Harley Davidson FLHRC 2006. Maintenance & Repair Manual

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Oil pan overfilled.

Inlet valve and/or valve seat worn or damaged.

Rocker housing gasket (bottom) installed upside down.

Float misadjusted.

Leaky or damaged float.

Low Oil Pressure

Excessive “pumping” of hand throttle grip.

Oil pan underfilled.

See TROUBLESHOOTING CHART in Section 4.

Faulty low oil pressure switch.

Oil pump O-ring(s) damaged or missing.

Oil pressure relief valve stuck in open position.

TRANSMISSION

Ball missing from cam support plate.

Transmission Shifts Hard

High Oil Pressure

Clutch dragging slightly.

Oil pan overfilled.

Primary chaincase overfilled with lubricant.

Oil pressure relief valve stuck in closed position.

Corners worn off shifter clutch dogs.

Shifter return spring bent or broken.

Bent shifter rod.

ELECTRICAL SYSTEM

Shifter forks sprung.

Transmission lubrication too heavy (winter operation).

Alternator Does Not Charge

Module not grounded.

Jumps Out Of Gear

Engine ground wire loose or broken.

Shifter rod improperly adjusted.

Faulty regulator-rectifier module.

Shifter drum damaged.

Loose or broken wires in charging circuit.

Shifter engaging parts (inside transmission) badly worn

Faulty stator and/or rotor.

and rounded.

Shifter forks bent.

Alternator Charge Rate Is Below Normal

Damaged gears.

Weak or damaged battery.

Loose connections.

Clutch Slips

Faulty regulator-rectifier module.

Clutch controls improperly adjusted.

Faulty stator and/or rotor.

Insufficient clutch spring tension.

Worn friction discs.

Speedometer Operates Erratically

Contaminated speedometer sensor (remove sensor and

Clutch Drags Or Does Not Release

clean off metal particles).

Loose connections.

Clutch controls improperly adjusted.

Lubricant level too high in primary chaincase.

Primary chain badly misaligned.

CARBURETOR

Clutch discs warped.

Insufficient clutch spring tension.

Carburetor Floods

Clutch Chatters

Dirt or other foreign matter between valve and its seat.

Inlet valve sticking.

Friction discs or steel discs worn or warped.

2006 Touring: Maintenance

1-39

HOME

BRAKES

HANDLING

Brake Does Not Hold Normally

Irregularities

Master cylinder reservoir low on fluid.

Improperly loaded motorcycle. Non-standard equipment

on the front end such as heavy radio receivers, extra

Brake system contains air bubbles.

lighting equipment or luggage tends to cause unstable

Master or wheel cylinder piston worn or parts damaged.

handling.

Brake pads contaminated with grease or oil.

Incorrect air suspension pressure.

Damaged tire(s) or improper front-rear tire combination.

Brake pads badly worn- friction material 0.04 inch (1.02

mm) thick or less.

Irregular or peaked front tire tread wear.

Brake disc badly worn or warped.

Incorrect tire pressure.

Brake fades due to heat build up - brake pads dragging

Shock absorber not functioning normally.

or excessive braking.

Loose wheel axle nuts. Tighten to recommended tight-

Brake drags - insufficient brake pedal free play.

ness.

Excessive wheel hub bearing play.

Improper vehicle alignment.

10.

Steering head bearings improperly adjusted. Correct

adjustment and replace pitted or worn bearings and

races.

11.

Tire and wheel unbalanced.

12.

Rims and tires out-of-round or eccentric with hub.

13.

Rims and tires out-of-true sideways.

14.

Shock absorber improperly adjusted.

15.

Worn engine stabilizer links.

16.

Damaged rear engine isolation mounts.

17.

Swingarm pivot shaft nut improperly tightened or assem-

bled.

1-40

2006 Touring: Maintenance

Table Of Contents

CHASSIS

SUBJECT

PAGE NO.

2.1 Specifications

2-1

2.2 Vehicle Identification Number (V.I.N.)

2-5

2.3 Front Wheel

2-6

2.4 Rear Wheel

2-11

2.5 Checking Rim Runout

2-18

2.6 Wheel Lacing-16 Inch Rim

2-19

2.7 Truing Laced Wheel

2-22

2.8 Tires And Tubes

2-24

2.9 Vehicle Alignment

2-28

2.10 Front Brake Master Cylinder

2-34

2.11 Rear Brake Master Cylinder

2-39

2.12 Front Brake Caliper

2-48

2.13 Rear Brake Caliper

2-55

2.14 Bleeding Hydraulic Brake System

2-62

2.15 Front Forks

2-64

2.16 Lower Fork Bracket Cover/Air Dam

2-70

2.17 Steering Head Bearings

2-71

2.18 Rear Air Suspension

2-75

2.19 Rear Shock Absorbers

2-79

2.20 Rear Swingarm

2-81

2.21 Throttle Cables (Non-Cruise)

2-88

2.22 Clutch Cable

2-93

2.23 Handlebars

2-97

2.24 Mirrors

2-101

2.25 Seat

2-102

2.26 Saddlebag

2-106

2.27 Tour-Pak

2-113

2.28 Tour-Pak Lights/Backrest/Speaker Box

2-121

2.29 Lower Fairing/Engine Guard

2-126

2.30 Upper Fairing/Windshield (FLHX, FLHT/C/U)

2-129

2.31 Upper Fairing/Windshield (FLTR)

2-136

2.32 Windshield/Headlamp Nacelle (FLHR/C/S)

2-146

2.33 Front Fender

2-150

2.34 Rear Fender

2-152

2.35 Rear Facia (FLHX)

2-156

2.36 Jiffy Stand

2-158

2.37 Footboards/Footrests

2-160

2.38 Exhaust System

2-164

Table Of Contents

CHASSIS

SUBJECT

PAGE NO.

2.1 Specifications

2-1

2.2 Vehicle Identification Number (V.I.N.)

2-5

2.3 Front Wheel

2-6

2.4 Rear Wheel

2-11

2.5 Checking Rim Runout

2-18

2.6 Wheel Lacing-16 Inch Rim

2-19

2.7 Truing Laced Wheel

2-22

2.8 Tires And Tubes

2-24

2.9 Vehicle Alignment

2-28

2.10 Front Brake Master Cylinder

2-34

2.11 Rear Brake Master Cylinder

2-39

2.12 Front Brake Caliper

2-48

2.13 Rear Brake Caliper

2-55

2.14 Bleeding Hydraulic Brake System

2-62

2.15 Front Forks

2-64

2.16 Lower Fork Bracket Cover/Air Dam

2-70

2.17 Steering Head Bearings

2-71

2.18 Rear Air Suspension

2-75

2.19 Rear Shock Absorbers

2-79

2.20 Rear Swingarm

2-81

2.21 Throttle Cables (Non-Cruise)

2-88

2.22 Clutch Cable

2-93

2.23 Handlebars

2-97

2.24 Mirrors

2-101

2.25 Seat

2-102

2.26 Saddlebag

2-106

2.27 Tour-Pak

2-113

2.28 Tour-Pak Lights/Backrest/Speaker Box

2-121

2.29 Lower Fairing/Engine Guard

2-126

2.30 Upper Fairing/Windshield (FLHX, FLHT/C/U)

2-129

2.31 Upper Fairing/Windshield (FLTR)

2-136

2.32 Windshield/Headlamp Nacelle (FLHR/C/S)

2-146

2.33 Front Fender

2-150

2.34 Rear Fender

2-152

2.35 Rear Facia (FLHX)

2-156

2.36 Jiffy Stand

2-158

2.37 Footboards/Footrests

2-160

2.38 Exhaust System

2-164

HOME

SPECIFICATIONS

2.1

DIMENSIONS (IN.)

DIMENSIONS (MM)

FLHX

FLHR/C/S

FLTR

FLHR/C/S

FLTR

FLHT/C/U

Wheel Base

63.5

Wheel Base

1613

94.5

2400

Overall Length

93.7

Overall Length

2380

93.7/97.5/98.3

2380/2476/2497

Overall Width

39.0

34.5/34.5/39.4

35.8

Overall Width

991

876/876/1001

909

4.7

119

Road Clearance

5.1/5.1/4.7

5.1

Road Clearance

130/130/119

130

5.1/5.1/5.1

130/130/130

52.2

1326

Overall Height

55.1/55.1/46.4

55.0

Overall Height

1399/1399/1179

1397

61.0/61.0/61.0

1549/1549/1549

26.3

668

Saddle Height*

27.3/26.9/26.1

26.9

Saddle Height*

693/683/663

683

27.3/27.3/27.3

693/693/693

* With 180 Lb. Rider

* With 81.6 kg Rider

WEIGHT (LBS.)

WEIGHT (KG)

FLHX

FLHR/C/S

FLTR

FLHR/C/S

FLTR

FLHT/C/U

745

338

DRY WEIGHT**

723/710/721

731

DRY WEIGHT**

328/322/327

758/776/788

344/352/358

332

GVWR

1259

GVWR

571

GAWR - Front

500

GAWR - Front

227

GAWR - Rear

827

GAWR - Rear

375

** As shipped from the factory

NOTE

Gross Vehicle Weight Rating (GVWR) (maximum allowable

loaded vehicle weight) and corresponding Gross Axle Weight

Ratings (GAWR) are given on a label located on the inside of

the right front frame downtube.

CAPACITIES (U.S.)

CAPACITIES (METRIC)

FLHX

FLHR/C/S

FLTR

FLHR/C/S

FLTR

FLHT/C/U

Fuel Tank (gallons)

Fuel Tank (liters)

Total***

18.9

Reserve

0.9

Reserve

3.4

Oil Tank (quarts)

Oil Tank (liters)

3.78

with filter

Transmission

20-24

591-710

(Ounces, approximate)

(Milliliters)

Primary Chaincase

946

(Ounces, approximate)

(Milliliters)

Left

Right

Left

Right

Left

Right

Left

Right

Left

Right

Left

Right

Front Fork (Ounces)

Front Fork (Milliliters)

10.8

11.1

10.8

319

328

319

*** Includes Reserve on Carbureted Models

2006 Touring: Chassis

2-1

HOME

TIRE DATA

TORQUE VALUES

Item

ft/in-lbs

1WARNING

Front brake disc TORX

Match tires, tubes, air valves and caps to the correct

16-24 ft-lbs

22-33 Nm

screws

wheel rim. Contact a Harley-Davidson dealer. Mismatch-

ing can result in damage to the tire bead, allow tire slip-

Front axle nut

50-55 ft-lbs

68-75 Nm

page on the rim or cause tire failure, which could result

Front axle holder nuts

132-180 in-lbs

14.9-20.3 Nm

in death or serious injury. (00023a)

Front brake caliper

28-38 ft-lbs

37.9-51.5 Nm

mounting bolts

1WARNING

Rear brake disc TORX

30-45 ft-lbs

41-61 Nm

screws

Using tires in ways other than those specified below may

adversely affect motorcycle stability. Instability may lead

Rear wheel sprocket bolts

55-65 ft-lbs

75-88 Nm

to loss of vehicle control, which could result in death or

Rear axle cone nut

95-105 ft-lbs

129-142 Nm

serious injury.

Wheel spokes

40-50 in-lbs

4.5-5.6 Nm

● Use tubeless tires on all Harley-Davidson cast and

Front engine mount to

15-20 ft-lbs

20-27 Nm

disc wheels.

frame bolts

Front engine mounting

● Tubeless tires fitted with the correct size inner tubes

bracket to rubber mount

15-20 ft-lbs

20-27 Nm

also may be used on all Harley-davidson laced

bolt

wheels, but protective rubber rim strips must be

Voltage regulator locknuts

70-100 in-lbs

7.9-11.3 Nm

installed to prevent damage to the inner tubes.

Handlebar clamp to

master cylinder housing

60-80 in-lbs

6.8-9.0 Nm

● Do not use inner tubes in radial tires. Do not use

TORX screws

radial tires on laced wheels.

Brake caliper bleeder

80-100 in-lbs

9.0-11.3 Nm

● Always use the correct size tires and tubes. Tire

valve

sizes are molded on the tire sidewall. Tube sizes are

Rear brake pedal shaft

15-20 ft-lbs

20-27 Nm

printed on the tube.

locknut

Brake pedal/master

cylinder assembly to

30-40 ft-lbs

41-54 Nm

1WARNING

mounting bracket hex nut

Do not inflate tire beyond maximum pressure as speci-

Banjo bolt to master

17-22 ft-lbs

23-30 Nm

fied on sidewall. Over inflated tires can blow out, which

cylinder

could result in death or serious injury. (00027a)

Banjo bolt to brake caliper

17-22 ft-lbs

23-30 Nm

Fairing

lower

U-bolt

35-40 in-lbs

4.0-4.5 Nm

Tire Pressure (Cold)

retainer locknuts

Dunlop Tires

Fairing lower to engine

90-100 in-lbs

10.2-11.3 Nm

Front

Rear

guard clamp TORX screw

Only

PSI

BARS

PSI

BARS

Fairing lower cap screws

10-15 in-lbs

1.1-1.7 Nm

Front brake master

Solo Rider

2.5

cylinder reservoir cover

6-8 in-lbs

0.7-0.9 Nm

Rider & One Passenger

2.5

2.8

screws

Rear brake master

cylinder reservoir cover

6-8 in-lbs

0.7-0.9 Nm

screws

REAR WHEEL SPROCKET

Brake caliper pad pins

180-200 in-lbs

20-23 Nm

Brake caliper bridge bolts

28-38 ft-lbs

38-52 Nm

70 teeth

Mirror stem acorn nut

60-96 in-lbs

6.8-10.8 Nm

Mirror flange nut (FLHX)

20-30 in-lbs

2.3-3.4 Nm

Rear bumper fender weld

45-85 in-lbs

5.1-9.6 Nm

stud flange nut

Continued ...

2-2

2006 Touring: Chassis

HOME

TORQUE VALUES (CONT.’D)

Item

ft/in-lbs

Item

ft/in-lbs

Fork oil drain plugs

72-96 in-lbs

8-11 Nm

Instrument nacelle to fork

15-20 ft-lbs

20-27 Nm

bracket TORX bolts (FLTR)

Fork pinch bolts

30-35 ft-lbs

41-48 Nm

Fairing bracket/steering

Fork stem nut

60-80 ft-lbs

81-109 Nm

20-30 ft-lbs

27.1-40.7 Nm

head thru bolt (FLTR)

Fork tube plug

22-58 ft-lbs

30-79 Nm

Radio bracket/inner fairing

to fairing bracket stud lock-

96-144 in-lbs

10.9-16.3 Nm

Fork cap bolt

50-60 ft-lbs

68-81 Nm

nuts (FLTR)

Damper rod 6mm screw

132-216 in-lbs

14.9-24.4 Nm

Headlamp nacelle handle-

Shock bottom mounting

bar clamp shroud Phillips

10-20 in-lbs

1.1-2.3 Nm

35-40 ft-lbs

47-54 Nm

bolt

screw

Shock top mounting bolt

33-35 ft-lbs

45-48 Nm

Headlamp nacelle trim

15-20 in-lbs

1.7-2.3 Nm

strip flange nut

Rear swingarm bracket

34-42 ft-lbs

46-57 Nm

bolts

Auxiliary lamp bracket to

fork bracket stud acorn

72-108 in-lbs

8.1-12.2 Nm

Rear swingarm pivot shaft

40-45 ft-lbs

54-61 Nm

nuts

locknut

Front fender mounting

Handlebar switch

16-20 ft-lbs

22-27 Nm

35-45 in-lbs

4-5 Nm

bolts

housing TORX screws

Rear fender TORX bolts

15-20 ft-lbs

20-27 Nm

Handlebar clamp to clutch

60-80 in-lbs

6.8-9.0 Nm

lever bracket screws

Jiffy stand leg stop flange

43-53 ft-lbs

58-72 Nm

Clutch release cover

nut

84-132 in-lbs

9.5-14.9 Nm

socket head screws

Intake flange adapter

96-144 in-lbs

10.9-16.3 Nm

Clutch cable fitting

36-60 in-lbs

4-7 Nm

screws

Transmission lubricant

Exhaust flange adapter

100-120 in-lbs

11.3-13.6 Nm

14-21 ft-lbs

19-28 Nm

nuts

drain plug

Exhaust pipe TORCA

Transmission filler plug/dip-

45-60 ft-lbs

61-81 Nm

25-75 in-lbs

2.8-8.5 Nm

clamps

stick

Heat shield worm drive

Battery cable bolt

60-96 in-lbs

6.8-10.9 Nm

20-40 in-lbs

2.3-4.5 Nm

clamps

Tour-Pak mounting bolts

96-108 in-lbs

10.8-12.2 Nm

Transmission exhaust

60-96 in-lbs

6.8-10.8 Nm

Tour-Pak speaker box bolts

25-35 in-lbs

2.8-4.0 Nm

bracket clamp bolt

Tour-Pak metal plate

Passenger footboard/

65-70 in-lbs

7.3-7.9 Nm

30-35 ft-lbs

40.7-47.5 Nm

flange nuts

footrest socket screws

Side marker light TORX

Rider footboard

25-35 in-lbs

2.8-4.0 Nm

84-108 in-lbs

9.5-12.2 Nm

screws

pivot bolt nut

Inner fairing screws

20-30 in-lbs

2.3-3.4 Nm

Air valve mount hex nut

40-50 in-lbs

4.5-5.6 Nm

Outer fairing screws (below

Handlebar upper clamp

25-30 in-lbs

2.8-3.4 Nm

12-16 ft-lbs

16.3-21.7 Nm

windshield)

screws

Fairing cap TORX screws

25-30 in-lbs

2.8-3.4 Nm

Handlebar lower clamp

30-40 ft-lbs

40.7-54.2 Nm

bolts (risers)

Speedometer/tachometer

10-20 in-lbs

1.1-2.3 Nm

bracket socket screws

Ignition switch nut

125-150 in-lbs

14.1-16.9 Nm

2 inch diameter gauge nuts

10-20 in-lbs

1.1-2.3 Nm

Throttle cable J-clamp

9-18 in-lbs

1.0-2.0 Nm

screw to wellnut (FLHR/C)

Auxiliary lamp bracket to

15-20 ft-lbs

20-27 Nm

Frame tube cover screw

25-40 in-lbs

2.8-4.5 Nm

fork bracket TORX bolts

Seat screw

20-40 in-lbs

2.3-4.5 Nm

Windshield wellnut screws

6-13 in-lbs

0.7-1.5 Nm

(FLTR)

Seat strap bracket screw

48-72 in-lbs

5.4-8.1 Nm

Front turn signal lamp

(FLHT/C/U)

bracket stud acorn nuts

40-50 in-lbs

4.5-5.7 Nm

New

Rear facia

80 in-lbs

9.0 Nm

(FLTR)

Stud Plate

flange nuts

Short fairing screws

Used

6-12 in-lbs

0.7-1.4 Nm

(FLHX)

20-30 in-lbs

2.3-3.4 Nm

(FLTR)

Stud Plate

Long fairing screws (FLTR)

10-15 in-lbs

1.1-1.7 Nm

Rear facia lamp TORX

18-22 in-lbs

2.0-2.5 Nm

screws (FLHX)

Instrument bezel TORX

25-35 in-lbs

2.8-4.0 Nm

screws (FLTR)

Continued ...

2006 Touring: Chassis

2-3

HOME

VEHICLE IDENTIFICATION NUMBER (V.I.N.)

2.2

See Figure 2-1. The full 17-digit serial number, or Vehicle

Sample V.I.N. as it appears on the steering head

Identification Number (V.I.N.), is stamped on the right side of

1HD1DJV136Y110000

the frame backbone at the rear of the steering head (and

Sample abbreviated V.I.N. as it appears on the crankcase -

under the main harness conduit). A label bearing the V.I.N.

DJV6110000

code is also affixed to the left side of the steering head. An

NOTE

abbreviated V.I.N. is stamped between the front and rear cyl-

Always give the complete V.I.N. when ordering parts or mak-

inders on the left side of the crankcase.

ing an inquiry about your motorcycle.

DJ V

110000

Figure 2-1. Vehicle Identification Number (V.I.N.)

Table 2-1. V.I.N. Description

ITEM

DESCRIPTION

VALUE

1=Domestic

Market destination

5=International

Manufacturer

HD=Harley-Davidson

Motorcycle type

1=Heavyweight

Model designation

See Table 2-2.

V=Carbureted

Engine type

W=Fuel injected

1=Regular

3=California

Introduction

2=Mid-year

4=Anniversary

V.I.N. check digit

Can be 0-9 or X

Model year

6=2006

K=Kansas City, MO

Assembly plant

Y=York, PA

Sequential number (last 6 digits)

Varies

Table 2-2. Model Designation

CODE

MODEL

CODE

MODEL

FLHT

FLTRI

FLHRI

FLHTI

FLHTCUI

FLHRI Shrine

FLHR

FLHRS

FLHTCI

FLHRSI

FLHTCUI W/SC

FLHX

FLHTCUI Shrine

FLHXI

FLHRCI

2006 Touring: Chassis

2-5

HOME

FRONT WHEEL

2.3

Remove both the upper and lower mounting bolts from

GENERAL

lugs of front fork leg to release brake caliper assembly.

Maximum tire mileage and good handling qualities are

Lift caliper upward to remove from brake disc. Allow the

directly related to care given wheels and tires. Wheels and

caliper to hang loose.

tires should be regularly inspected for wear. If handling prob-

Repeat steps 1 thru 3 to release caliper on opposite side

lems occur, see Section 1.21 TROUBLESHOOTING, HAN-

of wheel.

DLING, for possible causes.

Always keep tires inflated to the recommended pressure and

NOTE

balance the wheel whenever a tire or tube is replaced.

Do not operate the front brake hand lever with the front wheel

removed or the caliper pistons may be forced out. Reseating

pistons requires disassembly of the caliper.

PRELIMINARY INSPECTION

Insert screwdriver or steel rod through hole in axle on

Measure brake disc thickness for excessive wear. Mini-

right side of vehicle. While holding axle stationary,

mum acceptable thickness is stamped on side of disc.

remove the axle nut, lockwasher and flat washer on the

Also replace discs if warped or badly scored. Obtain

left side.

new T40 TORX screws if brake discs were removed.

Loosen the two axle holder nuts at bottom of right side

Whenever the wheel is removed for tire replacement or

fork leg.

any other purpose, inspect the wheel bearings as fol-

lows:

With soft mallet, tap axle toward right side of vehicle until

a. Insert finger into wheel bearing and rotate the inner

loose. Catching external spacers on left and right side,

race in both directions. Repeat step on opposite

pull axle from hub while supporting wheel.

side of wheel.

Move wheel to bench area and inspect bearings. See

b. Replace the wheel bearings if there is rough rota-

PRELIMINARY INSPECTION on this page.

tion, abnormal noise or anything unusual. Always

replace wheel bearings as a set. Never replace just

one wheel bearing.

DISASSEMBLY

REMOVAL

If wheel bearing replacement is necessary, proceed as

follows:

Use shop rag or tape to protect fender area adjacent to

caliper, as incidental contact can occur during caliper

a. Obtain the WHEEL BEARING REMOVER/IN-

removal.

STALLER (HD-44060). Pick out the wheel bearing

remover tools for the front wheel. See Figure 2-3.

b. To prolong service life and ensure smooth opera-

9428

tion, sparingly apply graphite lubricant to threads of

forcing screw.

c. Install hex nut, flat washer and Nice bearing on forc-

ing screw. Insert end of forcing screw through hole

in bridge.

d. Install steel ball inside larger collet. Install collet at

end of forcing screw.

e. Insert collet into bearing ID. Feel for inside edge of

bearing using lip at end of collet and then back off

slightly.

Holding forcing screw to prevent rotation, turn hex

on collet until lip makes firm contact with inside

edge of bearing. See upper frame of Figure 2-4.

Figure 2-2. Inspect Wheel Bearings

2-6

2006 Touring: Chassis

HOME

f1774x2x

f1769x2x

Graphite Lubricant

Nice Bearing

Forcing Screw

Bridge

Hex Nut

Steel Ball

Flat Washer

Larger Collet (1 Inch)

Figure 2-3. Front Wheel Bearing Remover Tools

(Part No. HD-44060)

f1775x2x

g. Holding forcing screw, turn hex nut until bearing is

free. See lower frame of Figure 2-4.

h. Remove spacer sleeve from wheel hub.

Repeat procedure to remove bearing on opposite

side of wheel. Discard bearings.

If necessary, remove five T40 TORX screws to release

brake disc from hub. Discard screws. Repeat procedure

to remove disc on opposite side of wheel. If the wheel is

to be assembled with the same discs, mark both the

wheel and discs, so that they can be installed in their

original positions.

If tire replacement is necessary, see Section 2.8 TIRES

AND TUBES.

If the wheel is laced, and hub, spoke or rim replacement

is necessary, loosen all spoke nipples and disassemble

hub from rim.

CLEANING AND INSPECTION

Forcing Screw

Bridge

Thoroughly clean all parts in solvent.

Hex Nut

Larger Collet (1 Inch)

Inspect all parts for damage or excessive wear.

Flat Washer

Wheel Bearing

Nice Bearing

Always replace bearing assemblies as a complete set.

Inspect brake discs. Replace discs if warped or badly

Figure 2-4. Remove Sealed Wheel Bearings

scored. Measure disc thickness for excessive wear. Min-

imum acceptable thickness is stamped on side of disc.

2006 Touring: Chassis

2-7

HOME

Axle Nut

Lockwasher

Flat Washer

T40 Torx Screw (10)

Brake Disc (Left Side)

Left Side

External Spacer (Long)

Sealed Bearing (2)

Cast Wheel

Spacer Sleeve

10. Brake Disc (Right Side)

11. External Spacer (Short)

12. Axle

13. Laced Wheel

Right Side

f2042x2x

Figure 2-5. Front Wheel (Exploded View)

Install new wheel bearings as follows:

ASSEMBLY

NOTE

On laced wheels, if the hub and rim were disassembled,

assemble the hub, spokes and rim. See Section 2.6

Always install first of two bearings on the left side (opposite

WHEEL LACING-16 INCH RIM.

the valve stem side of the wheel).

a. Obtain the WHEEL BEARING REMOVER/IN-

1WARNING

STALLER (HD-44060). Pick out the wheel bearing

Be sure that brake fluid or other lubricants do not con-

installer tools for the front wheel. See Figure 2-6.

tact brake pads or discs. Such contact can adversely

b. To prolong service life and ensure smooth opera-

affect braking ability, which could cause loss of control,

tion, sparingly apply graphite lubricant to threads of

resulting in death or serious injury. (00290a)

threaded rod.

If removed, install new T40 TORX screws to fasten brake

c. Slide support plate onto threaded rod. Slide rod

discs to hub. Be sure to install discs in their original posi-

through hub on the valve stem side of the wheel.

tions. Alternately tighten screws to 16-24 ft-lbs (22-33

See upper frame of Figure 2-7.

Nm).

2-8

2006 Touring: Chassis

HOME

f1771x2x

Graphite Lubricant

Nice Bearing

Threaded Rod

Flat Washer

Support Plate

Hex Nut

Larger Pilot (1 Inch)

f1777x2x

Figure 2-6. Front Wheel Bearing Installer Tools

(Part No. HD-44060)

d. On opposite side of wheel, slide bearing onto

threaded rod with lettered side facing outboard.

e. Install larger pilot, Nice bearing, flat washer and

hex nut onto rod.

Holding threaded rod on opposite side of wheel to

prevent rotation, turn hex nut to install bearing. See

lower frame of Figure 2-7. Bearing is fully seated

when it makes firm contact with the counterbore.

g. Disassemble and remove tool, but leave support

plate on threaded rod.

h. Slide threaded rod through installed wheel bearing

and hub of wheel.

On the valve stem side of the wheel, slide spacer

f1773x2x

sleeve down threaded rod until it contacts installed

wheel bearing.

Repeat steps 3(d) through 3(g) to complete installa-

Support Plate

Nice Bearing

tion of second wheel bearing. Bearing is fully seated

Threaded Rod

Flat Washer

when hex nut can no longer be turned.

Wheel Bearing

Hex Nut

Larger Pilot (1 Inch)

Verify that wheel is true. See CHECKING CAST RIM

RUNOUT or TRUING LACED WHEEL, whichever

applies.

Figure 2-7. Install Sealed Wheel Bearings

Install rim strip on wheel rim, if applicable. Install tube

and tire, if applicable. Verify that wheel is balanced.

Supporting wheel, insert threaded end of axle through

right fork leg. Push axle through fork, short external

spacer and wheel hub until it begins to emerge from left

side.

INSTALLATION

With the three notches on the bearing side, push axle

through long external spacer and left fork leg until axle

Place wheel into position between forks with the valve

shoulder contacts external spacer on right fork side.

stem on the right side of the vehicle.

Coat the axle with ANTI-SEIZE LUBRICANT.

Install flat washer, lockwasher and axle nut.

2006 Touring: Chassis

2-9

HOME

e. Tighten upper caliper mounting bolt to 28-38 ft-lbs

f1783x2x

(37.9-51.5 Nm).

Repeat step 10 to install caliper on opposite side of

wheel.

1WARNING

After servicing brakes and before moving motorcycle,

pump brakes to build brake system pressure. Insuffi-

cient pressure can adversely affect brake performance,

which could result in death or serious injury. (00279a)

11. Depress front brake hand lever several times to set

brake pads to proper operating position within caliper.

Fork Leg (Right Side)

7/16 Inch Drill Bit

Axle

Axle Holder Nuts

Short Spacer

Figure 2-8. Align Front Wheel

Insert screwdriver or steel rod through hole in axle on

right side of vehicle. While holding axle stationary,

tighten axle nut to 50-55 ft-lbs (68-75 Nm).

Insert 7/16 inch drill bit into hole in axle. See Figure 2-8.

Pull fork leg so that it just contacts drill bit, and then

tighten axle holder nuts to 132-180 in-lbs (14.9-20.3

Nm).

Remove drill bit from axle hole.

10.

Install brake caliper as follows:

a. Use shop rag or tape to protect fender area adja-

cent to caliper, as incidental contact can occur dur-

ing caliper installation.

b. With the bleeder valve topside, position caliper so

that brake disc is situated between friction pads. Pry

inner and outer brake pads back for additional clear-

ance, if necessary.

c. Align upper mounting hole in caliper with upper

mounting lug on fork leg. Loosely install long caliper

mounting bolt into upper lug of fork leg.

d. Install short caliper mounting bolt into lower lug of

fork leg. Tighten lower mounting bolt to 28-38 ft-lbs

(37.9-51.5 Nm).

2-10

2006 Touring: Chassis

HOME

REAR WHEEL

2.4

On models equipped with low profile shock absorbers

GENERAL

(FLHS and FLHX), remove left side lower saddlebag

support rail as follows:

Maximum tire mileage and good handling qualities are

directly related to care given wheels and tires. Wheels and

a. Remove outside T40 TORX screw (and flange nut)

tires should be regularly inspected for wear. If handling prob-

to release saddlebag support rail from saddlebag

lems occur, see Section 1.21 TROUBLESHOOTING, HAN-

support bracket.

DLING, for possible causes.

b. Remove T40 TORX screw to release opposite end

of saddlebag support rail from frame weldment.

Always keep tires inflated to the recommended pressure and

balance the wheel whenever a tire or tube is replaced.

Standing on right side of vehicle, remove E-clip from

groove at end of axle.

Remove cone nut and adjuster cam from axle.

PRELIMINARY INSPECTION

Using a soft mallet, gently tap end of axle towards left

side to loosen. Catching external spacers on right and

Measure brake disc thickness for excessive wear. Mini-

left side of hub, pull axle free of wheel and rear

mum acceptable thickness is stamped on side of disc.

swingarm.

Also replace disc if warped or badly scored.

Pull wheel to release brake disc from caliper. Pry inner

Whenever the wheel is removed for tire replacement or

and outer brake pads back for additional clearance, if

any other purpose, inspect the wheel bearings as fol-

necessary. Use a putty knife with a wide thin blade to

lows:

avoid scoring or scratching the brake disc.

a. Insert finger into wheel bearing and rotate the inner

Remove caliper from anchor weldment on rear swing-

race. Repeat step on opposite side of wheel.

arm, and carefully hang over lower saddlebag support

rail.

b. Replace the wheel bearings if there is rough rota-

tion, abnormal noise or anything unusual. Always

Move wheel forward and slip belt off sprocket.

replace wheel bearings as a set. Never replace just

10.

Move wheel to bench area and inspect bearings. See

one wheel bearing.

PRELIMINARY INSPECTION on this page.

NOTE

REMOVAL

Do not operate the rear brake pedal with the rear wheel

removed or the caliper pistons may be forced out. Reseating

Remove saddlebags. See Section 2.26 SADDLEBAG,

pistons requires disassembly of the caliper.

REMOVAL.

Remove left side muffler as follows:

a. Open worm drive clamps to remove heat shield

DISASSEMBLY

from crossover pipe.

b. Using a bungee cord, tie the muffler to the lower

If wheel bearing replacement is necessary, proceed as

saddlebag support rail.

follows:

c. Loosen TORCA clamp between crossover pipe and

a. Remove five bolts (with flat washers) securing belt

muffer.

sprocket to hub.

NOTE

b. Obtain the WHEEL BEARING REMOVER/IN-

STALLER (HD-44060). Pick out the wheel bearing

To facilitate removal, spray PB Blaster or other suitable pene-

remover tools for the rear wheel. See Figure 2-9.

trating oil in and around joint of exhaust pipes. For best

results, be sure to allow sufficient time for the penetrating oil

NOTE

to work.

The smaller 3/4 inch collet (and pilot) is only used to replace

d. Remove two screws (with lockwashers) to detach

the rear wheel bearings on 2000-01 Touring models.

muffler from lower saddlebag support rail.

c. To prolong service life and ensure smooth opera-

e. Remove bungee cord to release muffler from lower

tion, sparingly apply graphite lubricant to threads of

saddlebag support rail.

forcing screw.

2006 Touring: Chassis

2-11

HOME

f1774x2x

f1769x2x

Graphite Lubricant

Nice Bearing

Forcing Screw

Bridge

Hex Nut

Steel Ball

Flat Washer

Larger Collet (1 Inch)

Figure 2-9. Rear Wheel Bearing Remover Tools

(Part No. HD-44060)

d. Install hex nut, flat washer and Nice bearing on forc-

f1775x2x

ing screw. Insert end of forcing screw through hole

in bridge.

e. Install steel ball inside larger collet. Install collet at

end of forcing screw.

Insert collet into bearing ID. Feel for inside edge of

bearing using lip at end of collet and then back off

slightly.

g. Holding forcing screw to prevent rotation, turn hex

on collet until lip makes firm contact with inside

edge of bearing. See upper frame of Figure 2-10.

h. Holding forcing screw, turn hex nut until bearing is

free. See lower frame of Figure 2-10.

Remove spacer sleeve from wheel hub.

Repeat procedure to remove bearing on opposite

side of wheel. Discard bearings.

If necessary, remove five T45 TORX screws to release

brake disc from hub. If the wheel is to be assembled with

the same disc, mark both the wheel and disc, so that it

can be installed in its original position.

Remove tire, if necessary. Remove tube from the rim, if

applicable. See Section 2.8 TIRES AND TUBES.

Forcing Screw

Bridge

If it is necessary to remove the hub from a laced wheel,

Hex Nut

Larger Collet (1 Inch)

loosen all spoke nipples and remove the rim and spokes.

Flat Washer

Wheel Bearing

Nice Bearing

CLEANING AND INSPECTION

Figure 2-10. Remove Sealed Wheel Bearings

Thoroughly clean all parts in solvent.

2-12

2006 Touring: Chassis

HOME

Axle

External Spacer (Large)

Bolt (5)

Flat Washer (5)

Belt Sprocket

Sealed Bearing (2)

Left Side

Spacer Sleeve

Cast Wheel

Brake Disc

10. T45 TORX Screw (5)

11. External Spacer (Small)

12. Adjuster Cam

13. Cone Nut

14. E-Clip

15. Laced Wheel

Right Side

f2044x2x

Figure 2-11. Rear Wheel (Exploded View)

Inspect all parts for damage or excessive wear.

ASSEMBLY

Always replace bearings as a complete set.

On laced wheels, if the hub and rim were disassembled,

Inspect brake disc. Replace disc if warped or badly

assemble the hub, spokes and rim. See Section 2.6

scored. Measure disc thickness for excessive wear. Min-

WHEEL LACING-16 INCH RIM.

imum acceptable thickness is stamped on side of disc.

Verify that wheel is true. See Section 2.5 CHECKING

RIM RUNOUT or Section 2.7 TRUING LACED WHEEL,

Check the belt sprocket for wear, tooth damage, cracks

whichever applies.

or pitting. Replace if necessary.

On laced wheels, replace spokes, rim or hub if dam-

1WARNING

aged.

Be sure that brake fluid or other lubricants do not con-

tact brake pads or discs. Such contact can adversely

affect braking ability, which could cause loss of control,

resulting in death or serious injury. (00290a)

2006 Touring: Chassis

2-13

HOME

f1771x2x

Graphite Lubricant

Nice Bearing

Threaded Rod

Flat Washer

Support Plate

Hex Nut

Larger Pilot (1 Inch)

f1777x2x

Figure 2-12. Rear Wheel Bearing Installer Tools

(Part No. HD-44060)

If removed, install five T45 TORX screws (and locknuts

on laced wheels) to fasten brake disc to hub. Always

install brake disc in its original position. Use new screws

after three use cycles. Alternately tighten screws to 30-

45 ft-lbs (41-61 Nm).

Install new wheel bearings as follows:

NOTE

Always install first of two bearings on the right side (the valve

stem side of the wheel).

a. Obtain the WHEEL BEARING REMOVER/IN-

STALLER (HD-44060). Pick out the wheel bearing

installer tools for the rear wheel. See Figure 2-12.

b. To prolong service life and ensure smooth opera-

f1773x2x

tion, sparingly apply graphite lubricant to threads of

threaded rod.

c. Slide support plate onto threaded rod. Slide rod

Support Plate

Nice Bearing

through hub on the sprocket side of the wheel. See

Threaded Rod

Flat Washer

upper frame of Figure 2-13.

Wheel Bearing

Hex Nut

Larger Pilot (1 Inch)

d. On the valve stem side of the wheel, slide bearing

onto threaded rod with lettered side facing out-

board.

Figure 2-13. Install Sealed Wheel Bearings

e. Install larger pilot, Nice bearing, flat washer and

hex nut onto rod.

On the other side of the wheel, slide spacer sleeve

Holding threaded rod on opposite side of wheel to

down threaded rod until it contacts installed wheel

prevent rotation, turn hex nut to install bearing. See

bearing.

lower frame of Figure 2-13. Bearing is fully seated

Repeat steps 4(d) through 4(g) to complete installa-

when it makes firm contact with the counterbore.

tion of second wheel bearing. Bearing is fully seated

g. Disassemble and remove tool, but leave support

when hex nut can no longer be turned.

plate on threaded rod.

h. Slide threaded rod through installed wheel bearing

Install rim strip on wheel rim, if applicable. Install tube

and hub of wheel.

and tire, if applicable. Verify that wheel is balanced.

2-14

2006 Touring: Chassis

HOME

Apply two drops of Loctite High Strength Threadlocker

271 (red) to threads of five belt sprocket bolts. Always

Torque Wrench

use new bolts after three use cycles. Install bolts with

Axle Nut Torque Adapter

flat washers to secure sprocket to hub. Alternately

(HD-47925)

tighten bolts to 55-65 ft-lbs (75-88 Nm).

90°

INSTALLATION

Place wheel in rear swingarm. Slide wheel far enough

forward to slip belt over sprocket and then slide the

wheel back.

f2369x2x

CAUTION

Do not bend or fold belt backward or into loops smaller

than 5 inches (127 mm) in diameter. Sharp bending can

weaken the belt and cause premature failure.

Seat caliper on anchor weldment of rear swingarm. Posi-

tion wheel in swingarm, so that brake disc is centered

between brake pads.

Coat the axle with ANTI-SEIZE LUBRICANT.

With the larger OD on the outboard side, hold external

spacer between rear swingarm and belt sprocket. Slide

axle through left side of rear swingarm, external spacer,

9292

and belt sprocket into wheel hub.

Figure 2-14. Install Tool Perpendicular to Torque Wrench

When axle emerges from hub on brake disc side of

wheel, push axle through short external spacer, caliper

bracket and right side of rear swingarm.

Rotate axle so that the flat on the threaded end is top-

side. With the thumb down and the cam forward, install

CAUTION

adjuster cam on end of axle.

Since any extension can act as a torque multiplier, the

Apply a thin film of ANTI-SEIZE LUBRICANT to the

torque wrench must be perpendicular to the torque

inboard side of the cone nut avoiding contact with

adapter when the cone nut is tightened. The 90 degree

threads. Install cone nut on axle, but finger tighten only.

orientation between the tools cancels the multiplier

effect and prevents the cone nut from being over-tight-

Obtain torque wrench with 1/2 inch drive head and AXLE

ened. If the torque adapter is kept inline with the torque

NUT TORQUE ADAPTER (HD-47925). Proceed as fol-

wrench, the multiplier effect is in force and parts damage

lows:

will occur.

NOTE

c. Verify that adjuster cam just contacts weld nub on

The Axle Nut Torque Adapter simplifies the belt adjustment

both sides of rear swingarm. If necessary, push

procedure by allowing the cone nut to be properly tightened

wheel forward slightly to achieve the desired result.

without having to remove the right side muffler. The tool also

Snug the cone nut to 15-20 ft-lbs (20-27 Nm). See

can be used to loosen the cone nut, as well as rotate the

Figure 2-15.

weld nut on the left side.

a. Install torque adapter perpendicular to torque

Check deflection at the loosest spot in the belt. Use

wrench as shown in Figure 2-14.

BELT TENSION GAUGE (HD-35381A), or install adapter

(HD-35381-3) on old style gauge, and apply 10 lbs. (4.5

b. Insert tool up between rear wheel and muffler to

capture cone nut. For best clearance with muffler,

kg) of force at the midpoint of the bottom belt strand. Belt

be sure torque adapter is on the outboard side.

deflection should be as follows:

2006 Touring: Chassis

2-15

Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 3