Howto use your service manual This Service Manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair. Secondly, it will introduce to the...
Preparation for service Warning! Gasoline is extremely flammable and highly explosive. Always stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near the work site. Inadequate safety precautions could result in death or...
Use genuine replacement parts Warning. When replacement parts are required, use only genuine Harley-Davidson parts or parts with equivalent characteristics (which include type, strength and material). Failure to do so may result in product malfunction. This could result in death...
Warnings and cautions Statements in this service manual preceded by the following words are of special significance. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially...
Servicing a new motorcycle Warning! Always follow the listed service and maintenance recommendations, since they affect the safe operation of the motorcycle and the personal welfare of the rider. Failure to follow recommendations could result in death or serious injury....
Safe operating maintenance Caution! Do not attempt to retighten engine head bolts. Retightening can cause engine damage. During the initial break-in period, use only Harley-Davidson 20W50 engine oil. Failure to use the recommended oil will result in improper break-in of the...
Shop practices Repair notes Note: General maintenance practices are given in this section. Eepair = Disassembly/Assembly. Replace = Removal/lnstallation. All special tools and torque values are noted at the point of use. All required parts or materials can be...
Repair and replacement procedures Hardware and threaded parts Install helical thread inserts when inside threads 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 in...
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...
Fuel and oil for motorcycle Fuel Warning! Remove filler cap slowly and fill fuel tank slowly to prevent spillage; do not overfill or fill above the bottom of the filler neck insert. In addition, leave air space to allow for fuel expansion. Expansion can cause an overfilled...
Maintenance schedule First scheduled maintenance A Harley-Davidson dealer should perform the first scheduled service listed in the Owner’s Manual. See the Maintenance and Lubrication section in your Owner’s Manual for more information. Maintenance task and service data...
Airbox and air filter Airbox removal 1. Unlock seat. 2. See Figure 1-1. Remove airbox cover by turning bailhead fastener 1/4 turn counterclockwise (CCW). Pull airbox cover away from locating holes. Figure 1-1. Airbox cover 3. See Figure 1-2. Remove IAT connector (1) by...
Checking coolant level in overflow bottle 1. See Figure 1-10. Remove fastener at upper corner of right side cover and remove cover. Figure 1-10. Removing fastener and cover to check coolant level Warning! Do not remove the filler cap when the engine is hot. The cooling system is under...
Check for coolant in system Coolant may be visible in the overflow bottle but not present in the rest of the cooling system. To ensure coolant is present: 1. Remove air filter top. See 1.4 Airbox and air filter . Figure 1-12. Cooling system air bleed plug 2. See Figure 1-12....
Checking and adding oil Check engine oil level: As part of the pre-ride inspection. At every scheduled service interval. At every fuel stop. Note. This engine has a wet sump, an integral transmission, gear driven primary drive and wet clutch. This design allows engine oil...
Changing oil and filter PART NO. SPECIALTY TOOL HD-44067 Oil filter wrench Change engine oil and filter: At the first scheduled service interval. At every 8000 km (5000 mile) service interval thereafter. When storing or removing the motorcycle for the season. Notes: If the...
Battery maintenance — general Warning! All batteries contain electrolyte. Electrolyte is a sulfuric acid solution that is highly corrosive and can cause severe chemical burns. Avoid contact with skin, eyes, and clothing. Avoid spillage. Always wear protective face shield,...
Battery — disconnection and removal Warning! Always disconnect the negative battery cable first. If the positive battery cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion that could result in death or serious personal...
Battery — installation and connection Caution! Attach the cables to the correct battery terminals using the proper torque. Overtightening bolts can damage battery terminals and incorrect connections may damage the motorcycle’s electrical system. Warning! Always connect the positive...
Battery — storage Warning! Store the battery out of the reach of children. Inadequate safety precautions could result in death or serious injury. Caution! The electrolyte in a discharged battery will freeze if exposed to freezing temperatures. Freezing may crack the...
Brake fluid inspection Check brake fluid reservoir level and condition: At the first scheduled service interval. At every 5000 mile (8000 km) service interval thereafter. When storing or removing the motorcycle for the season. Also, check for fluid leaks at every service...
Rear brake pedal adjustment If adjustment is needed: 1. See Figure 1-27. With a wrench holding the push rod (1), loosen jam nut (2). Figure 1-27. Rear brake pedal: 1. Push rod; 2. Jam nut; 3. Rod end; 4. Clevis pin; 5. 18-22 mm (0.690-0.890 in) 2. Turn push rod (1) to set...
Bleeding brakes Caution! Direct contact of DOT 5 brake fluid with eyes may cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 5 brake...
Brake pads and discs — inspection Check brake pads and discs: At every scheduled service interval. Whenever the components are removed during service procedures. Brake pads Caution! Direct contact of DOT 5 brake fluid with eyes may cause eye irritation, swelling, and redness. Avoid...
Brake pad replacement Rear brake caliper 1. Remove the rear master cylinder reservoir cap. As the pistons are pushed back into the caliper, fluid level may rise more than 3.2 mm (1/8 in.). You may have to remove fluid to allow for this. 2. See Figure 1-31. Loosen, but do...
Tires and wheels Tires Warning! For your own personal safety, tires, rims and air valves must be correctly matched to wheel rims. See your Harley-Davidson dealer. Mismatching tires, tubes, rims and air valves may result in damage to the tire bead during mounting or...
Checking clutch fluid level The clutch is hydraulically actuated. A hand lever actuated master cylinder creates pressure in a clutch fluid line that activates a secondary clutch actuator mounted in the engine right side cover. The secondary clutch actuator piston extends and...
Bleeding clutch fluid line Warning! Be sure NO clutch fluid gets on rear tire, wheel or brakes when adding clutch fluid. Traction will be adversely affected which could result in loss of control of the motorcycle and death or serious injury. Warning! Do NOT allow foreign...
Rear belt deflection — inspection PART NO. SPECIALTY TOOL HD-35381 Belt tension gauge Check rear belt deflection: As part of the pre-ride inspection. At every scheduled service interval. Note. Customers may purchase belt tension gauge from an authorized Harley-Davidson dealer....
Rear belt and sprockets — inspection General Inspect the drive belt and rear sprocket: At the first scheduled service interval. At every 8000 km (5000 mile) service interval thereafter. Note. When a drive belt is replaced for any reason other than stone damage, it is recommended that...
Rear shock preload — adjustment PART NO. SPECIALTY TOOL HD-94700-52C Spanner wrench The rear shock absorber springs can be adjusted for the weight the motorcycle is to carry. There is a spanner wrench for this purpose. Warning! Both shock absorber adjuster plates must be adjusted...
Steering head bearings — adjustment (fall-away) Check steering head: At the 1600 km (1000 mile) service interval, adjust steering head bearing fall away. At every 48,280 km (30,000 mile) service interval, disassemble, inspect and repack the steering head bearing. See 2.29 Steering head . 1....
Replacing front fork oil Replace front fork oil in models with hydraulic forks: At every 48,000 km (30,000 mile) service interval. Prior to extended storage. PART NO. SPECIALTY TOOL HD-41177 Fork tube holder HD-59000A Pro-level oil gauge 1. Support the motorcycle so the...
Spark plug/coil — removal, inspection and installation General The spark plugs have been carefully selected for the performance characteristics of the VRSC motor. Use only 10R12A spark plugs in the VRSC motor. Caution! Use only Harley-Davidson spark plugs made for the VRSC. Use of other spark plugs may...
Cable and chassis lubrication General Inspect and lubricate the front brake lever, clutch hand lever, throttle control cables, and jiffy stand: At the first scheduled service interval. At every 8000 km (5000 mile) service interval thereafter. If service is on muddy or dusty...
Throttle cable inspection, lubrication and adjustment Inspect the throttle cables: At the first scheduled service interval. At every 8000 km (5000 mile) service interval thereafter. Inspection and Lubrication 1. See Figure 1-52. Turn the cable adjusters (2, 4) and jamnuts (3) as short as they will go....
Valve lash measurment Part No. Specialty Tool HD-45314 Crankshaft rotating wrench 1. Remove airbox assembly. See 1.4 Airbox and air filter . 2. Remove battery. See 1.7 Battery maintenance . 3. See Figure 1-53. Remove fuel lines. a. At the fuel rail, disconnect pressure...
Verify cam timing PART NO. SPECIALTY TOOL HD-45653 TDC positioning tool HD-45306 Crankshaft locking pin HD-45314 Crankshaft rotating wrench 1. See Figure 1-63. Install TDC POSITIONING TOOL (HD-45653) in front spark plug hole. Figure 1-63. Top Dead center positioning...
Valve lash adjustment PART NO. SPECIALTY TOOL HD-45314 Crankshaft rotating wrench HD-45340 Gasket alignment tool 1. See Figure 1-66. Using CRANKSHAFT ROTATING WRENCH (HD-45314), rotate the engine counter-clockwise (direction of operation) to position front cylinder cam...
Secondary cam chain — adjustment On high mileage engines with good oil pressure, if there is a noise at start-up which goes away, check secondary cam chain wear. Before beginning procedure, note if the rattle is heard during engine start-up. PART NO. SPECIALTY TOOL HD-45314...
Headlamp alignment — inspection Warning! Do not modify ignition wiring to permit motorcycle operation with headlamp off. Operating with headlamp off may reduce your visibility to other motorists and cause an accident, which could result in death or serious injury. Check headlamp...
Critical fasteners — inspection Inspect critical fasteners, except head bolts: At the first scheduled service interval. At every 16,000 km (10,000 mile) service interval thereafter. See Table 1-8. Tighten all critical fasteners, except head bolts, to service manual specifications....
Preparation for storage motorcycle Warning! Gasoline is flammable. Do not store a motorcycle having gasoline in tank within the home or garage where open flames, pilot lights, sparks or electric motors are present. Inadequate safety precautions could result in death or serious...
Tools for repair and maintenance motorcycle Part No. HD-01289 Rim protectors Part No. HD-25070 Robinair heat Gun Part No. HD-21000 Tire spreader Part No. HD-28431В Black light fluorescent additive. Used with HD-35457. Part No. HD-23568 Coolant tester - fahrenheit; Part No. HD-23688 coolant...
Linear conversion table MILLIMETERS to INCHES (mm x 0.03937 = inches) 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 29 1.142 62 2.441 95...
Fastener torque values General Torque specifications for specific components are listed in each section at the point of use. When converting to Newtonmeters, use the formulas given under the metric chart. For all other steel fasteners, use the values listed in one of the...
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....