-18Compression Test.............................................................3-18Cylinder Leakdown Test...................................................3-18Diagnosing Smoking Engine or High Oil Consumption.....3-19

Check Prior To Cylinder Head Removal....................3-19Check After Cylinder Head Removal.........................3-19

3.9 HOW TO USE THIS SECTIONTop End Repair.................................................................3-20Bottom End Repair...........................................................3-20Typical Symptoms.............................................................3-20

3.10 TOP END SERVICEEngine in Chassis.............................................................3-21Engine Removed from Chassis........................................3-22

3.11 CAM COMPARTMENT SERVICEEngine in Chassis.............................................................3-23Engine Removed From Chassis.......................................3-24

3.12 STRIPPING MOTORCYCLE FORSERVICEProcedure.........................................................................3-25

3.13 ASSEMBLING MOTORCYCLE AFTERSERVICEProcedure.........................................................................3-26

3.14 REMOVING ENGINE FROM CHASSISProcedure.........................................................................3-27

3.15 INSTALLING ENGINE IN CHASSISProcedure.........................................................................3-28

3.16 TOP END OVERHAUL: DISASSEMBLYGeneral.............................................................................3-30Rocker Covers..................................................................3-30Rocker Arm Support Plate................................................3-30Pushrods, Lifters and Covers...........................................3-32Cylinder Head...................................................................3-32Cylinder.............................................................................3-33Piston................................................................................3-34

3.17 BREATHER ASSEMBLYDisassembly.....................................................................3-36Cleaning and Inspection...................................................3-36Assembly..........................................................................3-36

3.18 ROCKER ARM SUPPORT PLATEDisassembly.....................................................................3-37Cleaning and Inspection...................................................3-37

Inspection..................................................................3-37Rocker Shaft Fit.........................................................3-37Rocker Arm Shaft to Bushing....................................3-38Replace Rocker Arm Bushings.................................3-38

Assembly..........................................................................3-39

3.19 PUSHRODS, LIFTERS AND COVERSDisassembly.....................................................................3-40Cleaning and General Inspection.....................................3-40Lifter Inspection................................................................3-41Assembly..........................................................................3-41

3.20 CYLINDER HEADDisassembly.....................................................................3-42Cleaning............................................................................3-43Inspection.........................................................................3-43

Cylinder Head............................................................3-43Valve Guides.............................................................3-44Valves........................................................................3-44Valve Springs.............................................................3-44Tapered Keepers.......................................................3-44Valve Seats................................................................3-44

Valve Guide Replacement................................................3-44Removal....................................................................3-44Installation.................................................................3-45

Valve and Seat Refacing..................................................3-48Assembly..........................................................................3-50

3.21 CYLINDERCleaning............................................................................3-52Inspection.........................................................................3-52Deglazing Cylinder............................................................3-54Boring and Honing Cylinder..............................................3-54

3.22 PISTONDisassembly.....................................................................3-56

Piston Rings..............................................................3-56

TABLE OF CONTENTS VII

TABLE OF CONTENTS

Cleaning............................................................................3-56Inspection.........................................................................3-56Assembly..........................................................................3-58

Checking Piston Ring Gap........................................3-58Installing Piston Rings...............................................3-58

3.23 TOP END OVERHAUL: ASSEMBLYGeneral.............................................................................3-60Piston................................................................................3-60Cylinder.............................................................................3-61Cylinder Head...................................................................3-63Pushrods, Lifters and Covers...........................................3-67Rocker Arm Support Plate................................................3-68Breather and Rocker Cover..............................................3-69

3.24 CAM COMPARTMENT ANDCOMPONENTSCam Support Plate and Cover Removal..........................3-70

Prepare Engine..........................................................3-70Cam Chain and Sprockets Removal.........................3-70Cam Support Plate Removal.....................................3-71

Cam Support Plate Cleaning and Inspection....................3-72Oil Pressure Valve.....................................................3-72Cam Support Plate....................................................3-72

Camshafts.........................................................................3-73Removal....................................................................3-73Installation.................................................................3-73

Oil Pressure Relief Valve..................................................3-75Removal....................................................................3-75Inspection..................................................................3-75Installation.................................................................3-75

Cam Needle Bearings.......................................................3-75Removal....................................................................3-75Installation.................................................................3-77

Cam Support Plate and Cover Installation.......................3-78

3.25 OIL PUMPRemoval............................................................................3-82Cleaning and Inspection...................................................3-82Installation.........................................................................3-83

3.26 CRANKCASE DISASSEMBLY ANDREPAIRCrankcase Disassembly...................................................3-84Counterbalancer Assembly..............................................3-84Cleaning and Inspection...................................................3-86Right Crankcase Half........................................................3-87

Chain Guide Screen..................................................3-87Main Bearing Removal..............................................3-87Main Bearing Installation...........................................3-88Piston Jets Removal..................................................3-88Piston Jets Installation...............................................3-88

Left Crankcase Half..........................................................3-89Main Bearing Removal..............................................3-89Main Bearing Installation...........................................3-90

Sprocket Shaft Bearing Inner Race..................................3-90Removal....................................................................3-90Installation.................................................................3-91

Cylinder Studs..................................................................3-93Removal....................................................................3-93Installation.................................................................3-93

Pipe Plugs and Oil Fittings................................................3-93Removal/Installation..................................................3-93

3.27 FLYWHEEL AND CONNECTING RODSGeneral.............................................................................3-94

Symptoms..................................................................3-94No Oil Pressure.........................................................3-94Vibration....................................................................3-94

Inspection.........................................................................3-94Measuring Crankshaft Runout..........................................3-94

Crankshaft Installed...................................................3-94Crankshaft Removed.................................................3-95

3.28 COUNTERBALANCER ASSEMBLYREPAIRCleaning, Inspection, and Repair.....................................3-97

General......................................................................3-97Balance Shaft Removal.............................................3-97Bearing Removal.......................................................3-98Balance Shaft Installation..........................................3-98Balance Shaft Support Bearings Removal................3-99Balance Shaft Support Bearings Installation.............3-99Front and Rear Balance Sprockets.........................3-100Hydraulic Tensioners...............................................3-100Chain Tensioner Guides..........................................3-100Balance Shaft Support............................................3-100Balance Chain.........................................................3-101

3.29 CRANKCASE ASSEMBLYCounterbalancer Assembly Installation..........................3-102Crankcase.......................................................................3-105

3.30 OIL TANK: ALL BUT FXSBRemoval and Disassembly.............................................3-108

Oil Tank....................................................................3-108Oil Line Fittings/Retainers.......................................3-110

Installation.......................................................................3-111

3.31 OIL TANK: FXSBRemoval and Disassembly.............................................3-112

Oil Tank....................................................................3-112Oil Line Fittings/Retainers.......................................3-114

Installation.......................................................................3-115

FUEL SYSTEM


4.2 SPECIFICATIONS: FUEL SYSTEMSpecifications......................................................................4-3

4.3 AIR CLEANER ASSEMBLYRemoval..............................................................................4-4Installation...........................................................................4-4Backplate Assembly: HDI Models......................................4-5

4.4 FUEL SUPPLY LINEPurging Fuel Supply Line....................................................4-6Disconnecting Fuel Supply Line.........................................4-6

VIII TABLE OF CONTENTS

TABLE OF CONTENTS

4.5 FUEL PRESSURE TESTGeneral...............................................................................4-7Testing................................................................................4-7

4.6 FUEL TANKGeneral...............................................................................4-9Removal..............................................................................4-9Cleaning and Inspection...................................................4-10Installation.........................................................................4-11

4.7 CONSOLE: FXS, FXSBRemoval............................................................................4-12Installation.........................................................................4-12

4.8 THROTTLE POSITION SENSOR (TPS)General.............................................................................4-13Removal............................................................................4-13Installation.........................................................................4-13

4.9 INTAKE AIR TEMPERATURE SENSOR(IAT)General.............................................................................4-14Removal............................................................................4-14Installation.........................................................................4-14

4.10 ENGINE TEMPERATURESENSOR (ET)General.............................................................................4-15Removal............................................................................4-15Installation.........................................................................4-15

4.11 INDUCTION MODULERemoval............................................................................4-16Installation.........................................................................4-17

4.12 IDLE AIR CONTROL (IAC)General.............................................................................4-18Removal............................................................................4-18Installation.........................................................................4-18

4.13 MANIFOLD ABSOLUTE PRESSURESENSOR (MAP)Removal............................................................................4-19Installation.........................................................................4-19

4.14 OXYGEN (O2) SENSORGeneral.............................................................................4-20Removal............................................................................4-20

Front O2 Sensor........................................................4-20Rear O2 Sensor.........................................................4-20

Installation.........................................................................4-20Front O2 Sensor........................................................4-20Rear O2 Sensor.........................................................4-20

4.15 FUEL INJECTORSGeneral.............................................................................4-22Removal............................................................................4-22Installation.........................................................................4-22

4.16 FUEL PUMP AND FUEL GAUGESENDING UNITGeneral.............................................................................4-24Removal............................................................................4-24Vapor Valve.......................................................................4-25Disassembly and Assembly..............................................4-26

Fuel Filter...................................................................4-26Regulator...................................................................4-26Inlet sock...................................................................4-27Fuel Pump.................................................................4-27

Installation.........................................................................4-28

4.17 EXHAUST SYSTEMMufflers: FLSTC, FXST, FXSB.........................................4-30

Removal....................................................................4-30Assembly...................................................................4-30

System: FLSTC, FXST, FXSB..........................................4-30Removal....................................................................4-30Installation.................................................................4-30

Mufflers: FLSTN, FLSTF/B, FLS, FXS..............................4-32Removal....................................................................4-32Assembly...................................................................4-32

System: FLSTN, FLSTF/B, FLS, FXS..............................4-32Removal....................................................................4-32Installation.................................................................4-32

4.18 INTAKE LEAK TESTGeneral.............................................................................4-34Leak Tester.......................................................................4-34

Parts List....................................................................4-34Tester Assembly........................................................4-34Tester Adjustment......................................................4-34

Procedure.........................................................................4-34

4.19 EVAPORATIVE EMISSIONS CONTROLSYSTEMGeneral.............................................................................4-36Charcoal Canister.............................................................4-37

Removal....................................................................4-37Installation.................................................................4-37

Purge Solenoid.................................................................4-37Removal....................................................................4-37Installation.................................................................4-37

Hose Routing/Replacement..............................................4-37Fuel Tank Vent Hose.................................................4-37Purge Solenoid-to-Induction Module Tube................4-37Charcoal Canister-to-Purge Solenoid Tube...............4-38Vent Tube-to-Charcoal Canister Tube.......................4-38

DRIVE


5.2 SPECIFICATIONS: DRIVESpecifications......................................................................5-2

5.3 PRIMARY CHAINCASE COVERGeneral...............................................................................5-3Removal..............................................................................5-3

TABLE OF CONTENTS IX

TABLE OF CONTENTS

Installation...........................................................................5-3

5.4 DRIVE COMPONENTSRemoval..............................................................................5-4Installation...........................................................................5-6

5.5 PRIMARY CHAINCASE HOUSINGRemoval..............................................................................5-9Inspection...........................................................................5-9Mainshaft Bearing and Seal...............................................5-9

Removal......................................................................5-9Installation...................................................................5-9

Mainshaft Bearing Inner Race..........................................5-10Removal....................................................................5-10Installation.................................................................5-10

Installation.........................................................................5-11

5.6 CLUTCHRemoval and Installation..................................................5-13Clutch Pack Only..............................................................5-13

Partial Disassembly...................................................5-13Cleaning And Inspection...........................................5-13Assembly...................................................................5-14

Clutch Pack and Bearing..................................................5-15Complete Disassembly..............................................5-15Assembly...................................................................5-16

5.7 TRANSMISSION SPROCKETRemoval............................................................................5-18Cleaning and Inspection...................................................5-19Installation.........................................................................5-19

5.8 DRIVE BELTRemoval............................................................................5-21Inspection.........................................................................5-21Installation.........................................................................5-21

TRANSMISSION


6.2 SPECIFICATIONS: TRANSMISSIONSpecifications......................................................................6-2Service Wear Limits............................................................6-2

6.3 TRANSMISSIONPower Flow.........................................................................6-4

Neutral.........................................................................6-4First Gear.....................................................................6-4Second Gear...............................................................6-4Third Gear...................................................................6-4Fourth Gear.................................................................6-4Fifth Gear.....................................................................6-4Sixth Gear....................................................................6-4

6.4 SHIFTERAdjustment..........................................................................6-6Shifter Rod Adjustment.......................................................6-6Shift Lever Replacement....................................................6-6

6.5 CLUTCH RELEASE COVERRemoval and Disassembly.................................................6-8Cleaning and Inspection.....................................................6-8Assembly and Installation...................................................6-9

6.6 TRANSMISSION ASSEMBLYRemoval............................................................................6-10Disassembly.....................................................................6-11

Shifter Cam/Shifter Forks..........................................6-11Mainshaft...................................................................6-13Countershaft..............................................................6-16Removing Bearing Housing Bearings.......................6-17

Cleaning and Inspection...................................................6-18Assembly..........................................................................6-18

Installing Bearing Housing Bearings.........................6-18Countershaft..............................................................6-19Mainshaft...................................................................6-19Shifter Cam/Shifter Forks..........................................6-20

Installation.........................................................................6-22

6.7 MAIN DRIVE GEAR AND BEARINGRemoval............................................................................6-23Cleaning and Inspection...................................................6-24

Needle Bearing Replacement...................................6-25Installation.........................................................................6-26

Installing Main Drive Gear Bearing............................6-26Installing Main Drive Gear.........................................6-27Installing Main Drive Gear Large Seal.......................6-27

6.8 TRANSMISSION CASERemoval............................................................................6-30Installation.........................................................................6-30Disassembly.....................................................................6-31

Shifter Arm Assembly................................................6-31Cleaning and Inspection...................................................6-31Assembly..........................................................................6-32

Countershaft Needle Bearing Replacement..............6-32Shifter Pawl Lever Assembly.....................................6-32

ELECTRICAL


7.2 SPECIFICATIONS: ELECTRICALSpecifications......................................................................7-4

7.3 ELECTRICAL PANELGeneral...............................................................................7-5Removal: All But FXSB.......................................................7-5Installation: All But FXSB....................................................7-6Removal: FXSB..................................................................7-6Installation: FXSB...............................................................7-6

7.4ELECTRONICCONTROLMODULE (ECM)General...............................................................................7-8Removal: All But FXSB.......................................................7-8Installation: All But FXSB....................................................7-8Removal: FXSB..................................................................7-8Installation: FXSB...............................................................7-8

X TABLE OF CONTENTS

TABLE OF CONTENTS

7.5 BODY CONTROL MODULE (BCM)General...............................................................................7-9BCM Configuration.............................................................7-9Removal: All But FSXB.......................................................7-9Installation: All But FXSB....................................................7-9Removal: FXSB................................................................7-10Installation: FXSB.............................................................7-10

7.6 H-DSSS ACTUATIONSidecar Configuration.......................................................7-11Actuation...........................................................................7-11Fob Assignment................................................................7-11

7.7 PERSONAL IDENTIFICATION NUMBER(PIN)General.............................................................................7-12Changing the PIN.............................................................7-12

Modifying an Existing PIN.........................................7-12

7.8 HD-SSS MAINTENANCEFob Battery.......................................................................7-14

Battery Replacement Schedule.................................7-14Battery Replacement.................................................7-14

Smart Siren (If Installed)...................................................7-14Battery Replacement Schedule.................................7-14Battery Replacement.................................................7-14

7.9 SECURITY SIRENRemoval: All But FXSB.....................................................7-15Installation: All But FXSB..................................................7-15Removal: FXSB................................................................7-16Installation: FXSB.............................................................7-16

7.10 FUSESRemoval............................................................................7-17Installation.........................................................................7-17

7.11 IGNITION AND LIGHT SWITCHGeneral.............................................................................7-18Removal and Installation: All But FXS/B..........................7-18Removal and Installation: FXS/B......................................7-19

7.12 BATTERY CABLESRouting Procedure............................................................7-20

7.13 STARTERGeneral.............................................................................7-22Removal............................................................................7-22Drive Assembly.................................................................7-22

Disassembly..............................................................7-22Inspection..................................................................7-22Assembly...................................................................7-23

Solenoid............................................................................7-23Cover and Plunger Removal.....................................7-23Short Post Contact: Starter.......................................7-23Long Post Contact: Battery Positive..........................7-24Plunger and Cover Installation..................................7-24

Installation.........................................................................7-24

7.14 HEADLAMPGeneral.............................................................................7-26Headlamp Assembly Removal and Installation................7-26


Bulb Removal and Installation..........................................7-26FXST, FXS and FXSB Models...................................7-27FLSTC, FLSTF/B, FLSTN and FLS Models..............7-27

7.15 TAIL LAMP: ALL BUT FLSTNGeneral.............................................................................7-29Bulb Replacement............................................................7-29Base Replacement...........................................................7-29

7.16 TAIL LAMP: FLSTNBulb Replacement............................................................7-31Tail Lamp Replacement....................................................7-31

7.17 AUXILIARY LAMPS: FLSTC, FLSTNAuxiliary Lamp Bulb..........................................................7-33


FLSTC Models..................................................................7-33Auxiliary Lamp Bracket Removal..............................7-33Auxiliary Lamp Bracket Installation...........................7-34Auxiliary Lamp Housing Removal.............................7-34Auxiliary Lamp Housing Installation..........................7-34

FLSTN Models..................................................................7-36Auxiliary Lamp Bracket Removal..............................7-36Auxiliary Lamp Bracket Installation...........................7-36Auxiliary Lamp Housing Removal.............................7-37Auxiliary Lamp Housing Installation..........................7-37

Adjustment: FLSTC/FLSTN Models.................................7-38

7.18 TURNSIGNALSANDRUNNINGLIGHTSBulb Replacement: Bullet Style........................................7-40Bulb Replacement: Flat Lens Style..................................7-40Lamp Replacement...........................................................7-40

All Models..................................................................7-40Front Turn Signals.....................................................7-41Front Turn Signals: FLSTC, FLSTN..........................7-42Rear Turn Signals: All But FLSTN, FXS, FLS,FXSB.........................................................................7-42Rear Turn Signals: FLS, FXS....................................7-42Rear Turn Signals: FXSB..........................................7-44Rear Turn Signals: FLSTN........................................7-45

7.19 CRANK POSITION SENSOR (CKP)General.............................................................................7-47Removal............................................................................7-47Installation.........................................................................7-47

7.20AUTOMATICCOMPRESSIONRELEASE(ACR)General.............................................................................7-49Removal............................................................................7-49Installation.........................................................................7-49

7.21 IGNITION COILRemoval............................................................................7-51

TABLE OF CONTENTS XI

TABLE OF CONTENTS

All Except FXS/B.......................................................7-51FXS/B........................................................................7-51

Installation.........................................................................7-51All Except FXS/B.......................................................7-51FXS/B........................................................................7-51

7.22 SPARK PLUG CABLESGeneral.............................................................................7-53Removal............................................................................7-53Installation.........................................................................7-53

7.23 VOLTAGE REGULATORDisassembly.....................................................................7-54Installation.........................................................................7-54

7.24 ALTERNATORRemoval............................................................................7-55Cleaning and Inspection...................................................7-55Installation.........................................................................7-55

7.25 FUEL GAUGEGeneral.............................................................................7-56Removal............................................................................7-56Installation.........................................................................7-56

7.26 SPEEDOMETERGeneral.............................................................................7-58Removal: All But FXS/B....................................................7-58Installation: All But FXS/B.................................................7-58Removal: FXS...................................................................7-58Installation: FXS................................................................7-59Removal: FXSB................................................................7-59Installation: FXSB.............................................................7-59

7.27 VEHICLE SPEED SENSOR (VSS)General.............................................................................7-61Removal............................................................................7-61Installation.........................................................................7-61

7.28 INDICATOR LAMPSGeneral.............................................................................7-62Removal: All But FXS/B....................................................7-62Installation: All But FXS/B.................................................7-62Removal: FXS...................................................................7-63Installation: FXS................................................................7-64Removal: FXSB................................................................7-64Installation: FXSB.............................................................7-64

7.29 NEUTRAL SWITCHGeneral.............................................................................7-66Removal............................................................................7-66Installation.........................................................................7-66

7.30 OIL PRESSURE SWITCHGeneral.............................................................................7-67Removal............................................................................7-67Installation.........................................................................7-67

7.31 REAR STOP LAMP SWITCHGeneral.............................................................................7-68

Removal............................................................................7-68Installation.........................................................................7-68

7.32 HORNInspection.........................................................................7-69Removal and Installation: All But FXS/B..........................7-69Removal and Installation: FXS/B......................................7-70

7.33 ACTIVE EXHAUSTGeneral.............................................................................7-71Removal............................................................................7-71Repair...............................................................................7-71Installation.........................................................................7-71

7.34 MAIN WIRING HARNESSRemoval............................................................................7-72Installation.........................................................................7-73

7.35 HANDLEBAR CONTROL MODULESGeneral.............................................................................7-75Repair Procedures............................................................7-75

7.36 RIGHT HANDLEBAR CONTROLMODULERemoval............................................................................7-76Installation.........................................................................7-77Front Brake Switch Replacement.....................................7-78

7.37LEFTHANDLEBARCONTROLMODULERemoval............................................................................7-79Installation.........................................................................7-79Clutch Switch Replacement..............................................7-80

APPENDIX A CONNECTOR REPAIR

A.1 AUTOFUSE UNSEALED ELECTRICALCONNECTORSAutofuse Unsealed Connector Repair................................A-1

General.......................................................................A-1Disassembly................................................................A-1Assembly.....................................................................A-1

A.2 BOSCH COMPACT 1.1M CONNECTORBosch Compact 1.1M Connector.......................................A-2

General.......................................................................A-2Housings.....................................................................A-2Removing Socket Terminal.........................................A-2Installing Socket Terminal...........................................A-2

A.3 DELPHI 100W MICRO-PACK SEALEDCONNECTORDelphi 100W Micro-Pack Sealed Connector Repair..........A-3

General.......................................................................A-3Separating Socket Housing From ECM......................A-3Mating Socket Housing To ECM.................................A-3Removing Socket Terminal.........................................A-3Installing Socket Terminal...........................................A-3

Crimping Terminals.............................................................A-4

XII TABLE OF CONTENTS

TABLE OF CONTENTS

A.4 DELPHI 150 METRI-PACK SEALEDCONNECTORSDelphi 150 Metri-Pack Sealed Connector Repair..............A-5

General.......................................................................A-5Separating Pin and Socket Housings.........................A-5Mating Pin and Socket Housings................................A-5Removing Socket Terminal.........................................A-5Inserting Socket Terminal............................................A-5

A.5 DELPHI 280 METRI-PACK UNSEALEDCONNECTORSFuse Block Repair..............................................................A-7

Removing Socket Terminals.......................................A-7Installing Socket Terminals.........................................A-7Crimping Terminals.....................................................A-7

A.6 DELPHI 480 METRI-PACK UNSEALEDCONNECTORSDelphi 480 Metri-Pack Unsealed Connector Repair..........A-8

General.......................................................................A-8Separating Pin and Socket Housings.........................A-8Mating Pin and Socket Housings................................A-8Removing Socket Terminals.......................................A-8Installing Socket Terminals.........................................A-8

A.7 DELPHI 630 METRI-PACK UNSEALEDCONNECTORSDelphi 630 Metri-Pack Unsealed Connector Repair..........A-9

Separating Pin and Socket Housings.........................A-9Mating Pin and Socket Housings................................A-9Removing Socket Terminal.........................................A-9Installing Socket Terminal...........................................A-9

A.8DELPHI 800METRI-PACKSEALEDMAINFUSE HOUSINGDelphi 800 Metri-Pack Sealed Main Fuse HousingRepair...............................................................................A-10

Removing Socket Terminals.....................................A-10Installing Socket Terminals.......................................A-10

A.9 DELPHI METRI-PACK TERMINALREPAIRMetri-Pack Terminal Crimps.............................................A-11

Matching Terminal To Crimper..................................A-11Preparing Wire Lead.................................................A-11Crimping Wire Core...................................................A-11Crimping Insulation/Seal...........................................A-11Inspecting Crimps.....................................................A-12

A.10 DELPHI MICRO 64 SEALEDCONNECTORSDelphi Micro 64 Sealed Connector Repair.......................A-13

General.....................................................................A-13Separating Pin and Socket Housings.......................A-13Mating Pin and Socket Housings..............................A-13Removing Terminal...................................................A-13Installing Terminal.....................................................A-14Preparing Wire Leads for Crimping...........................A-14Crimping Terminals...................................................A-14

Inspecting Crimps.....................................................A-14

A.11 DELPHI GT 150 SEALEDCONNECTORSDelphi GT 150 Sealed Connector Repair.........................A-16

General.....................................................................A-16Separating Pin and Socket Housings.......................A-16Mating Pin and Socket Housings..............................A-16Removing Socket Terminals.....................................A-16Installing Socket Terminals.......................................A-16

A.12 DELPHI GT 280 SEALED 73-TERMINALECM CONNECTORDelphi GT 280 Sealed 73-Terminal ECM Connector.......A-18

Separating Socket Housing From ECM....................A-18Mating Socket Housing To ECM...............................A-18Socket Terminal.........................................................A-18ECM Ground Terminal..............................................A-18

A.13 DEUTSCHDT SEALEDCONNECTORSDeutsch DT Sealed Connector Repair.............................A-20

General.....................................................................A-20Separating Pin and Socket Housings.......................A-20Mating Pin and Socket Housings..............................A-20Removing Socket Terminals.....................................A-20Installing Socket Terminals.......................................A-20Removing Pin Terminals...........................................A-22Installing Pin Terminals.............................................A-22Crimping Terminals...................................................A-23

A.14 DEUTSCH DT SEALED TERMINALREPAIRDeutsch DT Sealed Terminal Crimps...............................A-24

Preparing Wire Leads for Crimping...........................A-24Crimping Terminal to Lead........................................A-24Inspecting Crimps.....................................................A-24

A.15 DEUTSCH DTM SEALED MINITERMINAL REPAIRDeutsch DTM Sealed Mini Terminal Crimps....................A-25

Preparing Wire Leads for Crimping...........................A-25Crimping a Mini Terminal to Wire Lead.....................A-25Inspecting Crimps.....................................................A-25

A.16 DEUTSCH DTM SEALED SOLIDBARREL MINI TERMINAL REPAIRDeutsch DTM Sealed Solid Barrel Terminal Crimps........A-26

Preparing Wire Leads For Crimping.........................A-26Adjusting Crimper Tool..............................................A-26Crimping a Barrel Contact To Wire Lead..................A-26Inspecting Crimps.....................................................A-26

A.17 JAE MX19 SEALED CONNECTORSJAE MX19 Sealed Connectors.........................................A-28

Connector Housings.................................................A-28Removing Terminals.................................................A-28Installing Terminals....................................................A-28

Crimping Terminals...........................................................A-28

TABLE OF CONTENTS XIII

TABLE OF CONTENTS

A.18 MOLEX CMC SEALED CONNECTORSMolex CMC Sealed Connectors.......................................A-29

Separating the Connector.........................................A-29Removing Terminals.................................................A-29Installing Terminals....................................................A-29

Crimping Terminals...........................................................A-30

A.19 MOLEX MX 150 SEALEDCONNECTORSMolex MX 150 Sealed Connector Repair.........................A-31

Separating Pin and Socket Housings.......................A-31Mating Pin and Socket Housings..............................A-31Removing Terminals.................................................A-31Installing Terminals....................................................A-31

Crimp Terminal to Lead..............

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2013 HD Softail Service Manual