PART NUMBER | TOOL NAME |
HD-45967 | SHOP DOLLY |
HD-45968 | FAT JACK |
HD-46284 | ENGINE HOOK |
FASTENER | TORQUE VALUE | |
Isolator mount, front, screw | 25-35 ft·lbs | 33.9-47.5 Nm |
Isolator mount, rear, screw | 25-35 ft·lbs | 33.9-47.5 Nm |
Fork, rear, pivot/engine mount bolt | 60-70 ft·lbs | 81.4-95.0 Nm |
Engine mount, front, bolt | 95-105 ft·lbs | 129-142 Nm |
Stop lamp switch bracket screw | 72-120 in·lbs | 8.1-13.6 Nm |
Brake hose clamp to frame, rear, screw | 30-40 in·lbs | 3.4-4.5 Nm |
Brake master cylinder reservoir, rear, mounting screw | 20-25 in·lbs | 2.3-2.8 Nm |
Footrest mount fastener | 45-50 ft·lbs | 61.0-67.8 Nm |
Stabilizer link, lower, frame bracket mounting screw | 25-35 ft·lbs | 33.9-47.5 Nm |
Stabilizer link screw | 25-35 ft·lbs | 33.9-47.5 Nm |
Stabilizer link cylinder head bracket | 55-65 ft·lbs | 74.6-88.2 Nm |
Stabilizer link screw | 25-35 ft·lbs | 33.9-47.5 Nm |
Stabilizer link screw | 25-35 ft·lbs | 33.9-47.5 Nm |
Stabilizer link screw | 25-35 ft·lbs | 33.9-47.5 Nm |
Ignition switch mounting screw | 34-45 in·lbs | 4.0-5.1 Nm |
Fuel tank mounting screw | 15-20 ft·lbs | 20.4-27.1 Nm |
Exhaust pipe clamp bracket screw | 30-33 ft·lbs | 40.7-44.8 Nm |
Sprocket cover, forward and lower screws | 80-120 in·lbs | 9.0-13.6 Nm |
Axle, rear, nut | 95-105 ft·lbs | 129-142 Nm |
1. See Figure 3-17. Make sure pivot shaft (4) and rear pivot lockplate (5) are mounted on engine mounting boss at rear of engine. Position right rear isolator (7) on pivot shaft on rear of engine. Do not Install left rear isolator at this time.
2. Position right front isolator (8) on front of engine. Do not Install left front isolator at this time.
3. Attach ENGINE HOOK (Part No. HD-46284) and engine hoist to engine.
4. Lift engine and swing assembly into chassis from left side. Swing front of engine in first.
5. Install left rear isolator (7) over pivot shaft (4). Install rear isolator mount (2) over left rear isolator and attach to frame with two screws (3). Do not tighten screws at this time.
6. Raise or lower engine until right front isolator lines up with mounting hole in frame.
7. Install left front isolator (8) and front isolator mount (9) to left side of frame with two screws (11). Do not tighten screws at this time.
8. Insert front engine mount bolt (10) from left side, through isolators and crankcase boss. Place nut (12) on bolt but do not tighten at this time.
9. Tighten two screws (11) securing front isolator mount (9) to 25-35 ft·lbs (33.9-47.5 Nm).
10. Tighten two screws (3) securing rear isolator mount (2) to 25-35 ft·lbs (33.9-47.5 Nm).
11. Using new hose clamp, install oil tank vent hose at oil tank. See 3.24 OIL TANK.
12. Install rear fork with pivot/engine mount bolts (1). Tighten to 60-70 ft·lbs (81.4-95.0 Nm).
13. Tighten front engine mount bolt (10) and nut (12) to 95105 ft·lbs (129-142 Nm).
14. Remove ENGINE HOOK (Part No. HD-46284).
15. With the aid of a FAT JACK (Part No. HD-45968), remove motorcycle from SHOP DOLLY (Part No. HD-45967).
16. Install stop lamp switch and brake lines.
- a. Carefully move the stop lamp switch and brake lines into place.
- b. Secure switch assembly to battery tray with bolt. Tighten to 72-120 in·lbs (8.1-13.6 Nm).
- c. Secure flexible brake hose to battery tray with p-clamp and screw. Tighten to 30-40 in·lbs (3.4-4.5 Nm).
- d. Plug rear stop lamp switch connectors [121] into rear stop lamp switch. See 6.21 REAR STOP LAMP SWITCH.
17. Install rear brake master cylinder remote reservoir. Secure with screw with captive washer. Tighten to 20-25 in·lbs (2.3-2.8 Nm). Install reservoir cover. See 2.13 REAR BRAKE MASTER CYLINDER RESERVOIR.
18. Models with Passenger Footrests: Install left passenger footrest assembly. Tighten mounting screws to 45-50 ft·lbs (61.0-67.8 Nm). See 2.43 PASSENGER FOOTRESTS.
19. Install shift lever and rider left footrest and mounting bracket assembly:
- a. Models with Mid-mount Controls: See 2.40 RIDER FOOT CONTROLS: XL MID-MOUNT CONTROLS.
- b. Models with Forward Controls: See 2.41 RIDER FOOT CONTROLS: XL FORWARD CONTROLS.
Note. Check each end of the stabilizer links for excessive wear prior to installation. The spherical ball end may rotate loosely, but should not have any lateral movement. Replace the link if lateral movement exists.
20. See Figure 3-16. Install lowerfront stabilizer link and frame bracket:
- a. Install lower frame bracket (2) with stabilizer link (1). Secure with screws (4) and washers (5). Tighten to 25-35 ft·lbs (33.9-47.5 Nm).
- b. Install screw (3) securing stabilizer link to engine crankcase boss. Tighten to 25-35 ft·lbs (33.9-47.5 Nm).
21. See Figure 3-15. Install upper stabilizer link (2), upper frame bracket (3) and cylinder head bracket (1) :
- a. Install stabilizer link bracket to front head with two screws and lockwashers. Tighten to 55-65 ft·lbs (74.688.2 Nm).
- b. Install upper frame bracket with stabilizer link, horn bracket (9) (models with front mounted horn), screws (5) and washers (8). Tighten to 25-35 ft·lbs (33.9-47.5 Nm).
- c. Install screw (4) securing stabilizer link to engine bracket (1). Tighten to 25-35 ft·lbs (33.9-47.5 Nm).
22. See Figure 3-14. Install spacer (5), rear stabilizer link (1), grounding strap (2) and screws (3, 4). Tighten to 25-35 ft·lbs (33.9-47.5 Nm).
Note. XL Models: Verify that the EVAP canister mounting hardware does not contact the rear stabilizer ground strap.
23. EVAP Controlled Models: Install EVAP canister and hoses. See 4.20 EVAPORATIVE EMISSIONS CONTROL.
24. Install induction module and intake manifold. See 4.8 INDUCTION MODULE: XL MODELS.
25. Position left and right wire harness caddies on either side of frame backbone. Plug in the following connectors, located in the caddies:
- a. Instruments connector [20].
- b. Headlamp connector [38].
- c. Right hand control connector (black) [22].
- d. Left hand control connector (gray) [24].
- e. Front turn signal connector [31].
26. Mount caddies together. Verify tabs on caddies engage each other and frame backbone bracket. Secure with screw. See 6.27 MAIN WIRING HARNESS.
27. Position ignition coil and bracket on frame behind steering head. Position the wiring harnesses, the right wire harness caddy and the throttle cables between the coil bracket uprights.
28. Plug ignition coil harness connector [83] into coil. See 6.13 IGNITION COIL. Mount ignition switch to coil bracket with screw. Tighten screw to 34-45 in·lbs (4.0-5.1 Nm). Secure right wire harness caddy to coil bracket with new push-in fastener.
29. Connect clutch cable to clutch lever on handlebar. Attach clutch cable (along with wiring harness and front O2 sensor harness) to frame front left downtube with cable clips. Adjust clutch. See 2.29 CLUTCH CONTROL.
30. Plug the following electrical connectors into the engine:
- a. Engine Temperature (ET) sensor connector [90]. Secure sensor harness to ECM caddy with barbed cable strap. To avoid damage to sensor during vehicle operation, secure harness with a loop between sensor and ECM caddy. Press barbed prong of cable strap into hole in boss in ECM caddy. See 4.7 ENGINE TEMPERATURE (ET) SENSOR.
- b. Starter relay wire (GN) at starter motor. See 6.10 STARTER.
- c. Vehicle speed sensor (VSS) connector [65]. See 6.25 VEHICLE SPEED SENSOR (VSS).
- d. Neutral indicator switch connector [136]. See 6.26 NEUTRAL INDICATOR SWITCH.
- e. Alternator AC connector [46]. See 6.23 VOLTAGE REGULATOR.
- f. Crank position (CKP) sensor connector [79]. See 6.22 CRANK POSITION SENSOR (CKP).
- g. Oil pressure switch connector [120]. See 6.31 OIL PRESSURE SWITCH.
- h. Spark plug wires.
- i. Ground wire at powertrain ground stud on crankcase.
31. Connect the following connectors to the induction module. See 4.8 INDUCTION MODULE: XL MODELS.
- a. Throttle position sensor (TPS) connector [88].
- b. Idle air control (IAC) connector [87].
- c. Temperature/manifold absolute pressure (TMAP) sensor connector [80].
- d. Fuel injector connectors [84], [85].
32. Install horn. See 6.32 HORN.
33. Install air cleaner assembly.
- a. XL Models except XL 1200V: See 4.3 AIR CLEANER ASSEMBLY, XL Models except XL 1200V.
- b. XL 1200V: See 4.3 AIR CLEANER ASSEMBLY, XL 1200V.
- c. EVAP Controlled Models: Install EVAP purge hose on induction module. See 4.20 EVAPORATIVE EMISSIONS CONTROL.
Warning! When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
34. Install fuel tank and screw. Tighten to 15-20 ft·lbs (20.427.1 Nm). Attach quick-connect fitting on fuel line to fuel tank fitting. Gently tug on quick-connect fitting to make sure it is securely locked in place. See 4.4 FUEL TANK: XL MODELS.
35. Route oil drain hose down through drain hose sleeve in rear of engine crankcase. Using new hose clamps, install oil tank feed, drain and return hoses onto oil tank. Install drain plug in end of drain hose. Secure with worm drive clamp. Tighten clamp securely. See 3.24 OIL TANK.
36. Install exhaust system interconnect. See 4.13 EXHAUST SYSTEM: XL MODELS.
37. Install transmission sprocket. See 5.15 TRANSMISSION SPROCKET.
38. Install rear drive belt and hand-tighten rear axle. Final belt adjustment will be performed later. See 5.6 DRIVE BELT.
39. Install sprocket cover. Secure with two screws. Note that long screw goes in top hole, short screw in bottom hole. Do not tighten screws at this time.
40. Install exhaust pipe clamp bracket, washer and screw to sprocket cover. Tighten to 30-33 ft·lbs (40.7-44.8 Nm). Now tighten other two sprocket cover screws to 80-120 in·lbs (9.0-13.6 Nm).
41. Install right front footrest assembly and rear brake linkage.
- a. Models with Mid-mount Controls: See 2.40 RIDER FOOT CONTROLS: XL MID-MOUNT CONTROLS.
- b. Models with Forward Controls: See 2.41 RIDER FOOT CONTROLS: XL FORWARD CONTROLS.
42. Install exhaust pipes and mufflers. Plug in O2 sensor connectors [137], [138]. Route the rear O2 sensor harness toward left side of motorcycle. Loop the harness back to the harness connector. The harness cannot contact the exhaust pipe or port. See 4.13 EXHAUST SYSTEM: XL MODELS.
43. Fill oil tank. See 1.6 ENGINE OIL AND FILTER, Changing Oil and Filter.
44. Fill primary chaincase/transmission with FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT. See 1.10 TRANSMISSION LUBRICANT.
45. Adjust belt tension and rear wheel alignment. Tighten rear axle nut to 95-105 ft·lbs (129-142 Nm). Install new E-clip. See 1.24 WHEEL ALIGNMENT.
Warning! Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury.
46. Connect battery. See 1.22 BATTERY MAINTENANCE.
47. Install left side cover. See 2.18 LEFT SIDE COVER.
Warning! After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.
48. Install seat.