Harley-Davidson Owners Manual Close Window Print

Maintenance and Lubrication

Safe Operating Maintenance


en Warning

Perform the service and maintenance operations as indicated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or serious injury. (00010a)

Good maintenance creates a safe motorcycle. A careful check of certain equipment must be made after periods of storage. Also, frequently inspect the motorcycle between the regular service intervals to determine if additional maintenance is necessary.

Check the following items:

  1. Tires for correct pressure, abrasions or cuts.

  2. Belt and primary chain for proper tension, wear or damage.

  3. Brakes, steering and throttle for responsiveness and freedom from binding.

  4. Brake fluid level and condition. Hydraulic lines and fittings for leaks. Also, check brake pads and discs for wear.

  5. Cables for fraying or crimping and free operation.

  6. Engine oil and primary chaincase/transmission fluid levels.

  7. Headlamp, tail lamp, brake lamp and turn signals for proper operation.

NOTE:

Refer to the side view photographs in the front of this manual to locate the items discussed in this section.

Break-in Maintenance: Softail Models


NOTE:

The performance of new motorcycle initial service is required to keep your new motorcycle warranty in force and to assure proper emissions system operation.

Refer to Regular Service Intervals: 2006 Softail Models. After a new motorcycle has been ridden its first 1000 miles (1600 kilometers), it should be taken to the dealer from whom it was purchased for initial service operations.

NOTE:

Because of unique design features, Springer models require the first scheduled maintenance at 500 miles (800 kilometers).

Engine Lubrication


en Caution

Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a)

Engine oil is a major factor in the performance and service life of the engine. Always use the proper grade of oil for the lowest temperature expected before the next scheduled oil change. Refer to Recommended Engine Oils. Your authorized dealer has the proper oil to suit your requirements.

If it is necessary to add oil and Harley-Davidson oil is not available, use an oil certified for diesel engines. Acceptable diesel engine oil designations include: CF-4, CG-4, CH-4 and CI-4.

The preferred viscosities for the diesel engine oils in descending order are: 20W50, 15W40 and 10W40.

At the first opportunity, see an authorized dealer to change back to 100 percent Harley-Davidson oil.

Recommended Engine Oils

H-D TYPE

VISCOSITY

H-D RATING

LOWEST AMBIENT TEMPERATURE

COLD WEATHER STARTS BELOW 50° F (10° C)

H-D Multi-grade

SAE 10W40

HD 360

Below 40° F (4° C)

Excellent

H-D Multi-grade

SAE 20W50

HD 360

Above 40° F (4° C)

Good

H-D Regular Heavy

SAE 50

HD 360

Above 60° F (16° C)

Poor

H-D Extra Heavy

SAE 60

HD 360

Above 80° F (27° C)

Poor



Checking Oil Level: Softail Models


en Caution

Oil level cannot be accurately measured on a cold engine. For pre-ride inspection, with motorcycle leaning on jiffy stand on level ground, oil should register on dipstick between arrows when engine is cold. Do not add oil to bring the level to the FULL mark on a COLD engine. (00185a)

For dipstick location, see Checking Oil Tank Level: Softail Models.

NOTE:

The motorcycle should be on jiffy stand when checking oil level.

Oil Level Cold Check


Perform engine oil level COLD CHECK as follows:

  1. For preride inspection with the vehicle on jiffy stand on level ground, wipe off the dipstick and insert it back into the oil tank with the plug pushed completely into the fill spout.

  2. Remove the dipstick and verify oil registers on the dipstick between the two marks.

    1. See Engine Oil Level: Softail Models. If oil level registers on the dipstick, proceed to Oil Level Hot Check.

    2. If oil does not register on the dipstick, proceed to step 3.

  3. With the dipstick removed, look into the dipstick opening and verify the oil level is at the filler neck weld.

    1. If the oil level is at or near the filler neck weld, proceed to Oil Level Hot Check.

    2. If the oil level is not at or near the filler neck weld, add only enough oil to bring the level to the filler neck weld. Then proceed to Oil Level Hot Check.

Oil Level Hot Check


Perform engine oil level HOT CHECK as follows:

  1. Ride motorcycle until engine is at normal operating temperature.

  2. With the vehicle upright on level ground, allow engine to idle for 1-2 minutes. Turn engine off.

  3. With vehicle on jiffy stand remove and wipe off the dipstick. Insert dipstick back into the oil tank with the plug pushed completely into the filler neck.

  4. Remove the dipstick and note the level of the oil. Add only enough oil to bring the level to the FULL mark on the dipstick. Do not overfill.

  5. NOTE:

    Refer to Recommended Engine Oils. Use only recommended oil specified under Engine Lubrication.

  6. Start engine and carefully check for oil leaks around drain plug and oil filter.

Engine oil level should be checked only when engine is at normal operating temperature.

NOTE:

The engine will require a longer warm up period in colder weather.

en Caution

Do not allow hot oil level to fall below Add/Fill mark on dipstick. Doing so can result in equipment damage and/or equipment malfunction. (00189a)

en Caution

Do not overfill oil tank. Doing so can result in oil carryover to the air cleaner leading to equipment damage and/or equipment malfunction. (00190a)

Checking Oil Tank Level: Softail Models
  1. Filler neck
  2. Dipstick

Checking Oil Tank Level: Softail Models

Engine Oil Level: Softail Models
  1. Full mark
  2. Fill mark

Engine Oil Level: Softail Models

Changing Oil and Oil Filter: Softail Models


Oil filter is located on an oil filter mount in front of the engine.

en Caution

Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a)

en Warning

Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d)

Twin Cam 88B equipped vehicles require the premium oil filter (Part No. 63798-99 Chrome or Part No. 63731-99 Black).

  1. See Checking Oil Tank Level: Softail Models. Remove the oil filler plug/dipstick by pulling steadily while moving plug back and forth.

  2. See Oil Tank Drain Plug: Softail Models. Remove engine oil drain plug with o-ring (2). Allow oil to completely drain into a suitable container.

Oil Tank Drain Plug: Softail Models
  1. Frame connection for oil tank drain hose
  2. Oil tank drain plug and o-ring

Oil Tank Drain Plug: Softail Models

Oil Filter Wrench (Part No. HD-44067)

Oil Filter Wrench (Part No. HD-44067)

en Caution

Use Harley-Davidson OIL FILTER WRENCH for filter removal. This tool can prevent damage to crankshaft position sensor and/or sensor cable. (00192a)

NOTE:

Dispose of oil and oil filter in accordance with local regulations.

  1. See Oil Filter Wrench (Part No. HD-44067). Remove the oil filter using the OIL FILTER WRENCH (Part No. HD-44067) . Clean the oil filter mount flange of any old gasket material (surface should be smooth and free of any debris or old gasket material).

  2. Inspect o-ring for tears or damage. Replace if required. Wipe any foreign material from plug.

  3. Install o-ring and drain plug and tighten to 14-21 ft-lbs (19.0-28.5 Nm).

  4. See Applying Thin Oil Film. Apply a thin film of oil to gasket contact surface on mounting plate, gasket and new oil filter.

  5. Screw filter onto adapter until gasket contacts plate surface, then apply another 3/4-1 full turn.

  6. Fill oil tank with no more than 3.5 quarts (3.3 liters) of oil. Use the proper grade of oil for the lowest temperature expected before next oil change.

  7. en Caution

    Do not overfill oil tank. Doing so can result in oil carryover to the air cleaner leading to equipment damage and/or equipment malfunction. (00190a)

  8. Start engine and carefully check for oil leaks around drain plug and oil filter.

  9. Check engine oil level.

Applying Thin Oil Film
  1. Thin oil film ONLY
  2. Oil filter
  3. Mounting plate

Applying Thin Oil Film

Winter Lubrication


In colder climates, the engine oil change interval should be shorter than normal. Motorcycles used only for short runs must have the engine oil changed more frequently and have a thorough tank flush-out before new oil is put in. See an authorized dealer.

NOTE:

The further below freezing the temperature drops, the shorter the oil change interval should be.

Water vapor is a normal by-product of combustion in any engine. During cold weather operation, some of the water vapor condenses to liquid form on the cool metal surfaces inside the engine. In freezing weather this water will become slush or ice and, if allowed to accumulate too long, may block the oil lines and cause damage to the engine.

If the engine is run frequently and allowed to thoroughly warm up, most of this water will become vapor again and will be blown out through the crankcase breather.

If the engine is not run frequently and allowed to thoroughly warm up, this water will accumulate, mix with the engine oil and form a sludge that is harmful to the engine.

Transmission Lubrication


The transmission lubricant level should be checked monthly.

Refer to Regular Service Intervals: 2006 Softail Models. The transmission should be drained and refilled with fresh lubricant at proper intervals.

NOTE:

When checking the transmission lubricant level, motorcycle should be standing straight up. Keep motorcycle upright for a short period of time to equalize lubricant level in the transmission compartments.

Check Lubricant Level


  1. Ride motorcycle until engine is warmed up to normal operating temperature.

  2. When the engine reaches normal operating temperature, turn the engine off and position motorcycle straight up and level.

  3. See Transmission Filler Plug/Dipstick Lubricant Level. Remove the threaded filler plug/dipstick by turning the plug counterclockwise and pulling outward.

  4. Wipe off filler plug/dipstick. Place in filler hole and remove. (Dipstick should rest on lip of filler. Do not screw in tight. Lubricant level should be at the F(ULL) mark on the plug/dipstick when removed.)

  5. NOTE:

    Lubricant level should be between the two marks on the dipstick.

    en Warning

    Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d)

    en Caution

    When draining or adding lubricant, do not allow dirt, debris or other contaminants to enter the engine. (00198a)

  6. Add lubricant, if necessary. Do not overfill or leakage may occur.

  7. NOTES:
    • When filling the transmission, use GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05 quart).
    • The transmission fluid capacity is approximately 24 ounces (0.71 liters).
    • Inspect o-ring for tears or damage. Replace if required. Wipe any foreign material from plug.
  8. Install threaded filler plug/dipstick and tighten to 25-75 in-lbs (2.8-8.5 Nm).

Transmission Filler Plug/Dipstick Lubricant Level

Transmission Filler Plug/Dipstick Lubricant Level

Changing Transmission Fluid


  1. See Transmission Lubricant Check/Fill. Remove the threaded check/fill plug.

  2. See Transmission Drain Plug and O-ring. Remove transmission drain plug and drain lubricant into a suitable container.

  3. en Caution

    When draining or adding lubricant, do not allow dirt, debris or other contaminants to enter the engine. (00198a)

    NOTE:

    Do not overfill or leakage may occur. The transmission fluid capacity is approximately 24 ounces (0.71 liters).

    en Warning

    Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d)

    NOTE:

    Dispose of transmission lubricant in accordance with local regulations.

  4. Inspect o-ring for tears or damage on the drain plug. Replace if required. Wipe any foreign material from plug.

  5. Install drain plug and tighten to 14-21 ft-lbs (19.0-28.5 Nm).

  6. Fill the transmission with 20-24 oz. (591-710 ml) of GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05 quart).

  7. Install threaded filler/check plug and tighten to 25-75 in-lbs (2.8-8.5 Nm).

  8. Start engine and carefully check for oil leaks around drain plug.

Transmission Lubricant Check/Fill

Transmission Lubricant Check/Fill

Transmission Drain Plug and O-ring
  1. O-ring
  2. Transmission drain plug

Transmission Drain Plug and O-ring

Primary Chaincase Lubrication


Lubrication is a major factor in the performance and service life of the clutch components. Use the appropriate Harley-Davidson chaincase lubricant for all operating temperatures.

NOTE:

For model specific information regarding the primary chaincase capacity, refer to the appropriate Service Manual or see a Harley-Davidson dealer.

Primary Chain Adjustment


Refer to Regular Service Intervals: 2006 Softail Models. Primary (front) chain adjustment should be inspected at proper intervals.

NOTE:

If the chain is allowed to run loose, it will cause the motorcycle to jerk when running at low speed, and chain and sprockets will wear excessively. If this happens, see a Harley-Davidson dealer or proceed as follows.

en Warning

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)

  1. Remove seat. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal. See Battery: Softail Models.

  2. See Primary Chaincase Cover. On the left side of the vehicle, remove the four T27 TORX screws with flat washers to free the primary chain inspection cover from the primary chaincase cover. Discard inspection cover gasket.

  3. Check the primary chain tension. Push on the upper strand to verify that it has free up and down movement midway between the engine compensating sprocket (front) and the clutch sprocket (rear).

  4. Refer to Primary Chain Adjustment Table: Softail Models. Measure the free play to be sure that it falls within the ranges specified for a hot or cold engine.

  5. en Caution

    Do not adjust the primary chain tighter than specified. Running chain too tight will result in excessive wear. (00202a)

  6. If the chain is too tight or too loose, then adjustment is necessary. Proceed as follows:

    1. See Chain Tensioner Assembly. Locate the chain tensioner assembly and loosen the top center nut a maximum of two turns.

    2. Refer to Primary Chain Adjustment Table: Softail Models. Raise or lower the chain tensioner assembly as necessary to obtain the specified free play.

    3. Tighten the top center nut of the chain tensioner assembly to 21-29 ft-lbs (28.5-39.3 Nm).

  7. NOTES:
    • As chains stretch and wear, they run tighter at one spot than another. Always adjust the free play at the tightest spot in the chain.
    • Replace the primary chain if it is worn to the point where it cannot be properly adjusted.
    • Allowing the chain to run loose will cause the motorcycle to jerk when running at low speed resulting in excessive chain and sprocket wear.
  8. See Primary Chaincase Cover. Using a new gasket, position the primary chain inspection cover in the primary chaincase cover. Install four screws (with flat washers). Tighten the screws to 84-108 in-lbs (9.5-12.2 Nm).

Primary Chain Adjustment Table: Softail Models

FREE PLAY

IN.

MM

COLD engine

5/8-7/8

15.9-22.2

HOT engine

3/8-5/8

9.5-15.9



Primary Chaincase Cover
  1. Primary chain inspection cover
  2. Clutch inspection cover
  3. Screw tightening sequence

Primary Chaincase Cover

Chain Tensioner Assembly
  1. Center bolt nut
  2. Primary chain
  3. Shoe assembly

Chain Tensioner Assembly

Chaincase Lubricant


The chaincase lubricant level should be checked monthly.

Refer to Regular Service Intervals: 2006 Softail Models. The chaincase lubricant should be drained and refilled with fresh lubricant at proper intervals.

NOTE:

When checking the chaincase lubricant level, motorcycle should be standing STRAIGHT UP, not leaning on the jiffy stand. Keep motorcycle upright for a short period of time to equalize lubricant level in the chaincase compartments.

Check Lubricant Level


  1. Ride motorcycle until engine is warmed up to normal operating temperature.

  2. When motorcycle reaches normal operating temperature, turn engine off and position motorcycle STRAIGHT UP and LEVEL.

  3. See Clutch Cover. Using a T27 TORX drive head, remove five screws (3) (with captive washers) to free clutch inspection cover (2) from primary chaincase cover.

  4. en Caution

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

  5. See Lubricant Level with Motorcycle Upright. With vehicle standing upright, not leaning on the jiffy stand, the lubricant level must be visible in the bottom of the chaincase and must not be any higher than the bottom of the diaphragm spring.

  6. NOTE:

    Use only GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 98851-05 quart).

  7. Refer to procedure in Changing Chaincase Lubricant to install gasket and clutch inspection cover.

Clutch Cover
  1. Gasket
  2. Clutch inspection cover
  3. Screws with captive washer

Clutch Cover

Lubricant Level with Motorcycle Upright

Lubricant Level with Motorcycle Upright

Changing Chaincase Lubricant


  1. Ride motorcycle until engine is warmed up to normal operating temperature.

  2. en Caution

    When draining or adding lubricant, do not allow dirt, debris or other contaminants to enter the engine. (00198a)

  3. See Clutch Cover. Using a T27 TORX drive head, remove five screws (3) (with captive washers) to free clutch inspection cover (2) from primary chaincase cover.

  4. See Removal/Installation of Chaincase Drain Plug. Remove magnetic drain plug at bottom of primary chaincase cover. Drain lubricant into suitable container.

  5. NOTE:

    Dispose of chaincase lubricant in accordance with local regulations.

  6. Clean drain plug. If plug has accumulated a lot of debris, inspect the condition of the chaincase components.

  7. Inspect drain plug o-ring for cuts, tears or signs of deterioration. Replace as necessary.

  8. Install drain plug back into primary chaincase cover. Tighten plug to 36-60 in-lbs (4.1-6.8 Nm).

  9. en Caution

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

  10. Pour 26 ounces (0.77 liter) of GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 98851-05 quart) through the clutch inspection cover opening.

  11. en Warning

    Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d)

    en Caution

    When draining or adding lubricant, do not allow dirt, debris or other contaminants to enter the engine. (00198a)

    NOTE:

    Use only GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 98851-05 quart).

  12. To avoid punching holes in the clutch inspection cover gasket or enlarging existing holes, install clutch inspection cover and new gasket as follows:

    1. Align the triangular shaped hole in the gasket with the top hole in the clutch inspection cover. Be sure the rubber molding and the words "towards clutch" face the motorcycle.

    2. Insert screw (with captive washer) through clutch inspection cover and carefully thread it all the way through triangular shaped hole in gasket. Do not push screw through hole.

    3. Hang the clutch inspection cover on the primary chaincase cover flange by starting the top cover screw.

    4. Start the remaining four screws (with captive washers).

    5. Using a T27 TORX drive head, alternately tighten screws to 84-108 in-lbs (9.5-12.2 Nm) in the pattern shown in Clutch Cover.

Removal/Installation of Chaincase Drain Plug
  1. 36-60 in-lbs (4.1-6.8 Nm)

Removal/Installation of Chaincase Drain Plug

Rear Drive Belt: Softail Models


General


The inner tooth surface of the secondary belt has a thin coating of polyethylene lubricant. During initial operation, this coating will wear off as it is burnished into the belt fabric. This is a normal condition and not an indication of belt wear.

Refer to Regular Service Intervals: 2006 Softail Models. Belt tension is set at the factory and should be checked after the first 1000 miles (1600 kilometers) and at proper intervals thereafter.

Checking Deflection


See Check Belt Deflection: Softail Models. With the rear wheel on the ground and one rider sitting on the motorcycle, use the BELT TENSION GAUGE (Part No. HD-35381) to apply 10 lbs. (4.5 kg) of force at the midpoint of the top belt strand. Belt deflection should be 1/4-5/16 in. (6.4-7.9 mm). If belt tension adjustment is necessary, see a Harley-Davidson dealer or follow the instructions given in the applicable Service Manual.

en Warning

Be sure wheel and brake caliper are aligned. Riding with a misaligned wheel or brake caliper can cause the brake disc to bind and lead to loss of control, which could result in death or serious injury. (00050a)

Check rear brake caliper position on rear brake disc. Disc should run true within brake caliper.

Check Belt Deflection: Softail Models
  1. Transmission sprocket
  2. Rear wheel sprocket
  3. Force of 10 lbs (4.5 kg)
  4. Deflection of 1/4-5/16 in. (6.4-7.9 mm)

Check Belt Deflection: Softail Models

Chassis Lubrication


Refer to Regular Service Intervals: 2006 Softail Models for all maintenance schedules.

en Caution

Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a)

  1. Use recommended special purpose grease for steering head bearings. Use a multipurpose chassis grease for other applications.

  2. Remove and lubricate handlebar throttle control grip sleeve with fresh graphite at proper intervals.

  3. Lubricate throttle control cables and clutch control cable at proper intervals.

  4. Lubricate front brake hand lever and clutch control hand lever only if necessary.

  5. Inspect rear fork pivot shaft bearings.

  6. Pack the steering head bearings with fresh grease at proper intervals.

  7. Lubricate the jiffy stand mechanism with LOCTITE AEROSOL ANTI-SEIZE at proper intervals.

NOTE:

For model specific information regarding the chassis lubrication, refer to the appropriate Service Manual or see a Harley-Davidson dealer.

Oil Applications


Refer to Regular Service Intervals: 2006 Softail Models for all control connections and parts. Vehicle should be oiled at regular intervals, particularly after washing motorcycle or driving in wet weather.

Front Fork Oil


Refer to Regular Service Intervals: 2006 Softail Models. Drain front fork oil and refill at proper intervals. If fork does not appear to be working properly or an appreciable amount of oil leakage should develop, see a Harley-Davidson dealer. If there is insufficient oil in either side of fork, the rebound action will be incorrect.

Fuel Strainer


Carbureted Models Only


See Fuel Supply Valve. A screen type fuel strainer is located on top of the supply valve inside the fuel tank. Screen should be inspected/cleaned at proper intervals. Check the fuel valve, lines and fittings for leakage as part of the preride inspection. Refer to Regular Service Intervals: 2006 Softail Models.

Fuel Filter


EFI Models Only


Fuel injected motorcycles have a fuel filter attached to the fuel pump.

NOTE:

For model specific information regarding fuel filter maintenance, refer to the appropriate Service Manual or see a Harley-Davidson dealer.

Clutch


en Caution

The clutch control cable must be oiled and adjusted periodically to compensate for lining wear. See Service Interval Table. Failure to oil and adjust the clutch control cable can result in equipment damage. (00203a)

The need for attention to clutch and controls will be indicated by the clutch slipping under load or dragging when released. In this situation, check the control cable adjustment first. See a Harley-Davidson dealer for proper service.

Hydraulic Lifters


The hydraulic lifters are self-adjusting. They automatically adjust length to compensate for engine expansion and valve mechanism wear. This keeps the valve mechanism free of lash when the engine is running.

When starting an engine which has been turned off even for a few minutes, the valve mechanism may be slightly noisy until the hydraulic units completely refill with oil. If at any time the valve mechanism becomes abnormally noisy, other than for a short period immediately after engine is started, it is an indication that one or more of the hydraulic units may not be functioning properly.

Always check the oil supply in the oil tank first since normal circulation of oil through the engine is necessary for proper operation of the hydraulic units.

If there is oil in the tank, the units may not be functioning properly because of dirt in the oil supply passages leading to the lifter units. See a Harley-Davidson dealer for service.

Front Fork Bearings


en Warning

Adjustments to front fork bearings should be performed by a Harley-Davidson dealer. Improperly adjusted bearings can adversely affect handling and stability, which could result in death or serious injury. (00051a)

Refer to Regular Service Intervals: 2006 Softail Models. Check front fork for proper bearing adjustment and lubricate bearings at proper intervals.

With motorcycle front end raised off the floor, be sure front fork turns freely without any binding or interference and that there is no appreciable front to rear fork shake indicating excessive bearing looseness. Steering head bearings should be adjusted according to Service Manual procedure, if necessary.

Rear Fork Pivot Shaft


Refer to Regular Service Intervals: 2006 Softail Models. Check the tightness of the rear fork pivot shaft fastener at proper intervals.

NOTE:

For model specific information regarding the rear fork pivot shaft, refer to the appropriate Service Manual or see a Harley-Davidson dealer.

Brakes


en Warning

Inspect brake pads for wear at service maintenance intervals. If you ride under adverse conditions (steep hills, heavy traffic, etc.), inspect more frequently. Excessively worn brake pads can lead to brake failure, which could result in death or serious injury. (00052a)

NOTES:
  • Master cylinder cover specifies correct brake fluid.
  • When adding or changing brake fluid, be sure to use only the type specified for your motorcycle.
  • Use only Harley-Davidson D.O.T. 4 HYDRAULIC BRAKE FLUID (Part No. 99953-99A).
  • Do not mix D.O.T. 4 with D.O.T. 5 brake fluid.
  1. Refer to Regular Service Intervals: 2006 Softail Models. Check brake pads and brake discs for wear at proper intervals.

  2. Check the fluid level in the master cylinder reservoirs at proper intervals.

  3. If level is low, clean dirt and debris from reservoir cover before removing.

  4. en Caution

    D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b)

    en Caution Mark

    Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a)

  5. Add D.O.T. 4 HYDRAULIC BRAKE FLUID (Part No. 99953-99A) if necessary.

NOTE:

Use only D.O.T. 4 HYDRAULIC BRAKE FLUID (Part No. 99953-99A) approved for brake system use and available from your Harley-Davidson dealer.

Harley-Davidson has provided your new motorcycle with the optimum brake pad friction material available. It is selected to give the best performance possible under dry, wet and high operating temperature conditions. It exceeds all regulatory requirements currently in effect. However, during some braking conditions you may experience noise. This is normal for this friction material.

en Warning

Brakes are a critical safety component. Contact a Harley-Davidson dealer for brake repair or replacement. Improperly serviced brakes can adversely affect brake performance, which could result in death or serious injury. (00054a)

See Measuring Brake Outer Pads. Visual inspection of brake pads can be made without removing the caliper. View the lower area of each caliper with a flashlight.

en Warning

Perform routine scheduled brake maintenance. Lack of maintenance at recommended intervals can adversely affect brake performance, which could result in death or serious injury. (00055a)

en Warning

Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a)

NOTES:
  • If the brake pad friction material is 0.04 in. (1.02 mm) thick or less, the pads must be replaced immediately.
  • Always replace brake pads in pairs.

The rear brake outer pad on all models can be measured from the caliper bracket side using a thin plastic 6.0 in. (152.4 mm) rule. Place the rule against the brake disc through the space alongside the caliper.

The outer surface of the brake pad backing plate should measure 0.04 in. (1.02 mm) or more away from the brake disc.

NOTE:

Replace pads if brake friction material (1) is 0.04 in. (1.02 mm) or less above the backing plate.

Measuring Brake Outer Pads
  1. Front brake bottom view
  2. Rear brake top view

Measuring Brake Outer Pads

Brakes: Springer Models


Springer models have a single piston front brake. If the brake pad friction material is 0.06 in. (1.59 mm) thick or less (the thickness of a nickel), the pads must be replaced IMMEDIATELY.

Tires


See Specifications: 2006 Softail Models for tire pressures and sizes.

  • Be sure to keep tires properly inflated.
  • Follow tire data for correct cold tire inflation pressures.
  • Check before riding when tires are cold.
  • Do not over-inflate tires.
en Warning

Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out, which could result in death or serious injury. (00027a)

en Warning

Match tires, tubes, air valves and caps to the correct wheel rim. Contact a Harley-Davidson dealer. Mismatching can result in damage to the tire bead, allow tire slippage on the rim or cause tire failure, which could result in death or serious injury. (00023a)

Check inflation pressure and inspect tread for punctures, cuts, breaks, etc., at least weekly if in daily use. Check before each trip if used occasionally.

en Warning

Be sure tires are properly inflated, balanced and have adequate tread. Inspect your tires regularly and see a Harley-Davidson dealer for replacements. Riding with excessively worn, unbalanced or under-inflated tires can adversely affect stability and handling, which could result in death or serious injury. (00014a)

Same as original equipment tires should be used. Other tires may not fit correctly, could adversely affect handling, and may be hazardous to use.

en Warning

Tires are a critical safety component. Contact a Harley-Davidson dealer for tire repair or replacement. Improper tire service can adversely affect stability and handling, which could result in death or serious injury. (00057a)

en Warning

Replace punctured or damaged tires. In some cases, small punctures in the tread area may be repaired from within the demounted tire by a Harley-Davidson dealer. Speed should NOT exceed 50 mph (80 km/h) for the first 24 hours after repair, and the repaired tire should NEVER be used over 80 mph (130 km/h). Failure to follow this warning could result in death or serious injury. (00015a)

en Warning

Striking an object, such as a curb, can cause internal tire damage. If an object is struck, remove and inspect both the inside and outside of the tire. A damaged tire can adversely affect stability and handling, which could result in death or serious injury. (00058a)

Tire Replacement


Inspection


en Warning

Harley-Davidson tires are equipped with wear bars that run horizontally across the tread. When wear bars become visible and only 1/32 in. (0.8 mm) tread depth remains, replace tire immediately. Using a worn tire can adversely affect stability and handling, which could result in death or serious injury. Use only Dunlop Harley-Davidson replacement tires. (00090a)

See Tire Sidewall. Arrows on tire sidewalls pinpoint location of wear bar indicators.

Tread wear indicator bars will appear on tire tread surfaces when 1/32 in. (0.8 mm) or less of tire tread remains. See Tread Surface. Always replace tires before the tread wear indicator bars appear.

When To Replace Tires


New tires are needed if any of the following conditions exist:

  1. Tread wear indicator bars become visible on the tread surfaces.

  2. Tire cords or fabric become visible through cracked sidewalls, snags or deep cuts.

  3. A bump, bulge or split in the tire.

  4. Puncture, cut or other damage to the tire that cannot be repaired.

Tire Sidewall

Tire Sidewall

Tread Surface

Tread Surface

Shock Absorbers


Refer to Regular Service Intervals: 2006 Softail Models. Inspect shock absorbers and rubber bushings for leaks and bushing deterioration at proper intervals.

Spark Plugs


Refer to Regular Service Intervals: 2006 Softail Models. Check the spark plugs at proper intervals.

en Caution Mark

Do NOT pull on any electrical wires. Pulling on electrical wires may damage the internal conductor causing high resistance, which may result in minor or moderate injury. (00168a)

Disconnect spark plug cables from plugs by pulling on the molded connector caps. To reconnect, simply snap-on spark plug cables to tops of spark plugs.

Refer to Ignition System: 2006 Twin Cam Models before servicing spark plugs.

  1. Check spark plug type. Only use those spark plugs specified for your model motorcycle.

  2. Check spark plug gap against table specifications.

  3. Always tighten to the proper torque. Spark plugs must be tightened to the torque specified for proper heat transfer.

NOTE:

If a torque wrench is not available, tighten plugs finger tight and then tighten an additional one quarter turn with a spark plug wrench.

Ignition


The engine in your motorcycle has been designed specifically to achieve optimum fuel economy within exhaust emission controls. Factory programmed ignition characteristics provide maximum engine performance and driveability.

NOTE:

The ignition control unit monitors engine load. In certain transient load conditions (as the throttle is opened), the timing changes from normal to fully advanced. At this point, the operator can sometimes hear a noise that is similar to pre-ignition detonation.

This noise should not be confused with detonation which can be stopped by the use of a higher grade fuel. It is caused by the instant pressure rise in the combustion chambers as the spark advances rapidly. This noise doesn't affect engine performance.

Carburetor


The carburetor has been specifically designed for emissions control operation. All jets are fixed at the factory.

Carburetor controls include throttle, enrichener and idle speed adjusting screw. Operation should be checked and adjusted at proper intervals. Refer to Regular Service Intervals: 2006 Softail Models.

en Caution

Operation at higher altitudes (approximately 4000 ft. (1200 meters) elevation) can require carburetor modifications for best engine performance. See a Harley-Davidson dealer for these adjustments. Failure to do so could result in equipment damage. (00206a)

We recommend that any carburetor service be performed by a Harley-Davidson dealer.

Air Cleaner


See Air Cleaner: Twin Cam Models. The engine air cleaner is a paper/wire mesh air filter element.

Refer to Regular Service Intervals: 2006 Softail Models. Remove air cleaner cover and inspect filter element at proper intervals. Under dusty conditions, inspect more often.

The paper/wire mesh air filter element should be washed in luke warm water with a mild detergent.

en Warning

Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates. (00061a)

  • Allow filter to either air dry or blow it dry, from the inside, with low pressure air.
  • Do not use an air cleaner filter oil on the Harley-Davidson paper/wire mesh air filter element.
en Caution

Install air filter before running engine. Failure to do so can draw debris into the engine and could result in engine damage. (00207a)

Air Cleaner: Twin Cam Models
  1. Backplate
  2. Filter element
  3. Cover
  4. Cover screw
  5. Screws

Air Cleaner: Twin Cam Models

Headlamp


See Headlamp Bulbs: Softail Models. The headlamp assembly uses a replaceable quartz halogen bulb.

NOTE:

Refer to Bulb Chart: 2006 Softail Models and see a service manual for more details.

en Caution

When replacement is required, use only the specified sealed beam unit or bulb, available from a Harley-Davidson dealer. An improper wattage sealed beam or bulb, can cause charging system problems. (00209a)

en Caution

Never touch the quartz bulb. Fingerprints will etch the glass and decrease bulb life. Grab the bulb with paper or a clean, dry cloth. Failure to do so could result in bulb damage. (00210a)

en Warning

Handle bulb carefully and wear eye protection. Bulb contains Halogen gas under pressure, which, if not handled carefully, could cause serious eye injury. (00062a)

Headlamp Bulbs: Softail Models
  1. Bulb for FXST or FXSTB
  2. Lamp for FLSTC, FLST, FLSTF, FLSTN
  3. Bulb for FXSTS, FXSTD, FLSTS

Headlamp Bulbs: Softail Models

Headlamp Alignment: Softail Models


General


en Warning

The automatic-on headlamp feature provides increased visibility of the rider to other motorists. Be sure headlamp is on at all times. Poor visibility of rider to other motorists can result in death or serious injury. (00030b)

Check headlamp for proper height and lateral alignment:

  • When the new owner takes delivery of the motorcycle.
  • When there is a change in load such as additional luggage, etc.
  1. Refer to Tire Pressures: 2006 Softail Models. Verify correct front and rear tire pressure.

  2. Place motorcycle on level floor (or pavement) in an area with minimum light.

  3. Position motorcycle 25 ft. (7.6 m) away from a screen or wall. Measure the distance from directly below the front axle to the base of the screen/wall.

  4. Set mark for alignment purposes.

    1. See Headlamp Alignment: FX Softails and FLSTC/FLSTF/FLST/FLSTN International Models. For FXSTD, FXST, FXSTB, FXSTS, FLSTSC (and International FLSTC,FLST,FLSTF, FLSTN) vehicles, draw a horizontal line 35 in. (0.9 m) above floor on screen/wall.

    2. See Headlamp Alignment: FLSTC/FLST/FLSTF/FLSTN Domestic Models. For FLSTC, FLST, FLSTF, FLSTN vehicles, draw a horizontal line level with the center of the headlamp.

  5. Load vehicle with rider, passenger (if normally present) and any cargo. Weight will compress vehicle suspension slightly.

  6. Stand motorcycle upright with both tires resting on floor and with front wheel held in straight alignment (directly forward).

  7. See Headlamp Switch High Beam Setting. Turn ignition switch ON. Set handlebar headlamp switch to HIGH beam position.

  8. Check light beam for alignment.

    1. The main beam, which is a broad, flat pattern of light, should be centered equally above and below the horizontal line.

    2. The main beam of light should also be directed straight ahead. Properly adjusted headlamps project an equal area of light to right and left of center.

    3. Adjust headlamp alignment if necessary.

Headlamp Alignment: FX Softails and FLSTC/FLSTF/FLST/FLSTN International Models
  1. 25 feet (7.6 meters)
  2. 25 inches (0.9 meters) above floor

Headlamp Alignment: FX Softails and FLSTC/FLSTF/FLST/FLSTN International Models

Headlamp Alignment: FLSTC/FLST/FLSTF/FLSTN Domestic Models
  1. Level with center of headlamp
  2. 25 feet (7.6 meters)

Headlamp Alignment: FLSTC/FLST/FLSTF/FLSTN Domestic Models

Headlamp Switch High Beam Setting

Headlamp Switch High Beam Setting

FXSTS/FLSTSC Models


  1. See Headlamp Adjustment: FXSTS. Set vertical adjustment.

    1. Loosen the two vertical adjustment fasteners (1).

    2. Tilt headlamp up or down in relationship to the horizontal line from the headlamp alignment inspection.

    3. Tighten both fasteners to 25-35 ft-lbs (33.9-47.5 Nm).

  2. en Caution

    Position FXSTS headlamp as far forward as the slot will allow. This will prevent the headlamp from contacting the springs which can result in vehicle damage. (00250a)

  3. Set horizontal adjustment.

    1. Loosen the horizontal adjustment fastener (2).

    2. Tilt headlamp left or right to direct light beam straight ahead.

    3. Move headlamp adjustment mechanism forward to the end of the bracket slot.

    4. Tighten fastener to 25-35 ft-lbs (33.9-47.5 Nm).

FLSTC/FLSTF/FLST/FXSTB/FXST/FLSTN Models


  1. See Headlamp Adjustment: FLSTC, FLSTF, FXSTB, FXST. Loosen horizontal adjusting bolt (2) to adjust headlamp beam side to side.

  2. Tighten fastener to 30-35 ft-lbs (40.7-47.5 Nm).

  3. Loosen vertical adjusting bolt (1) to adjust headlamp up or down.

  4. Tighten fastener to 35-45 ft-lbs (47.5-61.0 Nm).

FXSTD Models


  1. See Headlamp Adjustment: FXSTD. Loosen horizontal adjusting bolt (2) to adjust headlamp beam side to side.

  2. Tighten fastener 25-30 ft-lbs (33.9-40.7 Nm).

  3. Loosen vertical adjusting bolt (1) to adjust headlamp up or down.

  4. Tighten fastener to 25-30 ft-lbs (33.9-40.7 Nm).

Headlamp Adjustment: FXSTS
  1. Vertical adjusting fastener (2)
  2. Horizontal adjusting fastener

Headlamp Adjustment: FXSTS

Headlamp Adjustment: FLSTC, FLSTF, FXSTB, FXST
  1. Vertical adjusting bolt (2)
  2. Horizontal adjusting bolt

Headlamp Adjustment: FLSTC, FLSTF, FXSTB, FXST

Headlamp Adjustment: FXSTD
  1. Vertical adjusting bolt
  2. Horizontal adjusting bolt

Headlamp Adjustment: FXSTD

Turn Signal Bulbs: Bullet Style


Replacement


  1. See Lens Cap Notch. To access the front or rear turn signal bulbs for replacement, locate a notch on the turn signal lens cap.

  2. Insert a coin in the lens cap notch, and carefully twist until the lens cap pops out of the lamp housing.

  3. Push in and twist the lamp bulb counterclockwise and pull lamp bulb out of the socket.

  4. Orient index pins on new lamp bulb with pin guides inside bulb socket.

  5. Push lamp bulb in and turn clockwise to lock in place.

  6. Snap lens cap back into the lamp holder.

Alignment


Refer to service manual for alignment procedure.

Lens Cap Notch

Lens Cap Notch

Turn Signal Bulbs: FLSTC Models


Replacement


  1. Loosen two screws on turn signal lens cap to detach lens cap.

  2. Push in and twist the lamp bulb counterclockwise and pull lamp bulb out of the socket.

  3. Orient index pins on new lamp bulb with pin guides inside bulb socket.

  4. Push lamp bulb in and turn clockwise to lock in place.

  5. Reinstall lens cap.

Tail Lamp: FLSTSC/FLSTN


Bulb Replacement


  1. See Tail Lamp Assembly: FLSTSC/FLSTN. Remove the lens.

  2. Turn the bulb 1/4 turn while pressing the bulb into the housing.

  3. Remove the bulb.

  4. Replace the bulb and reinstall the lens.

NOTE:

If after replacing bulb the tail lamp will not light, check the wiring, the ground at the socket and/or the switch.

Tail Lamp Assembly: FLSTSC/FLSTN
  1. Screws (3)
  2. Tail lamp connector
  3. Lamp housing
  4. Lens
  5. Nuts (3)
  6. Rubber grommet

Tail Lamp Assembly: FLSTSC/FLSTN

FXSTD Tail Lamp/License Plate Bulbs


Tail Lamp Access


  1. See Tail Lamp Removal Access Hole: FXSTD Models. Insert a small screwdriver into the middle hole of the license plate lamp cover. Push forward to release the clip on the tail lamp assembly.

  2. See Tail Lamp Removed: FXSTD Models. Lift the tail lamp assembly upward exposing the electrical connectors, tail lamp socket and the two license plate lamp sockets.

Tail Lamp Bulb Removal/Installation


  1. See Tail Lamp Assembly: FXSTD Models. Remove the tail lamp bulb socket by turning the socket counterclockwise and pulling outward away from the tail lamp housing.

  2. Push in and twist the lamp bulb counterclockwise and pull lamp bulb out of the socket.

  3. Orient index pins on new lamp bulb with pin guides inside bulb socket.

  4. Push lamp bulb into lamp bulb socket and turn clockwise to lock in place.

Tail Lamp Assembly Installation


  1. Orient the tail lamp bulb socket with the keyed indents in the tail lamp housing. Push in the tail lamp bulb socket and turn clockwise to lock in place.

  2. Route electrical connectors and cables to either side of the fender lamp well, away from the tail lamp bulb socket.

  3. NOTE:

    When installing the tail lamp assembly, make sure the tail lamp bulb is pointed toward the rear of the vehicle.

  4. See Tail Lamp Assembly: FXSTD Models. Install the tail lamp assembly, top first, with the indent in the clip touching the fender to lock in place. Then push the tail lamp assembly toward the front of the vehicle. Engage the rear cup into the opening in the fender lamp well and push down to lock in place. You will hear an audible click.

  5. NOTE:

    The clip indent must engage with the rear fender opening for the tail lamp to remain locked into position on the rear fender.

License Plate Lamp Bulb Removal/Installation


  1. Remove tail lamp housing assembly from fender well.

  2. See Tail Lamp Removed: FXSTD Models. Remove the license plate lamp bulb socket by twisting the bulb socket out of the license plate bulb holder.

  3. Pull lamp bulb out of the socket.

  4. Install new license plate lamp bulb by pushing bulb into socket.

  5. Install license plate lamp bulb socket back into the license plate bulb holder.

  6. Reinstall tail lamp housing assembly.

Tail Lamp Removal Access Hole: FXSTD Models

Tail Lamp Removal Access Hole: FXSTD Models

Tail Lamp Removed: FXSTD Models
  1. Tail lamp socket
  2. License plate lamp socket and lamp bulbs under fender

Tail Lamp Removed: FXSTD Models

Tail Lamp Assembly: FXSTD Models
  1. Housing
  2. Clip
  3. Tail lamp bulb socket
  4. Bulb

Tail Lamp Assembly: FXSTD Models

Alternator/Voltage Regulator


Charging Rate


The alternator output is controlled and changed to direct current by the voltage regulator.

  • The voltage regulator increases charging rate when battery is low or lamps are lit.
  • The voltage regulator decreases charging rate when battery charge is up.
en Caution

It is possible to overload your motorcycle's charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle's charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b)

NOTES:
  • This unit requires no interval attention. If any electrical system trouble is experienced that might be traceable to the alternator or voltage regulator, the motorcycle should be taken to a Harley-Davidson dealer who has the necessary electrical testing equipment to give the required attention.
  • For model specific information regarding the voltage regulator, refer to the appropriate Service Manual or see a Harley-Davidson dealer.

Battery: General


Type


Your motorcycle uses a permanently sealed, maintenance-free, lead/calcium and sulfuric acid battery. All batteries are shipped precharged and ready to be put into service. Do not attempt to open the battery for any reason.

Antidotes for Battery Acid

CONTACT

TREATMENT

External

Flush with water.

Internal

Drink large quantities of milk or water, followed by milk of magnesia, vegetable oil or beaten eggs. Get immediate medical attention.

Eyes

Flush with water. Get immediate medical attention.



en Warning

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

en Warning

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

en Warning

Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. (00019d)

en Warning

Never remove warning label attached to top of battery. Failure to read and understand all precautions contained in warning, could result in death or serious injury. (00064a)

Battery Warning Label
  1. Contents are corrosive
  2. Wear safety glasses
  3. Contents are explosive
  4. Keep flames away
  5. Read instructions
  6. Keep away from children

Battery Warning Label

Battery Warning Label Location

Battery Warning Label Location

Voltmeter Test


Refer to Voltmeter Test. The voltmeter test provides a general indicator of battery condition. Check the voltage of the battery to verify that it is in a 100 percent fully charged condition. If the open circuit (disconnected) voltage reading is below 12.6V, charge the battery and then re-check the voltage after the battery has set for one to two hours.

Voltmeter Test

READING IN VOLTS

PERCENT OF CHARGE

12.7

100

12.6

75

12.3

50

12.0

25

11.8

0



Cleaning and Inspection


Battery top must be clean and dry. Dirt and electrolyte on top of the battery can cause battery to self-discharge.

  1. Clean battery top with a solution of baking soda (sodium bicarbonate) and water. Use 5 teaspoons baking soda per quart or liter of water.

  2. When the solution stops bubbling, rinse off the battery with clean water.

  3. Clean cable connectors and battery terminals using a wire brush or fine grit sandpaper to remove any oxidation.

  4. Inspect and clean the battery screws, clamps and cables. Check for breakage, loose connections and corrosion.

  5. Check the battery posts for melting or damage caused by overtightening.

  6. Inspect the battery for discoloration, a raised top or a warped or distorted case. This might indicate that the battery has been frozen, overheated or overcharged.

  7. Inspect the battery case for cracks or leaks.

Charging


Never charge a battery without first reviewing the instructions for the charger being used. In addition to the manufacturer's instructions, follow these general safety precautions.

Charge the battery if any of the following conditions exist:

  • Vehicle lamps appear dim.
  • Electric starter sounds weak.
  • Battery has not been used for an extended period of time.
en Warning

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

en Warning

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

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

  2. en Caution

    Remove battery from motorcycle before charging. Electrolyte leakage will damage motorcycle parts. (00213a)

  3. Remove the battery from the motorcycle. See Battery: Softail Models.

  4. Place the battery on a level surface.

  5. en Warning

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

    en Warning

    Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)

    en Warning

    Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)

    en Caution

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

    NOTES:
    • The figures listed in the Amp-hour table assume that the battery is charging at room temperature. If warmer than room temperature, use a slightly shorter charging time. If colder, use a slightly longer charging time.
    • The use of constant current chargers to charge sealed maintenance free batteries is not recommended. Any overcharge will cause dry-out and premature battery failure. If a constant current charger is the only type available, do not exceed the charge times listed in 19 Amp Hour Battery Charging Rates/Times and do not continue charging the battery if it gets hot. When charging, never exceed 15 volts.
  6. Connect the red battery charger lead to positive (+) terminal of the battery.

  7. Connect the black battery charger lead to negative (-) terminal of the battery.

  8. NOTE:

    If the battery is still in the vehicle, connect the negative lead to the chassis ground. Make sure that the ignition and all electrical accessories are turned off.

  9. Step away from the battery and turn on the charger.

  10. en Warning

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

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

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

  13. Mark the charging date on the battery.

19 Amp Hour Battery Charging Rates/Times

READING

(VOLTS)

PERCENT

OF CHARGE

3 AMP

CHARGER

6 AMP

CHARGER

10 AMP

CHARGER

20 AMP

CHARGER

12.7

100

-

-

-

-

12.6

75

1 hour

50 minutes

55 minutes

30 minutes

15 minutes

12.3

50

3 hours

40 minutes

1 hour

50 minutes

1 hour

5 minutes

30 minutes

12.0

25

5 hours

15 minutes

2 hours

40 minutes

1 hours

35 minutes

45 minutes

11.8

0

7 hours

3 hours

30 minutes

2 hours

5 minutes

1 hour

5 minutes



Storage


en Caution

Turn engine over a few times to be sure there is no oil in the crankcase and that all oil has been pumped back into the oil tank. Stop engine and re-check oil level. Failure to do so can result in engine damage. (00071a)

en Caution

Do not allow battery to completely discharge. The electrolyte in a discharged battery will freeze. The more discharged a battery is, the more easily it can freeze and crack the battery case. (00218a)

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

If the motorcycle is to be stored with the battery installed, it will be necessary to connect a battery tender to maintain charge. See an authorized dealer for more information.

Self-discharge is a normal condition and occurs continuously. The rate of self-discharge depends on the ambient temperature and the battery's state of charge.

  • Batteries discharge at a faster rate at higher ambient temperatures.
  • To reduce the self-discharge rate, store battery in a cool (not freezing), dry place.
  • Charge the battery every month if stored at temperatures below 60° F. (16° C).
  • Charge the battery more frequently if stored in a warm area above 60° F. (16° C).
Effective Rate of Temperature on Battery Self-discharging Rate
  1. Capacity
  2. Months of stand
  3. Measured at 105 F (40 C)
  4. Measured at 77 F (25 C)

Effective Rate of Temperature on Battery Self-discharging Rate

Battery: Softail Models


Disconnection and Removal


Before you can inspect or disconnect your battery you must read the section containing information about seat removal.

en Warning

Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)

  1. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal.

  2. Unthread bolt and remove battery positive cable (red) from battery positive (+) terminal.

  3. Lift battery from battery box within oil tank cavity.

Installation and Connection


en Caution

Do not over-tighten bolts on battery terminals. Use recommended torque values. Over-tightening battery terminal bolts could result in damage to battery terminals. (00216a)

en Warning

Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)

en Warning

Do not allow positive (+) battery cable to contact ground with negative (-) cable connected. Resulting sparks can cause a battery explosion, which could result in death or serious injury. (00069a)

  1. Place the fully charged battery into the battery box located within oil tank cavity, terminal side forward.

  2. Install battery positive cable (+) (red) to battery positive (+) terminal.

  3. Tighten fastener to 60-96 in-lbs (6.8-10.8 Nm).

  4. Install battery negative cable (black) to battery negative (-) terminal.

  5. Tighten fastener to 60-96 in-lbs (6.8-10.8 Nm).

  6. en Caution

    Keep battery clean and lightly coat terminals with petroleum jelly to prevent corrosion. Failure to do so could result in damage to battery terminals. (00217a)

  7. Apply a light coat of petroleum jelly or corrosion retardant material to both battery terminals.

  8. en Warning

    After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)

  9. Install seat.

Jump Starting


Harley-Davidson does not recommend jump-starting a motorcycle. However, there may be circumstances when it is necessary to do so. Therefore, we suggest jump-starting be performed as follows:

en Warning

Be sure jumper cables touch only appropriate battery terminals or ground. Allowing jumper cables to touch each other can result in sparks and a battery explosion, which could result in death or serious injury. (00072a)

en Warning

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

en Caution

Harley-Davidson motorcycles have a 12 Volt battery. Be sure the booster vehicle has a 12 Volt system. Failure to do so could result in vehicle damage. (00220a)

NOTE:

This procedure presumes the BOOSTER battery is in another vehicle.

  1. Turn off all unnecessary lamps and accessories.

Positive Cable


  1. See Jump Start Cable Connections. Connect one end of a jumper cable to the DISCHARGED battery positive (+) terminal (1).

  2. Connect the other end of the same cable to the BOOSTER battery positive (+) terminal (2).

Negative Cable


en Warning

Do not connect negative (-) cable to or near the discharged battery negative (-) terminal. Doing so could cause a spark and explosion, which could result in death or serious injury. (00073a)

  1. Connect one end of a jumper cable to the BOOSTER battery negative (-) terminal (3).

  2. en Caution

    Do not connect the negative (-) cable to painted or chrome parts. Doing so could result in discoloration at the attachment point. (00221a)

  3. Connect other end of the same cable (4) to a safe ground, (away from the DISCHARGED battery).

  4. Start motorcycle.

  5. Disconnect cables in reverse order of steps 2, 3, 4, 5. That is: steps 5, 4, 3, 2.

Jump Start Cable Connections
  1. Discharged battery positive (+) terminal
  2. Booster battery positive (+) terminal
  3. Booster battery negative (-) terminal
  4. Ground

Jump Start Cable Connections

Electrical Protection: Softail Models


Fuses


See Fuse Block Location: Softail Models. The fuse block is below the seat and behind the battery. The block on carbureted models contains six 15 ampere replaceable fuses. The block on EFI models contains eight 15 ampere replaceable fuses. Additional spare fuses may be carried if the rider chooses to do so.

Fuse Removal


  1. Remove seat.

  2. en Warning

    To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)

  3. Disconnect and remove battery negative (-) cable (black) from battery negative (-) terminal.

  4. Pull cover away from fuse block.

  5. en Caution

    Always use replacement fuses that are of the correct type and amperage rating. Use of incorrect fuses can result in damage to electrical systems. (00222a)

  6. See Fuse Block: Softail Models (top view). Replace suspect fuse.

Fuse Installation


  1. Place cover over fuse block.

  2. Install battery negative cable (black) to battery negative (-) terminal.

  3. Tighten fastener to 60-96 in-lbs (6.8-10.8 Nm).

  4. en Warning

    After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)

  5. Install seat.

Fuse Block: Softail Models (top view)
  1. ECM 15 amp (EFI only)
  2. Fuel pump 15 amp (EFI only)
  3. Empty
  4. Empty
  5. Battery
  6. Accessories
  7. Instruments
  8. Ignition
  9. Lamps
  10. Start relay
  11. System relay
  12. Spare fuse (15 amp)
  13. Spare fuse (15 amp)
  14. Empty

Fuse Block: Softail Models (top view)

Fuse Block Location: Softail Models
  1. Battery
  2. Fuse block

Fuse Block Location: Softail Models

Seats: Softail Models


General


See Seat Tongue and Frame Back. All Softail Harley-Davidson motorcycles have a tongue underneath the seat that slides into a slot in the back end of frame.

Seat Tongue
  1. Tongue
  2. Seat bottom

Seat Tongue

Frame Back

Frame Back

Seats: FL Softail Models (Except FLSTSC/FLSTN)


Removal


  1. See Seat: FLSTC/FLSTF. Remove seat mounting screw from top of rear fender.

  2. Remove two mounting fasteners (5) located on both sides of the seat.

  3. See Seat Strap: Softail Models. Locate the seat strap bracket on the LEFT side of the motorcycle.

  4. Loosen strap bracket by grasping and pressing down firmly.

  5. See Pushing/Pulling Strap Bracket. Pull out to free the left side of the strapbracket.

  6. See Seat Tongue. Push seat rearward to free tongue at front of seat from slot or bracket located in frame back.

  7. NOTES:
    • For FLSTC/FLST models skip step 7 and proceed to step 9.
    • For FLSTF models proceed to step 7.
  8. Turn seat over to reveal a looped snap on the seat strap.

  9. Unsnap loop to loosen seat strap.

  10. Slide seat through seat strap to remove.

  11. NOTE:

    To detach pillion seat from drivers seat, remove the pillion mounting fasteners.

Installation


NOTES:
  • See Seat: FLSTC/FLSTF. To attach pillion seat to driver's seat, tighten the pillion mounting fasteners until snug.
  • For FLSTC/FLST models skip step 1 and proceed to step 3.
  • For FLSTF models proceed with step 1.
  1. Locate looped snap on seat strap.

  2. See Seat: FLSTC/FLSTF. Place seat through the seat strap.

  3. Snap loop together to tighten seat strap.

  4. Slide seat toward front of motorcycle until the tongue locks into the open end of the frame back.

  5. Install the two seat (5) mounting fasteners to the frame; secure until snug.

  6. Install pillion mounting fastener on fender. Secure until snug.

  7. See Pushing/Pulling Strap Bracket. Place seat strap bracket end over mounting fasteners in frame.

  8. See Pushing/Pulling Strap Bracket. Pull up on strap bracket to ensure fit. Secure until snug.

  9. en Warning

    After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)

  10. See Seat Strap: Softail Models. Pull up on seat to verify that it is properly secured.

Seat: FLSTC/FLSTF
  1. Pillion
  2. Seat mounting bracket
  3. Pillion mounting fasteners
  4. Driver seat
  5. Seat mounting fasteners
  6. Seat strap

Seat: FLSTC/FLSTF

Seat Strap: Softail Models

Seat Strap: Softail Models

Pushing/Pulling Strap Bracket

Pushing/Pulling Strap Bracket

Remove/Placing Strap Bracket

Remove/Placing Strap Bracket

Seats: FLSTSC/FLSTN/FLST


Removal/Installation


en Warning

After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)

See Seat: FLSTSC/FLSTN/FLST Models and Seat Mounting Stud. The passenger seat attaches with a single thumbscrew (1) at the rear and engages the seat mounting nuts (4) at the front.

To remove seat, remove passenger seat (2, 7) and seat mounting nuts (4). When installing seat, insert tang at front of seat into the channel in the frame and install seat mounting nuts. Install passenger seat.

Seat: FLSTSC/FLSTN/FLST Models
  1. Thumbscrew
  2. Passenger seat (FLSTSC/FLST)
  3. Seat strap (FLSTSC/FLST)
  4. Seat mounting nut (2)
  5. Seat (FLSTSC/FLST)
  6. Seat (FLSTN)
  7. Passenger seat (FLSTN)

Seat: FLSTSC/FLSTN/FLST Models

Seat Mounting Stud

Seat Mounting Stud

Seats: FX Softail Models


Removal


  1. See Seat: FX Softail Models. Remove seat mounting screw from top of rear fender.

  2. See Seat Tongue. Push seat rearward to free tongue at front of seat from slot or bracket in frame back.

  3. Remove seat from frame.

  4. Install seat mounting screws to fender. Secure until snug.

NOTE:

The FXSTB model does not have a removable seat bracket. It is riveted to the bottom of the seat.

Installation


  1. Place seat on frame back.

  2. Slide seat toward front of motorcycle until the tongue locks into the bracket or slot in the frame back.

  3. Push seat forward until rear fender seat retention nut is centered in hole of mounting bracket.

  4. Install seat mounting screw.

  5. en Warning

    After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)

  6. Pull up on seat to verify that it is properly secured.

Seat: FX Softail Models
  1. Seat mounting fastener
  2. Seat

Seat: FX Softail Models

Motorcycle Storage


Placing Motorcycle in Storage


en Caution

Proper storage is important for the trouble-free operation of your motorcycle. See your Owner's Manual for storage recommendations or see a Harley-Davidson dealer. Improper storage procedures can lead to equipment damage. (00046a)

If the motorcycle will not be operated for several months, such as during the winter season, there are several tasks which should be performed. These steps will protect parts against corrosion, preserve the battery and prevent the build-up of gum and varnish in the fuel system.

en Warning

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

NOTE:

Make a list of everything you do and fasten it to a handgrip. When you take the motorcycle out of storage, this list will be your reference/checklist to get your motorcycle in operating condition.

  1. Fill fuel tank and add a gasoline stabilizer. Use one of the commercially available gasoline stabilizers and follow the manufacturer's instructions.

  2. Warm motorcycle to operating temperature. Change oil and turn engine over to circulate the new oil.

  3. Adjust the belt.

  4. Check tire inflation. Adjust to proper inflation pressure.

  5. To protect the vehicle's body panels, engine, chassis and wheels from corrosion, follow the cosmetic care procedures described in the Accessory Maintenance section of this owner's manual prior to storage.

  6. Prepare battery for winter storage. See Battery: General.

  7. en Warning

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

  8. If the motorcycle is to be stored with security system armed, it will be necessary to connect a Battery Tender to maintain battery charge. If security system will not be armed and a Battery Tender is not available, either:

    1. Disconnect negative battery cable.

    2. Remove Maxi-fuse (if applicable).

  9. If motorcycle is to be covered, use a material such as light canvas that will breathe. Plastic materials that do not breathe promote the formation of condensation.

Removing Motorcycle From Storage


en Warning

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

  1. See Battery: General for proper battery care. Charge and install the battery.

  2. Remove and inspect the spark plugs. Replace if necessary.

  3. Clean the air cleaner element.

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

  5. Check amount of oil in the oil tank.

  6. Check the transmission lubricant level.

  7. Check controls to be sure they are operating properly. Operate the front and rear brakes, throttle, clutch and shifter.

  8. Check steering for smoothness by turning the handlebars through the full operating range.

  9. en Warning

    Be sure tires are properly inflated, balanced and have adequate tread. Inspect your tires regularly and see a Harley-Davidson dealer for replacements. Riding with excessively worn, unbalanced or under-inflated tires can adversely affect stability and handling, which could result in death or serious injury. (00014a)

  10. Check tire pressure. Incorrect pressure will result in poor riding characteristics and can affect handling and stability.

  11. Check all electrical equipment and switches including the stop lamp, turn signals and horn for proper operation.

  12. Check for any fuel, oil or brake fluid leaks.

en Caution

Turn engine over a few times to be sure there is no oil in the crankcase and that all oil has been pumped back into the oil tank. Stop engine and re-check oil level. Failure to do so can result in engine damage. (00071a)