Fastener torque values in this chapter The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE Notes: Air cleaner cover screw 36-60 in·lbs 4.1-6.8 Nm 1.5 MAINTENANCE SCHEDULE , General Air cleaner cover screw 36-60 in·lbs 4.1-6.8 Nm 1.7 AIR...
Servicing a new motorcycle Warning! Perform the service and maintenance operations as indicated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or...
Fuel and oil for motorcycle Fuel Always use a good quality unleaded gasoline. Octane ratings are usually found on the pump. Refer to Table 1-1. Warning! Avoid spills. Slowly remove filler cap. Do not fill above bottom of filler neck insert, leaving air space for fuel...
Bulb requirements chart Table 1-3. Bulb chart LAMP DESCRIPTION (ALL LAMPS 12 V) BULBS REQUIRED CURRENT DRAW (AMPERAGE) HARLEY-DAVIDSON PART NUMBER Headlamp High beam/low beam 1 5.0/4.58 68329-03 Position lamp international 1 0.32 53436-97 Indicator lamp module All...
Checking and adding oil Removing and replacing oil filler cap 1. Park the motorcycle on level ground on the jiffy stand. 2. See Figure 1-1. Remove the filler cap from the oil tank. a. Press straight down on the filler cap and release. The cap will pop up. b. Pull up on the...
Changing oil and filter PART NUMBER TOOL NAME HD-42311 HARLEY-DAVIDSON OIL FILTER WRENCH HD-44067-A HARLEY-DAVIDSON OIL FILTER WRENCH FASTENER TORQUE VALUE Oil drain hose worm clamp 6-10 in·lbs 0.7-1.1 Nm Notice: Do not switch lubricant brands indiscriminately because some...
Air filter (XL models, except XL 1200V) — removal and installation FASTENER TORQUE VALUE Air filter screw 40-60 in·lbs 4.5-6.8 Nm Air cleaner cover screw 36-60 in·lbs 4.1-6.8 Nm Removal 1. See Figure 1-9. Remove the two fasteners (1) and the trim insert (2) from the air cleaner cover (3). Figure 1-9. Air Filter...
Air filter (XL 1200V models) — removal and installation FASTENER TORQUE VALUE Air filter screw 40-60 in·lbs 4.5-6.8 Nm Air cleaner cover screw 36-60 in·lbs 4.1-6.8 Nm Removal 1. See Figure 1-10. Remove the fastener (1) from the air cleaner cover (2). Figure 1-10. Air Filter Element: XL 1200V: 1. Screw;...
Air filter (XR 1200X models) — removal and installation Removal Warning! Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. 1. Remove...
Cleaning air filter element Warning! Do not use gasoline or solvents to clean filter element. Flammable cleaning agents can cause an intake system fire, which could result in death or serious injury. Note. Do not tap the filter on a hard surface. 1. Wash the filter in warm...
Tires and wheels — air pressure Warning! Be sure tires are properly inflated, balanced, undamaged, and have adequate tread. Inspect your tires regularly and see a Harley-Davidson dealer for replacements. Riding with excessively worn, unbalanced, improperly inflated, overloaded or...
Tire replacement Tread wear Warning! Replace tire immediately with a Harley-Davidson specified tire when wear bars become visible or only 1/32 in (0.8 mm) tread depth remains. Riding with a worn tire could result in death or serious injury. Harley-Davidson tires are...
Recommended motorcycle tires Warning! Match tires, tubes, rim strips or seals, air valves and caps to the correct wheel. Contact a Harley-Davidson dealer. Mismatching can lead to tire damage, allow tire slippage on the wheel or cause tire failure, which could result in death or...
Wheel bearings Note. Replace bearings in sets only. See 2.5WHEELS, Sealed Wheel Bearings. 1. Replace when bearings exceed end play service wear limit of 0.002 in (0.051 mm). 2. Inspect any time the wheels are removed. a. Inspectthe play of the wheel bearings by...
Wheel spokes PART NUMBER TOOL NAME HD-48985 SPOKE TORQUE WRENCH HD-94681-80 SPOKE NIPPLE WRENCH FASTENER TORQUE VALUE Spoke nipple 55 in·lbs 6.2 Nm Warning! Spokes that are too tight can draw nipples through the rim or distort hub flanges. Spokes that are too...
Primary chain — free play adjustment FASTENER TORQUE VALUE Primary chain adjuster locknut 20-25 ft·lbs 27.1-33.9 Nm Primary chain inspection cover 90-120 in·lbs 10.2-13.6 Nm Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse...
Clutch adjustment FASTENER TORQUE VALUE Clutch inspection cover screws 90-120 in·lbs 10.3-13.6 Nm Clutch cable adjuster jamnut 120 in·lbs 13.6 Nm Release the clutch cable tension Warning! To prevent accidental vehicle start-up, which could cause death or serious...
Drive belt and sprockets — inspection General Warning! Never bend belt forward into a loop smaller than the drive sprocket diameter. Never bend belt into a reverse loop. Over bending can damage belt resulting in premature failure, which could cause loss of control and death or serious...
Throttle control — lubrication and adjustment Cable inspection and lubrication FASTENER TORQUEVALUE Switch housing screw 35-45 in·lbs 4.0-5.1 Nm 1. Release the throttle cable tension. See 1.13 THROTTLE CONTROL, Cable Adjustment . 2. See Figure 1-35. Remove screws (1) to separate the upper...
Cable and chassis lubrication General Inspect and lubricate the following items according to 1.5 MAINTENANCE SCHEDULE . Front brake hand lever Clutch hand lever Throttle control cables Throttle control grip sleeve Clutch cable Foot shift lever pivot (if applicable) Rear brake...
Brake lines maintenance General The front and rear brakes are fully hydraulic disc brake systems that require little maintenance. Warning! Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which...
Brake pads and discs: XL models — inspection Inspection Brake pads Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 4 brake fluid...
Brake pads and discs: XR 1200X — inspection Inspection Brake pads Warning! Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. Caution! Direct contact of DOT 4 brake fluid with eyes can cause...
Spark plugs maintenance — removal, installation and inspection Removal Warning! Disconnecting spark plug cable with engine running can result in electric shock and death or serious injury. Note. Allow the engine to cool before servicing. 1. Disconnect spark plug cables. 2. Remove spark plugs. Inspection Note....
Steering head bearings Fall-away FASTENER TORQUE VALUE Fork stem pinch bolt 30-35 ft·lbs 40.7-47.5 Nm Fork bracket pinch screw 30-35 ft·lbs 40.7-47.5 Nm Measurement 1. Raise the front wheel off the floor. 2. Remove the components that interfere with front fork swing. 3....
Checking torques on fasteners Inspect critical fasteners at the scheduled service intervals. Replace any damaged or missing fasteners. 1. Attempt to turn the fastener using a torque wrench set to the minimum torque specification for that fastener. Refer to Table 1-20. a. If the...
Engine mounts and stabilizer links — inspection Inspection Check engine mounts and stabilizer links as follows: 1. See Figure 1-66. Check for cracks ortears in engine mount isolator rubber (17, 18). 2. Check for lateral movement at each end of the three stabilizer links (8). Any lateral movement...
Battery maintenance General Warning! Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. Warning!...
Exhaust system leak check 1. Check entire exhaust system for loose or missing fasteners, damaged pipe clamps or brackets, and obvious signs of leakage (carbon tracks at pipe joints, etc.). 2. Check for loose or damaged heat shields. Repair or replace as necessary. 3. Check...
Checking wheel alignment PART NUMBER TOOL NAME HD-48856-A AXLE ALIGNMENT PLUGS FASTENER TORQUE VALUE Axle, rear, nut 95-105 ft·lbs 129-142 Nm Checking wheel alignment Warning! Check vehicle alignment according to following procedures. Incorrect alignment can adversely...
Suspension adjustments Front fork: XR 1200X Warning! Adjust both forks equally. Improper fork adjustment can lead to loss of control, which could result in death or serious injury. Notice: Compression and rebound adjusting valves may be damaged if too much force is used...
Headlamp alignment Warning! The automatic-on headlamp feature provides increased visibility of the rider to other motorists. Be sure headlamp is on at all times. Poor visibility of rider to other motorists can result in death or serious injury. Note. Adjust the...
Placing motorcycle in storage PART NUMBER TOOL NAME 98716-87A STORAGE COVER Warning! Do not store motorcycle with gasoline in tank within the home or garage where open flames, pilot lights, sparks or electric motors are present. Gasoline is extremely flammable and highly...
Metric conversion table Table D-1. Metric conversions Millimeters to inches (mm x 0.03937 = in) mm in mm in mm in mm in .1 .0039 25 .9842 58 2.283 91 3.582 .2 .0078 26 1.024 59 2.323 92 3.622 .3 .0118 27 1.063 60 2.362 93 3.661 .4 .0157 28 1.102 61 2.401 94 3.701 .5 .0197...
Fluid volume conversions United states system Unless otherwise specified, all fluid volume measurements in this service manual are expressed in United States (U.S.) units-of-measure. See below: 1 pint (U.S.) = 16 fluid ounces (U.S.) 1 quart (U.S.) = 2 pints (U.S.) = 32 fl....
Torque conversions United states system The U.S. units of torque, foot pounds and inch pounds, are used in this service manual. To convert units, use the following equations: foot pounds ( ft·lbs) X 12.00000 = inch pounds (in·lbs). inch pounds (in·lbs) X 0.08333 =...
Acronyms and abbreviations Table E-1. Acronyms and abbreviations ACRONYM OR ABBREVIATION DESCRIPTION A Amperes AAT Ambient air temperature ABS Anti-lock braking system AC Alternating current ACC Accessory position on ignition switch ACR Automatic compression release AGM...
Tools used in this manual PART NUMBER TOOL NAME Notes: 94448-82B SHOCK ADJUSTMENT SPANNER 1.25 SUSPENSION ADJUSTMENTS , Shock Absorber Preload: All Models 98716-87A STORAGE COVER 1.27 STORAGE , Placing in Storage 99863-01A GLOBAL BATTERY CHARGER 1.22 BATTERY MAINTENANCE ,...
All torque values for motorcycle repair FASTENER TORQUE VALUE Notes: Air box to bracket fasteners: XR 1200X 36-60 in·lbs 4.1-6.7 Nm 4.5 FUEL TANK: XR 1200X , Installing Fuel Tank Air cleaner breather screw 84-120 in·lbs 9.5-13.6 Nm 4.3 AIR CLEANER ASSEMBLY , XL Models except XL 1200V Air...