Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 4

 

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Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 4

 

 

HOME
LEFT SIDE
RIGHT SIDE
Increase
Reduce
Belt
Belt
Deflection
Deflection
4
2
1
2
5
8398
8407
3
1.
Weld Nut
4.
Cone Nut
2.
Weld Nub
5.
E-Clip
3.
Adjuster Cam
Figure 2-15. Move Rear Wheel Forward Until Adjuster Cams Just Contact Weld Nubs
c. Check belt deflection. Apply 10 lbs. (4.5 kg) of force
Table 2-3. Belt Deflection in the Air
at the midpoint of the bottom belt strand. Belt
deflection should be within the range specified in
Orientation
Inches
Millimeters
Table 2-3.
Motorcycle Upright
3/16 - 1/4
4.8
- 6.4
d. If belt is still too tight, repeat steps 11(a) through
With Rear Wheel in the Air
11(c). If belt is now too loose, move to step 10.
NOTE
See Section 1.10 DRIVE BELT for belt deflection specification
12. Holding weld nut on left side of axle, tighten cone nut on
with motorcycle on jiffy stand.
right side to 95-105 ft-lbs (128.8-142.4 Nm).
10.
If belt is too tight, move to step
11 to increase belt
NOTE
deflection. If belt is too loose, reduce belt deflection as
If the axle moves during tightening of the cone nut, then the
described below:
belt deflection procedure must be restarted.
a. Rotate weld nut on left side of axle in a clockwise
direction.
13. Recheck belt deflection to verify that it is still within spec-
ification.
b. Check belt deflection. Apply 10 lbs. (4.5 kg) of force
at the midpoint of the bottom belt strand. Belt
If the belt deflection is not within specification, loosen
deflection should be within the range specified in
cone nut and then snug to 15-20 ft-lbs (20-27 Nm)
Table 2-3.
before returning to step 10.
c. If belt is still too loose, repeat steps 10(a) through
14. With the flat side out, install new E-clip in groove on right
10(b). If belt is now too tight, move to step 11.
side of axle.
11.
If belt is too tight, increase belt deflection as follows:
15. On models equipped with low profile shock absorbers
a. Rotate weld nut on left side of axle in a counter-
(FLHS and FLHX), install left side lower saddlebag sup-
clockwise direction.
port rail as follows:
b. Push wheel forward slightly so that adjuster cam
a. At rear left side of motorcycle, start outside T40
just contacts weld nub on both sides of rear swing-
TORX screw (and flange nut) to fasten saddlebag
arm. See Figure 2-15.
support rail to saddlebag support bracket.
2-16
2006 Touring: Chassis
HOME
b. Start T40 TORX screw to fasten opposite end of
saddlebag support rail to frame weldment.
1WARNING
c. Alternately tighten screws to
15-20 ft-lbs
(20-27
After servicing brakes and before moving motorcycle,
Nm).
pump brakes to build brake system pressure. Insuffi-
16. Install left side muffler as follows:
cient pressure can adversely affect brake performance,
which could result in death or serious injury. (00279a)
NOTE
TORCA clamps have eliminated the need for silicone or
17. Depress rear brake pedal several times to set brake
graphite tape during assembly. To ensure sealing integrity
pads to proper operating position within caliper.
and prevent the possibility of leakage, always discard
18. Install saddlebags. See Section
2.26 SADDLEBAG,
TORCA clamps whenever they are removed.
INSTALLATION.
a. Slide new TORCA clamp onto free end of crossover
pipe.
b. Using a bungee cord, tie muffler to lower saddlebag
support rail. Install muffler on crossover pipe. Place
TORCA clamp into position between crossover and
muffler.
c. Install two screws (with lockwashers) to fasten the
muffler to the lower saddlebag support rail. Alter-
nately tighten screws to 96-144 in-lbs (10.8-16.3
Nm).
d. Verify that exhaust pipes are in alignment and do
not contact the vehicle frame or mounted compo-
nents.
e. Tighten the TORCA clamp to 45-60 ft-lbs (61-81
Nm).
f.
Open worm drive clamps and install heat shield on
crossover pipe. Position each worm drive clamp so
that screw is on the outboard side in the most
accessible position and then tighten to 20-40 in-lbs
(2.3-4.5 Nm).
g. Remove bungee cord from muffler.
2006 Touring: Chassis
2-17
HOME
CHECKING RIM RUNOUT
2.5
INSPECTION
f1379x2x
Check wheels for lateral and radial runout before installing a
new tire or tube.
1.
Install truing arbor in wheel hub and place wheel in
WHEEL TRUING STAND, Part No. HD-99500-80.
2.
See Figure 2-16. To check rim lateral runout, place a
gauge rod or dial indicator near the rim bead. If lateral
runout exceeds 0.040 inch (1.02 mm), replace the wheel
if cast. Retrue the wheel if laced.
3.
See Figure 2-17. Check the rim radial runout as shown.
If radial runout exceeds 0.030 inch (0.76 mm), replace
the wheel if cast. Retrue the wheel if laced.
NOTE
Radial
Runout
Rim lateral and radial runout is adjustable on laced wheels.
See Section 2.7 TRUING LACED WHEEL.
Gauge
f1378x2x
Figure 2-17. Checking Rim Radial Runout
4.
If working with a laced wheel, proceed to Section 2.7
TRUING LACED WHEEL to check the wheel offset
dimension.
Lateral
Runout
Gauge
Figure 2-16. Checking Rim Lateral Runout
2-18
2006 Touring: Chassis
HOME
WHEEL LACING-16 INCH RIM
2.6
GENERAL
WHEEL LACING
1.
If front wheel, place the hub on a table with the wider
CAUTION
flange side up. If rear wheel, place hub so that brake
disc side is up. Insert a spoke in each hole of the lower
While the steel laced and chrome aluminum laced profile
row as shown below. Angle the spokes in a clockwise
wheels use the same hub, exercise caution to avoid mix-
direction.
ing or interchanging any other parts. Do not install the
chrome plated spokes and/or spoke nipples on a steel
rim. Likewise, do not install the zinc plated spokes and/
f1150d2x
or spoke nipples on a chrome plated rim. Mixing or inter-
changing parts can result in wheel damage.
The spoke nipple fittings use a TORX style fastener and
requires a special T-30 I.P. (TORX Plus) driver (HD-42135)
for removal and installation. See A of Figure 2-18. Use of a
standard T-30 TORX bit will result in nipple damage.
A
Figure 2-19.
2.
Center rim over hub with the valve stem side up. Using
any lower row spoke, place the first spoke into the rim
f1150a2x
hole to the left of the valve stem hole on the upper half of
the rim centerline.
Narrow Flange
Belt Sprocket Side
B
Wide Flange
First
Lower Row Spoke
Valve Stem Hole
f1150b2x
Valve Stem Flat
Tombstone Shaped
on Steel Rim
C
f1150c2x
f1150e2x
Figure 2-18. Spoke Nipple, Hub and Rim
Figure 2-20.
2006 Touring: Chassis
2-19
HOME
3.
Install the rest of the lower row spokes in every fourth
5.
Install the nine remaining upper row spokes into every
hole.
fourth hole remaining above the rim centerline.
f1150f2x
f1150h2x
Figure 2-21.
Figure 2-23.
4.
Place the first upper row spoke into the hub as shown
6.
Turn the wheel over. Place any lower row spoke into the
below. Angle the spoke counterclockwise crossing four
hub. Angle the spoke clockwise and place into rim hole
lower row spokes. The spoke must enter the hole to the
angled to accept it.
left of the valve stem hole.
First
First
Upper Row Spoke
Lower Row Spoke
1
4
2
3
f1150g2x
f1150i2x
Figure 2-22.
Figure 2-24.
2-20
2006 Touring: Chassis
HOME
7.
Angled clockwise, place the nine remaining lower row
9.
Install the nine remaining upper row spokes into hub and
spokes into hub and rim.
rim.
f1150j2x
f1150l2x
Figure 2-25.
Figure 2-27.
8.
Insert any upper row spoke into the hub and angle spoke
counterclockwise. Place spoke into appropriate rim hole
CAUTION
crossing four lower row spokes.
The hub is made of aluminum alloy and should not be
clamped in a vise or gripped with pliers, or the hub mate-
First
rial may be damaged.
Upper Row Spoke
10. Verify that wheel is true. See Section
2.7 TRUING
LACED WHEEL for truing procedure and spoke torque
specification.
SPOKE TIGHTNESS
See Section 1.6 WHEEL SPOKES.
4
1
3
2
f1150k2x
Figure 2-26.
2006 Touring: Chassis
2-21
HOME
TRUING LACED WHEEL
2.7
PROCEDURE
1.
Divide the wheel spokes into ten groups of four and
mark the center of each group with a piece of tape. The
groups should be directly across from one another and
approximately 90ο apart. Tighten the spokes in these
four groups finger tight, leaving all others loose.
2.
See Figure 2-29. Install truing arbor in wheel hub and
place wheel in WHEEL TRUING STAND, Part No. HD-
99500-80. Tighten arbor nuts so hub will turn on its bear-
ings.
3.
Lay a straightedge across the hub brake disc flange
(valve stem side of dual disc front wheel) and one of the
marked spoke groups. Measure the distance from the
straightedge to the edge of the rim as shown in Figure 2-
28. Be sure to subtract the thickness of the straightedge.
f1155b2x
See Figure 2-30. The offset dimension must be as fol-
lows:
Figure 2-28. Checking Steel Laced Hub Offset Dimension
Table 2-4. Offset Dimensions
f1379x2x
RIM TYPE
RIM SIZE
IN.
MM.
Steel Laced
Front
16
1.555-1.575
39.5-40.0
Rear
16
1.472-1.492
37.4-37.9
Chrome Aluminum Laced Profile
Front
16
1.270-1.290
32.3-32.8
Rear
16
1.190-1.210
30.2-30.7
If the dimension is not correct, tighten the four spokes
accordingly. Use the special T-30 I.P. (TORX Plus) driver
(HD-42135). For example, If the measurement on the
right rim edge side is less than it should be, loosen the
Radial
two spokes attached to the hub right side and tighten the
Runout
two spokes attached to the hub left side. Turn all four
spokes an equal number of turns until offset dimension
is correct.
Gauge
CAUTION
Always loosen the appropriate spokes before tightening
the other two. Reversing this procedure will cause the
rim to become out-of-round.
Figure 2-29. Truing Steel Laced Rim Radially
4.
Repeat Step 3 for all four groups on the wheel.
5.
See Figure 2-29. After rim has been trued sideways it
must be checked and trued radially. Adjust truing stand
gauge to the rim's tire bead seat as shown. The rim
should be trued within 1/32 inch (0.79 mm).
2-22
2006 Touring: Chassis
HOME
6.
Spin the rim slowly. If the rim contacts the gauge on or
near a marked group of spokes, loosen the spokes in the
Steel Laced Rim
marked group on the opposite side of the rim. Now
tighten the spokes in the group where the rim makes
contact. Loosen and tighten spokes an equal number of
turns.
7.
If the rim contacts the gauge between two marked
groups, loosen the spokes in both opposite groups and
tighten the spoke groups on the side of the rim that
makes contact.
8.
When the wheel is centered and trued, start at the valve
stem hole and tighten the rest of the spoke nipples one
turn at a time until they are snug. Repeat step tightening
each spoke nipple to 40-50 in-lbs (4.5-5.6 Nm).
Offset:
1WARNING
1.472-1.492 in.
Spokes that are too tight can draw nipples through the
rim or distort hub flanges. Spokes that are too loose can
continue to loosen when put in service. Either condition
can adversely affect stability and handling, which could
result in death or serious injury. (00286a)
9.
File or grind off ends of spokes protruding through nip-
ples to prevent puncturing tube when tire is mounted.
10. Check the rim lateral and radial runout as described
under Section 2.5 CHECKING RIM RUNOUT.
NOTE
After installation of front wheel, visually check the relation-
ship of the front wheel to the fork fender bosses. The front
Offset:
wheel should be approximately centered between the
1.190-1.210 in.
bosses.
Chrome Aluminum
Laced Profile Rim
f2334x2x
Figure 2-30. Laced Hub Offset Dimension (16 Inch Rear)
2006 Touring: Chassis
2-23
HOME
TIRES AND TUBES
2.8
GENERAL
1634
Tires should be inspected for punctures, cuts, breaks and
wear at least weekly.
Whenever a tube type tire is replaced, the tube should also
be replaced. Inner tubes should be patched only as an emer-
gency measure. Replace a damaged tube as soon as possi-
ble. Inner tubes must be used on all Harley-Davidson laced
wheels.
1WARNING
Excessively worn tires are more susceptible to penetra-
tions. Always remove tires from service before they
reach the tread wear indicator bars, which indicates that
1/32 inch (0.79 mm) tread pattern depth remains. Worn/
unworn tire combinations and worn tires used in wet
conditions can ad-versely affect handling and lead to
loss of vehicle control, which could result in death or
serious injury.
Figure 2-31. Starting Bead Off Rim
1WARNING
Tubeless tires may be repaired in the tread area only and
2.
Loosen both tire beads from rim flange. See Figure 2-31.
then the puncture must be 1/4 inch (6.4 mm) or smaller.
In most cases, a bead breaker machine will be required
Never repair a tire with less than 1/16 inch (1.6 mm) tread
to loosen the bead from the rim.
depth. All repairs must be made from inside the tire. Use
of faulty or defective tires can adversely affect handling
3.
Using tire tools (not sharp instruments), and RIM PRO-
and lead to loss of vehicle control, which could result in
TECTORS, Part No. HD-01289, start upper bead over
death or serious injury.
edge of rim at valve. Do not use excessive force when
starting bead over rim. Bead wires may be damaged
NOTE
ruining the tire. Repeat all around rim until first bead is
Acceptable repair methods include a patch and plug combi-
over rim. Remove the tube.
nation, chemical or hot vulcanizing patches or head-type
plugs.
NOTE
When repairing tubeless tires, use TIRE SPREADER, Part
It is not necessary to use tools to remove tubeless tires.
No. HD-21000 to spread the tire sidewalls.
Make sure beads are well lubricated before removing from
rim.
1WARNING
4.
Push lower bead into rim well on one side and insert tire
tool underneath bead from opposite side. Pry bead over
Always check both tire sidewalls for arrows indicating
rim edge. Remove tire from rim.
proper forward tire rotation. Some tires require different
tire rotation depending on whether tire is used on front
NOTE
or rear wheel. Improper mounting can result in poor tire
It is not always necessary to completely remove tire from rim.
mileage. In wet weather, improper mounting can ad-
Removing one side allows the tube to be replaced and allows
versely affect handling and lead to loss of vehicle con-
for inspection of tire.
trol, which could result in death or serious injury.
CLEANING AND INSPECTION
REMOVAL
1.
Remove wheel from motorcycle. Let the air out of the
1.
Clean the inside of tire, rim and tube. If rim is dirty or
tube or tire.
rusty, clean with a stiff wire brush.
2-24
2006 Touring: Chassis
HOME
1635
Indicator
Ring
Figure 2-32. Snap-in Tubeless Tire Valves
2.
Inspect the tire and tube for wear.
INSTALLATION
Figure 2-33. Starting Bead on Rim
1WARNING
1636
Use the correct inner tube and tire. See TIRE DATA in
SPECIFICATIONS. Use of incorrect tires or tubes can
adversely affect handling or result in tire failure, which
could result in death or serious injury.
1WARNING
Only install original equipment tire valves and valve
caps. A valve, or valve and cap combination, that is too
long or too heavy can strike adjacent components and
damage the valve, causing rapid tire deflation. Rapid tire
deflation can cause loss of vehicle control, which could
result in death or serious injury. (00281a)
1.
On tubeless wheels, damaged or leaking valves must be
replaced. To replace a snap-in type valve proceed as fol-
Figure 2-34. Starting Second Bead on Rim
lows:
a. See Figure 2-32. Moisten the valve with water and
insert valve stem through rim hole.
is a balance mark and should be located next to valve
stem hole.
b. Thread plug tool on valve stem and pull valve
through rim until all of the indicator ring is visible.
5.
Inflate tube just enough to round it out. Lubricate thor-
oughly 360˚ around the tube base. Insert tube in tire with
2.
On laced wheels, install a rim strip into the rim well.
valve stem in hole.
Make sure no spokes protrude through nipples and be
sure to align the valve stem hole in rim strip with hole in
6.
See Figure 2-34. Starting 180˚ from valve stem, start the
second bead onto the rim. Work the bead onto the rim
rim.
with tire tools, working toward valve in both directions.
3.
Thoroughly lubricate the rim flanges and both beads of
Remove the valve core from the rim hole before prying
the tire with tire lubricant. Install RIM PROTECTORS,
the remaining bead over the rim flange.
Part No. HD-01289 to prevent scarring rims.
Make sure inner tube valve stem moves in and out freely,
4.
See Figure 2-33. Starting at the valve stem, start the first
then inflate the tire to recommended pressure to seat the
bead into the rim well. Work the bead on as far as possi-
bead. See TIRE DATA at the beginning of this section.
ble by hand. Use the tire tool to pry the remaining bead
Deflate tire to allow inner tube to smooth out, and then
over the rim flange. If tire has colored dot on sidewall, it
inflate again to recommended pressure to seat the bead.
2006 Touring: Chassis
2-25
HOME
NOTE
Do not inflate tire over 40 psi (2.8 bars) to seat beads. If the
f1386b2x
beads fail to seat, deflate and relubricate the bead and rim.
Reinflate to seat beads, but do not exceed 40 psi (2.8 bars).
1WARNING
Do not exceed manufacturer's recommended pressure
to seat beads. Exceeding recommended bead seat pres-
sure can cause tire rim assembly to burst, which could
result in death or serious injury. (00282a)
CAUTION
Gauge
When mounting tire and tube on the rim, use extreme
care so the inner tube is not pinched.
7.
Use the BEAD EXPANDER (Part No. HD-28700) to seat
Tire Radial Runout
beads on tubeless tires.
Figure 2-35. Checking Tire Radial Runout
Checking Tire Radial Runout
1.
Check runout by turning wheel on axle, measuring
amount of radial displacement from a fixed point near
the tire. See Figure 2-35.
Tire Lateral
Runout
2.
Tire tread runout should be no more than 0.090 inch
(2.28 mm) If tire tread runout exceeds this specification,
remove tire from rim and check rim runout to see if rim is
at fault. (See Section 2.5 CHECKING RIM RUNOUT).
NOTE
Make sure bead is properly seated on rim. Deflate and reseat
tire if necessary.
3.
If rim runout is less than 1/32 inch (0.79 mm), tire is at
fault and should be replaced. If rim runout exceeds this
Gauge
specification, correct by replacing cast wheel or truing
f1386a2x
laced wheel.
Figure 2-36. Checking Tire Lateral Runout
Checking Tire Lateral Runout
1.
Check runout by turning wheel on axle, measuring tread
runout. See Figure 2-36.
Wheel Balancing
2.
Tire tread runout should be no more than 0.080 inch
Wheel balancing is recommended to improve handling and
(2.03 mm). If tire tread runout exceeds this specifica-
tion, remove tire from rim and check rim bead runout to
reduce vibration, especially at high road speeds. Cast alumi-
num wheels require special self-adhesive weights. Gold
see if rim is at fault (see Section 2.5 CHECKING RIM
Color - 1 oz. (28g) weight, 1/2 oz. (14g) weight, Silver Color
RUNOUT).
1/2 oz. (14g) and 1/4 oz. (7g), and Black 1/4 oz. (7g) weight.
NOTE
Laced wheels use balance weights which press over the
Make sure bead is properly seated on rim. Deflate and reseat
spoke nipples. 1 oz. (28g), 3/4 oz. (21g) and 1/2 oz. (14g)
tire if necessary.
weights are available.
3.
If rim bead runout is less than 1/32 inch (0.79 mm), tire
is at fault and should be replaced. If rim bead runout
1.
Self adhesive wheel weights should be applied to the flat
exceeds this specification, correct by replacing cast
surface of the rim. Make sure that area of application is
wheel or truing laced wheel.
completely clean, dry and free of oil and grease.
2-26
2006 Touring: Chassis
HOME
NOTE
3.
In most cases, static balancing using WHEEL TRUING
STAND, Part No. HD-99500-80, will produce satisfactory
If 1 oz. (28g) or more weight must be added at one location,
results. However, dynamic balancing, utilizing a wheel
split the amount so that half is applied to each side of the rim.
spinner, should be used to produce finer tolerances for
2.
Remove paper backing from weight and apply three
best high and low speed handling characteristics. Follow
drops of Loctite® SUPERBONDER® 420 to the adhe-
the instructions supplied with the balance machine you
sive side of the weight. Place the weight on rim, press
are using. Wheels should be balanced to within 1/2 oz.
firmly in place and hold for 10 seconds. Full adhesive
(14g) at 60 mph (96 km/h). The maximum permissible
cure takes 8 hours.
weight to accomplish balance is 3-1/2 oz. (99g) total.
2006 Touring: Chassis
2-27
HOME
VEHICLE ALIGNMENT
2.9
1WARNING
Check vehicle alignment according to following proce-
dures. Incorrect alignment can adversely affect stability
and handling, which could result in death or serious
injury. (00287a)
METHOD A
f2117x2x
NOTE
Figure 2-37. Vehicle Alignment Tool
Use this procedure to realign the powertrain to the frame
(Part No. HD-46247)
whenever major disassembly or engine replacement occurs.
For acceptable results, a careful inspection should be
performed (wheel and tire runout, laced wheel offset, rubber
f2118x2x
mount condition, etc.) to ensure that it is conducted with
serviceable components. See INSPECTION for more infor-
mation.
1
1.
Place the motorcycle on a hydraulic center stand or
place blocking under the frame to support the vehicle
and lift the rear wheel off the ground. Be sure the motor-
cycle is positioned as level as possible.
2.
Remove socket screw with lockwasher to remove left
passenger footboard from rear swingarm bracket.
Tighten both rear swingarm bracket bolts to 34-42 ft-lbs
2
(46-57 Nm). Repeat step on right side of motorcycle.
3
3.
Remove the decorative chrome plug from both rear
swingarm brackets. While holding the left side pivot shaft
locknut, tighten the right side locknut to 40-45 ft-lbs (54-
1.
Alignment Fixture
61 Nm). Then hold the right side pivot shaft locknut and
2.
Pilot
tighten the left side locknut to 40-45 ft-lbs (54-61 Nm).
3.
Alignment Screw
4.
Verify that belt deflection is within specification and that
Figure 2-38. Install Vehicle Alignment Tool (Left Side)
adjuster cams are tight against rear swingarm weld
nubs. Holding weld nut on left side of axle, tighten cone
nut on right side to 95-105 ft-lbs (128.8-142.4 Nm).
c. Loosen both top stabilizer link jam nuts.
5.
Remove seat. See Section 2.25 SEAT, REMOVAL.
d. Remove the top stabilizer link eyelet to top engine
6.
Partially remove fuel tank to gain access to top engine
mounting bracket bolt. See B of Figure 2-39.
mounting bracket and stabilizer link. See Section 4.7
FUEL TANK (CARBURETED), PARTIAL REMOVAL,
8.
Front Engine Mount:
FLHX, FLHT, or FLHR/S. For fuel injected models, see
a. Remove flange locknuts from studs on lower frame
Section 9.4 FUEL TANK (FUEL INJECTED), PARTIAL
crossmember. Remove voltage regulator from studs
REMOVAL, FLHXI, FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
and allow to hang by cables at front of motorcycle.
7.
Top Engine Mount:
b. Tighten two engine to front engine mounting bracket
a. On left side of motorcycle, tighten the two top
bolts to 33-38 ft-lbs (45-52 Nm). See H of Figure 2-
engine mounting bracket to front and rear cylinder
39.
head bolts to 35-40 ft-lbs (48-54 Nm). See A of Fig-
c. Tighten front stabilizer link eyelet bolt to block on
ure 2-39.
front engine mounting bracket to 18-22 ft-lbs (24-30
b. Moving to right side of motorcycle, tighten the top
Nm). See E of Figure 2-39.
stabilizer link eyelet to frame weldment bolt to 18-22
ft-lbs (24-30 Nm). See C of Figure 2-39.
d. Loosen both front stabilizer link jam nuts.
2-28
2006 Touring: Chassis
HOME
B
C
A
LEFT SIDE
RIGHT SIDE
Top Stabilizer Link and Engine Mounting Bracket
f2181x2x
f2111x2x
Jam Nut
H
E
D
Front
Stabilizer Link
Front Engine
F
Mounting Bracket
G
f1303x2x
Front Stabilizer Link and Engine Mounting Bracket
Top
Bottom
A Top Engine Mounting Bracket to Cylinder Heads
D Eyelet to Frame Weldment
B Eyelet to Top Engine Mounting Bracket
E Eyelet to Front Engine Mounting Bracket
C Eyelet to Frame Weldment
F Front Engine Mounting Bracket to Rubber Mount
G Front Engine Mount to Frame Crossmember
H Engine to Front Engine Mounting Bracket
Figure 2-39. Engine Mounting Bracket Bolts
e. Remove front stabilizer link eyelet to frame weld-
f.
Remove the center front engine mounting bracket to
ment bolt. See D of Figure 2-39.
rubber mount bolt (with washers and nut). See F of
Figure 2-39.
2006 Touring: Chassis
2-29
HOME
9.
Obtain Vehicle Alignment Tool (HD-46247). See Figure
Tighten the two front engine mount to frame cross-
2-37. Proceed as follows:
member bolts to 15-20 ft-lbs (20-27 Nm). See G of
Figure 2-39.
a. Back off alignment screws and pilot so that no con-
tact is made with pivot shaft during initial installa-
Install center front engine mounting bracket to rub-
tion.
ber mount bolt (with washers and nut) and tighten to
15-20 ft-lbs (20-27 Nm). See F of Figure 2-39.
b. Position alignment fixture so that pilot begins to
engage hole in rear swingarm bracket and then
b. If centering or relaxation of the mount is required,
start 5/16 allen head screw (with flat washer) into
proceed as follows:
lower hole of passenger footboard mount. Leave fix-
Loosen the two front engine mount to frame cross-
ture loosely installed. Repeat step on other side of
member bolts. See G of Figure 2-39.
motorcycle.
NOTE
Push on the rubber mount to center it with the thru
bolt hole in the mounting plate. It may be necessary
Alignment fixtures are stamped L(eft) and R(ight) for easy
to bounce or wiggle the engine to unload any
identification. When installing alignment fixture on right side
binding of the rubber mount on the mounting plate.
of motorcycle, first remove hex screw to free brake hose P-
clamp from rear swingarm bracket. The relief in right side fix-
After the mount is centered, tighten the two front
ture accommodates hex screw boss.
engine mount to frame crossmember bolts to 15-20
ft-lbs (20-27 Nm). See G of Figure 2-39.
c. Holding alignment fixture tight against rear swing-
arm bracket, use knurling to rotate pilot until it bot-
Install center front engine mounting bracket to rub-
toms in rear swingarm bracket. Without disturbing
ber mount bolt (with washers and nut) and tighten to
setting of pilot, tighten allen head screw to passen-
15-20 ft-lbs (20-27 Nm). See F of Figure 2-39.
ger footboard mount to 18-22 ft-lbs (24-30 Nm).
Repeat step on other side of motorcycle.
15.
Slide voltage regulator over studs on lower frame cross-
d. Hand turn alignment screw until it bottoms against
member at front of vehicle. Install flange locknuts on
end of pivot shaft. Repeat step on other side of
studs and tighten to 70-100 in-lbs (7.9-11.3 Nm).
motorcycle.
16.
Install fuel tank. For carbureted models, see Section 4.7
e. Tighten alignment screw to 60-80 in-lbs (6.8-9.0
FUEL TANK (CARBURETED), INSTALLATION (AFTER
Nm). Repeat step on other side of motorcycle. See
PARTIAL REMOVAL), INSTALLATION (AFTER PAR-
Figure 2-38.
TIAL REMOVAL), or FLHR/S. For fuel injected models,
see Section
9.4 FUEL TANK
(FUEL INJECTED),
10.
Adjust each stabilizer link as follows:
INSTALLATION (AFTER PARTIAL REMOVAL), FLHXI,
FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
a. Install bolts removed under steps 7(d) and 8(e), and
using the center hex to maintain equal thread
17.
Verify minimum clearance between the powertrain and
engagement at both eyelets, adjust stabilizer links
the following frame mounted components:
so that bolts thread in without any stress or engine
a. Top Engine/Horn Mounting Bracket to Fuel Tank:
movement. See B and D of Figure 2-39.
0.328 inch (8.3 mm).
b. Alternately tighten bolts to 18-22 ft-lbs (24-30 Nm).
b. Rocker Covers to Fuel Tank: 0.375 inch (9.5 mm).
c. Holding the stabilizer link adjuster and mounting
c. Carburetor Top Cover to Fuel Tank: 0.375 inch (9.5
eyelets to prevent movement or binding, tighten jam
mm).
nuts on top and front stabilizer links.
d. Rear Spark Plug Boot to Fuel Valve: 0.250 inch (6.4
mm).
11.
Remove vehicle alignment tool from rear swingarm
brackets.
e. Top Stabilizer Link to Induction Module: 0.375 inch
(9.5 mm).
12.
Snap the chrome plugs back into the rear swingarm
brackets.
f.
Front Stabilizer Link to Voltage Regulator: 0.375
inch (9.5 mm).
13.
Install socket screw with lockwasher to fasten passenger
footboard to rear swingarm bracket. Tighten screw to 30-
g. Inner Primary Chaincase to Lower Frame Tube:
35 ft-lbs (40.7-47.5 Nm). Repeat step on other side of
0.187 inch (4.8 mm).
motorcycle.
h. Exhaust Crossover Pipe to Primary Housing: 0.125
inch (3.2 mm).
14.
Verify that front rubber mount is centered under the front
mounting plate bolt hole and has not been bound by the
i.
Tire to Rear Fender: 0.100 inch (2.5 mm).
plate dragging across the isolator.
j.
Perform the procedure under Method B to trouble-
a. If the front rubber mount is centered and free of
shoot clearance problems and to identify offending
binding, proceed as follows:
component(s).
2-30
2006 Touring: Chassis
HOME
18. Install seat. See Section 2.25 SEAT, INSTALLATION.
c. Loosen both top stabilizer link jam nuts.
19. Test ride the motorcycle.
d. Remove the top stabilizer link eyelet to top engine
mounting bracket bolt. See B of Figure 2-39.
NOTE
8.
Front Engine Mount:
Vehicle leads that require more than 2-lbs pull to correct
need further diagnosis. Perform the procedure under Method
a. Remove flange locknuts from studs on lower frame
B in this section.
crossmember. Remove voltage regulator from studs
and allow to hang by cables at front of motorcycle.
b. Tighten two engine to front engine mounting bracket
bolts to 33-38 ft-lbs (45-52 Nm). See H of Figure 2-
METHOD B
39.
c. Tighten front stabilizer link eyelet to frame weldment
NOTE
bolt to 18-22 ft-lbs (24-30 Nm). See D of Figure 2-
39.
Use this procedure to determine the cause of vehicle mis-
alignment and to locate clearance problems, or as an
d. Tighten front stabilizer link eyelet bolt to block on
alternative to use of the Vehicle Alignment Tool (HD-46247)
front engine mounting bracket to 18-22 ft-lbs (24-30
described under Method A. For acceptable results, a careful
Nm). See E of Figure 2-39.
inspection should be performed (wheel and tire runout, laced
e. Remove the center front engine mounting bracket to
wheel offset, rubber mount condition, etc.) to ensure that it is
rubber mount bolt (with washers and nut). See F of
conducted with serviceable components. See INSPECTION
Figure 2-39.
for more information.
9.
To verify alignment, install alignment bars or other suit-
1.
Place the motorcycle on a hydraulic center stand or
able device on both the left and right side of motorcycle.
place blocking under the frame to support the vehicle
Proceed as follows:
and lift the rear wheel off the ground. Be sure the motor-
cycle is positioned as level as possible.
NOTE
If the front tire is wider than the rear, then the alignment bars
2.
Remove socket screw with lockwasher to remove left
passenger footboard from rear swingarm bracket.
must either be shimmed out equally at the points of contact
Tighten both rear swingarm bracket bolts to 34-42 ft-lbs
on the rear tire, notched at the front to clear the front tire, or
attached to the front tire with all measurements performed at
(46-57 Nm). Repeat step on right side of motorcycle.
the rear. For explanatory purposes, the following procedure
3.
Remove the decorative chrome plug from both rear
assumes the alignment bars are secured to the rear tire.
swingarm brackets. While holding the left side pivot shaft
locknut, tighten the right side locknut to 40-45 ft-lbs (54-
a. Place a set of straightedges on both the left and
61 Nm). Then hold the right side pivot shaft locknut and
right sides of the motorcycle alongside the front and
tighten the left side locknut to 40-45 ft-lbs (54-61 Nm).
rear tires.
4.
Verify that belt deflection is within specification and that
b. Verify that both alignment bars firmly contact the
adjuster cams are tight against rear swingarm weld
rear wheel at two points. Use clamp or bungee
nubs. Holding weld nut on left side of axle, tighten cone
cords to hold the bars in place. Tension should be
nut on right side to 95-105 ft-lbs (128.8-142.4 Nm).
equal to avoid spreading or pinching the bars.
5.
Remove seat. See Section 2.25 SEAT, REMOVAL.
c. Verify that the bars are straight by matching the
6.
Partially remove fuel tank to gain access to top engine
width measurements at both ends.
mounting bracket and stabilizer link. See Section 4.7
d. Straighten the front end and verify that the
FUEL TANK (CARBURETED), PARTIAL REMOVAL,
measurements from the front wheel to the bar on
FLHX, FLHT, or FLHR/S. For fuel injected models, see
one side of the motorcycle are equal at two points,
Section 9.4 FUEL TANK (FUEL INJECTED), PARTIAL
both fore and aft.
REMOVAL, FLHXI, FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
e. Measure the front wheel to the bar on the other side
7.
Top Engine Mount:
of the motorcycle, both fore and aft, and compare
a. On left side of motorcycle, tighten the two top
the results to the measurements obtained under
engine mounting bracket to front and rear cylinder
step 9(d). Measurements from left to right should be
head bolts to 35-40 ft-lbs (48-54 Nm). See A of Fig-
equal +/- 0.030 inch (0.76 mm).
ure 2-39.
f.
Loosen jam nuts, and using the center hex, adjust
b. Moving to right side of motorcycle, tighten the top
the front stabilizer link as required to obtain equal
stabilizer link eyelet to frame weldment bolt to 18-22
measurements at all four points (+/- 0.030 inch or
ft-lbs (24-30 Nm). See C of Figure 2-39.
0.76 mm). See Figure 2-40.
2006 Touring: Chassis
2-31
HOME
Chassis
Chassis
To Correct:
Powertrain
Powertrain
Adjust front stablizer link.
To Correct:
Adjust top stablizer link.
FLT0239
FLT0240
Figure 2-40. Horizontally Misaligned
Figure 2-41. Vertically Misaligned
NOTE
After the mount is centered, tighten the two front
engine mount to frame crossmember bolts to 15-20
After each adjustment, unload any binding of the front rubber
ft-lbs (20-27 Nm). See G of Figure 2-39.
mount and verify that the alignment bars and front wheel are
still correctly positioned.
Install center front engine mounting bracket to rub-
ber mount bolt (with washers and nut) and tighten to
15-20 ft-lbs (20-27 Nm). See F of Figure 2-39.
g. Holding the front stabilizer link adjuster and
mounting eyelets to prevent movement or binding,
10.
Slide voltage regulator over studs on lower frame cross-
tighten both jam nuts.
member at front of vehicle. Install flange locknuts on
studs and tighten to 70-100 in-lbs (7.9-11.3 Nm).
h. Verify that the front rubber mount is centered under
the thru bolt hole in the mounting plate.
11.
Adjust the top stabilizer link as follows:
i.
If the front rubber mount is centered and free of
a. Using the center hex to maintain equal thread
binding, proceed as follows:
engagement at both eyelets, adjust stabilizer link so
that bolt removed under step 7(d) threads in without
Tighten the two front engine mount to frame cross-
any stress or engine movement.
member bolts to 15-20 ft-lbs (20-27 Nm). See G of
Figure 2-39.
b. Tighten the stabilizer link eyelet to top engine
mounting bracket bolt to 18-22 ft-lbs (24-30 Nm).
Install center front engine mounting bracket to rub-
See B of Figure 2-39.
ber mount bolt (with washers and nut) and tighten to
15-20 ft-lbs (20-27 Nm). See F of Figure 2-39.
c. Holding the top stabilizer link adjuster and mounting
eyelets to prevent movement or binding, tighten
j.
If centering or relaxation of the mount is required,
both jam nuts.
proceed as follows:
12.
Lower motorcycle to floor and remove hydraulic center
Loosen the two front engine mount to frame cross-
stand or blocking.
member bolts. See G of Figure 2-39.
13.
After verifying that the motorcycle is level, check vertical
Push on the rubber mount to center it with the thru
alignment placing an inclinometer on both front and rear
bolt hole in the mounting plate. It may be necessary
brake rotors. Front and rear lean angles should be equal
to bounce or wiggle the engine to unload any
+/-
1/2 degree. See Figure 2-41. If vertical alignment
binding of the rubber mount on the mounting plate.
exceeds specification, proceed as follows:
2-32
2006 Touring: Chassis
HOME
a. Loosen the top stabilizer link eyelet to top engine
INSPECTION
mounting bracket bolt. See B of Figure 2-39. Verify
that bolt is unloaded and threads freely in and out of
See Section
1.2 MAINTENANCE SCHEDULE for the
the mounting bracket hole. If necessary, loosen jam
required service interval. Perform inspection sooner if any
nuts and adjust stabilizer link to a achieve a free
sag in the powertrain is observed or abnormal handling char-
state. Tighten bolt to 18-22 ft-lbs (24-30 Nm) and
acteristics/vibrations are experienced.
then tighten jam nuts before rechecking vertical
alignment.
b. Look for components that are worn, damaged or out
Front Rubber Mount
of specification. See INSPECTION on the next
page.
1.
Verify condition and torque of the mounting hardware.
14.
Remove the alignment bars from both the left and right
Visually inspect for wear, damage or improper installa-
side of the motorcycle.
tion. Replace hardware as necessary.
15.
Snap the chrome plugs back into the rear swingarm
2.
Examine carefully at the bottom of the motorcycle paying
brackets.
special attention to the area between the large flat metal
washer and the bracket on the frame. There should be a
16.
Install socket screw with lockwasher to fasten passenger
gap between the mounting plate and the cushion portion
footboard to rear swingarm bracket. Tighten screw to 30-
of the rubber mount.
35 ft-lbs (40.7-47.5 Nm). Repeat step on other side of
motorcycle.
3.
Replace the rubber mount if there are any signs of
cracking or shearing.
17.
Install fuel tank. For carbureted models, see Section 4.7
FUEL TANK (CARBURETED), INSTALLATION (AFTER
PARTIAL REMOVAL), INSTALLATION (AFTER PAR-
Rear Swingarm Mounts
TIAL REMOVAL), or FLHR/S. For fuel injected models,
see Section
9.4 FUEL TANK
(FUEL INJECTED),
1.
Verify condition and torque of the mounting hardware.
INSTALLATION (AFTER PARTIAL REMOVAL), FLHXI,
Visually inspect for wear, damage or improper installa-
FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
tion. Replace hardware as necessary.
18.
Verify minimum clearance between the powertrain and
2.
Examine rubber mount to be sure there is no twisting or
the following frame mounted components:
binding at the parting line.
a. Top Engine/Horn Mounting Bracket to Fuel Tank:
0.328 inch (8.3 mm).
b. Rocker Covers to Fuel Tank: 0.375 inch (9.5 mm).
Engine Stabilizer Links
c. Carburetor Top Cover to Fuel Tank: 0.375 inch (9.5
1.
Verify condition and torque of the mounting hardware.
mm).
Visually inspect for wear, damage or improper installa-
tion. Replace hardware as necessary.
d. Rear Spark Plug Boot to Fuel Valve: 0.250 inch (6.4
mm).
2.
Using flats machined into the stabilizer eyelet, gently
rock the link and check for separation of the molded-in
e. Top Stabilizer Link to Induction Module: 0.375 inch
sleeve. Replace as necessary.
(9.5 mm).
f.
Front Stabilizer Link to Voltage Regulator: 0.375
Wear in the link also can be measured with a dial indica-
tor by hand compressing and then releasing the link.
inch (9.5 mm).
Replace any link that exceeds 0.025 inch (0.64 mm) of
g. Inner Primary Chaincase to Lower Frame Tube:
play or wear.
0.187 inch (4.8 mm).
h. Exhaust Crossover Pipe to Primary Housing: 0.125
inch (3.2 mm).
i.
Tire to Rear Fender: 0.100 inch (2.5 mm).
19.
Install seat. See Section 2.25 SEAT, INSTALLATION.
20.
Test ride the motorcycle.
NOTE
Vehicle leads that require more than 2-lbs pull to correct
need further diagnosis. See INSPECTION on this page.
2006 Touring: Chassis
2-33
HOME
FRONT BRAKE MASTER CYLINDER
2.10
GENERAL
f1284x2x
Dual Disc
Master cylinders designed for dual disc (two caliper) opera-
tion have an 11/16 inch bore, while those that are designed
for single disc (one caliper) operation have a 9/16 inch bore.
The bore size is stamped on the master cylinder assembly
inboard of the handlebar clamp bracket. See Figure 2-42.
1WARNING
Do not use parts from single caliper repair kits (9/16 inch
Bore Size
bore) on dual caliper models. Likewise, do not use parts
Stamp
from dual caliper repair kits (11/16 inch bore) on single
caliper models. Using incorrect parts can cause brake
failure, which could result in death or serious injury.
(00278a)
REMOVAL/DISASSEMBLY
Single Disc
CAUTION
Figure 2-42. Verify Correct Bore Size Before Use
DOT 4 brake fluid will damage painted and molded-in
color surfaces it comes in contact with. Always use cau-
tion and protect surfaces from spills whenever brake
work is performed. Failure to comply can result in cos-
2.
Place the cardboard insert between the brake lever and
metic damage. (00239a)
lever bracket. See Figure 2-43.
3.
Remove two T27 TORX screws with flat washers to
IMPORTANT NOTE
release handlebar clamp from the master cylinder hous-
Immediately wipe up any brake fluid spillage with a
ing. Remove the clamp and brake lever/master cylinder
clean, dry, soft cloth. Follow up by thoroughly wiping
assembly from the handlebar. See Figure 2-44.
affected area with a clean, damp, soft cloth (small spills)
or washing with a large quantity of soapy water (large
4.
Remove the cardboard insert (or cable strap eyelet)
spills).
between the brake lever and lever bracket.
1.
Remove banjo bolt and two steel/rubber washers to dis-
connect fitting of hydraulic brake line from master cylin-
1WARNING
der housing. Hold suitable container under banjo bolt
bore to allow reservoir to drain. Discard steel/rubber
Wear safety glasses or goggles when removing or
washers.
installing retaining rings. Retaining rings can slip from
the pliers and could be propelled with enough force to
cause serious eye injury. (00312a)
CAUTION
5. Remove retaining ring from pivot pin groove at bottom of
Do not remove or install the master cylinder assembly
master cylinder bracket. Discard retaining ring.
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
6.
Remove pivot pin and brake hand lever from master cyl-
installing the master cylinder assembly without the
inder assembly.
insert in place may result in damage to the rubber boot
and plunger on the front stoplight switch. (00324a)
7.
Carefully remove wiper with pick or similar tool.
NOTE
8.
Remove piston cap.
Use the eyelet of a small cable strap if the cardboard insert is
9.
Remove piston with O-ring and primary cup.
not available.
2-34
2006 Touring: Chassis
HOME
7959
1WARNING
Use denatured alcohol to clean brake system compo-
nents. Do not use mineral-based solvents (such as gaso-
line or paint thinner), which will deteriorate rubber parts
even after assembly. Deterioration of these components
can cause brake failure, which could result in death or
serious injury. (00291a)
3.
Carefully inspect all parts for wear or damage and
replace as necessary.
4.
Inspect the piston bore in the master cylinder housing for
scoring, pitting or corrosion. Replace the housing if any
of these conditions are found.
5.
Inspect the outlet port that mates with the brake line fit-
ting. As a critical sealing surface, replace the housing if
any scratches, dents or other damage is noted.
6.
Inspect the cover gasket for cuts, tears or general deteri-
Figure 2-43. Install Cardboard Insert
oration. If gasket and/or sight glass replacement is nec-
essary, proceed as follows:
a. From inboard side, push sight glass toward top of
10. Remove spring.
cover until free.
b. Pull rubber gasket from cover.
CAUTION
c. Fit nipple of new gasket into hole of cover aligning
To prevent dirt and other contaminants from entering the
gasket and cover thru holes.
master cylinder reservoir, thoroughly clean the cover
d. From bottom of gasket, push flat end of sight glass
before removal.
through nipple until top of glass is flush with top of
gasket. Verify that glass is square in bore. If some
11. Remove two Phillips screws to release cover from mas-
lubrication is necessary, use a small quantity of
ter cylinder reservoir.
clean brake fluid.
CLEANING AND INSPECTION
ASSEMBLY/INSTALLATION
1.
Fit O-ring into groove on outboard side of piston (pin
side). See Figure 2-44.
1WARNING
2.
Fit primary cup over lip on inboard side of piston, so that
Do not use parts from single caliper repair kits (9/16 inch
closed side (smaller OD) contacts shoulder.
bore) on dual caliper models. Likewise, do not use parts
from dual caliper repair kits (11/16 inch bore) on single
3.
Coat piston bore of master cylinder reservoir with spe-
caliper models. Using incorrect parts can cause brake
cial lubricant supplied in the service parts kit. Also apply
failure, which could result in death or serious injury.
the lubricant to OD of installed O-ring and primary cup.
(00278a)
4.
Insert metal retainer end of spring into piston bore, so
that it seats against counterbore (recess) at bottom.
1.
Always reassemble the master cylinder using new parts
from the correct repair kit.
5.
Slide piston over spring.
6.
Fit wiper over piston cap so that flat side of wiper con-
2.
Clean all parts with denatured alcohol or DOT 4 BRAKE
tacts cap shoulder.
FLUID. Do not contaminate with mineral oil or other sol-
vents. Wipe dry with a clean, lint free cloth. Blow out
7.
Fit piston cap over piston pin.
drilled passages and bore with a clean air supply. Do not
8.
Press down on wiper until it contacts the counterbore.
use a wire or similar instrument to clean drilled pas-
Larger OD of wiper must be completely seated in groove
sages in bottom of reservoir.
on outlet side of piston bore.
2006 Touring: Chassis
2-35

 

 

 

 

 

 

 

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