Harley Davidson Softail 2000-2005. Service manual - page 4

d. Remove the bearing from its wrapper and secure it

with a piece of heavy wire bent to hold it in the pot.
Hang the bearing in the pot so it does not touch
the bottom or sides of the pot.

e. Turn the heat on and monitor the thermometer.

When the oil temperature rises to approximately

120° C (248° F), remove the bearing from the pot
and quickly install it. If necessary, place a socket on
the inner bearing race and tap the bearing into place.
As the bearing chills, it will tighten on the shaft, so
installation must be done quickly. Make sure the
bearing is installed completely.

2. Follow this step to install a bearing in a housing. Bear-
ings are generally installed in a housing with a slight inter-
ference fit. Driving the bearing into the housing using
normal methods may damage the housing or cause bear-
ing damage. Instead, heat the housing before the bearing
is installed. Note the following:

CAUTION

Before heating the housing in this proce-
dure, wash the housing thoroughly with de-
tergent and water. Rinse and rewash the
cases as required to remove all traces of oil
and other chemical deposits.

a. Heat the housing to approximately 100° C (212° F)

in an oven or on a hot plate. An easy way to check
that it is the proper temperature is to place tiny
drops of water on the housing; if they sizzle and
evaporate immediately, the temperature is correct.
Heat only one housing at a time.

CAUTION

Do not heat the housing with a propane or
acetylene torch. Never bring a flame into
contact with the bearing or housing. The di-
rect heat will destroy the case hardening of
the bearing and will likely warp the housing.

b. Remove the housing from the oven or hot plate, and

hold onto the housing with a kitchen potholder,
heavy gloves or heavy shop cloth. It is hot!

NOTE

Remove and install the bearings with a suit-
able size socket and extension.

c. Hold the housing with the bearing side down and tap

the bearing out. Repeat for all bearings in the housing.

d. Before heating the bearing housing, place the new

bearing in a freezer if possible. Chilling a bearing
slightly reduces its outside diameter while the
heated bearing housing assembly is slightly larger
due to heat expansion. This will make bearing in-
stallation easier.

NOTE

Always install bearings with the manufac-
turer’s mark or number facing outward.

GENERAL INFORMATION

Bearing

Shaft

Socket

Shaft

Bearing

Housing

Spacer

Shaft

Driver

e. While the housing is still hot, install the new bear-

ing(s) into the housing. Install the bearings by hand,
if possible. If necessary, lightly tap the bearing(s)
into the housing with a socket placed on the outer
bearing race (Figure 53). Do not install new bear-
ings by driving on the inner-bearing race. Install the
bearing(s) until it seats completely.

Seal Replacement

Seals (Figure 56) are used to contain oil, water, grease or

combustion gasses in a housing or shaft. Improper removal
of a seal can damage the housing or shaft. Improper installa-
tion of the seal can damage the seal. Note the following:

1. Prying is generally the easiest and most effective method
of removing a seal from a housing. However, always place a
rag underneath the pry tool (Figure 57) to prevent damage to
the housing.

2. Pack waterproof grease in the seal lips before the seal is
installed.

3. In most cases, install seals with the manufacturer’s num-
bers or marks face out.

4. Install seals with a socket placed on the outside of the seal
as shown in Figure 58. Drive the seal squarely into the hous-
ing. Never install a seal by hitting against the top of the seal
with a hammer.

STORAGE

Several months of non-use can cause a general deterio-

ration of the motorcycle. This is especially true in areas of
extreme temperature variations. This deterioration can be
minimized with careful preparation for storage. A prop-
erly stored motorcycle will be much easier to return to ser-
vice.

Storage Area Selection

When selecting a storage area, consider the following:

1. The storage area must be dry. A heated area is best, but
not necessary. It should be insulated to minimize extreme
temperature variations.

2. If the building has large window areas, mask them to
keep sunlight off the motorcycle.

3. Avoid buildings in industrial areas where corrosive
emissions may be present. Avoid areas close to saltwater.

4. Consider the area’s risk of fire, theft or vandalism.
Check with an insurer regarding motorcycle coverage
while in storage.

Preparing the Motorcycle for Storage

The amount of preparation a motorcycle should un-

dergo before storage depends on the expected length of
non-use, storage area conditions and personal preference.
Consider the following list the minimum requirement:
1. Wash the motorcycle thoroughly. Make sure all dirt,
mud and road debris are removed.
2. Start the engine and allow it to reach operating temper-
ature. Drain the engine oil and transmission oil, regardless
of the riding time since the last service. Fill the engine and
transmission with the recommended type of oil.

CHAPTER ONE

Dust lip

Main lip

Reinforcement

Oil

Spring

3. Drain all fuel from the fuel tank, run the engine until all
the fuel is consumed from the lines and carburetor or fuel
injection module.
4. Remove the spark plugs and pour a teaspoon of engine
oil into the cylinders. Place a rag over the openings and
slowly turn the engine over to distribute the oil. Reinstall
the spark plugs.
5. Remove the battery. Store the battery in a cool and dry
location.
6. Cover the exhaust and intake openings.
7. Reduce the normal tire pressure by 20 percent.
8. Apply a protective substance to the plastic and rubber
components, including the tires. Make sure to follow the
manufacturer’s instructions for each type of product being
used.
9. Place the motorcycle on a stand or wooden blocks, so
the wheels are off the ground. If this is not possible, place
a piece of plywood between the tires and the ground. In-

flate the tires to the recommended pressure if the motorcy-
cle can not be elevated.

10. Cover the motorcycle with old bed sheets or some-
thing similar. Do not cover it with plastic material that will
trap moisture.

Returning the Motorcycle to Service

The amount of service required when returning a mo-

torcycle to service after storage depends on the length of
non-use and storage conditions. In addition to performing
the reverse of the above procedure, make sure the brakes,
clutch, throttle and engine stop switch work properly be-
fore operating the motorcycle. Refer to Chapter Three and
evaluate the service intervals to determine which areas re-
quire service.

GENERAL INFORMATION

Table 1 MODEL DESIGNATION

FLSTC/FLSTCI* Heritage Classic
FLSTF/FLSTFI* Fat Boy
FLSTS/FLSTSI* Heritage Springer
FXST/FXSTI* Softail Standard
FXSTB/FXSTBI* Night Train
FXSTS/FXSTSI* Springer Softail
FXSTD/FXSTDI* Softail Deuce

*The I designation indicates models equipped with fuel injection from 2001-on.

Table 2 GENERAL DIMENSIONS

Item/model

in.

Wheel base

FLSTC/FLSTCI*

64.5

1638.3

FLSTF/FLSTFI*

64.5

1638.3

FLSTS/FLSTSI*

64.2

1630.7

FXST/FXSTI*

66.9

1699.3

FXSTB/FXSTBI*

66.9

1699.3

FXSTS/FXSTSI*

65.4

1661.2

FXSTD/FXSTDI*

66.6

1691.6

Overall length

FLSTC/FLSTCI*

94.5

2400.3

FLSTF/FLSTFI*

94.5

2400.3

FLSTS/FLSTSI*

94.1

2390.1

FXST/FXSTI*

95.0

2413.0

FXSTB/FXSTBI*

95.0

2413.0

FXSTS/FXSTSI*

93.5

2374.9

FXSTD/FXSTDI*

95.4

2423.2

(continued)

Table 2 GENERAL DIMENSIONS (continued)

Item/model

in.

Overall width

FLSTC/FLSTCI*

37.5

952.5

FLSTF/FLSTFI*

40.2

1021.1

FLSTS/FLSTSI*

35.0

889.0

FXST/FXSTI*

37.9

962.66

FXSTB/FXSTBI*

30.9

784.9

FXSTS/FXSTSI*

32.6

828.0

FXSTD/FXSTDI*

35.9

911.9

Road clearance

FLSTC/FLSTCI*

5.1

129.5

FLSTF/FLSTFI*

5.1

129.5

FLSTS/FLSTSI*

4.9

124.5

FXST/FXSTI*

5.6

142.2

FXSTB/FXSTBI*

5.6

142.2

FXSTS/FXSTSI*

5.4

137.2

FXSTD/FXSTDI*

5.6

142.2

Overall height

FLSTC/FLSTCI*

57.8

1468.1

FLSTF/FLSTFI*

44.5

1130.3

FLSTS/FLSTSI*

46.0

1168.4

FXST/FXSTI*

46.4

1178.0

FXSTB/FXSTBI*

44.9

1140.0

FXSTS/FXSTSI*

47.3

1201.4

FXSTD/FXSTDI*

46.4

1178.0

Saddle height

FLSTC/FLSTCI*

25.4

645.2

FLSTF/FLSTFI*

25.5

647.7

FLSTS/FLSTSI*

25.9

657.9

FXST/FXSTI*

26.1

662.9

FXSTB/FXSTBI*

25.2

640.1

FXSTS/FXSTSI*

25.9

657.9

FXSTD/FXSTDI*

26.0

660.4

*The I designation indicates models equipped with fuel injection from 2001-on.

Table 3 MOTORCYCLE WEIGHT (DRY)

Model

lbs.

FLSTC/FLSTCI*

695.6

315.5

FLSTF/FLSTFI*

665

301.6

FLSTS/FLSTSI*

716.6

325

FXST/FXSTI*

628.6

285.1

FXSTB/FXSTBI*

629.6

285.6

FXSTS/FXSTSI*

652.6

296

FXSTD/FXSTDI*

644.6

292.4

*The I designation indicates models equipped with fuel injection from 2001-on.

Table 4 GROSS VEHICLE WEIGHT RATINGS

Model

lbs.

Gross vehicle weight rating (GVWR)

FLSTC/FLSTCI

1160

526.1

FLSTF/FLSTFI

1160

526.1

FLSTS/FLSTSI

1175

532.09

All FXST models

1125

510.3

CHAPTER ONE

(continued)

Table 4 GROSS VEHICLE WEIGHT RATINGS (continued)

Model

lbs.

Gross axle weight rating (GAWR)

Front axle

All FLST models

430

195

All FXST models

415

188.2

Rear axle

FLSTC/FLSTCI

730

331.1

FLSTF/FLSTFI

730

331.1

FLSTS/FLSTSI

745

337.9

All FXST models

710

322.1

1. GVWR is the maximum allowable vehicle weight. This includes combined vehicle, rider(s) and accessory weight.
2. The I designation indicates models equipped with fuel injection from 2001-on.

Table 5 FUEL TANK CAPACITY

Model

U.S. gal

Liters

Total

FXSTD/FXDT

4.9

18.55

All other models

5.0

18.9

Reserve

0.9

3.4

Table 6 DECIMAL AND METRIC EQUIVALENTS

Decimal

Metric

Decimal

Metric

Fractions

in.

Fractions

in.

1/64

0.015625

0.39688

33/64

0.515625

13.09687

1/32

0.03125

0.79375

17/32

0.53125

13.49375

3/64

0.046875

1.19062

35/64

0.546875

13.89062

1/16

0.0625

1.58750

9/16

0.5625

14.28750

5/64

0.078125

1.98437

37/64

0.578125

14.68437

3/32

0.09375

2.38125

19/32

0.59375

15.08125

7/64

0.109375

2.77812

39/64

0.609375

15.47812

1/8

0.125

3.1750

5/8

0.625

15.87500

9/64

0.140625

3.57187

41/64

0.640625

16.27187

5/32

0.15625

3.96875

21/32

0.65625

16.66875

11/64

0.171875

4.36562

43/64

0.671875

17.06562

3/16

0.1875

4.76250

11/16

0.6875

17.46250

13/64

0.203125

5.15937

45/64

0.703125

17.85937

7/32

0.21875

5.55625

23/32

0.71875

18.25625

15/64

0.234375

5.95312

47/64

0.734375

18.65312

1/4

0.250

6.35000

3/4

0.750

19.05000

17/64

0.265625

6.74687

49/64

0.765625

19.44687

9/32

0.28125

7.14375

25/32

0.78125

19.84375

19/64

0.296875

7.54062

51/64

0.796875

20.24062

5/16

0.3125

7.93750

13/16

0.8125

20.63750

21/64

0.328125

8.33437

53/64

0.828125

21.03437

11/32

0.34375

8.73125

27/32

0.84375

21.43125

23/64

0.359375

9.12812

55/64

0.859375

22.82812

3/8

0.375

9.52500

7/8

0.875

22.22500

25/64

0.390625

9.92187

57/64

0.890625

22.62187

13/32

0.40625

10.31875

29/32

0.90625

23.01875

27/64

0.421875

10.71562

59/64

0.921875

23.41562

7/16

0.4375

11.11250

15/16

0.9375

23.81250

29/64

0.453125

11.50937

61/64

0.953125

24.20937

15/32

0.46875

11.90625

31/32

0.96875

24.60625

31/64

0.484375

12.30312

63/64

0.984375

25.00312

1/2

0.500

12.70000

1.00

25.40000

GENERAL INFORMATION

Table 7 GENERAL TORQUE SPECIFICATIONS

Type

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

SAE 2

155

206

310

SAE 5

114

154

257

382

587

SAE 7

110

154

215

360

570

840

SAE 8

119

169

230

380

600

700

1. Convert ft.-lb. specification to N•m by multiplying by 1.3558.
2. Fastener strength of SAE bolts can be determined by the bolt head grade markings. Unmarked bolt heads and cap screws
are usually mild steel. More grade markings indicate higher fastener quality.

Table 8 CONVERSION FORMULAS

Multiply:

By:

To get the equivalent of:

Length

Inches

25.4

Millimeter

Inches

2.54

Centimeter

Miles

1.609

Kilometer

Feet

0.3048

Meter

Millimeter

0.03937

Inches

Centimeter

0.3937

Inches

Kilometer

0.6214

Mile

Meter

3.281

Feet

Fluid volume

U.S. quarts

0.9463

Liters

U.S. gallons

3.785

Liters

U.S. ounces

29.573529

Milliliters

Imperial gallons

4.54609

Liters

Imperial quarts

1.1365

Liters

0.2641721

U.S. gallons

Liters

1.0566882

U.S. quarts

Liters

33.814023

U.S. ounces

Liters

0.22

Imperial gallons

Liters

0.8799

Imperial quarts

Milliliters

0.033814

U.S. ounces

Milliliters

1.0

Cubic centimeters

Milliliters

0.001

Liters

Torque

Foot-pounds

1.3558

Newton-meters

Foot-pounds

0.138255

Meters-kilograms

Inch-pounds

0.11299

Newton-meters

0.7375622

Foot-pounds

Newton-meters

8.8507

Inch-pounds

Meters-kilograms

7.2330139

Foot-pounds

Volume

Cubic inches

16.387064

Cubic centimeters

0.0610237

Cubic inches

CHAPTER ONE

SAE 2

SAE 7

SAE 5

SAE 8

(continued)

Table 8 CONVERSION FORMULAS (continued)

Multiply:

By:

To get the equivalent of:

Temperature

Fahrenheit

(°F

–

32)

0.556

Centigrade

(°C

1.8)

Fahrenheit

Weight

Ounces

28.3495

Grams

Pounds

0.4535924

Kilograms

Grams

0.035274

Ounces

Kilograms

2.2046224

Pounds

Pressure

Pounds per square inch

0.070307

Kilograms per

square centimeter

Kilograms per square

14.223343

Pounds per square inch

centimeter

Kilopascals

0.1450

Pounds per square inch

6.895

Kilopascals

Speed

Miles per hour

1.609344

Kilometers per hour

0.6213712

Miles per hour

Table 9 TECHNICAL ABBREVIATIONS

ABDC

After bottom dead center

ATDC

After top dead center

BBDC

Before bottom dead center

BDC

Bottom dead center

BTDC

Before top dead center

BAS

Bank angle sensor

Celsius (centigrade)

Cubic centimeters

cid

Cubic inch displacement

CKP

Crankshaft position sensor

CDI

Capacitor discharge ignition

CMP

Camshaft position sensor

cu. in.

Cubic inches

ECM

Electronic control module

Engine temperature sensor

Fahrenheit

ft.

Feet

ft.-lb.

Foot-pounds

gal.

Gallons

H/A

High altitude

HDI

Harley-Davidson International

IAC

Idle air control

IAT

Intake air temperature sensor

Horsepower

in.

Inches

in.-lb.

Inch-pounds

I.D.

Inside diameter

Kilograms

kgm

Kilogram meters

Kilometer

kPa

Kilopascals

Liter

Meter

MAG

Magneto

MAP

Manifold absolute pressure sensor

GENERAL INFORMATION

(continued)

Table 9 TECHNICAL ABBREVIATIONS (continued)

Milliliter

Millimeter

N•m

Newton-meters

O.D.

Outside diameter

oz.

Ounces

psi

Pounds per square inch

PTO

Power take off

pt.

Pint

qt.

Quart

rpm

Revolutions per minute

Throttle position sensor

TSM

Turn signal module

TSSM

Turn signal security module

Table 10 AMERICAN TAP AND DRILL SIZES

Tap thread

Drill size

Tap thread

Drill size

#0-80

3/64

1/4-28

No. 3

#1-64

No. 53

5/16-18

#1-72

No. 53

5/16-24

#2-56

No. 51

3/8-16

5/16

#2-64

No. 50

3/8-24

#3-48

5/64

7/16-14

#3-56

No. 46

7/16-20

#4-40

No. 43

1/2-13

27/64

#4-48

No. 42

1/2-20

29/64

#5-40

No. 39

9/16-12

31/64

#5-44

No. 37

9/16-18

33/64

#6-32

No. 36

5/8-11

17/32

#6-40

No. 33

5/18-18

37/64

#8-32

No. 29

3/4-10

21/32

#8-36

No. 29

3/4-16

11/16

#10-24

No. 25

7/8-9

49/64

#10-32

No. 21

7/8-14

13/16

#12-24

No. 17

1-8

7/8

#12-28

No. 15

1-14

15/16

1/4-20

No. 8

Table 11 METRIC TAP AND DRILL SIZES

Metric

Drill

Decimal

size

equivalent

fraction

Nearest fraction

0.50

No. 39

0.0995

3/32

0.60

3/32

0.0937

3/32

0.70

No. 30

0.1285

1/8

0.75

1/8

0.125

1/8

0.80

No. 19

0.166

11/64

0.90

No. 20

0.161

5/32

1.00

No. 9

0.196

13/64

1.00

16/64

0.234

15/64

1.00

0.277

9/32

1.25

17/64

0.265

17/64

1.00

5/16

0.3125

5/16

1.25

5/16

0.3125

5/16

CHAPTER ONE

(continued)

Refer to Figure 60 for various types of drive belt wear

or damage. Replace the drive belt if it is worn or damaged.

WHEEL RUNOUT

1. Remove the front or rear wheel as described in this
chapter.

2. Install the wheel in a wheel truing stand and check the
wheel for excessive wobble or runout.

3. If the wheel is not running true, remove the tire from
the rim as described in this chapter. Then remount the

wheel into the truing stand, and measure axial and lateral
runout (Figure 61) with a pointer or dial indicator. Com-
pare actual runout readings with the service limit specifi-
cation in Table 1. Note the following:

a. Disc or cast wheels—if the runout meets or exceeds

the service limit in Table 1, check the wheel bear-
ings as described under

Front and Rear Hub

in this

chapter. If the wheel bearings are acceptable, re-
place the cast or disc wheel as it cannot be serviced.
Inspect the wheel for cracks, fractures, dents or
bends. Replace a damaged wheel.

WARNING

Do not try to repair damage to a disc wheel
as it will result in an unsafe riding condi-
tion.

b. Laced wheels—if the wheel bearings, spokes, hub

and rim assembly are not damaged, the runout can
be corrected by truing the wheel. Refer to

Spoke Ad-

justment

in this chapter. If the rim is dented or dam-

aged, replace the rim and rebuild the wheel.

4. While the wheel is off, perform the following:

a. Check the brake disc mounting bolts (Figure 44)

for tightness as described in Chapter Thirteen.

b. On the rear wheel, check the driven sprocket bolts

for tightness as described in this chapter.

RIM AND LACED WHEEL SERVICE

The laced wheel assembly consists of a rim, spokes,

nipples and hub containing the bearings, and spacer collar.

Component Condition

Wheels are subjected to a significant amount of punish-

ment. Inspect the wheel regularly for lateral (side-to-side)
and radial (up-and-down) runout, even spoke tension and
visible rim damage. When a wheel has a noticeable wob-
ble, it is out of true. This is usually cause by loose spokes,
but it can be caused by an impact-damaged rim.

Truing a wheel corrects the lateral and radial runout to

bring the wheel back into specification. The condition of
the individual wheel components will effect the ability to
successfully true the wheel. Note the following:
1. Spoke condition—Do not attempt to true a wheel with
bent or damaged spokes. Doing so places an excessive
amount of tension on the spoke and rim. The spoke may
break and/or pull through the spoke nipple hole in the rim.
Inspect the spokes carefully and replace any spokes that
are damaged.

WHEELS, HUBS AND TIRES

399

2. Nipple condition—When truing the wheels, the nip-
ples should turn freely on the spoke. It is common for the
spoke threads to become corroded and make turning the
nipple difficult. Spray a penetrating liquid onto the nipple
and allow sufficient time for it to penetrate before trying
to force the nipple loose. Work the spoke wrench in both
directions and continue to apply penetrating liquid. If the
spoke wrench rounds off the nipple, remove the tire from
the rim and cut the spoke(s) out of the wheel.

3. Rim condition—Minor rim damage can be corrected
by truing the wheel; however, trying to correct excessive
runout caused by impact damage causes hub and rim dam-
age due to spoke overtightening. Inspect the rims for
cracks, flat spots or dents. Check the spoke holes for
cracks or enlargement. Replace rims with excessive dam-
age.

Wheel Truing Preliminaries

Before checking runout and truing the wheel, note the

following:

1. Make sure the wheel bearings are in good condition.
Refer to

Front and Rear Hubs

in this chapter.

2. A small amount of wheel runout is acceptable, do not
try to true the wheel to a perfect zero reading. Doing so
causes excessive spoke tension and possible rim and hub
damage. Table 1 lists the lateral (side-to-side) and radial
(up-and-down) runout limit specifications.

3. The runout can be checked on the motorcycle by
mounting a pointer against the fork or swing arm and
slowly rotating the wheel.

4. Perform major wheel truing with the tire removed and
the wheel mounted in a truing stand (Figure 61). If a stand
is not available, mount the wheel on the motorcycle with
spacers on each side of the wheel to prevent it from sliding
on the axle.

5. Use a spoke nipple wrench of the correct size. Using
the wrong type of tool or one that is the incorrect size will
round off the spoke nipples, making adjustment difficult.
Quality spoke wrenches have openings that grip the nip-
ple on four corners to prevent nipple damage.

6. Refer to the spoke nipple torque specification in Table
2 when using a torque wrench.

Wheel Truing Procedure

1. Position a pointer facing toward the rim (Figure 61).
Then spin the wheel slowly and check the lateral and ra-
dial runout. If the rim is out of adjustment, continue with
Step 2.

400

CHAPTER NINE

DRIVE BELT INSPECTION

Stone

1. Internal tooth cracks
2. Missing teeth
3. Fuzzy edge core
4. Stone damage
5. External tooth cracks
6. Chipping
7. Hook wear

Content .. 2 3 4 5 ..