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 serious injury.
Perform necessary set-up tasks before customer delivery. See applicable model year predelivery and set-up instructions.
The performance of new motorcycle initial service is required to keep warranty in force and to verify proper emissions systems operation. See 1.5 MAINTENANCE SCHEDULE.
Safe operating maintenance
Notes:
- Do not attempt to tighten engine head bolts or engine damage may result.
- During the initial break-in period, use only GENUINE HARLEY-DAVIDSON H-D 360 MOTORCYCLE OIL 20W50. Failure to use the recommended oil will result in improper break-in of the engine cylinders and piston rings.
Inspect motorcycle on a regular basis for additional maintenance needs. Routinely check components between regular maintenance intervals. Always inspect motorcycle after periods of storage before riding.
Check:
- 1. Tires for correct pressure, excessive wear or any signs of tire damage.
- 2. Drive belt tension and condition.
- 3. Brakes, steering and throttle for responsiveness.
- 4. Brake fluid level and condition. Hydraulic lines and fittings for leaks. Also, check brake pads and discs for wear.
- 5. Cables for fraying, crimping and free operation.
- 6. Engine oil and transmission fluid levels.
- 7. Headlamp, auxiliary/fog lamp, tail lamp, stop lamp, horn and turn signal operation.
Shop practices
Repair notes
General maintenance practices are given in this section.
Notes:
- Repair = Disassembly/Assembly
- Replacement = Substitute a new part for existing component.
All special tools and torque values are noted at the point of use.
All required parts or materials can be found in the parts catalog.
Safety
Safety is always the most important consideration when performing any job.
Always have a complete understanding of the task.
Use common sense.
Use the proper tools.
Protect yourself and bystanders with approved eye protection.
Don't just do the job, do the job safely.
Removing parts
Always consider the weight of a part when lifting. Use a hoist whenever necessary. Do not lift heavy parts by hand. If a hoist and adjustable lifting beam or sling are needed to remove some parts, verify that:
The lengths of multiple chains or cables from the hoist to the part are equal and parallel.
Slings, chains and cables are positioned directly over the center of the part.
No obstructions will interfere with the lifting operation.
Parts are not left suspended.
Warning! Be sure to check capacity rating and condition of hoists, slings, chains and cables before use. Exceeding capacity ratings or using lifting devices that are in poor condition can lead to an accident, which could result in death or serious injury.
Always use blocking or proper stands to support the part that has been hoisted. If a part cannot be removed, verify that all bolts and attaching hardware have been removed. Verify that no parts are in the way of the part being removed.
When removing hoses, wiring or tubes, always tag each part to verify proper installation.
Cleaning
Always clean around lines or covers before they are removed. Plug, tape or cap holes and openings to keep out dirt, dust and debris. Clean and inspect all parts as they are removed. Verify all holes and passages are clean and open. After cleaning, cover all parts with clean lint-free cloth, paper or other material. Verify the part is clean when installed.
Thoroughly clean all parts to be reused before assembly. Clean parts promote better component operation and longer life. Seals, filters and covers used in this vehicle keep out extraneous dirt and dust. Keep these items in good condition to guarantee satisfactory operation.
When instructed to clean fastener threads or threaded holes, always:
- Clean all threadlocking material from fastener threads and threaded holes.
- Use a wire brush to clean fastener threads.
- Use a thread chaser or other suitable tool to clean threaded holes.
- Use PJ1 cleaner or equivalent to remove all traces of oil and contaminants from threads.
- Clear all threaded holes with low pressure compressed air.
Always verify cleanliness of blind holes before assembly. Tightening a screw with dirt, water or oil in the hole can cause castings to crack or break.
Disassembly and assembly
Always assemble or disassemble one part at a time. Do not work on two assemblies simultaneously. Make all necessary adjustments. Inspect your work when finished to verify that everything is done.
Operate the vehicle to perform any final check or adjustments. If all is correct, the vehicle is ready to go back to the customer.
Checking torques on fasteners
Check torque using a torque wrench set to the minimum specification for that fastener. If the fastener does not rotate, the torque has been maintained. If the fastener rotates, remove it to determine if it has a threadlocking agent.
If it has a threadlocking agent, clean all material from the threaded hole. Replace the fastener with a new one or clean the original fastener threads and apply the appropriate threadlocking product. Install and tighten the fastener to specification.
If the fastener does not use a threadlocking agent, install and tighten it to specification.
Magnetic parts trays
Magnetic parts trays are common in the service facility because they are convenient and can keep parts from becoming lost during a repair procedure. However, hardened steel parts can become magnetized when held in magnetic parts trays.
Metal fragments from normal wear are usually trapped in the oil filter or by the magnetic drain plug. Magnetized parts in the engine can retain these fragments, potentially causing accelerated engine wear and damage.
Never place parts that will be returned to service inside the vehicle's powertrain such as gears, thrust washers and especially bearings in magnetic parts trays.
Repair and replacement procedures
Hardware and threaded parts
Install thread repair inserts when threaded holes in castings are stripped, damaged or not capable of withstanding specified torque.
Replace bolts, nuts, studs, washers, spacers and small common hardware if missing or damaged. Clean up or repair minor thread damage with a suitable tap or die.
Replace all damaged or missing lubrication fittings.
Use LOCTITE 565 THREAD SEALANT on pipe fitting threads.
Threadlocking agents
Always follow specific service manual procedures when working with fasteners containing preapplied threadlocking agents when fastener replacement is recommended. When re-using fasteners containing threadlocking agents, thoroughly clean all fasteners and threaded holes. Always use the recommended threadlocking agent for the specific procedure.
Wiring, hoses and lines
Replace hoses, clamps, electrical wiring, electrical switches or fuel lines if they do not meet specifications.
Instruments and gauges
Replace damaged or defective instruments and gauges.
Bearings
Always use the proper tools and fixtures when servicing bearings.
Anti-friction bearings must be handled in a special way. To keep out dirt and abrasives, cover the bearings as soon as they are removed from the package.
When bearings are installed against shoulders, always verify that the chamfered side of the bearing faces the shoulder. Lubricate bearings and all metal contact surfaces before pressing into place. Only apply pressure on the part of the bearing that makes direct contact with the mating part. Install bearings with numbered side facing out.
Only remove bearings if necessary. Removal usually damages bearings requiring replacement with new parts.
Bushings
Do not remove a bushing unless damaged, excessively worn or loose in its bore. Press out bushings requiring replacement.
When pressing or driving bushings, always apply pressure in line with the bushing bore. Use a bearing/bushing driver or a bar with a smooth, flat end. Never use a hammer to drive bushings.
Verify that all oil holes are properly aligned during installation.
Gaskets
Always discard gaskets after removal. Replace with new gaskets. Never use the same gasket twice. Verify that gasket holes match up with holes in the mating part. Be aware that sections of a gasket may be used to seal passages.
Lip-type seals
Lip seals are used to seal oil or grease and are usually installed with the sealing lip facing the contained lubricant. Seal orientation, however, may vary under different applications.
Do not remove seals unless necessary. Only remove seals to gain access to other parts or if seal damage or wear dictates replacement.
Leaking oil or grease usually means that a seal is damaged. Replace leaking seals to prevent overheated bearings.
Always discard seals after removal. Do not use the same seal twice.
O-Rings
Always discard O-rings after removal. Many O-rings are similar in size and appearance. Always use new O-rings keeping them packaged until use to avoid confusion. To prevent leaks, lubricate the O-rings before installation with the same type of lubricant as that being sealed. Be sure that all gasket, O-ring and seal mating surfaces are thoroughly clean before installation.
Gears
Always check gears for damaged or worn teeth.
Remove burrs and rough spots with a honing stone or crocus cloth before installation.
Lubricate mating surfaces before pressing gears on shafts.
Shafts
If a shaft does not come out easily, check that all nuts, bolts or retaining rings have been removed. Check to see if other parts are in the way before using force to remove.
Shafts fitted to tapered splines should be very tight. If shafts are not tight, disassemble and inspect tapered splines. Discard parts that are worn. Verify that tapered splines are clean, dry and free of burrs before putting them in place. Press mating parts together tightly.
Clean all rust from the machined surfaces of new parts.
Part replacement
Warning! Harley-Davidson parts and accessories are designed for Harley-Davidson motorcycles. Using non-Harley-Davidson parts or accessories can adversely affect performance, stability or handling, which could result in death or serious injury.
Always install new genuine Harley-Davidson parts and accessories. This will provide best service life and maintain compliance with noise and emissions regulations.
Installing non-Harley-Davidson, off-road or competition parts can void warranty or result in an unsafe vehicle.
Cleaning
Part protection
Before cleaning, protect rubber parts (such as hoses, boots and electrical insulation) from cleaning solutions. Use a greaseproof barrier material. Remove the rubber part if it cannot be properly protected.
Cleaning process
Any cleaning method may be used as long as it does not result in parts damage. Thorough cleaning is necessary for proper parts inspection. Strip rusted paint areas to bare metal before priming and repainting.
Rust or corrosion removal
Remove rust and corrosion with a wire brush, abrasive cloth, sand blasting, vapor blasting or rust remover. Use buffing crocus cloth on highly polished parts that are rusted.
Bearings
Wash bearings in a non-flammable petroleum cleaning solution. Never use a solution that contains chlorine. Knock out packed lubricant by tapping the bearing against a wooden block. Wash bearings again.
Warning! Using compressed air to "spin dry" bearings can cause bearing to fly apart, which could result in death or serious injury.
Cover bearings with a clean shop towel and allow to air dry. Do not spin bearings while they are drying. Never use compressed air to dry bearings.
When dry, coat bearings with clean oil. Wrap bearings in clean paper.
Tool safety
Air tools
Always use approved eye protection equipment when performing any task using air-operated tools.
On all power tools, use only recommended accessories with proper capacity ratings.
Do not exceed air pressure ratings of any power tools.
Bits should be placed against work surface before air hammers are operated.
Disconnect the air supply line to an air hammer before attaching a bit.
Never point an air tool at yourself or another person.
Protect bystanders with approved eye protection.
Wrenches
Never use an extension on a wrench handle.
If possible, always pull on a wrench handle and adjust your stance to prevent a fall if something suddenly releases.
Always keep the wrench squarely installed on the fastener.
Never use a hammer on any wrench other than a STRIKING FACE wrench.
Discard any wrench with damaged or battered points.
Never use a pipe wrench to bend, raise or lift a pipe.
Pliers/cutters/pry bars
Plastic- or vinyl-covered pliers handles are not intended to act as insulation. Do not use them on live electrical circuits.
Do not use pliers or cutters for cutting hardened wire unless they were designed for that purpose.
Always cut at right angles.
Do not use any pry bar as a chisel, punch or hammer.
Hammers
Never strike a hammer against a hardened object, such as another hammer.
Always grasp a hammer handle firmly, close to the end.
Strike the object with the full face of the hammer.
Never work with a hammer which has a loose head or cracked handle.
Discard hammer if face is chipped or mushroomed.
Wear approved eye protection when using striking tools.
Protect bystanders with approved eye protection.
Punches/chisels
Never use a punch or chisel with a chipped or mushroomed end. Dress mushroomed chisels and punches with a grinder.
Hold a chisel or a punch with a tool holder if possible.
When using a chisel on a small piece, clamp the piece firmly in a vise and chip toward the stationary jaw.
Always wear approved eye protection when using these tools.
Protect bystanders with approved eye protection.
Screwdrivers
Do not use a screwdriver for prying, punching, chiseling, scoring or scraping.
Use the right type of screwdriver for the job. Match the tip of a screwdriver to the fastener.
Do not interchange POZIDRIV, PHILLIPS or REED AND PRINCE screwdrivers.
Screwdriver handles are not intended to act as insulation. Do not use them on live electrical circuits.
Do not use a screwdriver with rounded edges because it will slip. Redress with a grinder.
Ratchets and handles
Periodically clean and lubricate ratchet mechanisms with a light grade oil. Do not replace parts individually. Ratchets should be rebuilt with the entire contents of service kit.
Never hammer on a ratchet or put a pipe extension on a ratchet handle for added leverage.
Always support the ratchet head when using socket extensions, but do not put your hand on the head or you may interfere with the action of its reversing mechanism.
When breaking a fastener loose, apply a small amount of pressure as a test to be sure the ratchet's gear wheel is engaged with the pawl.
Sockets
Never use hand sockets on power or impact wrenches. Select only impact sockets for use with air or electric impact wrenches.
Select the right size socket for the job.
Always keep the wrench or socket squarely on the fastener.
Replace sockets showing cracks or wear.
Keep sockets clean.
Always use approved eye protection when using power or impact sockets.
Storage units
Do not open more than one loaded drawer at a time. Close each drawer before opening anotherto prevent the cabinet from unexpectedly tipping over.
Close lids and lock drawers and doors before moving storage units.
Do not pull on a tool cabinet. Always push tool cabinets in front of you.
Set the brakes on the locking casters after the cabinet has been rolled into position.