2015 Trike Models SM Supp

2015 Harley-Davidson Trike Models
Service Manual Supplement

99601-15
©2014 H-D.
IMPORTANT NOTICE
Harley-Davidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards
and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture.
To maintain the safety, dependability, and emission and noise control performance, it is essential that
the procedures, specifications and service instructions in this manual are followed.
Any substitution, alteration or adjustment of emission system and noise control components outside of
factory specifications may be prohibited by law.
Harley-Davidson Motor Company

2015 Harley-Davidson Trike
Models Service Manual
Supplement
©2014 H-D.
ALL RIGHTS RESERVED
99601-15
Printed in the U.S.A.
VISIT THE HARLEY-DAVIDSON WEB SITE

http://www.harley-davidson.com
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NOTES
ABOUT THIS MANUAL
GENERAL In figure legends, the number following the name of a part
indicates the quantity necessary for one complete assembly.
This service manual supplement has been designed to be used
with the current service manual and has been prepared with PREPARATION FOR SERVICE
two purposes in mind.
• It will acquaint the user with the construction of the Harley- PART NUMBER TOOL NAME
Davidson product and assist in the performance of basic HD-48650 DIGITAL TECHNICIAN II
maintenance and repair.
• It will introduce to the professional Harley-Davidson
Technician the latest field-tested and factory-approved
major repair methods. Stop the engine when refueling or servicing the fuel
We sincerely believe that this service manual supplement will system. Do not smoke or allow open flame or sparks near
make your association with Harley-Davidson products more gasoline. Gasoline is extremely flammable and highly
pleasant and profitable. explosive, which could result in death or serious injury.
(00002a)
NOTE
Good preparation is very important for efficient service work.
This service manual supplement provides information unique Start each job with a clean work area. This will allow the repair
to this model motorcycle. Any information not presented in this to proceed as smoothly as possible. It will also reduce the
supplement can be found in the appropriate service manual or incidence of misplaced tools and parts.
electrical diagnostic manual. Refer to Table i-1.
Clean a motorcycle that is excessively dirty before work starts.
Cleaning will occasionally uncover sources of trouble. Gather
Table i-1. Relevant Model Year Publications
any tools, instruments and any parts needed for the job before
PUBLICATION PART NUMBER work begins. Interrupting a job to locate tools or parts is a dis-
traction and causes needless delay.
Touring Models Service Manual 99483-15
Touring Models Electrical Diagnostic 99497-15 NOTES
FOREWORD
Manual • To avoid unnecessary disassembly, carefully read all
related service information before repair work begins.
HOW TO USE YOUR SERVICE MANUAL • In figure legends, the number which follows the name of
SUPPLEMENT a part indicates the quantity necessary for one complete
assembly.
Use the TABLE OF CONTENTS (which follows this FORE-
WORD) and the INDEX (at the back of this manual) to quickly • When servicing a vehicle equipped with the Harley-
locate subjects. Sections and topics in this manual are Davidson Smart Security System (H-DSSS), first disarm
sequentially numbered for easy navigation. the system. Keep the fob close to the vehicle or use
DIGITAL TECHNICIAN II (Part No. HD-48650) to disable
NO. CHAPTER the system. Activate the system after service is completed.
1 Maintenance
SERVICE BULLETINS
2 Chassis
In addition to the information presented in this service manual
3 Engine supplement and the appropriate service manual, Harley-
4 Fuel System Davidson Motor Company will periodically issue Service Bul-
letins to Harley-Davidson dealers. Service bulletins cover
5 Drive
interim engineering changes and supplementary information.
6 Transmission Consult the service bulletins to keep your product knowledge
7 Electrical current and complete.
A Appendix A Wiring WARNINGS AND CAUTIONS

B Appendix B Reference Statements in this manual preceded by the following words
are of special significance.
For example, a cross-reference shown as 2.1
SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1
SPECIFICATIONS.
If the subject you seek is not in this supplement, refer to the WARNING indicates a potentially hazardous situation
corresponding chapter in the appropriate service manual. which, if not avoided, could result in death or serious
Check the title page located in the front of each chapter to find injury. (00119a)
the subject.
For quick and easy reference, all pages contain a chapter
number followed by a page number. For example, page 3-5 CAUTION indicates a potentially hazardous situation which,
refers to page 5 in chapter 3. if not avoided, may result in minor or moderate injury.
(00139a)
I
When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool
or instrument may be substituted.
NOTICE indicates a potentially hazardous situation which,
if not avoided, may result in property damage. (00140b) Special Tools
NOTE All tools mentioned in this manual with a part number beginning
with "HD", "J" or "B" must be ordered through your local Harley-
Refers to important information. It is recommended that you Davidson dealer. Special tools may only be purchased, serviced
take special notice of these items. or warrantied through a Harley-Davidson dealer.
Proper service and repair are important for the safe, reliable
operation of all mechanical products. The service procedures
LOCTITE Sealing and THREADLOCKING
recommended and described in this manual are effective Products
methods for performing service operations. Some procedures in this manual call for the use of LOCTITE
products. If you have any questions regarding LOCTITE product
usage or retailer/wholesaler locations, contact Loctite Corp. at
www.loctite.com.
Always wear proper eye protection when using hammers,
arbor or hydraulic presses, gear pullers, spring com- PRODUCT REGISTERED MARKS
pressors, slide hammers and similar tools. Flying parts
could result in death or serious injury. (00496b) Apple, Alcantara S.p.A., Allen, Amp Multilock, Bluetooth,
Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E.
Some of these service operations require the use of tools Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod,
specially designed for the purpose. These special tools should Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Magnaflux,
be used when and as recommended. It is important to note Marson Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin,
that some warnings against the use of specific service methods, MPZ, Mulitilock, nano, NGK, Novus, Packard, Pirelli, Permatex,
which could damage the motorcycle or render it unsafe, are Philips, PJ1, Pozidriv, Robinair, S100, Sems, SiriusXM, Snap-
stated in this manual. However, remember that these warnings on, Teflon, Threadlocker, Torca, Torco, TORX, Tufoil, Tyco,
are not all-inclusive. Inadequate safety precautions could result Ultratorch, Velcro, X-Acto, XM Satellite Radio, and zūmo are
in death or serious injury. among the trademarks of their respective owners.
Since Harley-Davidson could not possibly know, evaluate or H-D U.S.A., LLC TRADEMARK
advise the service trade of all possible ways in which service
might be performed, or of the possible hazardous con- INFORMATION
sequences of each method, we have not undertaken any such Bar & Shield, Boom!, Cross Bones, Cruise Drive, CVO, Digital
broad evaluation. Accordingly, anyone who uses a service Tech, Digital Technician, Digital Technician II, Dyna, Electra
procedure or tool which is not recommended by Harley- Glide, Evolution, Fat Bob, Fat Boy, Forty-Eight, Glaze, Gloss,
Davidson must first thoroughly satisfy himself that neither his H-D, H-Dnet.com, Harley, Harley-Davidson, HD, Heritage
nor the operator's safety will be jeopardized as a result. Failure Softail, Iron 883, Low Rider, Night Rod, Nightster, Night Train,
to do so could result in death or serious injury. Profile, Reflex, Revolution, Road Glide, Road King, Road Tech,
Rocker, Screamin' Eagle, Seventy-Two, Softail, Sportster,
USE GENUINE REPLACEMENT PARTS
Street Glide, Street Rod, Sun Ray, Sunwash, Super Glide,
SuperLow, Switchback, SYN3, TechLink, TechLink II, Tour-
Pak, Tri Glide, Twin Cam 88, Twin Cam 88B, Twin Cam 96,
Twin Cam 96B, Twin Cam 103, Twin Cam 103B, Twin Cam
Harley-Davidson parts and accessories are designed for
110, Twin Cam 110B, Twin-Cooled, Ultra Classic, V-Rod,
Harley-Davidson motorcycles. Using non-Harley-Davidson
VRSC and Harley-Davidson Genuine Motor Parts and Genuine
parts or accessories can adversely affect performance,
Motor Accessories are among the trademarks of H-D U.S.A.,
stability or handling, which could result in death or serious
LLC.
injury. (00001b)
To achieve satisfactory and lasting repairs, carefully follow the CONTENTS
service manual instructions and use only genuine Harley- All photographs, illustrations and procedures may not neces-
Davidson replacement parts. Behind the emblem bearing the sarily depict the most current model or component, but are
words GENUINE HARLEY-DAVIDSON stand more than 100 based on the latest production information available at the time
years of design, research, manufacturing, testing and inspecting of publication.
experience. This is your assurance that the parts you are using
will fit right, operate properly and last longer. Since product improvement is our continual goal, Harley-
Davidson reserves the right to change specifications, equipment
PRODUCT REFERENCES or designs at any time without notice and without incurring
obligation.
Read and follow warnings and directions on all products.

Failure to follow warnings and directions can result in
death or serious injury. (00470b)
II FOREWORD
MAINTENANCE 1.14 STEERING HEAD BEARINGS
Maintenance.....................................................................1-27
1.1 FASTENER TORQUE VALUES
1.15 STEERING DAMPER
Fastener Torque Values in this Chapter..............................1-1
Inspection.........................................................................1-28
1.2 LIFTING MOTORCYCLE WITH A JACK
1.16 FORK OIL
Jacking Points.....................................................................1-3
Procedure.........................................................................1-29
1.3 BULB REQUIREMENTS
1.17 HEADLAMP ALIGNMENT
General...............................................................................1-4
FLHTCUTG HDI Dual LED Headlamps............................1-30
1.4 MAINTENANCE SCHEDULE Check Alignment.......................................................1-30
Adjust Alignment........................................................1-30
General...............................................................................1-5
Headlamp: FLRT..............................................................1-31
Alignment...................................................................1-31
1.5 LUBRICANTS
Adjustment.................................................................1-31
Engine Oil Level................................................................1-11
Oil Level Cold Check.................................................1-11 1.18 TROUBLESHOOTING
Oil Level Hot Check...................................................1-11
General.............................................................................1-32
Checking Transmission Lubricant Level...........................1-12
Engine...............................................................................1-32
Starter Motor Does Not Operate or Does Not Turn Engine
1.6 BRAKES
Over ..........................................................................1-32
Hydraulically Linked Brake System Operation.................1-13 Engine Turns Over But Does Not Start ....................1-32
Fluid Inspection.................................................................1-13 Starts Hard................................................................1-32
Brake Fluid Replacement.................................................1-14 Starts But Runs Irregularly or Misses .......................1-32
Brake Lines Inspection.....................................................1-15 A Spark Plug Fouls Repeatedly................................1-33
TABLE OF CONTENTS
Pre-Ignition or Detonation (Knocks or Pings)............1-33
1.7 BRAKE PADS AND DISCS Overheating...............................................................1-33
Inspection.........................................................................1-17 Valve Train Noise.......................................................1-33
General Inspection....................................................1-17 Excessive Vibration...................................................1-33
Brake Pads................................................................1-17 Check Engine Light Illuminates During Operation.....1-33
Brake Disc Thickness................................................1-17 Lubrication System...........................................................1-33
Brake Disc Lateral Runout........................................1-17 Oil Does Not Return To Oil Reservoir........................1-33
Brake Pad Replacement...................................................1-17 Engine Uses Too Much Oil Or Smokes Excessively..1-33
Rear Caliper Disassembly.........................................1-17 Engine Leaks Oil From Cases, Pushrods, Hoses,
Rear Caliper Assembly..............................................1-18 Etc.............................................................................1-34
Front Caliper Disassembly........................................1-19 Low Oil Pressure.......................................................1-34
Front Caliper Assembly.............................................1-19 High Oil Pressure......................................................1-34
Electrical System..............................................................1-34
1.8 PARKING BRAKE Alternator Does Not Charge......................................1-34
Adjustment........................................................................1-20 Alternator Charge Rate Is Below Normal..................1-34
Wheels on the Ground..............................................1-20 Speedometer Operates Erratically............................1-34
Wheels off the Ground...............................................1-20 Transmission....................................................................1-34
Shifts Hard.................................................................1-34
1.9 REAR TIRES Jumps Out Of Gear...................................................1-34
Clutch Slips................................................................1-34
Inspection.........................................................................1-21
Clutch Drags Or Does Not Release..........................1-34
Tire Pressure.............................................................1-21
Clutch Chatters..........................................................1-34
Tire Wear ..................................................................1-21
Handling............................................................................1-34
Tire Replacement......................................................1-21
Irregularities...............................................................1-34
Tire Balancing............................................................1-21
Brakes...............................................................................1-35
1.10 HYDRAULIC CLUTCH FLUID Brake Does Not Operate Normally............................1-35
Parking Brake Does Not Hold Normally....................1-35
General.............................................................................1-22 Reverse Motor..................................................................1-35
Fluid Inspection.................................................................1-22 Reverse Motor Does Not Operate/Cannot Enable.....1-35
1.11 DRIVE BELT CHASSIS
Checking Drive Belt Deflection.........................................1-23
Setting Deflection..............................................................1-23
2.1 FASTENER TORQUE VALUES
1.12 REAR WHEEL COMPENSATOR Fastener Torque Values in this Chapter..............................2-1
Checking Isolator Wear....................................................1-25
2.2 SPECIFICATIONS
1.13 REAR SUSPENSION ADJUSTMENTS General...............................................................................2-5
General.............................................................................1-26
III
TABLE OF CONTENTS
2.3 VEHICLE IDENTIFICATION NUMBER Rear Circuit................................................................2-24
(VIN) 2.13 PARKING BRAKE ASSEMBLY
Vehicle Identification Number (VIN)....................................2-6 Pedal Assembly................................................................2-25
General........................................................................2-6 Removal....................................................................2-25
Location.......................................................................2-6 Disassembly and Inspection......................................2-25
Abbreviated VIN..........................................................2-6 Assembly...................................................................2-26
Installation.................................................................2-26
2.4 FRONT WHEEL Pedal Mounting Bracket............................................2-26
Removal..............................................................................2-8 Parking Brake Sensor.......................................................2-26
Installation...........................................................................2-8 Adjust Sensor Gap....................................................2-26
Sensor Replacement.................................................2-27
2.5 FRONT AXLE COVERS: HDI MODELS Magnet.......................................................................2-27
Replacement.......................................................................2-9 Cables...............................................................................2-27
Front Cable................................................................2-27
2.6 REAR WHEELS Rear Cable Removal.................................................2-28
Removal............................................................................2-10 Rear Cable Installation..............................................2-28
Installation.........................................................................2-10 Equalizer Bracket Removal.......................................2-29
Equalizer Bracket Installation....................................2-29
2.7 FRONT BRAKE MASTER CYLINDER
2.14 CLUTCH MASTER CYLINDER AND
Disassembly.....................................................................2-11
Cleaning and Inspection...................................................2-11 RESERVOIR
Assembly..........................................................................2-12 Disassembly.....................................................................2-30
Cover Assembly........................................................2-12 Cleaning and Inspection...................................................2-30
Assembly..........................................................................2-31
2.8 FRONT BRAKE CALIPERS Cover Assembly........................................................2-31
Removal............................................................................2-13
Installation.........................................................................2-13 2.15 CLUTCH FLUID LINE: FLRT
Line Replacement.............................................................2-32
2.9 REAR BRAKE MASTER
CYLINDER/PEDAL 2.16 HANDLEBAR
General.............................................................................2-14 Adjustment: FLRT.............................................................2-33
Removal............................................................................2-14 Handlebar Replacement...................................................2-33
Installation.........................................................................2-14
Disassembly.....................................................................2-15
2.17 TRUNK DOOR: FLHTCUTG
Cleaning and Inspection...................................................2-15 Removal............................................................................2-34
Assembly..........................................................................2-15 Disassembly.....................................................................2-35
Rear Brake Reservoir.......................................................2-16 Assembly..........................................................................2-35
Removal....................................................................2-16 Installation.........................................................................2-35
Installation.................................................................2-16
2.18 TRUNK DOOR LOCKSET: FLHTCUTG
2.10 REAR BRAKE CALIPERS Lockset.............................................................................2-37
Removal............................................................................2-17 Removal/Disassembly...............................................2-37
Installation.........................................................................2-17 Assembly/Installation.................................................2-37
Latch Assembly................................................................2-38
2.11 BRAKE LINES Removal....................................................................2-38
Front Brake Lines.............................................................2-18 Lock Assembly Removal...........................................2-38
Front Master Cylinder Line Removal.........................2-18 Lock Assembly Installation........................................2-38
Front Master Cylinder Line Installation......................2-18 Latch Mechanism Replacement................................2-39
Front Caliper Line Removal.......................................2-19 Installation.................................................................2-39
Front Caliper Line Installation....................................2-19 Latch Pin...........................................................................2-40
Rear Brake Line................................................................2-20 Removal....................................................................2-40
Removal....................................................................2-20 Installation.................................................................2-40
Installation.................................................................2-21
2.19 TRUNK DOOR: FLRT
2.12 BLEEDING BRAKES Repair...............................................................................2-41
General.............................................................................2-23 Removal....................................................................2-41
Procedure.........................................................................2-23 Installation.................................................................2-41
General Bleeding Overview.......................................2-23 Trunk Door Hinge......................................................2-41
Front Circuit...............................................................2-24 Seal Inspection..........................................................2-41
Seal Replacement.....................................................2-41
IV TABLE OF CONTENTS
TABLE OF CONTENTS
Striker........................................................................2-42 2.28 LATERAL ALIGNMENT
Adjust Trunk Door.............................................................2-42
Procedure.........................................................................2-61
2.20 TRUNK DOOR LOCKSET: FLRT
2.29 SHOCK ABSORBERS
Lock and Latch Assembly.................................................2-43
Removal............................................................................2-62
Assembly Removal....................................................2-43
Installation.........................................................................2-62
Assembly Installation.................................................2-43
Lock Cover................................................................2-43
2.30 PANHARD ROD
Latch Cover...............................................................2-43
Removal............................................................................2-63
2.21 TOUR-PAK Installation.........................................................................2-63
Adjustment........................................................................2-64
Tour-Pak Adjustment........................................................2-44
Removal............................................................................2-44
2.31 HEADLAMP NACELLE
Installation.........................................................................2-44
Removal............................................................................2-65
2.22 BODY Installation.........................................................................2-66
Removal............................................................................2-45
2.32 STEERING DAMPER ASSEMBLY
Installation.........................................................................2-45
Disassembly: FLHTCUTG................................................2-46 Removal............................................................................2-67
Assembly: FLHTCUTG.....................................................2-46 Installation.........................................................................2-67
Disassembly: FLRT..........................................................2-46
Assembly: FLRT...............................................................2-46 2.33 ENGINE STABILIZER
Passenger Grab Handles: FLRT......................................2-46 Stabilizer Link...................................................................2-69
Removal....................................................................2-46 Removal....................................................................2-69
Installation.................................................................2-47 Installation.................................................................2-69
Repair...............................................................................2-47 Bracket......................................................................2-69
Threaded Inserts.......................................................2-47
Trunk Door Seal: FLHTCUTG..........................................2-47 ENGINE
Inspection..................................................................2-47
Replacement.............................................................2-47 3.1 SPECIFICATIONS: ENGINE
2.23 REAR FENDERS General Specifications: Twin Cam 103™...........................3-1
Removal............................................................................2-49
Tail Lamp Bracket: FLRT...........................................2-49
FUEL SYSTEM
Installation.........................................................................2-49
Tail Lamp Bracket: FLRT...........................................2-49 4.1 FUEL SYSTEM
No Unique Content.............................................................4-1
2.24 REAR FRAME
Removal............................................................................2-51 DRIVE
Disassembly.....................................................................2-51
Assembly..........................................................................2-51 5.1 FASTENER TORQUE VALUES
Installation.........................................................................2-51
2.25 INTERMEDIATE FRAME
5.2 SPECIFICATIONS
Removal............................................................................2-53
Disassembly.....................................................................2-53 General...............................................................................5-2
Assembly..........................................................................2-53
Installation.........................................................................2-54
5.3 CLUTCH
NO UNIQUE CONTENT.....................................................5-3
2.26 FRONT FORK
Servicing Forks.................................................................2-56
5.4 AXLE
Fork Removal: FLRT.................................................2-56 Removal..............................................................................5-4
Fork Installation: FLRT..............................................2-56 Disassembly.......................................................................5-4
Assembly............................................................................5-5
2.27 REAR FORK Installation...........................................................................5-6
Removal............................................................................2-57
Repair...............................................................................2-58
5.5 AXLE HOUSING/DIFFERENTIAL
Bearing Removal.......................................................2-58 Removal..............................................................................5-7
Bearing Installation....................................................2-58 Disassembly.......................................................................5-8
Installation.........................................................................2-60 Bearings......................................................................5-8
Sprocket......................................................................5-8
TABLE OF CONTENTS V
TABLE OF CONTENTS
Ring Gear....................................................................5-8 Installation.................................................................7-10
Differential...................................................................5-8
Assembly............................................................................5-9 7.6 TAIL LAMPS/REAR TURN SIGNALS
Differential...................................................................5-9 Removal............................................................................7-11
Ring Gear....................................................................5-9 Incandescent Type....................................................7-11
Sprocket......................................................................5-9 LED Type...................................................................7-11
Bearings......................................................................5-9 Installation.........................................................................7-11
Installation.........................................................................5-10 Incandescent Type....................................................7-11
LED Type...................................................................7-11
5.6 DRIVE BELT REPLACEMENT
Removal............................................................................5-11 7.7 LICENSE PLATE LAMPS/BRACKET:
Installation.........................................................................5-11 FLHTCUTG
TRANSMISSION Removal............................................................................7-13
Installation.........................................................................7-13
6.1 TRANSMISSION 7.8 REAR LIGHTS HARNESS: FLHTCUTG

General...............................................................................6-1 Removal............................................................................7-14
Specifications......................................................................6-1 Installation.........................................................................7-14
ELECTRICAL 7.9 REAR LIGHTS HARNESS: FLRT

Removal............................................................................7-17
7.1 FASTENER TORQUE VALUES Installation.........................................................................7-17
7.10 BANK ANGLE SENSOR (BAS)
7.2 SYSTEM FUSES AND RELAYS Removal............................................................................7-19
Installation.........................................................................7-19
System Fuses and Relays..................................................7-4
Main Fuse....................................................................7-4
7.11 REVERSE CONTROL SYSTEM
System Fuses and Relays...........................................7-4
Switch Replacement.........................................................7-20
7.3 BATTERY TRAY RCM Replacement...........................................................7-20
Removal....................................................................7-20
Removal..............................................................................7-5
Installation.................................................................7-20
Installation...........................................................................7-5
Reverse Solenoid Replacement.......................................7-20
7.4 FRONT LIGHTING Removal....................................................................7-20
Installation.................................................................7-20
Removal, Repair and Installation........................................7-6 Circuit Breaker Replacement............................................7-21
FLHTCUTG: DOM.......................................................7-6 Removal....................................................................7-21
FLHTCUTG: JPN.........................................................7-6 Installation.................................................................7-21
FLHTCUTG: HDI.........................................................7-6
FLRT Headlamp Repair...............................................7-6 7.12 REVERSE JUMPER CABLES/WIRES
Headlamp Bulb Replacement: FLRT..................................7-6
General.............................................................................7-23
Bulb Removal..............................................................7-6
Vehicle Starter to Circuit Breaker Power Lead.................7-23
Bulb Installation...........................................................7-6
Removal....................................................................7-23
Front Turn Signal Lamp: FLRT...........................................7-7
Installation.................................................................7-23
Removal......................................................................7-7
Circuit Breaker to RCM Solenoid......................................7-23
Installation...................................................................7-7
Removal....................................................................7-23
7.5 FRONT LIGHTING: HDI Installation.................................................................7-23
RCM Solenoid to Reverse Motor Solenoid Energizer
General...............................................................................7-9 Lead..................................................................................7-23
Headlamp Cover..........................................................7-9 Removal....................................................................7-23
Headlamp Bulb Replacement: FLHTCUTG HDI................7-9 Installation.................................................................7-24
Removal......................................................................7-9 Circuit Breaker to Reverse Motor Solenoid Power Lead...7-24
Installation...................................................................7-9 Removal....................................................................7-24
Lamps Bracket....................................................................7-9 Installation.................................................................7-24
Removal......................................................................7-9 Reverse Motor to Battery Ground.....................................7-25
Installation.................................................................7-10 Removal....................................................................7-25
Turn Signal Lamps............................................................7-10 Installation.................................................................7-25
Removal....................................................................7-10
Installation.................................................................7-10 7.13 REVERSE MOTOR AND BRACKET
Headlamp Housing...........................................................7-10
Removal............................................................................7-26
Removal....................................................................7-10
Disassembly.....................................................................7-26
VI TABLE OF CONTENTS
TABLE OF CONTENTS
Assembly..........................................................................7-27 15. Neutral Circuit Test..............................................7-41
Installation.........................................................................7-27 16. Accessory Circuit Open Test...............................7-41
17. Ground Circuit Open Test....................................7-41
7.14 INITIAL DIAGNOSTICS 18. Backup Light Power Test.....................................7-41
Description and Operation................................................7-29 19. Reverse Enable Feedback Test..........................7-41
20. Reverse Activate Test..........................................7-41
7.15 REVERSE MOTOR SYSTEM 21. Reverse Activate Input Open Test.......................7-41
DIAGNOSTICS 7.16 REVERSE MOTOR TESTING
Description and Operation................................................7-31
Testing Reverse Motor On Motorcycle.............................7-42
Operation...................................................................7-31
Reverse Motor Current Draw Test.............................7-42
Conditions for Settings..............................................7-33
Testing Reverse Motor on Bench.....................................7-42
Diagnostic Tips..........................................................7-33
Free Running Current Draw Test...............................7-42
Connector Information...............................................7-33
Reverse Motor Solenoid...................................................7-43
DTC P1772.......................................................................7-36
Solenoid Pull-In Test.........................................................7-43
1. Reverse Enable Feedback Short to Ground Test...7-36
Solenoid Hold-In Test........................................................7-43
2. Wiggle Test............................................................7-36
Solenoid Return Test........................................................7-44
DTC P1775.......................................................................7-36
1. Reverse Enable Feedback Short to Voltage Test...7-36 7.17 INDICATOR LAMP DIAGNOSTICS
2. Reverse Enable Feedback Open Test...................7-36
3. Backup Light Power Open Test.............................7-36 Description and Operation................................................7-45
4. Backup Light Power Short to Ground Test............7-37 Parking Brake Lamp..................................................7-46
5. Backup Light Power Short to Voltage Test............7-37 Reverse Lamp...........................................................7-46
6. Wiggle Test............................................................7-37 Diagnostic Tips..........................................................7-46
DTC P1777.......................................................................7-37 Connector Information...............................................7-46
1. Reverse Actuator Input Short to Ground Test.......7-37 Parking Brake Lamp Always On.......................................7-48
2. Wiggle Test............................................................7-37 1. Parking Brake Circuit Test.....................................7-48
DTC P1778.......................................................................7-37 2. Switch Test............................................................7-48
1. Reverse Actuator Input Short to Voltage Test.......7-37 3. Open BK/GN Test..................................................7-48
2. Wiggle Test............................................................7-37 4. Open TN/GN at [39] Test.......................................7-48
Reverse Motor Spins But Does Not Drive........................7-38 5. Open TN/GN at [242] Test.....................................7-48
1. Ring Gear Test.......................................................7-38 6. BCM Test...............................................................7-48
2. Reverse Motor Solenoid Test................................7-38 Parking Brake Lamp Inoperative......................................7-48
Reverse Motor Stalls or Spins Too Slowly........................7-38 1. Parking Brake Switch Test.....................................7-48
1. Circuit Breaker Test...............................................7-38 2. Grounded TN/GN at [39] Test................................7-49
2. Reverse Motor Solenoid Voltage Drop Test..........7-38 3. Grounded TN/GN at [242] Test..............................7-49
3. Reverse Motor Solenoid Circuit Test.....................7-38 Reverse Indicator Lamp Always On.................................7-49
4. Circuit Breaker Voltage Drop Test.........................7-38 1. Reverse Indicator Function Test............................7-49
5. Vehicle Starter Test................................................7-38 Reverse Indicator Lamp Inoperative.................................7-49
6. Ground Circuit Test................................................7-38 1. Reverse Indicator Function Test............................7-49
7. Reverse Motor Current Draw On Vehicle Test......7-38
8. Reverse Motor Test...............................................7-38
7.18 REAR LIGHTING DIAGNOSTICS
9. Reverse Motor Free Running Current Draw Test...7-39 Rear Lighting....................................................................7-50
Reverse Motor Runs On...................................................7-39 General......................................................................7-50
1. Reverse Solenoid Control Circuit Test...................7-39 Rear Running Lamps................................................7-50
2. RCM Solenoid Circuit Test....................................7-39 Brake Lamps and Rear Turn Signals........................7-50
3. Reverse Motor Solenoid Control Circuit Test........7-39 LED Tail Lamps.........................................................7-50
4. RCM Solenoid Control Circuit Test........................7-39 Diagnostics.......................................................................7-50
Reverse Motor Inoperative...............................................7-39 Diagnostic Tips..........................................................7-50
1. Reverse Switch Function Test...............................7-39 Connector Information...............................................7-50
2. RCM Circuit Test....................................................7-40 Brake Lamps Inoperative..................................................7-53
3. Reverse Motor High Current Circuit Test...............7-40 1. Stop Lamp Switch Test..........................................7-53
4. Ground Circuit Test................................................7-40 2. Brake Switch Test..................................................7-53
5. Reverse Motor Solenoid Test................................7-40 3. Brake Switch Ground Test.....................................7-53
6. Reverse Motor Control Circuit Test.......................7-40 4. Brake Switch Input Test.........................................7-53
7. RCM Solenoid Control Circuit Test........................7-40 5. RHCM Test............................................................7-53
8. RCM Solenoid Ground Circuit Test.......................7-40 6. Bulb Test................................................................7-53
9. RCM Ground Circuit Test......................................7-40 7. Inoperative Lamp Voltage Test..............................7-53
10. RCM Solenoid Control Circuit Open Test............7-40 8. Inoperative Lamp Ground Circuit Test...................7-53
11. Circuit Breaker Supply Voltage Test....................7-40 9. Circuit Board Ground Test.....................................7-53
12. Reverse Motor Solenoid Test..............................7-40 10. Inoperative LED Voltage Test..............................7-54
13. Reverse Motor Circuit Solenoid Test...................7-40 11. Inoperative LED Ground Test..............................7-54
14. Circuit Breaker Test.............................................7-41
TABLE OF CONTENTS VII

TABLE OF CONTENTS
7.19 HEADLAMP DIAGNOSTICS 2. Wiggle Test............................................................7-65
DTC B2226.......................................................................7-65
Description and Operation................................................7-55
1. System Power Test................................................7-65
Conditions for Setting................................................7-55
2. BAS Ground Test...................................................7-65
Diagnostic Tips..........................................................7-55
3. BAS Input Open Test.............................................7-65
Connector Information...............................................7-55
FLRT, High Beam Inoperative...........................................7-57 7.21 REVERSE SWITCH SYMPTOMS AND
1. Headlamp Inspection Test.....................................7-57
2. Ground Circuit Open Test......................................7-57
DIAGNOSTICS
3. Power Circuit Open Test........................................7-57 Description and Operation................................................7-66
4. BCM Test...............................................................7-57 Conditions for Settings..............................................7-66
FLRT, DTC B2132............................................................7-57 Diagnostic Tips..........................................................7-66
1. Headlamp Test.......................................................7-57 DTC P1781.......................................................................7-66
2. DTC Test................................................................7-57 1. Switch Test............................................................7-66
FLRT, DTC B2133, B2134................................................7-58
1. High Beam Circuit Test..........................................7-58 APPENDIX A WIRING
2. DTC Test................................................................7-58
FLRT, Low Beam Inoperative...........................................7-58 A.1 CONNECTORS
1. Headlamp Inspection Test.....................................7-58
2. Ground Circuit Open Test......................................7-58 Connectors.........................................................................A-1
3. Power Circuit Open Test........................................7-58
4. BCM Test...............................................................7-58
A.2 WIRING DIAGRAMS
FLRT, DTC B2137............................................................7-59 Wiring Diagram Information................................................A-2
1. Headlamp Test.......................................................7-59 Wire Color Codes........................................................A-2
2. DTC Test................................................................7-59 Wiring Diagram Symbols............................................A-2
FLRT, DTC B2138, B2139................................................7-59 Wiring Diagrams.................................................................A-4
1. Low Beam Circuit Test...........................................7-59
2. DTC Test................................................................7-59 A.3 CONNECTOR END VIEWS
Dual Lamp, High Beam Inoperative..................................7-60 Connector End Views.......................................................A-29
1. Ground Circuit Open Test......................................7-60
2. Power Circuit Open Test........................................7-60 A.4 COMPONENT LOCATION VIEWS
3. BCM Test...............................................................7-60 Component Locations......................................................A-36
Dual Lamp, DTC B2132....................................................7-60
1. Headlamp Test.......................................................7-60 APPENDIX B REFERENCE
2. DTC Test................................................................7-60
Dual Lamp, DTC B2133, B2134.......................................7-61
1. High Beam Circuit Test..........................................7-61 B.1 LENGTH CONVERSION
2. DTC Test................................................................7-61 Conversion Table................................................................B-1
Dual Lamp, Low Beam Inoperative..................................7-61
1. Ground Circuit Open Test......................................7-61 B.2 FLUID CONVERSION
2. Power Circuit Open Test........................................7-61 United States System.........................................................B-2
3. BCM Test...............................................................7-61 Metric System.....................................................................B-2
Dual Lamp, DTC B2137....................................................7-62 British Imperial System.......................................................B-2
1. Headlamp Test.......................................................7-62
2. DTC Test................................................................7-62 B.3 TORQUE CONVERSION
Dual Lamp, DTC B2138, B2139.......................................7-62
United States System.........................................................B-3
1. Low Beam Circuit Test...........................................7-62
Metric System.....................................................................B-3
2. DTC Test................................................................7-62
B.4 GLOSSARY
7.20 BAS DIAGNOSTICS
Acronyms and Abbreviations.............................................B-4
General.............................................................................7-63
BAS Operation...........................................................7-63 REFERENCE MATERIAL
Bank Angle Sensor (BAS).........................................7-63
Diagnostics.......................................................................7-63
Diagnostic Tips..........................................................7-63 TOOLS...........................................................I
Tip Over Reset..........................................................7-63
Connector Information...............................................7-63 TORQUE VALUES........................................V
DTC B2228.......................................................................7-65
1. BAS Input Short to Ground Test............................7-65 INDEX........................................................XIII
VIII TABLE OF CONTENTS

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
1.1 FASTENER TORQUE VALUES.................................................................................................1-1
1.2 LIFTING MOTORCYCLE WITH A JACK...................................................................................1-3
1.3 BULB REQUIREMENTS............................................................................................................1-4
1.4 MAINTENANCE SCHEDULE....................................................................................................1-5
1.5 LUBRICANTS..........................................................................................................................1-11
1.6 BRAKES..................................................................................................................................1-13
1.7 BRAKE PADS AND DISCS......................................................................................................1-17
1.8 PARKING BRAKE....................................................................................................................1-20
1.9 REAR TIRES...........................................................................................................................1-21
1.10 HYDRAULIC CLUTCH FLUID...............................................................................................1-22
1.11 DRIVE BELT...........................................................................................................................1-23
1.12 REAR WHEEL COMPENSATOR..........................................................................................1-25
1.13 REAR SUSPENSION ADJUSTMENTS.................................................................................1-26
1.14 STEERING HEAD BEARINGS..............................................................................................1-27
1.15 STEERING DAMPER............................................................................................................1-28
1.16 FORK OIL..............................................................................................................................1-29
1.17 HEADLAMP ALIGNMENT.....................................................................................................1-30
1.18 TROUBLESHOOTING...........................................................................................................1-32
MAINTENANCE
NOTES
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FASTENER TORQUE VALUES 1.1

FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.
FASTENER TORQUE VALUE NOTES

Axle adjustment screw jamnut 15-25 ft-lbs 20.3-34.0 Nm 1.11 DRIVE BELT, Setting Deflection
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 1.11 DRIVE BELT, Checking Drive Belt Deflection
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 1.11 DRIVE BELT, Setting Deflection
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 1.12 REAR WHEEL COMPENSATOR, Checking
Isolator Wear
Brake caliper, front, mounting screws 28-38 ft-lbs 37.9-51.5 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
Replacement
Brake caliper, front, pad pin 23-27 ft-lbs 31.2-36.6 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
Replacement
Brake caliper, rear, mount bushing bolts 32-36 ft-lbs 43.4-48.8 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
Replacement
Brake caliper, rear, mounting bracket 41-45 ft-lbs 55.6-61.0 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
screws Replacement/Apply LOCTITE MEDIUM
STRENGTH THREADLOCKER AND SEALANT
243 (blue) to screws.
Brake caliper bleeder valve, front 80-100 in-lbs 9.0-11.3 Nm 1.6 BRAKES, Brake Fluid Replacement
Brake caliper bleeder valve, front 80-100 in-lbs 9.0-11.3 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
Replacement
Brake caliper bleeder valve, rear 31-33 in-lbs 3.5-3.7 Nm 1.6 BRAKES, Brake Fluid Replacement
Brake caliper bleeder valve, rear 31-33 in-lbs 3.5-3.7 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
Replacement
Brake master cylinder cover screws, 6-8 in-lbs 0.7-0.9 Nm 1.6 BRAKES, Brake Fluid Replacement
FLRT, rear reservoir
Brake master cylinder cover screws, 6-8 in-lbs 0.7-0.9 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
FLRT, rear reservoir Replacement
Brake master cylinder reservoir cover 6-8 in-lbs 0.7-0.9 Nm 1.6 BRAKES, Brake Fluid Replacement
screws, front reservoir
Brake master cylinder reservoir cover 6-8 in-lbs 0.7-0.9 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
screws, front reservoir Replacement
Clutch reservoir cover screws 6-8 in-lbs 0.7-0.9 Nm 1.10 HYDRAULIC CLUTCH FLUID, Fluid Inspec-
tion
Headlamp horizontal adjustment screw: 30-35 ft-lbs 40.7-47.5 Nm 1.17 HEADLAMP ALIGNMENT, Headlamp: FLRT
FLRT
Headlamp nut: HDI Models 20-24 ft-lbs 27.1-32.5 Nm 1.17 HEADLAMP ALIGNMENT, FLHTCUTG HDI
Dual LED Headlamps
Headlamp vertical adjustment screw: 35-45 ft-lbs 47.5-61.0 Nm 1.17 HEADLAMP ALIGNMENT, Headlamp: FLRT
FLRT
Lug nuts 90-100 ft-lbs 122.0-135.6 Nm 1.11 DRIVE BELT, Setting Deflection/Always check
lug nut torque within 500-1000 mi (805-1610 km)
after wheel installation.
Parking brake adjuster jamnut 72-120 in-lbs 8.1-13.6 Nm 1.8 PARKING BRAKE, Adjustment
2015 Trike Service Supplement Maintenance 1-1

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Pinch block screws 41-45 ft-lbs 55.6-61.0 Nm 1.11 DRIVE BELT, Setting Deflection/Use LOCTITE
243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Transmission dipstick 25-75 in-lbs 2.8-8.5 Nm 1.5 LUBRICANTS, Checking Transmission Lub-
ricant Level
1-2 2015 Trike Service Supplement Maintenance

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LIFTING MOTORCYCLE WITH A JACK 1.2

JACKING POINTS sm06445
When lifting a motorcycle using a jack, be sure jack con-

tacts both lower frame tubes where down tubes and lower
frame tubes converge. Never lift by jacking on cross-
members, oil pan, mounting brackets, components or
housings. Failure to comply can cause serious damage
resulting in the need to perform major repair work. (00586d)
NOTES
• Never use differential housing as lifting point.
• Set the parking brake and block the wheels as necessary
to prevent the vehicle from rolling.
• Lift against the forgings where the down tubes and lower
frame tubes join. Figure 1-1. Jack Placement Under Front
• Never lift using the passenger hand grab handles.
Because the balance point is toward the rear of the motorcycle,
sm06448
special consideration must be made when lifting with a jack
for service.
See Figure 1-1. When lifting the front to remove the front tire
or check steering head bearings, and so forth, engage the
parking brake. Place the jack under the forward portion of the
frame, approximately centered under the crankshaft, and make
sure it contacts the frame tube forgings on both sides. Verify
that the jack is not contacting the parking brake components.
See Figure 1-2. When lifting the rear of the motorcycle, secure
the front tire in a wheel vise and secure front end to the
motorcycle lift using straps. Place the jack under the rear por-
tion of the frame, approximately centered under the clutch
cover, and make sure it contacts the frame tube forgings on
both sides.
Alternatively, each rear wheel can be raised by placing a jack Figure 1-2. Jack Placement Under Rear
under the left or right side of the axle.

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BULB REQUIREMENTS 1.3

GENERAL
Table 1-1. Bulb Chart
LAMP DESCRIPTION BULBS HARLEY-DAVIDSON

(ALL LAMPS 12 VOLT) REQUIRED PART NUMBER
Headlamp FLHTCUTG (DOM, CAN, JPN) * LED 67700066
FLHTCUTG (HDI) * LED 67700077
FLRT 1 68329-03
Auxiliary/fog lamps: FLHTCUTG (DOM, LED 68000020
CAN) *
Tail/stop/rear turn FLHTCUTG, FLRT (DOM, CAN) 2 68167-04
signal lamp FLHTCUTG (HDI, JPN) * LED See parts catalog
Front turn signal FLHTCUTG, FLRT (DOM, CAN) 2 68168-89A
lamp FLHTCUTG (HDI, JPN) LED See parts catalog
Additional lighting Tour-Pak side lamps * LED 53788-06 (right side)
FLHTCUTG 53789-06 (left side)
Fender tip lamp, front (if equipped) * LED See parts catalog
FLHTCUTG
License plate lamp 2-4 52441-95
FLHTCUTG
Instruments Speedometer * See parts catalog
(FLRT) Indicator panel on fuel tank *
Instruments Instrument cluster * See parts catalog
(FLHTCUTG) Voltmeter *
Fuel gauge *
Items with * Illuminated with LEDs. Replace assembly upon failure.

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MAINTENANCE SCHEDULE 1.4

GENERAL Use the lubricants, greases and sealants table to identify
maintenance supplies. Refer to Table 1-4.
At each regular service interval, perform the required mainten-
ance. Refer to Table 1-2. NOTE
Grease is added to the differential during manufacturing and
Use the quick reference maintenance chart for torque values,
will last the life of the motorcycle. Never add grease to the dif-
lubricants or cross references to maintenance procedures.
ferential. Adding grease can cause the differential to be over-
Refer to Table 1-3.
filled resulting in damage to grease seals.
Table 1-2. Regular Service Intervals: 2015 Trike Models

ITEM SERVICED PROCEDURE 1000 MI 5000 MI 10000 15000 20000 25000 30000 35000 40000 45000 50000 NOTES
1600 KM 8000 KM MI MI MI MI MI MI MI MI MI
16000 24000 32000 40000 48000 56000 64000 72000 80000
KM KM KM KM KM KM KM KM KM
Electrical equip- Check operation X X X X X X X X X X X
ment and switches
Front tire Check pressure, X X X X X X X X X X X 1
inspect tread
Front brake fluid Inspect sight glass X X X X X X X X X X X 2, 3
Clutch (hydraulic Inspect sight X X X X X X X X X X X 2, 4
operated) glass
Reservoir cover Check torque X X X X X X 1, 5, 6
screw: front brake,
rear brake (FLRT)
and hydraulic
clutch
Hand control Check switch X X X X X X 1, 5, 6
fasteners housing screw
torque
Check clutch X X X X X X 1, 5, 6
handlebar clamp
screw torque
Check front brake X X X X X X 1, 5, 6
handlebar clamp
screw torque
Steering head Disassemble, X X 5, 7
bearings inspect, lubricate
and adjust
Hydraulic steering Check for leaks X X X X X X X X X X X 8
damper smooth damper
action, mounting
fastener torque
Air cleaner Inspect, service as X X X X X X X X X X 9
required
Engine oil and filter Replace X X X X X X X X X X X 1, 9
Engine coolant Check freeze point, X X X X X X X X X X X
inspect for leaks
Replace coolant Replace every 30,000 mi (48,000 km) 5
Clean radiators X X X X X X X X X X X
Primary chaincase Replace X X X X X X 9
lubricant
Transmission lub- Replace X X X 9
ricant
Right front engine Check torque X X X X X X 1, 5, 10
mount end cap
screws
Engine mount to Check torque X X X X X X 1, 5, 6
front crankcase
screws
Engine stabilizer Check torque X X X X X X 1, 5, 10
link screw torque
including bracket to
head screws
Oil lines and brake Inspect for leaks, X X X X X X X X X X X 1, 5
system contact or abrasion

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16000 24000 32000 40000 48000 56000 64000 72000 80000
Fuel lines and fit- Inspect for leaks, X X X X X X X X X X X 1, 5
tings contact or abrasion
Rear brake fluid Inspect sight glass X X X X X X X X X X X 2, 3
Brake pads and Inspect for wear X X X X X X X X X X X
discs
Front brake and Check torque X X X X X X 1, 5, 6
clutch master cyl-
inder banjo bolts
Front circuit mani- Check torque X X X X X X 1, 5, 6
fold banjo bolt (12
mm)
Front caliper banjo Check torque X X X X X X 1, 5, 6
bolts
Rear master cyl- Check torque X X X X X X 1, 5, 6
inder banjo bolt
Rear caliper banjo Check torque X X X X X X 1, 5, 6
bolt
Rear circuit mani- Check torque X X X X X X 1, 5, 6
fold banjo bolt (10
mm)
Brake and clutch Check, adjust and X X X X X X X X X X X 5
controls lubricate
with HARLEY
LUBE
Parking brake Inspect and adjust X X X X X X X X X X X 5
Rear tires Check pressure, X X X X X X X X X X X 1
inspect tread
Drive belt and Inspect, adjust belt X X X X X X X X X X X 5
sprockets
Rear sprocket isol- Inspect for wear X X 5
ators
Rear lug nuts Check torque X X X X X X 1, 5, 6,
11
Rear fork Check pivot shaft X X X X X X 1, 5, 10
nut torque
Air suspension Check pressure, X X X X X X X X X X X 1, 5, 9
operation and
leakage
Exhaust system Inspect for leaks, X X X X X X X X X X X 1, 9
cracks, and loose
or missing
fasteners or
exhaust shields
Battery Battery terminal Check annually 1
Check battery and torque
clean connections.
Clean and lubricate Perform annually 1
terminals
with ELECTRICAL
CONTACT LUB-
RICANT
Spark plugs Replace every two years or every 30,000 mi (48,000 km), whichever comes first.
Fuel door Lubricate hinge and X X X X X X X X X X X
latch
with HARLEY
LUBE
Front forks Rebuild X 5, 12
Fuel filter element Replace every 100,000 mi (160,000 km). 5

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16000 24000 32000 40000 48000 56000 64000 72000 80000
Road test Verify component X X X X X X X X X X X 13
and system func-
tions
NOTES: 1. Perform annually or at specified intervals, whichever comes first.
2. Replace DOT 4 hydraulic fluid and flush system every two years.
3. Brake fluid level will drop as brake pads wear.
4. Clutch fluid level will rise as clutch wears.
5. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified.
6. Attempt to turn the fastener using a torque wrench set to the minimum torque specification for that fastener. If the fastener does not rotate,
the fastener torque has been maintained. No further attention is necessary. If fastener moves, tighten to specification.
7. Disassemble, inspect, lubricate and adjust every 25,000 mi (40,000 km).
8. Replace or have rebuilt at 50,000 mi (80,000 km).
9. Perform maintenance more frequently in severe riding conditions such as extreme temperatures, dusty environments, mountainous or rough
roads, long storage conditions, short runs, heavy stop/go traffic or poor fuel quality.
10. Attempt to turn the fastener using a torque wrench set to the minimum torque specification for that fastener. If the fastener does not rotate,
the fastener torque has been maintained. No further attention is necessary. If the fastener moves, clean all locking material from the threaded
hole. Replace the fastener with a new one or clean the original fastener threads and apply the appropriate locking agent (see appropriate pro-
cedure). Install fastener. Tighten to specification.
11. Always check lug nut torque within 500-1000 mi (805-1610 km) after wheel installation.
12. Disassemble, inspect, rebuild forks and replace fork oil every 50,000 mi (80,000 km).
13. Check reverse operation at each service interval.
Table 1-3. Quick Reference Maintenance and Torque Chart: Trike
ITEM SERVICED SPECIFICATION DATA

Air cleaner Air cleaner cover bracket screw torque 108-132 in-lbs (12.2-14.9 Nm)
Air cleaner cover screw torque 36-60 in-lbs (4.1-6.8 Nm)
Air cleaner cover screw threadlocker LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue)
Axle nut Front 70-75 ft-lbs (94.9-101.7 Nm)
Battery Terminal screw torque 60-70 in-lbs (6.8-7.9 Nm)
Top caddy screw torque 72-96 in-lbs (8.1-10.9 Nm)
Brake fluid level (Check Type DOT 4 BRAKE FLUID
sight glass. If fluid is low, Fluid level Front: Between upper and lower step on boss
remove reservoir cover Rear: MAX mark
and re-check.)
Master cylinder reservoir cover screw torque Front: 6-8 in-lbs (0.7-0.9 Nm)
Rear, FLHTCUTG: Hand-tighten
Rear, FLRT: 6-8 in-lbs (0.7-0.9 Nm)
Brakes Minimum brake pad thickness Front: 0.040 in (1.02 mm)
Rear: 0.040 in (1.02 mm)
Minimum brake disc thickness Front: 0.195 in (4.95 mm)
Rear: 0.220 in (5.59 mm)
Maximum brake disc lateral runout (warpage) 0.008 in (0.20 mm)
Brake caliper banjo bolts Front: 17-22 ft-lbs (23.1-29.8 Nm)
Rear: 17-22 ft-lbs (23.1-29.8 Nm)
Master cylinder banjo bolts Front: 17-22 ft-lbs (23.1-29.8 Nm)
Rear: 27-29 ft-lbs (36.6-39.3 Nm)
Brake line manifold banjo bolts Front circuit (12mm): 27-29 ft-lbs (36.6-39.3 Nm)
Rear circuit (10mm): 17-22 ft-lbs (23.1-29.8 Nm)

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Clutch fluid level Type DOT 4 BRAKE FLUID
(hydraulic operated) Fluid level (with new clutch) *** FILL level
(Check sight glass. If the
entire sight glass is not Clutch reservoir cover screw torque 6-8 in-lbs (0.7-0.9 Nm)
dark, remove reservoir
cover and re-check.)
Drive belt deflection Upward force applied at midpoint of bottom belt 10 lbs (4.5 kg)
strand
Deflection 3/8-7/16 in (9.5-11.1 mm)
Engine coolant Coolant type GENUINE HARLEY-DAVIDSON EXTENDED LIFE
ANTIFREEZE AND COOLANT
Coolant capacity 1.1 qt. (1.0 L)
Engine oil and filter Drain plug torque 14-21 ft-lbs (19.0-28.5 Nm)
Oil capacity * 4 qt. (3.8 L)
Filter Hand tighten 1/2-3/4 turn after gasket contact
Engine mount and stabil- Engine mount, front, bolts See the service manual.
izers Engine stabilizer link screws including bracket to See 2.33 ENGINE STABILIZER.
head screws
Front fork oil Amount See 2.26 FRONT FORK.
Type TYPE 'E' HYDRAULIC FORK OIL
Hand controls Switch housing screws 35-45 in-lbs (4.0-5.1 Nm)
Clutch lever bracket handlebar clamp screws 60-80 in-lbs (6.8-9.0 Nm)
Master cylinder reservoir handlebar clamp screws 60-80 in-lbs (6.8-9.0 Nm)
Pivot shaft Fasteners See 2.27 REAR FORK.
Primary chain lubricant Lubricant type and capacity FORMULA+ TRANSMISSION AND PRIMARY
CHAINCASE LUBRICANT
or
SCREAMIN' EAGLE SYN3 FULL SYNTHETIC
MOTORCYCLE LUBRICANT 20W50
Wet: 38 oz. (1124 ml)
Dry: 45 oz. (1331 ml)
Primary chaincase drain plug torque 14-21 ft-lbs (19.0-28.5 Nm)
Rear wheel Lug nuts 90-100 ft-lbs (122.0-135.6 Nm)
Spark plugs Type HD-6R12
Gap 0.038-0.043 in (0.97-1.09 mm)
Torque 12-18 ft-lbs (16.3-24.4 Nm)
Tire pressure and wear Pressure: solo rider or with passenger Front: 36 psi (248 kPA)
Rear: 26 psi (179 kPA)
Wear Replace if less than 1/32 in (0.8 mm) of tread pat-
tern

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Transmission lubricant Lubricant level Dipstick between ADD and FULL marks with
motorcycle on level surface and filler plug threaded
in until O-ring touches the case.
Lubricant type and capacity ** FORMULA+ TRANSMISSION AND PRIMARY
CHAIN LUBRICATION
or
32 oz (0.95 L)
Transmission drain plug torque 14-21 ft-lbs (19.0-28.5 Nm)
Transmission dipstick torque 25-75 in-lbs (2.8-8.5 Nm)
* Capacity is approximate. When changing oil, initially add 3.0 qt (2.8 L). Run engine until warm. Check and fill as necessary.
** Capacity is approximate. When changing lubricant, initially add 28 oz (0.83 L). Check and fill as necessary.
*** Clutch fluid level will rise as clutch wears.
Table 1-4. Lubricants, Greases, Sealants
ITEM PART NUMBER PACKAGE

3M 847 Adhesive 021200-19718 * 5 oz tube
3M General Purpose Adhesive Remover 15 oz aerosol
Anti-Seize Lubricant 98960-97 1 oz squeeze tube
CCI #20 Brake Grease 42830-05 squeeze packet (included in master cylinder
rebuild kit)
DOT 4 Brake Fluid 99953-99A 12 oz bottle
Dow Corning Moly 44 Grease 94674-99 2 cc packet
Electrical Contact Lubricant 11300004 1 oz squeeze tube
Formula+ Transmission and Primary Chaincase 99851-05 1 qt bottle
Lubricant
G40M Brake Grease 42820-04 squeeze packet
Genuine Harley-Davidson Extended Life Antifreeze 99822-02 1 gal container
and Coolant
Genuine Harley-Davidson H-D 360 20W50 99816-2050/00QT 1 qt bottle
Motorcycle Oil
Harley-Davidson Adhesive (Griplock) 99839-95 10 g tube
Harley-Davidson High Performance Sealant - Gray 99650-02 1.9 oz squeeze tube
Harley-Davidson Leather Dressing 98261-91V 6 oz can
Harley-Davidson Seal Grease 11300005 1 oz tube
Harley Lube 94968-09 1/4 oz needle dispenser
Hylomar Gasket and Thread Sealant 99653-85 3.5 oz tube
Loctite 222 Low Strength Threadlocker and Sealant (purple) 99811-97 6 mL tube
Loctite 243 Medium Strength Threadlocker and Sealant (blue) 99642-97 6 mL tube
11100005 50 mL bottle
Loctite 246 Medium Strength/High Temperature Threadlocker
(blue)
Loctite 262 High Strength Threadlocker and Sealant (red) 94759-99 6 mL tube
Loctite 271 High Strength Threadlocker and Sealant (red) 6 mL tube
11100006 50 mL bottle

HOME
Table 1-4. Lubricants, Greases, Sealants
ITEM PART NUMBER PACKAGE

Loctite 411 Prism Instant Adhesive
Loctite 420 Super Bonder Adhesive
Loctite 565 Thread Sealant 99818-97 6 mL tube
Loctite 770 Prism Primer
Loctite 7649 Cleaner/Primer 98968-99 1.75 oz bottle
RTV Silicone Sealer 99650-02 1.9 oz tube
Screamin' Eagle Assembly Lube 11300002 4 oz bottle
Screamin' Eagle SYN3 Full Synthetic Motorcycle 99824-03/00QT 1 qt bottle
Lubricant 20W50
Special Purpose Grease 99857-97A 14 oz cartridge
Type "E" Hydraulic Fork Oil 62600026 16 oz bottle
Wheel Bearing Grease 99855-89 1 lb can
99856-92 14 oz cartridge
* Not a Harley-Davidson part number

HOME
LUBRICANTS 1.5
ENGINE OIL LEVEL 2. Place motorcycle on level ground. Allow engine to idle for
1-2 minutes. Turn engine off.
3. See Figure 1-3. Remove filler plug/dipstick and wipe off
the dipstick. Insert the dipstick and tighten into the fill
Prolonged or repeated contact with used motor oil may spout.
be harmful to skin and could cause skin cancer. Promptly
wash affected areas with soap and water. (00358b) 4. See Figure 1-4. Remove filler plug/dipstick and check oil
level. Oil level must register between the ADD QT and
FULL HOT marks on the VEHICLE UPRIGHT gauge. If
oil level is at or below the ADD QT mark, add only enough
Do not overfill oil. Doing so can result in oil carryover to oil to bring the level to the FULL HOT mark. Do not overfill.
the air cleaner leading to equipment damage and/or 5. Start engine and carefully check for oil leaks around drain
equipment malfunction. (00190b) plug and oil filter.
Check engine oil level at each complete fuel refill. This motor-
cycle was originally equipped with GENUINE HARLEY- om01566
DAVIDSON H-D 360 MOTORCYCLE OIL 20W50. H-D 360 is
the preferred oil under normal operating conditions. If operation
under extreme cold or heat are expected, refer to Table 1-5
for alternative choices. See the service manual for more
information.
Oil Level Cold Check

1. For pre-ride inspection, place motorcycle on level ground.
2. See Figure 1-3. Remove filler plug/dipstick and wipe off
the dipstick. Insert the dipstick and tighten into the fill
spout.
NOTE
Oil level on a cold engine should never be above the midway
point.
3. See Figure 1-4. Remove filler plug/dipstick and check oil
level. The correct oil level is midway (2) between the ADD
QT and FULL HOT marks on the VEHICLE UPRIGHT Figure 1-3. Engine Oil Filler Plug
gauge.
NOTE
sm06088
If oil level is at or below the ADD QT mark, add only enough
oil to bring the level midway (2) between the ADD QT and FULL
HOT marks. Never bring the level to the FULL HOT mark on
a cold engine.
Oil Level Hot Check
Do not allow hot oil level to fall below Add/Fill mark on

3
dipstick. Doing so can result in equipment damage and/or 2
equipment malfunction. (00189a)
1
NOTE
Perform engine oil level hot check only with engine at normal 1. ADD QT mark
operating temperature. 2. Cold check level
3. FULL HOT mark
1. Ride motorcycle until engine is at normal operating tem-
perature. Figure 1-4. Engine Oil Dipstick (VEHICLE UPRIGHT Gauge)

HOME
Table 1-5. Recommended Engine Oils
TYPE VISCOSITY RATING LOWEST AMBIENT COLD-WEATHER

TEMPERATURE STARTS BELOW
50 °F (10 °C)
Screamin' Eagle SYN 3 Full Synthetic SAE 20W50 HD 360 Above 30 °F (-1 °C) Excellent
Motorcycle Lubricant
Genuine Harley-Davidson H-D 360 SAE 20W50 HD 360 Above 40 °F (4 °C) Good
Motorcycle Oil
Genuine Harley-Davidson H-D 360 SAE 50 HD 360 Above 60 °F (16 °C) Poor
Motorcycle Oil
Genuine Harley-Davidson H-D 360 SAE 60 HD 360 Above 80 °F (27 °C) Poor
Motorcycle Oil
Genuine Harley-Davidson H-D 360 SAE 10W40 HD 360 Below 40 °F (4 °C) Excellent
Motorcycle Oil
CHECKING TRANSMISSION LUBRICANT

om01567
LEVEL
FASTENER TORQUE VALUE
Transmission dipstick 25-75 in-lbs 2.8-8.5 Nm
Check the transmission lubricant level with engine turned off

and motorcycle on level surface.
NOTE
Allow vehicle to rest for a few moments before checking lub-
ricant level. This will allow lubricant level to normalize.
1. See Figure 1-5. Remove transmission lubricant dipstick.
Wipe dipstick clean.
2. Insert dipstick into transmission. Thread dipstick in until
O-ring makes contact with case. Do not tighten.
3. See Figure 1-6. Remove dipstick and check lubricant level
on dipstick. If lubricant level is at or below the ADD (A) Figure 1-5. Transmission Dipstick Location
mark on the dipstick, add only enough lubricant to bring
level to between ADD (A) mark and FULL (F) mark on
dipstick.
om01041
4. Install dipstick. Tighten to 25-75 in-lbs (2.8-8.5 Nm).
Table 1-6. Recommended Lubricant
LUBRICANT REFILL
QUANTITY *
FORMULA+ TRANSMISSION AND PRIMARY 28 oz (0.83 L)
CHAIN LUBRICANT 2
or 1
*Approximate. Check and add as needed to bring level within
specification.
1. Add (A)
2. Full (F)
Figure 1-6. Transmission Dipstick Lubricant Level

HOME
BRAKES 1.6
HYDRAULICALLY LINKED BRAKE SYSTEM pistons in each 6-piston front caliper is actuated along with
both rear calipers.
OPERATION
The front brake system remains independent and is applied
See Figure 1-7. Trike models employ a hydraulically linked using the front brake lever. The front brake lever actuates the
brake system. This system applies both the front and rear remaining two sets of pistons in each front caliper to provide
brakes when using the rear brake pedal. The center set of added stopping power while maintaining traditional motorcycle
braking controls.
sm07870a
1
2
7
5
6
4
11 12 8
3
9
10
1. Front circuit 7. Rear circuit manifold

2. Rear circuit 8. Front calipers
3. Rear bleeders 9. Front master cylinder
4. Rear brake lamp switch 10. Rear master cylinder
5. Remote reservoir 11. Rear circuit bleeders
6. Front circuit manifold 12. Front circuit bleeders
Figure 1-7. Linked Brake System
FLUID INSPECTION 2. See Figure 1-8. Place vehicle on a flat level surface.
a. Front brake: Position motorcycle and handlebar so
NOTE
that master cylinder reservoir is level.
Fluid level in the reservoir will decrease with brake wear.
Reservoir volume is adequate to provide fluid to the wear limits b. Rear brake: Position motorcycle so that master cyl-
of the pads and rotors. A brake system that was properly filled inder reservoir is level.
when new should never need fluid added. If the level is below
3. View the reservoir sight glass and verify fluid presence.
the full level, suspect worn brake pads and rotors or leakage.
• Front: Sight glass must appear dark.
1. The front brake hand lever and rear brake foot pedal must
have a firm feel when applied. If not, bleed the system • Rear, FLHTCUTG: Fluid must be between the MIN and
using only DOT 4 BRAKE FLUID. See 2.12 BLEEDING MAX lines.
BRAKES.
• Rear, FLRT: Fluid must be above the MIN line.

HOME
BRAKE FLUID REPLACEMENT
D.O.T. 4 brake fluid will damage painted and body panel PART NUMBER TOOL NAME
surfaces it comes in contact with. Always use caution and SNAP-ON BB200A BASIC VACUUM BRAKE BLEEDER
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b) FASTENER TORQUE VALUE
Brake caliper bleeder valve, 80-100 in-lbs 9.0-11.3 Nm
• If DOT 4 brake fluid contacts painted surfaces, IMMEDI-
front
ATELY flush area with clear water.
4. If the fluid level is in question, remove the cover and verify
rear
fluid level. If necessary, add DOT 4 BRAKE FLUID to
reservoir. Refer to Table 1-7 and Figure 1-9. Brake master cylinder reser- 6-8 in-lbs 0.7-0.9 Nm
voir cover screws, front reser-
5. If the fluid level fails inspection, check the brake system voir
for fluid leaks. Check that brake pads are properly installed
and not worn beyond service wear limits. Perform any Brake master cylinder cover 6-8 in-lbs 0.7-0.9 Nm
necessary repairs. See 1.7 BRAKE PADS AND DISCS. screws, FLRT, rear reservoir
NOTES
sm08505
1 • BASIC VACUUM BRAKE BLEEDER (Part No. Snap-on
BB200A) or equivalent tool is required.
• This procedure is meant to replace fluid without introducing
2
air. If any air enters lines during this procedure, revert to
2.12 BLEEDING BRAKES.
1. Remove bleeder screw cap. Install vacuum brake bleeder
to bleeder screw.
2. Position vehicle or handlebar so master cylinder reservoir
3 is level.
NOTES
• Wrap a clean shop towel around the outside of the master
cylinder reservoir to protect from brake fluid spills.
1. Front master cylinder reservoir
2. Rear master cylinder reservoir: FLHTCUTG • Clean master cylinder reservoir cover before removal.
3. Rear master cylinder reservoir: FLRT 3. Remove master cylinder reservoir cover.
Figure 1-8. Brake Fluid Sight Glass 4. Add brake fluid as necessary. Refer to Table 1-7.
A plugged or covered relief port can cause brake drag or

lock-up, which could lead to loss of control, resulting in
death or serious injury. (00288a)
5. Verify proper operation of the front master cylinder relief
port by actuating the brake lever. A slight spurt of fluid will
break the fluid surface in the reservoir if internal compon-
ents are working properly. The spurt will not be seen in
the remote reservoir on rear system.
NOTES
• Pay careful attention to fluid level in the master cylinder
reservoir. Add fluid before it empties to avoid drawing air
into the brake lines.
• Hold banjo bolt while opening and closing rear bleeder
screw.

HOME
6. Operate vacuum bleeder while maintaining fluid level in

sm08421
master cylinder reservoir.
a. Following the sequence in Table 1-9, open bleeder
screw about 3/4 turn.
b. Continue until specified volume has been replaced.
Refer to Table 1-9.
c. Tighten bleeder screw to specification. Refer to
Table 1-8. Install bleeder screw cap.
7. Repeat with each caliper following the sequence in

Table 1-9 until all brake lines have been serviced.
8. Fill reservoir to specified level. Refer to Table 1-7 and
Figure 1-9.
NOTE
Front master cylinder reservoir: Orient the cover with the Figure 1-9. FILL Level Boss (front master cylinder)
thin edge toward the lever.
9. Clean gasket and sealing surfaces of debris. Install master
cylinder reservoir cover. Tighten to specification. Refer to Table 1-8. Torque Specifications
Table 1-8. FASTENER TORQUE VALUE
10. Apply brakes to check proper lamp operation. Brake caliper bleeder valve Front: 80-100 in-lbs (9.0-11.3
Nm)
Rear: 31-33 in-lbs (3.5-3.7
Nm)
After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds Brake master cylinder 6-8 in-lbs (0.7-0.9 Nm)
can cause loss of control, which could result in death or reservoir, front, cover screws
serious injury. (00289a) Brake master cylinder FLHTCUTG: Hand-tighten
11. Test ride motorcycle. Repeat the bleeding procedure if reservoir, rear, cover FLRT: 6-8 in-lbs (0.7-0.9 Nm)
brakes feel spongy.
Table 1-9. Bleeding Sequence
Table 1-7. Fluid Level
CIRCUIT BLEEDER VOLUME
ITEM SPECIFICATION LOCATION
Front reservoir Between upper and lower step on boss Front Front left 4 oz (118.3 cc)
Rear reservoir MAX line Front right 2 oz (59.1 cc)
Rear Front left 2 oz (59.1 cc)
Front right 4 oz (118.3 cc)
Rear left 4 oz (118.3 cc)
Rear right 2 oz (59.1 cc)
BRAKE LINES INSPECTION

Inspect brake lines for leaks, contact or abrasion. Refer to
Table 1-10.
Table 1-10. Brake Line Inspection
LINE TYPE INSPECTION REMEDY

Steel lines No marks OK/Monitor
Slight mark in paint or plating*
Copper colored-paint/plating worn off*
Silver colored base material-no noticeable feel of wear*
Silver colored base material-noticeable feel of wear* Replace
Brake fluid leak or other damage

HOME
Table 1-10. Brake Line Inspection
LINE TYPE INSPECTION REMEDY

Flexible lines No marks OK/Monitor
Slight dent in protective cover or flattening of ribs*
Worn through protective cover or to bottom of ribs Replace
Protective cover No marks OK/Monitor
(steel, rubber, plastic or braided) Slight dent in covering*
Slight dent or flattening of plastic covering*

Worn or cut-through covering-exposed brake line material Replace
* If there is line contact, reposition the line. If base material is visible, prevent corrosion with touch-up paint.

HOME
BRAKE PADS AND DISCS 1.7

INSPECTION Inspect brake disc for excessive wear. Replace disc if worn to
wear limit.
Check brake pads and discs:
Brake Disc Lateral Runout
• At every scheduled service interval.
Inspect brake disc lateral runout and warpage. Replace disc
• Whenever components are removed for service. if either is greater than specification.
• Refer to Table 1-11 for wear limits.
Table 1-11. Brake Wear Limit Specifications
General Inspection
Inspect brake system for leaks and repair as necessary. Inspect FRONT REAR
brake lines and hoses for damage or wear. Friction pad 0.040 in (1.02 mm) 0.040 in (1.02 mm)
thickness *
Always adjust parking brake whenever brake pads are
replaced. Disc thickness 0.195 in (4.95 mm) 0.220 in (5.59 mm)
Rear: See Figure 1-10. Rear pad wear can be visually Disc runout 0.008 in (0.20 mm) 0.008 in (0.20 mm)
inspected without rear wheel removal. Compare the end of * Friction material thickness above backing plate.
tabs (2) to the surface of the outboard caliper bracket (1). If
tab is flush or below the surface, disassemble and measure BRAKE PAD REPLACEMENT
brake pad friction material thickness.
Front: Measure the thickness of the brake pad friction material. FASTENER TORQUE VALUE
Check each pad. Brake caliper, rear, mounting 41-45 ft-lbs 55.6-61.0 Nm
bracket screws
sm08016
1 Brake caliper, rear, mount 32-36 ft-lbs 43.4-48.8 Nm
bushing bolts
front
rear
Brake master cylinder reser- 6-8 in-lbs 0.7-0.9 Nm
2 voir cover screws, front reser-
voir
Brake master cylinder cover 6-8 in-lbs 0.7-0.9 Nm
screws, FLRT, rear reservoir
Brake caliper, front, mounting 28-38 ft-lbs 37.9-51.5 Nm
screws
Brake caliper, front, pad pin 23-27 ft-lbs 31.2-36.6 Nm
1. Caliper bracket surface This vehicle employs linked brakes meaning both front and
2. Tabs rear brakes are applied when the brake pedal is operated. The
front brake lever applies additional braking to the front wheel
Figure 1-10. Rear Brake Pad Inspection only. Service and bleeding differ from models having separate
front and rear systems.
Brake Pads Rear Caliper Disassembly
1. Remove the rear wheels. See 2.6 REAR WHEELS.
2. Release parking brake. Completely loosen the parking
Always replace brake pads in complete sets for correct brake adjustment. See 1.8 PARKING BRAKE.
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)
Replace all brake pads (inner and outer pads of both left and
right side calipers) on the axle if the friction material of any Always replace brake pads in complete sets for correct
single pad is worn to wear limit. and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)
Brake Disc Thickness
3. See Figure 1-11. Hold bushing pins (7) by the flats and
Inspect brake disc surface condition. Replace disc if pitted, remove bushing bolts (4). Remove the caliper.
grooved or scored.

HOME
4. Remove the brake pads (1) and pad spring (5). NOTE
Always check lug nut torque within 500-1000 mi (805-1610
NOTE
km) after wheel installation.
Do not operate the brake pedal with the caliper removed or
the piston may be forced out. This caliper contains no service 8. Install the rear wheels. See 2.6 REAR WHEELS.
parts.
9. Adjust the parking brake. See 1.8 PARKING BRAKE.
5. Remove the cover from the rear brake master cylinder
10. Apply brakes to check proper lamp operation.
reservoir.
NOTE
Fluid level rises as the piston is pushed into the caliper.
Remove fluid from reservoir if necessary. After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
6. Push the piston into the caliper until seated.
can cause loss of control, which could result in death or
7. Verify that bushing pins (7) slide smoothly in the caliper serious injury. (00289a)
bores without rocking or sticking. Remove the bushing
NOTE
pins from the caliper.
Avoid making hard stops for the first 100 mi (160 km) to allow
8. Clean debris from the bushing pins and bushing bores. the new pads to become conditioned to the brake discs.
9. Clean grooves (6) that the pads slide in. 11. Test ride motorcycle.
10. Inspect bushing pin O-rings (8) for damage. Replace as

sm06456a
necessary. 3 4
11. If necessary, remove rear rotor: 2
a. Remove screws (2). Remove mount bracket (3).
b. Remove rotor. 1 5
Rear Caliper Assembly
1. See Figure 1-11. If removed, install rotor:
a. Install rotor on axle.
b. Apply a drop of LOCTITE 243 MEDIUM STRENGTH 8 6
THREADLOCKER AND SEALANT (blue) to the
threads of each screw (2). 7
c. Install brake mount bracket (3) with screws (2).
1. Brake pads
Tighten to 41-45 ft-lbs (55.6-61.0 Nm).
2. Screw (2)
2. Lubricate bushing pin O-rings, OD of the bushing pins and 3. Mount bracket
bushing pin bores in the caliper using grease supplied in 4. Mount bushing bolt (2)
the brake pad kit. Do not apply grease to the threads of 5. Pad spring (install in upper groove)
the bushing bolts or bushing pins. 6. Grooves
7. Mount bushing pin (2)
3. Install a new pad spring (5) in the upper groove (6). 8. O-ring (4)
4. Install new pads in grooves (6) of the caliper bracket. Figure 1-11. Rear Brake Caliper Assembly (left side shown)
Verify that the friction material of both pads will face the
disc.
5. Install the caliper with bushing bolts (4). Tighten to 32-36 Table 1-12. Fluid Level
ft-lbs (43.4-48.8 Nm).
ITEM SPECIFICATION
Front reservoir Between upper and lower step on boss
Rear reservoir MAX line
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
6. Operate brake pedal several times to set brake pads to
proper operating position.
7. Check the fluid level. Install the reservoir cover. Refer to
Table 1-12 and Table 1-13.

HOME
4. Tighten pad pin (2) to 23-27 ft-lbs (31.2-36.6 Nm).

Table 1-13. Torque Specifications
5. Secure the fender tip lamp wires to the brake hoses with
FASTENER TORQUE VALUE new cable straps.
Brake caliper bleeder valve Front: 80-100 in-lbs (9.0-11.3 NOTE
Nm) Because this vehicle has linked brakes, both the front and rear
Rear: 31-33 in-lbs (3.5-3.7 master cylinders are affected when the front calipers are ser-
Nm) viced.
Brake master cylinder 6-8 in-lbs (0.7-0.9 Nm) 6. Operate front and rear brakes to set the pads to the proper
reservoir, front, cover screws operating position.
Brake master cylinder FLHTCUTG: Hand-tighten 7. Check the brake fluid level in each master cylinder reser-
reservoir, rear, cover FLRT: 6-8 in-lbs (0.7-0.9 Nm) voir. Install the master cylinder reservoir covers. Refer to
Table 1-12 and Table 1-13.
Front Caliper Disassembly
NOTE
Protect the front fender to prevent cosmetic damage.
1. Remove cable straps securing the fender tip lamp wires If brakes are not operating properly, testing at high speeds
to the left brake hoses. can cause loss of control, which could result in death or
serious injury. (00289a)
2. See Figure 1-12. Loosen pad pin (2).
NOTE
3. Remove screws (5) securing the caliper. Remove the Avoid making hard stops for the first 100 mi (160 km) to allow
caliper. the new pads to become conditioned to the brake discs.
NOTE 8. Test ride motorcycle.
Do not operate the brake pedal or hand lever with the caliper
removed or pistons may be forced out. This caliper contains
sm07720
no service parts.
1
4. Remove the covers from the front and rear brake master 2
cylinder reservoirs.
NOTE
3
Fluid level rises as pistons are pushed into the caliper. Remove
fluid from reservoir if necessary.
5. Push each pad back until pistons are fully seated in caliper
bores.
6. Remove pad pin (2). Remove pads.
7. Inspect pad spring (4). Replace if damaged. 4
5
Front Caliper Assembly
1. If replacing pad spring, seat new pad spring in the caliper. 1. Caliper
Engage the pad spring clips to the caliper. 2. Pad pin
3. Brake pads
2. See Figure 1-12. Place the new pads in the caliper and
4. Pad spring
loosely install pad pin (2).
5. Caliper mounting screw (2)
3. Install the caliper with screws (5). Tighten to 28-38 ft-lbs
Figure 1-12. Front Brake Caliper Assembly
(37.9-51.5 Nm).

HOME
PARKING BRAKE 1.8

ADJUSTMENT 6. Push the parking brake pedal two more clicks to the third
click. Wheels should not rotate. If wheels turn, release
FASTENER TORQUE VALUE brake and lengthen adjuster (3). Check and repeat until
wheels will not turn.
Parking brake adjuster jamnut 72-120 in-lbs 8.1-13.6 Nm
7. Release the parking brake pedal and verify wheels rotate
Parking brake adjuster jamnut 72-120 in-lbs 8.1-13.6 Nm
freely.
Wheels on the Ground NOTE

Apply a coat of grease to the adjuster threads to ease future
1. Place the vehicle on a flat level surface. adjustments.
2. See Figure 1-14. Inspect the return spring for damage. 8. Hold adjuster and tighten jamnut to 72-120 in-lbs (8.1-
Replace as necessary. 13.6 Nm).
3. Release parking brake. Verify the vehicle moves easily 9. Install the boot over the adjuster.
when pushed by hand.
NOTE
4. See Figure 1-13. Pull the boot back. Loosen jamnut (2). Verify parking brake operates properly when parking on a slope.
5. Push the parking brake pedal to the first click (1). Attempt
to roll the vehicle. sm06457c
a. If some resistance is felt, go to next step.

b. If wheels turn freely, release brake and lengthen
adjuster (3). Check and repeat until resistance is felt.
1
6. Push the parking brake pedal two more clicks to the third
click. Vehicle should not move when pushed. If wheels
turn, release brake and lengthen adjuster (3). Check and
repeat until wheels will not turn.
7. Release the parking brake pedal and verify vehicle moves
freely.
NOTE 3
2
Apply a coat of grease to the adjuster threads to ease future
adjustments.
8. Hold adjuster and tighten jamnut to 72-120 in-lbs (8.1-
13.6 Nm). 1. First notch
2. Jamnut
9. Install the boot over the adjuster.
3. Adjuster
NOTE
Figure 1-13. Parking Brake Adjustment
Verify parking brake operates properly when parking on a slope.
Wheels off the Ground

1. Place the vehicle on a flat level surface. Raise both rear sm07771
wheels.
2. See Figure 1-14. Inspect the return spring for damage.
Replace as necessary.
3. Release parking brake. Verify both rear wheels rotate
freely.
4. See Figure 1-13. Pull the boot back. Loosen jamnut (2).
5. Push the parking brake pedal to the first click (1). Attempt
to rotate the rear wheels.
a. If some resistance is felt, go to next step.
Figure 1-14. Return Spring
b. If wheels turn freely, release brake and lengthen
adjuster (3). Check and repeat until resistance is felt.

HOME
REAR TIRES 1.9

INSPECTION Tire Balancing
Tire Pressure NOTES
Always maintain proper tire pressure as specified in Table 2-3. • The Trike rear wheel assemblies must be statically bal-
Do not load tires beyond GAWR specified in Table 2-2. anced within 0.5 oz (14 g).
Underinflated, over-inflated or overloaded tires can fail. • The maximum weight permitted to be added to a wheel
Check pressure when tire is cold. Refer to Table 2-3. assembly is 3.5 oz (99 g).
• Always check lug nut torque within 500-1000 mi (805-1610
Tire Wear km) after wheel installation.
om01351
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. (00090c)
Harley-Davidson tires are equipped with wear bars that run
horizontally across the tread. When a tire is worn to the point
that the wear bars are visible, or 1/32 in. (0.8 mm) tread depth
remains, the tire can:
• Be more easily damaged leading to tire failure.
• Provide reduced traction.
• Adversely affect stability and handling.
1. See Figure 1-15. Locate arrows on tire sidewalls. The
arrows point to location of tread wear bars.
NOTE
See Figure 1-16. Tread wear bars will be at the tread surface
when 1/32 in (0.8 mm) or less of tread remains. As wear may
be uneven, always replace the tire before any single tread wear Figure 1-15. Rear Tire Tread Wear Bar Indicator
bar is at the tread surface.
2. Also replace tire if any of the following conditions are
om01582
evident:
a. Tire cords or fabric are visible through cracked side-
wall.
b. Bumps, bulges or splits.
c. Punctures, cuts or other damage that cannot be
repaired.
Tire Replacement
Use only Harley-Davidson specified tires. See a Harley-

Davidson dealer. Using non-specified tires can adversely
affect stability, handling or braking, which could result in
death or serious injury. (00024b)
Refer to Table 2-3.
Figure 1-16. Dunlop Rear Tire Wear Bar Appearance

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HYDRAULIC CLUTCH FLUID 1.10

GENERAL 4. If the sight glass is not dark:
a. Check for fluid leaks in hydraulic clutch system.
The clutch is hydraulically actuated. The master cylinder cre-
ates pressure in the clutch fluid line. This pressure activates b. Remove master cylinder cover. Check fluid level in
the secondary clutch actuator. The secondary clutch actuator clutch reservoir.
piston extends and contacts a pushrod to disengage the clutch.
c. See Figure 1-18. Add DOT 4 BRAKE FLUID as
necessary. Do NOT exceed FILL level. Over-filling
can damage seals or cause premature clutch wear.
Direct contact of D.O.T. 4 brake fluid with eyes can cause d. Attach cover with screws. Tighten to 6-8 in-lbs (0.7-
irritation. Avoid eye contact. In case of eye contact flush 0.9 Nm).
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten- pd00513
3
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a) 2
D.O.T. 4 hydraulic brake fluid is used in the hydraulic

clutch. Do not use other types of fluids as they are not 1
compatible and could cause equipment damage. (00353a)
D.O.T. 4 brake fluid will damage painted and body panel

surfaces it comes in contact with. Always use caution and
(00239b)
• If DOT 4 brake fluid contacts painted surfaces, IMMEDI- 1. Clutch master cylinder reservoir
ATELY flush area with clear water. 2. Reservoir cover
3. Sight glass
FLUID INSPECTION
Figure 1-17. Clutch Master Cylinder Reservoir
Clutch reservoir cover screws 6-8 in-lbs 0.7-0.9 Nm
sm08442
NOTES
• Fluid should never need to be added or removed from the LL
FIL
E
system during normal wear. Clutch fluid volume increases
VE
L
with clutch wear.

• If fluid level is substantially above the FILL level, a worn
clutch may be the cause.
• Check that clutch hand lever returns completely.
1. Place vehicle on a flat level surface.
2. Position motorcycle and handlebar so that master cylinder
reservoir is level.
3. See Figure 1-17. Verify that sight glass (3) appears dark.
Figure 1-18. FILL LEVEL Boss (clutch master cylinder)
Do not allow dirt or debris to enter the master cylinder

reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)

HOME
DRIVE BELT 1.11

CHECKING DRIVE BELT DEFLECTION
om00156
PART NUMBER TOOL NAME 2

HD-35381A BELT TENSION GAUGE
1

Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
NOTE
Always use BELT TENSION GAUGE (Part No. HD-35381A)
to measure belt deflection. Do not rely on "feel" as this can
result in belts that are under tensioned. Loose belts will fail due 3
to "ratcheting" (jumping a tooth).
Check belt deflection:
4
• With transmission in neutral. 1. Transmission sprocket
• With motorcycle at ambient temperature. 2. Rear wheel sprocket
3. 10 lb (4.5 kg) of force
• With the rear wheels elevated or on the ground without 4. Amount of deflection
rider or luggage.
Figure 1-19. Checking Belt Deflection
SETTING DEFLECTION
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
Axle adjustment screw jamnut 15-25 ft-lbs 20.3-34.0 Nm
1. Disconnect battery negative cable.
Pinch block screws 41-45 ft-lbs 55.6-61.0 Nm
2. Slide O-ring on gauge toward 0 lbs (0 kg) mark.
Lug nuts 90-100 ft-lbs 122.0-135.6
3. See Figure 1-19. Fit cradle against bottom of belt midway Nm
between transmission sprocket and rear sprocket.
4. Push upward on knob until O-ring slides to the 10 lb (4.5
kg) mark on the tool and compare belt deflection to scale 1. Remove rear wheels. See 2.6 REAR WHEELS.
on debris deflector.
2. See Figure 1-20. Loosen four pinch block bolts (1) on each
5. Belt must be adjusted if not within specification. Refer to side.
Table 1-14.
3. Loosen jamnut (2) on both adjustment screws (3).
Table 1-14. Belt Deflection 4. Check axle alignment before adjusting belt tension.
a. Verify the axle housing is tight against the head of
MODELS IN MM the adjustment screw (3). Use a scale or dial caliper
All models 3/8-7/16 9.5-11.1 to measure the distance (4) from the face of the
adapter plate to the front of the axle housing on both
6. Connect battery negative cable. Tighten to 60-70 in-lbs sides.
(6.8-7.9 Nm).
b. Distance (4) must be within 0.062 in (1.6 mm) on each
side. Turn the adjustment screws (3) until measure-
ment is within specification.
5. Reduce or increase belt deflection by turning the adjust-

ment screw on each side in or out an equal number of
turns.
6. Verify that firm contact is made with heads of adjustment
screws and check belt deflection. See 1.11 DRIVE BELT,
Checking Drive Belt Deflection.
7. Repeat steps until belt deflection is within specification.

HOME
8. Snug jamnut against rear of each adapter plate and again

check axle alignment measurement (4). Tighten jamnuts
to 15-25 ft-lbs (20.3-34.0 Nm).
After installing seat, pull upward on seat to be sure it is
9. Remove one pinch block bolt (1) at a time and remove all locked in position. While riding, a loose seat can shift
residual threadlocking compound from threaded hole in causing loss of control, which could result in death or
pinch block. Use compressed air to blow out any debris. serious injury. (00070b)
10. If bolt is to be reused, remove all threadlocking compound 16. Install seat.
using a wire brush or wire wheel. Apply LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND SEALANT sm06048a
(blue). 4
11. Install bolt with flat washer and tighten until snug.
12. Tighten all pinch block bolts in a crosswise pattern to 41-
45 ft-lbs (55.6-61.0 Nm).
13. Verify belt deflection. Rotate the rear tires a few rotations
by hand and verify the belt does not contact either the 1
battery tray or frame. If either is the case, adjust the rear
axle lateral alignment. See 2.28 LATERAL ALIGNMENT. 2
14. Install rear wheels and tighten lug nuts in a crosswise 3
pattern to 90-100 ft-lbs (122.0-135.6 Nm). See 2.6 REAR
WHEELS.
NOTE
Always check lug nut torque within 500-1000 mi (805-1610 1. Pinch block bolts (4 each side)
km) after wheel installation. 2. Jamnut
3. Adjustment screw
15. Connect battery negative cable. Tighten to 60-70 in-lbs 4. Measured distance
(6.8-7.9 Nm).
Figure 1-20. Adjust Axle

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REAR WHEEL COMPENSATOR 1.12

CHECKING ISOLATOR WEAR 11. Release parking brake.
FASTENER TORQUE VALUE sm06149
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm A

1. Remove seat.
To prevent accidental vehicle start-up, which could cause 2 1

2. Disconnect negative battery cable.
NOTE
Although this procedure can be done with the vehicle on the
ground, it is easer to do with it raised on a lift.
3. Raise motorcycle on lift.
4. Engage parking brake.
5. Rotate rear drive sprocket forward by hand as far as pos-
sible and hold.
6. See Figure 1-21. Draw a horizontal line from the flat of a
B
ring gear tooth to the edge of the sprocket. Use a paint
pen or felt marker for best results.
7. Hold the ring gear and rotate sprocket rearward by hand
until sprocket stops and hold in place.
8. If the line on the sprocket moves further than the flat of
the next ring gear tooth, then free play is more than 4
degrees or 0.409 in (10.4 mm) and isolators must be
replaced. See 5.5 AXLE HOUSING/DIFFERENTIAL for
removal and disassembly instructions.
9. Connect negative battery cable. Tighten to 60-70 in-lbs
(6.8-7.9 Nm).
3

locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or 1. Ring gear tooth paint mark
serious injury. (00070b) 2. Sprocket paint mark
3. Maximum free play
10. Install seat.
Figure 1-21. Check Isolator Wear, Reverse Equipped

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REAR SUSPENSION ADJUSTMENTS 1.13

GENERAL
PART NUMBER TOOL NAME Use caution when bleeding air from the suspension.
HD-34633 AIR SUSPENSION PUMP AND GAUGE Moisture combined with lubricant may leak onto the rear
wheel, tire and/or brake components and adversely affect
traction, which could result in death or serious injury.
See Figure 1-22. Adjust rear air suspension pressure by adding
(00084a)
or removing air from the air valve located behind the right side
cover.
Do not exceed maximum air pressure for suspension. Air

components fill rapidly. Therefore, use low air line pres-
Do not exceed the motorcycle's Gross Vehicle Weight
sure. Failure to do so can result in possible damage to
Rating (GVWR) or Gross Axle Weight Rating (GAWR).
components. (00165b)
Exceeding these weight ratings can lead to component
failure and adversely affect stability, handling and perform-
ance, which could result in death or serious injury. (00016f) om01317d
NOTES
• Use a no-loss air gauge such as AIR SUSPENSION PUMP
AND GAUGE (Part No. HD-34633) to check air pressure.
Check suspension pressure weekly if driven daily or before
each trip if only used occasionally.
• Improper inflation of rear air suspension components also
can result in a reduction of available suspension travel,
reduced rider comfort and possible damage to shock
absorbers.
Air pressure may be varied to suit load conditions, riding style
and personal comfort. Less initial pressure does not necessarily
result in a softer ride.
Refer to Table 1-15 as a starting point in determining suitable
rear air suspension pressures. Do not exceed maximum GVWR Figure 1-22. Rear Air Suspension Air Valve
when loading vehicle. Do not pressurize system in excess of
50 psi (345 kPa).
Table 1-15. Rear Suspension Recommended Air Pressure
SHOCK LOAD TOTAL WEIGHT PRESSURE

PSI kPa
Solo rider up to 150 lb (68 kg) 5-10 34-69
150-200 lb (68-91 kg) 10-20 69-138
200-250 lb (91-113 kg) 20-30 138-206
250-300 lb (113-136 kg) 30-40 206-276
300 lb (136 kg) to maximum added weight allowed* 40-50 276-345
Solo rider with capacity luggage of 80 lb up to 150 lb (68 kg) 25-30 172-206
(36 kg) 150-200 lb (68-91 kg) 30-40 206-276
200-250 lb (91-113 kg) 40-50 276-345
250 lb (113 kg) to maximum added weight allowed* 50 345
Rider plus passenger All weights up to maximum added weight allowed* 50 345
Maximum loaded vehicle Maximum added weight allowed* 50 345
Do not exceed 50 psi (345 kPa) rear shock pressure.
*Refer to Table 2-2 for maximum added weight allowed on the motorcycle.

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STEERING HEAD BEARINGS 1.14

MAINTENANCE 4. Verify that there is no clunk:
a. Grasp both forks near the front axle.
Steering head bearings on Trike do not require a swing-back
check during periodic maintenance inspections. Perform the b. Shake forks front to rear checking for a clunk. A clunk
following checks: indicates loose fork stem. Disassemble and inspect.
See the service manual.
1. Raise the front wheel off the ground.
2. Remove the steering damper. See 1.15 STEERING 5. Install steering damper. See 1.15 STEERING DAMPER.
DAMPER. 6. Inspect and lubricate the bearings as specified in
3. Move forks from stop to stop to check for smooth opera- Table 1-2. See the service manual.
tion. Rough operation indicates damaged bearings. See
the service manual to replace bearings.

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STEERING DAMPER 1.15

INSPECTION 3. Replace the steering damper if there is oil leakage or a
lack of damping at any point in the range. See
2.32 STEERING DAMPER ASSEMBLY.
NOTE
When lifting a motorcycle using a jack, be sure jack con- If the vehicle is out of warranty and the steering damper needs
tacts both lower frame tubes where down tubes and lower to be repaired, return to:
members, oil pan, mounting brackets, components or Ohlins USA
housings. Failure to comply can cause serious damage 703-C Old Spartanburg Road
Hendersonville, NC 28792
1. Raise motorcycle so that front wheel is off the ground. See
1.2 LIFTING MOTORCYCLE WITH A JACK. 828-692-4525
2. Turn handlebars through the full range of motion at least Ohlins provides a complete rebuilding service for the steering
two cycles. Observe the action of the damper for even damper used on Trike models.
force throughout the range of motion.

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FORK OIL 1.16

PROCEDURE
sm01639a
PART NUMBER TOOL NAME

HD-59000B FORK OIL LEVEL GAUGE
Fork oil change also requires rebuilding the forks. See the 1
service manual for complete disassembly and assembly pro-
cedures. Use the following specifications in place of the ones
in those procedures.
3
2
Incorrect amount of fork oil can adversely affect handling
and lead to loss of vehicle control, which could result in
death or serious injury. (00298a) 4
1. Inspect upper fork spring for damage or distortion. Replace
rebound spring whenever upper fork spring is replaced.
2. Pour slightly more than 26 oz (771 cc) of Harley-Davidson
TYPE "E" HYDRAULIC FORK OIL into fork tube.
1. Fork oil level
3. Set FORK OIL LEVEL GAUGE (Part No. HD-59000B) to
2. Tube
measure 3.8 in (96 mm).
3. Collar
4. Assemble and install fork. 4. Thumb lock
Figure 1-23. Oil Level Gauge

HOME
HEADLAMP ALIGNMENT 1.17

FLHTCUTG HDI DUAL LED HEADLAMPS ately centered under the right auxiliary/fog lamp centerlines
as shown in Figure 1-25.
FASTENER TORQUE VALUE 6. Tighten headlamp nut to 20-24 ft-lbs (27.1-32.5 Nm).
Headlamp nut: HDI Models 20-24 ft-lbs 27.1-32.5 Nm
7. Install turn signal. See 7.5 FRONT LIGHTING: HDI.
NOTE
om01321a
Refer to the service manual for headlamp alignment on
FLHTCUTG models other than HDI. 2
4 5
Check Alignment
1. Check tire pressure.
2. Adjust rear shocks for the rider and intended load.
3. Fill fuel tank or add an equal amount of ballast.
NOTE
Choose a wall in minimum light. 1
3
4. See Figure 1-24. Park the motorcycle on a line (1) perpen-
dicular to the wall. 1. Perpendicular line
5. Position motorcycle so that front axle is 25 ft (7.6 m) from 2. Vertical centerline
wall. 3. 25 ft (7.6 m)
4. Low beam bulb centerline
6. Draw a vertical centerline (2) on the wall. 5. Horizontal line at low beam centerline
NOTE Figure 1-24. Headlamp Alignment: LED
The upper lens is low beam on LED headlamps.
7. With the motorcycle loaded normally, point the front wheel
straight forward at wall. Measure the distance (4) from the sm07644
floor to the center of the low beam bulbs. 1 2
8. Draw a horizontal line (5) at the measured distance (4).
9. Measure the horizontal distance from the vehicle vertical
centerline to the vertical centerline of each headlamp. 3 4
10. See Figure 1-25. Mark the headlamp centerlines (1, 2) on
the wall to intersect the horizontal line.
NOTE 1. Left headlamp centerlines
LED headlamps create a beam that is nearly flat on the top. 2. Right headlamp centerlines
3. Left high intensity beam area
11. Verify headlamp alignment:
4. Right high intensity beam area
a. Set headlamps to low beam.
Figure 1-25. Headlamp Alignment: HDI
b. The headlamp is aligned when the light beam is loc-
ated as shown in Figure 1-25.
Adjust Alignment
1. Place the vehicle facing a target wall as described above.
2. Remove the turn signal lamps from the headlamp mounting
brackets. See 7.5 FRONT LIGHTING: HDI.
3. Loosen the headlamp nuts only enough to allow movement
of the lamp.
4. Turn the headlamps on low beam. Cover the right head-
lamp. Adjust the left headlamp so the top of the high
intensity zone (3) is below and approximately centered
under the left centerlines as shown in Figure 1-25.
5. Cover the left headlamp. Adjust the right headlamp so the
top of the high intensity zone (4) is below and approxim-

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HEADLAMP: FLRT sm08395
FASTENER TORQUE VALUE 2

Headlamp horizontal adjust- 30-35 ft-lbs 40.7-47.5 Nm 4 5
ment screw: FLRT
Headlamp vertical adjustment 35-45 ft-lbs 47.5-61.0 Nm
screw: FLRT
Alignment
1
3
The automatic-on headlamp feature provides increased 1. Perpendicular line
visibility of the rider to other motorists. Be sure headlamp 2. Vertical centerline
is on at all times. Poor visibility of rider to other motorists 3. 25 ft (7.6 m)
can result in death or serious injury. (00030b) 4. High beam bulb centerline
1. Check tire pressure. 5. Horizontal line 2.1 in (53.3 mm) lower than bulb
centerline
2. Fill fuel tank or add an equal amount of ballast.
Figure 1-26. Headlamp Alignment: FLRT
3. Adjust rear shocks for the rider and intended load.
NOTE Adjustment
Choose a wall in minimum light.
1. Point the front wheel straight forward.
4. See Figure 1-26. Park the motorcycle on a line (1) perpen-
dicular to the wall. 2. See Figure 1-27. Loosen horizontal adjustment screw (2).
Tilt headlamp left or right to direct light beam straight
5. Position motorcycle with front axle is 25 ft (7.6 m) from ahead.
wall.
3. Tighten screw (2) to 30-35 ft-lbs (40.7-47.5 Nm).
6. Draw a vertical line (2) on the wall.
4. Loosen vertical adjustment screw (1). Tilt headlamp up or
NOTE down until light beam hot spot is located over the intersec-
As the weight of the rider compresses the suspension, seat a tion of lines.
person approximately the same weight as the rider.
5. Tighten vertical adjustment screw (1) to 35-45 ft-lbs (47.5-
7. With the motorcycle loaded normally, point the front wheel
61.0 Nm).
straight forward at wall. Measure the distance (4) from the
floor to the center of the high beam bulb.
sm08396
8. Draw a horizontal line (5) through the vertical line on the
wall 2.1 in (53.3 mm) lower than the measured bulb
centerline.
NOTE
The headlamp is aligned when the light beam hot spot is loc-
ated over the intersection of the lines.
9. With the high beam activated, verify headlamp alignment.
1
Adjust as necessary.
1. Vertical adjusting screw

2. Horizontal adjusting screw
Figure 1-27. Headlamp Adjustment: FLRT

HOME
TROUBLESHOOTING 1.18
GENERAL 8. Bank Angle Sensor tripped and ignition switch not cycled
OFF then back to IGNITION.
9. Fuel filter clogged.
The Troubleshooting section of this manual is a guide to 10. Sticking or damaged valve(s) or wrong length pushrod(s).
diagnose problems. Read the appropriate sections of this 11. Plugged fuel injectors.
manual before performing any work. Improper repair and/or
maintenance could result in death or serious injury. Starts Hard
(00528b)
1. Spark plugs in bad condition or have improper gap or are
Use the symptoms listed for general troubleshooting. More partially fouled.
than one condition may be present at a time. Check all possible
items to keep motorcycle in good operating condition. 2. Spark plug cables in poor condition.
NOTE 3. Battery nearly discharged.

See the electrical diagnostic manual for additional information. 4. Damaged wire or loose wire connection at one of the bat-
tery terminals, ignition coil or ECM connector.
ENGINE
5. Water or dirt in fuel system.
Starter Motor Does Not Operate or Does Not 6. Intake air leak.
Turn Engine Over
7. Fuel tank vent hose, filler cap vent or vapor valve plugged,
1. Ignition switch not in IGNITION position. or fuel line closed off, restricting fuel flow.
2. Engine run switch in OFF position. 8. Engine lubricant too heavy (winter operation).
3. Discharged battery, loose or corroded connections NOTE
(solenoid chatters). For cold weather starts, always disengage clutch.
4. Starter control circuit, relay, or solenoid faulty. 9. Ignition not functioning properly (possible sensor failure).
5. Electric starter shaft pinion gear not engaging or overrun- 10. Faulty ignition coil.
ning clutch slipping.
11. Valves sticking.
6. TSM/TSSM/HFSM Bank Angle Sensor tripped and
ignition/light key switch not cycled OFF then back to 12. Partially plugged fuel injector(s).
IGNITION.
Starts But Runs Irregularly or Misses
7. Security system activated.
1. Spark plugs in poor condition or partially fouled.
8. Motorcycle in gear and clutch not pulled in and front or
2. Spark plug cables in poor condition and shorting or leaking.
rear brake applied.
3. Spark plug gap too close or too wide.
9. Main fuse not in place.
4. Faulty ignition coil, ECM, or sensor.
Engine Turns Over But Does Not Start
5. Battery nearly discharged.
1. Fuel tank empty.
6. Damaged wire or loose connection at battery terminals,
2. Fouled spark plugs. ignition coil or ECM connector.
3. Discharged battery, loose or damaged battery terminal 7. Intermittent short circuit due to damaged wire insulation.
connections.
8. Water or dirt in fuel system.
4. Engine lubricant too heavy (winter operation).
9. Fuel tank vent system plugged.
NOTE
For cold-weather starts, always disengage clutch. 10. Air leak at intake manifold or air cleaner.
5. Spark plug cables in bad condition and shorting, cable 11. Loose or dirty ECM connector.
connections loose or cables connected to incorrect cylin-
12. Faulty Sensor(s): Temperature Manifold Absolute Pressure
ders.
(TMAP), Crank Position (CKP) or Oxygen (O2).
6. Damaged wire or loose wire connection at ignition coil,
13. Incorrect valve timing.
battery, or ECM connector.
14. Weak or damaged valve springs.
7. Ignition timing incorrect due to faulty ignition coil, ECM or
sensors. 15. Damaged intake or exhaust valve.
16. Partially plugged fuel injector(s).

HOME
A Spark Plug Fouls Repeatedly Excessive Vibration

1. Fuel mixture too rich. 1. Wheels bent or damaged and/or tires worn or damaged.
2. Incorrect spark plug for the kind of service. 2. Engine/Transmission/Rear Wheel not aligned properly.
3. Piston rings badly worn or damaged. 3. Primary chain badly worn or links tight as a result of
insufficient lubrication or misalignment.
4. Valve guides or seals badly worn.
4. Engine to transmission mounting bolts loose.
Pre-Ignition or Detonation (Knocks or Pings)
5. Upper engine mounting bracket loose/damaged or
1. Fuel octane rating too low. mounting bracket pre-loaded.
2. Faulty spark plugs. 6. Ignition timing advanced due to faulty sensor inputs (TMAP
3. Incorrect spark plug for the kind of service. and/or CKP)/poorly tuned engine.
4. Excessive carbon deposit on piston head or in combustion 7. Internal engine problem.

chamber. 8. Damaged frame.
5. Ignition timing advanced due to faulty sensor inputs (TMAP 9. Stabilizer links worn or loose, or stabilizer link brackets
and/or CKP). loose or damaged.
6. Ignition timing advanced due to ECM or sensors (CKP, 10. Isolators worn or isolator bolts loose or damaged.
ET or TMAP) defective.
11. Rubber mounts loose or worn.
7. Intake manifold vacuum leak.
12. Rear fork pivot shaft fasteners loose.
Overheating
13. Front engine mounting bolts loose.
1. Insufficient oil supply or oil not circulating.
Check Engine Light Illuminates During
2. Insufficient air flow over engine.
Operation
3. Heavy carbon deposits.
1. Fault detected. See the electrical diagnostic manual for
4. Ignition timing retarded due to defective ECM or faulty more information.
sensor(s) (TMAP and/or CKP).
LUBRICATION SYSTEM
5. Leaking valve(s).
6. Low coolant level.
Oil Does Not Return To Oil Reservoir
1. Oil reservoir empty.
7. Restricted radiator air flow.
2. Oil pump not functioning.
8. Defective thermostat.
3. Restricted oil lines or fittings.
9. Coolant pump or fans inoperative.
4. Restricted oil filter.
10. Vent hose crimped.
5. O-ring damaged or missing from oil pump/crankcase
11. Air in coolant.
junction (also results in poor engine performance).
NOTE
See the service manual COOLING chapter for additional Engine Uses Too Much Oil Or Smokes
cooling system troubleshooting. Excessively
Valve Train Noise 1. Oil reservoir overfilled.
1. Low oil pressure caused by oil feed pump not functioning 2. Restricted oil return line to oil reservoir.
properly or oil passages obstructed. 3. Restricted breather operation.
2. Faulty hydraulic lifter(s). 4. Restricted oil filter.
3. Bent pushrod(s). 5. Oil pump misaligned or in poor condition.
4. Incorrect pushrod length. 6. Piston rings badly worn or broken.
5. Rocker arm binding on shaft. 7. Valve guides or seals worn or damaged.
6. Valve sticking in guide. 8. O-ring damaged or missing from oil pump/crankcase
7. Chain tensioning spring or shoe worn. junction (also results in poor engine performance).
8. Cam(s), cam gear(s) or cam bushing(s) worn. 9. Plugged crankcase scavenge port.
9. Cam timing incorrect. 10. Oil diluted with gasoline.

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Engine Leaks Oil From Cases, Pushrods, TRANSMISSION

Hoses, Etc. Shifts Hard
1. Loose parts.
1. Primary chaincase overfilled with lubricant.
2. Imperfect seal at gaskets, pushrod covers, washers, etc.
2. Clutch not fully disengaging.
3. Restricted breather passages or hose to air cleaner.
3. Transmission lubricant too heavy (winter operation).
4. Restricted oil filter.
4. Shifter return spring (inside transmission) bent or otherwise
5. Oil reservoir overfilled. damaged.
6. Lower rocker housing gasket installed incorrectly (upside 5. Bent shifter rod.
down).
6. Shifter forks (inside transmission) sprung.
7. Restricted oil return line to oil reservoir.
7. Corners worn off shifter clutch dog rings (inside transmis-
8. Porosity. sion).
Low Oil Pressure Jumps Out Of Gear

1. Oil reservoir underfilled. 1. Shifter rod improperly adjusted.
2. Faulty low oil pressure switch. 2. Shifter drum (inside transmission) improperly adjusted or
damaged/worn.
3. Oil pump O-ring damaged or missing.
3. Shifter engaging parts (inside transmission) badly worn
4. Bypass valve stuck in open position. and rounded.
5. Ball missing or leaking in cam support plate. 4. Shifter forks bent.
6. Worn oil pump gerotor(s). 5. Damaged gears.
7. Oil diluted with gasoline.
Clutch Slips
High Oil Pressure 1. Reservoir over-full.
1. Oil reservoir overfilled. 2. Clutch lever not returning completely.
2. Bypass valve stuck in closed position. 3. Damaged or binding secondary clutch actuator.
ELECTRICAL SYSTEM 4. Insufficient clutch spring tension.
NOTE 5. Worn friction discs.
For diagnostic information see the electrical diagnostic manual.
Clutch Drags Or Does Not Release
Alternator Does Not Charge 1. Lubricant level too high in primary chaincase.
1. Voltage regulator module not grounded. 2. Air in hydraulic clutch system.
2. Engine ground wire loose or damaged. 3. Primary chain badly misaligned or too tight.
3. Faulty voltage regulator module. 4. Insufficient clutch spring tension.
4. Loose or damaged wires in charging circuit. 5. Clutch discs warped.
5. Faulty stator and/or rotor.
Clutch Chatters
Alternator Charge Rate Is Below Normal Friction discs or steel discs worn or warped.
1. Weak or damaged battery.
HANDLING
2. Loose connections.
Irregularities
3. Faulty voltage regulator module.
1. Improperly loaded motorcycle. Non-standard equipment
4. Faulty stator and/or rotor. on the front end such as heavy radio receivers, extra
lighting equipment or luggage tends to cause unstable
Speedometer Operates Erratically handling.
1. Contaminated vehicle speed sensor (remove sensor and 2. Damaged tire(s) or improper front-rear tire combination.
clean off metal particles).
3. Irregular or peaked front tire tread wear.
2. Loose connections.
4. Incorrect tire pressure.
5. Shock absorber not functioning normally.

HOME
6. Incorrect air suspension pressure. 2. Brake system contains air bubbles.

7. Loose front wheel axle nuts or rear wheel lug nuts. Tighten 3. Master cylinder or caliper piston seals worn or parts
to recommended torque specification. damaged.
8. Excessive front wheel hub bearing play. 4. Brake pads contaminated with grease or oil.
9. Rear axle out of alignment with frame and front wheel. 5. Brake pads or disc worn.
10. Steering head bearings improperly adjusted. Correct 6. Brake drags: insufficient brake pedal or hand lever free
adjustment and replace pitted or worn bearings and races. play, caliper piston worn or damaged, or excessive brake
fluid in reservoir.
11. Damaged or inoperative steering damper.
7. Brake fades due to heat buildup - brake pads dragging or
12. Tire and wheel unbalanced.
excessive braking.
13. Rims and tires out-of-round or eccentric with hub.
8. Brake fluid leak when under pressure.
14. Rims and tires out-of-true sideways.
Parking Brake Does Not Hold Normally
15. Rear fork pivot assembly: improperly tightened or
1. Parking brake requires adjustment.
assembled, or loose/pitted or damaged pivot bearings.
2. Rear brake pads or discs worn. Replace parts and adjust
16. Engine mounts and/or stabilizer links loose, worn or
parking brake.
damaged.
17. Uneven rear brake operation. REVERSE MOTOR
18. Loose rear axle bearing cap bolts or bearing retainer nuts. Reverse Motor Does Not Operate/Cannot
BRAKES Enable
1. Vehicle not started or vehicle not in neutral.
Brake Does Not Operate Normally
2. Reverse motor circuit breaker open/tripped.
1. Master cylinder reservoir low on fluid, system leaking or
pads worn.

NOTES

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
2.2 SPECIFICATIONS.....................................................................................................................2-5
2.3 VEHICLE IDENTIFICATION NUMBER (VIN)............................................................................2-6
2.4 FRONT WHEEL.........................................................................................................................2-8
2.5 FRONT AXLE COVERS: HDI MODELS....................................................................................2-9
2.6 REAR WHEELS.......................................................................................................................2-10
2.7 FRONT BRAKE MASTER CYLINDER....................................................................................2-11
2.8 FRONT BRAKE CALIPERS.....................................................................................................2-13
2.9 REAR BRAKE MASTER CYLINDER/PEDAL..........................................................................2-14
2.10 REAR BRAKE CALIPERS.....................................................................................................2-17
2.11 BRAKE LINES........................................................................................................................2-18
2.12 BLEEDING BRAKES.............................................................................................................2-23
2.13 PARKING BRAKE ASSEMBLY..............................................................................................2-25
2.14 CLUTCH MASTER CYLINDER AND RESERVOIR..............................................................2-30
2.15 CLUTCH FLUID LINE: FLRT.................................................................................................2-32
2.16 HANDLEBAR.........................................................................................................................2-33
2.17 TRUNK DOOR: FLHTCUTG..................................................................................................2-34
2.18 TRUNK DOOR LOCKSET: FLHTCUTG................................................................................2-37
2.19 TRUNK DOOR: FLRT............................................................................................................2-41
2.20 TRUNK DOOR LOCKSET: FLRT..........................................................................................2-43
CHASSIS
2.21 TOUR-PAK.............................................................................................................................2-44
2.22 BODY.....................................................................................................................................2-45
2.23 REAR FENDERS...................................................................................................................2-49
2.24 REAR FRAME.......................................................................................................................2-51
2.25 INTERMEDIATE FRAME.......................................................................................................2-53
2.26 FRONT FORK........................................................................................................................2-56
2.27 REAR FORK..........................................................................................................................2-57
2.28 LATERAL ALIGNMENT.........................................................................................................2-61
2.29 SHOCK ABSORBERS...........................................................................................................2-62
2.30 PANHARD ROD.....................................................................................................................2-63
2.31 HEADLAMP NACELLE..........................................................................................................2-65
2.32 STEERING DAMPER ASSEMBLY........................................................................................2-67
2.33 ENGINE STABILIZER............................................................................................................2-69
NOTES
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CHAPTER
in this chapter.

Air valve nut 12-15 in-lbs 1.4-1.7 Nm 2.25 INTERMEDIATE FRAME, Installation
Axle adapter plate screws 41-45 ft-lbs 55.6-61.0 Nm 2.28 LATERAL ALIGNMENT, Procedure/Use
LOCTITE 243 MEDIUM STRENGTH THREAD-
Axle cover set screw 60-84 in-lbs 6.8-9.5 Nm 2.5 FRONT AXLE COVERS: HDI
MODELS, Replacement/LOCTITE 262 HIGH
(red)
Bank angle sensor bracket screws 72-108 in-lbs 8.1-12.2 Nm 2.25 INTERMEDIATE FRAME, Assembly
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 2.6 REAR WHEELS, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 2.22 BODY, Installation
Battery tray screws 72-96 in-lbs 8.1-10.9 Nm 2.25 INTERMEDIATE FRAME, Installation
Body attachment screws (inside trunk) 14-17 ft-lbs 19.0-23.1 Nm 2.22 BODY, Installation/Apply LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue).
Body attachment screws (outside trunk) 23-28 ft-lbs 31.2-38.0 Nm 2.22 BODY, Installation/Apply LOCTITE 243
SEALANT (blue).
Brake caliper, front, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.8 FRONT BRAKE CALIPERS, Installation
Brake caliper, front, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.11 BRAKE LINES, Front Brake Lines
Brake caliper, front, mounting screws 28-38 ft-lbs 37.9-51.5 Nm 2.8 FRONT BRAKE CALIPERS, Installation/metric
Brake caliper, rear, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.10 REAR BRAKE CALIPERS, Installation
Brake caliper, rear, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.11 BRAKE LINES, Rear Brake Line
Brake caliper, rear, mount bushing bolts 32-36 ft-lbs 43.4-48.8 Nm 2.10 REAR BRAKE CALIPERS, Installation
Brake caliper, rear, mounting bracket 41-45 ft-lbs 55.6-61.0 Nm 2.10 REAR BRAKE CALIPERS, Installation/Use
screws Loctite Medium Strength Threadlocker 243 (blue)
Brake caliper bleeder valve, front 80-100 in-lbs 9.0-11.3 Nm 2.12 BLEEDING BRAKES, Procedure
Brake caliper bleeder valve, rear 31-33 in-lbs 3.5-3.7 Nm 2.12 BLEEDING BRAKES, Procedure
Brake line, rear, tee locknut 59-63 in-lbs 6.7-7.1 Nm 2.11 BRAKE LINES, Rear Brake Line
Brake line, rear, tee locknut 59-63 in-lbs 6.7-7.1 Nm 2.27 REAR FORK, Installation/Use new locknut
Brake line P-clamp screw 80-100 in-lbs 9.0-11.3 Nm 2.11 BRAKE LINES, Rear Brake Line
Brake manifold, front circuit, banjo bolt 27-29 ft-lbs 36.6-39.3 Nm 2.11 BRAKE LINES, Front Brake Lines
Brake manifold, rear circuit, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.11 BRAKE LINES, Front Brake Lines
Brake manifold, rear circuit, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.11 BRAKE LINES, Rear Brake Line
Brake manifold mounting screw 96-120 in-lbs 10.8-13.6 Nm 2.11 BRAKE LINES, Front Brake Lines
Brake master cylinder, front, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.11 BRAKE LINES, Front Brake Lines
Brake master cylinder, front, clamp 60-80 in-lbs 6.8-9.0 Nm 2.7 FRONT BRAKE MASTER CYL-
screws INDER, Assembly
Brake master cylinder, rear, banjo bolt 27-29 ft-lbs 36.6-39.3 Nm 2.9 REAR BRAKE MASTER CYL-
INDER/PEDAL, Installation
Brake master cylinder, rear, banjo bolt 27-29 ft-lbs 36.6-39.3 Nm 2.11 BRAKE LINES, Rear Brake Line
2015 Trike Service Supplement Chassis 2-1

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Brake master cylinder, rear, mounting 30-40 ft-lbs 40.7-54.2 Nm 2.9 REAR BRAKE MASTER CYL-
bracket nut INDER/PEDAL, Installation/Apply LOCTITE 243
SEALANT (blue).
Brake master cylinder, rear, mounting 126-150 in-lbs 14.2-16.9 Nm 2.9 REAR BRAKE MASTER CYL-
bracket screws INDER/PEDAL, Installation
Brake master cylinder cover screws, 6-8 in-lbs 0.7-0.9 Nm 2.12 BLEEDING BRAKES, Procedure
Brake master cylinder reservoir cover 6-8 in-lbs 0.7-0.9 Nm 2.12 BLEEDING BRAKES, Procedure
Brake pedal shaft locknut 15-20 ft-lbs 20.3-27.1 Nm 2.9 REAR BRAKE MASTER CYL-
Clutch line P-clamp 40-48 in-lbs 4.5-5.4 Nm 2.15 CLUTCH FLUID LINE: FLRT, Line Replace-
ment
Clutch line P-clamp 40-48 in-lbs 4.5-5.4 Nm 2.31 HEADLAMP NACELLE, Installation
Clutch master cylinder clamp screws 60-80 in-lbs 6.8-9.0 Nm 2.14 CLUTCH MASTER CYLINDER AND
RESERVOIR, Assembly
Clutch reservoir cover screws 6-8 in-lbs 0.7-0.9 Nm 2.14 CLUTCH MASTER CYLINDER AND
RESERVOIR, Assembly
Engine mount end cap screws, front 42-48 ft-lbs 56.9-65.0 Nm 2.11 BRAKE LINES, Rear Brake Line
Engine stabilizer bracket screws 30-35 ft-lbs 40.7-47.5 Nm 2.33 ENGINE STABILIZER, Stabilizer Link/Apply
LOCTITE 272 HIGH STRENGTH/HIGH TEMPER-
ATURE THREADLOCKER AND SEALANT
(red/orange) to threads
Engine stabilizer link screws 30-35 ft-lbs 40.7-47.5 Nm 2.33 ENGINE STABILIZER, Stabilizer Link
Fairing double studs 120-180 in-lbs 13.6-20.3 Nm 2.32 STEERING DAMPER ASSEMBLY, Installation
Fender, rear, screws 108-132 in-lbs 12.2-14.9 Nm 2.23 REAR FENDERS, Installation/Apply LOCTITE
SEALANT (blue).
Frame connection bracket screws 41-45 ft-lbs 55.6-61.0 Nm 2.25 INTERMEDIATE FRAME, Assembly
Front axle nut 70-75 ft-lbs 94.9-101.7 Nm 2.4 FRONT WHEEL, Installation
Front axle pinch screw (metric) 18-22 ft-lbs 24.4-29.8 Nm 2.4 FRONT WHEEL, Installation
Ground strap to forward stud (inside 14-17 ft-lbs 19.0-23.1 Nm 2.22 BODY, Installation
trunk)
Ground strap to upper stud: FLHTCUTG 96-120 in-lbs 10.8-13.5 Nm 2.22 BODY, Assembly: FLHTCUTG
Handlebar cover screws: FLRT 10-20 in-lbs 1.1-2.3 Nm 2.31 HEADLAMP NACELLE, Installation
Headlamp mounting screw: FLRT 30-35 ft-lbs 40.7-47.5 Nm 2.31 HEADLAMP NACELLE, Installation
Headlamp nacelle acorn nuts 96-132 in-lbs 10.8-14.9 Nm 2.31 HEADLAMP NACELLE, Installation
Headlamp nacelle top cover screws 84-120 in-lbs 9.5-13.5 Nm 2.31 HEADLAMP NACELLE, Installation
Intermediate frame screws 40-45 ft-lbs 54.2-61.0 Nm 2.25 INTERMEDIATE FRAME, Installation
Left electrical caddy screw 72-96 in-lbs 8.1-10.9 Nm 2.25 INTERMEDIATE FRAME, Installation
License plate bracket screws: 18-30 in-lbs 2.0-3.4 Nm 2.17 TRUNK DOOR: FLHTCUTG, Assembly/Use
FLHTCUTG LOCTITE 243 MEDIUM STRENGTH THREAD-
Lug nuts 90-100 ft-lbs 122.0-135.6 Nm 2.6 REAR WHEELS, Installation/Always check lug
nut torque within 500-1000 mi (805-1610 km) after
wheel installation.
Muffler bracket screws 14-18 in-lbs 19.0-24.4 Nm 2.24 REAR FRAME, Installation
Panhard rod adjustment jamnut 25-35 ft-lbs 33.9-47.5 Nm 2.30 PANHARD ROD, Adjustment
2-2 2015 Trike Service Supplement Chassis

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Panhard rod clevis screw 55-60 ft-lbs 74.6-81.4 Nm 2.30 PANHARD ROD, Installation
Panhard rod clevis screw 55-60 ft-lbs 74.6-81.4 Nm 2.30 PANHARD ROD, Adjustment
Panhard rod locknut 55-60 ft-lbs 74.6-81.4 Nm 2.30 PANHARD ROD, Installation
Parking brake cable anchor bracket 41-45 ft-lbs 55.6-61.0 Nm 2.13 PARKING BRAKE ASSEMBLY, Cables
screws
Parking brake pawl locknut 60-96 in-lbs 6.8-10.8 Nm 2.13 PARKING BRAKE ASSEMBLY, Pedal
Assembly
Parking brake pedal bracket screws 36-42 ft-lbs 48.8-56.9 Nm 2.13 PARKING BRAKE ASSEMBLY, Pedal
Assembly
Parking brake pedal locknut 15-20 ft-lbs 20.3-27.1 Nm 2.13 PARKING BRAKE ASSEMBLY, Pedal
Assembly
Parking brake sensor jamnut 30-35 in-lbs 3.4-4.0 Nm 2.13 PARKING BRAKE ASSEMBLY, Parking Brake
Sensor
Passenger grab handles: FLRT 96-120 in-lbs 10.8-13.6 Nm 2.22 BODY, Assembly: FLRT
Passenger grab handle screws: FLRT 96-120 in-lbs 10.8-13.6 Nm 2.22 BODY, Passenger Grab Handles: FLRT
Passenger handrail screws 60-96 in-lbs 6.8-10.9 Nm 2.25 INTERMEDIATE FRAME, Assembly
Pinch block screws 41-45 ft-lbs 55.6-61.0 Nm 2.29 SHOCK ABSORBERS, Installation/Use
Rear fork bracket bolts 55-65 ft-lbs 74.6-88.1 Nm 2.27 REAR FORK, Installation/Apply two drops of
LOCKER AND SEALANT (blue) to threads
Rear fork pivot shaft locknut 50 ft-lbs + 180 67.8 Nm + 180 2.27 REAR FORK, Installation/Always use new
degrees addi- degrees addi- locknuts and cup washers
tional rotation tional rotation
Rear frame screws 41-45 ft-lbs 55.6-61.0 Nm 2.24 REAR FRAME, Installation/ Use LOCTITE
262 HIGH STRENGTH THREADLOCKER AND
SEALANT (red)
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 2.24 REAR FRAME, Installation/Use LOCTITE 262
HIGH STRENGTH THREADLOCKER AND
SEALANT (red)
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 2.29 SHOCK ABSORBERS, Installation/Use
LOCTITE 262 HIGH STRENGTH THREAD-
LOCKER AND SEALANT (red)
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 2.30 PANHARD ROD, Adjustment/Use LOCTITE
SEALANT (red)
Steering damper acorn nut 16-20 ft-lbs 21.7-27.1 Nm 2.32 STEERING DAMPER ASSEMBLY, Installation
Steering damper bracket to frame screw: 22-28 ft-lbs 29.8-38.0 Nm 2.32 STEERING DAMPER ASSEMBLY, Installation
FLRT
Steering damper locknut 16-20 ft-lbs 21.7-27.1 Nm 2.32 STEERING DAMPER ASSEMBLY, Installation
Steering damper side bracket acorn nuts: 120-180 in-lbs 13.6-20.3 Nm 2.32 STEERING DAMPER ASSEMBLY, Installa-
FLHTCUTG tion/ These also retain the auxiliary/fog/HDI head-
lamp brackets.
Steering damper side bracket to fork 20-25 ft-lbs 27.1-33.9 Nm 2.32 STEERING DAMPER ASSEMBLY, Installation
bracket screws: FLRT
Stop lamp switch, rear 12-15 ft-lbs 16.3-20.3 Nm 2.11 BRAKE LINES, Rear Brake Line/Use
LOCTITE 565 THREAD SEALANT
Tail lamp bracket: FLRT 72-96 in-lbs 8.1-10.8 Nm 2.23 REAR FENDERS, Installation
Tour-Pak mounting nuts 60-72 in-lbs 6.8-8.1 Nm 2.21 TOUR-PAK, Tour-Pak Adjustment

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Tour-Pak mounting nuts 60-72 in-lbs 6.8-8.1 Nm 2.21 TOUR-PAK, Installation
Trunk bulkhead cover screws 72-96 in-lbs 8.1-10.8 Nm 2.22 BODY, Assembly: FLRT
Trunk door cover screws: FLHTCUTG 30-54 in-lbs 3.4-6.1 Nm 2.17 TRUNK DOOR: FLHTCUTG, Installation
Trunk door hinge cover screws: FLRT 25-35 in-lbs 2.8-3.9 Nm 2.19 TRUNK DOOR: FLRT, Repair
Trunk door hinge locknuts: FLHTCUTG 60-84 in-lbs 6.8-9.5 Nm 2.17 TRUNK DOOR: FLHTCUTG, Installation/Use
new locknuts
Trunk door hinge screws: FLHTCUTG 48-72 in-lbs 5.4-8.1 Nm 2.17 TRUNK DOOR: FLHTCUTG, Assembly/Use
Trunk door hinge to body screws: FLRT 72-96 in-lbs 8.1-11.0 Nm 2.19 TRUNK DOOR: FLRT, Repair
Trunk door hinge to door screws: FLRT 72-96 in-lbs 8.1-11.0 Nm 2.19 TRUNK DOOR: FLRT, Repair
Trunk door lanyard screws: FLHTCUTG 48-72 in-lbs 5.4-8.1 Nm 2.17 TRUNK DOOR: FLHTCUTG, Installation
Trunk door latch: FLRT 96-120 in-lbs 10.8-13.6 Nm 2.20 TRUNK DOOR LOCKSET: FLRT, Lock and
Latch Assembly
Latch Assembly
Trunk door latch housing screws: 48-60 in-lbs 5.4-6.8 Nm 2.18 TRUNK DOOR LOCKSET: FLHTCUTG, Latch
FLHTCUTG Assembly
Trunk door latch mechanism screws: 8-10 in-lbs 0.9-1.1 Nm 2.18 TRUNK DOOR LOCKSET: FLHTCUTG, Latch
FLHTCUTG Assembly
Trunk door latch pin bracket screws: 48-72 in-lbs 5.4-8.1 Nm 2.17 TRUNK DOOR: FLHTCUTG, Installation
FLHTCUTG
Trunk door latch pin jamnut: FLHTCUTG 48-72 in-lbs 5.4-8.1 Nm 2.17 TRUNK DOOR: FLHTCUTG, Assembly
Trunk door latch pin jamnut: FLHTCUTG 48-72 in-lbs 5.4-8.1 Nm 2.18 TRUNK DOOR LOCKSET: FLHTCUTG, Latch
Pin
Trunk door lock housing nuts: 9-11 in-lbs 1.0-1.2 Nm 2.18 TRUNK DOOR LOCKSET: FLHTCUTG, Latch
FLHTCUTG Assembly
Trunk door striker pin: FLRT 35-40 ft-lbs 47.0-54.0 Nm 2.19 TRUNK DOOR: FLRT, Repair
Trunk door striker pin: FLRT 35-40 ft-lbs 47.0-54.0 Nm 2.19 TRUNK DOOR: FLRT, Adjust Trunk Door
Trunk door striker screws: FLRT 72-96 in-lbs 8.1-11.0 Nm 2.19 TRUNK DOOR: FLRT, Repair
Trunk door tether reel screws: FLRT 72-96 in-lbs 8.1-10.8 Nm 2.22 BODY, Assembly: FLRT
Trunk door tether to door screws: FLRT 16-22 in-lbs 1.8-2.5 Nm 2.19 TRUNK DOOR: FLRT, Repair
Trunk latch cover screws: FLRT 20-25 in-lbs 2.3-2.8 Nm 2.20 TRUNK DOOR LOCKSET: FLRT, Lock and
Latch Assembly
Trunk latch housing cover screw: 25-28 in-lbs 2.8-3.2 Nm 2.18 TRUNK DOOR LOCKSET:
FLHTCUTG FLHTCUTG, Lockset
Trunk lock cover: FLRT 72-96 in-lbs 8.1-10.8 Nm 2.20 TRUNK DOOR LOCKSET: FLRT, Lock and
Latch Assembly
Latch Assembly
Trunk lock knob nut: FLRT 13-16 ft-lbs 17.6-21.7 Nm 2.20 TRUNK DOOR LOCKSET: FLRT, Lock and
Latch Assembly
Upper handlebar clamp fastener, rear: 16-20 ft-lbs 21.7-27.1 Nm 2.16 HANDLEBAR, Adjustment: FLRT
all models
Wheel center cap clamp screw 72-96 in-lbs 8.1-10.9 Nm 2.6 REAR WHEELS, Installation/Use LOCTITE
SEALANT (blue)

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SPECIFICATIONS 2.2
GENERAL running weight. For example, a motorcycle with GVWR of 1200
lbs (544 kg) having a running weight of 800 lbs (363 kg), would
allow a maximum of an additional 400 lbs (181 kg) combined
Table 2-1. Dimensions weight of the rider, passenger, riding gear, cargo and installed
ITEM FLHTCUTG FLRT accessories.
IN MM IN MM
Table 2-2. Weights
Length 105.1 2670 103.1 2620
ITEM FLHTCUTG FLRT
Overall Width 54.7 1390 54.9 1394
LB KG LB KG
Overall Height 56.3 1430 46.7 1186
Running weight* 1215 551 1082 491
Wheelbase 65.7 1670 66.0 1675
Maximum added 485 220 618 290
Ground clearance 4.5 115 4.9 124
weight allowed**
Saddle height* 27.1 688 26.9 683
GVWR 1700 771 1700 771
*With 180 lb (81.7 kg) rider on seat.
GAWR front 500 227 500 227
GAWR rear 1200 544 1200 544
* The total weight of the motorcycle as delivered with all
Do not exceed the motorcycle's Gross Vehicle Weight oil/fluids and approximately 90% of fuel.
Rating (GVWR) or Gross Axle Weight Rating (GAWR). ** The total weight of accessories, cargo, riding gear, pas-
Exceeding these weight ratings can lead to component senger and rider must not exceed this weight.
failure and adversely affect stability, handling and perform-
ance, which could result in death or serious injury. (00016f)
• GVWR is the sum of the weight of the motorcycle,
accessories, and the maximum weight of the rider, pas- Use only Harley-Davidson specified tires. See a Harley-
senger and cargo that can be safely carried. Davidson dealer. Using non-specified tires can adversely
affect stability, handling or braking, which could result in
• GAWR is the maximum amount of weight that can be death or serious injury. (00024b)
safely carried on each axle.
• The GVWR and GAWR are shown on the information NOTE
label, located on the frame down tube. Harley-Davidson does not perform any testing with only
nitrogen in tires. Harley-Davidson neither recommends nor
The maximum additional weight allowed on the motorcycle
discourages the use of pure nitrogen to inflate tires.
equals the Gross Vehicle Weight Rating (GVWR) minus the
Table 2-3. Specified Tires
MODEL MOUNT SIZE SPECIFIED TIRE PRESSURE (COLD)

PSI kPa
FLHTCUTG Front 16 in. Dunlop D402F MT90B16 72H 36 248
FLRT Front 19 in. Dunlop D408F 130/60B19 61H 36 248
FLHTCUTG, FLRT Rear 15 in. Dunlop P205/65 R15 92T 26 179

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VEHICLE IDENTIFICATION NUMBER (VIN) 2.3

VEHICLE IDENTIFICATION NUMBER (VIN) om01391
General
See Figure 2-2. A unique 17-digit serial or Vehicle Identification
Number (VIN) is assigned to each motorcycle. For a description
of each item in the VIN, refer to Table 2-4.
Location
See Figure 2-1. The full 17-digit VIN (1) is stamped on the right
side of the frame near the steering head. In some destinations, 2
a printed VIN label (2) is also attached to the front downtube.
Abbreviated VIN
1
An abbreviated VIN showing the vehicle model, engine type,
model year, and sequential number is stamped on the left side
of the crankcase between the engine cylinders.
NOTE
Always give the full 17-digit Vehicle Identification Number when
ordering parts or making any inquiry about your motorcycle.
1. Stamped VIN
2. VIN label
Figure 2-1. VIN Locations

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om01283g
1 2 3 4 5 6 7 8 9
1HD 1 MA L 1 3 F B 111000
Figure 2-2. Typical Harley-Davidson VIN: 2015 Trike Models
Table 2-4. Harley-Davidson VIN Breakdown: 2015 Trike Models
POSITION DESCRIPTION POSSIBLE VALUES

1 World manufacturer identifier 1HD=Originally manufactured in the United States
5HD=Originally manufactured in the United States for sale outside of the
United States
932=Originally manufactured in Brazil
MEG=Originally manufactured in India
2 Motorcycle type 1=Heavyweight motorcycle (901 cm3 or larger)
3 Model MA=FLHTCUTG Tri Glide™ Ultra
MC=FLRT Freewheeler™
4 Engine type L=Twin-Cooled™ 1690 cm3 High Output Twin Cam 103™, fuel-injected
M=Air-Cooled 1690 cm3 High Output Twin Cam 103™, fuel-injected
5 Calibration/configuration, introduc- Normal Introduction Mid-year or Special Introduction
tion 1=Domestic (DOM) 2, 4=Domestic (DOM)
3=California (CAL) 5, 6=California (CAL)
A=Canada (CAN) B=Canada (CAN)
C=HDI D=HDI
E=Japan (JPN) F=Japan (JPN)
6 VIN check digit Can be 0-9 or X
7 Model year F=2015
8 Assembly plant B=York, PA U.S.A.
9 Sequential number Varies

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FRONT WHEEL 2.4

REMOVAL 4. Install flat washer (5) and axle nut (7).
1. Engage parking brake. 5. Insert screwdriver or steel rod through hole in right side
of axle to hold axle stationary. Tighten axle nut to 70-75
2. Raise front wheel using a suitable lifting device. See ft-lbs (94.9-101.7 Nm).
1.2 LIFTING MOTORCYCLE WITH A JACK.
6. Install cotter pin (6) and bend ends. If necessary, further
3. Inspect wheel bearings. See the service manual. tighten axle nut a maximum of 15 degrees to align axle
4. Remove both brake calipers. See 2.8 FRONT BRAKE hole and nut slot.
CALIPERS. Secure calipers to engine guard so that caliper 7. Push right fork slider inboard until it contacts outer spacer
is not suspended by brake hose. (2). Hold in this position and tighten axle pinch screw to
NOTE 18-22 ft-lbs (24.4-29.8 Nm).
Do not operate brakes with the caliper removed or the caliper 8. Install brake calipers. See 2.8 FRONT BRAKE CALIPERS.
pistons may be forced out. Brake caliper has no serviceable
parts and would result in the need to replace the caliper 9. HDI: Install axle covers. See 2.5 FRONT AXLE COVERS:
assembly. HDI MODELS.
5. HDI: Remove axle covers. See 2.5 FRONT AXLE

COVERS: HDI MODELS.
6. See Figure 2-3. Remove cotter pin (6). After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
7. Insert round punch or steel rod through hole in right side pressure can adversely affect brake performance, which
of axle to hold axle stationary. Remove axle nut (7) and could result in death or serious injury. (00279a)
flat washer (5).
10. Operate front brake hand lever and foot brake pedal sev-
8. Loosen axle pinch screw (metric) at bottom of right side eral times to set brake pads to proper operating position
fork slider. within caliper.
9. Using a soft mallet, gently tap end of axle towards right
side of motorcycle. Catching outer spacers (2), pull axle sm06469
free of fork sliders and wheel hub. 6 8

10. See service manual for wheel repair procedures. 5
INSTALLATION
4
Front axle nut 70-75 ft-lbs 94.9-101.7
3
Nm
3
Front axle pinch screw (metric) 18-22 ft-lbs 24.4-29.8 Nm 2
1. Place wheel into position with the valve stem on the right 1
side of the motorcycle.
2. See Figure 2-3. Apply a light coat of ANTI-SEIZE LUB-
RICANT to axle, bearing bores and bore of inner spacer 1. Axle
(4). 2. Outer spacer
NOTE 3. Bearing (2)
Be sure that grooves on outer spacers are on the outboard 4. Inner spacer
side. Outer spacers on left and right side of wheel hub are 5. Flat washer
interchangeable. 6. Cotter pin
7. Nut
3. Slide axle through right fork slider, outer spacer, wheel 8. Axle cover (2) (HDI models)
hub, second outer spacer and left fork slider.
Figure 2-3. Front Wheel (typical)

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FRONT AXLE COVERS: HDI MODELS 2.5

REPLACEMENT 6. Repeat steps for the opposite side.
FASTENER TORQUE VALUE sm08059
Axle cover set screw 60-84 in-lbs 6.8-9.5 Nm
1. See Figure 2-4. Loosen but do not remove set screw.

Remove cover.
2. Remove set screw from cover.
3. Liberally apply LOCTITE 262 HIGH STRENGTH
THREADLOCKER AND SEALANT (red) to set screw
threads.
4. Orient cover over axle end so that set screw is on the
bottom. Tighten set screw against a flat on the axle nut.
5. Install cover with set screw. Tighten to 60-84 in-lbs (6.8-
9.5 Nm).
Figure 2-4. Front Axle Cover

HOME
REAR WHEELS 2.6

REMOVAL INSTALLATION
1. Remove seat.
Wheel center cap clamp screw 72-96 in-lbs 8.1-10.9 Nm
Lug nuts 90-100 ft-lbs 122.0-135.6
To prevent accidental vehicle start-up, which could cause Nm
2. Disconnect battery negative cable. 1. If removed, install center caps. Apply LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND SEALANT
(blue) to center cap clamp screw. Install screw with flat
washer. Tighten to 72-96 in-lbs (8.1-10.9 Nm).
tacts both lower frame tubes where down tubes and lower 2. Install wheel and tighten lug nuts to 90-100 ft-lbs (122.0-
frame tubes converge. Never lift by jacking on cross- 135.6 Nm) in a crosswise pattern.
members, oil pan, mounting brackets, components or 3. FLRT: Install center hub cap.
resulting in the need to perform major repair work. (00586d) NOTE
3. Position jack to lift rear of motorcycle. See 1.2 LIFTING km) after wheel installation.
MOTORCYCLE WITH A JACK.
4. Connect battery negative cable. Tighten to 60-70 in-lbs
4. FLRT: Carefully remove center hub cap. (6.8-7.9 Nm).
5. Before lifting motorcycle, set parking brake and loosen
four lug nuts in a crosswise pattern. Raise jack.
6. Remove lug nuts and pull wheel from axle flange studs. After installing seat, pull upward on seat to be sure it is
7. If necessary, remove center cap. locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
5. Install seat.

HOME
FRONT BRAKE MASTER CYLINDER 2.7

DISASSEMBLY
sm08423
NOTE
3
Clean master cylinder reservoir cover before removal.
1. Remove master cylinder. See the service manual.
2. Remove cover and gasket. Turn housing upside down to 2
remove remaining brake fluid from reservoir.
1
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the 4
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
3. Remove brake hand lever:
1. Seal
a. Remove retaining ring. 2. Piston assembly
b. Remove pivot pin. Remove hand lever. 3. Groove
4. Spring with retainer
4. See Figure 2-5. Using a toothpick or small screwdriver,
Figure 2-5. Disassemble Master Cylinder
gently pry outer edge of seal (1) from groove (3) in piston
bore.
5. Remove piston assembly (2) and spring.
CLEANING AND INSPECTION
Use denatured alcohol to clean brake system components.

Direct contact of D.O.T. 4 brake fluid with eyes can cause
Do not use mineral-based solvents (such as gasoline or
irritation. Avoid eye contact. In case of eye contact flush
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
digestive discomfort. If swallowed, obtain medical atten-
injury. (00291a)
CHILDREN. (00240a)
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
(00239b) 1. Clean all parts with denatured alcohol. Wipe dry with a
clean, lint free cloth.
ATELY flush area with clear water. 2. Verify that reservoir is completely free of dust, dirt or
residue.
3. Using a clean air supply, blow out piston bore and other
drilled passages. Do not use a wire or similar instrument.
4. Inspect for damage. Replace master cylinder assembly if
damaged.
a. Inspect banjo seating surface for scratches or nicks.
b. Inspect piston bore for scratches, nicks, scoring, pit-
ting, corrosion or other damage.
c. Inspect seal retaining groove for damage.
5. Inspect piston seals, dust seal and reservoir cover gasket

for damage. Install new piston kit as necessary.

HOME
ASSEMBLY sm08431
1 2 3 4 5
Brake master cylinder, front, 60-80 in-lbs 6.8-9.0 Nm
clamp screws
6
1. See Figure 2-6. Verify backup ring (2) is oriented as

shown.
2. Verify primary cup (1) is installed with tapered end seated
in backup ring (2).
1. Primary cup
3. Verify that O-ring (3) is seated in piston groove. 2. Backup ring
4. Install seal (4) on piston cap (5) with flat side against 3. O-ring
flange. Place on piston. 4. Seal
5. Piston cap
5. Using lubricant in service parts kit, thoroughly coat outside 6. Spring with retainer
diameters of primary cup, backup ring and O-ring. Coat
master cylinder piston bore. Figure 2-6. Piston Assembly Cross Section
6. Verify retainer is in end of spring (6). Insert spring and

retainer into piston bore, so that it seats against counter- Cover Assembly
bore (recess) at bottom. The cover assembly contains no service parts. If necessary,
7. Install piston assembly over spring and into bore. assemble as shown in Figure 2-7.
8. See Figure 2-5. Press down on seal until it contacts the sm08422
counterbore. Larger OD of seal must be seated in groove
(3). 1
NOTE
Install cover with thin edge toward lever.
9. Loosely install cover assembly.
2

installing retaining rings. Retaining rings can slip from the 3
10. Install brake hand lever: 4
a. Verify that bushing is in place in lever and in good
condition.
b. Secure with pivot pin.
1. Cover
c. Install new retaining ring in pivot pin groove. Verify 2. Baffle
that retaining ring is completely seated in groove. 3. Gasket
4. Sight glass
11. Install the master cylinder. See the service manual. Tighten
clamp screws to 60-80 in-lbs (6.8-9.0 Nm). Figure 2-7. Front Reservoir Cover Assembly
12. Bleed brake system. See 2.12 BLEEDING BRAKES.

HOME
FRONT BRAKE CALIPERS 2.8

NOTES
• If only replacing brake pads, see 1.7 BRAKE PADS AND
Brake caliper, front, mounting 28-38 ft-lbs 37.9-51.5 Nm
DISCS.
screws
• Wrap banjo fittings with pieces of lint-free shop towel to
Brake caliper, front, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm
absorb any loss of brake fluid.
1. Cut cable straps securing fender tip wires to brake hose. 1. If necessary, assemble caliper with pad spring and brake
pads. See 1.7 BRAKE PADS AND DISCS.
2. Remove banjo bolts. Discard sealing washers.
2. Install caliper with two screws. Tighten to 28-38 ft-lbs
3. See Figure 2-8. Remove two caliper mounting screws (5).
(37.9-51.5 Nm).
Remove caliper.
3. Secure brake lines to caliper with banjo bolts and new
sm07720
sealing washers. Tighten to 17-22 ft-lbs (23.1-29.8 Nm).
1 4. Secure fender tip lamp wires to brake hose:
2 a. Place upper cable strap at upper crimp.
b. Place second cable strap at the approximate midpoint
3 of the brake hose.
NOTE
When installing a bleeder valve, check for the presence of an
O-ring used during manufacturing. To prevent improper sealing,
remove and discard the O-ring. Replacement parts do not have
an O-ring nor is one required.
4
5. Fill and bleed brake system. See 2.12 BLEEDING
5 BRAKES.
1. Caliper
2. Pad pin
3. Brake pads
4. Pad spring
5. Caliper mounting screw (2)
Figure 2-8. Front Brake Caliper Assembly

HOME
REAR BRAKE MASTER CYLINDER/PEDAL 2.9

GENERAL sm07910
3 4
2
with large amounts of water and get medical attention. 1
6 5
CHILDREN. (00240a)

protect surfaces from spills whenever brake work is per- 1. Washer
formed. Failure to comply can result in cosmetic damage. 2. Hose from reservoir
(00239b) 3. Mounting nut (not visible)
4. Brake pedal assembly
• If DOT 4 brake fluid contacts painted surfaces, IMMEDI- 5. Clevis pin
ATELY flush area with clear water. 6. Cotter pin
Figure 2-9. Rear Brake Pedal/Master Cylinder Assembly
Do not allow dirt or debris to enter the master cylinder INSTALLATION

reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c) FASTENER TORQUE VALUE
REMOVAL Brake master cylinder, rear, 126-150 14.2-16.9 Nm
mounting bracket screws in-lbs
1. Remove the right side rider footboard. See the service
manual. Brake master cylinder, rear, 30-40 ft-lbs 40.7-54.2 Nm
mounting bracket nut
NOTE
Clean master cylinder reservoir cover before removal. Brake pedal shaft locknut 15-20 ft-lbs 20.3-27.1 Nm
2. Remove cover from master cylinder reservoir. Brake master cylinder, rear, 27-29 ft-lbs 36.6-39.3 Nm
banjo bolt
3. Remove banjo bolt from master cylinder. Allow reservoir
to drain. Discard sealing washers. 1. See Figure 2-9. Install master cylinder assembly onto
NOTE brake pedal flange. Install clevis pin (5) from the outboard
Wrap banjo fittings with pieces of lint-free shop towel to absorb side. Install flat washer (1) and cotter pin (6) on clevis pin.
any loss of brake fluid. 2. Apply a light coat of WHEEL BEARING GREASE to the
4. See Figure 2-9. Remove clamp securing the reservoir brake pedal shaft and bore. Install new O-ring on each
hose (2). See Crimp Clamps in COOLING in the service side of bore.
manual. Remove hose from the master cylinder. 3. Install brake pedal/master cylinder assembly on the pedal
5. Remove nut (3) securing master cylinder assembly to the shaft. Install flat washer and new locknut on pedal shaft.
mounting bracket. 4. Insert threaded end of master cylinder through opening in
6. Remove two screws securing the master cylinder mounting mounting bracket. Apply LOCTITE 243 MEDIUM
bracket to the engine mount end cap. STRENGTH THREADLOCKER AND SEALANT (blue) to
threads. Start mounting nut.
7. Remove the mounting bracket from the brake pedal/master
cylinder assembly. 5. Secure mounting bracket to engine mount end cap.
Tighten to 126-150 in-lbs (14.2-16.9 Nm).
8. Remove the locknut securing brake pedal assembly to the
pedal shaft. Pull brake pedal/master cylinder assembly 6. Tighten mounting nut (3) to 30-40 ft-lbs (40.7-54.2 Nm).
from pedal shaft. Discard O-rings from each side of brake 7. Tighten brake pedal shaft locknut to 15-20 ft-lbs (20.3-27.1
pedal shaft bore. Nm).
9. Remove cotter pin (6), flat washer (1) and clevis pin (5)
from the brake pedal flange.

HOME
8. Attach brake line to master cylinder reservoir with banjo

sm06462a
bolt (metric) and new sealing washers. Tighten to 27-29
ft-lbs (36.6-39.3 Nm).
2
1
3
9. Install reservoir hose (2) with a new clamp. See Crimp
Clamps in COOLING in the service manual.
4
5
10. Install rider footboard. See the service manual. 6
11. Bleed brake system. See 2.12 BLEEDING BRAKES. 8
9
After repairing the brake system, test brakes at low speed. 10
serious injury. (00289a) 7
12. Test ride motorcycle.
1. Retaining ring
DISASSEMBLY 2. Large washer
3. Dust boot
NOTE 4. Spring retainer
See Figure 2-10. Do not disassemble the cartridge assembly 5. Spring
(8). The cartridge assembly components are not sold separ- 6. Retaining ring
ately. Replace the cartridge assembly if leakage is evident. 7. O-ring (2)
8. Cartridge assembly
1. Thoroughly clean exterior of master cylinder assembly
9. Slot
with denatured alcohol.
10. Housing
2. Stand master cylinder assembly upright on a clean shop
Figure 2-10. Rear Master Cylinder
towel on the banjo sealing surface.

installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause Use denatured alcohol to clean brake system components.
serious eye injury. (00312a) Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
3. See Figure 2-10. Push down and hold large flat washer
(2). Remove retaining ring (1). Discard retaining ring.
4. Remove large flat washer (2), dust boot (3), spring retainer injury. (00291a)
(4) and spring (5).
1. Clean all metal parts, except the cartridge body assembly.
5. Push on threaded end of cartridge assembly (8) to remove. Dry with compressed air. Clean all rubber parts using
Use hand pressure only. Exercise caution to keep cartridge denatured alcohol.
assembly free of dirt and grease.
2. Inspect housing bore for scratches. Replace housing if
6. If reservoir housing (10) will be replaced, remove O-rings damage is present.
(7) from cartridge assembly.
3. Check dust boot for damage. Replace as necessary.
4. Inspect threads on cartridge body. Replace master cylinder
assembly if threads are damaged.
5. Inspect spring for distortion, cracks or broken coils.
Replace as necessary.
6. Clean O-ring grooves on cartridge body using a soft cotton
cloth moistened with alcohol. Allow to dry. Inspect grooves
for scratches.
ASSEMBLY
NOTE
O-rings (7) are included with replacement cartridge assembly.

HOME
1. See Figure 2-10. If O-rings (7) have been removed, lub- 2. See Figure 2-11 or Figure 2-12. Slide rear wing (2) of
ricate new O-rings with DOT 4 BRAKE FLUID and install reservoir bracket onto grommet behind fuel tank mount.
in grooves of cartridge assembly. Start lower portion of retainer in right steering head caddy.
2. Wipe bore of housing with DOT 4 BRAKE FLUID. 3. Secure brake line (4) in retainer. Rotate upper portion into
place until latch (3) engages.
3. Verify that large retaining ring (6) is installed on cartridge
assembly. 4. FLHTCUTG: Secure clutch fluid line (5) in retainer.
NOTE 5. Reservoir only, FLHTCUTG: Secure reservoir to reservoir
Use hand pressure only to assemble cartridge into housing. bracket.
4. Insert cartridge assembly into housing aligning tab in 6. FLRT: Install brake line in retainer (5) on fluid reservoir.
housing bore with slot (9) on cartridge. Cartridge assembly
7. Install hose (1) using a new clamp. See Crimp Clamps in
is fully installed when large retaining ring (6) contacts
COOLING in the service manual.
housing.
8. Fill reservoir. Check brake system operation and bleed if
5. Stand master cylinder assembly upright on a clean shop
necessary.
towel on the banjo sealing surface.
6. Install spring (5), spring retainer (4), dust boot (3), and sm07911
large flat washer (2).
3
7. Push down on large flat washer and hold spring in a 4
compressed state. Install new retaining ring (1) in groove
2
of clevis.
8. Seat dust boot over lip on housing. 5
9. Rotate boot so that drain/air hole is at the bottom.
REAR BRAKE RESERVOIR 1

Removal
1. Hose
2. Rear wing
3. Latch
4. Brake line
5. Clutch fluid line
(00239b)
Figure 2-11. Rear Brake Fluid Reservoir: FLHTCUTG
1. See Figure 2-11 or Figure 2-12. FLRT: Release brake line
from retainer (5) on fluid reservoir.
sm08399
3
2
2. Reservoir only, FLHTCUTG: Release reservoir from
reservoir bracket. Remove reservoir.
3. FLHTCUTG: Release clutch fluid line (5) from steering
head retainer.
4. Release latch (3) and pull retainer away from steering
head. Release brake line (4) from retainer.
4
5. Remove reservoir/bracket assembly. 5
6. Remove reservoir cover. Pour fluid into a suitable con- 1
tainer.
7. Remove hose (1) from reservoir. See Crimp Clamps in
1. Hose
COOLING in the service manual.
2. Rear wing
Installation 3. Latch
4. Brake line in retainer
1. Inspect grommet for damage. 5. Retainer on reservoir
Figure 2-12. Rear Brake Fluid Reservoir: FLRT

HOME
REAR BRAKE CALIPERS 2.10

REMOVAL 3. If removed, install caliper mount bushing bolts (2). Tighten
to 32-36 ft-lbs (43.4-48.8 Nm).
NOTE
4. Install the parking brake cable end in the notch of the
If only replacing the brake pads, see 1.7 BRAKE PADS AND
pulley.
DISCS.
5. Wrap the cable around the pulley and engage the cable
1. Remove rear wheel. See 2.6 REAR WHEELS.
housing in the bracket. Install the retaining ring.
2. Release parking brake. Completely loosen the parking
6. Secure the brake line with the banjo bolt and two new
brake adjustment. See 1.8 PARKING BRAKE.
sealing washers. Tighten to 17-22 ft-lbs (23.1-29.8 Nm).
3. Remove the parking brake cable retaining ring. Remove
7. Fill and bleed the brake system. See 2.12 BLEEDING
the cable housing from the bracket.
BRAKES.
4. Unwrap the cable from the pulley. Remove end of cable
8. Adjust the parking brake. See 1.8 PARKING BRAKE.
from pulley.
9. Install the rear wheel. See 2.6 REAR WHEELS.
NOTE
Do not rotate the cable pulley after the cable is removed. NOTE
Damage to the caliper could occur requiring replacement of Any time a rear wheel is removed and installed, the lug nut
the caliper assembly. torque must be checked within 500-1000 mi (805-1610 km).
5. See Figure 2-13. If the caliper will be separated from
mount bracket (3), loosen mount bushing bolts (4) before sm06456a
3 4
removing the caliper assembly.
NOTE
2
Wrap banjo fittings with pieces of lint-free shop towel to absorb
any loss of brake fluid. 1 5
6. Remove the banjo/bleeder bolt and two sealing washers
to release the brake line. Discard the washers.
7. Remove two screws (2) and remove the caliper assembly.
INSTALLATION
8 6
Brake caliper, rear, mounting 41-45 ft-lbs 55.6-61.0 Nm
7
bracket screws
1. Brake pads
Brake caliper, rear, mount 32-36 ft-lbs 43.4-48.8 Nm 2. Screw (2)
bushing bolts 3. Mount bracket
Brake caliper, rear, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 4. Mount bushing bolt (2)
5. Pad spring (install in upper groove)
6. Grooves
1. See Figure 2-13. Install the caliper assembly with brake
7. Mount bushing pin (2)
pads onto disc.
8. O-ring (4)
2. Apply a drop of LOCTITE 243 MEDIUM STRENGTH
Figure 2-13. Rear Brake Caliper Assembly (left side shown)
THREADLOCKER AND SEALANT (blue) to the threads
of screws (2) and install. Tighten to 41-45 ft-lbs (55.6-61.0
Nm).

HOME
BRAKE LINES 2.11

FRONT BRAKE LINES 3. Attach brake line to master cylinder with banjo bolt and
new sealing washers. Tighten to 17-22 ft-lbs (23.1-29.8
FASTENER TORQUE VALUE Nm).
Brake master cylinder, front, 17-22 ft-lbs 23.1-29.8 Nm 4. Tighten manifold banjo bolt (2) to 27-29 ft-lbs (36.6-39.3
banjo bolt Nm).
Brake manifold, front circuit, 27-29 ft-lbs 36.6-39.3 Nm 5. FLHTCUTG: See Figure 2-15.
banjo bolt a. Secure brake line and clutch line to right handlebar
Brake manifold mounting 96-120 in-lbs 10.8-13.6 Nm riser with new cable strap (2).
screw
b. Secure brake line to clutch line with new cable strap
Brake caliper, front, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm (1).
Brake manifold, front circuit, 27-29 ft-lbs 36.6-39.3 Nm c. Install the inner fairing. See the service manual.
banjo bolt
d. Install outer fairing. See the service manual.
Brake manifold, rear circuit, 17-22 ft-lbs 23.1-29.8 Nm
banjo bolt 6. FLRT: See Figure 2-16.
a. Secure brake line to right handlebar riser with new
Front Master Cylinder Line Removal cable strap (2).
1. FLHTCUTG: b. Install nacelle and headlamp. See 2.32 STEERING
a. Remove outer fairing. See the service manual. DAMPER ASSEMBLY.
b. Rotate inner fairing. See the service manual. 7. Bleed brake system. See 2.12 BLEEDING BRAKES.
c. See Figure 2-15. Cut cable strap to release brake line
from right handlebar riser. sm07732
2. FLRT: 2
a. Remove nacelle and headlamp. See 2.32 STEERING 1
DAMPER ASSEMBLY.
b. See Figure 2-16. Cut cable strap to release brake line
from right handlebar riser.
3
3. Turn handlebars until the master cylinder reservoir is level.
NOTE
4. Remove cover from master cylinder reservoir. 6 4
5. Remove banjo bolt from master cylinder. Allow reservoir 4
to drain into suitable container. Discard sealing washers.
5
NOTE
Wrap banjo fittings with pieces of lint-free shop towel to absorb 5
any loss of brake fluid.
6. Wipe remaining fluid from the master cylinder reservoir
using a clean shop cloth.
1. Banjo bolt, rear circuit manifold
7. See Figure 2-14. Remove banjo bolt (2). Discard sealing 2. Banjo bolt, front circuit manifold
washers. 3. Cable straps
8. Remove brake line. 4. Banjo bolt, rear circuit
5. Banjo bolt, front circuit
Front Master Cylinder Line Installation 6. Screw, manifold
1. See Figure 2-14. Position the front brake line and loosely Figure 2-14. Front Brake Lines
attach to front circuit manifold with banjo bolt (2) and new
sealing washers.
2. See Figure 2-15 or Figure 2-16. Route line over upper fork
bracket and to front master cylinder.

HOME
4. Remove screw (6) securing circuit manifold to lower fork

sm08420
bracket.
5. Disconnect brake lines (4 or 5) from both front brake cal-
3 ipers. Discard sealing washers.
2 6. Remove front brake line assembly.
1 Front Caliper Line Installation

1. Position the front brake line assembly and loosely attach
to manifold with banjo bolt and new sealing washers.
2. Secure manifold with screw (6). Tighten to 96-120 in-lbs
(10.8-13.6 Nm).
3. Route brake lines to each front caliper. Secure with banjo
bolts and new sealing washers. Tighten to 17-22 ft-lbs
(23.1-29.8 Nm).
1. Clutch line to brake line 4. Tighten manifold banjo bolt:
2. Clutch line and brake line to right riser
3. Clutch line to left riser a. Front circuit manifold: 27-29 ft-lbs (36.6-39.3 Nm).
Figure 2-15. Capture Clutch and Brake Fluid Lines: b. Rear circuit manifold: 17-22 ft-lbs (23.1-29.8 Nm).
FLTHCUTG (Fairing removed for photo clarity)
5. Secure lines together along with fender tip lamp wires
using three new cable straps (3) on each side:
a. Locate cable straps approximately 2.5 in (64 mm)
sm08397
from each hose crimp.
2 b. Locate the third cable strap midway between hose
crimps.
3
6. Install steering damper. See 2.32 STEERING DAMPER
ASSEMBLY.
7. Bleed brake system. See 2.12 BLEEDING BRAKES.
1. Rear brake line to brake reservoir

2. Front brake line to right riser
3. Rear brake line to right caddy
Figure 2-16. Capture Brake Fluid Lines: FLRT
Front Caliper Line Removal

NOTE
The front calipers employ two separate brake circuits.
Replacement procedures are the same for each.
1. Remove steering damper. See 2.32 STEERING DAMPER
ASSEMBLY.
2. See Figure 2-14. Cut cable straps (3) securing lines
together.
NOTE
Wrap banjo fittings with pieces of lint-free shop towel to absorb
any loss of brake fluid.
3. Remove circuit manifold banjo bolt (1 or 2). Discard sealing
washers.

HOME
REAR BRAKE LINE 8. Remove cover from master cylinder reservoir.

NOTE
PART NUMBER TOOL NAME For best results, use the BASIC VACUUM BRAKE BLEEDER
SNAP-ON BB200A BASIC VACUUM BRAKE BLEEDER (Part No. Snap-on BB200A) or equivalent tool to drain the
brake systems.
FASTENER TORQUE VALUE 9. Drain rear brake line:
Brake line, rear, tee locknut 59-63 in-lbs 6.7-7.1 Nm a. Attach vacuum brake bleeder to left rear caliper
bleeder screw. Loosen screw 3/4 turn.
Stop lamp switch, rear 12-15 ft-lbs 16.3-20.3 Nm
b. Operate vacuum bleeder to evacuate all fluid from
Engine mount end cap screws, 42-48 ft-lbs 56.9-65.0 Nm
line.
front
Brake master cylinder, rear, 27-29 ft-lbs 36.6-39.3 Nm c. Repeat with right caliper.
banjo bolt
NOTE
Brake line P-clamp screw 80-100 in-lbs 9.0-11.3 Nm Wrap banjo fittings with pieces of lint-free shop towel to absorb
Brake caliper, rear, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm any loss of brake fluid.
Brake manifold, rear circuit, 17-22 ft-lbs 23.1-29.8 Nm 10. See Figure 2-17. Remove banjo bolt (9) from master cyl-
banjo bolt inder. Discard sealing washers.
11. Free rear brake line from electrical harness conduit clips
Removal (6).
12. Remove screw (13).
13. Release line from retainers (14, 15).
surfaces it comes in contact with. Always use caution and 14. Remove nut (1) securing brake line tee to rear fork stud.
protect surfaces from spills whenever brake work is per- 15. Free rear brake line hose from cable clips (16) on top of
formed. Failure to comply can result in cosmetic damage. rear fork.
(00239b)
16. Remove reservoir hose (11) from master cylinder.
ATELY flush area with clear water. 17. Remove banjo bolt from rear circuit manifold (3). Discard
sealing washers.
1. Disconnect the battery.
18. Remove two clamps (5). Release line from retainer (2) on
2. Remove right side cover.
right side of steering head.
3. Remove rear wheels. See 2.6 REAR WHEELS.
19. FLRT: Release line from retainer on brake fluid reservoir.
4. Remove right side passenger footboard. See the service
20. Support front of engine.
manual.
21. Remove right side front engine mount cap with rider foot-
5. FLHTCUTG: Remove outer fairing. See the service
board and master cylinder attached. Rotate and allow to
manual.
lay on the surface. See the service manual.
6. FLRT: Remove headlamp nacelle. See 2.31 HEADLAMP
22. Remove terminals from rear stop lamp switch (10).
NACELLE.
23. Remove banjo bolts from rear brake calipers. Discard
7. Cut cable straps as necessary. Record locations for
sealing washers.
assembly.
24. Remove rear brake line.
NOTE

HOME
sm07734
1
2
16
6 3
15 5
4
14 10
13
11
7
8
12 9
1. Locknut 9. Banjo bolt, master cylinder

2. Retainer 10. Brake lamp switch
3. Rear circuit manifold 11. Reservoir hose
4. Front circuit manifold 12. Master cylinder/pedal assembly
5. Clamps 13. Screw, P-clamp
6. Electrical harness/brake line clips 14. Line retainer
7. Banjo bolt, rear circuit 15. Line retainer
8. Banjo bolt, front circuit 16. Cable clip (4)
Figure 2-17. Rear Brake Line Assembly (typical)
Installation NOTE
If installing new rear stop lamp switch (10), apply LOCTITE
1. Place brake line in approximate position. 565 THREAD SEALANT to threads and start switch into rear
NOTE brake line. Tighten to 12-15 ft-lbs (16.3-20.3 Nm).
Calipers and lines have anti-rotation features. Verify they are 7. Install right side front engine mount cap with rider foot-
engaged during assembly. board and master cylinder attached:
2. Loosely secure brake line to calipers using new sealing a. Connect terminals onto rear stop lamp switch (10).
washers.
NOTE
3. See Figure 2-17. Secure tee to rear fork with locknut (1). Confirm oil switch/sender wires are inboard of rubber
Tighten to 59-63 in-lbs (6.7-7.1 Nm). Capture rear brake engine mount.
line hose in cable clips (16) on rear fork.
b. Install engine mount end cap. Tighten to 42-48 ft-lbs
4. Route line to manifold (3). Loosely secure with line rear- (56.9-65.0 Nm).
ward of anti-rotation pin using new sealing washers.
c. Remove support under front of engine.
5. FLRT: Capture line in retainer on brake fluid reservoir.
8. Secure brake line to master cylinder reservoir with banjo
6. Capture line in retainer (2) and clamps (5). Rotate toward bolt (9) and new sealing washers. Tighten to 27-29 ft-lbs
the front to provide adequate clearance from the exhaust (36.6-39.3 Nm).
pipe.
9. Capture rear brake line to electrical harness/brake line
clips (6) and retainers (14, 15).

HOME
10. Secure P-clamp with screw (13). Tighten to 80-100 in-lbs 18. FLRT: Install headlamp nacelle. See 2.31 HEADLAMP
(9.0-11.3 Nm). NACELLE.
11. HDI: Secure active exhaust cable to the brake line at 19. Install right side cover.
retainer (15).
20. Install rear wheels. See 2.6 REAR WHEELS.
12. Tighten brake caliper banjo bolts to 17-22 ft-lbs (23.1-29.8
21. Connect battery.
Nm).
13. Tighten manifold (3) banjo bolt to 17-22 ft-lbs (23.1-29.8
Nm).
Be sure headlamp, tail and stop lamp and turn signals are
14. Install reservoir hose (11) to master cylinder with a new
operating properly before riding. Poor visibility of rider to
clamp.
other motorists can result in death or serious injury.
15. Install cable straps removed during removal. (00478b)
16. Bleed brake system. See 2.12 BLEEDING BRAKES. 22. Check brake lamp operation.
17. FLHTCUTG: Install outer fairing. See the service manual.

HOME
BLEEDING BRAKES 2.12

GENERAL PROCEDURE

SNAP-ON BB200A BASIC VACUUM BRAKE BLEEDER
Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even FASTENER TORQUE VALUE
after assembly. Deterioration of these components can Brake caliper bleeder valve, 80-100 in-lbs 9.0-11.3 Nm
cause brake failure, which could result in death or serious front
injury. (00291a)
rear
Brake master cylinder reser- 6-8 in-lbs 0.7-0.9 Nm
Direct contact of D.O.T. 4 brake fluid with eyes can cause voir cover screws, front reser-
irritation. Avoid eye contact. In case of eye contact flush voir
Brake master cylinder cover 6-8 in-lbs 0.7-0.9 Nm
screws, FLRT, rear reservoir
NOTE
CHILDREN. (00240a)
For best results, use the BASIC VACUUM BRAKE BLEEDER
(Part No. Snap-on BB200A). Refer to the instructions provided
with the tool. If a vacuum brake bleeder is not available, follow
D.O.T. 4 brake fluid will damage painted and body panel the correct sequence using a manual bleeding procedure.
General Bleeding Overview
formed. Failure to comply can result in cosmetic damage. 1. Position vehicle or handlebar so master cylinder reservoir
(00239b) is level.
If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY NOTE
flush area with clear water. Protect paint from brake fluid spills. Wrap a clean shop cloth
around the outside of the master cylinder reservoir.
2. Remove cover from master cylinder reservoir.
When any hydraulic brake component, line or connection
is loosened or replaced on an ABS motorcycle, Digital
Technician II must be used during the brake bleeding
procedure to verify all air is removed from the system. A plugged or covered relief port can cause brake drag or
Failure to properly bleed the brake system could adversely lock-up, which could lead to loss of control, resulting in
affect braking, which could result in death or serious injury. death or serious injury. (00288a)
(00585c) 3. Top off the reservoir. Verify proper operation of the master
cylinder relief port by actuating the brake pedal or lever.
A slight spurt of fluid will break the fluid surface in the
reservoir if internal components are working properly. The
Do not allow dirt or debris to enter the master cylinder spurt will not be seen in the remote reservoir on rear
reservoir. Dirt or debris in the reservoir can cause improper system.
operation and equipment damage. (00205c)
NOTE
Verify front brake hand lever and rear brake foot pedal have a Pay careful attention to the fluid level in the master cylinder
firm feel when applied. Bleed system as necessary. reservoir during bleeding. Add fluid before it empties to avoid
drawing air into the brake lines.
4. Proceed with the appropriate procedure.
NOTE
Always bleed all calipers in a circuit.
5. Tighten bleeder screw to specification. Install bleeder
screw cap.
6. Fill reservoir to specified level. Refer to Table 2-5 and
Figure 2-18.

HOME
NOTE 5. Tighten bleeders to specification. Refer to Table 2-6.

Front master cylinder reservoir: Orient the cover with the
6. Verify brake operation.
thin edge toward the lever.
7. Clean gasket and sealing surfaces of debris. Install master sm08421
cylinder reservoir cover. Tighten to specification. Refer to
Table 2-6.

serious injury. (00289a)
8. Check operation of rear lamps.
9. Test ride motorcycle. Repeat the bleeding procedure if
brakes feel spongy.
Figure 2-18. FILL Level Boss (front master cylinder)
Front Circuit
1. Beginning at the front left caliper, vacuum bleed at the
Table 2-5. Fluid Level
upper bleeder.
ITEM SPECIFICATION
2. Repeat with the front right caliper.
Front reservoir Between upper and lower step on boss
3. Tighten bleeders to specification. Refer to Table 2-6.
Rear reservoir MAX line
4. Verify brake operation.
Rear Circuit Table 2-6. Torque Specifications

NOTE FASTENER TORQUE VALUE
Always hold banjo bolt when loosening bleeder on rear calipers. Brake caliper bleeder valve Front: 80-100 in-lbs (9.0-11.3
1. Beginning at the lower bleeder of the front left caliper, Nm)
vacuum bleed the caliper until no air bubbles are present. Rear: 31-33 in-lbs (3.5-3.7
Tighten bleeder. Nm)
2. Continue to the lower bleeder of the front right caliper. Brake master cylinder 6-8 in-lbs (0.7-0.9 Nm)
reservoir, front, cover screws
3. Continue to the rear left caliper.
Brake master cylinder FLHTCUTG: Hand-tighten
4. Continue to the rear right caliper. reservoir, rear, cover FLRT: 6-8 in-lbs (0.7-0.9 Nm)

HOME
PARKING BRAKE ASSEMBLY 2.13

PEDAL ASSEMBLY 2. See Figure 2-19. Disconnect spring (2).
3. Remove locknut (11), washer (12) and O-ring (13).
4. Pull pedal away from frame slightly while removing clevis
Parking brake pawl locknut 60-96 in-lbs 6.8-10.8 Nm
pin securing cable end to pedal assembly.
Parking brake pedal locknut 15-20 ft-lbs 20.3-27.1 Nm
5. Remove pedal assembly from shaft.
Parking brake pedal bracket 36-42 ft-lbs 48.8-56.9 Nm
screws 6. Remove remaining O-ring (14).
Removal
1. Loosen cable adjustment. See 1.8 PARKING BRAKE.
sm06893
6
4 7
5
15 16 3 8
17
9
2
10
1 4
13
12
14 11
1. Mount bracket 7. Spring, pawl 13. O-ring

2. Spring, pedal 8. Screw 14. O-ring
3. Locknut 9. Pedal weldment 15. Anchored cable strap
4. Spacer 10. Pad 16. Sensor
5. Bushing 11. Locknut 17. Jamnut
6. Pawl 12. Washer
Figure 2-19. Parking Brake Pedal Assembly
Disassembly and Inspection 6. Inspect components for wear or damage.
1. See Figure 2-20. Rotate pawl (2) clockwise to release

spring (1) from notch (3).
2. Squeeze legs of spring together while removing from pedal
weldment.
3. See Figure 2-19. Remove locknut (3) and screw (8).
4. Remove pawl (6), spacers (4) and sleeve (5).
5. Pull off pedal pad (10) from pedal weldment.

HOME
5. Remove retaining ring (4). Remove cable from bracket.

sm06892
6. Remove three screws (1).
7. Remove bracket.
1 2
NOTE
Remove all thread locking compound from screws and threaded
holes.
8. LOCTITE 246 MEDIUM STRENGTH/HIGH TEMPER-
ATURE THREADLOCKER (blue) to screws (1). Install
pedal mounting bracket. Tighten to 36-42 ft-lbs (48.8-56.9
Nm).
3 9. Install cable. Secure with retaining ring (3).
10. Attach cable end to pedal arm. Secure with clevis pin (3)
and retaining pin (2).
11. Install the left rider footboard. See the service manual.
1. Pawl spring 12. Connect sensor connector.

2. Pawl 13. Adjust cable. Check parking brake operation. See
3. Notch 1.8 PARKING BRAKE.
Figure 2-20. Parking Brake Pawl 14. Verify parking brake lamp operation.
Assembly sm06971
1. See Figure 2-19. Assemble sleeve (5), pawl (6) and

spacers (4). Orient as shown and install screw (8) and
locknut (3). Tighten locknut to 60-96 in-lbs (6.8-10.8 Nm). 1
2. See Figure 2-20. Install pawl spring (1) oriented as shown.
3. Engage spring into notch (3) of pawl and rotate pawl
counterclockwise. Pawl will rotate over center and keep
spring engaged.
4. Install pedal pad (10). Lubricate with window cleaner to
ease installation. 2
Installation
1. See Figure 2-19. Install new O-ring (14) onto shaft.
2. Slide pedal assembly onto shaft and connect pedal return 3
spring (2). 4
3. Connect cable to pedal arm using clevis pin. Secure with
retaining pin.
4. Install new O-ring (13), flat washer (12) and locknut (11).
Tighten locknut to 15-20 ft-lbs (20.3-27.1 Nm).
1. Screw (3)
5. Adjust cable. Check parking brake operation. See 2. Retaining pin
1.8 PARKING BRAKE. 3. Clevis pin
4. E-ring
Pedal Mounting Bracket
Figure 2-21. Parking Brake Assembly
NOTE
The parking brake pedal and mounting bracket can be removed
PARKING BRAKE SENSOR
as an assembly if desired.
1. Disconnect sensor connector. FASTENER TORQUE VALUE
2. See Figure 2-21. Remove the left rider's footboard. See Parking brake sensor jamnut 30-35 in-lbs 3.4-4.0 Nm
the service manual.
3. Loosen cable adjustment. See 1.8 PARKING BRAKE. Adjust Sensor Gap
4. Remove clevis pin (3). Remove cable from pedal lever. 1. Pull pedal outward to remove free play.

HOME
2. Verify gap between end of sensor and magnet in pedal CABLES

weldment is 0.177-0.197 in (4.50-5.00 mm). Adjust if
necessary: FASTENER TORQUE VALUE
a. Disconnect sensor connector. Parking brake cable anchor 41-45 ft-lbs 55.6-61.0 Nm
b. Loosen jamnut. Turn sensor to adjust gap. bracket screws
c. Tighten jamnut to 30-35 in-lbs (3.4-4.0 Nm).

Front Cable
d. Mate sensor connector.
1. Remove left wheel.
3. Verify parking brake lamp operation. 2. Loosen parking brake cable adjustment.
Sensor Replacement 3. See Figure 2-23. Remove cable retaining ring securing
left rear cable (4). Pull cable from equalizer bracket and
1. Remove left rider footboard. See the service manual.
release both rear cable ends from equalizer (3).
2. See Figure 2-19. Loosen jamnut (17).
4. Remove cable retaining ring securing front cable (1).
3. Separate sensor connector. Remove cable from equalizer bracket.
4. Release cable strap (15) securing sensor harness to 5. Cut cable strap (6).
mounting bracket. Remove sensor from mounting bracket.
6. Remove retaining pin and clevis pin from forward end of
5. Position jamnut at about half way point of sensor threads. cable.
6. Apply LOCTITE 246 MEDIUM STRENGTH/HIGH TEM- 7. Remove cable retaining ring securing cable to pedal
PERATURE THREADLOCKER (blue) to threads 5-11 of mounting bracket.
sensor.
NOTE
7. Install sensor. Adjust sensor gap. Note cable routing and anchor points during removal.
8. Secure harness with cable strap (15). Mate connector. 8. Remove cable from vehicle.
9. Install rider footboard. 9. Route new cable in the approximate final location.
Magnet 10. Install forward end of front cable housing in pedal mounting
bracket. Secure with cable retaining ring.
1. See Figure 2-22. Remove magnet from pedal weldment.
11. Secure cable end to parking brake pedal with clevis pin
2. Thoroughly remove remaining adhesive. Clean mounting and retaining pin.
area with isopropyl alcohol.
12. Install cable housing (1) in equalizer bracket. Secure with
3. Install new magnet using a small amount of HARLEY- retaining ring.
DAVIDSON HIGH PERFORMANCE SEALANT - GRAY.
Remove all excess adhesive and verify that the magnet 13. Attach ends of both rear cables in equalizer (3). Install left
face is free from adhesive. Hold in place with a piece of rear cable (4) in equalizer bracket. Secure with retaining
tape for 12 hours. ring.
4. Adjust sensor gap. 14. Secure cable housing to frame with new cable strap (6).
Install a second cable strap at lower frame junction cap-
turing cable and fuel tank vent hose.
sm08398
15. Adjust cable. Check parking brake operation. See
1 1.8 PARKING BRAKE.
2
NOTE
Any time a rear wheel is removed and installed, the lug nut
torque must be checked within 500-1000 mi (805-1610 km).
16. Install left wheel. See 2.6 REAR WHEELS.
17. Verify parking brake lamp operation.
1. Pedal assembly
2. Magnet
Figure 2-22. Parking Brake Sensor Magnet

HOME
sm06972a
5 7 8
2 6
3
1
1. Front cable 5. Front cable cable strap

2. Equalizer bracket 6. Rear cables cable strap: FLHTCUTG only
3. Equalizer 7. Protective sleeve
4. Left rear cable 8. Cable straps
Figure 2-23. Parking Brake Equalizer and Rear Cables
Rear Cable Removal NOTE

Install washer on cable housing before installing in caliper
NOTE anchor bracket.
Replacement of either rear cable is essentially the same.
3. Secure cable housing in rear caliper anchor bracket with
1. Remove both rear wheels. See 2.6 REAR WHEELS. retaining ring.
2. Loosen cable adjustment. See 1.8 PARKING BRAKE. 4. See Figure 2-23. Install cable end in equalizer (3). Secure
cable housing in equalizer bracket. Install retaining ring.
3. See Figure 2-23. Remove cable retaining ring. Pull cable
to be replaced from equalizer bracket (2). Release anchor 5. FLHTCUTG: Secure cables together with new cable strap
ball from equalizer (3). (6).
4. FLHTCUTG: Cut cable strap (6) securing cables together. 6. Locate protective sleeve (7) on cable to absorb contact at
rear frame.
5. Remove cable housing from bracket at rear caliper.
Remove cable end from actuator pulley. 7. Right cable: Secure cable to each end of the rear frame
crossmember using new cable straps (8).
6. Note anchor locations and remove cable from vehicle.
NOTE
Rear Cable Installation Any time a rear wheel is removed and installed, the lug nut
1. Route new cable in the approximate final location. torque must be checked within 500-1000 mi (805-1610 km).
2. Install rear cable end in actuator pulley. 8. Install rear wheels. See 2.6 REAR WHEELS.
9. Adjust cable. Check parking brake operation. See
1.8 PARKING BRAKE.

HOME
10. Verify parking brake lamp operation. 5. Install left wheel. See 2.6 REAR WHEELS.
Equalizer Bracket Removal sm06973

2
1. Remove left rear wheel.
2. Loosen cable adjustment. See 1.8 PARKING BRAKE.
1
3. Remove all cables from rear anchor bracket.
4. See Figure 2-24. Remove screws (2). Remove bracket
(1) from rear fork.
Equalizer Bracket Installation

1. Apply LOCTITE MEDIUM STRENGTH THREADLOCKER
AND SEALANT 243 (blue) to the threads of screws (2).
2. Install bracket using screws (2). Tighten screws to 41-45
ft-lbs (55.6-61.0 Nm).
3. Install cables. Secure with retaining rings. Adjust as
necessary. See 1.8 PARKING BRAKE.
1. Equalizer bracket
4. Check parking brake operation. 2. Screw
NOTE Figure 2-24. Equalizer Bracket
Any time a rear wheel is removed and installed, the lug nut
torque must be checked within 500-1000 mi (805-1610 km).

HOME
CLUTCH MASTER CYLINDER AND RESERVOIR 2.14

DISASSEMBLY
sm04960a
NOTE
Clean master cylinder reservoir cover before removal. 4
1. Remove the master cylinder. See the service manual.
2. Remove cover and gasket. Turn housing upside down to
remove remaining clutch fluid from reservoir. 3
2
1
3. Remove clutch hand lever. See the service manual.
4. See Figure 2-25. Using a toothpick or small screwdriver, 1. Boot
gently pry outer edge of piston boot (1) from groove (4) in 2. Piston assembly
piston bore. 3. Spring
4. Groove
5. Remove piston assembly (2) and spring (3).
Figure 2-25. Disassemble Master Cylinder

digestive discomfort. If swallowed, obtain medical atten- Use denatured alcohol to clean brake system components.
tion. Use in well ventilated area. KEEP OUT OF REACH OF Do not use mineral-based solvents (such as gasoline or
CHILDREN. (00240a) paint thinner), which will deteriorate rubber parts even
injury. (00291a)
D.O.T. 4 hydraulic brake fluid is used in the hydraulic
clutch. Do not use other types of fluids as they are not
compatible and could cause equipment damage. (00353a)
D.O.T. 4 brake fluid will damage painted and body panel use your hand to check for air leaks or to determine air
surfaces it comes in contact with. Always use caution and flow rates. (00061a)
protect surfaces from spills whenever brake work is per- 1. Clean all parts with denatured alcohol. Wipe dry with a
formed. Failure to comply can result in cosmetic damage. clean, lint free cloth.
(00239b)
2. Inspect banjo seating surface for scratches or nicks.
ATELY flush area with clear water. 3. Verify that reservoir is completely free of dust, dirt or
residue.
4. Using a clean air supply, blow out piston bore and other
drilled passages. Do not use a wire or similar instrument.
5. Inspect for damage. Replace master cylinder assembly if
damaged.
a. Inspect banjo seating surface for scratches or nicks.
b. Inspect piston bore for scratches, nicks, scoring, pit-
ting, corrosion or other damage.
c. Inspect boot retaining groove for damage.

HOME
6. Inspect piston seals, dust boot and reservoir cover gasket

sm02046
for damage. Install new piston kit as necessary.
ASSEMBLY 1 2 3
Clutch master cylinder clamp 60-80 in-lbs 6.8-9.0 Nm
screws
Clutch reservoir cover screws 6-8 in-lbs 0.7-0.9 Nm
1. See Figure 2-26. Install boot (1) on piston until it fits into
thin groove in piston. 1. Boot in piston groove
2. Secondary cup flare
2. Using lubricant in service parts kit, thoroughly coat outside
3. Primary cup
diameters of primary and secondary cups. Coat master
cylinder piston bore. Figure 2-26. Assembled Cups and Piston
3. See Figure 2-25. With tapered end out, install spring into
bore of piston assembly. Cover Assembly
4. Install piston assembly into bore. The cover assembly contains no service parts. If necessary,
assemble as shown in Figure 2-27.
NOTES
• Do not damage piston sealing boot during installation.
sm08422
• Install boot so hole faces down when master cylinder is
installed.
1
5. Compress and hold piston even with the end of the bore.
Using a small dull-bladed screwdriver or similar tool, gently
work sealing edges of boot until entire circumference is
seated in cylinder bore groove. 2
NOTE
Install cover with thin edge toward lever.
6. Loosely install cover with gasket. 3
Wear safety glasses or goggles when removing or 4

7. Install clutch hand lever. See the service manual. 1. Cover
2. Baffle
8. Install the master cylinder. See the service manual. Tighten 3. Gasket
clamp screws to 60-80 in-lbs (6.8-9.0 Nm). 4. Sight glass
9. Bleed the system. See the service manual. Tighten Figure 2-27. Front Reservoir Cover Assembly
reservoir cover screws to 6-8 in-lbs (0.7-0.9 Nm).

HOME
CLUTCH FLUID LINE: FLRT 2.15

LINE REPLACEMENT sm08406

1
Clutch line P-clamp 40-48 in-lbs 4.5-5.4 Nm
See Figure 2-28. Clutch fluid line replacement is similar to other

models except for line routing.
NOTES
• Orient upper P-clamp with screw toward the outboard side. 1
2
• Orient lower P-clamp with screw toward the front.
1. Route line through two P-clamps (1), forward of left frame
downtube, behind right frame downtube and above the 3
right engine rubber mount (3).
2. Tighten P-clamp screws to 40-48 in-lbs (4.5-5.4 Nm).
3. Secure to right frame downtube using a new cable strap
(2) through the hole in the crossmember. Secure at
grommet on fluid line. 1. P-clamp
4. Secure to the main harness along the lower frame rail 2. Cable strap
following the procedure in the service manual. 3. Engine rubber mount
Figure 2-28. Clutch Fluid Line Routing: FLRT

HOME
HANDLEBAR 2.16
ADJUSTMENT: FLRT HANDLEBAR REPLACEMENT
Handlebar replacement is similar to the OE with following
exceptions:
Upper handlebar clamp 16-20 ft-lbs 21.7-27.1 Nm
fastener, rear: all models • The FLRT has internally wired handlebar similar to OE
FLTR models.
1. Remove trim insert from riser cover. • FLRT: See Figure 2-30. Secure the TGS harness to the
handlebar and upper clamp with a cable strap.
2. Loosen handlebar rear clamp screws one half turn.
3. See Figure 2-29. Place a straight edge across the wind-
sm08427
shield bushings.
1
NOTE
Measure at a right angle to the straight edge.
2
3
4. Measure from the straight edge to the front of the
handlebar just below the upper bend.
5. Rotate the handlebar in the risers until the gap measures
4 in (101.6 mm).
6. Tighten rear clamp screws to 16-20 ft-lbs (21.7-27.1 Nm).
7. Install trim insert.
sm08460
1. Upper handlebar clamp

1 2. Cable strap
90° 3. TGS harness
Figure 2-30. Secure TGS Harness
1. 4 in (101.6 mm)
Figure 2-29. Handlebar Adjustment: FLRT

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TRUNK DOOR: FLHTCUTG 2.17

REMOVAL 3. Disconnect license plate lamps connector (8) and trunk
light connector if equipped.
1. See Figure 2-31. Remove screw (1) to release lanyard (5)
from trunk door (both sides). 4. Release harness from retainer clips.
2. Remove screws (4) and remove trunk door cover. 5. Remove bottom trunk liner.
6. Remove locknuts with flat washers (6) from each hinge
and remove door.
sm06907
14
12
11
10 9
7
6
2
13
4
1. Screw, lanyard (4) 8. License plate lamp assembly with connector
2. Hinge (2) 9. Cover, license plate lamp
3. Threaded insert (2) 10. Contact pad, rubber
4. Screw, trunk door cover (4) 11. Bracket, license plate, top
5. Lanyard assembly (2) 12. Bracket, license plate, bottom
6. Locknuts with flat washers (4) 13. Hinge screws (3 each side)
7. Latch bracket screw (3) 14. Reflector
Figure 2-31. Trunk Door

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DISASSEMBLY sm06909
1. See Figure 2-31. Remove screws (13) to release hinge

(both sides). 3 1
2
2. Remove three screws (7) to release latch pin bracket.
3. Remove license plate lamps/bracket (9, 10, 11, 12). See
7.7 LICENSE PLATE LAMPS/BRACKET: FLHTCUTG.
4. Remove screws to release license plate bracket. Gently
pull upper half of bracket to release contact pad (10) from
trunk door.
1. Surface of bracket
ASSEMBLY 2. Adjustment dimension
3. Jamnut
Figure 2-32. Adjust Latch Pin
License plate bracket screws: 18-30 in-lbs 2.0-3.4 Nm
FLHTCUTG
INSTALLATION
Trunk door latch pin jamnut: 48-72 in-lbs 5.4-8.1 Nm
FLHTCUTG
Trunk door hinge screws: 48-72 in-lbs 5.4-8.1 Nm
Trunk door hinge locknuts: 60-84 in-lbs 6.8-9.5 Nm
FLHTCUTG
FLHTCUTG
1. Install license plate bracket: Trunk door latch pin bracket 48-72 in-lbs 5.4-8.1 Nm
screws: FLHTCUTG
a. Install three screws into upper half of license plate
bracket and start into trunk door to properly locate Trunk door cover screws: 30-54 in-lbs 3.4-6.1 Nm
adhesive pad. FLHTCUTG
b. Remove screws and apply LOCTITE 243 MEDIUM Trunk door lanyard screws: 48-72 in-lbs 5.4-8.1 Nm
STRENGTH THREADLOCKER AND SEALANT FLHTCUTG
(blue).
1. Install the hinges over the mounting studs. If equipped
c. Secure upper and lower brackets with screws. with trunk light, also install the trunk light switch bracket
d. Tighten to 18-30 in-lbs (2.0-3.4 Nm). on the left forward stud.
2. Secure hinges to stud plates in body with new locknuts
2. Install license plate lamps/bracket. See 7.7 LICENSE
and flat washers. Tighten to 60-84 in-lbs (6.8-9.5 Nm).
PLATE LAMPS/BRACKET: FLHTCUTG.
3. Lubricate hinges with HARLEY® LUBE if necessary.
3. Install latch pin bracket and loosely secure with three
screws approximately centered in each slot. Adjustment 4. Install bottom trunk liner.
will be made at a later time.
5. Connect license plate lamp connector.
4. See Figure 2-32. If latch pin was removed, install and
6. Capture rear lighting harness under retainer clips.
adjust to 1.050 in (26.67 mm) from upper surface of
bracket to end of pin. Use a dial caliper to measure dis- 7. See Figure 2-32. Adjust latch pin:
tance (2). a. With latch pin bracket screws finger-tight, close and
5. Hold latch pin and tighten jamnut to 48-72 in-lbs (5.4-8.1 latch door to center the latch pin.
Nm). b. Open door and tighten screws to 48-72 in-lbs (5.4-
6. Apply LOCTITE 243 MEDIUM STRENGTH THREAD- 8.1 Nm).
LOCKER AND SEALANT (blue) and install screws to c. Close and open door to verify operation. Adjust pin
secure each hinge to trunk door. Tighten to 48-72 in-lbs bracket location or pin height if necessary.
(5.4-8.1 Nm) in a crosswise pattern.
NOTE
See Figure 2-33. Route rear lighting harness through gap in
front left corner of trunk door cover.
8. Install trunk door cover. Tighten to 30-54 in-lbs (3.4-6.1
Nm) in a crosswise pattern.
9. Twist lanyard 1/2 turn toward the door opening and secure
to door with screw. Tighten to 48-72 in-lbs (5.4-8.1 Nm).
Repeat step on other side.
10. Verify that each lanyard rotates freely at both ends.

HOME
sm06108a
Figure 2-33. Trunk Door Cover

HOME
TRUNK DOOR LOCKSET: FLHTCUTG 2.18

LOCKSET 7. See Figure 2-34. With the lockset compressed into the
lock mechanism, slide U-clip (5) into installed position.
When correctly installed the ends of the U-clip will protrude
from opposite side of bezel.
HD-34736-B VALVE SPRING COMPRESSOR
8. Install latch cover with screws (7). Tighten to 25-28 in-lbs
(2.8-3.2 Nm).
NOTE
Trunk latch housing cover 25-28 in-lbs 2.8-3.2 Nm
If water spray is directed at the lock for an extended time, water
screw: FLHTCUTG
may enter through the lock tumblers.
Removal/Disassembly
sm06906
1. See Figure 2-34. Remove screws (7) and latch housing 2 3
cover (6). 1
2. Remove U-clip (5). Use a small screwdriver for best res-
ults.
3. Remove lockset (1) from bore. 4
4. Inspect foam washer (2) and remove from body if neces- 5
sary.
5. If necessary, remove lock assembly from bezel:
a. See Figure 2-35. Press pin out of lock bezel. 6
b. Push lock assembly from bezel.
Assembly/Installation
1. Obtain new U-clip if bent or distorted.
NOTE
8
7
The pin retaining the lock assembly in the bezel is used during
manufacturing and is not necessary for repair. Installation is 1. Lockset assembly
optional. 2. Foam washer
3. O-ring
2. See Figure 2-36. If the lockset is disassembled, inspect
4. Latch housing
condition of the internal O-ring and replace if necessary.
5. U-clip
Apply a light film of H-D ELECTRICAL CONTACT LUB-
6. Latch housing cover
RICANT to O-ring and install lock assembly into bezel.
7. Screw (2)
NOTE 8. Screw (4)
Always install the U-clip for the vehicle LEFT side. Bezel failure
Figure 2-34. Trunk Door Lock Assembly
will result if installed from the right side.
3. See Figure 2-37. Start U-clip (1) into slots of lock assembly
from LEFT side and verify that both ends of U-clip are sm06155
visible.
4. Retract U-clip until bore is not obstructed.
5. See Figure 2-34. If removed, install new foam washer (2)
on lockset (1) with the adhesive side facing body. Remove
backing from foam seal and install lockset into body.
6. See Figure 2-38. Compress the lockset into the lock
mechanism to ease installation of U-clip.
a. Use VALVE SPRING COMPRESSOR (Part No. HD-
34736-B) (1) with the large adapter (3).
b. Install a 5/8 in. deep well socket (2) in the adapter to
press against the outer lockset bezel.
c. Turn the clamp screw only enough to install U-clip to
avoid over-tightening and possible damage to the lock
mechanism. Figure 2-35. Push Pin Out

HOME
sm06598 sm06998
2 3
Figure 2-36. Install O-Ring
sm06153
1. Valve spring compressor

2. Socket
3. Large adapter
Figure 2-38. Install Trunk Lockset
LATCH ASSEMBLY
1 Trunk door lock housing nuts: 9-11 in-lbs 1.0-1.2 Nm
FLHTCUTG
Trunk door latch mechanism 8-10 in-lbs 0.9-1.1 Nm
screws: FLHTCUTG
Trunk door latch housing 48-60 in-lbs 5.4-6.8 Nm
screws: FLHTCUTG
Removal
1. Remove lockset. See 2.18 TRUNK DOOR LOCKSET:
FLHTCUTG, Lockset.
2. See Figure 2-34. Remove four screws (8) to release latch
housing (4) from body.
2 3. Remove O-ring (3).
Lock Assembly Removal

1. Insert 1. See Figure 2-39. Remove two screws (1) and nuts (5) to
2. Retract release lock assembly (2) from latch housing.
Figure 2-37. Install U-clip 2. Disconnect lock arm from link (12). If necessary, remove
link from latch lever (11).
Lock Assembly Installation

1. If removed, attach latch link (12) to latch lever (11).
2. Engage arm of lock assembly to link.
3. Install lock assembly (2) into latch housing and secure
with two nuts (5) and screws (1). Tighten to 9-11 in-lbs
(1.0-1.2 Nm).
4. Verify operation of latch mechanism.

HOME
sm06908
3
2
1
7
6
11
10 9
12 8
1. Screw (2)
2. Lock assembly
3. Latch housing
4. Return spring
5. Nut (2)
6. Spring sleeve
7. Cover
8. Screw (2)
9. Screw (3)
10. Retainer plate
11. Latch lever
12. Latch link
Figure 2-39. Trunk Door Latch Assembly
Latch Mechanism Replacement Installation

1. See Figure 2-39. Disconnect return spring (4) and sleeve 1. See Figure 2-34. Use a small amount of grease to hold
(6). new O-ring (3) in place. Install latch housing assembly (4)
and secure with four screws (8). Tighten to 48-60 in-lbs
2. Remove three screws (9).
(5.4-6.8 Nm).
3. Remove retainer plate (10) and latch lever (11) from
2. Install lockset (1). See 2.18 TRUNK DOOR LOCKSET:
housing. Disconnect from link (12).
FLHTCUTG, Lockset.
4. Connect latch lever to link (12).
3. Check and adjust trunk door. See 2.17 TRUNK DOOR:
NOTE FLHTCUTG, Installation.
Screws (9) must be replaced with new. Do not use liquid
threadlocker or binding may occur.
5. Install latch lever (11) and retainer plate (10) and secure
with three new screws (9). Tighten to 8-10 in-lbs (0.9-1.1
Nm).
6. Install return spring (4).

HOME
LATCH PIN 4. Check door latch operation and adjust latch pin bracket
as necessary. See 2.17 TRUNK DOOR: FLHTCUTG,
FASTENER TORQUE VALUE Installation.
Trunk door latch pin jamnut: 48-72 in-lbs 5.4-8.1 Nm

sm06909
FLHTCUTG
3 1
Removal 2
1. See Figure 2-40. Hold latch pin with a wrench and loosen
jamnut (3).
2. Remove latch pin and jamnut.
Installation
1. Install latch pin with jamnut.
1. Surface of bracket
2. See Figure 2-40. Adjust the latch pin to 1.050 in (26.67 2. Adjustment dimension
mm) from surface of latch bracket to end of pin. Use a dial 3. Jamnut
caliper to measure distance (2).
Figure 2-40. Adjust Latch Pin
3. Hold latch pin and tighten jamnut (3) to 48-72 in-lbs (5.4-
8.1 Nm).

HOME
TRUNK DOOR: FLRT 2.19

REPAIR Trunk Door Hinge
1. See Figure 2-42. Remove trunk door.
2. Remove screws (4). Remove hinge (3).
HD-25070 ROBINAIR HEAT GUN
3. Remove screws (1) and covers (2) if necessary.
FASTENER TORQUE VALUE 4. Secure hinge with screws (4). Tighten to 72-96 in-lbs (8.1-
Trunk door hinge to door 72-96 in-lbs 8.1-11.0 Nm 11.0 Nm).
screws: FLRT 5. If removed, install covers (2) with screws (1). Tighten to
Trunk door tether to door 16-22 in-lbs 1.8-2.5 Nm 25-35 in-lbs (2.8-3.9 Nm).
screws: FLRT
6. Install trunk door.
Trunk door hinge to body 72-96 in-lbs 8.1-11.0 Nm
screws: FLRT sm08411
Trunk door hinge cover 25-35 in-lbs 2.8-3.9 Nm

3
2
screws: FLRT
1
Trunk door striker screws: 72-96 in-lbs 8.1-11.0 Nm
FLRT
Trunk door striker pin: FLRT 35-40 ft-lbs 47.0-54.0 Nm
Removal 4
1. Remove screws to release lanyard from trunk door.
2. See Figure 2-41. Remove screws (2) from hinge (1).
Remove door.
Installation
1. Screw (4)
1. See Figure 2-41. Install hinge (1) with screws (2). Do not 2. Cover (L and R)
tighten. 3. Hinge
2. Center cast-in pins (4) on door with holes (3) in hinge. 4. Screw (6)
3. Tighten to 72-96 in-lbs (8.1-11.0 Nm). Figure 2-42. Trunk Door Hinge: FLRT
4. Install screws to secure lanyard to trunk door. Tighten to

16-22 in-lbs (1.8-2.5 Nm). Seal Inspection
1. Inspect for accumulation of dirt, grime or debris. Clean
sm08407
2 with warm soapy water, if necessary.
3 2. Inspect for damage or excessive wear. Replace if brittle,
cracked, torn or shredded.
3. Verify seal is adhered securely. Replace if seal is not
1 4 securely adhered at any point.
Seal Replacement
NOTE
The use of ROBINAIR HEAT GUN (Part No. HD-25070) may
improve seal removal.
1. Remove old seal and all residual adhesive using 3M
GENERAL PURPOSE ADHESIVE REMOVER or equi-
valent.
1. Hinge assembly
2. Screw (6) NOTE
3. Hole Do not touch the cleaned area with fingers after cleaning.
4. Pin
2. Thoroughly clean the surface around the door opening
Figure 2-41. FLRT Trunk Door using a clean cloth and isopropyl alcohol.

HOME
NOTE 2. Install striker assembly with screws (2). Tighten to 72-96

Install the new seal with the holes toward the inside of the in-lbs (8.1-11.0 Nm).
opening.
3. See Figure 2-44. If striker pin was removed:
3. See Figure 2-43. Beginning at the rear middle of the door, a. Install washer on pin so cupped side will face base.
peel back a few inches of backing material and adhere
the end (4) of the seal. Work only a few inches at a time. b. Align pin with mark on base.
NOTE c. Install flange nut. Tighten to 35-40 ft-lbs (47.0-54.0

To prevent the possibility of water intrusion, be careful the seal Nm).
flows smoothly around each corner and does not bunch or kink
at the corners. sm08409
4. Continue around the opening until the seal returns to the

point of beginning. Use care at the corners to prevent
bunching or kinking of the seal.
2 3
NOTE 1 4
Do not cut seal long. Doing so may cause seal to bunch
allowing a path of water intrusion.
5. Cut the seal squarely so the ends mate tightly together
but do not cut long.
6. After the entire seal is initially installed, go back around
the entire seal and press firmly in place to be sure it is
securely adhered. Visually inspect the seal contact.
7. Check and adjust trunk door. See 2.19 TRUNK DOOR: 1. Striker pin
FLRT, Adjust Trunk Door. 2. Cupped washer
3. Base
sm08408 4. Flange nut
3
Figure 2-44. Striker Assembly: FLRT
ADJUST TRUNK DOOR

2 4
1 Trunk door striker pin: FLRT 35-40 ft-lbs 47.0-54.0 Nm
1. Close the trunk door. Press down on the trunk door to

engage latch. Pull to make sure that trunk door is secure.
2. Visually compare gap on left (hinge) side to the right (latch)
side. Gap must be approximately the same.
1. Striker 3. Adjust striker pin:
2. Screw (3)
a. See Figure 2-44. Loosen nut (4) only enough to allow
3. Seal
pin (1) to move.
4. Ends
b. Adjust striker pin. Snug the nut.
Figure 2-43. Trunk Door Seal: FLRT
c. Close and latch door to assess gap. Repeat until gap
is approximately the same.
Striker
d. Tighten nut (4) to 35-40 ft-lbs (47.0-54.0 Nm).
1. See Figure 2-43. Remove screws (2). Remove striker
assembly. e. Close and open door to verify operation.

HOME
TRUNK DOOR LOCKSET: FLRT 2.20

LOCK AND LATCH ASSEMBLY 1. Remove latch assembly from body.
2. See Figure 2-46. Remove screws (2) securing latch cover
FASTENER TORQUE VALUE (4) to latch.
Trunk lock knob nut: FLRT 13-16 ft-lbs 17.6-21.7 Nm
3. Release cable from latch cover. Remove latch cover.
Trunk lock cover: FLRT 72-96 in-lbs 8.1-10.8 Nm
4. Assembly is the reverse of disassembly. Tighten screws
Trunk door latch: FLRT 96-120 in-lbs 10.8-13.6 Nm (2) to 20-25 in-lbs (2.3-2.8 Nm).
Trunk lock cover: FLRT 72-96 in-lbs 8.1-10.8 Nm 5. See Figure 2-45. Install latch (4) with screws (3). Tighten
Trunk latch cover screws: 20-25 in-lbs 2.3-2.8 Nm to 96-120 in-lbs (10.8-13.6 Nm).
FLRT
Trunk door latch: FLRT 96-120 in-lbs 10.8-13.6 Nm sm08410
4
3
Assembly Removal
1. See Figure 2-45. Remove screws (3) and latch (4).
2. Remove screws (2). Remove lock cover (5).
3. Release cable from retaining clips in trunk. Remove latch
2
assembly.
5
4. Remove nut (1) and tabbed washer. 1
5. Remove knob (6) from bore. 6
Assembly Installation
1. Inspect seal on knob. Replace if damaged. 1. Nut
2. See Figure 2-45. Install knob (6) with larger flat on threads 2. Screw (2)
facing up. 3. Screw (2)
4. Latch
NOTE 5. Lock cover
Install tabbed washer with tab toward body. 6. Knob
3. Install tabbed washer and nut (1). Tighten to 13-16 ft-lbs Figure 2-45. Trunk Door Lock Assembly: FLRT
(17.6-21.7 Nm).
4. Install lock cover (5) with screws (2). Tighten to 72-96
in-lbs (8.1-10.8 Nm). sm08414
1
5. Install latch (4) with screws (3). Tighten to 96-120 in-lbs
(10.8-13.6 Nm).
6. Secure cable in three retaining clips. 3
7. Adjust latch. See 2.22 BODY.
Lock Cover
1. See Figure 2-46. Remove lock cover (3) from body. 4
2. Remove retaining ring (1).
3. Disengage cable from lock cover (3) to separate. 2
4. Assembly is the reverse of disassembly.
1. Cable retainer
5. Verify the cable housing is securely installed in the lock
2. Screw (3)
cover.
3. Lock cover
6. See Figure 2-45. Install lock cover (5) with screws (2). 4. Latch cover
Figure 2-46. Trunk Door Lock Components: FLRT
Latch Cover
NOTE
The latch and cable are serviced as an assembly only.

HOME
TOUR-PAK 2.21
TOUR-PAK ADJUSTMENT
sm07996

Tour-Pak mounting nuts 60-72 in-lbs 6.8-8.1 Nm
Tour-Pak mounting nuts 60-72 in-lbs 6.8-8.1 Nm
NOTE
The Tour-Pak can be secured in either the forward or rearward
position.
1. See Figure 2-47. Separate Tour-Pak electrical connectors.
2. See Figure 2-48. Remove six flange nuts (3) to release
Tour-Pak and support from body.
1
3. Remove four flange nuts (2) to release Tour-Pak from
support. 2
4. Secure Tour-Pak in preferred position with flange nuts (2).
Tighten to 60-72 in-lbs (6.8-8.1 Nm) in a crosswise pat-
tern.
5. Attach Tour-Pak and support with six flange nuts (3).
6. See Figure 2-47. Mate Tour-Pak electrical connectors.
3
Secure to anchors.
1. Support
REMOVAL 2. Flange nut (4)
NOTE 3. Flange nut (6)
For Tour-Pak repair, see the service manual. Figure 2-48. Tour-Pak Mount
1. Remove Tour-Pak liner.
INSTALLATION
2. See Figure 2-47. Separate Tour-Pak electrical connectors.
3. See Figure 2-48. Remove six flange nuts (3) to release FASTENER TORQUE VALUE
Tour-Pak and support from body. Tour-Pak mounting nuts 60-72 in-lbs 6.8-8.1 Nm
4. Remove four flange nuts (2) to release Tour-Pak from Tour-Pak mounting nuts 60-72 in-lbs 6.8-8.1 Nm
support.
1. See Figure 2-48. Attach Tour-Pak to support with four
sm07449 flange nuts (2). Tighten to 60-72 in-lbs (6.8-8.1 Nm) in a
1
crosswise pattern.
2. Attach Tour-Pak and support with six flange nuts (3).
3. See Figure 2-47. Mate Tour-Pak electrical connectors.
4 Secure to anchors.
4. Install Tour-Pak liner.
2
1. Audio
2. CB antenna
3. Radio antenna
4. Rear lights
Figure 2-47. Tour-Pak Connectors

HOME
BODY 2.22
REMOVAL
sm08412
1. Remove seat.
PLACEHOLDER TRILOGY REAR LIGHTING
CONNECTOR
3. Remove side covers.
4. Remove trunk liner.
NOTE
FLRT: Remove liner in the following order:
• Bottom Figure 2-50. Rear Lighting Connector: FLRT
• Bulkhead panel
• Wrap-around INSTALLATION
5. See Figure 2-49 or Figure 2-50. Disconnect rear lighting
harness connector from main harness.
Body attachment screws 14-17 ft-lbs 19.0-23.1 Nm
6. Remove four lower screws and washers (internal). (inside trunk)
NOTE Body attachment screws (out- 23-28 ft-lbs 31.2-38.0 Nm
FLHTCUTG: The left-front fastener is used as a ground stud. side trunk)
Remove locknut with two flat washers from front left ground
Ground strap to forward stud 14-17 ft-lbs 19.0-23.1 Nm
stud. Remove ground strap.
(inside trunk)
7. Remove front fasteners and washers securing body to Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
intermediate frame (internal).
8. Remove two screws and washers to release front external NOTES
brackets from intermediate frame downtubes. • Clean all residual locking residue from screws.
9. Place towels on the muffler ends to protect against contact • Start all screws before tightening any. If any screws are
with the body. misaligned or difficult to start, the rear frame may not be
NOTE properly aligned. To align frame, loosen four intermediate-
FLRT: Due to the wrap-around design, lift the front of the body to-rear frame screws on each side and move rear frame
slightly and slide rearward to clear the rear frame. until all body fasteners align.
10. With assistance, lift body off rear frame. • If rear frame was adjusted, clean all locking agent from
screws and threaded holes, and adjust the panhard rod
as outlined in 2.24 REAR FRAME.
is07768
1. FLHTCUTG: Temporarily move the rear lighting harness
to the left side to prevent it from becoming trapped when
securing the body.
2. Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue) to all body fasteners.
Apply to the longer end of the ground stud on Tour-Pak
equipped models.
NOTE
FLRT: Due to the wrap-around design, lift the front of the body
slightly and slide forward onto the rear frame.
3. Place towels on the muffler ends to protect against contact
with the body.
4. With assistance, set the body in place.
Figure 2-49. Rear Lighting Connector: FLHTCUTG 5. Start the front lower left screw and washer.

HOME
6. FLHTCUTG: Start longer end of ground stud with washer 3. Install rack and Tour-Pak. See 2.21 TOUR-PAK.
to fasten left-front body to intermediate frame.
4. Secure ground strap to upper ground stud with washer
7. FLRT: Install two screws with washers to fasten body to and locknut. Tighten locknut to 96-120 in-lbs (10.8-13.5
intermediate frame. Nm).
8. Start all remaining screws and washers. 5. Install trunk door seal. See 2.22 BODY, Trunk Door Seal:
FLHTCUTG.
9. Tighten all internal screws to 14-17 ft-lbs (19.0-23.1 Nm).
6. Install trunk door latch assembly and lockset. See
10. Tighten two front (external) screws to 23-28 ft-lbs (31.2-
2.18 TRUNK DOOR LOCKSET: FLHTCUTG.
38.0 Nm).
7. Install trunk door. See 2.17 TRUNK DOOR: FLHTCUTG.
11. FLHTCUTG: Position flat washer on each side of ground
strap. Install on left-front stud with new locknut. Tighten DISASSEMBLY: FLRT
to 14-17 ft-lbs (19.0-23.1 Nm).
1. Remove screws securing passenger grab handles.
12. Mate rear lighting harness to main harness.
2. Remove screws securing bulkhead cover.
13. Install trunk liner.
3. Remove rear fenders. See 2.23 REAR FENDERS.
FLRT: Install in the following order:
a. Wrap-around 4. Remove rear lighting harness. See 7.9 REAR LIGHTS
HARNESS: FLRT.
b. Bulkhead panel
5. Remove screws securing trunk door tether reel to bulk-
c. Bottom head.
14. Install side covers. 6. Remove trunk door and hinge. See 2.19 TRUNK DOOR:
FLRT.
(6.8-7.9 Nm). 7. Remove trunk door lockset and latch assembly. See
2.20 TRUNK DOOR LOCKSET: FLRT.
ASSEMBLY: FLRT
locked in position. While riding, a loose seat can shift FASTENER TORQUE VALUE
causing loss of control, which could result in death or Trunk bulkhead cover screws 72-96 in-lbs 8.1-10.8 Nm
Trunk door tether reel screws: 72-96 in-lbs 8.1-10.8 Nm
16. Install seat. FLRT
DISASSEMBLY: FLHTCUTG Passenger grab handles: 96-120 in-lbs 10.8-13.6 Nm

FLRT
1. Remove Tour-Pak and rack. See 2.21 TOUR-PAK.
2. Remove locknut with flat washer to release ground strap 1. Install rear fenders. See 2.23 REAR FENDERS.
from upper ground stud. 2. Install rear lighting harness. See 7.9 REAR LIGHTS
3. Remove rear fenders. See 2.23 REAR FENDERS. HARNESS: FLRT.
4. Remove rear lighting harness. See 7.8 REAR LIGHTS 3. Install trunk bulkhead cover. Tighten to 72-96 in-lbs (8.1-
HARNESS: FLHTCUTG. 10.8 Nm).
5. Remove trunk door. See 2.17 TRUNK DOOR: FLHTCUTG. 4. Install trunk door latch assembly and lockset. See
2.20 TRUNK DOOR LOCKSET: FLRT.
6. Remove trunk door lockset and latch assembly. See
2.18 TRUNK DOOR LOCKSET: FLHTCUTG. 5. Install trunk door. See 2.19 TRUNK DOOR: FLRT.
7. Remove trunk door seal. See 2.22 BODY, Trunk Door 6. Install tether reel to bulkhead. Tighten to 72-96 in-lbs (8.1-
Seal: FLHTCUTG. 10.8 Nm).
7. Install passenger grab handles. Tighten to 96-120 in-lbs
ASSEMBLY: FLHTCUTG (10.8-13.6 Nm).
FASTENER TORQUE VALUE PASSENGER GRAB HANDLES: FLRT
Ground strap to upper stud: 96-120 in-lbs 10.8-13.5 Nm
FLHTCUTG FASTENER TORQUE VALUE
Passenger grab handle 96-120 in-lbs 10.8-13.6 Nm
1. Install rear fenders. See 2.23 REAR FENDERS. screws: FLRT
2. Install rear lighting harness. See 7.8 REAR LIGHTS
HARNESS: FLHTCUTG. Removal
1. Remove rear wheel. See 2.6 REAR WHEELS.

HOME
2. Remove two screws securing the grab handle. Remove

sm07002a
grab handle.
Installation
1. Install the grab handle with long standoff toward the front.
2. Install rear wheel. See 2.6 REAR WHEELS.
REPAIR
Threaded Inserts
NOTE
Not all threaded inserts are serviceable. Refer to the parts
catalog before continuing to be sure the damaged insert can
be replaced. Figure 2-52. Apply Adhesive
1. See Figure 2-51. Remove damaged insert. Thread in a
bolt or tap and use pliers to pull insert from body.
sm07004a
2. Clean bonding area using isopropyl alcohol. Allow to dry
completely.
3. See Figure 2-52. Install new insert onto a bolt.
4. Thoroughly mix two-part epoxy that is recommended for
use on plastic. Roll insert in adhesive to apply adhesive
to insert.
5. See Figure 2-53. Tap insert into body until flush with sur-
face using a plastic hammer. Remove bolt.
NOTE
Do not use solvent to clean adhesive from threads or area
surrounding the insert. Weakening of the bond will result.
6. Carefully remove excess adhesive. If adhesive gets into
threads of insert, allow to cure and remove using a tap. Figure 2-53. Install Insert
7. Allow adhesive to cure at least 24 hours before applying

torque. TRUNK DOOR SEAL: FLHTCUTG
sm07003a
HD-25070 ROBINAIR HEAT GUN
Inspection
1. Inspect for accumulation of dirt, grime or debris. Clean
with warm soapy water, if necessary.
2. Inspect for damage or excessive wear. Replace if brittle,
cracked, torn or shredded.
3. Verify seal is adhered securely. Replace if seal is not
securely adhered at any point.
Replacement
NOTE
The use of ROBINAIR HEAT GUN (Part No. HD-25070) may
Figure 2-51. Remove Insert improve seal removal.
1. Remove old seal and all residual adhesive using 3M
GENERAL PURPOSE ADHESIVE REMOVER or equi-
valent.
NOTE
Do not touch the cleaned area with fingers after cleaning.

HOME
2. Thoroughly clean the surface around the door opening

sm06538
using a clean cloth and isopropyl alcohol.
1
NOTE
Install the new seal with the holes toward the inside of the
opening.
3. See Figure 2-54. Beginning at the bottom middle of the
opening, peel back a few inches of backing material and
adhere the end (2) of the seal even with the edge of the
flange as shown in Figure 2-55. Work only a few inches
at a time.
NOTE
To prevent the possibility of water intrusion, be careful the seal
flows smoothly around each corner and does not bunch or kink 2
at the corners.
4. Continue around the opening until the seal returns to the 1. Seal, trunk door (cut to fit)
point of beginning. Use care at the corners to prevent 2. Ends of seal
bunching or kinking of the seal.
Figure 2-54. Trunk Door Seal
NOTE
Do not cut seal long. Doing so may cause seal to bunch
allowing a path of water intrusion.
sm06804
2 3
5. Cut the seal squarely so the ends mate tightly together
but do not cut long. A gap of up to 0.062 in (1.6 mm) is
allowed.
1
6. After the entire seal is initially installed, go back around
the entire seal and press firmly in place to be sure it is
securely adhered. Visually inspect the seal contact.
7. Check and adjust trunk door. See 2.17 TRUNK DOOR:
FLHTCUTG, Installation.
1. Trunk door seal

2. Hole
3. Edge of door opening flange
Figure 2-55. Cross Section of Gasket Placement

HOME
REAR FENDERS 2.23

REMOVAL
NOTE
Be sure that all lights and switches operate properly before
Rear fender replacement does not require body removal. operating motorcycle. Low visibility of rider can result in
1. Remove rear wheel. See 2.6 REAR WHEELS. death or serious injury. (00316a)
2. Remove tail lamp/turn signal. 8. Check operation of all lamps.
3. FLHTCUTG: If necessary, remove tail lamp base (incan- Tail Lamp Bracket: FLRT
descent type) or bracket (LED type). See 7.6 TAIL
See Figure 2-57. Tighten screws (1) to 72-96 in-lbs (8.1-10.8
LAMPS/REAR TURN SIGNALS.
Nm).
4. Feed tail lamp connector through opening to inboard side
of fender. sm06124a
5. Release rear lighting harness from anchor clips in fender

well. Feed harness through holes to underside of body.
NOTE
If threaded body insert spins, hold it with a wrench from inside
the trunk.
6. Remove six screws with flat washers to release fender
from body.
Tail Lamp Bracket: FLRT

1. See Figure 2-57. remove screws (1).
2. Remove tail lamp bracket (2).
INSTALLATION Figure 2-56. FLHTCUTG

Fender, rear, screws 108-132 12.2-14.9 Nm sm08403
in-lbs
Tail lamp bracket: FLRT 72-96 in-lbs 8.1-10.8 Nm
1. See Figure 2-56 or Figure 2-57. Inspect adhesive rubber

pads on side of body. Replace if necessary.
2. Apply LOCTITE 243 MEDIUM STRENGTH THREAD- 2
LOCKER AND SEALANT (blue) to threads of six screws.
3. Install screws with flat washers to fasten fender to body.
4. Route rear lighting harness through hole to inboard side
1
of fender. Capture harness in anchor clips in fender well.
5. Connect and install tail lamp/turn signal. See 7.6 TAIL 1. Screw (4)
LAMPS/REAR TURN SIGNALS. 2. Tail lamp bracket
6. If installing new fender: Figure 2-57. FLRT

a. All except HDI: Install new reflector on side of fender.
Center reflector over rear axle and 0.75 in (19.1 mm)
above the bottom edge of the fender.
b. HDI: See Figure 2-58. Install new reflector on rear
tip of fender.
7. Install rear wheel. See 2.6 REAR WHEELS.

NOTE

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sm08404
1
1. 0.25-0.75 in (6.3-19.1 mm)
2. 2.8-3.3 in (71-84 mm)
Figure 2-58. Install Rear Fender Reflector: FLHTCUTG

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REAR FRAME 2.24

REMOVAL ASSEMBLY
1. Remove body. See 2.22 BODY. 1. Install rubber mount into rear frame bracket.
2. Release both mufflers from mounting brackets. 2. Install muffler bracket into rubber mount.
3. Repeat step on other side.
INSTALLATION
tacts both lower frame tubes where down tubes and lower FASTENER TORQUE VALUE
members, oil pan, mounting brackets, components or Rear frame screws 41-45 ft-lbs 55.6-61.0 Nm
housings. Failure to comply can cause serious damage Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm
Muffler bracket screws 14-18 in-lbs 19.0-24.4 Nm
3. Place jack under frame, positioned to lift rear of motor-
cycle. See 1.2 LIFTING MOTORCYCLE WITH A JACK. NOTE
Lift rear of motorcycle until rear tires are just touching. Clean threadlocking compound from all fasteners and threaded
4. Cut cable straps securing parking brake cable to rear holes prior to assembly.
frame. 1. See Figure 2-59. Install rear frame onto intermediate frame
5. See Figure 2-59. Remove upper shock screws from both bosses (4).
sides. 2. Apply LOCTITE 262 HIGH STRENGTH THREADLOCKER
6. Disconnect panhard rod from right side axle pinch block. AND SEALANT (red) and start eight screws (3) with
See 2.30 PANHARD ROD. washers. If reusing original rear frame, align marks made
during removal.
7. If rear frame is to be reused, make vertical and horizontal
alignment marks between intermediate frame boss (4) and 3. If installing a new rear frame, side-to-side level of rear
rear frame (2) on each side. Remove eight screws with frame should be checked:
washers to release rear frame from intermediate frame. a. Set the vehicle on a flat level surface.
8. Remove rear frame from intermediate frame bosses. b. Set the front wheel straight forward.
c. Check the front wheel with an inclinometer on either
sm06125a front brake disc to verify it is vertical.
4 3
NOTE
2 Comparison of front to rear measurement is not critical.
The side-to-side measurement of the front pair of tabs or
1 rear pair is the important measurement.
d. See Figure 2-60. Measure the distance from the level
surface to the top of each body mounting tab.
e. Adjust rear frame until the side-to-side measurement
of either pair of tabs are within 0.125 in (3.17 mm) of
each other.
3 4. Tighten screws to 41-45 ft-lbs (55.6-61.0 Nm) in a cross-

wise pattern.
1. Upper shock screw
2. Rear frame NOTE
3. Rear frame screw The length of the panhard rod must be adjusted whenever a
4. Intermediate frame boss new rear frame is installed. If installing the original rear frame,
the rod may not require adjustment. Verify adjustment and
Figure 2-59. Rear Frame (Left Side)
adjust as necessary. See 2.30 PANHARD ROD, Adjustment.
5. Install and adjust panhard rod. See 2.30 PANHARD ROD,
DISASSEMBLY Installation.
1. Remove muffler brackets from rubber mounts. Remove 6. Apply LOCTITE 262 HIGH STRENGTH THREADLOCKER
rubber mounts from rear frame brackets. AND SEALANT (red) and install upper shock screws.
2. Remove nut and flat washer to release eyelet of panhard Tighten screws to 55-60 ft-lbs (74.6-81.4 Nm).
rod and two nylon bushings from weld stud.

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7. Fasten mufflers to rubber-mounted brackets using screws

sm07236
with lockwashers. Tighten screws to 14-18 in-lbs (19.0-
24.4 Nm).
8. Secure parking brake cable to rear frame with new cable
straps.
9. Install body. See 2.22 BODY.
Figure 2-60. Measure Rear Frame

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INTERMEDIATE FRAME 2.25

REMOVAL
sm06473b
1. Separate rear lighting harness connector from main har-
ness. Remove connector anchor.
2. Remove top caddy and lay aside. Remove battery. See
service manual.
1
3. Feed harnesses and radio antenna cable into battery box.
4. Cut cable straps to release harnesses from upper frame
tubes.
5. Remove body. See 2.22 BODY.
6. Remove rear frame. See 2.24 REAR FRAME. 2 3
7. See Figure 2-61. Remove two screws (2) to release battery
tray. 1. Rear caddy screw
8. Disconnect BAS connector. See 7.10 BANK ANGLE 2. Upper frame screws
SENSOR (BAS). 3. Lower frame screw
9. Remove air valve from right side of intermediate frame Figure 2-62. Left Side Frame
and cut cable straps to release air tubes. Draw air valve
and tubes out through opening at rear of intermediate DISASSEMBLY
frame.
1. Remove two screws to release frame connection bracket
10. Cut cable straps securing reverse motor cables (if (both sides).
equipped) from right side intermediate frame.
2. FLHTCUTG: Remove two screws to release passenger
11. See Figure 2-62. Remove screw (1) to release rear of left handrail.
side caddy.
3. Remove two screws to free BAS and bracket.
12. Remove three screws (2, 3) and washers from each side
and remove intermediate frame. 4. Remove side cover grommets, if necessary (three each
side).
sm07546
ASSEMBLY
1 FASTENER TORQUE VALUE
Frame connection bracket 41-45 ft-lbs 55.6-61.0 Nm
screws
Passenger handrail screws 60-96 in-lbs 6.8-10.9 Nm
Bank angle sensor bracket 72-108 in-lbs 8.1-12.2 Nm
screws
2
NOTE
Orient frame connection brackets so that the threaded hole is
toward the front.
1. Install frame connection brackets to intermediate frame.
Tighten to 41-45 ft-lbs (55.6-61.0 Nm).
2. FLHTCUTG: Install passenger handrail. Tighten to 60-96
in-lbs (6.8-10.9 Nm).
3. Install side cover grommets.
4. Install BAS and bracket. Tighten to 72-108 in-lbs (8.1-
12.2 Nm).
1. Top caddy fasteners
2. Rear battery tray fasteners
Figure 2-61. Upper Caddy Fasteners

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INSTALLATION 5. Route air valve and tubes in through opening at rear of

intermediate frame and secure air valve to frame. Tighten
FASTENER TORQUE VALUE to 12-15 in-lbs (1.4-1.7 Nm). Install cap.
Intermediate frame screws 40-45 ft-lbs 54.2-61.0 Nm 6. See Figure 2-64. Install three new cable straps to secure
air tubes.
Left electrical caddy screw 72-96 in-lbs 8.1-10.9 Nm
Air valve nut 12-15 in-lbs 1.4-1.7 Nm 7. See Figure 2-61. Secure battery tray with screws (2).
Battery tray screws 72-96 in-lbs 8.1-10.9 Nm
8. Route Tour-Pak lights harness and radio antenna cables
1. Fit the intermediate frame to the main frame and start two back through left side of intermediate frame.
lower screws and hardened washers. Install four remaining 9. Install new cable straps to secure harnesses to upper left
upper screws and hardened washers. and right frame tubes.
2. See Figure 2-63. Tighten screws in the sequence shown 10. Install battery and top caddy. See the service manual.
to 40-45 ft-lbs (54.2-61.0 Nm).
11. Install rear frame. See 2.24 REAR FRAME.
3. See Figure 2-62. Install screw (1). Tighten to 72-96 in-lbs
(8.1-10.9 Nm). 12. Install body. See 2.22 BODY.
4. Install new cable straps to secure reverse motor energizer 13. Connect rear lighting harness to main harness. Push
lead and power cable, reverse control module harness, connector anchor into hole in rear of intermediate frame.
and HO2 sensor harnesses to intermediate frame right
upper tube.
sm05936
1
6
Figure 2-63. Intermediate Frame Screw Torque Sequence

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sm05946
Figure 2-64. Secure Air Tubes Using Three Cable Straps

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FRONT FORK 2.26

SERVICING FORKS 2. Follow the procedure in the service manual to remove and
repair forks.
Front fork service is the same as two-wheeled vehicles with
the following exceptions: Fork Installation: FLRT
• Initially fill with slightly more than 26 fl oz (770 cc). 1. Follow the procedure in the service manual to install forks.
• Set oil level gauge to 3.78 in (96 mm). 2. Install headlamp nacelle. See 2.31 HEADLAMP NACELLE.
Fork Removal: FLRT

1. Remove headlamp nacelle. See 2.31 HEADLAMP
NACELLE.

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REAR FORK 2.27

REMOVAL 14. See Figure 2-66. Remove two fasteners (6) to free rear
fork bracket (4).
15. Remove chrome plug (5) from right side rear fork bracket.
Disconnect negative (-) battery cable first. If positive (+) NOTES

cable should contact ground with negative (-) cable con- • Use a 6-point socket for removal of the pivot shaft locknuts.
nected, the resulting sparks can cause a battery explosion, • Use an air impact wrench to remove the right-side nut.
which could result in death or serious injury. (00049a) Applying heat to the right-side nut may also improve
1. Disconnect battery negative cable. removal. If the left-side nut loosens first, remove left-side
mount and use double 1/2-20 nuts to hold pivot shaft while
2. Remove body. See 2.22 BODY. removing right-side nut.
3. Remove left side muffler and crossover pipe. See the 16. Hold left side locknut (7) and use an air impact wrench to
service manual. Discard exhaust clamp and gasket. remove locknut (13) from right side of pivot shaft. Discard
4. Release brake lines from four cable clips on top of rear locknut.
fork. 17. Remove cup washer (3) from right side of pivot shaft and
5. Remove brake line manifold from rear fork stud. discard.
18. Tap pivot shaft (11) toward left side of motorcycle.
19. Pull pivot shaft assembly with locknut (7), cup washer (3),
When lifting a motorcycle using a jack, be sure jack con- rubber mount (8) and outer spacer (9) out of transmission
tacts both lower frame tubes where down tubes and lower and rear fork.
frame tubes converge. Never lift by jacking on cross- 20. Work rear fork free of transmission mount. Carefully lower
members, oil pan, mounting brackets, components or rear fork and remove.
resulting in the need to perform major repair work. (00586d) 21. Remove outer spacer (9) from right side rear fork tube.
NOTE 22. If necessary, remove rubber mount (14) from right side.
The center of gravity is toward the rear of the motorcycle. Verify
23. Clamp the pivot shaft assembly in a vise with soft jaws
that front wheel is secured in wheel vise and tie down straps
and disassemble:
are in place when lifting rear wheels.
a. Remove locknut (7) and discard.
6. Position jack under motorcycle to support rear of main
frame. See 1.2 LIFTING MOTORCYCLE WITH A JACK. b. Remove cup washer (3) and left mount (8).
NOTE 24. If necessary, remove adapter plates from axle housing.

Repeat the following steps for both sides of the rear fork.
7. See Figure 2-65. To aid in initial alignment during sm06443a
1
assembly, use a paint pen to mark the adjustment screw 2
(4) where it exits the front of adapter plate on both sides
of motorcycle.
8. Loosen the jamnut. Turn the adjustment screw in as far
as it will go.
9. Loosen four pinch block bolts (1). 3
NOTE
Removal of lower screws in left side fork flange will also release
parking brake equalizer bracket.
10. Remove four screws (3).
4
11. Push adapter plates (2) toward axle housing until flange
1. Bolt, pinch block (4 per side)
contacts pinch block.
2. Adapter plate
12. Place a jack under rear of oil pan to support transmission. 3. Screw, adapter plate (4 per side)
4. Adjustment screw
13. Remove both passenger footboards and brackets.
Figure 2-65. Rear Fork

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sm06450
4
3 5
2
6
7
1 8
9
10
14
3 11
12
9
5
13
1. Adjustment screw and jamnut (2)

2. Adapter plate (2)
3. Cup washer (2)
4. Rear fork bracket
5. Chrome plug (2)
6. Fastener (2)
7. Pivot shaft locknut, left side
8. Left mount
9. Outer spacer (2)
10. Screw, adaptor plate (4 each side)
11. Pivot shaft
12. Bearing (2)
13. Pivot shaft locknut, right side
14. Right mount
Figure 2-66. Rear Fork Components
REPAIR Bearing Installation

1. Bearings and spacers must be assembled before installa-
PART NUMBER TOOL NAME tion.
HD-45327 REAR FORK BEARING INSTALLER a. Place new bearing flat on suitable press plate.
HD-49796 BEARING SPACER TOOL b. See Figure 2-67. With the collar topside, start spacer
into bearing.
Bearing Removal c. Press spacer until it bottoms against bearing.
See the service manual for bearing removal instructions.

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sm02930 SM06485
2
1
2
1. Spacer
2. Bearing
Figure 2-67. Press Spacer into Bearing
1. Bearing installer
2. Fork tube
sm03535
Figure 2-69. Install Left Rear Fork Bearing
6. See Figure 2-70. Remove tool and turn rear fork over with
left side (4) resting on a socket (5) large enough to contact
the outer race of the left bearing.
1 2 NOTE
If BEARING SPACER TOOL (Part No. HD-49796) is unavail-
able, one can be fabricated using a piece of steel at least the
diameter of the flanges on inner bushings. Machine the tool to
the length of 4.507 +0.002/ -0.000 in. (114.35 +0.051/ -0.000
1. Drive side driver mm).
2. Brake side driver 7. Place BEARING SPACER TOOL (Part No. HD-49796) (3)
Figure 2-68. Rear Fork Bearing Installer centered on lower bearing and parallel to cutout between
bearing bosses. Press right-side bearing using tool
stamped "Drive Side" (1). Press bearing until it just con-
2. Coat the bearing bores in the rear fork and OD of bearings tacts end of spacer tool. Shoulder on press tool will not
with a light coat of SPECIAL PURPOSE GREASE. make contact with fork tube. Bearing press depth is correct
3. See Figure 2-69. Support fork squarely on press bed with when spacer tool can be rotated by hand with a slight drag.
the left side on top.
4. Insert bearing into fork assembly with spacer down.
NOTE
Note that the drivers supplied with the REAR FORK BEARING
INSTALLER (Part No. HD-45327) are stamped "BRAKE SIDE"
and "DRIVE SIDE". Use the "DRIVE SIDE" driver for both sides.
5. Using REAR FORK BEARING INSTALLER (Part No. HD-
45327) (1) stamped "Drive Side", center driver under ram
and press bearing until bearing is bottomed in fork tube
(2).

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positions. Install left side fork bracket (4) fitting index tab
sm06466
into rubber mount slot.
9. Apply two drops of LOCTITE 243 MEDIUM STRENGTH
1 THREADLOCKER AND SEALANT (blue) to fork bracket
fasteners (6). Secure fork bracket. Tighten to 55-65 ft-lbs
2 (74.6-88.1 Nm).
3 NOTE
Never reuse locknuts or cup washers when assembling the
rear fork pivot shaft components.
10. Install new cup washer (3) on left side with concave side
4 facing the mount. Be sure that cup washer is over shoulder
on shaft and start the locknut (7).
11. Slide new cup washer (3) onto right side of pivot shaft with
the concave side facing the mount.
5
12. Be sure that cup washer is over shoulder on shaft and
1. Tool labeled "Drive Side" install new locknut (13) onto right side of pivot shaft. Hold
2. Right side housing one locknut and tighten the other locknut to 50 ft-lbs + 180
3. Spacer tool degrees additional rotation (67.8 Nm + 180 degrees
4. Left side housing additional rotation).
5. Socket 13. Verify that rear fork assembly moves freely.
Figure 2-70. Install Right Rear Fork Bearing 14. Start screws to fasten adapter plates to rear fork flanges.
Capture parking brake equalizer bracket on left side using
INSTALLATION longer screws in lower holes.
15. Tighten screws in a crosswise pattern until snug. Final
FASTENER TORQUE VALUE torque will be applied during lateral alignment.
Rear fork bracket bolts 55-65 ft-lbs 74.6-88.1 Nm 16. Adjust lateral alignment. See 2.28 LATERAL ALIGNMENT.
Rear fork pivot shaft locknut 50 ft-lbs + 180 67.8 Nm + 180
17. Secure brake line tee to rear fork stud using a new locknut.
degrees addi- degrees addi-
Tighten locknut to 59-63 in-lbs (6.7-7.1 Nm).
Brake line, rear, tee locknut 59-63 in-lbs 6.7-7.1 Nm 18. Capture brake lines in cable clips on top of rear fork.
19. Adjust drive belt deflection. See 1.11 DRIVE BELT,
1. Clean all residual locking agent from the threads of the Checking Drive Belt Deflection.
pivot shaft.
20. Install left side muffler and cross-over pipe using a new
2. See Figure 2-71. If removed, install rubber mount on inner- clamp and gasket. See the service manual.
right side of frame with the slot on the outboard side
between the 12 and 1 o'clock positions. Make sure that 21. Install body. See 2.22 BODY.
index tab in mount cavity fully engages slot in rubber
mount. sm05797
3. See Figure 2-66. Place outer spacer (9) into right side rear
fork tube flange facing outward.
4. Place belt on inboard side of rear fork and work rear fork
into position on transmission mount.
5. Coat pivot shaft with ANTI-SEIZE LUBRICANT. Avoid
getting anti-seize on threads of pivot shaft.
6. Install pivot shaft (11) from left side of motorcycle, through
left side fork and transmission mount. Guide end of pivot
shaft through hole in right rubber mount. Use jack under
oil pan to align components as necessary.
7. With the flange facing outward, slide outer spacer (9) onto
left end of pivot shaft. Figure 2-71. Right-Side Mount
8. Install left mount (8) with the flat side facing outer spacer.
Rotate mount so the slot is between the 11 and 12 o'clock

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LATERAL ALIGNMENT 2.28

PROCEDURE 9. Tighten adapter plate screws to 41-45 ft-lbs (55.6-61.0
FASTENER TORQUE VALUE 10. Install rear wheels. See 2.6 REAR WHEELS.
Axle adapter plate screws 41-45 ft-lbs 55.6-61.0 Nm
NOTE
1. Remove rear wheels. See 2.6 REAR WHEELS. km) after wheel installation.
2. Rotate differential by hand to observe belt tracking along 11. Adjust and connect panhard rod. See 2.30 PANHARD
top of drive belt. ROD.
NOTE
Verify there is adequate clearance between belt and battery sm06127
box after adjustment. Belt tracking does not need to be equal
distance from frame and battery box.
3. Check lateral alignment as follows:
a. See Figure 2-72. Secure magnetic base laser or hold
a long straight edge against axle flange with laser
beam directed forward.
NOTE
Fore/aft axle alignment must be within 0.062 in. (1.6 mm)
to provide an accurate lateral alignment check. See
1.11 DRIVE BELT.
b. See Figure 2-73. Remove chrome plug from fork
bracket. Measure distance from end of pivot shaft nut
to light beam or straight edge on both sides. Figure 2-72. Place Laser Against Axle Flange
c. Measurements A and B must be within 0.062 in. (1.6
mm). If adjustment is necessary, proceed to the next
step. sm06128
A B
4. Remove screw retaining panhard rod to right axle clevis.
5. Loosen eight axle-to-adapter plate screws and move axle
housing left or right until alignment is within specification.
6. Verify that belt does not contact battery box or frame.
7. Install chrome plugs in rear fork brackets.
Figure 2-73. Measure Both Sides
8. Remove one adapter plate screw at a time and clean
threads as follows:
a. Remove all residual thread locking compound from
hole in adapter plate. Use compressed air to blow out
any debris.
b. If reusing screw, completely remove all thread locking
compound.
c. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) and install
screw finger-tight.
d. Repeat steps for all remaining adapter plate screws.

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SHOCK ABSORBERS 2.29

REMOVAL 1. If removed, install three screws to fasten lower shock
mount to pinch blocks.
PART NUMBER TOOL NAME a. Using an appropriate thread chaser, completely
remove all residual threadlocking compound from
HD-34633 AIR SUSPENSION PUMP AND GAUGE
holes in pinch block. Use compressed air to blow out
any debris.
b. If reusing screws, completely remove all threadlocking
2. Place jack to support rear of motorcycle frame. See compound using a wire brush or wire wheel, and then
1.2 LIFTING MOTORCYCLE WITH A JACK. apply LOCTITE 243 MEDIUM STRENGTH
3. Using the no-loss AIR SUSPENSION PUMP AND GAUGE THREADLOCKER AND SEALANT (blue).
(Part No. HD-34633), add 3-5 psi (20.7-34.5 kPa) to purge c. Install screws with flat washers and tighten 41-45 ft-
lines of any oil. lbs (55.6-61.0 Nm).
4. Release air from shocks and remove air tube from com-
pression fitting. 2. Completely remove threadlocking compound from
threaded shock mounting holes using a thread chaser.
5. Remove upper shock mount screw. Completely remove threadlocking compound from shock
absorber mounting screws using a wire brush or wire
6. Raise jack until lower shock mount screw clears rear frame
wheel.
and remove screw.
3. Apply LOCTITE 262 HIGH STRENGTH THREADLOCKER
NOTE
AND SEALANT (red) to screw and fasten shock absorber
Always keep shock absorber upright in a fully vertical position.
to lower shock mount.
Laying shock absorber down can cause oil to drain out through
the compression fitting. Any loss of oil requires replacement 4. Lower jack until upper shock eye is aligned with rear frame
of the shock absorber. boss.
7. If necessary, remove three screws to release lower shock 5. Apply LOCTITE 262 HIGH STRENGTH THREADLOCKER
mount from pinch blocks. AND SEALANT (red) and start upper shock screw.
INSTALLATION 6. Tighten upper and lower screws to 55-60 ft-lbs (74.6-81.4

Nm).
FASTENER TORQUE VALUE 7. Connect air tube to compression fitting. Gently tug on tube
Pinch block screws 41-45 ft-lbs 55.6-61.0 Nm to verify that it is locked in place.
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 8. Pressurize air suspension system and check for leaks.
sm05974
NOTE
See Figure 2-74. The left and right side lower shock mounts
are not interchangeable but are not stamped for location. If
both have been removed, be sure that they are installed with
the boss on the outboard side.
Figure 2-74. Orient With Lower Shock Mount Boss

Outboard

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PANHARD ROD 2.30

REMOVAL 1. See Figure 2-75. Hold panhard rod so that long bend end
(11) is on the left side.
2. Place nylon bushing (3) on each side of left ball-end con-
2. See Figure 2-75. Remove screw (6) and flat washer (5) nector (12) and install on stud (4). Install flat washer (2)
from clevis (7). and new locknut (1). Verify nylon washers are correctly
3. Remove locknut (1) and flat washer (2) to release left ball- aligned and not being pinched. Tighten nut to 55-60 ft-lbs
end connector (12) and two nylon bushings (3) from stud (74.6-81.4 Nm).
(4) on rear frame rail. 3. Secure right ball-end connector (8) in clevis (7) at top of
right side pinch block with screw (6) and flat washer (5).
INSTALLATION Tighten to 55-60 ft-lbs (74.6-81.4 Nm).
FASTENER TORQUE VALUE NOTE
Adjust the panhard rod whenever a new rod, a new rear frame
Panhard rod locknut 55-60 ft-lbs 74.6-81.4 Nm
or a new axle/differential housing are installed, or if the rod is
Panhard rod clevis screw 55-60 ft-lbs 74.6-81.4 Nm suspected of being misadjusted. See 2.30 PANHARD ROD,
Adjustment, if necessary.
NOTE
Panhard rod is directional and can cause damage if installed
backwards. Take care to orient the rod correctly.
sm05922
4 5
A
2
1
12 11 10
9 8
1. Locknut 7. Clevis
2. Flat washer 8. Right ball-end connector
3. Nylon bushing 9. Right end jamnut
4. Stud 10. Short bend end
5. Flat washer 11. Long bend end
6. Screw 12. Left ball-end connector
Figure 2-75. Panhard Rod

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ADJUSTMENT 4. With the left ball-end connector (12) attached, position the
right ball-end connector (8) in clevis (7) at the top of the
FASTENER TORQUE VALUE right side pinch block. Verify that screw (6) passes
smoothly through the clevis and ball-end connector.
Panhard rod clevis screw 55-60 ft-lbs 74.6-81.4 Nm
5. If adjustment is not correct, loosen jamnut (9), remove
Panhard rod adjustment 25-35 ft-lbs 33.9-47.5 Nm
ball-end connector from clevis and adjust length until screw
jamnut
(6) passes through easily.
Panhard rod adjustment 25-35 ft-lbs 33.9-47.5 Nm
jamnut 6. When adjustment is correct, secure ball-end connector
(8) in clevis with screw (6) and flat washer (5). Tighten to
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 55-60 ft-lbs (74.6-81.4 Nm).
NOTE NOTE
The panhard rod could contact the reverse ring gear if not
Adjust the panhard rod whenever a new rod, a new rear frame
positioned properly. Be sure to hold panhard rod up and away
or a new axle/differential housing are installed, or if the rod is
from the differential when tightening the right adjustment
suspected of being misadjusted.
jamnut.
1. Raise the vehicle using a suitable lifting device so the rear
7. Loosen left ball-end connector jamnut. Hold panhard rod
tires are just touching the lift. See 1.2 LIFTING MOTOR-
up as far as it will easily rotate and tighten right jamnut (9)
CYCLE WITH A JACK.
to 25-35 ft-lbs (33.9-47.5 Nm).
NOTE
8. Allow panhard rod to rotate down slightly until right ball-
Adjustment is easiest with the rear tires and wheels installed.
end connector is approximately centered in clevis. Hold
If they have been removed, support the rear axle on each side
panhard rod in this position and tighten left jamnut to 25-
with equally adjusted jack stands.
35 ft-lbs (33.9-47.5 Nm).
2. See Figure 2-75. Disconnect the upper shock absorber
NOTE
screw on both sides. Move the shocks away from the
Completely clean threadlocking compound from threads of rear
upper mount and loosely install the upper screws to aid
shock screws and threaded holes.
making measurement.
9. Apply LOCTITE 262 HIGH STRENGTH THREADLOCKER
3. Adjust the jack until the distance (A) between the center
AND SEALANT (red) to upper shock screws and secure
of the upper shock mounting screw and lower shock eye
shock absorbers. Tighten screws to 55-60 ft-lbs (74.6-81.4
is 11.5 in. (292.0 mm) on both sides.
Nm).

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HEADLAMP NACELLE 2.31

REMOVAL 7. Remove screw securing clutch line P-clamp to nacelle.
1. Remove windshield if equipped. NOTE

Turn signal lamp/bracket assemblies are attached to the left
2. See Figure 2-76. Carefully pry off the fork lock trim insert and right rear covers (13) with double-sided tape. Separate
(1). Remove two screws (2). only if needed.
3. Lift the rear of the handlebar riser cover (3). Slide rearward 8. See Figure 2-76. Remove the turn signal lamp brackets
to release catch. (9).
4. Remove screws (4) securing top cover (5). Remove cover. a. Remove acorn nuts (6) and grommets (7).
5. Remove headlamp assembly. b. Remove lamp/bracket assemblies (9).

a. Remove screw (11) securing the headlamp.
9. Remove studs (8) from one side only. Leaving at least one
b. See Figure 2-77. Disconnect headlamp connector stud prevents the nacelle (12) from unexpectedly falling.
(1). Remove the headlamp assembly.
10. Remove the headlamp nacelle.
6. Disconnect both turn signal lamp connectors (2, 3) on the
steering head caddies.
sm08251
3
1
6
2 7
8
4
9
5
13
8 10
7
6 11
12
1. Trim insert 8. Stud (4)

2. Screw (2) 9. Lamp and bracket assembly
3. Riser cover 10. Headlamp assembly
4. Screw (2) 11. Screw
5. Top cover 12. Nacelle
6. Acorn nut (4) 13. Rear cover (right side shown)
7. Grommet (4)
Figure 2-76. Nacelle Assembly

HOME
sm08252
4 5
1. Headlamp connector 4. Left steering head caddy

2. Left turn signal connector 5. Right steering head caddy
3. Right turn signal connector
Figure 2-77. Turn Signal Connectors: FLRT
INSTALLATION 2. Install turn signal lamp/bracket.

a. Route lamp wires behind fork.
b. Install rear cover and lamp bracket. Secure with acorn
Headlamp nacelle acorn nuts 96-132 in-lbs 10.8-14.9 Nm nuts.
Headlamp mounting screw: 30-35 ft-lbs 40.7-47.5 Nm c. Verify that lamp wire is routed through relief in lower
FLRT portion of rear cover and behind fork.
Headlamp nacelle top cover 84-120 in-lbs 9.5-13.5 Nm
d. Tighten to 96-132 in-lbs (10.8-14.9 Nm).
screws
Handlebar cover screws: 10-20 in-lbs 1.1-2.3 Nm e. Repeat with remaining lamp/bracket assembly.
FLRT
3. See Figure 2-77. Mate turn signal lamp connectors (2, 3).
Clutch line P-clamp 40-48 in-lbs 4.5-5.4 Nm
4. Mate headlamp connector (1).
NOTE 5. See Figure 2-76. Install headlamp assembly. Secure with
Installing studs to full thread depth can allow the stud to contact screw (11). Tighten to 30-35 ft-lbs (40.7-47.5 Nm).
the fork. Only install until end of stud is visible on fork side of 6. Install top cover (5) with screws (4). Tighten to 84-120
threaded boss. in-lbs (9.5-13.5 Nm).
1. See Figure 2-76. Install headlamp nacelle housing on fork 7. Install the handlebar riser cover (3):
brackets.
a. Engage catch on riser cover (3) into nacelle. Lower
a. Apply LOCTITE 243 MEDIUM STRENGTH into position.
THREADLOCKER AND SEALANT (blue) to the fork
bracket end threads of stud. b. Install screws (2). Tighten to 10-20 in-lbs (1.1-2.3
Nm).
b. While holding nacelle housing in place, install stud in
each hole. Install only until end of stud is visible on c. Install fork lock plate (1).
fork side of threaded boss.
8. Secure clutch line P-clamp to nacelle. Tighten to 40-48
in-lbs (4.5-5.4 Nm).
9. Install windshield, if equipped.
10. Align headlamp. See 1.17 HEADLAMP ALIGNMENT.

HOME
STEERING DAMPER ASSEMBLY 2.32

REMOVAL 3. FLRT: See Figure 2-79. If removed, install frame damper
bracket.
NOTE
a. Secure frame damper mount (5) and special nut (4)
Use a clean shop towel to protect front fender while removing with screw (10).
damper.
b. Tighten to 22-28 ft-lbs (29.8-38.0 Nm).
1. See Figure 2-78 or Figure 2-79. Remove locknut (1), nylon
washer (2) and steering damper from frame bracket stud. NOTE
Install nylon washer (2) either above or below the steering
2. Remove acorn nut (8), spacer (7) and screw (6) to release
damper.
steering damper eyelet from side mounting bracket (9).
4. Install steering damper (3), nylon washer (2) and locknut
3. If necessary, remove side mounting bracket (9).
(1) onto frame bracket stud. Tighten locknut to 16-20 ft-
a. FLHTCUTG: Remove front left lamps and bracket. lbs (21.7-27.1 Nm).
See 7.5 FRONT LIGHTING: HDI, Lamps Bracket
(HDI) or the service manual (DOM). NOTE
FLHTCUTG: Install acorn nut (8) to the rear for clearance of
b. Remove double studs on left side. Remove bracket nearby components.
(9).
5. Insert screw (6) through side mounting bracket (9), spacer
a. FLRT: See Figure 2-79. Remove two screws (12). (7) and steering damper eyelet. Install acorn nut (8) and
tighten to 16-20 ft-lbs (21.7-27.1 Nm).
b. Remove bracket from fork bracket.
4. FLRT: See Figure 2-79. Remove screw (11). Release sm06289

clutch line P-clamp.
4 5
5. Remove screw (10), frame damper mount (5) and frame
bracket special nut (4).
INSTALLATION 10
Fairing double studs 120-180 13.6-20.3 Nm
in-lbs
Steering damper side bracket 120-180 13.6-20.3 Nm
acorn nuts: FLHTCUTG in-lbs 8
Steering damper side bracket 20-25 ft-lbs 27.1-33.9 Nm
to fork bracket screws: FLRT
Steering damper bracket to 22-28 ft-lbs 29.8-38.0 Nm
frame screw: FLRT
3 7 6
Steering damper locknut 16-20 ft-lbs 21.7-27.1 Nm
Steering damper acorn nut 16-20 ft-lbs 21.7-27.1 Nm
1. FLHTCUTG: See Figure 2-78. If removed, install side 2

mounting bracket (9): 1
a. Secure bracket with double studs. Tighten to 120-180
1. Locknut
in-lbs (13.6-20.3 Nm).
2. Nylon washer
b. Secure lamps bracket with acorn nuts. Tighten to 120- 3. Steering damper
180 in-lbs (13.6-20.3 Nm). 4. Frame bracket
5. Engine guard (Tri Glide models)
2. FLRT: See Figure 2-79. If removed, install side mounting 6. Screw
bracket: 7. Spacer
a. Secure bracket with two screws. 8. Acorn nut
9. Side mounting bracket
b. Tighten to 20-25 ft-lbs (27.1-33.9 Nm). 10. Screw
Figure 2-78. Steering Damper: FLHTCUTG

HOME
sm08401a
5 9 6
7
11
12
4
10
3 8
2
1
1. Locknut
2. Nylon washer
3. Steering damper
4. Frame bracket special nut
5. Frame damper mount
6. Screw
7. Spacer
8. Acorn nut
9. Side mounting bracket
10. Screw
11. Screw, P-clamp
12. Screw (2)
Figure 2-79. Steering Damper: FLRT

HOME
ENGINE STABILIZER 2.33

STABILIZER LINK NOTE
Be sure to install spacers (7) as shown.
FASTENER TORQUE VALUE 4. Attach bracket to cylinder head with screws, washers and
Engine stabilizer link screws 30-35 ft-lbs 40.7-47.5 Nm spacers. Tighten screws (6) to 30-35 ft-lbs (40.7-47.5 Nm).
Engine stabilizer bracket 30-35 ft-lbs 40.7-47.5 Nm 5. Attach stabilizer link to bracket with screw (3) and washer
screws (2). Place washer between link and attaching point.
Engine stabilizer link screws 30-35 ft-lbs 40.7-47.5 Nm 6. Tighten to 30-35 ft-lbs (40.7-47.5 Nm).
Removal sm06895
1. See Figure 2-80. Remove screws (3) and washers (2) 3 4

from each end of stabilizer link (4).
2
2. Remove link.
3. Check each end of the stabilizer link for excessive wear.
The spherical ball end may rotate freely, but should not
have any lateral movement. Replace the link if lateral 1
movement exists.
Installation
1. See Figure 2-80. Secure stabilizer link with screws (3) and
washers (2) between link and attaching point. 5
2. Tighten to 30-35 ft-lbs (40.7-47.5 Nm). 7
Bracket 6
1. See Figure 2-80. Disconnect stabilizer link from bracket
(1).
1. Stabilizer bracket
2. Remove two screws (6) and washers (5). Remove bracket 2. Washer (2)
(1) and spacers (7) from cylinder head. 3. Screw (2)
4. Stabilizer
3. Apply LOCTITE 272 HIGH STRENGTH/HIGH TEMPER-
5. Washer (2)
ATURE THREADLOCKER AND SEALANT (red/orange)
6. Screw (2)
to threads of screws (6).
7. Spacer (2)
Figure 2-80. Engine Stabilizer

NOTES

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
3.1 SPECIFICATIONS: ENGINE......................................................................................................3-1
ENGINE
NOTES
HOME
SPECIFICATIONS: ENGINE 3.1

GENERAL SPECIFICATIONS: TWIN CAM
Table 3-3. Oiling System
103™
OIL PUMP DATA
Table 3-1. Engine: Air-Cooled High Output Twin Cam 103 Type Twin gerotor, dual scavenge, crank
mounted and driven, internal oil pump,
ITEM SPECIFICATION dry sump
Number of cylinders 2 Pressure 30-38 PSI (207-262 kPa) at 2000 RPM
Type 4-cycle, 45 degree and normal operating temperature of 230
V-Type, air-cooled °F (110 °C)
Compression ratio 9.7:1 Filtration 5 micron media, filtered between pump
and engine
Bore 3.875 in 98.42 mm
Cooling: Twin Cam Thermostat controlled oil cooler
Stroke 4.374 in 111.1 mm
103™ (Air-cooled models only)
Displacement 103.1 in3 1690 cm3
Lubrication system Pressurized, dry sump
with oil cooler
Table 3-2. Engine: Twin-Cooled High Output Twin Cam

103
ITEM SPECIFICATION
Number of cylinders 2
Type 4-cycle, 45 degree
V-Type, Twin-Cooled™
Compression ratio 10.0:1
Bore 3.875 in 98.42 mm
Stroke 4.374 in 111.1 mm
Displacement 103.1 in3 1690 cm3
Lubrication system Pressurized, dry sump
Cooling system Liquid-cooled cylinder heads
with lower fairing-mounted radiators,
electric pump and thermostat
2015 Trike Service Supplement Engine 3-1

NOTES
3-2 2015 Trike Service Supplement Engine

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
4.1 FUEL SYSTEM..........................................................................................................................4-1
FUEL SYSTEM
NOTES
HOME
FUEL SYSTEM 4.1

NO UNIQUE CONTENT
Any information not presented in this supplement can be found
in the service manual.
2015 Trike Service Supplement Fuel System 4-1

NOTES
4-2 2015 Trike Service Supplement Fuel System

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
5.2 SPECIFICATIONS.....................................................................................................................5-2
5.3 CLUTCH....................................................................................................................................5-3
5.4 AXLE..........................................................................................................................................5-4
5.5 AXLE HOUSING/DIFFERENTIAL.............................................................................................5-7
5.6 DRIVE BELT REPLACEMENT................................................................................................5-11
DRIVE
NOTES
HOME

CHAPTER
in this chapter.

Air valve nut 12-15 in-lbs 1.4-1.7 Nm 5.5 AXLE HOUSING/DIFFERENTIAL, Installation
Axle bearing retainer locknuts 40-45 ft-lbs 54.2-61.0 Nm 5.4 AXLE, Installation/Use new locknuts
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 5.5 AXLE HOUSING/DIFFERENTIAL, Installation
Brake reaction plate screws 40-45 ft-lbs 54.2-61.0 Nm 5.4 AXLE, Installation
Differential assembly screws 65-70 ft-lbs 88.1-94.9 Nm 5.5 AXLE HOUSING/DIFFEREN-
TIAL, Assembly/Use new screws
Differential bearing cap screws 39-44 ft-lbs 52.9-59.7 Nm 5.5 AXLE HOUSING/DIFFERENTIAL, Installation
Ring gear screws 22-26 ft-lbs 29.8-35.3 Nm 5.5 AXLE HOUSING/DIFFERENTIAL, Assembly
2015 Trike Service Supplement Drive 5-1

HOME
SPECIFICATIONS 5.2
GENERAL
Table 5-2. Overall Drive Ratios
Table 5-1. Sprocket Teeth GEAR RATIO

1st Gear 10.534
DRIVE ITEM NUMBER OF
TEETH 2nd Gear 7.302
Primary Engine 34 3rd Gear 5.423
Clutch 46 4th Gear 4.392
Final Transmission 30 5th Gear 3.741
Rear wheel 70 6th Gear 3.157
NOTE
Transmission gear ratios indicate the number of mainshaft
revolutions required to drive the output sprocket one revolution.
5-2 2015 Trike Service Supplement Drive

HOME
CLUTCH 5.3
NO UNIQUE CONTENT
For clutch disassembly and assembly, see Clutch: Assist and
Slip in the service manual.

HOME
AXLE 5.4
REMOVAL
sm06045

HD-49303 AXLE PULLER

2. Remove rear wheels. See 2.6 REAR WHEELS. Figure 5-2. Remove Axle Using Slide Hammer
3. Remove rear brake calipers with mounting brackets. See

2.10 REAR BRAKE CALIPERS. DISASSEMBLY
4. See Figure 5-1. Remove four locknuts and T-bolts to 1. See Figure 5-3. If necessary, remove and install axle
release bearing retainer plate from axle housing. flange studs (7) using a suitable press.
5. See Figure 5-2. Pull axle out of axle housing. If necessary, 2. Remove retaining ring (2) and discard.
attach AXLE PULLER (Part No. HD-49303) to axle flange
NOTE
using lug nuts. Attach a slide hammer and remove axle.
See Figure 5-4. A minimum 25 ton I-beam style hydraulic press
6. If necessary, remove four screws to free brake reaction is recommended for bearing removal and installation.
plate.
3. See Figure 5-5. Position axle so that bearing is properly
supported between press plates and remove bearing and
sm06046 axle shaft retainer. Discard retainer and bearing.
4. If necessary, remove bearing retainer plate (5).
sm06078
1
3
2
4 5
Figure 5-1. Remove Bearing Retainer From Axle Housing
6
7
1. Axle
2. Retaining ring
3. Axle shaft retainer
4. Bearing
5. Bearing retainer plate
6. Axle flange
7. Axle flange stud
Figure 5-3. Axle Assembly

HOME
NOTE
sm06176
See Figure 5-6. Hold bearing retainer plate (3) up during the
press procedure to prevent it from being captured between
bearing and axle shoulder.
5. Verify that assembly is square and apply pressure with
ram until bearing makes firm contact with axle shoulder.
6. Remove bearing support tube and slide new axle shaft
retainer onto axle.
7. See Figure 5-7. Press axle shaft retainer in a similar
manner until it makes firm contact with bearing. Remove
assembly from press.
8. Install new retaining ring in groove and verify that it is fully
seated.
sm06178
2
Figure 5-4. I-Beam Style Hydraulic Press
sm06177
3
1. Bearing support tube

2. Press bar
3. Bearing retainer plate
Figure 5-6. Install Axle Bearing
Figure 5-5. Remove Axle Bearing
ASSEMBLY

HD-34634 FORK OIL SEAL INSTALLER
1. Slide bearing retainer plate down axle and allow to lay on

axle flange.
2. Slide new bearing onto axle until it contacts shoulder.
3. See Figure 5-6. Slide suitable bearing support tube (1) or
FORK OIL SEAL INSTALLER (Part No. HD-34634) onto
axle until it contacts bearing inner race.
4. Position axle with support tube (1) supported between
press plates. Place press bar (2) or other suitable driver
between ram and center of axle flange.

HOME
sm06179
INSTALLATION
Brake reaction plate screws 40-45 ft-lbs 54.2-61.0 Nm
Axle bearing retainer locknuts 40-45 ft-lbs 54.2-61.0 Nm
NOTE
Install the shorter axle on the left side.
1. If removed, install brake reaction plates with four screws
each. Tighten to 40-45 ft-lbs (54.2-61.0 Nm).
2. Push axle into axle housing and rotate until the splines
engage.
3. See Figure 5-1. Secure bearing retainer plate to axle
housing using four T-bolts and new locknuts. Tighten to
40-45 ft-lbs (54.2-61.0 Nm) in a crosswise pattern.
4. Install brake rotor onto axle. Install caliper. See 2.10 REAR
BRAKE CALIPERS.
5. Install rear wheels. See 2.6 REAR WHEELS.
NOTE
6. Connect battery negative cable.
Figure 5-7. Install Bearing Retainer

HOME
AXLE HOUSING/DIFFERENTIAL 5.5

REMOVAL
sm06048a
1. Remove seat.
4

1
3. Remove body. See 2.22 BODY. 2
4. Remove both axles. See 5.4 AXLE. 3
5. If reverse motor equipped, remove reverse motor and
bracket. See 7.13 REVERSE MOTOR AND BRACKET.
6. See Figure 5-8. Mark the adjustment screws (3) on both 1. Pinch block bolts (4 each side)
sides of motorcycle with a paint pen where they exit the 2. Jamnut
front of adapter plates. Optionally make a note of dimen- 3. Adjustment screw
sion (4). 4. Measured distance
7. Loosen four pinch block bolts (1) on each side. Loosen Figure 5-8. Adjust Axle
jamnut (2) and back off adjustment screws. Push axle
housing forward to remove all drive belt tension.
NOTE sm06477
See Figure 5-9. Handle bearing caps with care as they are not
sold separately. Damage to bearing caps or differential housing
requires replacement of the axle/differential housing assembly.
1
8. Remove two screws (3) to release each bearing cap (2).
NOTE
Place masking tape at rear of rear fork to protect painted sur-
faces. 2
9. Move differential/sprocket assembly forward to remove
drive belt from sprocket. 3
10. Move axle housing rearward as far as it will move. Remove
differential/sprocket assembly from the front. For best
results, pull differential forward until it almost contacts rear
fork, then rotate sideways to remove. 3
NOTE 1. Differential/sprocket assembly
If servicing differential, proceed to 5.5 AXLE HOUSING/DIF- 2. Bearing cap (2)
FERENTIAL, Disassembly. If replacing drive belt or axle 3. Screw (4)
housing, proceed with the following steps. Figure 5-9. Differential and Sprocket Assembly
NOTE
If removing axle housing for belt replacement, do not detach
shock absorbers. Remove upper shock bolts only.
11. Remove both rear shock absorbers. See 2.29 SHOCK
ABSORBERS.
NOTE
Always keep shock absorbers in an upright position with the
air line connector at the top to prevent the loss of oil. Any oil
loss requires shock absorber replacement.
12. Remove rear frame. See 2.24 REAR FRAME.

HOME
13. Pull axle housing rearward to release pinch blocks from 2. Rotate ring gear (5) to align bosses with cutouts on com-
adapter plate bosses and remove from vehicle. pensator bowl (4) and separate sprocket from compensator
bowl.
DISASSEMBLY
Differential
PART NUMBER TOOL NAME NOTE
HD-43644-3 CAMSHAFT BEARING INSTALLER See Figure 5-12. Due to high torque on screws (11), com-
HD-49762 PULLER pensator bowl may rotate in vise if not properly clamped.
HD-95635-46 ALL-PURPOSE CLAW PULLER 1. Tighten flange of compensator bowl in soft-jawed vise so
that a ring gear mounting boss is in contact with top of
Bearings vise. Remove ten screws with flat washers. Remove differ-
ential (2) from compensator bowl.
NOTE
NOTE
Both bearings are removed in a similar manner. The sprocket Do not separate halves of differential housing. Internal compon-
side bearing must be removed to remove the sprocket. Remove ents are not sold separately.
the opposite side bearing only if bearing replacement is
necessary. 2. If necessary, remove grease seal (3) on each end of dif-
ferential.
1. See Figure 5-10. Sparingly apply graphite lubricant to
threads of forcing screw of ALL-PURPOSE CLAW NOTE
PULLER (Part No. HD-95635-46) (1). Start forcing screw Never add grease to the differential. The grease added at the
into puller. factory will last the life of the motorcycle.
2. Install suitable driver such as CAMSHAFT BEARING

INSTALLER (Part No. HD-43644-3) (3) into differential sm05876
bore.
1
3. Center press plug (2) on driver and engage claws on
inboard side of bearing.
4. Verify that tool is square and remove bearing. Hold puller
body with a wrench to prevent rotation while removing
bearing.
Sprocket
1. See Figure 5-12. Remove retaining ring (8) from groove
in differential.
2
2. See Figure 5-11. Obtain three 3/8-24 UNF bolts approxim-
3
ately 5 in. (127 mm) long with three hardened washers.
3. Sparingly apply graphite lubricant to threads of forcing
screw of PULLER (Part No. HD-49762) and install in puller.
4. See Figure 5-12. Attach puller to sprocket (7) using bolts
and hardened washers. Thread bolts into sprocket an 1. All-purpose claw puller
equal number of turns. 2. Press plug
3. Camshaft bearing installer
5. Install suitable driver such as CAMSHAFT BEARING
INSTALLER (Part No. HD-43644-3) into differential bore. Figure 5-10. Bearing Removal Tools
6. Center press plug supplied with puller on driver and turn

forcing screw until it makes firm contact with press plug.
7. Verify that tool is square and turn forcing screw until
sprocket is free.
NOTE
Sprocket bearing is not sold separately. Replace sprocket
assembly if bearing replacement is necessary.
8. Remove six isolators (6) from compensator bowl (4).
Ring Gear
1. See Figure 5-12. Remove four screws (10).

HOME
sm05913
ASSEMBLY

HD-35316-12 MAIN DRIVE GEAR INSTALLER

Differential assembly screws 65-70 ft-lbs 88.1-94.9 Nm
Ring gear screws 22-26 ft-lbs 29.8-35.3 Nm
Differential
1. See Figure 5-12. If removed, press new grease seals (3)
into bore on each end of differential using a suitable press
tool.
NOTE
Figure 5-11. Puller Tool Due to high torque on screws (11), compensator bowl (4) may
rotate in vise if not properly clamped.
2. Tighten flange of compensator bowl in soft-jawed vise so
sm06480
9 that a ring gear mounting boss is in contact with top of
8 vise.
7 3. Install differential (2) in compensator bowl. Start ten new
6 screws (11) with flat washers. Tighten to 65-70 ft-lbs (88.1-
5 94.9 Nm) in a crosswise pattern.
4 Ring Gear
1. Clamp ring gear in soft-jawed vise and install compensator
3 bowl onto ring gear.
2
1 2. Install four screws (10). Tighten to 22-26 ft-lbs (29.8-35.3
10 Sprocket
NOTE
11
Replace isolators in complete sets only.
1. Bearing, ring gear side
1. See Figure 5-12. Lubricate each isolator (6) with 50/50
2. Differential assembly
mix of isopropyl alcohol and water. Do not use a petro-
3. Seal (2)
leum-based lubricant.
4. Compensator bowl
5. Ring gear (if equipped) 2. Push each isolator into compensator bowl (4) so that strap
6. Isolators (6) engages slot in rib. Verify that each isolator bottoms in
7. Sprocket compensator bowl and that each segment is flush against
8. Retaining ring side walls of rib. Leave one isolator raised slightly to be
9. Bearing, sprocket side used as a guide when positioning sprocket.
10. Screw (4)
3. Using a 50/50 mix of isopropyl alcohol and water, lubricate
11. Screw (10)
sides of each isolator where contact occurs with sprocket
Figure 5-12. Differential/Sprocket Assembly lugs.
4. Align lugs on sprocket (7) with gaps between isolators and
install sprocket onto compensator bowl.
5. Using a suitable driver such as MAIN DRIVE GEAR
INSTALLER (Part No. HD-35316-12), press on sprocket
bearing inner race until sprocket bottoms on compensator
bowl.
6. Install new retaining ring (8) in groove of differential.
Bearings
1. See Figure 5-12. Using a suitable driver such as MAIN
DRIVE GEAR INSTALLER (Part No. HD-35316-12), press

HOME
inner race of new sprocket side bearing (9) until it bottoms 10. See Figure 5-9. Install bearing caps (2). Tighten screws
against sprocket. (3) to 39-44 ft-lbs (52.9-59.7 Nm) in a crosswise pattern.
2. Repeat previous step to install bearing (1) on opposite 11. Pull axle housing rearward and turn each adjustment screw
side. until paint mark made during disassembly is aligned with
adapter plate.
INSTALLATION
12. Remove protective tape from rear fork.
FASTENER TORQUE VALUE 13. Align axle and adjust belt tension. See 1.11 DRIVE BELT,
Air valve nut 12-15 in-lbs 1.4-1.7 Nm Setting Deflection.
Differential bearing cap screws 39-44 ft-lbs 52.9-59.7 Nm 14. Install reverse motor bracket and motor. See
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.13 REVERSE MOTOR AND BRACKET.
15. Install axles. See 5.4 AXLE.
1. If removed, install shock absorber mounts on pinch blocks.
2. Push axle housing forward until pinch blocks engage
adapter plate bosses. 17. Connect negative battery cable. Tighten to 60-70 in-lbs
(6.8-7.9 Nm).
3. Install air valve:
a. Route air valve and tubes forward through opening
at rear of intermediate frame.
b. Secure air valve in frame with nut (flat side inboard). locked in position. While riding, a loose seat can shift
Tighten to 12-15 in-lbs (1.4-1.7 Nm). causing loss of control, which could result in death or
c. Install cap. serious injury. (00070b)
18. Install seat.
4. See Figure 5-13. Install three new cable straps to secure
air tubes to intermediate frame.
sm05946
5. Install rear frame. See 2.24 REAR FRAME.
6. Install and adjust panhard rod. See 2.30 PANHARD ROD.
7. Install shock absorbers. See 2.29 SHOCK ABSORBERS.
8. Place differential into differential housing.
NOTE
Be careful that differential does not roll out of axle housing
when moving axle housing forward.
9. Verify that axle adjuster screws are backed off completely
and move axle housing forward as far as it will go. Install
drive belt on sprocket.
NOTE
Differential housing and bearing caps are stamped L(eft) and
R(ight) to prevent improper assembly. Letter stamp on each
cap must be right side up when installed. Figure 5-13. Secure Air Tubes

HOME
DRIVE BELT REPLACEMENT 5.6

1. Remove primary chaincase assembly. See PRIMARY 1. Slip new drive belt between left side adapter plate and
CHAINCASE in the service manual. pinch blocks without over bending, twisting or kinking.
2. Remove differential to release drive belt from rear wheel 2. Pull drive belt forward past pivot shaft joint and work rear
sprocket. Remove axle housing. See 5.5 AXLE fork into position on transmission mount.
HOUSING/DIFFERENTIAL.
3. Install rear fork and pivot shaft. See 2.27 REAR FORK.
3. Remove drive belt from transmission sprocket.
4. Install drive belt onto transmission sprocket.
4. Remove rear fork pivot shaft and move rear fork back
5. Install axle housing and differential. See 5.5 AXLE
away from transmission to allow clearance for belt to pass.
HOUSING/DIFFERENTIAL.
See 2.27 REAR FORK.
6. Install primary chaincase assembly. See the service
5. Remove drive belt.
manual.

NOTES

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
6.1 TRANSMISSION........................................................................................................................6-1
TRANSMISSION
NOTES
HOME
TRANSMISSION 6.1
GENERAL
Table 6-2. Overall Drive Ratios
Transmission servicing on Trike Models is essentially the same
as the 2-wheel Touring Models except removal and installation GEAR RATIO
of the rear fork. Follow the general steps outlined in the service 1st Gear 10.534
manual but refer to 2.27 REAR FORK in this manual to remove
2nd Gear 7.302
and install the rear fork. Pay special attention to the installation
and torque procedure of the pivot shaft. 3rd Gear 5.423
4th Gear 4.392
SPECIFICATIONS
5th Gear 3.741
Table 6-1. Sprocket Teeth 6th Gear 3.157
DRIVE ITEM NUMBER OF

TEETH
Primary Engine 34
Clutch 46
Final Transmission 30
Rear wheel 70
2015 Trike Service Supplement Transmission 6-1

NOTES
6-2 2015 Trike Service Supplement Transmission

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
7.2 SYSTEM FUSES AND RELAYS................................................................................................7-4
7.3 BATTERY TRAY........................................................................................................................7-5
7.4 FRONT LIGHTING.....................................................................................................................7-6
7.5 FRONT LIGHTING: HDI............................................................................................................7-9
7.6 TAIL LAMPS/REAR TURN SIGNALS......................................................................................7-11
7.7 LICENSE PLATE LAMPS/BRACKET: FLHTCUTG.................................................................7-13
7.8 REAR LIGHTS HARNESS: FLHTCUTG.................................................................................7-14
7.9 REAR LIGHTS HARNESS: FLRT............................................................................................7-17
7.10 BANK ANGLE SENSOR (BAS).............................................................................................7-19
7.11 REVERSE CONTROL SYSTEM............................................................................................7-20
7.12 REVERSE JUMPER CABLES/WIRES..................................................................................7-23
7.13 REVERSE MOTOR AND BRACKET.....................................................................................7-26
7.14 INITIAL DIAGNOSTICS.........................................................................................................7-29
7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS......................................................................7-31
7.16 REVERSE MOTOR TESTING...............................................................................................7-42
7.17 INDICATOR LAMP DIAGNOSTICS.......................................................................................7-45
7.18 REAR LIGHTING DIAGNOSTICS.........................................................................................7-50
ELECTRICAL
7.19 HEADLAMP DIAGNOSTICS.................................................................................................7-55
7.20 BAS DIAGNOSTICS..............................................................................................................7-63
7.21 REVERSE SWITCH SYMPTOMS AND DIAGNOSTICS.......................................................7-66
NOTES
HOME

CHAPTER
in this chapter.

Bank angle sensor bracket screws 72-108 in-lbs 8.1-12.2 Nm 7.10 BANK ANGLE SENSOR (BAS), Installation
Bank angle sensor screw 20-30 in-lbs 2.2-3.4 Nm 7.10 BANK ANGLE SENSOR (BAS), Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.11 REVERSE CONTROL SYSTEM, Reverse
Solenoid Replacement
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Vehicle
Starter to Circuit Breaker Power Lead
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Breaker to RCM Solenoid
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER CABLES/WIRES, RCM
Solenoid to Reverse Motor Solenoid Energizer
Lead
Breaker to Reverse Motor Solenoid Power Lead
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER
CABLES/WIRES, Reverse Motor to Battery Ground
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
tion
Battery tray screws 132-156 in-lbs 14.9-17.6 Nm 7.3 BATTERY TRAY, Installation
Headlamp bracket nuts, HDI 120-150 in-lbs 13.6-16.9 Nm 7.5 FRONT LIGHTING: HDI, Lamps Bracket
Headlamp cover bracket screws 22-32 in-lbs 2.5-3.6 Nm 7.5 FRONT LIGHTING: HDI, General
Headlamp cover screw 9-18 in-lbs 1.0-2.0 Nm 7.5 FRONT LIGHTING: HDI, General
Headlamp ring screw, HDI 9-14 in-lbs 1.0-1.6 Nm 7.5 FRONT LIGHTING: HDI, Headlamp Bulb
Replacement: FLHTCUTG HDI
License plate lamp housing locknuts: 60-72 in-lbs 6.8-8.1 Nm 7.7 LICENSE PLATE LAMPS/BRACKET:
FLHTCUTG FLHTCUTG, Installation/Use new locknuts
License plate lamp screws: FLHTCUTG 9-12 in-lbs 1.0-1.4 Nm 7.7 LICENSE PLATE LAMPS/BRACKET:
FLHTCUTG, Installation
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm 7.11 REVERSE CONTROL SYSTEM, Reverse
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm 7.12 REVERSE JUMPER CABLES/WIRES, RCM
Lead
RCM solenoid screws 32-40 in-lbs 3.6-4.5 Nm 7.11 REVERSE CONTROL SYSTEM, Reverse
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Vehicle
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
2015 Trike Service Supplement Electrical 7-1

HOME

Reverse circuit breaker screw 32-40 in-lbs 3.6-4.5 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Reverse motor bracket screws 39-44 ft-lbs 52.9-59.7 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
tion/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
Reverse motor screws 39-44 ft-lbs 52.9-59.7 Nm 7.12 REVERSE JUMPER
CABLES/WIRES, Reverse Motor to Battery
Ground/Use LOCTITE 243 MEDIUM STRENGTH
Reverse motor screws 39-44 ft-lbs 52.9-59.7 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
Reverse motor solenoid energizer lead 24-30 in-lbs 2.7-3.4 Nm 7.12 REVERSE JUMPER CABLES/WIRES, RCM
nut Solenoid to Reverse Motor Solenoid Energizer
Lead
Reverse motor solenoid energizer lead 24-30 in-lbs 2.7-3.4 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
nut tion
Reverse motor solenoid power lead nut 60-84 in-lbs 6.8-9.5 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Reverse motor solenoid power lead nut 60-84 in-lbs 6.8-9.5 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
tion
Reverse motor solenoid screws 70 in-lbs 7.9 Nm 7.13 REVERSE MOTOR AND
BRACKET, Assembly
Right caddy to battery tray screw 36-40 in-lbs 4.1-4.5 Nm 7.3 BATTERY TRAY, Installation
Solenoid to reverse motor jumper nut 45 in-lbs 5.1 Nm 7.13 REVERSE MOTOR AND
BRACKET, Assembly
Starter mounting screws 25-27 ft-lbs 33.9-36.6 Nm 7.12 REVERSE JUMPER
Starter solenoid post nut 70-90 in-lbs 7.9-10.2 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Vehicle
Tail lamp/turn signal base screw 36-48 in-lbs 4.1-5.4 Nm 7.6 TAIL LAMPS/REAR TURN SIGNALS, Installa-
tion/Use LOCTITE 222 LOW STRENGTH
THREADLOCKER AND SEALANT (purple)
Tail lamp/turn signal bracket screw, HDI 36-48 in-lbs 4.1-5.4 Nm 7.6 TAIL LAMPS/REAR TURN SIGNALS, Installa-
Tail lamp/turn signal screws 21-24 in-lbs 2.4-2.7 Nm 7.6 TAIL LAMPS/REAR TURN SIGNALS, Installa-
tion
tion
Tail lamp/turn signal screws 21-24 in-lbs 2.4-2.7 Nm 7.8 REAR LIGHTS HARNESS:
Tail lamp/turn signal screws 21-24 in-lbs 2.4-2.7 Nm 7.9 REAR LIGHTS HARNESS: FLRT, Installation
Transmission ground post nut 66-114 in-lbs 7.5-12.9 Nm 7.12 REVERSE JUMPER
Trunk door cover screws: FLHTCUTG 30-54 in-lbs 3.4-6.1 Nm 7.7 LICENSE PLATE LAMPS/BRACKET:
Trunk door cover screws: FLHTCUTG 30-54 in-lbs 3.4-6.1 Nm 7.8 REAR LIGHTS HARNESS:
7-2 2015 Trike Service Supplement Electrical

HOME

Turn signal, front, lamp to bracket screw 12-16 ft-lbs 16.3-21.7 Nm 7.4 FRONT LIGHTING, Front Turn Signal Lamp:
FLRT
Turn signal lamp, front, mounting screw, 96-131 in-lbs 10.9-14.8 Nm 7.5 FRONT LIGHTING: HDI, Turn Signal Lamps
HDI

HOME
SYSTEM FUSES AND RELAYS 7.2

SYSTEM FUSES AND RELAYS System Fuses and Relays
NOTE 1. Remove left side cover.
All Trike model motorcycles use a common fuse block. Actual 2. Siren equipped models: With security fob present, turn
fuse assignment may vary based on model and options. ignition switch ON.
Fuse blocks are mounted to the electrical caddy under the left 3. See Figure 7-1. Remove main fuse.
side cover. See the service manual for removal and installation
of fuse blocks or the main fuse holder. 4. Press in tabs on the left and right sides of fuse block cover.
Remove the cover.
Main Fuse 5. Remove system fuse or relay from fuse block. Replace
1. Remove left side cover. fuse if the element is burned. Automotive type ATO fuses
are used.
2. Siren equipped models: With security fob present, turn
ignition switch ON. 6. Install system fuse or relay in fuse block.
3. See Figure 7-1. Pull main fuse from main fuse holder. 7. Install fuse block cover.
4. Insert main fuse into main fuse holder. 8. Install main fuse.
5. Install left side cover. 9. Install left side cover.
sm07593
1 2 3
4 5 6 11
7 8 9
10
50
1. Radio power (20 A) 5. Cooling (10 A) 9. Spare (7.5 A)

2. System power (7.5 A) 6. Spare (5 A) 10. Spare (20 A)
3. Battery (5 A) 7. P&A relay 11. Main fuse (50 A)
4. P&A (20 A) 8. Cooling relay
Figure 7-1. Fuses

HOME
BATTERY TRAY 7.3

REMOVAL 3. Install screw to retain caddy to battery tray. Tighten to
36-40 in-lbs (4.1-4.5 Nm).
1. Remove left and right side covers.
4. Install four screws securing battery tray to frame. Tighten
2. Remove battery. See service manual. to 132-156 in-lbs (14.9-17.6 Nm).
3. Remove BAS. See 7.10 BANK ANGLE SENSOR (BAS). 5. If active exhaust actuator is not used, connect actuator
4. Remove screws securing left side caddy. connector to battery tray.
5. Pull BAS harness from left side of battery tray. NOTE

Route BAS harness through opening in battery tray while
6. Remove screws securing ignition coil and battery hold- installing left side caddy.
down bracket. Remove bracket. See service manual.
6. Install left side caddy. See service manual.
7. Remove screw securing right side caddy.
7. Install BAS. See 7.10 BANK ANGLE SENSOR (BAS).
8. Remove four screws securing battery tray to frame.
8. Install ignition coil and battery hold-down bracket. See
9. If active exhaust actuator is not used, disconnect actuator service manual.
connector from battery tray.
9. Install battery and top caddy. See service manual.
10. Remove four screws securing battery tray to frame.
10. Install left and right side covers.
11. Release caddy from dovetails while lowering battery tray
into frame.
12. Roll front of battery tray up and out of frame.
INSTALLATION locked in position. While riding, a loose seat can shift
FASTENER TORQUE VALUE serious injury. (00070b)
Right caddy to battery tray 36-40 in-lbs 4.1-4.5 Nm 11. Install seat.
screw
Battery tray screws 132-156 14.9-17.6 Nm
in-lbs
operating motorcycle. Low visibility of rider can result in
1. Roll rear of battery tray down into frame.
2. Engage right side caddy onto dovetails while lifting battery 12. Test all switches and lights for proper operation.
tray up into position.

HOME
FRONT LIGHTING 7.4

REMOVAL, REPAIR AND INSTALLATION Bulb Removal
NOTE
Service of FLHTCUTG is similar to Touring models except the
steering damper bracket is secured under the left lamp bracket To prevent accidental vehicle start-up, which could cause
on Trike. death or serious injury, remove main fuse before pro-
ceeding. (00251b)
FLHTCUTG: DOM
See the service manual to service DOM models. NOTE
Record components during disassembly to aid in correct
FLHTCUTG: JPN assembly.
JPN models do not have auxiliary/fog lamps. The lamp brackets
1. Remove main fuse. See 7.2 SYSTEM FUSES AND
support turn signal lamps only. See the service manual to
RELAYS, System Fuses and Relays.
service JPN models.
2. See Figure 7-2. Remove trim ring hardware (1). Remove
FLHTCUTG: HDI trim ring (2).
For service of HDI models, see 7.5 FRONT LIGHTING: HDI.
3. Remove mounting ring (3).
FLRT Headlamp Repair 4. Disconnect headlamp connector (7) from bulb (5).
1. Remove headlamp. See 2.31 HEADLAMP NACELLE.
5. Remove boot (8) from back of headlamp lens (4).
2. Remove headlamp bulb. See 7.4 FRONT LIGHTING.
6. Remove wire retaining clip (6) from headlamp base.
3. See Figure 7-2. Remove screw (11) and nut (14). Remove
7. Remove bulb from headlamp assembly.
mount block (10).
NOTE Bulb Installation
Harness (9) is not serviced separately.
4. Secure mount block (10) with screw (11), flat washers
(12), lockwasher (13) and nut (14). Hand-tighten only. Never touch the quartz bulb. Fingerprints will etch the
glass and decrease bulb life. Handle the bulb with paper
5. Install headlamp bulb. See 7.4 FRONT LIGHTING.
or a clean, dry cloth. Failure to do so could result in bulb
6. Install and align headlamp. See 2.31 HEADLAMP damage. (00210b)
NACELLE.
NOTE
HEADLAMP BULB REPLACEMENT: FLRT When installing a new bulb, make sure that connector contacts
are clean for good electrical contact.
1. Install new bulb and assemble the headlamp components.
Handle bulb carefully and wear eye protection. Bulb con-
2. Verify slots and tabs in headlamp and trim ring are aligned.
tains gas under pressure, which, if not handled carefully,
could cause serious eye injury. (00062b) 3. Install boot on the headlamp lens assembly.
4. Connect the headlamp connector.
5. Install trim ring and hardware.
When replacement is required, use only the specified
sealed beam unit or bulb, available from a Harley-Davidson 6. Verify that ignition switch is in OFF position. Install main
dealer. An improper wattage sealed beam or bulb, can fuse.
cause charging system problems. (00209a)
Replace failed bulbs. Refer to Table 1-1 for bulbs.
7. Check operation of all lamps.
8. Align headlamp. See 1.17 HEADLAMP ALIGNMENT,
Headlamp: FLRT.

HOME
sm08402
9
7
8
6
5
4
10
14 3
2
13
11 12
1. Trim ring hardware 8. Boot

2. Trim ring 9. Harness
3. Mounting ring 10. Mount block
4. Headlamp lens 11. Screw
5. Bulb 12. Flat washer
6. Wire retaining clip 13. Lockwasher
7. Headlamp connector 14. Nut
Figure 7-2. Headlamp Assembly: FLRT
FRONT TURN SIGNAL LAMP: FLRT

Table 7-1. Front Turn Signal Lamp Connectors
FASTENER TORQUE VALUE LEFT SIDE [31L] RIGHT SIDE [31R]
Turn signal, front, lamp to 12-16 ft-lbs 16.3-21.7 Nm WIRE COLOR CHAMBER WIRE COLOR CHAMBER
bracket screw
Black 1 Black 1
Removal Violet 2 Violet 2

Blue 3 Blue 3
1. Remove turn signal lamp/bracket assembly. See
2.31 HEADLAMP NACELLE. Empty 4
2. See Figure 7-3. Remove terminals from connector housing Empty 5

(6). See the service manual. Empty 6
3. Remove screw (5) and washer (4). Remove lamp
assembly from bracket.
4. Remove reflector assembly if necessary. See the service
manual.
Installation
1. If removed, install reflector assembly and lens. See the
service manual.
2. See Figure 7-3. Install lamp on mounting bracket. Tighten
to 12-16 ft-lbs (16.3-21.7 Nm).
3. Install terminals into connector housing. Refer to Table 7-1.
4. Install turn signal lamp/bracket assembly. See
2.31 HEADLAMP NACELLE.

5. Test lamp operation.

HOME
sm08253
2
1
5 3
6
4
1. Bracket
2. Turn signal
3. Stand-off
4. Washer
5. Screw
6. Connector housing
Figure 7-3. Turn Signal Lamp and Bracket

HOME
FRONT LIGHTING: HDI 7.5

GENERAL Removal
1. See Figure 7-5. Remove screw (1). Remove trim ring (2)
from lamp housing.
Headlamp cover bracket 22-32 in-lbs 2.5-3.6 Nm
2. Disconnect headlamp connector.
screws
Headlamp cover screw 9-18 in-lbs 1.0-2.0 Nm 3. Remove headlamp bulb assembly and nesting ring.
Installation
HDI models do not have a central headlamp or auxiliary lamps.
The side-mounted headlamps are used instead. A cover is 1. See Figure 7-5. Place nesting ring (4) on back of new bulb
installed in place of the central headlamp. (3) with the index tab facing away from bulb.
Headlamp Cover 2. Install bulb assembly.
1. See Figure 7-4. Remove screw (1). Rotate cover (2) a few 3. Mate connector to bulb.
degrees counterclockwise. Pull cover straight forward to 4. Engage index tab of nesting ring with slot at bottom of
remove. lamp housing.
2. Remove screws (3). Remove mounting bracket (4). 5. Engage index tabs on bulb assembly with slots in nesting
3. Secure mounting bracket with screws (3). Tighten to 22-32 ring.
in-lbs (2.5-3.6 Nm). 6. Install trim ring on lamp housing with screw centered at
4. With the cover rotated a few degrees counterclockwise, bottom. Tighten to 9-14 in-lbs (1.0-1.6 Nm).
push cover straight into place. Rotate clockwise until screw 7. Check headlamp alignment. See 1.17 HEADLAMP
can be installed. ALIGNMENT, FLHTCUTG HDI Dual LED Headlamps.
5. Secure cover (2) with screw (1). Tighten to 9-18 in-lbs
(1.0-2.0 Nm). sm07647
2
sm07652
3
2
1 4
3
4
1 1. Screw
2. Ring
1. Screw 3. Headlamp bulb
2. Cover 4. Nesting ring
3. Screw (4) Figure 7-5. Headlamp Assembly
4. Bracket
Figure 7-4. Headlamp Cover LAMPS BRACKET
HEADLAMP BULB REPLACEMENT: FASTENER TORQUE VALUE

FLHTCUTG HDI Headlamp bracket nuts, HDI 120-150 13.6-16.9 Nm
in-lbs
Headlamp ring screw, HDI 9-14 in-lbs 1.0-1.6 Nm Removal
1. Remove two acorn nuts securing lamps bracket.
NOTE
2. Pull bracket away from fork and disconnect two con-
HDI models have LED headlamps. LED lamps contain no
nectors.
replacement bulbs. Replace the entire assembly if failure
occurs.

HOME
Installation NOTE
It is not necessary to completely remove the turn signal lamp
1. Mate two connectors. to gain access to the headlamp retaining nut.
2. Secure lamps bracket with acorn nuts. Tighten to 120-150 4. See Figure 7-6. Remove turn signal lamp. See 7.5 FRONT
in-lbs (13.6-16.9 Nm). LIGHTING: HDI, Turn Signal Lamps.
TURN SIGNAL LAMPS 5. Remove nut, lockwasher and cone washer securing
headlamp housing.
6. Pull wires through bracket as lamp is removed.
Turn signal lamp, front, 96-131 in-lbs 10.9-14.8 Nm
mounting screw, HDI Installation
1. Pull wires through bracket as new lamp is put into position.
Removal
2. See Figure 7-6. Secure with cone washer, lockwasher and
1. Remove lamps and bracket assembly. See 7.5 FRONT nut. Do not tighten at this time.
LIGHTING: HDI, Lamps Bracket.
3. Install terminals in connectors. Refer to Table 7-2.
2. Remove terminals 1, 2, 3 from 4-terminal connector. See
JAE MX19 SEALED CONNECTORS in the service 4. Install lamps and bracket assembly. See 7.5 FRONT
manual. LIGHTING: HDI, Lamps Bracket.
3. See Figure 7-6. Remove screw and lockwasher securing 5. Install headlamp bulb. See 7.5 FRONT LIGHTING: HDI,
lamp. Headlamp Bulb Replacement: FLHTCUTG HDI.
4. Pull wires through bracket as lamp is removed. 6. Adjust headlamp alignment. See 1.17 HEADLAMP
ALIGNMENT.
NOTE
HDI turn signal lamps contain no service parts. Failure requires
Table 7-3. Headlamp Connector, HDI [38]
replacement of the entire lamp assembly.
WIRE COLOR CHAMBER NUMBER
Installation
Blue/yellow 1
1. Pull wires through bracket as new lamp is put into position.
Blue/white 2
2. See Figure 7-6. Secure lamp with screw and lockwasher.
sm07648
3. Install terminals in connector. Refer to Table 7-2.
4. Install lamps and bracket assembly. See 7.5 FRONT
Table 7-2. Front Turn Signal Connector, HDI [31]
WIRE COLOR CHAMBER NUMBER

White 1
Red 2
Black (turn signal) 3
Black (headlamp) 4
HEADLAMP HOUSING
Removal
1. Remove headlamp bulb. See 7.5 FRONT LIGHTING: HDI,
Headlamp Bulb Replacement: FLHTCUTG HDI.
2. Remove lamps and bracket assembly. See 7.5 FRONT
3. Remove terminals from 2-terminal connector and BK from
terminal 4 of 4-terminal connector. See JAE MX19
SEALED CONNECTORS in the service manual.
Figure 7-6. Lamps and Bracket: HDI

HOME
TAIL LAMPS/REAR TURN SIGNALS 7.6

REMOVAL
Incandescent Type Be sure that all lights and switches operate properly before
1. Remove two screws to release tail lamp/turn signal. operating motorcycle. Low visibility of rider can result in
2. See Figure 7-7. Disconnect tail lamp/turn signal connector
(1). 6. Check operation of all lamps.
3. Disconnect rear lighting harness connector (2). Feed
sm06105
connector housing through opening (3) to inboard side of
fender. 4 2
4. FLHTCUTG: If necessary, remove screw (4) with flat
washer to release chrome base from fender bracket.
1
5. See Figure 7-8. Remove pin housing and circuit board
from chrome base. Remove pin housing from circuit board.
LED Type
1. See Figure 7-9. Remove two screws to release tail
lamp/turn signal.
2. Disconnect tail lamp/turn signal connector.
3. If necessary, remove screw to release tail lamp bracket
from fender.
NOTE
LED tail lamps contain no service parts. Failure requires 3
replacement of the entire lamp assembly.
1. Tail lamp/turn signal connector
INSTALLATION
2. Rear lighting harness connector
3. Opening
4. Chrome base screw
Tail lamp/turn signal base 36-48 in-lbs 4.1-5.4 Nm
screw Figure 7-7. Remove Chrome Base: FLHTCUTG
Tail lamp/turn signal screws 21-24 in-lbs 2.4-2.7 Nm

Tail lamp/turn signal bracket 36-48 in-lbs 4.1-5.4 Nm sm03626
screw, HDI
Incandescent Type
1. See Figure 7-8. Place pin housing over circuit board. Install
assembly into base.
2. See Figure 7-7. FLHTCUTG: Apply LOCTITE 222 LOW
STRENGTH THREADLOCKER AND SEALANT (purple)
to screw (4). Secure base with flat washer and screw.
H-D
3. Feed connector housing through opening (3) to outboard USA
side of fender. Install connector (2). 68830-98
4. Connect tail lamp/turn signal connector (1).

5. Install tail lamp/turn signal lens with two screws. Tighten Figure 7-8. Remove Pin Housing From Circuit Board
to 21-24 in-lbs (2.4-2.7 Nm).
NOTE LED Type
Over-tightening screws can crack the lens.
1. See Figure 7-9. If removed, install tail lamp bracket to
fender. Tighten to 36-48 in-lbs (4.1-5.4 Nm).
2. Connect tail lamp/turn signal connector.

HOME
3. Secure tail lamp/turn signal with two screws. Tighten to

sm07649
21-24 in-lbs (2.4-2.7 Nm).
2
1

4. Check operation of all lamps.
4 3
1. Bracket
2. Screw, bracket
3. Screws, tail lamp
4. Reflector
Figure 7-9. LED Tail Lamp

HOME
LICENSE PLATE LAMPS/BRACKET: FLHTCUTG 7.7

REMOVAL 3. See Figure 7-10. Feed terminals and harness with
grommet to inboard side of trunk door. Seat grommet (2)
1. Remove four screws and remove trunk door inner cover. in hole. Install terminals into connector housing.
2. See Figure 7-10. Disconnect license plate lamp connector 4. Install two new locknuts with flat washers to fasten license
(1) from rear lighting harness. plate lamp bracket to trunk door. Tighten to 60-72 in-lbs
3. Remove terminals from connector housing. (6.8-8.1 Nm).
NOTE 5. Connect license plate lamp connector (1) to rear lighting

For instructions on removing terminals, see service manual. harness.
4. Remove two locknuts and flat washers to release license 6. Install trunk door cover and tighten screws in a crosswise
plate lamp bracket. pattern to 30-54 in-lbs (3.4-6.1 Nm).
NOTE
License plate lamp bracket also serves as the trunk door
handle. Be sure that all lights and switches operate properly before
5. Draw harness to outboard side of trunk door while pushing operating motorcycle. Low visibility of rider can result in
grommet (2) through hole. death or serious injury. (00316a)
6. Remove screws to release lens/bulb assembly from license 7. Test license plate lamp operation.
plate lamp bracket.
sm06081a
INSTALLATION
1
License plate lamp screws: 9-12 in-lbs 1.0-1.4 Nm
FLHTCUTG
2
License plate lamp housing 60-72 in-lbs 6.8-8.1 Nm
locknuts: FLHTCUTG
Trunk door cover screws: 30-54 in-lbs 3.4-6.1 Nm
FLHTCUTG
1. Secure lens/bulb assembly to license plate lamp bracket

with screws. Tighten to 9-12 in-lbs (1.0-1.4 Nm). 1. License plate lamp connector
2. If replacing lens/bulb assembly, place new unit next to old 2. Grommet
unit and cut wires to proper length. Crimp new socket Figure 7-10. Inside Trunk Door
terminals onto wires.

HOME
REAR LIGHTS HARNESS: FLHTCUTG 7.8

REMOVAL
sm06080a
1. Remove seat.
2. See Figure 7-11. Disconnect rear lighting harness from
main harness.
1
3. Remove rear wheels. See 2.6 REAR WHEELS. 2
4. Remove trunk door inner cover.
5. See Figure 7-12. Disconnect license plate lamp connector
(3) and optional trunk light connector (4) if equipped.
4
6. Release harness from anchor clips (1).
7. Remove trunk liner. 3
8. Release harness from anchor clips inside trunk. 1. Anchor clips
2. Grommet
9. Remove grommet in front-left corner of body and feed 3. License plate lamp connector
harness through hole to underside of body. 4. P&A trunk light connector
NOTE Figure 7-12. Inside Trunk Door
See Figure 7-14. Models equipped with LED rear lights have
connectors (1, 2) located under the body. These models do
not require removal of the tail/stop lamps. Separate the con-
nectors and proceed to last step. sm06106
1
10. Disconnect harness from fenders:
a. Remove tail lamp/turn signal.
b. See Figure 7-13. Disconnect rear lighting harness
connector (1). Feed harness and connector to inboard
side of fender.
c. Release harness from three adhesive clips in fender
well. Feed harness through hole to underside of body.
d. Repeat steps on opposite fender.
11. Release harness from remaining anchor clips at underside

of body.
is07768
2
1. Rear lighting harness connector

2. Opening
Figure 7-13. Chrome Base
INSTALLATION
Trunk door cover screws: 30-54 in-lbs 3.4-6.1 Nm
FLHTCUTG
NOTE
Figure 7-11. Rear Lighting Connector: FLHTCUTG The harness is captured in a total of 25 anchor clips. There
are fourteen at underside of body, three in each fender well
and five inside trunk.

HOME
1. See Figure 7-14. Capture harness in anchor clips at 4. Capture harness in five anchor clips inside trunk.
underside of body:
5. See Figure 7-12. Mate license plate lamp harness con-
a. With the 8-place connector at front of body, route nector (3) and optional trunk light connector (4) if equipped.
harness rearward and then to left side of body through Secure harness to trunk door with anchor clips (1).
two adhesive clips (1, 2).
NOTE
NOTE Route harness through gap in front left corner of trunk door
HDI models equipped with LED rear lights have connectors cover.
(1, 2) located under the body.
6. Install trunk door cover. Tighten in a crosswise pattern to
b. HDI: Route connector (2) toward the right side and 30-54 in-lbs (3.4-6.1 Nm).
capture in clips (3-5). Mate connectors (1, 2). Proceed
to step 3. 7. Install trunk liner.
c. Route right tail lamp (longer branch) of harness ter- 8. Connect rear lighting harness to main harness.
minating in 6-place connector to right side of body 9. Install rear wheels. See 2.6 REAR WHEELS.
and then rearward through seven anchor clips (3-9).
NOTE
d. Route left tail lamp (shorter branch) of harness termin- Always check lug nut torque within 500-1000 mi (805-1610
ating in 6-place connector rearward along left side of km) after wheel installation.
body through five anchor clips (10-14).
2. Secure harness to fenders:

a. Route harness through holes and capture in three After installing seat, pull upward on seat to be sure it is
anchor clips in fender well. locked in position. While riding, a loose seat can shift
b. See Figure 7-13. Feed connector to outboard side of causing loss of control, which could result in death or
fender and connect to tail lamp base. serious injury. (00070b)
c. Install tail lamp/turn signal with two screws. Tighten 10. Install seat.
to 21-24 in-lbs (2.4-2.7 Nm).
d. Repeat steps on opposite fender.
3. Feed branch of harness terminating in two 2-place Multi- operating motorcycle. Low visibility of rider can result in
lock connectors into trunk through hole in front-left corner death or serious injury. (00316a)
of body. Install grommet into body hole.
11. Test rear lighting for proper operation.

HOME
sm05955a
2
2 1
10
1 11
3 4 5 6
12 7
13 8
14 9
15 18
16 19
17 20
1. Connector, HDI, left

2. Connector, HDI, right
Figure 7-14. Adhesive Clip Location (As Viewed From the Top)

HOME
REAR LIGHTS HARNESS: FLRT 7.9

REMOVAL 1. See Figure 7-16. Beginning at anchor clip (2), capture
harness in anchor clips at underside of body:
1. Remove seat.
a. With the 8-place connector at front- right side of body,
2. See Figure 7-15. Disconnect rear lighting harness from route longer branch of harness rearward and then to
main harness. left side of body through hole leading to fender well.
3. Remove rear wheels. See 2.6 REAR WHEELS. b. Route right tail lamp (shorter branch) of harness to
right side of body through hole leading to fender well.
4. Remove tail lamp/turn signal. See 7.6 TAIL LAMPS/REAR
TURN SIGNALS. 2. Capture harness in clips (1-6, 11, 12).
5. Feed harness to inboard side of fender. 3. Secure harness to fenders:
6. See Figure 7-16. Release harness from adhesive clips in a. Capture in four anchor clips in fender well.
fender well. Feed harness through hole to underside of
b. Route harness through loop in tail lamp bracket and
body.
to outboard side of fender.
7. Repeat steps on opposite fender.
c. Connect to tail lamp.
8. Release harness from remaining anchor clips at underside
d. Install tail lamp/turn signal with two screws. Tighten
of body.
to 21-24 in-lbs (2.4-2.7 Nm).
sm08412
e. Repeat steps on opposite fender.
PLACEHOLDER TRILOGY REAR LIGHTING 4. Connect rear lighting harness to main harness.
CONNECTOR 5. Install rear wheels. See 2.6 REAR WHEELS.
NOTE

6. Install seat.
Figure 7-15. Rear Lighting Connector: FLRT
INSTALLATION
FASTENER TORQUE VALUE operating motorcycle. Low visibility of rider can result in
7. Test rear lighting for proper operation.
NOTES
• See Figure 7-16. The harness is captured in a total of 16
anchor clips. There are eight at underside of body and
four in each fender well.
• The left branch of harness has violet tape at each anchor
point. The right branch has brown tape. The main branch
has no tape.

HOME
sm08413
13 7
15 12 11 2 3 4 5 6 9
16 14 8 10
2
1
1. Right tail lamp bracket loop

2. Left tail lamp bracket loop
Figure 7-16. Adhesive Clip Location (As Viewed From the Bottom)

HOME
BANK ANGLE SENSOR (BAS) 7.10

REMOVAL
1. Remove main fuse.
2. Remove seat and top caddy. See the service manual. locked in position. While riding, a loose seat can shift
3. See Figure 7-17. Remove screws (2) and remove sensor causing loss of control, which could result in death or
with bracket. serious injury. (00070b)
4. Install top caddy and seat.
4. Disconnect bank angle sensor connector.
5. Install main fuse.
5. Remove screw (1) and sensor from bracket.
INSTALLATION sm06482

Bank angle sensor screw 20-30 in-lbs 2.2-3.4 Nm
Bank angle sensor bracket 72-108 in-lbs 8.1-12.2 Nm
screws 1
NOTE
See Figure 7-17. Use ONLY the correct original equipment
screws to install the BAS bracket. If longer screws are used,
the BAS can send an errant "vehicle has been tipped" signal
to the ECM.
1. Secure sensor to bracket with screw (1). Tighten to 20-30
in-lbs (2.2-3.4 Nm).
2. Mate sensor connector. 1. Sensor screw
2. Bracket screw (2)
3. Install bracket and sensor with screws (2). Tighten to 72-
108 in-lbs (8.1-12.2 Nm). Figure 7-17. Bank Angle Sensor (BAS) (battery removed
for clarity)

HOME
REVERSE CONTROL SYSTEM 7.11

SWITCH REPLACEMENT REVERSE SOLENOID REPLACEMENT
The reverse switch is part of a modular switch assembly and
not serviced separately. See the service manual for switch
module assembly replacement. RCM solenoid screws 32-40 in-lbs 3.6-4.5 Nm
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm
RCM REPLACEMENT
Removal
1. Remove main fuse. Removal
2. Remove right side cover. 1. Remove right side cover.
3. See Figure 7-18. Separate connector (3) located under
caddy.
4. Remove cable strap (2) securing RCM (1) to electrical To prevent accidental vehicle start-up, which could cause
caddy. death or serious injury, disconnect negative (-) battery
5. Remove RCM.
sm07997 3. See Figure 7-19. Disconnect 2-place connector (12).
Remove boot (14).
4. Remove nuts (8).
5. Remove RCM jumper (4) and reverse motor solenoid
energizer lead (13) from posts of solenoid.
1
6. Remove two screws (11) to release RCM solenoid.
Installation
1. See Figure 7-19. Install RCM solenoid with screws (11).
2. Install reverse motor solenoid energizer lead (13) and nut
2 (8) onto rear post of RCM solenoid.
3. Install RCM jumper (4) and nut (8) onto forward post.
3
4. Tighten nuts (8) to 26-40 in-lbs (2.9-4.5 Nm).
1. Reverse control module (RCM) 5. Route 2-place connector (12) through square shaped
2. Cable strap opening of boot (14) and install boot. Mate connector.
3. RCM connector (not visible)
Figure 7-18. Reverse Control Module (RCM) (6.8-7.9 Nm).
Installation
1. Secure RCM on right electrical caddy with new cable strap. After installing seat, pull upward on seat to be sure it is
2. Mate connector (3).
3. Install right side cover. serious injury. (00070b)
4. Install main fuse. 7. Install seat.

HOME
sm06780a
2
1
3
4
6
5
14
7
13 8
12
10 9
11
1. Power lead 8. Nut (2)
2. Nut 9. Right caddy
3. Screw 10. RCM solenoid
4. RCM jumper 11. Screw (2)
5. Power lead, reverse motor 12. RCM solenoid energizer lead
6. Positive post, starter motor 13. Reverse motor solenoid energizer lead
7. Circuit breaker 14. Boot
Figure 7-19. RCM Solenoid and Circuit Breaker
CIRCUIT BREAKER REPLACEMENT 3. See Figure 7-19. Remove nuts (2). Remove RCM jumper
(4) and power lead (5) from inboard post (stamped BAT).
FASTENER TORQUE VALUE 4. Remove reverse motor power lead (1) from outboard post
Reverse circuit breaker screw 32-40 in-lbs 3.6-4.5 Nm of circuit breaker (stamped AUX).
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 5. Remove screws (3) to release circuit breaker (7) from
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm caddy (9).
Installation
Removal
1. See Figure 7-19. Install circuit breaker and secure with
1. Remove right side cover. screws (3). Tighten screw to 32-40 in-lbs (3.6-4.5 Nm).
2. Install power lead (5) and RCM jumper (4) onto inboard
post of circuit breaker (stamped BAT). Install reverse motor
To prevent accidental vehicle start-up, which could cause power lead (1) onto outboard post (stamped AUX).
death or serious injury, disconnect negative (-) battery 3. Install nuts (2). Tighten to 50-60 in-lbs (5.6-6.8 Nm). Install
cable before proceeding. (00048a) boots.
2. Disconnect negative battery cable. 4. See Figure 7-20. If tripped, push reset lever (1) into circuit
breaker until an audible click is heard.

HOME

om01791
(6.8-7.9 Nm).
1 2

6. Install seat.
7. Install side cover.
1. Reset lever (push in direction of arrow to reset)

2. Manual trip pushbutton
Figure 7-20. Reverse Motor Circuit Breaker

HOME
REVERSE JUMPER CABLES/WIRES 7.12

GENERAL CIRCUIT BREAKER TO RCM SOLENOID
The reverse system uses the following jumper cables/wires:
• Vehicle starter to circuit breaker (power circuit) Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm
• Circuit breaker to RCM solenoid (energizer circuit) RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm
• RCM solenoid to reverse motor solenoid (energizer circuit) Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
• Circuit breaker to reverse motor (power circuit)
• Reverse motor to battery ground
Removal
VEHICLE STARTER TO CIRCUIT BREAKER
POWER LEAD
FASTENER TORQUE VALUE To prevent accidental vehicle start-up, which could cause
Starter solenoid post nut 70-90 in-lbs 7.9-10.2 Nm
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm
3. See Figure 7-19. Remove boot (14) from RCM solenoid.
Remove nut (8) and ring terminal from post of RCM
Removal solenoid.
4. Remove nut (2) and ring terminal from inner post of circuit
breaker. Remove jumper (4).
Installation
death or serious injury, disconnect negative (-) battery 1. See Figure 7-19. Install ring terminals of jumper (4) and
cable before proceeding. (00048a) power lead (5) onto inner post of circuit breaker with nut
(2). Tighten to 50-60 in-lbs (5.6-6.8 Nm).
2. Install ring terminal and nut (8) onto post of RCM solenoid.
3. See Figure 7-19. Disconnect cable (5) from starter solenoid Tighten to 26-40 in-lbs (2.9-4.5 Nm).
post (6).
3. Install boots.
4. Remove nut (2) and ring terminal from inboard post of
circuit breaker. Remove cable. 4. Connect negative battery cable. Tighten to 60-70 in-lbs
(6.8-7.9 Nm).
Installation
1. See Figure 7-19. Route jumper cable from circuit breaker
forward under frame crossmember to starter solenoid post
(6). After installing seat, pull upward on seat to be sure it is
2. Install jumper and battery positive cable ring terminals on causing loss of control, which could result in death or
starter solenoid post. Secure with nut. Tighten to 70-90 serious injury. (00070b)
in-lbs (7.9-10.2 Nm). Install boot.
5. Install seat.
3. Secure cable (5) and jumper (4) onto inboard post of circuit
6. Install right side cover.
breaker with nut (2). Tighten to 50-60 in-lbs (5.6-6.8 Nm).
Install boot. RCM SOLENOID TO REVERSE MOTOR
4. Connect negative battery cable. Tighten to 60-70 in-lbs SOLENOID ENERGIZER LEAD
(6.8-7.9 Nm).
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm
After installing seat, pull upward on seat to be sure it is Reverse motor solenoid ener- 24-30 in-lbs 2.7-3.4 Nm
locked in position. While riding, a loose seat can shift gizer lead nut
causing loss of control, which could result in death or Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
5. Install seat. Removal
6. Install right side cover. 1. Disconnect negative battery cable.

HOME
sm06051c

2. Remove right rear wheel. See 2.6 REAR WHEELS.
4. See Figure 7-19. Remove boot (14) from RCM solenoid.
5. Remove nut (8) securing ring terminal of energizer lead
(13).
6. Remove boot from lower post (silver) on reverse motor
solenoid. Remove nut (metric), lockwasher and ring ter-
minal. Figure 7-21. Secure Harnesses to Frame Tube
7. Cut cable straps to release jumper from upper frame tube
and the reverse motor power lead. Remove energizer lead CIRCUIT BREAKER TO REVERSE MOTOR
(13).
SOLENOID POWER LEAD
Installation
1. Secure energizer lead to rear post of RCM solenoid.
Tighten to 26-40 in-lbs (2.9-4.5 Nm). Install boot over Reverse motor solenoid power 60-84 in-lbs 6.8-9.5 Nm
RCM solenoid. lead nut
2. See Figure 7-22. Route jumper above and behind reverse Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm
motor to solenoid. Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
3. Install ring terminal, lockwasher and nut (metric) onto lower
post (2) of reverse motor solenoid. Tighten to 24-30 in-lbs Removal
(2.7-3.4 Nm). Install boot. 1. Remove seat. Disconnect battery negative cable.
4. Install cable straps (5) to secure cables together.
5. See Figure 7-21. Install new cable strap to secure power
lead and energizer jumper to upper frame tube. To prevent accidental vehicle start-up, which could cause
6. Install right rear wheel. See 2.6 REAR WHEELS. death or serious injury, disconnect negative (-) battery
NOTE
km) after wheel installation. 3. Remove right side cover.
7. Connect negative battery cable. Tighten to 60-70 in-lbs 4. Remove boot, nut (metric), lockwasher and ring terminal
(6.8-7.9 Nm). from front post (copper) on reverse motor solenoid.
5. See Figure 7-19. Remove boot, nut (5) and ring terminal
from outboard post of circuit breaker (stamped AUX).
After installing seat, pull upward on seat to be sure it is 6. Cut cable straps to release jumper from upper frame tube.
locked in position. While riding, a loose seat can shift Remove jumper (16).
serious injury. (00070b) Installation
8. Install seat. 1. See Figure 7-22. Install ring terminal onto front post (1) of
reverse motor solenoid. Install lockwasher and nut (metric).
2. Tighten nut to 60-84 in-lbs (6.8-9.5 Nm). Install boots.
3. Route lead around rear of reverse motor and up toward
the circuit breaker.
4. Install ring terminal and nut onto outboard post of circuit
breaker (stamped AUX). Tighten nut to 50-60 in-lbs (5.6-
6.8 Nm).
5. Install cable straps (5) to secure cables together.

HOME
6. See Figure 7-21. Install new cable straps to secure power 6. Remove nut and ground jumper from transmission ground
cable, energizer jumper, RCM harness and main harness post.
to upper frame tube.
7. Draw ground jumper rearward to remove.
7. Install right rear wheel. See 2.6 REAR WHEELS.
Installation
NOTE
Always check lug nut torque within 500-1000 mi (805-1610 1. From area of reverse motor, route new ground jumper
km) after wheel installation. forward over rear fork and rear brake line.
8. Connect battery negative cable. Tighten screw to 60-70 2. Secure ground jumper onto transmission ground post
in-lbs (6.8-7.9 Nm). (outboard of battery negative cable ring terminal) with nut.
3. Place starter into installed position. Apply LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND SEALANT
After installing seat, pull upward on seat to be sure it is (blue) and secure with two screws. Tighten to 25-27 ft-lbs
locked in position. While riding, a loose seat can shift (33.9-36.6 Nm).
serious injury. (00070b) 4. Remove all residual threadlocking compound from lower
hole in reverse motor bracket using an appropriate thread
9. Install seat. chaser.
10. Install right side cover. 5. If reusing reverse motor screw:
REVERSE MOTOR TO BATTERY GROUND a. Completely remove all threadlocking compound using
a wire brush or wire wheel.
FASTENER TORQUE VALUE b. Apply LOCTITE 243 MEDIUM STRENGTH
Transmission ground post nut 66-114 in-lbs 7.5-12.9 Nm THREADLOCKER AND SEALANT (blue) to threads
of screw.
Starter mounting screws 25-27 ft-lbs 33.9-36.6 Nm
Reverse motor screws 39-44 ft-lbs 52.9-59.7 Nm 6. See Figure 7-22. Secure ground jumper (3) and RCM
solenoid ground lead (4) with reverse motor screw. Tighten
to 39-44 ft-lbs (52.9-59.7 Nm).
Removal 7. Install right rear wheel. See 2.6 REAR WHEELS.
1. Disconnect negative battery cable. NOTE

death or serious injury, disconnect negative (-) battery 9. Connect negative battery cable. Tighten to 60-70 in-lbs
cable before proceeding. (00048a) (6.8-7.9 Nm).
4. See Figure 7-22. Remove lower reverse motor screw with locked in position. While riding, a loose seat can shift
lockwasher to release ground jumper (3) ring terminal. causing loss of control, which could result in death or
5. Remove two screws to release starter from primary serious injury. (00070b)
chaincase. Pull starter from bore and move as necessary 10. Install seat.
to access ground post at top of transmission case.

HOME
REVERSE MOTOR AND BRACKET 7.13

REMOVAL
sm06061
1. Remove seat.

2. Disconnect battery negative cable.
4. See Figure 7-22. Remove nut (metric) and lockwasher to
release reverse motor power cable (1).
5. Remove nut (metric) and lockwasher to release reverse
motor solenoid energize lead (2).
6. Remove two screws to release reverse motor from bracket.
7. Remove three screws to release reverse motor bracket.
Pull bracket from two dowel pins in flanges of differential
Figure 7-23. Remove Screws to Release Solenoid
housing.
sm06067a
sm06062a
1
2
5
4 1
2
3
4
3
1. Reverse motor power cable (with red shrink
tube)
2. Reverse motor solenoid energize lead
3. Battery ground jumper 1. Screws and lockwashers
4. RCM solenoid ground 2. Solenoid
5. Cable strap 3. Collar
Figure 7-22. Reverse Motor 4. Spring
Figure 7-24. Solenoid Assembly
DISASSEMBLY
1. Remove reverse motor.
2. Remove nut with lockwasher to release solenoid to reverse
motor jumper.
3. See Figure 7-23. Remove two screws with lockwashers.
4. Remove solenoid, disengaging slot in drive shaft from end
of lever on pinion gear.
5. See Figure 7-24. Remove collar (3) and spring (4).

HOME
ASSEMBLY 5. Pull pinion gear to the fully engaged position (out) to move
lever toward collar. Move lever sideways as necessary to
FASTENER TORQUE VALUE center between spring coils.
Reverse motor solenoid 70 in-lbs 7.9 Nm 6. See Figure 7-26. Hold solenoid with the lettered side up
screws and capture end of lever in slot of plunger.
Solenoid to reverse motor 45 in-lbs 5.1 Nm 7. Slowly move solenoid toward installed position and secure
jumper nut with screws. Tighten to 70 in-lbs (7.9 Nm).
8. Install reverse motor jumper and secure with nut and
1. See Figure 7-25. With spring oriented as shown, push
lockwasher. Tighten nut to 45 in-lbs (5.1 Nm).
spring into bore until it engages notch at middle of lever.
Verify that ends remain proud of mounting flange. 9. Install reverse motor.
2. Apply a small amount of grease where spring and lever INSTALLATION
mate.
sm06063
Reverse motor bracket screws 39-44 ft-lbs 52.9-59.7 Nm
Reverse motor screws 39-44 ft-lbs 52.9-59.7 Nm
Reverse motor solenoid ener- 24-30 in-lbs 2.7-3.4 Nm
gizer lead nut
Reverse motor solenoid power 60-84 in-lbs 6.8-9.5 Nm
lead nut
1. Remove all residual threadlocking compound from all

threaded holes in differential housing and reverse motor
bracket.
2. If reusing screws, remove all threadlocking compound
using a wire brush or wire wheel.
NOTE
Install new dowel pins if damaged or missing.
Figure 7-25. Engage Spring in Notch
LOCKER AND SEALANT (blue) to threads of three screws
and secure reverse motor bracket to differential housing.
sm06064
Tighten screws to 39-44 ft-lbs (52.9-59.7 Nm).
4. See Figure 7-22. Install lockwasher, RCM solenoid ground
(4) and battery ground jumper (3) on lower reverse motor
screw.
LOCKER AND SEALANT (blue) to threads of two screws
and fasten reverse motor to bracket. Tighten screws to
39-44 ft-lbs (52.9-59.7 Nm).
6. Install reverse motor solenoid energize lead (2) with nut
(metric) and lockwasher. Tighten to 24-30 in-lbs (2.7-3.4
Nm). Install boot.
7. Install reverse motor power cable (1) with nut (metric) and
lockwasher. Tighten to 60-84 in-lbs (6.8-9.5 Nm). Install
boot.
8. Install right rear wheel. See 2.6 REAR WHEELS.
Figure 7-26. Capture Lever in Slot NOTE
3. Engage ends of spring into chamfered holes in collar and km) after wheel installation.
push collar tight against mounting flange. 9. Connect battery negative cable. Tighten screw to 60-70
in-lbs (6.8-7.9 Nm).
4. Insert two screws with lockwashers through holes in
mounting flange and collar.

HOME
10. Install seat.


HOME
INITIAL DIAGNOSTICS 7.14

DESCRIPTION AND OPERATION Before diagnosing a concern, perform a general functional test
of the vehicle to verify the concern. This will also identify any
Use initial diagnostics as a starting point to efficiently other issues that may affect diagnostics. Use the procedures
troubleshoot concerns. A basic understanding of electronics in this chapter for initial diagnostics.
and a general knowledge of the vehicle are necessary to
effectively use this manual. NOTES
• When working through a diagnostic procedure, follow the
NOTES
steps in the order instructed. Never jump to a test in
• Certain diagnostic procedures require part removal. See another procedure. All "Go to test" statements refer to a
the service manual for details. test in that procedure.
• Certain diagnostic procedures require the use of special • To turn IGN ON the fob must be present while you press
tools. See diagnostic tools in the electrical diagnostic the engine stop switch.
manual.
• Certain diagnostic procedures require the use of tests that
have precise instructions. See diagnostics and
troubleshooting in the electrical diagnostic manual.
Table 7-4. Diagnostic Trouble Codes (DTCs) and Fault Conditions Priority Table
DTC PRIORITY FAULT CONDITION SOLUTION

ORDER
B2131 201 High beam output open 7.19 HEADLAMP DIAGNOSTICS
B2132 202 High beam output shorted high 7.19 HEADLAMP DIAGNOSTICS
B2133 203 High beam output shorted low 7.19 HEADLAMP DIAGNOSTICS
B2134 204 High beam output overloaded 7.19 HEADLAMP DIAGNOSTICS
B2136 197 Low beam output open 7.19 HEADLAMP DIAGNOSTICS
B2137 198 Low beam output shorted high 7.19 HEADLAMP DIAGNOSTICS
B2138 199 Low beam output shorted low 7.19 HEADLAMP DIAGNOSTICS
B2139 200 Low beam output overloaded 7.19 HEADLAMP DIAGNOSTICS
B2226 215 BAS input open 7.20 BAS DIAGNOSTICS
B2228 218 BAS input shorted low 7.20 BAS DIAGNOSTICS
P1772 271 Reverse actuator feedback low 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS
P1775 272 Reverse actuator feedback 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS
error
P1777 273 Reverse actuator low 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS
P1778 274 Reverse actuator high 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS
P1781 275 Reverse switch input error 7.21 REVERSE SWITCH SYMPTOMS AND DIAGNOSTICS
Table 7-5. Symptom Table
SYSTEM SYMPTOM DIAGNOSTIC PROCEDURE

Reverse Motor Reverse motor spins but does 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS
not drive
Reverse motor stalls or spins 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS
too slowly
Reverse motor runs on 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS
Reverse motor inoperative 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS

HOME
Table 7-5. Symptom Table
SYSTEM SYMPTOM DIAGNOSTIC PROCEDURE

Indicator Lamp Parking brake lamp always on 7.17 INDICATOR LAMP DIAGNOSTICS
Parking brake lamp inoperative 7.17 INDICATOR LAMP DIAGNOSTICS
Reverse indicator lamp always 7.17 INDICATOR LAMP DIAGNOSTICS
on
Reverse indicator lamp inoper- 7.17 INDICATOR LAMP DIAGNOSTICS
ative
Rear Lighting Brake lamps inoperative 7.18 REAR LIGHTING DIAGNOSTICS
Headlamp FLRT, high beam inoperative 7.19 HEADLAMP DIAGNOSTICS
FLRT, low beam inoperative 7.19 HEADLAMP DIAGNOSTICS
Dual lamp, high beam inoper- 7.19 HEADLAMP DIAGNOSTICS
ative
Dual lamp, low beam inoper- 7.19 HEADLAMP DIAGNOSTICS
ative

HOME
REVERSE MOTOR SYSTEM DIAGNOSTICS 7.15

DESCRIPTION AND OPERATION motor to engage and the vehicle to back up. Reverse is
disabled for any of the following conditions:
PART NUMBER TOOL NAME • Reverse switch on LHCM is released.
HD-41404 HARNESS CONNECTOR TEST KIT • Transmission is shifted into gear.
The reverse motor uses battery power to move the vehicle in • Engine is stopped.
reverse with the engine running and the transmission in neutral.
Table 7-6. Code Description
The reverse motor is designed for light load, short duration
use. Steep inclines, long distance travel in reverse or attempted DTC DESCRIPTION
operation with the brakes or parking brake applied or while the
P1772 Reverse actuator feedback low
vehicle is against resistance (such as a curb) will drain the
battery and may cause the reverse circuit breaker to trip. P1775 Reverse actuator feedback error
The reverse system is an electrical system with an output drive P1777 Reverse actuator low
connected directly to the vehicle drive when in operation. The P1778 Reverse actuator high
system uses a:
• Reverse motor.
ed03559
4
• Reverse motor solenoid.
• Reverse control solenoid. 3
5
• Reverse control module (RCM). 2
• 150 amp manual reset circuit breaker. 6
• Reverse hand switch (LHCM).
See Figure 7-28. The reverse motor and attached reverse 1
7
motor solenoid resembles a starter motor. The assembly is
single direction (reverse) only and cannot be used to move the
vehicle forward. Voltage to the reverse motor assembly is 8
provided through a 150 amp manual reset circuit breaker and
the RCM solenoid, in response to the output of the RCM.
Operation 1. RCM
2. 150 Amp circuit breaker [252B]
The ECM will enable reverse if conditions are correct.
3. RCM solenoid [251B]
• Reverse switch on LHCM is pressed. 4. RCM solenoid [251A]
5. 150 Amp circuit breaker [252A]
• Transmission is in neutral.
6. RCM solenoid [246]
• Vehicle is moving less than 2 mph (3 kph). 7. 150 Amp circuit breaker
8. RCM [245]
• Engine running at less than 1500 RPM.
Figure 7-27. Under Right Side Cover
• No reverse DTCs are present.
Upon enabling reverse function, the ECM will activate the
reverse telltale lamp located in the IM (FLHTCUTG) or
speedometer (FLRT) and indicate reverse enable status to
other modules via a CAN message.
1. Once the reverse enable status is acknowledged by the
BCM, the BCM supplies battery voltage through the (TN/V)
wire to RCM [245] terminal 3.
2. The RCM sends a signal to the ECM on the (TN/BE) wire.
3. See Figure 7-29. When reverse is enabled, the ECM sends
5 volts to the RCM through the (TN) wire. The RCM
activates the reverse control solenoid. The control solenoid
activates the reverse motor solenoid causing the reverse

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ed03552 ed03554
1
2
3 4
1. Reverse motor
Figure 7-29. LHCM: Reverse Switch
2. Reverse motor solenoid
3. Reverse motor solenoid terminal [248]
4. Reverse motor high current input terminal [249B]
5. Reverse motor solenoid high current input ter-
minal [249A]
Figure 7-28. Reverse Motor and Solenoid Assembly
ed03553

2. Reverse motor solenoid high current input terminal [249A]
4. Reverse motor and RCM ground
Figure 7-30. Reverse Motor and Solenoid Assembly

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Before proceeding with diagnostic tests, make sure to do all

pd00596
of the following:
• Check all fuses.
2 • Check that battery is fully charged.
1
• Check that charging system is working properly.
• Trip and reset the 150 Amp circuit breaker.
NOTE
See Figure 7-31. The circuit breaker is manually resettable
with a trip pushbutton and a reset lever.
To manually trip the circuit breaker:
1. Push down on the trip pushbutton.
2. Reset lever will extend out.
NOTE
1. Reset lever (push in direction of arrow to reset)
When the reset lever is extended as shown, the circuit breaker
2. Manual trip pushbutton
is open/tripped.
Figure 7-31. Reverse Motor Circuit Breaker 1. To reset, press the reset lever toward the circuit breaker
body until an audible click is heard and the lever is fully
Conditions for Settings seated against the circuit breaker body.
These DTCs will set while attempting to engage reverse. 2. If the circuit breaker repeatedly opens under non-strenuous
loading conditions, or if the reverse motor will not operate
• DTC P1772 will set if ECM [78-3] terminal 4 is shorted to
after resetting circuit breaker and checking fuses, proceed
ground.
with diagnostics.
• DTC P1775 will set if ECM has detected an error within
the reverse system. NOTES
• When the circuit breaker trips, the reverse motor pinion
• DTC P1777 will set if ECM [78-3] terminal 16 is shorted
gear engages the ring gear. This is normal.
to ground.
• There should be an audible "click" when resetting the cir-
• DTC P1778 will set if ECM [78-3] terminal 16 is shorted
cuit breaker. Press the reset switch until it is fully seated
to battery voltage.
against the circuit breaker body.
Diagnostic Tips • The reverse enable indicator may remain on while the
There is no breakout box available for testing the reverse motor circuit breaker is open.
system. When performing the diagnostic tests, use the HAR- It is very important that the vehicle starts and runs correctly. If
NESS CONNECTOR TEST KIT (Part No. HD-41404) and a the vehicle does not start and run properly, it can cause the
multimeter. reverse system to operate improperly.
The reverse system may not work properly if battery voltage
is lower than 10V. Connect battery to battery charger before
Connector Information
performing any diagnostic tests. For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
Raise the rear wheels off the ground by placing jack stands
the harness test kit terminal probes, see A.1 CONNECTORS.
under the rear axle before performing any diagnostic tests that
require pushing the reverse button.

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em01748
Instrument
ECM Cluster BCM
(BK) (GY) (BN)
Reverse Enable Feedback
Battery Fuse
Reverse Acviate Input
Reverse Light Power

Neutral Switch Input
CAN High
CAN Low
Accessory Power
Ground
System Power
System Power
Battery Fuse
CAN High
CAN Low
CAN High
CAN Low
8 2 5 7 [39A]
Ground
Ground
Ground
Ground
8 2 5 7 [39B]
[78A-1] [78A-2] [78A-3] [242A]
BK/GN
14 13 10 18 16 10 16 10 4 D2 D3 E2 G2 G4 L3 M2
W/BK
W/R
R/O
[78B-1] 14 13 10 [78B-2] 18 16 10 16 10 4 [78B-3] D2 D3 E2 G2 G4 L3 M2 [242B]
W/R
W/BK
R/GN
W/R
BK/GN
R/O
BK/GN
BK/GN
W/BK
R/GN
W
R/Y
BK/GN
TN/BE
TN
[1A]
TN/V
3 2 4 5
3 2 4 5 [1B]
W/R
W/BK
R/O
BK/GN
W/BK
[245A] [245B] W/R
RCM R/GN
To
Main
RCM Solenoid Ground 8 8 TN/GY
R/Y Harness
RCM Solenoid Power 7 7 TN/R
R/O
Reverse Enable Feedback 6 6 TN/BE V/GN
Ground 5 5 BK
Fuse Block
Reverse Activate Input 4 4 TN
[64B]
Reverse Light Power 3 3 TN/V System Power Fuse
Accesory Power 2 2 R/Y R/GN 4 3 V/GN
Battery Fuse
R/O 2 1 R
BK
[131B-2] 1 1 [131B-1]
[131A-2] 1 1 [131A-1]
TN/GY
TN/R
[246B] 1 2 Neutral
[246A] Switch Reverse Motor
1 2
Reverse Control [248] Solenoid [249A]
GN
BK
Solenoid
[251B]
BK BK (6AWG)
BK (14AWG)
BK
[252B]
GN
BK
[251A] [249B]
BK/GN
150A Manual
BK
Reverse Reset Circuit

[253] Motor Breaker
BK
[252A] GND 1
BK
BK
(14AWG)
Red Band
R
R
BK
BK
[5B] A B
BK
BK
BK
BK
Engine GND 1 Main

Battery Starter Fuse
Figure 7-32. Simplified Reverse Motor System FLHTCUTG

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em01749 ECM Speedometer BCM

(BK) (GY) (BN)
Battery Fuse
Reverse Light Power

CAN High
CAN Low
Accessory Power
Ground
W/BK
W/BK
W/R
W/R
System Power
System Power
Battery Fuse
CAN High
CAN Low
CAN High
CAN Low
4 5 10 11 [312B] 8 2 5 7 [39A]
Ground
Ground
Ground
Ground
4 5 10 11 [312A] 8 2 5 7 [39B]
W/R
W/R
W/BK
W/BK
[78A-1] [78A-2] [78A-3] [242A]
BK/GN
14 13 10 18 16 10 16 10 4 D2 D3 E2 G2 G4 L3 M2
W/BK
W/R
R/O
[78B-1] 14 13 10 [78B-2] 18 16 10 16 10 4 [78B-3] D2 D3 E2 G2 G4 L3 M2 [242B]
W/R
W/BK
R/GN
W/R
BK/GN
R/O
BK/GN
BK/GN
W/BK
R/GN
W
R/Y
BK/GN
TN/BE
TN
[20A]
TN/V
3 1 6 2
3 1 6 2 [20B]
W/R
W/BK
R/O
BK/GN
W/BK
[245A] [245B] W/R
RCM R/GN
To
Main
RCM Solenoid Ground 8 8 TN/GY
R/Y Harness
RCM Solenoid Power 7 7 TN/R
R/O
Reverse Enable Feedback 6 6 TN/BE V/GN
Ground 5 5 BK
Fuse Block
Reverse Activate Input 4 4 TN
[64B]
Reverse Light Power 3 3 TN/V System Power Fuse
Accesory Power 2 2 R/Y R/GN 4 3 V/GN
Battery Fuse
R/O 2 1 R
BK
[131B-2] 1 1 [131B-1]
[131A-2] 1 1 [131A-1]
TN/GY
TN/R
[246B] 1 2 Neutral
[246A] Switch Reverse Motor
1 2
Reverse Control [248] Solenoid [249A]
GN
BK
Solenoid
[251B]
BK BK (6AWG)
BK (14AWG)
BK
[252B]
GN
BK
[251A] [249B] BK/GN

150A Manual
BK
Reverse Reset Circuit

[253] Motor Breaker
BK
[252A] GND 1
BK
BK
(14AWG)
Red Band
R
R
BK
BK
[5B] A B
BK
BK
BK
BK
Engine GND 1 Main

Battery Starter Fuse
Figure 7-33. Simplified Reverse Motor System: FLRT

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DTC P1772 DTC P1775
PART NUMBER TOOL NAME PART NUMBER TOOL NAME

HD-41404 HARNESS CONNECTOR TEST KIT HD-41404 HARNESS CONNECTOR TEST KIT
HD-50390-1 BREAKOUT BOX HD-50390-1 BREAKOUT BOX
HD-50390-4 ECM CABLE HD-50390-2 BCM/RADIO CABLE
HD-50390-4-P ECM OVERLAY HD-50390-2-P BCM/RADIO OVERLAY
HD-50390-4 ECM CABLE
Table 7-7. DTC P1772 Diagnostic Faults HD-50390-4-P ECM OVERLAY
POSSIBLE CAUSES
Short to ground in reverse enable feedback wire Table 7-8. DTC P1775 Diagnostic Faults
RCM malfunction POSSIBLE CAUSES
Open in reverse enable feedback wire
1. Reverse Enable Feedback Short to
Open in backup light power
Ground Test
RCM malfunction
1. Turn IGN OFF.
2. Connect BREAKOUT BOX (Part No. HD-50390-1) and 1. Reverse Enable Feedback Short to
ECM CABLE (Part No. HD-50390-4) to wiring harness Voltage Test
[78B-1], [78B-2] and [78B-3], leaving ECM [78A-1], [78A-
2] and [78A-3] disconnected. 1. Turn IGN OFF.
3. Verify ECM OVERLAY (Part No. HD-50390-4-P) is in 2. Connect BREAKOUT BOX (Part No. HD-50390-1) and
position on BOB. ECM CABLE (Part No. HD-50390-4) to wiring harness
[78B-1], [78B-2] and [78B-3], leaving ECM [78A-1], [78A-
4. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 2] and [78A-3] disconnected.
41404), test continuity between BOB [78-3] terminal 4 and
ground. 3. Verify ECM OVERLAY (Part No. HD-50390-4-P) is in
position on BOB.
5. Is continuity present?
4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
a. Yes. Repair short to ground in (TN/BE) wire. 41404), test voltage between BOB [78-3] terminal 4 and
b. No. Go to Test 2. ground.
5. Turn IGN ON.
2. Wiggle Test
6. Is voltage present?
1. Perform wiggle test.
a. Yes. Repair short to voltage in (TN/BE) wire
2. Is an intermittent short present?
b. No. Go to Test 2.
a. Yes. Repair short to ground in (TN/BE) wire. (5041)
b. No. Replace RCM. (6968) 2. Reverse Enable Feedback Open Test
1. Turn IGN OFF.
2. Disconnect RCM [245].
3. Test continuity between BOB [78-3] terminal 4 and RCM
[245B] terminal 6.
a. Yes. Go to Test 3.
b. No. Repair open in (TN/BE) wire.
3. Backup Light Power Open Test

1. Remove ECM BOB and connect all [78].
2. Connect BREAKOUT BOX (Part No. HD-50390-1) and
BCM/RADIO CABLE (Part No. HD-50390-2) to wire har-
ness [242B], leaving [242A] disconnected.
3. Verify BCM/RADIO OVERLAY (Part No. HD-50390-2-P)
is in position on BOB.

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4. Test continuity between BOB terminal G2 and RCM [245B] 4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
terminal 3. 41404), test continuity between BOB [78-3] terminal 16
and ground.
a. Yes. Go to Test 4. 5. Is continuity present?
a. Yes. Repair short to ground in (TN) wire.
b. No. Repair open in (TN/V) wire. (5041)
4. Backup Light Power Short to Ground Test
1. Test continuity between BOB terminal G2 and ground.
2. Wiggle Test
a. Yes. Repair short to ground in (TN/V) wire. (5041) 2. Is an intermittent short present?
a. Yes. Repair short to ground in (TN) wire. (5041)
b. No. Replace RCM. (6968)
5. Backup Light Power Short to Voltage Test
1. Test voltage between BOB terminal G2 and ground.
DTC P1778
2. Turn IGN ON. PART NUMBER TOOL NAME
3. Is voltage present? HD-41404 HARNESS CONNECTOR TEST KIT
a. Yes. Repair short to voltage in (TN/V) wire. (5041) HD-50390-1 BREAKOUT BOX
b. No. Go to Test 6. HD-50390-4 ECM CABLE
HD-50390-4-P ECM OVERLAY
6. Wiggle Test
Table 7-10. DTC P1778 Diagnostic Faults
2. Is an intermittent open or short present?
a. Yes. Repair open/short in (TN/BE) or (TN/V) wire. POSSIBLE CAUSES
(5041) Short to voltage in reverse actuator input wire
b. No. Replace RCM. (6968) RCM malfunction
DTC P1777 1. Reverse Actuator Input Short to Voltage

Test
PART NUMBER TOOL NAME 1. Turn IGN OFF.
HD-41404 HARNESS CONNECTOR TEST KIT
HD-50390-1 BREAKOUT BOX ECM CABLE (Part No. HD-50390-4) to wiring harness
HD-50390-4 ECM CABLE [78B-1], [78B-2] and [78B-3], leaving ECM [78A-1], [78A-
2] and [78A-3] disconnected.
HD-50390-4-P ECM OVERLAY
3. Verify ECM OVERLAY (Part No. HD-50390-4-P) is in
position on BOB.
POSSIBLE CAUSES 41404), test voltage between BOB [78-3] 16 and ground.
Short to ground in reverse actuator input wire 5. Turn IGN ON.
RCM malfunction 6. Is voltage present?
a. Yes. Repair short to voltage in (TN) wire.
1. Reverse Actuator Input Short to Ground
Test b. No. Go to Test 2.
1. Turn IGN OFF. 2. Wiggle Test

2. Connect BREAKOUT BOX (Part No. HD-50390-1) and 1. Perform wiggle test.
ECM CABLE (Part No. HD-50390-4) to wiring harness
[78B-1], [78B-2] and [78B-3], leaving ECM [78A-1], [78A- 2. Is an intermittent short to voltage present?
2] and [78A-3] disconnected. a. Yes. Repair short to voltage in (TN) wire. (5041)
3. Verify ECM OVERLAY (Part No. HD-50390-4-P) is in b. No. Replace RCM. (6968)
position on BOB.

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REVERSE MOTOR SPINS BUT DOES NOT 2. Is voltage drop greater than 1 volt?
DRIVE a. Yes. Go to Test 3.
b. No. Replace reverse motor solenoid. (1832)
Table 7-11. Reverse Motor Spins But Does Not Drive
Diagnostic Faults 3. Reverse Motor Solenoid Circuit Test
POSSIBLE CAUSES 1. Perform voltage drop test from battery positive to reverse
motor solenoid terminal [252B] with reverse motor
Ring gear malfunction engaged.
Reverse motor malfunction
2. Is voltage drop greater than 1 volt?
Reverse motor solenoid malfunction
1. Ring Gear Test b. No. Repair/replace circuit breaker to reverse motor
1. Inspect ring gear for damage. solenoid wire. (5041)
2. Is damage present? 4. Circuit Breaker Voltage Drop Test

a. Yes. Replace ring gear. (1824) 1. Perform voltage drop test from battery positive to reverse
b. No. Go to Test 2. motor solenoid terminal [252A] with reverse motor
engaged.
2. Reverse Motor Solenoid Test 2. Is voltage drop greater than 1 Volt?
1. Perform reverse motor solenoid test. See 7.16 REVERSE a. Yes. Go to Test 5.
MOTOR TESTING, Reverse Motor Solenoid.
b. No. Replace circuit breaker. (1834)
2. Did reverse motor solenoid pass the test?
a. Yes. Replace reverse motor. (1825) 5. Vehicle Starter Test
b. No. Replace reverse motor solenoid. (1832) 1. Perform voltage drop between battery positive and the
high current power from the vehicle starter.
REVERSE MOTOR STALLS OR SPINS TOO 2. Is voltage drop greater than 1 Volt?
SLOWLY a. Yes. Repair/replace vehicle starter to battery positive
wire. (5041)
Table 7-12. Reverse Motor Stalls or Spins Too Slowly b. No. Repair/replace vehicle starter to circuit breaker
Diagnostic Faults wire. (5041)
POSSIBLE CAUSES
6. Ground Circuit Test
Manual circuit breaker malfunction
1. Perform voltage drop between battery negative and
reverse motor mounting bolts with reverse motor engaged.
2. Is voltage drop greater than 1 Volt?
Mechanical malfunction
a. Yes. Clean/repair mounting bolts and mounting sur-
face or ground cable from transmission case to
1. Circuit Breaker Test
reverse motor mounting bolt. (5041)
1. Inspect circuit breaker.
2. Reset if necessary.
3. Perform voltage drop test from battery positive to reverse 7. Reverse Motor Current Draw On Vehicle
motor solenoid terminal [249B] with reverse motor Test
engaged. 1. Perform reverse motor current draw test on vehicle. See
4. Is voltage drop greater than 1 volt? 7.16 REVERSE MOTOR TESTING.
a. Yes. Go to Test 2. 2. Are test results within range?
b. No. Go to Test 6. a. Yes. Go to Test 8.
2. Reverse Motor Solenoid Voltage Drop
Test 8. Reverse Motor Test
1. Perform voltage drop test from battery positive to reverse 1. Perform reverse motor solenoid test. See 7.16 REVERSE
motor solenoid terminal [249A] with reverse motor MOTOR TESTING, Reverse Motor Solenoid.
engaged.

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2. Did reverse motor solenoid pass the test? 3. Turn IGN ON.
a. Yes. Replace reverse motor. (1828) 4. With the reverse drive button not pushed, test voltage
b. No. Replace reverse motor solenoid. (1832) between [248] and ground.
5. Is battery voltage present?
9. Reverse Motor Free Running Current a. Yes. Repair short to voltage on (BK) wire. (5041)
Draw Test
b. No. Replace RCM solenoid. (1818)
1. Perform reverse motor free running current draw bench
test. See 7.16 REVERSE MOTOR TESTING, Testing 4. RCM Solenoid Control Circuit Test
Reverse Motor on Bench.
1. Turn IGN OFF.
2. Are tests results within range?
2. Disconnect [245].
a. Yes. Repair source of mechanical bind. (1827)
3. Turn IGN ON.
b. No. Replace reverse motor. (1828)
4. With the reverse drive button not pushed, test voltage
REVERSE MOTOR RUNS ON between [246B] and ground.
5. Is battery voltage present?
a. Yes. Repair short to voltage on (TN/R) wire. (5041)
b. No. Replace RCM. (1822)
Table 7-13. Reverse Motor Runs On Diagnostic Faults REVERSE MOTOR INOPERATIVE
POSSIBLE CAUSES
HD-50390-1 BREAKOUT BOX
Short to voltage in ground circuit
HD-50390-2 BCM/RADIO CABLE
Reverse switch malfunction
HD-50390-2-P BCM/RADIO OVERLAY
1. Reverse Solenoid Control Circuit Test HD-50390-4 ECM CABLE
1. Trip circuit breaker. HD-50390-4-P ECM OVERLAY
2. Disconnect reverse motor solenoid [248].
3. Reset circuit breaker. Table 7-14. Reverse Motor Inoperative Diagnostic Faults
4. Turn IGN ON. POSSIBLE CAUSES
5. Does reverse motor continue to run on? RCM malfunction

a. Yes. Replace reverse motor solenoid. (1818) Reverse motor malfunction
Short to voltage in ground circuit
2. RCM Solenoid Circuit Test Reverse switch malfunction
1. Turn IGN OFF.
1. Reverse Switch Function Test
1. Verify conditions are correct to enable reverse. See
3. Turn IGN ON. 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS.
4. With the reverse drive button not pushed and using HAR- 2. Start engine.
NESS CONNECTOR TEST KIT (Part No. HD-41404), test
voltage between [248] and ground. 3. Activate reverse button on LHCM.
5. Is battery voltage present? 4. Does reverse indicator illuminate?

a. Yes. Go to Test 3. a. Yes. Solid "R". Go to Test 2.
b. No. Go to Test 4. b. Yes. Flashing "R". Go to Test 15.

c. No. See 7.17 INDICATOR LAMP DIAGNOSTICS.
3. Reverse Motor Solenoid Control Circuit
Test
1. Turn IGN OFF.

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2. RCM Circuit Test 5. Is voltage greater than 10.0V?
1. With reverse drive button pressed and using HARNESS a. Yes. Go to Test 8.
CONNECTOR TEST KIT (Part No. HD-41404), test voltage b. No. Go to Test 10.
between reverse motor solenoid [248] and ground.
2. Is voltage greater than 10.0V? 8. RCM Solenoid Ground Circuit Test
a. Yes. Go to Test 3. 1. Turn IGN OFF.
b. No. Go to Test 6. 2. Test resistance between [246B] terminal 2 and ground.

3. Is resistance less than 1 Ohm?
3. Reverse Motor High Current Circuit Test
a. Yes. Replace RCM solenoid. (1832)
1. With reverse button pressed, test voltage between reverse
motor solenoid [249B] and ground. b. No. Go to Test 9.
2. Is voltage greater than 10.0V? 9. RCM Ground Circuit Test

a. Yes. Go to Test 4. 1. Disconnect [245].
b. No. Go to Test 12. 2. Test resistance between [245B] terminal 8 and [246B]
terminal 2 (TN/GY).
4. Ground Circuit Test
3. Is resistance less than 0.5 Ohm?
1. Turn IGN OFF.
a. Yes. Replace RCM. (1831)
2. Test continuity between reverse motor mounting bolt [253]
and ground. b. No. Repair open in (TN/GY) wire. (5041)
3. Is continuity present? 10. RCM Solenoid Control Circuit Open Test

a. Yes. Go to Test 5. 1. Turn IGN OFF.
b. No. Clean/repair mounting bolts and mounting sur- 2. Disconnect RCM [245].
face. (5041)
3. Test resistance between [246B] terminal 1 and [245B]
5. Reverse Motor Solenoid Test terminal 7 (TN/R).
1. Perform the reverse motor solenoid test. See 4. Is resistance less than 0.5 Ohm?
7.16 REVERSE MOTOR TESTING. a. Yes. Replace RCM.
2. Did reverse motor solenoid pass the test? b. No. Repair open in (TN/R) wire. (5041)
a. Yes. Replace reverse motor. (1828)
b. No. Replace reverse motor solenoid. (1832)
11. Circuit Breaker Supply Voltage Test
1. Test voltage between circuit breaker [252A] and ground.
6. Reverse Motor Control Circuit Test 2. Is voltage greater than 10.0V?
1. Start engine. a. Yes. Repair open between [251A] and [252A] (BK)
2. With reverse button pressed, test voltage at between wire. (5041)
reverse control solenoid [251A & B] and ground. b. No. Repair open between [252A] and starter (BK)
3. Is voltage greater than 10.0V at both terminals? wire. (1830)
a. Yes. Repair open between [251B] and [248] (BK)
wire. (5041)
12. Reverse Motor Solenoid Test
1. Start engine.
b. No, only terminal [251A]. Go to Test 7.
2. With reverse button pressed, test voltage between reverse
c. No, neither terminal. Go to Test 11. motor solenoid [249A] and ground.
7. RCM Solenoid Control Circuit Test 3. Is voltage greater than 10.0V?

1. Turn IGN OFF. a. Yes. Replace reverse motor solenoid. (1832)
2. Disconnect [246]. b. No. Go to Test 13.
3. Start engine. 13. Reverse Motor Circuit Solenoid Test

4. With reverse switch pressed, test voltage between [246B] 1. With reverse button pressed, test voltage between circuit
terminal 1 (TN/R) wire and ground. breaker [252B] and ground.

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2. Is voltage greater than 10.0V? 3. Verify BCM/RADIO OVERLAY (Part No. HD-50390-2-P)
a. Yes. Repair open between [249A] and [252B] (BK) is in position on BOB.
wire. (5041) 4. Start engine.
b. No. Go to Test 14. 5. With reverse button pressed, test voltage between BOB
terminal G2 and ground.
14. Circuit Breaker Test
6. Is voltage greater than 10.0V?
1. With reverse button pressed, test voltage between circuit
breaker [252A] and ground. a. Yes. Go to Test 19.
2. Is voltage greater than 10.0V? b. No. Replace BCM.
a. Yes. Replace circuit breaker. (1834) 19. Reverse Enable Feedback Test
b. No. Repair open in (BK) wire between [252A] and 1. Turn IGN OFF.
starter. (5041)
2. Remove BCM BOB, and connect [242].
15. Neutral Circuit Test 3. Connect BREAKOUT BOX (Part No. HD-50390-1) and
1. Verify transmission is in neutral. ECM CABLE (Part No. HD-50390-4) between wire harness
[78B-1], [78B-2], [78B-3] and ECM [78A-1], [78A-2], [78A-
2. Is neutral lamp functional? 3].
4. Verify ECM OVERLAY (Part No. HD-50390-4-P) is in
b. No. See neutral lamp diagnostics. position on BOB.
5. Start engine.
16. Accessory Circuit Open Test
1. Turn IGN OFF. 6. With reverse button pressed, test voltage between BOB
[78-3] terminal 4 and [78-2] terminal 18.
2. Disconnect RCM [245].
7. Is voltage greater than 10.0V?
3. Turn IGN ON. a. Yes. Go to Test 20.
4. Test voltage between [245B] terminal 2 (R/Y) wire and b. No. Replace RCM.
ground.
5. Is voltage greater than 10.0V? 20. Reverse Activate Test
a. Yes. Go to Test 17. 1. Press reverse button two times, test voltage between BOB
[78-3] terminal 16 and ground.
b. No. Repair open in (R/Y) wire. (5043)
2. Is voltage between 4-6V?
17. Ground Circuit Open Test a. Yes. Go to Test 21.
1. Turn IGN OFF. b. No. Replace ECM.
41404), test resistance between RCM [245B] terminal 5 21. Reverse Activate Input Open Test
and ground (BK) wire. 1. Turn IGN OFF.
3. Is resistance less than 0.5 Ohm? 2. Disconnect RCM [245].
3. Test resistance between BOB [78-3] terminal 16 and
b. No. Repair open in (BK) wire. (5041) [245B] terminal 4.
18. Backup Light Power Test
a. Yes. Replace RCM.
1. Connect [245].
b. No. Repair open in (TN) wire. (5041)
BCM/RADIO CABLE (Part No. HD-50390-2) to wire har-

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REVERSE MOTOR TESTING 7.16

TESTING REVERSE MOTOR ON TESTING REVERSE MOTOR ON BENCH
MOTORCYCLE Free Running Current Draw Test
Reverse Motor Current Draw Test 1. Place reverse motor in vise, using a clean shop towel to
prevent scratches or other damage.
NOTE
Make sure the battery is fully charged. 2. See Figure 7-35. Attach one heavy jumper cable (6 gauge
minimum).
See Figure 7-34. Check reverse motor current draw with an
induction ammeter before disconnecting battery. a. Connect one end to the starter mounting flange.
1. Raise rear wheels of vehicle off the ground. See b. Connect the other end to the negative (-) terminal of
1.2 LIFTING MOTORCYCLE WITH A JACK. a fully charged battery.
2. Verify the transmission is in neutral. 3. Connect a second heavy jumper cable (6 gauge minimum).
3. Clamp induction ammeter over positive battery cable next a. Connect one end to the positive (+) terminal of the
to reverse motor. battery.
4. Start engine. b. Connect the other end to the battery terminal 4 on

the reverse motor solenoid. Place an induction
5. Activate reverse motor controls while reading ammeter. ammeter over cable.
a. Typical reverse motor current draw is approximately
90 Amperes. 4. Connect a smaller jumper cable (14 gauge minimum).
a. Connect one end to the positive (+) terminal of the
b. If current draw exceeds 150 Amperes, the problem
battery.
may be in the reverse motor or reverse motor drive.
Remove reverse motor for further tests. See b. Connect the other end to the solenoid relay terminal.
7.16 REVERSE MOTOR TESTING, Testing Reverse
Motor on Bench. 5. Check ammeter reading.
a. Ammeter should show 90 Amps maximum.
NOTE
b. If reading is higher, replace the reverse motor
Use a DC current probe if an induction ammeter is not avail- assembly.
able.
c. If starter current draw on the vehicle was over 150
ed01876 Amps and this test was within specification, there may
3 be a problem with the mechanical components of the
2 reverse drive.
1. Reverse motor
2. Motor control solenoid
3. Induction ammeter
4. Battery
Figure 7-34. Reverse Motor Current Draw Test

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ed01877 ed01873
3
2 2
5
1 1
4
3
1. Reverse motor 1. Reverse motor

2. Motor control solenoid 2. Motor control solenoid
3. Induction ammeter 3. Battery
4. Battery
Figure 7-36. Pull-In Test
5. Solenoid terminal
6. Mounting flange bolt
Figure 7-35. Free Running Current Draw Test
SOLENOID HOLD-IN TEST
1. See Figure 7-37. With test leads still connected in the
manner specified in 7.16 REVERSE MOTOR TESTING,
REVERSE MOTOR SOLENOID
Solenoid Pull-In Test, disconnect solenoid motor ter-
Do not disassemble solenoid. Before testing, disconnect field minal/battery negative test lead at negative battery post
wire from motor terminal as shown in Figure 7-36. only; reconnect loose end of this test lead to positive bat-
tery post.
To prevent damage to the solenoid, perform each test for only
three to five seconds. 2. Observe reverse motor pinion.
Perform the solenoid pull-in, hold-in, and return tests together a. If reverse motor pinion remains extended, solenoid
in one continuous operation. Conduct all three tests one after is working properly.
the other in the sequence given without interruption.
b. If reverse motor pinion retracts, replace the solenoid.
SOLENOID PULL-IN TEST
1. See Figure 7-36. Use a 12 Volt battery and connect three
separate test leads as follows:
a. Solenoid housing to negative battery post.
b. Solenoid motor terminal to negative battery post.
c. Solenoid relay terminal to positive battery post.
2. Observe reverse motor pinion.

a. If reverse motor pinion extends strongly, solenoid is
working properly.
b. If reverse motor pinion does not extend strongly,
replace the solenoid.

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2. Observe reverse motor pinion.

ed01874
a. If reverse motor pinion retracts, solenoid is working
2 properly.
b. If reverse motor pinion does not retract, replace the
solenoid.
ed01875
1 2
1
3
1. Reverse motor
2. Motor control solenoid 3
3. Battery
Figure 7-37. Hold-In Test
SOLENOID RETURN TEST

1. Reverse motor
1. See Figure 7-38. With test leads still connected in the 2. Motor control solenoid
manner specified at the end of 7.16 REVERSE MOTOR 3. Battery
TESTING, Solenoid Hold-In Test, disconnect solenoid
relay terminal/positive battery post test lead at either end. Figure 7-38. Return Test

HOME
INDICATOR LAMP DIAGNOSTICS 7.17

DESCRIPTION AND OPERATION trolled through messages over the CAN bus and the HD-Link
communication systems.
See Figure 7-39. These are several gauges with indicators in
each gauge. These are integral to the gauges and are con-
ed03778
3 4 6
7 9
2 5
1 8 10
12
23 22 11
21 17
20 19 18 16 15 14 13 ABS
1. Fuel gauge 13. Not used

2. Low fuel lamp 14. Auxiliary/fog lamp indicator lamp
3. Speedometer 15. Reverse lamp
4. Security lamp 16. Headlamp high beam lamp
5. Not used 17. Cruise control lamp
6. Tachometer 18. Check engine lamp
7. Engine coolant temperature lamp 19. Neutral lamp
8. Light sensor (not an indicator) 20. Gear indicator
9. Battery discharge lamp 21. Odometer window
10. Voltmeter 22. Oil pressure lamp
11. Right turn signal indicator lamp 23. Left turn signal indicator lamp
12. Parking brake lamp
Figure 7-39. Indicator Lamps: FLHTCUTG

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ed03812 ed03556
R
9
Figure 7-41. Parking Brake Switch
8
ABS
1 7 Diagnostic Tips
2 6 If an indicator lamp is inoperative, perform a WOW test to verify
3 4 5 the lamp illuminates.
1. Not used Connector Information

2. Check engine lamp For additional information about the connectors in the following
3. Low fuel lamp diagram(s) and diagnostic procedure(s), including the color of
4. Odometer window the harness test kit terminal probes, see A.1 CONNECTORS.
5. Reverse lamp
6. Battery discharge lamp
7. Cruise control lamp
8. Parking brake lamp
9. Security lamp
Figure 7-40. Indicator Lamps: FLRT
Parking Brake Lamp

The parking brake switch opens when the parking brake is
engaged. This illuminates the parking brake indicator.
The parking brake indicator is controlled through the (TN/GN)
wire connected to the IM (FLHTCUTG) or BCM (FLRT). When
ground is removed from [39] terminal 4, the IM (FLHTCUTG)
or [242] terminal D4, the BCM (FLRT) illuminates the parking
brake indicator.
Table 7-15. Parking Brake Specification
SENSOR SPECIFICATION
Gap 0.177-0.197 in (4.5-5.0 mm)
Reverse Lamp
Upon enabling reverse function, the ECM will activate the
reverse telltale lamp located in the IM through a CAN message.
Solid "R" indicates conditions for engaging reverse are met.
Flashing "R" indicates conditions for engaging reverse are NOT
met.

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em01651 em01750
BCM IM
BCM
Parking Brake
Battery Fuse
Parking Brake Switch

CAN High
CAN High
Speedometer
CAN Low
CAN Low
Ground
Ground
Battery Fuse
CAN High
CAN High
CAN Low
CAN Low
G4 E2 D2 [242A] 8 2 5 7 4 [39A]
Ground
Ground
G4 E2 D2 [242B] 8 2 5 7 4 [39B]
W/R
W/BK
W/R
R/O
BK/GN
TN/GN
W/BK
BK/GN
G4 E2 D4 D2 [242A] 8 2 5 7 [39A]
Battery G4 E2 D4 D2 [242B] 8 2 5 7 [39B]
R/O
Fuse
W/R
W/BK
W/R
R/O
BK/GN
W/BK
BK/GN
TN/GN
R/O
Battery
W/R 2 2 W/R
Fuse
W/BK 3 3 W/BK
R/O 4 4 R/O
W/R 1 1 W/R
BK/GN 5 5 BK/GN
W/BK 3 3 W/BK
8 8
R/O 6 6 R/O
9 9
BK/GN 2 2 BK/GN
[1B] [1A]
[20B] [20A]
TN/GN 7 7 TN/GN
TN/GN 1 1
[2B] [2A] Parking
Brake
Switch
BK/GN 2 2
TN/GN 1 1
Parking
Brake [276A] [276B]
Switch
BK/GN 2 2
BK/GN
[276A] [276B]
BK/GN
GND 1
GND 1
Figure 7-42. Parking Brake Switch Circuit: FLHTCUTG Figure 7-43. Parking Brake Switch Circuit: FLRT

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PARKING BRAKE LAMP ALWAYS ON 4. Is resistance greater than 0.5 Ohms?

a. Yes. Repair open between [276A] terminal 2 and
PART NUMBER TOOL NAME ground (TN/GN). (5041)
HD-41404 HARNESS CONNECTOR TEST KIT b. No. FLHTCUTG Go to Test 4.
HD-42682 BREAKOUT BOX c. No. FLRT Go to Test 5.
HD-46601 BREAKOUT BOX ADAPTERS
4. Open TN/GN at [39] Test
HD-50390-1 BREAKOUT BOX
1. Connect BREAKOUT BOX ADAPTERS (Part No. HD-
46601) to [39]. Attach connectors from BREAKOUT BOX
HD-50390-2-P BCM/RADIO OVERLAY (Part No. HD-42682) to harness adapters, leaving [39A]
disconnected.
Table 7-16. Parking Brake Lamp Always On Diagnostic 2. Test resistance between BOB terminal 4 and [276A] ter-
Faults minal 1 (TN/GN).
POSSIBLE CAUSES 3. Is resistance greater than 0.5 Ohms?

a. Yes. Repair open between [276A] terminal 1 and IM
Open in parking brake switch circuit
[39B] terminal 4 (TN/GN). (5041)
Parking brake switch malfunction
b. No. Replace IM.
Incorrect gap between sensor and magnet
Missing magnet 5. Open TN/GN at [242] Test
NOTE BCM/RADIO CABLE (Part No. HD-50390-2) to wire har-
Before testing, verify the following: ness [242B], leaving [242A] disconnected.
• The magnet is present. 2. Verify BCM/RADIO OVERLAY (Part No. HD-50390-2-P)
• The gap between sensor and magnet is within specification
when parking brake is released. 3. Test resistance between BOB terminal D4 and [276A]
terminal 1 (TN/GN).
1. Parking Brake Circuit Test
4. Is resistance greater than 0.5 Ohms?
1. Release parking brake.
a. Yes. Repair open between [276A] terminal 1 and
2. Does parking brake lamp turn off? [242B] terminal D4 (TN/GN). (5041)
a. Yes. Test for intermittent. Perform wiggle test. b. No. Go to Test 6.
6. BCM Test
2. Switch Test 1. Turn IGN ON.
1. Turn IGN OFF. 2. Does parking brake lamp illuminate?
2. Disconnect parking brake switch [276]. a. Yes. Replace speedometer.
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD- b. No. Replace BCM.
41404), jumper between [276A] terminals 1 and 2.
4. Turn IGN ON. PARKING BRAKE LAMP INOPERATIVE
5. Did parking brake lamp turn off? PART NUMBER TOOL NAME
a. Yes. Replace parking brake switch. (6020) HD-41404 HARNESS CONNECTOR TEST KIT
3. Open BK/GN Test Table 7-17. Parking Brake Lamp Inoperative Diagnostic
Faults
1. Turn IGN OFF.
POSSIBLE CAUSES
2. Remove jumper from [276A].
Parking brake switch malfunction
3. Test resistance between [276A] terminal 2 and ground
Short to ground in parking brake circuit
(BK/GN).
1. Parking Brake Switch Test
1. Turn IGN OFF.
2. Disconnect parking brake switch [276].

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3. Turn IGN ON. REVERSE INDICATOR LAMP ALWAYS ON

4. Did parking brake lamp turn ON?
a. Yes. Replace parking brake switch. (6020) Table 7-18. Reverse Indicator Lamp Always On Diagnostic
Faults
b. No. FLHTCUTG Go to Test 2.
POSSIBLE CAUSES
c. No. FLRT Go to Test 3.
Indicator malfunction
2. Grounded TN/GN at [39] Test
1. Reverse Indicator Function Test
1. Turn IGN OFF.
1. Operate reverse switch.
2. Disconnect speedometer [39].
2. Does reverse mode function correctly?
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD- a. Yes. Replace IM. (6020)
41404), test continuity between [276A] terminal 1 and
ground. b. No. See reverse DTCs.
4. Is continuity present? REVERSE INDICATOR LAMP INOPERATIVE

a. Yes. Repair short to ground between [276A] terminal
1 and ground. (5041)
Table 7-19. Reverse Indicator Lamp Inoperative Diagnostic
b. No. Replace IM. Faults
POSSIBLE CAUSES
3. Grounded TN/GN at [242] Test
Indicator malfunction
1. Turn IGN OFF.
Reverse circuit
2. Disconnect BCM [242].
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 1. Reverse Indicator Function Test
41404), test continuity between [276A] terminal 1 and 1. Operate reverse switch.
ground.
2. Does reverse mode function correctly?
a. Yes. Replace IM. (6020)
a. Yes. Repair short to ground between [276A] terminal
1 and ground. (5041) b. No. See reverse DTCs.
b. No. Replace BCM.

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REAR LIGHTING DIAGNOSTICS 7.18

REAR LIGHTING ed01864
1 2
General
See Figure 7-45. The rear lighting system uses two similar tail
lamp assemblies and an independent license plate lamp
assembly. The tail lamps function as brake, running and turn
signals.
Rear Running Lamps

The bulb type tail lamp assemblies use one dual-filament bulb
each.
• One filament is for running lights and the other is for brake
and turn indication.
• The running lights are powered through the lighting fuse.
• The license plate lamp is a single filament bulb and oper- 1. Tail lamp connector [93]
ates with the running lights. 2. Harness connector [94]
• Tail lamps and the license plate lamp illuminate when the Figure 7-44. Tail Lamp Assembly (Bulb)
ignition switch is ON.
Brake Lamps and Rear Turn Signals DIAGNOSTICS

Brake and rear turn indicators use the same lamps in the tail PART NUMBER TOOL NAME
lamp assemblies, but different filaments. Pressing the brake
pedal or actuating the front brake lever causes the brake lamps HD-39978 DIGITAL MULTIMETER (FLUKE 78)
to illuminate. Applying brakes during a turn will illuminate the
opposite lamp from the indicating signal, if a signal has been When performing the diagnostic tests, use a DIGITAL MULTI-
selected. When indicating a right or left turn, the appropriate METER (FLUKE 78) (Part No. HD-39978) or equivalent, for
signal lamp flashes regardless of brakes being applied. voltage and resistance measurements, and where possible,
amperage.
LED Tail Lamps
Diagnostic Tips
LED tail lamp assemblies are 4-wire devices. Power is supplied
by the BCM. • Rear turn signals work in tandem with the front turn sig-
nals. If the rear or front turn signal lamp does not illuminate
when it should, check the integrity of the bulb or light for
the front LED turn signals in the affected turn signal before
proceeding with the diagnostics.
• If the brake lamps and license plate lamp are inoperative
at the same time, check the fuse. Other accessories will
also be inoperative at that time.
• Lighting ground is through the lighting harness to the
vehicle frame. Make sure the ground connections are good
before replacing parts and assemblies.
For additional information about the connectors in the following

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em01751
[259A] [259B]
BCM
Battery Power 1 1 R [5B]
Running Light Power J3 J3 BE R B
R
Main Fuse
Rear Right Turn Signal K2 K2 BE/BN Fuse R A
11 Block
Rear Left Turn Signal K4 K4 BE/V
Accessory Power M2 M2 R/Y P&A

BK
[242A] [242B] 12
[64B]
R/BE
R
Battery
R
Transmission
Starter
BK
BE/BN
R/BE
BE/V
R/Y
BE
BK
GND 2
[7A] 1 2 3 5 6 7
[7B] 1 2 3 5 6 7
R/Y
BE/BN
R/BE
BE/V
BE
BK
BE/BN
BE/V
BK
BE
BK
BE
6 5 4 3 2 1 [94LB] 6 5 4 3 2 1 [94RB]
6 5 4 3 2 1 [94LA] 6 5 4 3 2 1 [94RA]
1 1
2 2
R/BE 2 Trunk/Dome
Circuit BK 1 Lamp Circuit
Board FLHTCUTG Board
[279A]
R/Y
BK
1 1
2 2
4 4 BK 3 1 [233A] 4 4 BK
1 3 3 R/Y 1 3 3 R/Y
2 3 1 [233B] 2
3 1 1 BE 3 1 1 BE
BE
BK
[93LA] [93LB] [93RA] [93RB]
BK
R/Y
R/Y
BE
BK
BE
BK
BE
LP Lamp
FLHTCUTG
Left Right
STT STT
Figure 7-45. Rear Lighting System (Bulb)

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em01782
[259A] [259B]
BCM
Battery Power 1 1 R [5B]
Running Light Power J3 J3 BE R B
R
Main Fuse
Rear Right Turn Signal K2 K2 BE/BN Fuse R A
11 Block
Brake Light Power K3 K3 BE/R
Rear Left Turn Signal K4 K4 BE/V P&A

Accessory Power M2 M2 R/Y R BK
12
[64B]
[242A] [242B]
R/BE
R
Battery
R
Transmission
Starter
BK
BE/BN
BE/R
R/BE
BE/V
R/Y
BE
BK
GND 2
[7A] 1 2 3 4 5 6 7
[7B] 1 2 3 4 5 6 7
R/Y
BE/BN
BE/R
R/BE
BE/V
BE
BK
BE/BN
BE/R
BE/R
BE/V
BK
BE
BK
BE
[94LC] 1 2 3 4 1 2 3 4 [94RC]
[94LD] 1 2 3 4 1 2 3 4 [94RD]
R/BE 2 Trunk/Dome
BK 1 Lamp
BE/R
BE/V
BE/R
BE/V
BK
BE
BK
BE
R/Y
[279A]
BK
[94LB] 1 2 3 4 [233A] 1 3 1 2 3 4 [94RB]

[94LA] 1 2 3 4 [233B] 1 3 1 2 3 4 [94RA]
BK
BK
Left Right
STT LP STT
Lamp
Figure 7-46. Rear Lighting System (LED)

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BRAKE LAMPS INOPERATIVE 3. Verify BCM OVERLAY (Part No. HD-50390-2-P) is in

position on BOB.
PART NUMBER TOOL NAME 4. Test resistance between BOB terminal F3 and [121B-1]
HD-41404 HARNESS CONNECTOR TEST KIT terminal 1 (BE/GN) wire.
HD-50390-1 BREAKOUT BOX 5. Is resistance less than 0.5 Ohm?

HD-50390-2 BCM CABLE a. Yes. Replace BCM.
HD-50390-2-P BCM OVERLAY b. No. Repair open between [242B] terminal F3 and
[121B-1] (BE/GN) wire.
Table 7-20. Stop Lamp Inoperative Diagnostic Faults 5. RHCM Test

POSSIBLE CAUSES 1. Turn IGN OFF.
Open power to switch circuit 2. Disconnect [22].
Open ground circuit 3. Connect known good RHCM to [22].
Open stop lamp circuit 4. Turn IGN ON.
Stop lamp malfunction
5. Apply front brake lever.
Rear stop lamp switch malfunction
6. Does stop lamp illuminate?
RHCM malfunction
a. Yes. Replace RHCM.
1. Stop Lamp Switch Test b. No. Replace BCM.
1. Apply front brake while observing stop lamp.
6. Bulb Test
2. Apply rear brake while observing stop lamp.
1. Inspect inoperative bulb.
3. Does stop lamp illuminate?
2. Is bulb good?
a. Yes. Stop lamp illuminates only with front brake
applied. Go to Test 2. a. Yes. Go to Test 7.
b. Yes. Stop lamp illuminates only with rear brake b. No. Lamp is an LED. Go to Test 10.
applied. Go to Test 5. c. No. Replace bulb. (5197)
c. No. One or both stop lamps fail to illuminate. Go
to Test 6. 7. Inoperative Lamp Voltage Test
1. Disconnect tail lamp [93] on inoperative side.
2. Brake Switch Test
2. Turn IGN ON.
1. Disconnect rear stop lamp switch [121-1] and [121-2].
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), test voltage between [93] terminal 3 and ground
41404), jumper [121B-1] to [121B-2]. while activating front or rear brake controls.
3. Turn IGN ON. 4. Is battery voltage present?
4. Is brake lamp on? a. Yes. Go to Test 8.
a. Yes. Replace stop lamp switch. b. No. Replace circuit board on inoperative side. (5215)
8. Inoperative Lamp Ground Circuit Test
3. Brake Switch Ground Test 1. Turn IGN OFF.
1. Jumper [121B-1] terminal 1 (BE/GN) wire to ground. 2. Test resistance between [93A] terminal 4 (BK) and ground.
2. Is brake lamp on? 3. Is resistance less than 0.5 Ohms?
a. Yes. Repair open between [121B-2] (BK) wire and a. Yes. Repair or replace bulb socket assembly. (5215)
ground.
9. Circuit Board Ground Test
4. Brake Switch Input Test
1. Disconnect rear fender lights [94].
1. Turn IGN OFF.
2. Test resistance between [94B] terminal 6 and ground.
BCM CABLE (Part No. HD-50390-2) to wire harness
[242B], leaving [242A] disconnected.

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3. Is resistance less than 0.5 Ohms? 5. Is battery voltage present?

a. Yes. Replace circuit board on inoperative side. (5215) a. Yes. Go to Test 11.
b. No. Repair open or poor connection between [94B] b. No. Repair open in (BE/R) wire. (5041)
terminal 6 and ground. (5041)
11. Inoperative LED Ground Test
10. Inoperative LED Voltage Test 1. Test voltage between [94LB] or [94RB] terminals 1 and 3
1. Turn IGN OFF. while activating front or rear brake controls.
2. Disconnect rear fender lights [94LB] or [94RB] on inoper- 2. Is battery voltage present?
ative side. a. Yes. Replace lamp assembly on inoperative side.
3. Turn IGN ON. b. No. Repair open in (BK) wire. (5041)
41404), test voltage between [94LB] or [94RB] terminal 3
and ground while activating front or rear brake controls.

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HEADLAMP DIAGNOSTICS 7.19

DESCRIPTION AND OPERATION Diagnostic Tips
The headlamp switch activates either the high beam or the low Turn IGN to ACC.
beam headlamps. When the ignition is turned ON, the BCM • If low beam illuminates, this circuit is shorted to voltage.
defaults to the low beam position. Pressing the upper part of
the switch toggles to the high beam headlamp and the lower • If the high beam illuminates, this circuit is shorted to
part of the switch toggles to the low beam headlamp. voltage.
• In the low position, the BCM supplies power to illuminate Connector Information
the low beam headlamp.
• Push the low position again, the BCM supplies power to diagram(s) and diagnostic procedure(s), including the color of
the high beam headlamp to provide a flash to pass feature. the harness test kit terminal probes, see A.1 CONNECTORS.
• In the high position, BCM supplies power to the high beam
em01752 Headlamp
headlamp and sends a message to the speedometer over
the CAN bus to illuminate the high beam indicator.
LHCM
High
NOTE
Low
Battery Fuse
CAN High
CAN Low
See the electrical diagnostic manual for single headlamp con-
Ground
1 2 3 [38A-2]
figuration. 1 2 3 [38B-2]
4 3 2 1 [24C]
BK
W
Y
Table 7-21. Code Description 4 3 2 1 [24D]
1 2 3 4 [38A]
W/R
W/BK
BK/GN
R/O
DTC DESCRIPTION 1 2 3 4 [38B]
B2132 High beam output shorted high
BE/W
BE/Y
BE
BK
[24B] [24A]
B2133 High beam output shorted low
R/O 1 1 R/O
B2134 High beam output overloaded
BK/GN 2 2 BK/GN
B2137 Low beam output shorted high W/R 3 3 W/R
W/BK 4 4 W/BK
B2138 Low beam output shorted low
B2139 Low beam output overloaded Battery Fuse R/O
Conditions for Setting CAN High D2 D2 W/R
CAN Low E2 E2 W/BK

The headlamp DTCs may require either the high or low beam
headlamp be activated in order to set the DTC. Toggle back Running Position Light Power J3 J3 BE
BCM
and forth between the high and low beam headlamp positions Accessory Power M2 M2 R/Y
BK/GN
to check DTCs on both circuits. High Beam Power M3 M3 BE/W
Low Beam Power M4 M4 BE/Y
• DTC B2131 or B2136 will set if the corresponding head-
lamp circuit draws less than 1.2 Amps.
[242A] [242B]
• DTC B2134 or B2139 will set if the corresponding head- To Main
Harness GND 2 GND 1
lamp circuit draws more than 12 Amps.
Figure 7-47. FLRT Headlamp Circuit

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em01652
LHCM RHCM
IM
Battery Fuse
Battery Fuse
CAN High
CAN High
CAN Low
CAN Low
Ground
Ground
Battery Fuse
CAN High
CAN Low
Ground
[24C] 4 3 2 1 1 2 3 4 [22C-1]
[24D] 4 3 2 1 1 2 3 4 [22D-1]
[39A] 8 2 5 7
W/R
W/BK
BK/GN
R/O
W/R
W/BK
R/O
BK/GN
[39B] 8 2 5 7
W/R
W/BK
R/O
BK/GN
[24B] [24A] [22A-1] [22B-1]
R/O 1 1 R/O R/O 1 1 R/O

BK/GN 2 2 BK/GN BK/GN 2 2 BK/GN
W/R 3 3 W/R W/R 3 3 W/R
W/BK 4 4 W/BK W/BK 4 4 W/BK
Battery R/O
Fuse
[1B] [1A]
BCM
CAN High D2 D2 W/R W/R 2 2 W/R
CAN Low E2 E2 W/BK W/BK 3 3 W/BK
Ground G4 G4 BK/GN R/O 4 4 R/O
Accessory Power M2 M2 R/Y BK/GN 5 5 BK/GN
High Beam Power M3 M3 BE/W BE/W 8 8 BE/W

Low Beam Power M4 M4 BE/Y BE/Y 9 9 BE/Y
[242A] [242B]
BK A A BK BK 4 4 BK Left
Headlamp
[2B] [2A] [31LA-1] [31LB-1]
BK A A
High
To Main BE/W 2 2 BE/W BE/W B B
R/Y
Harness 1 1 C C Low
BE/Y BE/Y BE/Y
[38LA-1] [38LB-1] [38LB-2] [38LA-2]
[38RA-1] [38RB-1] [38RB-2] [38RA-2]
BE/Y 1 1 BE/Y BE/Y C C Low
BE/W 2 2 BE/W BE/W B B

High
BK/GN
BK A A
BK
[31RA-1] [31RB-1]
Right
GND 2 GND 1 BK 4 4 BK Headlamp
Figure 7-48. Dual Headlamp Circuit

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FLRT, HIGH BEAM INOPERATIVE 4. Does high beam headlamp illuminate?

a. Yes. Replace BCM.
PART NUMBER TOOL NAME b. No. Replace headlamp.
HD-50390-1 BREAKOUT BOX FLRT, DTC B2132
HD-50424 1.5 MM TERMINAL EXTRACTOR
Table 7-22. High Beam Inoperative Diagnostic Faults TOOL
POSSIBLE CAUSES
Open in high beam ground circuit Table 7-23. DTC B2132 Diagnostic Faults
Open in high beam power circuit POSSIBLE CAUSES
Headlamp malfunction Short to voltage in headlamp high beam circuit
1. Headlamp Inspection Test 1. Headlamp Test

1. Visually inspect headlamp. 1. Turn IGN OFF.
2. Is headlamp damaged? 2. Disconnect BCM [242].
a. Yes. Replace headlamp. 3. Using 1.5 MM TERMINAL EXTRACTOR TOOL (Part
b. No. Go to Test 2. No. HD-50424), remove terminal M3 (BE/W) from [242B].
4. Connect [242].
2. Ground Circuit Open Test
5. Turn IGN ON.
1. Turn IGN OFF.
2. Disconnect headlamp [38-2].
41404), test voltage between extracted terminal M3 and
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD- ground.
41404), test resistance between [38B-2] terminal 3 and
ground.
a. Yes. Repair short to voltage in (BE/W) or (W) wire.
b. No. Repair open in (BK) ground wire. 2. DTC Test
1. Install terminal M3 from [242B].
3. Power Circuit Open Test
2. Connect [242].
BCM/RADIO CABLE (Part No. HD-50390-2) between wire 3. Clear DTCs.
harness [242B] and [242A].
4. Turn IGN ON.
5. Observe headlamp in high and low beam positions.
6. Check DTCs.
3. Test resistance between BOB terminal M3 and [38B-2]
terminal 1 (W) wire. 7. Did DTC reset?
4. Is resistance less than 0.5 Ohm? a. Yes. Replace BCM.
a. Yes. Go to Test 4. b. No. Condition is intermittent.
b. No. Repair open in (W) or (BE/W) wire between BCM
and headlamp.
4. BCM Test
1. Connect [38B-2].
2. Turn IGN ON.
3. Jumper BOB terminals M2 and M3.

HOME
FLRT, DTC B2133, B2134 FLRT, LOW BEAM INOPERATIVE

HD-50390-2 BCM/RADIO CABLE HD-50390-2 BCM/RADIO CABLE
HD-50390-2-P BCM/RADIO OVERLAY HD-50390-2-P BCM/RADIO OVERLAY
Table 7-24. DTC B2133, B2134 Diagnostic Faults Table 7-25. Low Beam Inoperative Diagnostic Faults
POSSIBLE CAUSES POSSIBLE CAUSES

Short to ground in high beam headlamp circuit Open in low beam ground circuit
Accessory lighting overloading circuit Open in low beam power circuit
Headlamp malfunction Headlamp malfunction
1. High Beam Circuit Test 1. Headlamp Inspection Test

1. Turn IGN OFF. 1. Visually inspect headlamp.
2. Disconnect headlamp [38B-2]. 2. Is headlamp damaged?
3. Connect BREAKOUT BOX (Part No. HD-50390-1) and a. Yes. Replace headlamp.
BCM/RADIO CABLE (Part No. HD-50390-2) to wire har- b. No. Go to Test 2.
4. Verify BCM/RADIO OVERLAY (Part No. HD-50390-2-P) 2. Ground Circuit Open Test
is in position on BOB. 1. Turn IGN OFF.
5. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 2. Disconnect headlamp [38-2].
41404), test continuity between BOB terminal M3 and
ground. 3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), test resistance between [38B-2] terminal 3 and
6. Is continuity present? ground.
a. Yes. Repair short to ground in (W) or (BE/W) wire.
b. No. Go to Test 2. a. Yes. Go to Test 3.
2. DTC Test b. No. Repair open in (BK) ground wire.
1. Connect [242]. 3. Power Circuit Open Test

2. Clear DTCs. 1. Connect BREAKOUT BOX (Part No. HD-50390-1) and
3. Turn IGN ON. BCM/RADIO CABLE (Part No. HD-50390-2) between wire
harness [242B] and [242A].
4. Check DTCs.
5. Did DTC reset? is in position on BOB.
a. Yes. Verify no accessory lighting is causing issue. If 3. Test resistance between BOB terminal M4 and [38B-2]
no issue is found, replace BCM. terminal 2 (Y) wire.
b. No. Replace high beam headlamp. 4. Is resistance less than 0.5 Ohm?
b. No. Repair open in (Y) or (BE/Y) wire between BCM
and headlamp.
4. BCM Test
1. Connect [38B-2].
2. Turn IGN ON.
3. Jumper BOB terminal M2 to M4.

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4. Does low beam headlamp illuminate? FLRT, DTC B2138, B2139

b. No. Replace headlamp. PART NUMBER TOOL NAME
FLRT, DTC B2137 HD-50390-1 BREAKOUT BOX
HD-50424 1.5 MM TERMINAL EXTRACTOR
TOOL Table 7-27. DTC B2138, B2139 Diagnostic Faults
POSSIBLE CAUSES
Table 7-26. DTC B2137 Diagnostic Faults Short to ground in low beam headlamp circuit
POSSIBLE CAUSES Accessory lighting overloading circuit
Short to voltage in headlamp low beam circuit Headlamp malfunction
1. Headlamp Test 1. Low Beam Circuit Test

1. Turn IGN OFF. 1. Turn IGN OFF.
2. Disconnect BCM [242]. 2. Disconnect headlamp [38B-2].
3. Using 1.5 MM TERMINAL EXTRACTOR TOOL (Part 3. Connect BREAKOUT BOX (Part No. HD-50390-1) and
No. HD-50424), remove terminal from [242B] terminal M4 BCM/RADIO CABLE (Part No. HD-50390-2) to wire har-
(BE/Y). ness [242B], leaving [242A] disconnected.
4. Connect BCM [242]. 4. Verify BCM/RADIO OVERLAY (Part No. HD-50390-2-P)

5. Turn IGN ON.
6. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), test continuity between BOB terminal M4 and
41404), test voltage between removed terminal M4 and ground.
ground.
a. Yes. Repair short to ground in (Y) or (BE/Y) wire.
a. Yes. Repair short to voltage in (BE/Y) or (Y) wire.
2. DTC Test
2. DTC Test
1. Connect [242].
1. Install terminal M4 from [242B].
2. Clear DTCs.
2. Connect [242].
3. Turn IGN ON.
3. Clear DTCs.
4. Check DTCs.
4. Turn IGN ON.
5. Did DTC reset?
5. Observe headlamp in high and low beam positions.
a. Yes. Verify no accessory lighting is causing issue. If
6. Check DTCs. no issue is found, replace BCM.
7. Did DTC reset? b. No. Replace low beam headlamp.
b. No. Condition is intermittent.

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DUAL LAMP, HIGH BEAM INOPERATIVE DUAL LAMP, DTC B2132

HD-50390-1 BREAKOUT BOX HD-50424 1.5 MM TERMINAL EXTRACTOR
HD-50390-2 BCM CABLE TOOL
HD-50390-2-P BCM OVERLAY

Table 7-29. DTC B2132 Diagnostic Faults
Table 7-28. DTC B2131 Diagnostic Faults POSSIBLE CAUSES
POSSIBLE CAUSES Short to voltage in headlamp high beam circuit
Open in high beam ground circuit 1. Headlamp Test

Open in high beam power circuit 1. Turn IGN OFF.
Headlamp malfunction
2. Disconnnect BCM [242].
1. Ground Circuit Open Test 3. Using 1.5 MM TERMINAL EXTRACTOR TOOL (Part
No. HD-50424), remove terminal M3 from [242B] (BE/W).
1. Turn IGN OFF.
4. Connect [242].
2. Disconnect inoperative headlamp [38-2].
5. Turn IGN ON.
41404), test resistance between [38B-2] terminal A and 6. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
ground. 41404), test voltage between extracted terminal M3 and
ground.
a. Yes. Go to Test 2. 7. Is voltage present?
a. Yes. Repair short to voltage in (BE/W) wire.
b. No. Repair open in (BK) ground wire.
2. Power Circuit Open Test
1. Connect BREAKOUT BOX (Part No. HD-50390-1) and 2. DTC Test
BCM CABLE (Part No. HD-50390-2) between wire harness 1. Install terminal M3 from [242B].
[242B] and [242A].
2. Connect [242].
2. Verify BCM OVERLAY (Part No. HD-50390-2-P) is in
position on BOB. 3. Clear DTCs.
3. Test resistance between BOB terminal M3 and [38B-2] 4. Turn IGN ON.
terminal B (BE/W) wire. 5. Observe headlamp in high and low beam positions.
4. Is resistance less than 0.5 Ohm? 6. Check DTCs.
7. Did DTC reset?
b. No. Repair open between [242B] terminal M3 and a. Yes. Replace BCM.
[38B-2] terminal B (BE/W) wire.
b. No. Condition is intermittent. Perform wiggle test.
3. BCM Test
1. Connect [38B-2].
2. Turn IGN ON.
3. Jumper BOB terminals M2 to M3.
4. Does high beam headlamp illuminate?
b. No. Replace headlamp.

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DUAL LAMP, DTC B2133, B2134 DUAL LAMP, LOW BEAM INOPERATIVE

HD-50390-2 BCM CABLE HD-50390-2 BCM CABLE
HD-50390-2-P BCM OVERLAY HD-50390-2-P BCM OVERLAY
Table 7-30. DTC B2133, B2134 Diagnostic Faults Table 7-31. DTC B2136 Diagnostic Faults

Short to ground in high beam headlamp circuit Open in low beam ground circuit
Accessory lighting overloading circuit Open in low beam power circuit
Headlamp malfunction Headlamp malfunction
1. High Beam Circuit Test 1. Ground Circuit Open Test

1. Turn IGN OFF. 1. Turn IGN OFF.
2. Disconnect headlamp [38R-2] and [38L-2]. 2. Disconnect inoperative headlamp [38-2].
3. Connect BREAKOUT BOX (Part No. HD-50390-1) and 3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
BCM CABLE (Part No. HD-50390-2) to wire harness 41404), test resistance between [38B-2] terminal A and
[242B], leaving [242A] disconnected. ground.
4. Verify BCM OVERLAY (Part No. HD-50390-2-P) is in 4. Is resistance less than 0.5 Ohm?
position on BOB. a. Yes. Go to Test 2.
5. Using HARNESS CONNECTOR TEST KIT (Part No. HD- b. No. Repair open in (BK) ground wire.
41404), test continuity between BOB terminal M3 and
ground. 2. Power Circuit Open Test
6. Is continuity present? 1. Connect BREAKOUT BOX (Part No. HD-50390-1) and
a. Yes. Repair short to ground in (BE/W) wire. BCM CABLE (Part No. HD-50390-2) between wire harness
[242B] and [242A].
2. DTC Test position on BOB.
1. Connect [242]. 3. Test resistance between BOB terminal M4 and [38B-2]
terminal C (BE/Y).
2. Connect [38-2].
3. Clear DTCs.
4. Turn IGN ON.
b. No. Repair open in (BE/Y) wire between BCM and
5. Check DTCs. headlamp.
6. Did DTC reset?
3. BCM Test
a. Yes. Verify no accessory lighting is causing issue. If
no issue is found, replace BCM. 1. Connect [38B-2].
b. No. Replace high beam headlamp. 2. Turn IGN ON.

3. Jumper BOB terminal M2 to M4.
4. Does low beam headlamp illuminate?
b. No. Replace headlamp.

HOME
DUAL LAMP, DTC B2137 DUAL LAMP, DTC B2138, B2139

HD-50424 1.5 MM TERMINAL EXTRACTOR HD-50390-1 BREAKOUT BOX
TOOL HD-50390-2 BCM CABLE
HD-50390-2-P BCM OVERLAY
Table 7-32. DTC B2137 Diagnostic Faults
POSSIBLE CAUSES Table 7-33. DTC B2138, B2139 Diagnostic Faults

Short to voltage in headlamp low beam circuit POSSIBLE CAUSES
1. Headlamp Test Short to ground in low beam headlamp circuit
1. Turn IGN OFF. Accessory lighting overloading circuit
Headlamp malfunction
2. Disconnect BCM [242].
3. Using the 1.5 MM TERMINAL EXTRACTOR TOOL (Part 1. Low Beam Circuit Test
No. HD-50424), remove terminal M4 from [242B] (BE/Y).
1. Turn IGN OFF.
4. Connect BCM [242].
2. Disconnect headlamp [38B-2].
5. Turn IGN ON.
6. Using HARNESS CONNECTOR TEST KIT (Part No. HD- BCM CABLE (Part No. HD-50390-2) to wire harness
41404), test voltage between removed terminal M4 and [242B], leaving [242A] disconnected.
ground.
7. Is voltage present? position on BOB.
a. Yes. Repair short to voltage in (BE/Y) wire. 5. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
b. No. Go to Test 2. 41404), test continuity between BOB terminal M4 and
ground.
2. DTC Test 6. Is continuity present?
1. Install terminal M4 from [242B]. a. Yes. Repair short to ground in (BE/Y) wire.
2. Connect [242]. b. No. Go to Test 2.
3. Clear DTCs.
2. DTC Test
4. Turn IGN ON. 1. Connect [242].
5. Observe headlamp in high and low beam positions. 2. Clear DTCs.
6. Check DTCs. 3. Turn IGN ON.
7. Did DTC reset? 4. Check DTCs.
5. Did DTC reset?
b. No. Condition is intermittent. Perform wiggle test. a. Yes. Verify no accessory lighting is causing issue. If
no issue is found, replace BCM.
b. No. Replace low beam headlamp.

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BAS DIAGNOSTICS 7.20

GENERAL DIAGNOSTICS
BAS Operation PART NUMBER TOOL NAME
The BCM will disable turn signal lamps and starter activation HD-48650 DIGITAL TECHNICIAN II
and will send a message to the ECM to shut down the ignition
and the fuel pump if the vehicle is tipped over. The odometer
will display "tIP" when a tip-over condition is present. Diagnostic Tips
• Use DIGITAL TECHNICIAN II (Part No. HD-48650) to
Bank Angle Sensor (BAS)
verify the BCM is configured for Trike.
These DTCs set when a BCM is configured for Trike use and
a fault is detected in the BAS. • Verify no other circuits are tied to terminal H2 of the BCM.
• A tip-over event, short to ground, short to battery, and out-
ed03557 of-range fault cannot be detected when the security func-
tion is in the alarm mode (lights flashing, siren sounding).
If "tiP" is displayed on the odometer after the vehicle has been
returned to the upright position, then perform the procedure to
reset the "tiP" condition.
Tip Over Reset

1. Return the vehicle to an upright position.
2. Cycle the IGN OFF-ON before restarting the vehicle.
If the vehicle still displays "tiP", remove the BAS. Verify proper
length fasteners are mounting the BAS bracket to the frame.
If fasteners are too long, the procedure to reset the BAS by
cycling the ignition may not work.
Figure 7-49. BAS [134] Behind Battery Table 7-34. Trike Bank Angle Sensor (BAS) DTCs
DTC DESCRIPTION
B2226 BAS input open
B2228 BAS input shorted low

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em01653
Fuse
R/O
Block [5B]
2
BK R R B
Battery Main Fuse

BK
R A
1
Battery
[64B]
1
R
R
R
Transmission
R/BK
[259B] [259A]
BCM
2 1 1
R Battery Power
Starter
R/GN L3 L3 System Power
R/BK L2 L2 Starter Solenoid Power

[33A] [33B]
W/GN H2 H2 Security Siren
BCM Input 2 2 W/BE W/BE C3 C3 Ignition Switch Input
Ground 1 1 BK/GN BK/GN G4 G4 Ground
TN/BK B4 B4 BAS Input
Security [242B] [242A]

Siren [142A] [142B]
(Optional)
Power 1 1 R/O
BAS
Signal 2 2 W/GN
TN/BK A A BAS Input
Ground 3 3 BK BK/GN B B Ground

R/GN C C System Power
[134B] [134A]
BK/GN
R/GN
BK
GND 2 GND 1 To
Main
Harness
Figure 7-50. Siren Circuit

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DTC B2228 DTC B2226

HD-50390-2 BCM CABLE HD-50390-2 BCM CABLE
HD-50390-2-P BCM OVERLAY HD-50390-2-P BCM OVERLAY
Table 7-35. DTC B2228 Diagnostic Faults Table 7-36. DTC B2226 Diagnostic Faults

BAS malfunction Open in signal circuit
Short to ground in BAS input circuit Open in ground circuit
Open in ignition circuit
1. BAS Input Short to Ground Test
BAS malfunction
1. Turn IGN OFF.
2. Disconnect BAS [134]. 1. System Power Test
3. Connect BREAKOUT BOX (Part No. HD-50390-1) and 1. Turn IGN OFF.
BCM CABLE (Part No. HD-50390-2) to wire harness 2. Disconnect BAS [134].
3. Turn IGN ON.
position on BOB. 4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), test voltage between [134B] terminal C and
5. Using HARNESS CONNECTOR TEST KIT (Part No. HD- ground.
41404), test continuity between BOB terminal B4 and
ground. 5. Is battery voltage present?
a. Yes. Repair short to ground in BAS input circuit b. No. Repair open in system power circuit (R/O) wire.
(TN/BK) wire. (5041) (5041)
b. No. Go to Test 2. 2. BAS Ground Test

2. Wiggle Test 1. Test voltage between [134B] terminals B and C.
1. Perform wiggle test. 2. Is battery voltage present?

2. Is an intermittent short to ground present?
a. Yes. Repair short to ground in (TN/BK) wire. (5041) b. No. Repair open in ground circuit (BK/GN) wire.
(5041)
b. No. Replace BAS. (6968)
3. BAS Input Open Test
1. Turn IGN OFF.
BCM CABLE (Part No. HD-50390-2) to wire harness
position on BOB.
4. Test resistance between BOB terminal B4 and [134B]
terminal A.
a. Yes. Replace BAS. (6968)
b. No. Repair open in BAS input circuit (TN/BK) wire.
(5041)

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REVERSE SWITCH SYMPTOMS AND

DIAGNOSTICS 7.21
DESCRIPTION AND OPERATION Conditions for Settings
This DTC pertains to a stuck reverse switch or an internal fault If the switch is held or stuck for over two minutes with the IGN
in the LHCM. If the switch is open it will not set a DTC. In most ON, the stuck switch code will set.
cases, there will be symptoms.
Diagnostic Tips
Table 7-37. Switch Symptoms Clear the DTCs and operate the vehicle to verify the DTCs are
current. Stuck switch codes will take over two minutes to set.
OPEN SWITCH SYMPTOM
DTC P1781
Reverse No telltale on IM

Table 7-38. Code Description
POSSIBLE CAUSES
DTC DESCRIPTION
Damaged switch cap
P1781 Reverse switch input error
1. Switch Test
ed03554 1. Clear DTC.
2. Turn IGN ON and wait three minutes.
3. Operate vehicle.
4. Check DTCs.
5. Did DTC reset?
a. Yes. Replace LHCM.
b. No. Concern is intermittent. Switch may have been
pressed for an extended period of time.
Figure 7-51. LHCM: Reverse Switch

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
A.1 CONNECTORS.........................................................................................................................A-1
A.2 WIRING DIAGRAMS.................................................................................................................A-2
A.3 CONNECTOR END VIEWS....................................................................................................A-29
A.4 COMPONENT LOCATION VIEWS.........................................................................................A-36
APPENDIX A WIRING
NOTES
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CONNECTORS A.1
CONNECTORS
NOTE
Connectors associated with the optional reverse motor system
may not be present on motorcycle being serviced.
Table A-1. Connector Locations
NO. DESCRIPTION TYPE TERMINAL LOCATION

PROBE
COLOR
[7] Rear fender lights harness 8-way Molex MX150 Sealed Gray Top of rear fender (under seat)
(BK)
[31L] Left front turn signal 4-place JAE MX19 Sealed (BK) Yellow Inside left front turn signal/headlamp
(HDI) Gray support
6-place Tyco 070 Multilock Inside headlamp nacelle
Unsealed (BK)
[31R] Right front turn signal 4-place JAE MX19 Sealed (BK) Yellow Inside right front turn signal/head-
(HDI) Gray lamp support
3-place Tyco 070 Multilock Inside headlamp nacelle
Unsealed (BK)
[38L-1] Left headlamp 2-place JAE MX19 Sealed (BK) Yellow Inner fairing
(HDI) FLHT
[38L-2] Left headlamp 3-place Deutsch DT Sealed Black Inside left headlamp housing
(GY) (HDI) FLHT
[38R-1] Right headlamp 2-place JAE MX19 Sealed (BK) Yellow Inner fairing
(HDI) FLHT
[38R-2] Right headlamp 3-place Deutsch DT Sealed Black Inside right headlamp housing
(GY) (HDI) FLHT
[78-3] ECM 18-way Tyco (BN) Breakout Box Under seat
[134] BAS 3-place Delphi GT 150 Sealed Gray Under seat behind battery
[233] License plate lamp 3-place Tyco 070 Multilock Gray Under trunk door cover, left side
Unsealed (W) (FLHTCUTG)
[242] BCM 48-way Molex CMC Sealed Breakout Box Under left side cover
(BK)
[245] RCM 8-place Molex MX 150L Sealed Gray Under right side cover
[246] RCM solenoid 2-place Tyco 070 Multilock Gray Under right side cover
Unsealed (BK)
[248] Reverse motor solenoid Ring terminal Bottom of reverse motor solenoid
[249] Reverse motor solenoid/high Ring terminal Front of reverse motor solenoid
current
[251] RCM solenoid Ring terminal Under right side cover
[252] 150A circuit breaker Ring terminal Under right side cover
[253] Reverse motor ground Ring terminal Motor mounting flange
[276] Parking brake switch 3-place Molex MX150 Sealed Gray Behind voltage regulator
(BK)
[279] Trunk light 2-place Tyco 070 Multilock Gray Under trunk door cover, left side
Unsealed (BK) (FLHTCUTG)
[312] Trunk AUX Cap 12-place Molex MX150 Sealed Gray Under seat
2015 Trike Service Supplement Appendix A Wiring A-1

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WIRING DIAGRAMS A.2

WIRING DIAGRAM INFORMATION ed03175
5
Wire Color Codes
Wire traces on wiring diagrams are labeled with alpha codes. 3 4
Refer to Table A-2. 6
For Solid Color Wires: See Figure A-1. The alpha code
identifies wire color. 7
1 2
GN/Y
For Striped Wires: The code is written with a slash (/) between
W
the solid color code and the stripe code. For example, a trace
8
labeled GN/Y is a green wire with a yellow stripe. [21A] 1 2
Wiring Diagram Symbols [21B] 1 2

9
See Figure A-1. On wiring diagrams and in service/repair
GN/Y
instructions, connectors are identified by a number in brackets
[ ]. The letter inside the brackets identifies whether the housing 1 2 10
is a socket or pin housing.
A=Pin: The letter A and the pin symbol after a connector 11
number identifies the pin side of the terminal connectors.
13
B=Socket: The letter B the socket symbol after a connector
number identifies the socket side of the terminal connectors. 12
Other symbols found on the wiring diagrams include the fol-
1. Connector number
lowing:
2. Terminal code (A=pin, B=socket)
Diode: The diode allows current flow in one direction only in 3. Solid wire color
a circuit. 4. Striped wire color
5. Socket symbol
Wire break: The wire breaks are used to show option variances
6. Pin symbol
or page breaks.
7. Diode
No Connection: Two wires crossing over each other in a wiring 8. Wire break
diagram that are shown with no splice indicating they are not 9. No connection
connected together. 10. Circuit to/from
Circuit to/from: This symbol is used to identify there is a more 11. Splice
complete circuit diagram on another page. The symbol is also 12. Ground
identifying the direction of current flow. 13. Twisted pair
Splice: Splices are where two or more wires are connected Figure A-1. Connector/Wiring Diagram Symbols
together along a wiring diagram. The location of the splice
indicated in the wiring diagram is not the true location of the
splice in the actual harness but to identify that the wires are
spliced to that circuit.
Ground: Grounds can be classified as either clean or dirty
grounds. Clean grounds are identified by a (BK/GN) wire and
are normally used for sensors or modules. These grounds
usually do not have electric motors, coils or anything that may
cause electrical interference on the ground circuit. The dirty
grounds are identified by a (BK) wire and are used for compon-
ents that are not as sensitive to electrical interference.
Twisted pair: This symbol indicates the two wires are twisted
together in the harness. This minimizes the circuit's electromag-
netic interference from external sources. If repairs are neces-
sary to these wires they should remain as twisted wires.
A-2 2015 Trike Service Supplement Appendix A Wiring

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ed03380 Table A-2. Wire Color Codes
ALPHA CODE WIRE COLOR

6 5 4 3 2 1 BE Blue
8 1 2 BK Black
12 11 10 9 8 7
9 10 3 BN Brown
18 17 16 15
14 13
OMRON
G8VA-1A4T
OMRON
G8VA-1A4T GN Green
-R01 -R01 4
12VDC
7 JAPAN 12VDC
6 JAPAN
20 19 GY Gray
2755D5 2755D5 5 LBE Light Blue
24 23 22 21
LGN Light Green

O Orange
PK Pink
1. System power
R Red
2. Battery
3. Spare TN Tan
4. Spare V Violet
5. Spare
6. Cooling relay W White
7. P&A relay Y Yellow
8. P&A
9. Radio
10. Cooling
Figure A-2. Fuse Block [64B]

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WIRING DIAGRAMS
Wiring Diagram List

DIAGRAM LOCATION
Front Lighting and Hand Controls: 2015 Trike Models Figure A-3
Fairing Harness FLHTCUTG: 2015 Trike Model Figure A-4
Main Harness FLHTCUTG (1 of 3): 2015 Trike Model Figure A-5
Main Harness FLRT (1 of 3): 2015 Trike Model Figure A-8
Rear Lighting: 2015 Trike Models Figure A-11
Radio: 2015 Trike Models Figure A-12
Reverse FLHTCUTG: 2015 Trike Model Figure A-13
Reverse FLRT: 2015 Trike Model Figure A-14

et00682
FLHTCUTG
RHCM
[31RB] Right
[31RA-2] [31RB-2] Auxiliary [22D-2] [22C-2]
Lamp
Right Turn 1
W W 1 1 W W
and R R 2 2 R R 2 W/GY 1 1 Engine Stop Switch
Running Lamp BK BK 3 3 BK BK 3
4 [73RB] R/O 1 1 Battery Fuse Heated
BK
BK
BK/GN 2 2 Ground
Hand Grips
[31RB] (If Equipped)
W/R 3 3 CAN High TGS
[38RB] W/BK 4 4 CAN Low
GY/BK 4
A A BK BK BK 3
Right High
2
Right Turn [22D-1] [22C-1]
2
5V Sensor Ground 2
5V Sensor Ground 1
B B BE/W BE/W BN BN
Headlamp and DOM
5V Sensor Power 2
5V Sensor Power 1
Low C BE BE 1
BK
BK
C BE/Y BE/Y 1 Running Lamp
See Fairing
P&A Power
[38RA-2] [38RB-2] [38LB] Harness
Ground
TGS 2
TGS 1
[32B]
C C BE/Y BE/Y 1
Low
Left B B BE/W BE/W 2 See Fairing
Headlamp High Fender Tip Lamp O/W 1 1 O/W 1 Front Brake
GY
BN
BE
BK
BK
W
R
Harness
V
A A BK (If Equipped) BK 2 2 BK 2 Switch
[224B] 1 3 4 5 6 7 1 2 [237A]
[38LA-2] [38LB-2]
[31LB] [224A] 1 3 4 5 6 7 1 2 [237B]
[204B]
[31LB]
W
GY
BN
BE
BK
BK
R
V
GY/BK 4
[31LA-2] [31LB-2] GY See Main
BK BK 3 1
BK 4 Left Turn V 2 Harness
V V 2
BK BK 3 3 BK BK 3
and DOM 1 R 3 (2 of 3)
Left Turn BE BE
R R 2 2 R R 2 Running Lamp BK 4
and W W 1 1 W W 1 BE 5
GY/BK
Running Lamp BN 6
[22B-2]
[73LB]
Dual Headlamps BK W/GY 1
Left
FLHTCUTG Auxiliary R/O 1
Lamp BK/GN 2
W/R 3
Headlamp W/BK 4
BK
[38A]
W
[22B-1]
[206B] 1 2 See Main
A Harness
[206A] 1 2
Low
B See Fairing FLRT [24B]
BK/W
BK/W
High
C Harness
Position
D W/BK 4
[31RB] W/R 3
BK/GN 2
R/O 1
BK BK 1 Clutch
Right Turn 2
V V Switch
and DOM BE BE 3 R 1
Running Lamp
BK 2
BK/W
BK/W
BK
R
FLRT [189A]
Ground
Ground
P&A Power
P&A Power
Heated
See Main Hand Grips
BK
BK
Harness FLHT (If Equipped)
[38B] (1 of 3)
[38A-2] [38B-2] W/BK 4 4 Can Low
1
See Main [31LB] W/R 3 3 Can High
High
1 1 W W 2 Harness BK/GN 2 2 Ground
Low
2 2 Y Y 3 FLRT BK BK 1 R/O 1 1 Battery Fuse
(1 of 3) Left Turn
3 3 BK BK 4 V V 2
and DOM 3
BE BE
Running Lamp [24D] [24C]
4
5
6
LHCM
Figure A-3. Front Lighting and Hand Controls: 2015 Trike Models
Figure A-3. Figure A-3.
Front Lighting and Hand Controls: 2015 Trike Models Front Lighting and Hand Controls: 2015 Trike Models
et00683
Voltmeter
Right Front
H-D Link Output

Speaker
Battery Fuse
See Front
Ground
Lighting and
Hand Controls See Main Harness
FLHTCUTG (1 of 3) Front Power P&A Accessory A B D [111A]
Left Front Turn/Aux Lamps 1 2 3 4 5 7 8 9 10 11 12 13 [1A] Outlet Power A B D [111B]
[31RA] 1 2 3 4 1 2 3 4 [31RA] 1 1
1 2 [132C] 1 2 [299A]
W/GY
W/R
W/BK
W/Y
BE/W
V/W
R/O
BK/GN
BK/GN
R/O
BE/O
BE/Y
BE/PK
BE/BK
BE
BE/O
BE/O
BE
BK
BK
BE/BK
BE
BK
V/BE
V/BE
PK/BK
BK
BK
PK
See Front 1 2 [34A] 1 2 [132B]
Lighting and
Hand Controls HDI DOM 1 2 [34B] 1 2 [132A]
BE/O
BE/BK
BE
BK
PK/BK
V/BE
PK
BK
[22A-1] 1 2 3 4 1 [22A-2]
W/GY
W/R
W/BK
R/O
BK/GN
[38B]
1 BK
DOM
2 BE/Y
Headlamp
3 BE/W
4 BE
BK
BE/Y
See Front
Lighting and BE/W
Hand Controls [38RA] BE
[39B] [39A]
Right 1 BE/Y
Headlamp 2 BE/W
V/W 1 1 H-D Link Output
W/R 2 2 CAN High
1 BE/Y HDI
Left
TN/GN 4 4 Parking Brake
Headlamp 2 BE/W
R/O 5 5 Battery Fuse
IM
[38LA]
BK/GN 7 7 Ground
BE/PK
BE/BK
BE
BK
W/BK 8 8 CAN Low
HDI DOM W/Y 9 9 Fuel Level
PK/GY
BE/PK
BE/PK
BE/BK
PK/O
BE
BK
BK
BE
BK
[31LA] 1 2 3 4 1 2 3 4 [31LA] 2 1 [35B]

Left Front Turn/Aux Lamps 2 1 [35A]
BK/GN
BK/GN
PK/GY
TN/GN
PK/BK
W/BK
PK/O
V/BE
V/BE
W/R
V/W
R/O
R/O
BK
PK
BK
PK/BK
PK
See Front [189B] [117B]
[24A] 1 2 3 4
Lighting and [2A] 2 3 7 8 9 10 11 12 1 2 A B D
See Front Hand Controls See Main Harness 1 1 See Front A B D [117A]
BE
BK
Lighting and FLHTCUTG (1 of 3) Lighting and
Battery Fuse
H-D Link Output
Ground
Hand Controls Hand Controls
1 2 [32A]
Fender Tip
Lamp
(If Equipped)
Left Front Fuel Gauge
Speaker
Figure A-4. Fairing Harness FLHTCUTG: 2015 Trike Model

Fairing Harness FLHTCUTG: 2015 Trike Model Fairing Harness FLHTCUTG: 2015 Trike Model
Rider Headset CAV CIR DESCRIPTION
Audio In 1 Shield/Mono (-)

et00684 CB C.B. (If Equipped) ET
Audio In 1 Left/Mono (+)

1 BK MICROPHONE, COMMON (-)
Microphone Sum Out +

Module
Microphone Sum Out -

2 BK HEADSET, COMMON (-)
Antenna 3 PK/BE HEADSET, RT FRONT (+)
Sensor
Audio In 1 Right (+)

4 Horn
P&A Relay Power

[50A] R MICROPHONE, FRONT (+)
Engine Temperature
5 PK/GN HEADSET, LT FRONT (+)
AUX CAN High
5V Sensor Ground
AUX CAN Low
1 6 BK JUMPER
Horn Power
7 N/C
TAB SHIELD MIRCRPHONE, SHIELD
Ground
Ground
BK
TAB
P&A Audio [225B] 2 5 6 3 4 1
[280A] 1 2 3 4 5 6 7 8 9 10 11
1 2 3 4 5 6 7 8 9 10 11 12 [184B] [122A-2] 1 1 [122A-1]
PK/BE
Shield
R/W
PK/GN
PK/GN
LBE/W
PK/BE
BK/PK
V/BE
BK
BK
R
LBE/BN
[90A]
LBE/V
BK
[184A] A B
R
[51A] 1 2 3 4 5 6 7 8 9 10 11 12 [122B-2] [122B-1]
BK
See Radio 1 1
[162A] A B [90B]
W/BN
W/PK
W
W
1 2 3 4 5 6 7 8 9 10 14 15 16
R/BE
BK/Y
BK
BK
BK
R
R/V
BK
Shield
Antenna 1 [53B]
BK/W
BK 1 2 3 4 5 6
GN
LBE/W
BK/GN
R/Y
LBE/O
LBE/GY
BK/PK
BK
R
LBE/V
LBE/BK
LBE/PK
LBE
Shield
Radio R/BE [53A] 1 2 3 4 5 6
CAN High A1 A1 W/R
PK/GN
BK/PK
PK/BE
BK
R
Shield
CAN Low A2 A2 W/BK
AUX CAN Low A3 A3 W/BN
AUX CAN High A4 A4 W/PK
Ground B1 B1 BK
Rear Switch Input B2 B2 LBE/PK
Microphone Front (+) C1 C1 R
Microphone Common (-) C2 C2 BK
Microphone Sum Out (+) C3 C3 R
Microphone Rear (+) D1 D1 R/W
Microphone Shield D2 D2 BK/W BK
BK
Microphone Sum Out (-) D3 D3 BK
GN
Headset Left Rear (+) E1 E1 LBE/W
BK/W
Headset Right Rear (+) E2 E2 LBE/V W/Y
Headset Common (-) E3 E3 BK/PK W/V
Headset Left Front (+) F1 F1 PK/GN W/R
Headset Right Front (+) F2 F2 PK/BE
W/BK See Main
BK/GN Harness
External AMP Power Control F4 F4 LBE/BN R/GN FLHTCUTG
Speaker Left Rear (-) H1 H1 LBE/GY LGN/BN (2 of 3)
Audio In 1 Right (+) H2 H2 R GY/BE
GN/BE
Audio In 1 Shield/Mono (-) H3 H3 BK
R/O
Speaker Left Rear (+) J1 J1 LBE/O BK
Audio In 1 Left/Mono (+) J2 J2 W BK
Audio In 3 Left/Mono (+) J3 J3 W
Speaker Right Rear (+) K1 K1 LBE
Speaker Right Rear (-) K2 K2 LBE/BK
BE
Audio In 3 Right (+) K3 K3 R
V/BE
Audio In 3 Shield/Mono (-) K4 K4 BK/Y R/Y
Speaker Left Front (-) L1 L1 PK/GY R/V
Speaker Left Front (+) L2 L2 PK/O LBE/R
LBE/GN
Ground L3 L3 BK
BE/GY
Ground L4 L4 BK R/PK
Speaker Right Front (+) M1 M1 PK LBE/V See Main
Speaker Right Front (-) M2 M2 PK/BK
LBE/W Harness
W/BE FLHTCUTG
Radio Fuse M3 M3 R/PK LBE/Y (3 of 3)
Radio Fuse M4 M4 R/PK W/GY
BE/W
BE/Y
[27A] [27B] BE/O
BE/PK
BE/BK
TN/BK
TN/GN
BK
LBE/GN
BK/GN
TN/BK
BE/GY
R/GN
LBE/R
BK/W
V/BE
LGN/BN
W/V
[GND3B] 1
BK/GN
GN/BE
GY/BE
BK
TN/GN
PK/GY
PK/BK
W/BE
BK/GN
R/GN
BE/PK
BE/BK
PK/O
V/BE
W/GY
W/BK
BE/W
BE/O
BE/Y
[GND3A]
W/R
W/Y
R/O
1
BK
PK
[134B] A B C
BE
[105LB] 1 2 3 4 5 [107B] 1 2
[134A] [33B] 1 2 [83B] A B C D
BK
[2B] 2 3 7 9 10 11 12 [105LA] 1 2 3 4 5 [107A] A B C

1 2 [1B] 1 2 3 4 5 7 8 9 10 1112 13
LBE/W
Auxiliary Lamp Switch
LBE/V
LBE/Y
OE Switch Output 3
OE Switch Output 2
5V Sensor Ground
Bank Angle Sensor input

Ground
System Power
Ait Temperature
P&A Relay Power
[33A] [83A]
V/BE
Ground
See Fairing 1 2 A B C D
BK
Harness See Fairing
ION Sense
Rear Ignition Coil
Front Ignition Coil
System Power
OFF
Harness
BK
800
BK
[105RB] 1 2 3 4 5
BK
IGN
ACC
P&A Dash
Switch Pack
200
AAT Sensor
GND 3-1 GND 3-2 OE Dash BAS Ignition Ignition
Switch Pack Switch Coil
Figure A-5. Main Harness FLHTCUTG (1 of 3): 2015 Trike Model

Main Harness FLHTCUTG (1 of 3): 2015 Trike Model Main Harness FLHTCUTG (1 of 3): 2015 Trike Model
et00685
[203FA]
[203FB]
(1 of 3)
Harness
See Main
FLHTCUTG
1
1
V/GN System Power

2
2
ACR
Front
LGN/R ACR Enable
BK
BK
BK
BK
GN
R/O
W/V
W/Y
W/R
R/GN
W/BK
BK/W
GY/BE
GN/BE
BK/GN
LGN/BN
[84B]
[84A]
[78A-1]
[78B-1]
A
A
ECM
R/GN System Power
B
B
GN/Y Front Injector

Front
Rear Ignition Coil GY/BE

Front Ignition Coil GN/BE
Fuel Injector
Front HO2S Ground BK/O

VSS LGN/Y
Front Fuel Injector GN/Y
Rear Fuel Injector GY/Y
[211B]
[211A]
MAP Input GY
ION Sense LGN/BN 5V Sensor Ground 1
BK/W
(BK)
Ground BK/GN GY/O ETC Low
CAN Low W/BK GN/O ETC High
GY/V TPS 2
TCA
CAN High W/R

R/W 5V Sensor Power 1
Rear HO2S Ground BK/PK
1 2 3 4 5 6
1 2 3 4 5 6
GN/V TPS 1
CKP Sensor High R
Front HO2S GN/BN
CKP Sensor Low
1 2 3 4 5 6 7 9 10 13 14 15 16 17 18
1 2 3 4 5 6 7 9 10 13 14 15 16 17 18
BK
[80B]
[80A]
BK/GY 5V Sensor Ground 2

GN/GY IAT
[78A-2]
[78B-2]
R/GY 5V Sensor Power 2
TMAP
1 2 3 4
1 2 3 4
Sensor
Cooling Fan Relay Control GY MAP Input

BN/BK
Exhaust Actuator LGN/O
ACR Enable LGN/R
Purge Solenoid LGN/BK
[85B]
[85A]
IAT GN/GY
5V Sensor Ground 1 BK/W
A
A
ET GN R/GN System Power

5V Sensor Power 1 R/W
B
B
Rear Injector
Rear
GY/Y
(GY)
Ground BK/GN
Exhaust Feedback LGN/BE
Fuel Injector
TPS 2 GY/V
System Power R/GN
Rear HO2S GY/BN
[203RB]
[203RA]
Battery Fuse
2 3 4 5 6 7 8 9 10 14 15 16 17 18
2 3 4 5 6 7 8 9 10 14 15 16 17 18
R/O
1
1
V/GN System Power

2
2
ACR
ACR Enable
Rear
LGN/R
[78A-3]
[78B-3]
Cooling Fan Left GN/BK
[95B]
[95A]
TPS 1 GN/V
AAT W/V
A
A
TN/BE V/GN System Power

Cooling Fan Right GY/BK
B
B
LGN/BK Purge Solenoid

Purge
ETC High GN/O

Solenoid
ETC Low GY/O

Ground BK/GN
(BN)
TGS 1 GN/W
TGS 2 GY/W
Coolant Temperature GY/GN
Reverse Input TN
5V Sensor Ground 2 BK/GY
5V Sensore Power 2
1 2 3 4 5 8 9 10 13 14 15 16 17 18
1 2 3 4 5 8 9 10 13 14 15 16 17 18
R/GY
[215B]
[215A]
[232LB]
[232LA]
[235B]
[235A]
GN/BK GN/BK
Fan
Left
1 2
1 2
B A
B A
A
A
BN/BE BN/BE BN/BE Cooling Relay Power

Cooling
B
B
GY/GN GY/GN BK Ground

3 4
3 4
A B
A B
BK/W BK/W
ECT
Cooling Pump
BK
[236A]
[236B]
[13A]
[13B]
[141B]
BK
BK R/BN R/BN W/Y
W/Y W/Y R/BN
BK/GN BK/GN BK/GN BK/GN
1 2 3 4
1 2 3 4
A B C D
BK BK BK
GND 2 GND 1
BK/GN
Fuel Pump and
Fuel Level Sender
BK
[232RA]
[232RB]
[97A]
1
1
GY/BK GY/BK
[65A]
[65B]
2
2
B A
BN/BE BN/BE
5V Sensor Power R/W
VSS Input LGN/Y
Right Cooling Fan
VSS
A B C
A B C
Ground BK/GN BK/GY

GY/W
R/GY
BK/W
GN/W
1 2 3 4 5 6
R/W
[131A-2]
[131B-2]
See Front Lighting
and Hand Controls
1
1
BK
[204A]
Switch
Neutral
1
1
W
1
1
R Security Antenna High

2
2
BK Security Antenna Low

Security
Antenna
[131A-1]
[131B-1]
[209B]
[209A]
1
1
Starter Solenoid Power R/BK

1
BK
Starter
CB
Antenna
R
R
BK
BK
BK
BK
TN
BK
TN/BE
BK/PK
BN/BK
LGN/BE
R/BK
BN/BE
R/BN
BK/O
V/GN
LGN/O
R/O
BK/GN
GY/BN
R/GN
GN/BN
BK/W
W/BK
W/R
[128A]
[128B]
[104A]
1
BK
Antenna
(3 of 3)
Harness
See Main
FLHTCUTG
[51D]
et00686 HO2S Front HO2S Rear Stator See Reverse FLHTCUTG Security
See Rear Siren
Heater Ground
Heater Ground
Lighting (If Equipped)
[245B] 2 3 4 5 6 7 8 1 2 [246B]
BK 5V Sensor
BK 5V Sensor
CKP DLC P&A Accessory
W Front O2
GY Front O2
Security Siren
W Rear O2
GY Rear O2
System
System
Ground
Ground
TN/GY
TN/GY
R/Y
TN/R
TN/R
Sensor
Sensor
TN/V
TN/BE
TN
BK
Power
Power
Sensor [91A] [4A]
[12B] 1 2 3 4 5 6 1 2 3 4 5 6 7 [7A] 1 2 3 5 6 1 2 3 4 5 6 7 8
Ground
Power
W/R
W/BN
W/BK
LBE/W
R/Y
LBE/GN
R/BE
CKP Sensor High
V/BE
BK
BK
LBE/R
LBE/Y
LBE/V
CKP Sensor Low
BE/BN
BE/R
R/Y
BE/BN
BE/R
R/BE
V/BE
BE/V
BE/V
BE
BK
BE
BK
[47B]
V
1 2 3
[138B] 1 2 3 4 [137B] 1 2 3 4 [47A] 1 2 3 [142A] 1 2 3
[138A] 1 2 3 4 [137A] 1 2 3 4 Voltage [142B] 1 2 3

Regulator
W/GN
R/O
BK
BK/W
BK/W
GN/BN
V/GN
GY/BN
V/GN
BK/O
BK/PK
[77A] N P
BK
R/BE
[77B] [281B]
BN/BE N P
BK/W 1 2 [79B]
BK
R
GN/BN R R 1 Battery
1 2 [79A]
BK/O BK 2 Tender
R/BE
GY/BN
BK
R
BK/PK
BK
TN
TN/BE Fuse Block
BK/GN
5A Battery [64B]
R
R/O 2 1 R
See Main BK
Harness R/O 7.5A
FLHTCUTG R/GN System Power
(2 of 3) R/BK R/GN 4 3 V/GN
R/BN
W
20A Radio
R/PK 6 5 R
BK
R 20A P&A
LGN/BE R/BE 12 11 R
LGN/O
5A Spare
BK
V/GN 8 7 BK
W/BK 7.5A Spare
W/R BK 14 13 BK
BN/BK
BK
20A Spare
BK 20 19
BE
V/BE
10A Cooling
R/Y BN 10 9 R
R/V P&A Relay
LBE/R
V/BE 24 5 87
LBE/GN
BE/GY R/BE 17 3 30
R/PK
R/Y 18 1 85
See Main LBE/V BK 23 2 86
Harness LBE/W
FLHTCUTG W/BE Cooling Relay
(1 of 3) LBE/Y
BN/BE 22 5 87
W/GY
BE/W BN 15 3 30
BE/Y BN 16 1 85
BE/O BN/BK 21 2 86
BE/PK
BE/BK
R
TN/BK
TN/GN
Red Band
BE/GN
BK/GN
BE/GY
BE/BN
TN/BK
BE/PK
BE/BK
W/GN
W/GY
W/BN
W/BE
W/BK
BE/W
R/GN
R/BN
BE/O
BE/R
R/BK
TN/V
BE/V
BE/Y
W/O
W/R
R/V
R/Y
BK
BK
BE
LGN/BE
W
R
R
LGN/O
V/GN
BE/GN
TN/GN
BK/GN
BK
[259B] 1 A2 A3 A4 B2 B3 B4 C3 C4 D2 D3 E2 E3 E4 F3 F4 G2 G4 H2 J2 J3 J4 K2 K3 K4 L2 L3 L4 M2 M3 M4 [242B]
BK
BK
BK
R
[259A] 1 A2 A3 A4 B2 B3 B4 C3 C4 D2 D3 E2 E3 E4 F3 F4 G2 G4 H2 J2 J3 J4 K2 K3 K4 L2 L3 L4 M2 M3 M4 [242A]
BK
[179B] 1 2 3 4
[276A] 1 2 [121B-1] 1 1 [121B-2] [5B] A B
Ignition/Accessory Switch Input

Start Enable
Security Antenna (+)
Security RF Antenna
Security Antenna (-)
Security Siren
Bank Angle Sensor Input
Run/Stop Switch input

CAN High
Oil Pressure Input
Ground
Neutral Switch input
CAN Low
Brake Switch Input
Starter Solenoid Power
Accessory Power
AUX Lamp Switch
Horn Power
Fuel Pump Power
System Power
High Beam Power

Low Beam Power
Rear Right Turn Signal
Rear Left Turn Signal

Brake Light Power
Running/Position Light Power
AUX Lamp Power

Reverse Light Power
Front Right Turn Signal
Front Left Turn Signal
BK
[179A]
R
1 2 3 4
[276B] 1 2 [121A-1] 1 1 [121A-2]
Ground
Exhaust Actuator
Exhaust Feedback
System Power
W/O
W/O
BK
[139B] A B
[139A] A B Battery Starter
50A
Main Fuse
Parking Rear
Active Brake Brake
Switch Switch Transmission
Exhaust
Actuator Oil Pressure
(If Equipped) Sender BCM

et00679 See Front Lighting and ET ACR
Hand Controls Sensor Front Front Fuel TCA
Engine Temperature
ACC See Front Lighting and Injector
5V Sensor Ground 1
5V Sensor Ground
5V Sensor Power 1
Switch Hand Controls Horn
System Power
System Power
Front Injector
[31RA] [31LA] [67A] [38A]
ACR Enable
1 2 3 1 2 3 5 6 1 4 1 2 3 4
Horn Power
ETC High
ETC Low
BE/W
BE/O
LBE/GN
V/BE
BE/Y
BE/PK
BE/BK
BE/BK
BK
BK
BE
BK
BE
BE
Ground
TPS 1
TPS 2
A B [90A] [122A-1] 1 1 [122A-2] 1 2 [203FA] A B [84A] 6 5 4 3 2 1 [211A]
A B [90B] [122B-1] 1 1 [122B-2] 1 2 [203FB] A B [84B] 6 5 4 3 2 1 [211B]
[22A-1]
R/GN
V/GN
GN/Y
LGN/R
R/W
BK/W
GN/O
BK/W
GY/O
GN/V
GN
GY/V
R/V
BK
1 R/O
See
2 BK/GN BE/Y
Front LBE/GN
Lighting 3 W/R
V/BE
and BE/W
Hand 4 W/BK
BE
Controls
R/Y
[22A-2] R
BK See Main
1 W/GY W/GY Harness
W/BE FLRT
BE/GY (3 of 3)
BK 1 1 BK W
R/V
BE/O
BK
BK
[GND3A] [GND3B]
BE/BK
BE/PK
R/BN
GND 3-1 GND 3-2
GN
Accessory Power 1 1 R/Y LGN/R
Auxiliary GY/V
Lamp Ground 3 3 BK
BK/W
Switch BE/GY BK
AUX Lamp Switch Input 4 4
V/GN
[109B] [109A] [24A] W/BK

R/W
R/GN
1 R/O
GY/W
2 BK/GN GY/O
BK/GN See Main
3 W/R
See BK/GN Harness
Front 4 W/BK LGN/Y FLRT
Lighting LGN/BN (2 of 3)
and R/O
[33A] [33B] Indicators Hand [204A]
LGN/BK
Controls GN/Y
IGN
1 BK/GY BK/GY
2 2 W/BE
Ignition 200 ACC
2 GY/W
GN/O
W/O
BE/W
W
R/O
R/O
R/O
R/O
R/O
BE/O
BE/PK
Switch 800
OFF
GN/V
1 1 BK/GN 3 R/GY R/GY
4 BK/W GN/W
GY/BE
5 GN/W GN/BE
[39A] [39B] 6 R/W R/W
Speedometer
LGN/BN
LGN/BK
BK/GN
GN/BE
GY/BE
R/GN
V/GN
Oil Pressure Indicator 1 1 W/O
W/Y
R/Y
BK
R
CAN High 2 2 W/R
High Beam Indicator 4 4 BE/W [20B] [20A] [117B] 1 2 4 [83B] A B C D [95B] A B [209B] 1 2
BK/GN
LGN/Y
Battery Fuse 5 5 R/O
R/W
[117A] [83A] [95A] [209A]
BK
1 2 4 A B C D A B 1 2
W
Neutral indicator 6 6 W W/R 1 1 W/R
Security Antenna High
Security Antenna Low

System Power
ION Sense
Rear Ignition Coil
Front Ignition Coil
System Power
Purge Solenoid
Ground 7 7 BK/GN BK/GN 2 2 BK/GN
BK/GN
[65B] A B C [131B-1] 1 1 [131B-2]
W/Y
R/Y
CAN Low 8 8 W/BK W/BK 3 3 W/BK

Fuel Level 9 9 W/Y W/Y 4 4 W/Y [65A] A B C [131A-1] 1 1 [131A-2]
5V Sensor Power
VSS Input
Ground
Left Turn Indicator 10 10 BE/PK W/BE 5 5 W/BE
Accessory Power
Fuel Level
Ground
Right Turn Indicator 12 12 BE/O R/O 6 6 R/O

R/BN 7 7 R/BN
BK 8 8 BK
Fuel Level A A W/Y Neutral
Fuel Pump Power B B R/BN Ignition Purge Security Switch
Coil Solenoid Antenna
Ground C C BK/GN
Ground D D BK
VSS
Fuel Gauge
Fuel Pump and
Fuel Level Sender [141A] [141B]
Figure A-8. Main Harness FLRT (1 of 3): 2015 Trike Model

Main Harness FLRT (1 of 3): 2015 Trike Model Main Harness FLRT (1 of 3): 2015 Trike Model
et00680
FLRT
(1 of 3)
Harness
See Main
BK
GN
R/O
R/W
W/R
GY/V
R/GY
GN/V
GN/Y
V/GN
GY/O
R/GN
GN/O
W/BK
BK/W
GY/W
GN/W
LGN/Y
GY/BE
BK/GY
LGN/R
GN/BE
BK/GN
BK/GN
LGN/BK
LGN/BN
1
1
BK/GY 5V Sensor Ground 2
[78A-1]
[78B-1]
2
2
GN/GY IAT
3
3
R/GY 5V Sensor Power 2

TMAP
1
Sensor
Rear Ignition Coil GY/BE

4
4
GY MAP Input
2
2
Front Ignition Coil GN/BE
3
3
Front HO2S Ground BK/O
4
4
VSS LGN/Y
[80B]
[80A]
5
5
Front Fuel Injector GN/Y
6
6
Rear Fuel Injector GY/Y
7
7
MAP Input GY
(BK)
ION Sense LGN/BN
Ground BK/GN
CAN Low W/BK
A
A
R/GN System Power

CAN High W/R
B
B
GY/Y Rear Injector

Injector
Rear HO2S Ground BK/PK

Rear Fuel
CKP Sensor High R

Front HO2S GN/BN
[85B]
[85A]
CKP Sensor Low
9 10 13 14 15 16 17 18
9 10 13 14 15 16 17 18
BK
[78A-2]
[78B-2]
3
3
Active Exhaust Actuator LGN/O V/GN System Power
4
4
1 2
1 2
ACR Enable LGN/R LGN/R ACR Enable

ACR
Rear
5
5
Purge Solenoid LGN/BK
6
6
ECM
IAT GN/GY
5V Sensor Ground 1 BK/W
7 8
7 8
ET GN
[203RB]
[203RA]
5V Sensor Power 1 R/W
(GY)
Ground BK/GN
TPS 2 GY/V
BK
System Power R/GN
Rear HO2S GY/BN BK/GN
Battery Fuse R/O
9 10 14 15 16 17 18
9 10 14 15 16 17 18
GND 1
BK/GN
TPS 1 GN/V
Reverse Enable Feedback TN/BE BK
2 4 8
2 4 8
GND 2
ETC High GN/O

ETC Low GY/O BK
Ground BK/GN
TGS 1 GN/W
(BN)
TGS 2 GY/W
Reverse Antenna Input TN
5V Sensor Ground 2
9 10 13 14 16 17
9 10 13 14 16 17
BK/GY
1
5V Sensore Power 2
18
18
R/GY
2
R/Y
3
TN/V
4
TN
5
[78A-3]
[78B-3]
BK
6
TN/BE
7
TN/R
1
1
Starter Solenoid Power R/BK

8
TN/GY
Starter
Solenoid

[128A]
[128B]
[245B]
1
1
System Power V/GN

2
2
Ground BK
See Reverse FLRT
3
3
Exhaust Actuator LGN/O

Active
Exhaust
Actuator
4
4

(If Equipped)
1
TN/R
2
TN/GY
[179A]
[179B]
[246B]
P
P
R
1 2 3
1 2 3
N
N
BK
System
1
1
V/GN V Power
Rear O2
2
2
BK/PK W Heater Ground

[47B]
[47A]
[77A]
[77B]
Rear O2
3
3
GY/BN GY
Sensor
Voltage
Regulator
HO2S Rear
5V Sensor
4
4
BK/W BK
Stator
Ground
[137A]
[137B]
System
1
1
V/GN V Power
Front O2
2
2
BK/O W
Heater Ground
Front O2
3
3
GN/BN GY
Sensor
5V Sensor
HO2S Front
4
4
BK/W BK
Ground
2
2
CKP Sensor High BK

BK
CKP
CKP Sensor Low

1
1
R
[138A]
[138B]
Sensor
R
BK
BK
TN/V
R/BK
R/Y
R/O
BK/GN
V/GN
R/GN
W/BK
W/BK
W/R
W/R
[79A]
[79B]
FLRT
(3 of 3)
Harness
See Main
et00681
Security
Siren
(If Equipped) BAS P&A Battery
W/BK
W/BK
See Rear Lighting DLC Accessory Tender
W/R
W/R
System Power
Security Siren
BK
[7A] 1 2 3 4 5 6 7 8 [91A] 1 2 3 5 6 [4A] 1 3 4 8 [281B] 1 2
BAS Input
[312B] 1 2 3 4 5 6 10 11 12
Ground
Ground
W/R
W/BN
W/BK
R/Y
LBE/GN
R/BE
Power
BK
V/BE
BK
BK
R
R/Y
BE/BN
BE/R
R/BE
BE/V
TN/V
BE
BK
[312A] 1 2 3 4 5 6 10 11 12
Fuse Block
[142A] [134A]
W/R
W/R
W/BK
W/BK
3 2 1 A B C
R/BE
V/BE
BK
BE
BK
[142B] [134B] [64B]
3 2 1 A B C
5A Battery
W/GN
R/GN
BK/GN
TN/BK
R/O
BK
R/O 2 1 R
R
R/BE R/BE
7.5A
BE/Y
System Power
R/BE
LBE/GN R/GN 4 3 V/GN
V/BE
BE/W 20A P&A
BE R/BE 12 11 R
R/Y
R 5A Spare
See Main BK
Harness 8 7 BK
W/GY
FLRT W/BE
(1 of 3) BE/GY 7.5A Spare
W BK 14 13 BK
R/V
BE/O 20A Spare
BE/BK BK 20 19
BE/PK
R/BN P&A Relay
V/BE 24 5 87
R/BE 17 3 30
R/Y 18 1 85
BK 23 2 86
TN/V
R/Y
R
BK
V/GN
See Main W/BK
Harness W/R
FLRT R/GN
(2 of 3) BK/GN
R/BK
R/O
BK
W/R
W/BK
Red Band
BK
R
BK
BK
[5B] A B
BK
R
BE/GN
TN/GN
BE/GN
BK/GN
BK/GN
TN/GN
BE/GY
BE/BN
TN/BK
BE/PK
BE/BK
W/GN
W/GY
W/BN
W/BE
W/BK
BE/W
R/GN
R/BN
BE/O
BE/R
R/BK
TN/V
BE/V
BE/Y
BK
W/O
W/O
W/R
R/V
R/Y
BK
BK
BK
BE
W
R
R
Battery Starter
40A
[121B-2] 1 1 [121B-1] 1 [120B] [242B] A2 A3 A4 B2 B3 B4 C3 C4 D2 D3 D4 E2 E3 E4 F3 F4 G2 G4 H2 J2 J3 J4 K2 K3 K4 L2 L3 L4 M2 M3 M4 1 [259B] 2 3 1 [276A] Main Fuse
[121A-2] 1 1 [121A-1] 1 [120A] [242A] A2 A3 A4 B2 B3 B4 C3 C4 D2 D3 D4 E2 E3 E4 F3 F4 G2 G4 H2 J2 J3 J4 K2 K3 K4 L2 L3 L4 M2 M3 M4 1 [259A] 2 3 1 [276B]
Start Enable
Security Antenna High
Security RF Antenna
Security Antenna Low
Aux Lamp Switch Input
BAS Input
Ignition Switch Input
Engine Stop Switch Input
CAN High
CAN Low
Oil Pressure Switch Input
Horn Power
Brake Switch Input
Fuel Pump Power
Ground
Security Siren
Right Front Turn Signal
Running Light Power
Left Front Turn Signal
Right Rear Turn Signal
Brake Light Power
Left Rear Turn Signal
Starter Solenoid Power
System Power
Front Running/Fog Light Power
Accessory Power
High Beam Power
Low Beam Power
Battery Power
Reverse Enable
Transmission
Oil Pressure
Rear Brake Switch
Switch Parking Brake
Switch
BCM

et00690
BK 2 Trunk/Dome
R/BE 1 Lamp
[279A] CB Antenna 1 BK
Ground
BE/BN 4 4 BE/V 4
BE/R 3 3 BE/R 3 Right [104A]
BE 2 2 BE 2 STT See Main
BK 1 1 BK 1 Harness BK
FLHTCUTG
7 R/BE (2 of 3) CB Antenna
[94RC] [94RD] [94RB]
BK
6 BK
See Main Cable
5 BE/V
Harness
4 BE/R
FLHTCUTG
3 BE
(3 of 3) 2 BE/BN
1 R/Y BK 3 LP
R/Y 1 Lamp CB Loading
Coil
[7B]
[233A] Right Side
Marker Lights
(If Equipped)
BE/V 4 4 BE/V 4
BE/R 3 3 BE/R 3 Left
BE 2 2 BE 2 STT
BE
BK
BK 1 1 BK 1
1 2 [12-2A]
(HDI) [94LC] [94LD] [94LB]
1 2 [12-2B]
Tour-Pak
Lights
V/BE
BK
[12A]
BK 2 Trunk/Dome Lamp
(DOM)
R/BE 1 FLHTCUTG 6 BK BE/R E E
See Main 5 BE/V BE/V D D
[279A] Harness 4 BE/R BE C C
FLHTCUTG 3 BE BK B B
(3 of 3) 2 BE/BN BE/BN A A
BK 1 V/BE
R/Y
BE
[287B] [287A]
2 V/BE
R/Y
BK
BE
1 BK
[94RB] [94RA] 4 3 1 [93RB]
V/BE
Right [258B]
BK
4 3 2 1
[93RA] 1 BK
1 1 STT Power Outlet
2 2 1 2 [12-3B]
BE 3 3 1 2 [12-3A]
BE/BN 4 4
1 2 1 2
BK
5 5
BE
BK
BK 6 6 1 2 3 [52-2B]
Circuit Board
AM/FM
7 R/BE License Left Side Antenna
6 BK BK
See Main BE Plate Lamp Marker Lights Base
5 BE/V FLHTCUTG (If Equipped)
Harness (3 of 3) [233A] [233B]
3 BE
2 BE/BN
1 R/Y BK 3 3 BK
R/Y 1 1 BE
[7B]
BK
R/Y
BE
AM/FM
[52A] Antenna
R/Y
BK
BE
See Main Base

[94RB] [94RA] 4 3 1 [93LB] Harness BK BK
FLHTCUTG
[93LA] Left (2 of 3)
4 3 2 1 STT AM/FM
1 1 Antenna
2 2 Cable
BE 3 3
BE/V 4 4
5 5 1 2 1 2
BK 6 6 1 2 3
Circuit Board
Figure A-11. Rear Lighting: 2015 Trike Models

Rear Lighting: 2015 Trike Models Rear Lighting: 2015 Trike Models
CB Rider Headset

et00687 CAV CIR DESCRIPTION
USB CB

Module [37B] [37A]
Microphone Sum Out +

1 BK MICROPHONE, COMMON (-)
Microphone Sum Out -

1 2 3 4 Antenna 2 BK HEADSET, COMMON (-)

3 PK/BE HEADSET, RT FRONT (+)
P&A Relay Power

[50A] 4 R MICROPHONE, FRONT (+) LBE/O 1 Left Rear
W
GN
BK
R
AUX CAN High

5 PK/GN HEADSET, LT FRONT (+)
AUX CAN Low

1 SPKR
6 BK JUMPER LBE/GY 2
7 N/C
TAB SHIELD MICROPHONE, SHIELD
TAB
Ground
[225B] 2 5 6 3 4 1
BK
1 GN
P&A Audio
2 R
HSD 3 W [280A] 1 2 3 4 5 6 7 8 9 10 11 12 [162A] [162B]
1 2 3 4 5 6 7 8 9 10 11 12 [184B]
PK/GN
PK/BE
4
BK/W
BK
R/W
BK
BK
PK/GN
LBE/W
[76B]
PK/BE
BK/PK
V/BE
BK
BK
R
LBE/BN
LBE/V
R
[51A] 1 2 3 4 5 6 7 8 9 10 11 12 [184A] LBE/O 1 1 LBE/O
LBE/GY 2 2 LBE/GY
W/BN
W/PK
W
R/BE
BK/Y
BK
BK
BK
R
R
Passenger
BK/W
LBE/W 3 3 PK/GN PK/GN 5
Antenna 1 BK [53B] 1 2 3 4 5 6
Headset
BK/PK 4 4 BK BK 2 CAV CIR DESCRIPTION
Radio R/BE [53A] 1 2 3 4 5 6 LBE/V 5 5 PK/BE PK/BE 3 1 BK MICROPHONE, COMMON (-)
2 BK HEADSET, COMMON (-)
CAN High A1 A1 W/R R/W 6 6 R R 4 3 PK/BE REAR RT HEADSET (+)
BK/W
PK/GN
BK/PK
PK/BE
BK
R
4 R REAR MICROPHONE (+)
BK 7 7 BK BK 1 5 PK/GN REAR LT HEADSET (+)
CAN Low A2 A2 W/BK
BK/W 8 8 BK/W BK/W TAB 6
AUX CAN Low A3 A3 W/BN LBE 9 9 LBE
7
TAB SHIELD MICROPHONE, SHIELD
AUX CAN High A4 A4 W/PK LBE/BK 10 10 LBE/BK
Ground B1 B1 BK R/Y 14 14 W/R
Rear Switch Input B2 B2 LBE/PK LBE/PK 15 15 W/BN
Front Microphone (+) C1 C1 R BK/GN 16 16 W
Microphone Common (-) C2 C2 BK [36B] [36A]
Microphone Sum Out (+) C3 C3 R BK 1
CB
Antenna LBE 1
Rear Microphone (+) D1 D1 R/W Right Rear
Microphone Shield D2 D2 BK/W [104A] LBE/BK 2 SPKR
Microphone Sum Out (-) D3 D3 BK BK 1 Antenna
Left Rear Headset (+) E1 E1 LBE/W
Right Rear Headset (+) E2 E2 LBE/V [51D] W/R Accessory Power
Speaker POD
Headset Common (-) E3 E3 BK/PK W Ground
Switch
BK/GN
W/BN Rear Switch Input 1
Left Front Headset (+) F1 F1 PK/GN
Right Front Headset (+) F2 F2 PK/BE
External AMP Power Control F4 F4 LBE/BN P&A Accessory
Left Rear Speaker (-) H1 H1 LBE/GY
[4A] 1 2 3 4 5 6 7 8
Audio In 1 Right (+) H2 H2 R
GND 1
LBE/W
LBE/GN
R/BE
V/BE
BK
LBE/R
LBE/Y
LBE/V
Audio In 1 Shield/Mono (-) H3 H3 BK
Left Rear Speaker (+) J1 J1 LBE/O
Right Rear Speaker (+) K1 K1 LBE
Right Rear Speaker (-) K2 K2 LBE/BK
Audio In 3 Right (+) K3 K3 R
Audio In 3 Shield/Mono (-) K4 K4 BK/Y
Left Front Speaker (-) L1 L1 PK/GY
Left Front Speaker (+) L2 L2 PK/O
Fuse Block
Ground L3 L3 BK
Ground L4 L4 BK 20A Radio
Right Front Speaker (+) M1 M1 PK R/PK 6 5 R
Right Front Speaker (-) M2 M2 PK/BK 20A P&A
Radio Fuse M3 M3 R/PK R/BE 12 11 R
Radio Fuse M4 M4 R/PK P&A Relay

V/BE 24 5 87
[27A] [27B] R/BE 17 3 30

W/BK
R/Y 18 1 85
W/R
BK 23 2 86
PK/GY
PK/BK
PK/O
[64B]
BK
To Main Harness
PK
BK
LBE/W
LBE/V
LBE/Y
V/BE
LBE/GN
BE/GY
BE/GY
LBE/R
BK
[2B] 9 10 11 12 V/BE
1 [GND3-B]
R/Y
BK
[2A] 9 10 11 12 [105RB] 1 2 3 4 5 1 [GND3-A] Red Band

GND 2 [105LB] 1 2 3 4 5 [242B] B3 M2
PK/O
PK/GY
P&A Dash
PK/BK
PK
R
BK
[105LA] 1 2 3 4 5 [242A] B3 M2 Switch Pack
A B [5B]
OE Switch Output 3
OE Switch Output 2
GND
Accessory Power
Aux/Fog Lamp Switch
Aux/Fog Lamp Switch
R
P&A Relay Power
BK
BK
BK
BK
BK
BK
[34A-1] [34B-1] [35B-1] [35A-1]
BK
Left Front 1 PK 1 1 PK PK/GY 2 2 PK/BK 2 Right Front
SPKR 2 PK/BK 2 2 PK/BK PK/O 1 1 PK 1 SPKR Starter 50A
GND 3-2 GND 3-1 GND 1 Main Fuse
OE Dash Battery
[34A-2] [34B-2] [35B-2] [35A-2] BCM
Switch Pack
Figure A-12. Radio: 2015 Trike Models

Radio: 2015 Trike Models Radio: 2015 Trike Models
et00688
LHCM IM
Bank Angle
RCM ECM Sensor
Parking Brake
Parking BCM
Battery Fuse
Battery Fuse
Brake
CAN High
Reverse Enable feedback
CAN High

CAN Low
CAN Low
Switch
Ground
Neutral
Ground
RCM Solenoid Ground
Reverse Activate Input

RCM Solenoid Power
Back Up Light Power

Back Up Light Power

Switch
Accessory Power
Accesory Power
System Power
System Power
System Power
[24C] 4 3 2 1 4 8 2 5 7 [30A]
Battery Fuse
CAN High
CAN High
CAN Low
CAN Low
[24D] 4 3 2 1 4 8 2 5 7 [30B]
Ground
Ground
Ground
Ground
Ground
Ground
2 1 [276B]
TN/GN
BK/GN
BK/GN
W/BK
W/BK
W/R
W/R
R/O
R/O
[78A-1] 14 13 10 [78A-2] 18 16 10 16 10 4 [78A-3] [131A-2] 1 1 [131A-1] C B A [134A] 2 1 [276A] B4 D2 D3 E2 G2 G4 L3 M2 [242A]
GN
BN
BE
BK
BK/GN
TN/GN
[78B-1] [78B-2] [78B-3] [131B-2] [131B-1] [134B] [242B]
R
Y
V
14 13 10 18 16 10 16 10 4 1 1 C B A [24B] 4 3 2 1 [2A] 7 3 2 4 5 [1A] B4 D2 D3 E2 G2 G4 L3 M2
[24A] [2B] [1B]
W/R
W/BK
R/GN
R/GN
7 3 2 4 5
BK/GN
R/O
BK/GN
BK/GN
BK/GN
4 3 2 1
W/R
W/BK
R/GN
W
TN/BE
TN/BK
TN
BK/GN
W
BK
R/Y
TN/BK
TN/V
2 3 4 5 6 7 8 [245A]
W/R
W/BK
BK/GN
R/O
W/R
W/BK
TN/GN
R/O
BK/GN
2 3 4 5 6 7 8 [245B]
TN/GY
R/Y
TN/R
TN/V
TN/BE
TN
BK
W/BK
W/R
To Main
R/GN
Harness
R/Y
FLHTCUTG
R/O
V/GN
Fuse Block
[64B]
System Power Fuse
R/GN 4 3 V/GN
Battery Fuse
R/O 2 1 R
Reverse
Reverse Motor [249A]
Control [248] Solenoid
[246B] [246A] Solenoid
[251B] BK
BK (6AWG)
TN/GY 2 2 BK BK
BK
(14AWG) [252B]
TN/R 1 1 GN GN
BK
[249B]
[251A] 150A Manual
BK
Reset Circuit
[253] Reverse Breaker
Motor
BK
[252A]
BK
BK
Red Band
R
BK
BK
BK
BK
BK
BK/GN
R
[5B] A B
GND 1 Starter
Battery Main GND 2
Fuse
Figure A-13. Reverse FLHTCUTG: 2015 Trike Model

Reverse FLHTCUTG: 2015 Trike Model Reverse FLHTCUTG: 2015 Trike Model
et00689
LHCM Speedometer
Bank Angle
RCM ECM Sensor BCM
Parking
Battery Fuse
Battery Fuse
Brake
CAN High
Reverse Enable feedback
CAN High

CAN Low
CAN Low
Switch
Ground
Neutral
Ground
RCM Solenoid Ground
Reverse Activate Input


RCM Solenoid Power

Switch
Accessory Power
Accesory Power
Reverse Enable
Reverse Enable
System Power
System Power
System Power
[24C] 4 3 2 1 8 2 5 7 [39A]
Battery Fuse
CAN High
CAN High
CAN Low
CAN Low
[24D] 4 3 2 1 8 2 5 7 [39B]
Ground
Ground
Ground
Ground
Ground
Ground
2 1 [276B]
BK/GN
BK/GN
W/BK
W/BK
W/R
W/R
R/O
R/O
[78A-1] 14 13 10 [78A-2] 18 16 10 16 10 4 [78A-3] [131A-2] 1 1 [131A-1] C B A [134A] 2 1 [276A] B4 D2 D3 D4 E2 G2 G4 L3 M2 [242A]
GN
BN
BE
BK
BK/GN
TN/GN
[78B-1] [78B-2] [78B-3] [131B-2] [131B-1] [134B] [242B]
R
Y
V
14 13 10 18 16 10 16 10 4 1 1 C B A [24B] 4 3 2 1 3 1 6 2 [20A] B4 D2 D3 D4 E2 G2 G4 L3 M2
[24A] [20B]
W/R
W/BK
R/GN
R/GN
3 1 6 2
BK/GN
R/O
BK/GN
BK/GN
BK/GN
4 3 2 1
W/R
W/BK
R/GN
W
TN/BE
TN/BK
TN
TN/GN
BK/GN
W
BK
R/Y
TN/BK
TN/V
2 3 4 5 6 7 8 [245A]
W/R
W/BK
BK/GN
R/O
W/R
W/BK
R/O
BK/GN
2 3 4 5 6 7 8
TN/GY [245B]
R/Y
TN/R
TN/V
TN/BE
TN
BK
W/BK
W/R To Main
R/GN Harness
R/Y FLRT
R/O
V/GN
Fuse Block
[64B]
System Power Fuse
R/GN 4 3 V/GN
Battery Fuse
R/O 2 1 R
Reverse
Reverse Motor [249A]
Control [248] Solenoid
[246B] [246A] Solenoid
[251B] BK
W/BK
W/BK
W/R
W/R
BK (6AWG)
TN/GY 2 2 BK BK
BK
(14AWG) [252B]
TN/R 1 1 GN GN
[312A]
BK
4 5 10 11
[249B]
[251A] 150A Manual [312B] 4 5 10 11
BK
Reset Circuit
Reverse
W/R
W/R
W/BK
W/BK
[253] Breaker
Motor
BK
[252A]
BK
BK
Red Band
R
BK
BK
BK
BK
BK
BK/GN
R
[5B] A B
GND 1 Starter
Battery Main GND 2
Fuse
Figure A-14. Reverse FLRT: 2015 Trike Model

Reverse FLRT: 2015 Trike Model Reverse FLRT: 2015 Trike Model
HOME
CONNECTOR END VIEWS A.3

CONNECTOR END VIEWS
Table A-5. Left Front Turn Signals (HDI) FLHT [31LA]
Table A-3. Rear Lighting [7A] TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 BE Running lamps
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
2 BE/PK Left front turn signal
1 R/Y Accessory power
3 BK Ground
2 BE/BN Right rear turn signal
4 BK Ground
3 BE Running lights power
4 BE/R Brake light power
ed03730
5 BE/V Left rear turn signal
6 BK Ground
7 R/BE P&A power 4 3 2 1
8 TN/V Reverse enable (FLRT)
ed03690
Figure A-17. Left Front Turn Signals (HDI) FLHT [31LA]
1 2 3 4
5 6 7 8
Table A-6. Front Left Turn/Auxiliary [31LA] FLRT

1 BK Ground
Figure A-15. Rear Lighting [7A] 2 BE/PK Left front turn signal
3 BE Running/position light power
Table A-4. Rear Lighting [7B] 4 - N/C
5 BE/BK Aux lamp power
2 BE/BN Right rear turn signal
ed03733
3 BE Running lights power
4 BE/R Brake light power (HDI)
5 BE/V Left rear turn signal 6 5 4 3 2 1
6 BK Ground
7 R/BE P&A power
8 - N/C
Figure A-18. Front Left Turn/Auxiliary [31LA] FLRT
ed03717
Table A-7. Left/Right Front Turn Signals (HDI) [31L/RB]

4 3 2 1
8 7 6 5
1 W Running lamps
2 R Left front turn signal
3 BK Ground
Figure A-16. Rear Lighting [7B] 4 BK Ground

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ed03685
Table A-10. Front Right Turn [31RA] FLRT

1 2 3 4 1 BK Ground
2 BE/O Right front turn signal
Figure A-19. Left/Right Front Turn Signals (HDI) FLHT

[31L/RB] ed03718
Table A-8. Front Left Turn/Auxiliary [31LB] FLRT 3 2 1

1 BK Ground
2 V Left front turn signal Figure A-22. Right Front Turn Signal [31RA] FLRT
4 - N/C
Table A-11. Front Right Turn [31RB] FLRT
5 - N/C
6 - N/C
1 BK Ground
2 V Right front turn signal
ed03802
1 2 3 4 5 6
ed03691
1 2 3
Figure A-20. Front Left Turn/Auxiliary [31LB] FLRT
Table A-9. Right Front Turn Signals (HDI) FLHT [31RA]

Figure A-23. Right Front Turn [31RB] FLRT
1 BE Running lamps
Table A-12. Left/Right Front Turn Signals (HDI) FLHT
2 BE/O Right front turn signal [31L/R-2]
3 BK Ground
4 BK Ground
1 W Running lamps
2 R Left/right front turn signal
ed03730
3 BK Ground
4 3 2 1 ed03734
1 2 3 3 2 1
Figure A-21. Right Front Turn Signals (HDI) FLHT [31RA]

[B] [A]
Figure A-24. Left/Right Front Turn Signals (HDI) FLHT

[31L/R-2]

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Table A-13. Left Front Turn Signals (DOM) FLHT [31LA] Table A-16. Right Front Turn Signals (DOM) FLHT [31RB]
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION TERMINAL WIRE COLOR CIRCUIT DESCRIPTION
1 BE Running lamps 1 BE Running lamps
2 BE/PK Left front turn signal 2 BN Right front turn signal
3 BK Ground 3 BK Ground
4 BE/BK Aux lamp power 4 GY/BK Aux lamp power
ed03730 ed03685
4 3 2 1 1 2 3 4
Figure A-25. Left Front Turn Signals (DOM) FLHT [31LA] Figure A-28. Right Front Turn Signals (DOM) FLHT [31RB]
Table A-14. Left Front Turn Signals (DOM) FLHT [31LB] Table A-17. Left/Right Headlamp (HDI) FLHT [38L/R-1]
1 BE Running lamps 1 BE/W High beam headlamp
2 V Left front turn signal 2 BE/Y Low beam headlamp
3 BK Ground
4 GY/BK Aux lamp power ed03672
ed03685 1 2 2 1
[B] [A]
1 2 3 4
Figure A-29. Left/Right Headlamp (HDI) FLHT [38L/R-1]
Figure A-26. Left Front Turn Signals (DOM) FLHT [31LB]

Table A-18. Left/Right Headlamp (HDI) FLHT [38L/RB-2]

Table A-15. Right Front Turn Signals (DOM) FLHT [31RA] A BK Ground
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION B BE/W High beam headlamp
1 BE Running lights C BE/Y Low beam headlamp
2 BE/O Right front turn signal
3 BK Ground ed03738

A B
ed03730 C
4 3 2 1
Figure A-30. Left/Right Headlamp (HDI) FLHT [38L/RB-2]
Figure A-27. Right Front Turn Signals (DOM) FLHT [31RA]

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Table A-19. Headlamp [38A] FLRT Table A-22. ECM [78-3] (BN)
1 BE Running/position light power 1 GN/BK Cooling fan left (FLHT)
(HDI) 2 GN/V TPS1
2 BE/W High beam power 3 W/V AAT
3 BE/Y Low beam power 4 TN/BE Reverse enable feedback
4 BK Ground 5 GY/BK Cooling fan right (FLHT)
6 - N/C
ed03797
7 - N/C
8 GN/O ETC high
9 GY/O ETC low
1 2 3 4
10 BK/GN Ground
11 - N/C
12 - N/C
Figure A-31. Headlamp [38A] FLRT
13 GN/W TGS 1
14 GY/W TGS 2
Table A-20. Headlamp [38B] FLRT 15 GY/GN Coolant temperature (FLHT)
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION 16 TN Reverse activate input
1 BE Running/position light power 17 BK/GY 5V sensor ground 2
(HDI) 18 R/GY 5V sensor power 2
2 W High beam power
3 Y Low beam power ed03660
4 BK Ground
9 8 7 6 5 4 3 2 1
ed03796 18 17 16 15 14 13 12 11 10
4 3 2 1 Figure A-34. ECM [78-3]
Table A-23. BAS [134]

Figure A-32. Headlamp [38B] FLRT
A TN/BK BAS input
Table A-21. Headlamp [38-2] FLRT
B BK/GN Ground
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION C R/GN System power
1 W High beam power
2 Y Low beam power ed03695
3 BK Ground
ed03798
C B A
1 3
Figure A-35. BAS [134]
Figure A-33. Headlamp [38B-2] FLRT

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Table A-24. LP Lamp [233]

1 R/W Accessory power
2 - N/C
3 BK Ground
ed03718
3 2 1
Figure A-36. LP Lamp [233]

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Table A-25. BCM [242] Table A-25. BCM [242]
A1 - N/C L4 BE/BK Front running/fog light power
A2 R Security antenna high M1 - N/C
A3 W/BN Start enable M2 R/Y Accessory power
A4 BK Security RF antenna M3 BE/W High beam power
B1 - N/C M4 BE/Y Low beam power
B2 BK Security antenna low
B3 BE/GY Aux lamp switch ed03681
B4 - N/C A B C D E F G H J K L M
4 4
C1 - N/C 3 3
2 2
C2 - N/C 1
A B C D E F G H J K L M
1
C3 W/BE Ignition switch input

C4 W/GY Engine stop switch input
D1 - N/C Figure A-37. BCM [242]
D2 W/R CAN high

D3 W Neutral switch input Table A-26. RCM [245]
D4 - N/C
E1 - N/C
1 - N/C
E2 W/BK CAN low
E3 W/O Oil pressure switch input
3 TN/V Reverse enable
E4 R/V Horn power
4 TN Reverse activate input
F1 - N/C
5 BK Ground
F2 - N/C
6 TN/BE Reverse enable feedback
F3 BE/GN Brake switch input
7 TN/R RCM solenoid power
F4 R/BN Fuel pump power
8 TN/GY RCM solenoid ground
G1 - N/C
G2 TN/V Reverse enable
ed03816
G3 - N/C
G4 BK/GN Ground 4 3 2 1
H1 - N/C 8 7 6 5
H2 W/GN Security siren

H3 - N/C
H4 - N/C Figure A-38. RCM [245]
J1 - N/C
J2 BE/O Right front turn signal
Table A-27. RCM Solenoid [246]
J3 BE Running lights
J4 BE/PK Left front turn signal
1 TN/R RCM solenoid power
K1 - N/C
2 TN/GY RCM solenoid ground
K2 BE/BN Right rear turn signal
K3 BE/R Brake lamp power
ed03666
K4 BE/V Left rear turn signal
L1 - N/C
L2 R/BK Starter solenoid power 2 1
L3 R/GN System power

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Figure A-39. RCM Solenoid [246]

ed03662
1 2 3 4 5 6
Table A-28. Parking Brake Switch [276]

7 8 9 10 11 12

1 TN/GN Parking brake
2 BK/GN Ground
Figure A-42. Trunk AUX [312A]
3 - N/C
ed03813 Table A-31. Trunk AUX [312B]

1 2 3 1 - N/C
2 - N/C
3 - N/C
4 W/R CAN +
Figure A-40. Parking Brake Switch [276]
5 W/BK CAN -
6 - N/C
Table A-29. Trunk Light [279] 7 - N/C
TERMINAL WIRE COLOR CIRCUIT DESCRIPTION 8 - N/C
1 R/BE P&A fuse power 9 - N/C
2 BK Ground 10 W/R CAN +
11 W/BK CAN -
ed03666 12 BK Tether
ed03815
2 1
6 5 4 3 2 1
12 11 10 9 8 7
Figure A-41. Trunk Light [279]
Figure A-43. Trunk AUX [312B]

Table A-30. Trunk AUX [312A]

1 R/BE P&A fuse
2 V/BE P&A relay power
3 BK Ground
4 W/R CAN +
5 W/BK CAN -
7 - N/C
8 - N/C
9 - N/C
10 W/R CAN +
11 W/BK CAN -
12 BK Tether

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COMPONENT LOCATION VIEWS A.4

COMPONENT LOCATIONS
ed03552
Some components and connectors are not easily located on 1
the motorcycle. The following figures show locations for these 2
components and connectors. The figures are generally ordered 3 4
from front to back around the motorcycle.
ed03559
4
3
5
2
6
5
1
7
1. Reverse motor
2. Reverse motor solenoid
8
5. Reverse motor solenoid high current input ter-
minal [249A]
1. RCM
2. 150 Amp circuit breaker [252B] Figure A-45. Reverse Motor and Solenoid Assembly
3. RCM solenoid [251B]
4. RCM solenoid [251A]
5. 150 Amp circuit breaker [252A]
6. RCM solenoid [246]
7. 150 Amp circuit breaker
8. RCM [245]
Figure A-44. Under Right Side Cover

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ed03553

2. Reverse motor solenoid high current input terminal [249A]
4. Reverse motor and RCM ground
Figure A-46. Reverse Motor and Solenoid Assembly
ed03556 ed03557
Figure A-47. Parking Brake Switch Figure A-48. BAS [134] Behind Battery

NOTES

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
B.1 LENGTH CONVERSION..........................................................................................................B-1
B.2 FLUID CONVERSION...............................................................................................................B-2
B.3 TORQUE CONVERSION..........................................................................................................B-3
B.4 GLOSSARY...............................................................................................................................B-4
APPENDIX B REFERENCE
NOTES
HOME
LENGTH CONVERSION B.1

CONVERSION TABLE
Table B-1. Metric Conversions
MILLIMETERS to INCHES INCHES to MILLIMETERS
(MM x 0.03937 = IN) (IN x 25.40 = MM)
mm in mm in mm in mm in in mm in mm in mm in mm
.1 .0039 25 .9842 58 2.283 91 3.582 .001 .025 .6 15.240 1-15/16 49.21 3-5/16 84.14
.2 .0078 26 1.024 59 2.323 92 3.622 .002 .051 5/8 15.875 2 50.80 3-3/8 85.72
.3 .0118 27 1.063 60 2.362 93 3.661 .003 .076 11/16 17.462 2-1/16 52.39 3.4 86.36
.4 .0157 28 1.102 61 2.401 94 3.701 .004 .102 .7 17.780 2.1 53.34 3-7/16 87.31
.5 .0197 29 1.142 62 2.441 95 3.740 .005 .127 3/4 19.050 2-1/8 53.97 3-1/2 88.90
.6 .0236 30 1.181 63 2.480 96 3.779 .006 .152 .8 20.320 2-3/16 55.56 3-9/16 90.49
.7 .0275 31 1.220 64 2.519 97 3.819 .007 .178 13/16 20.638 2.2 55.88 3.6 91.44
.8 .0315 32 1.260 65 2.559 98 3.858 .008 .203 7/8 22.225 2-1/4 57.15 3-5/8 92.07
.9 .0354 33 1.299 66 2.598 99 3.897 .009 .229 .9 22.860 2.3 58.42 3-11/16 93.66
1 .0394 34 1.338 67 2.638 100 3.937 .010 .254 15/16 23.812 2-5/16 58.74 3.7 93.98
2 .0787 35 1.378 68 2.677 101 3.976 1/64 .397 1 25.40 2-3/8 60.32 3-3/4 95.25
3 .1181 36 1.417 69 2.716 102 4.016 .020 .508 1-1/16 26.99 2.4 60.96 3.8 96.52
4 .1575 37 1.456 70 2.756 103 4.055 .030 .762 1.1 27.94 2-7/16 61.91 3-13/16 96.84
5 .1968 38 1.496 71 2.795 104 4.094 1/32 .794 1-1/8 28.57 2-1/2 63.50 3-7/8 98.42
6 .2362 39 1.535 72 2.834 105 4.134 .040 1.016 1-3/16 30.16 2-9/16 65.09 3.9 99.06
7 .2756 40 1.575 73 2.874 106 4.173 .050 1.270 1.2 30.48 2.6 66.04 3-15/16 100.01
8 .3149 41 1.614 74 2.913 107 4.212 .060 1.524 1-1/4 31.75 2-5/8 66.67 4 101.6
9 .3543 42 1.653 75 2.953 108 4.252 1/16 1.588 1.3 33.02 2-11/16 68.26 4-1/16 102.19
10 .3937 43 1.693 76 2.992 109 4.291 .070 1.778 1-5/16 33.34 2.7 68.58 4.1 104.14
11 .4331 44 1.732 77 3.031 110 4.331 .080 2.032 1-3/8 34.92 2-3/4 69.85 4-1/8 104.77
12 .4724 45 1.772 78 3.071 111 4.370 .090 2.286 1.4 35.56 2.8 71.12 4-3/16 106.36
13 .5118 46 1.811 79 3.110 112 4.409 .1 2.540 1-7/16 36.51 2-13/16 71.44 4.2 106.68
14 .5512 47 1.850 80 3.149 113 4.449 1/8 3.175 1-1/2 38.10 2-7/8 73.02 4-1/4 107.95
15 .5905 48 1.890 81 3.189 114 4.488 3/16 4.762 1-9/16 39.69 2.9 73.66 4.3 109.22
16 .6299 49 1.929 82 3.228 115 4.527 .2 5.080 1.6 40.64 2-15/16 74.61 4-5/16 109.54
17 .6693 50 1.968 83 3.268 116 4.567 1/4 6.350 1-5/8 41.27 3 76.20 4-3/8 111.12
18 .7086 51 2.008 84 3.307 117 4.606 .3 7.620 1-11/16 42.86 3-1/16 77.79 4.4 111.76
19 .7480 52 2.047 85 3.346 118 4.645 5/16 7.938 1.7 43.18 3.1 78.74 4-7/16 112.71
20 .7874 53 2.086 86 3.386 119 4.685 3/8 9.525 1-3/4 44.45 3-1/8 79.37 4-1/2 114.30
21 .8268 54 2.126 87 3.425 120 4.724 .4 10.160 1.8 45.72 3-3/16 80.96 4-9/16 115.89
22 .8661 55 2.165 88 3.464 121 4.764 7/16 11.112 1-13/16 46.04 3.2 81.28 4.6 116.84
23 .9055 56 2.205 89 3.504 122 4.803 1/2 12.700 1-7/8 47.62 3-1/4 82.55 4-5/8 117.47
24 .9449 57 2.244 90 3.543 123 4.842 9/16 14.288 1.9 48.26 3.3 83.82 4-11/16 119.06
2015 Trike Service Supplement Appendix B Reference B-1

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FLUID CONVERSION B.2

UNITED STATES SYSTEM BRITISH IMPERIAL SYSTEM
Unless otherwise specified, all fluid volume measurements in Fluid volume measurements in this manual do not include the
this manual are expressed in United States (U.S.) units-of- British Imperial (Imp.) system equivalents. The following con-
measure. See below: versions exist in the British Imperial system:
• 1 pint (U.S.) = 16 fluid ounces (U.S.) • 1 pint (Imp.) = 20 fluid ounces (Imp.)
• 1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.) • 1 quart (Imp.) = 2 pints (Imp.)
• 1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.) • 1 gallon (Imp.) = 4 quarts (Imp.)
METRIC SYSTEM Although the same unit-of-measure terminology as the U.S.

system is used in the British Imperial (Imp.) system, the actual
Fluid volume measurements in this manual include the metric volume of each British Imperial unit-of-measure differs from its
system equivalents. In the metric system, 1 liter (L) = 1,000 U.S. counterpart. The U.S. fluid ounce is larger than the British
milliliters (mL). To convert between U.S. units-of-measure and Imperial fluid ounce. However, the U.S. pint, quart, and gallon
metric units-of-measure, refer to the following: are smaller than the British Imperial pint, quart, and gallon,
• fluid ounces (U.S.) x 29.574 = milliliters respectively. To convert between U.S. units and British Imperial
units, refer to the following:
• pints (U.S.) x 0.473 = liters
• fluid ounces (U.S.) x 1.042 = fluid ounces (Imp.)
• quarts (U.S.) x 0.946 = liters
• pints (U.S.) x 0.833 = pints (Imp.)
• gallons (U.S.) x 3.785 = liters
• quarts (U.S.) x 0.833 = quarts (Imp.)
• milliliters x 0.0338 = fluid ounces (U.S.)
• gallons (U.S.) x 0.833 = gallons (Imp.)
• liters x 2.114 = pints (U.S.)
• fluid ounces (Imp.) x 0.960 = fluid ounces (U.S.)
• liters x 1.057 = quarts (U.S.)
• pints (Imp.) x 1.201 = pints (U.S.)
• liters x 0.264 = gallons (U.S.)
• quarts (Imp.) x 1.201 = quarts (U.S.)
• gallons (Imp.) x 1.201 = gallons (U.S.)
B-2 2015 Trike Service Supplement Appendix B Reference

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TORQUE CONVERSION B.3

UNITED STATES SYSTEM METRIC SYSTEM
The U.S. units of torque, foot pounds and inch pounds, are All metric torque specifications are written in Newton-meters
used in this manual. To convert units, use the following equa- (Nm). To convert metric to United States units and United
tions: States to metric, use the following equations:
• foot pounds (ft-lbs) X 12.00000 = inch pounds (in-lbs) • Newton meters (Nm) X 0.737563 = foot pounds (ft-lbs)
• inch pounds (in-lbs) X 0.08333 = foot pounds (ft-lbs) • Newton meters (Nm) X 8.85085 = inch pounds (in-lbs)
• foot pounds (ft-lbs) X 1.35582 = Newton meters (Nm)
• inch pounds (in-lbs) X 0.112985 = Newton meters (Nm)

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GLOSSARY B.4
ACRONYMS AND ABBREVIATIONS
Table B-2. 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 Absorbed glass mat (battery)
Ah Ampere-hour
AIS Active intake solenoid
AWG American wire gauge
B+ Battery voltage
bar Bar
BAS Bank angle sensor
BCM Body control module
BOB Breakout box
BTDC Before top dead center
°C Celsius (Centigrade)
CA California
CAL Calibration
CAN Controller area network
CB Tx CB send transmission
CB Rx CB receive transmission
cc Cubic centimeters
CCA Cold cranking amps
CCW Counterclockwise
CKP Crankshaft position
cm Centimeters
cm3 Cubic centimeters
CW Clockwise
DC Direct current
DLC Data link connector
DOM Domestic
DOT Department of Transportation
DTC Diagnostic trouble code
DVOM Digital volt ohm meter
ECM Electronic control module
ECT Engine coolant temperature
ECU Electronic control unit
EEPROM Electrically erasable programmable read only memory
EFI Electronic fuel injection

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EHCU Electro hydraulic control unit
ET Engine temperature
ETC Electronic throttle control
EVAP Evaporative emissions control system
°F Fahrenheit
fl oz Fluid ounce
FPS Fuel pressure sensor
ft Feet
ft-lbs Foot pounds
FTP Flash to pass
g Gram
gal Gallon
GAWR Gross axle weight rating
GND Ground (electrical)
GPS Global positioning system
GVWR Gross vehicle weight rating
HCU Hydraulic control unit
HDI Harley-Davidson International
HD-Link Networking system
H-DSSS Harley-Davidson smart security system
HFM Hands-free mode
HFSM Hands-free security module
Hg Mercury
H02S Heated oxygen sensor
hp Horsepower
hr Hour
IAC Idle air control
IAT Intake air temperature
IC Instrument cluster
ID Inside diameter
IGN Ignition light/key switch position
in inch
in3 Cubic inch
INJ PW Injector pulse width
INTCM Intercom
in-lbs Inch pounds
JSS Jiffy stand sensor
kg Kilogram
km Kilometer
km/h Kilometers per hour
kPa Kilopascal
kW Kilowatt
L Liter

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lb Pounds
LCD Liquid crystal display
LED Light emitting diode
LH Left hand
LHCM Left hand control module
LP License plate
LT Left
mA Milliampere
MAP Manifold absolute pressure
max Maximum
mi Mile
min Minimum
mL Milliliter
mm Millimeter
mph Miles per hour
ms Millisecond
Nm Newton-meter
NIM Navigation interface module
NiMH Nickel metal hydride
N/A Not applicable
O2 Oxygen
OD Outside diameter
OEM Original equipment manufacturer
oz Ounce
P&A Parts and Accessories
Part No. Part number
PIN Personal identification number
PND Personal navigation device
psi Pounds per square inch
PWM signal Pulse width modulated signal
qt Quart
RAD Radio
RCM Reverse control module
RDS Radio data system
RES Reserve mark on fuel supply valve
RH Right hand
RHCM Right hand control module
rpm Revolutions per minute
RT Right
s Seconds
SCFH Cubic feet per hour at standard conditions
SDARS Satellite digital audio radio service
SPDO Speedometer

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SPKR Speaker
STT Stop/tail/turn
TA Traffic announcement
TCA Throttle control actuator
TDC Top dead center
TGS Twist grip sensor
TPS Throttle position sensor
TSM Turn signal module
TSSM Turn signal/security module
USB Universal serial bus
V Volt
VAC Volts of alternating current
VDC Volts of direct current
VIN Vehicle identification number
VR Voice recognition
VSS Vehicle speed sensor
W Watt
WA Weather alert
WSS Wheel speed sensor

NOTES

Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-25070 ROBINAIR HEAT GUN 2.19 TRUNK DOOR: FLRT, Repair
HD-34633 AIR SUSPENSION PUMP AND GAUGE 1.13 REAR SUSPENSION ADJUSTMENTS, General
HD-34633 AIR SUSPENSION PUMP AND GAUGE 2.29 SHOCK ABSORBERS, Removal
HD-34634 FORK OIL SEAL INSTALLER 5.4 AXLE, Assembly
HD-34736-B VALVE SPRING COMPRESSOR 2.18 TRUNK DOOR LOCKSET: FLHTCUTG, Lockset
HD-35316-12 MAIN DRIVE GEAR INSTALLER 5.5 AXLE HOUSING/DIFFERENTIAL, Assembly
HD-35381A BELT TENSION GAUGE 1.11 DRIVE BELT, Checking Drive Belt Deflection
HD-39978 DIGITAL MULTIMETER (FLUKE 78) 7.18 REAR LIGHTING DIAGNOSTICS, Diagnostics
HD-41404 HARNESS CONNECTOR TEST KIT 7.15 REVERSE MOTOR SYSTEM DIA-
GNOSTICS, Description and Operation
HD-41404 HARNESS CONNECTOR TEST KIT 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS, DTC
P1772
P1775
P1777
P1778
HD-41404 HARNESS CONNECTOR TEST KIT 7.17 INDICATOR LAMP DIAGNOSTICS, Parking Brake
Lamp Always On
HD-41404 HARNESS CONNECTOR TEST KIT 7.17 INDICATOR LAMP DIAGNOSTICS, Parking Brake
Lamp Inoperative
HD-41404 HARNESS CONNECTOR TEST KIT 7.18 REAR LIGHTING DIAGNOSTICS, Brake Lamps
TOOLS
Inoperative
HD-41404 HARNESS CONNECTOR TEST KIT 7.18 REAR LIGHTING DIAGNOSTICS, Brake Lamps
Inoperative
HD-41404 HARNESS CONNECTOR TEST KIT 7.19 HEADLAMP DIAGNOSTICS, FLRT, DTC B2132
HD-41404 HARNESS CONNECTOR TEST KIT 7.19 HEADLAMP DIAGNOSTICS, FLRT, DTC B2133,
B2134
HD-41404 HARNESS CONNECTOR TEST KIT 7.19 HEADLAMP DIAGNOSTICS, FLRT, DTC B2137
HD-41404 HARNESS CONNECTOR TEST KIT 7.19 HEADLAMP DIAGNOSTICS, FLRT, DTC B2138,
B2139
HD-41404 HARNESS CONNECTOR TEST KIT 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, DTC
B2132
B2133, B2134
B2137
B2138, B2139
HD-41404 HARNESS CONNECTOR TEST KIT 7.20 BAS DIAGNOSTICS, DTC B2228
HD-42682 BREAKOUT BOX 7.17 INDICATOR LAMP DIAGNOSTICS, Parking Brake
Lamp Always On
HD-43644-3 CAMSHAFT BEARING INSTALLER 5.5 AXLE HOUSING/DIFFERENTIAL, Disassembly
HD-43644-3 CAMSHAFT BEARING INSTALLER 5.5 AXLE HOUSING/DIFFERENTIAL, Disassembly
HD-45327 REAR FORK BEARING INSTALLER 2.27 REAR FORK, Repair
HD-46601 BREAKOUT BOX ADAPTERS 7.17 INDICATOR LAMP DIAGNOSTICS, Parking Brake
Lamp Always On
HD-48650 DIGITAL TECHNICIAN II 7.20 BAS DIAGNOSTICS, Diagnostics
HD-49303 AXLE PULLER 5.4 AXLE, Removal
I
HD-49762 PULLER 5.5 AXLE HOUSING/DIFFERENTIAL, Disassembly
HD-49796 BEARING SPACER TOOL 2.27 REAR FORK, Repair
HD-50390-1 BREAKOUT BOX 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS, DTC
P1772
P1775
P1775
P1777
P1778
HD-50390-1 BREAKOUT BOX 7.15 REVERSE MOTOR SYSTEM DIA-
GNOSTICS, Reverse Motor Inoperative
HD-50390-1 BREAKOUT BOX 7.15 REVERSE MOTOR SYSTEM DIA-
HD-50390-1 BREAKOUT BOX 7.17 INDICATOR LAMP DIAGNOSTICS, Parking Brake
Lamp Always On
HD-50390-1 BREAKOUT BOX 7.18 REAR LIGHTING DIAGNOSTICS, Brake Lamps
Inoperative
HD-50390-1 BREAKOUT BOX 7.19 HEADLAMP DIAGNOSTICS, FLRT, High Beam
Inoperative
HD-50390-1 BREAKOUT BOX 7.19 HEADLAMP DIAGNOSTICS, FLRT, DTC B2133,
B2134
HD-50390-1 BREAKOUT BOX 7.19 HEADLAMP DIAGNOSTICS, FLRT, Low Beam
Inoperative
HD-50390-1 BREAKOUT BOX 7.19 HEADLAMP DIAGNOSTICS, FLRT, DTC B2138,
B2139
HD-50390-1 BREAKOUT BOX 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, High Beam
Inoperative
HD-50390-1 BREAKOUT BOX 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, DTC
B2133, B2134
HD-50390-1 BREAKOUT BOX 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, Low Beam
Inoperative
HD-50390-1 BREAKOUT BOX 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, DTC
B2138, B2139
HD-50390-1 BREAKOUT BOX 7.20 BAS DIAGNOSTICS, DTC B2228
HD-50390-1 BREAKOUT BOX 7.20 BAS DIAGNOSTICS, DTC B2226
HD-50390-2 BCM/RADIO CABLE 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS, DTC
P1775
HD-50390-2 BCM/RADIO CABLE 7.15 REVERSE MOTOR SYSTEM DIA-
HD-50390-2 BCM/RADIO CABLE 7.17 INDICATOR LAMP DIAGNOSTICS, Parking Brake
Lamp Always On
HD-50390-2 BCM CABLE 7.18 REAR LIGHTING DIAGNOSTICS, Brake Lamps
Inoperative
HD-50390-2 BCM/RADIO CABLE 7.19 HEADLAMP DIAGNOSTICS, FLRT, High Beam
Inoperative
II TOOLS
HD-50390-2 BCM/RADIO CABLE 7.19 HEADLAMP DIAGNOSTICS, FLRT, DTC B2133,
B2134
HD-50390-2 BCM/RADIO CABLE 7.19 HEADLAMP DIAGNOSTICS, FLRT, Low Beam
Inoperative
HD-50390-2 BCM/RADIO CABLE 7.19 HEADLAMP DIAGNOSTICS, FLRT, DTC B2138,
B2139
HD-50390-2 BCM CABLE 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, High Beam
Inoperative
HD-50390-2 BCM CABLE 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, DTC
B2133, B2134
HD-50390-2 BCM CABLE 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, Low Beam
Inoperative
HD-50390-2 BCM CABLE 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, DTC
B2138, B2139
HD-50390-2 BCM CABLE 7.20 BAS DIAGNOSTICS, DTC B2228
HD-50390-2 BCM CABLE 7.20 BAS DIAGNOSTICS, DTC B2226
HD-50390-2-P BCM/RADIO OVERLAY 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS, DTC
P1775
HD-50390-2-P BCM/RADIO OVERLAY 7.15 REVERSE MOTOR SYSTEM DIA-
HD-50390-2-P BCM/RADIO OVERLAY 7.17 INDICATOR LAMP DIAGNOSTICS, Parking Brake
Lamp Always On
HD-50390-2-P BCM OVERLAY 7.18 REAR LIGHTING DIAGNOSTICS, Brake Lamps
Inoperative
HD-50390-2-P BCM/RADIO OVERLAY 7.19 HEADLAMP DIAGNOSTICS, FLRT, High Beam
Inoperative
HD-50390-2-P BCM/RADIO OVERLAY 7.19 HEADLAMP DIAGNOSTICS, FLRT, DTC B2133,
B2134
HD-50390-2-P BCM/RADIO OVERLAY 7.19 HEADLAMP DIAGNOSTICS, FLRT, Low Beam
Inoperative
HD-50390-2-P BCM/RADIO OVERLAY 7.19 HEADLAMP DIAGNOSTICS, FLRT, DTC B2138,
B2139
HD-50390-2-P BCM OVERLAY 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, High Beam
Inoperative
HD-50390-2-P BCM OVERLAY 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, DTC
B2133, B2134
HD-50390-2-P BCM OVERLAY 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, Low Beam
Inoperative
HD-50390-2-P BCM OVERLAY 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, DTC
B2138, B2139
HD-50390-2-P BCM OVERLAY 7.20 BAS DIAGNOSTICS, DTC B2228
HD-50390-2-P BCM OVERLAY 7.20 BAS DIAGNOSTICS, DTC B2226
HD-50390-4 ECM CABLE 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS, DTC
P1772
P1775
P1777
TOOLS III
P1778
HD-50390-4 ECM CABLE 7.15 REVERSE MOTOR SYSTEM DIA-
HD-50390-4-P ECM OVERLAY 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS, DTC
P1772
P1775
P1777
P1778
HD-50390-4-P ECM OVERLAY 7.15 REVERSE MOTOR SYSTEM DIA-
HD-50424 1.5 MM TERMINAL EXTRACTOR TOOL 7.19 HEADLAMP DIAGNOSTICS, FLRT, DTC B2132
HD-50424 1.5 MM TERMINAL EXTRACTOR TOOL 7.19 HEADLAMP DIAGNOSTICS, FLRT, DTC B2137
HD-50424 1.5 MM TERMINAL EXTRACTOR TOOL 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, DTC
B2132
HD-50424 1.5 MM TERMINAL EXTRACTOR TOOL 7.19 HEADLAMP DIAGNOSTICS, Dual Lamp, DTC
B2137
HD-59000B FORK OIL LEVEL GAUGE 1.16 FORK OIL, Procedure
HD-95635-46 ALL-PURPOSE CLAW PULLER 5.5 AXLE HOUSING/DIFFERENTIAL, Disassembly
SNAP-ON BB200A BASIC VACUUM BRAKE BLEEDER 1.6 BRAKES, Brake Fluid Replacement
SNAP-ON BB200A BASIC VACUUM BRAKE BLEEDER 2.11 BRAKE LINES, Rear Brake Line
IV TOOLS
2015 Harley-Davidson Trike Models Service Manual
Supplement
Air valve nut 12-15 in-lbs 1.4-1.7 Nm 2.25 INTERMEDIATE FRAME, Installation
Air valve nut 12-15 in-lbs 1.4-1.7 Nm 5.5 AXLE HOUSING/DIFFERENTIAL, Installation
Axle adapter plate screws 41-45 ft-lbs 55.6-61.0 Nm 2.28 LATERAL ALIGNMENT, Procedure/Use
Axle adjustment screw jamnut 15-25 ft-lbs 20.3-34.0 Nm 1.11 DRIVE BELT, Setting Deflection
Axle bearing retainer locknuts 40-45 ft-lbs 54.2-61.0 Nm 5.4 AXLE, Installation/Use new locknuts
Axle cover set screw 60-84 in-lbs 6.8-9.5 Nm 2.5 FRONT AXLE COVERS: HDI
MODELS, Replacement/LOCTITE 262 HIGH
(red)
Bank angle sensor bracket screws 72-108 in-lbs 8.1-12.2 Nm 2.25 INTERMEDIATE FRAME, Assembly
Bank angle sensor bracket screws 72-108 in-lbs 8.1-12.2 Nm 7.10 BANK ANGLE SENSOR (BAS), Installation
Bank angle sensor screw 20-30 in-lbs 2.2-3.4 Nm 7.10 BANK ANGLE SENSOR (BAS), Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 1.11 DRIVE BELT, Checking Drive Belt Deflection
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 1.11 DRIVE BELT, Setting Deflection
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 1.12 REAR WHEEL COMPENSATOR, Checking
Isolator Wear
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 2.6 REAR WHEELS, Installation
TORQUE VALUES
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 2.22 BODY, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 5.5 AXLE HOUSING/DIFFERENTIAL, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.11 REVERSE CONTROL SYSTEM, Reverse
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Vehicle
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER CABLES/WIRES, RCM
Lead
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
tion
Battery tray screws 72-96 in-lbs 8.1-10.9 Nm 2.25 INTERMEDIATE FRAME, Installation
Battery tray screws 132-156 in-lbs 14.9-17.6 Nm 7.3 BATTERY TRAY, Installation
Body attachment screws (inside trunk) 14-17 ft-lbs 19.0-23.1 Nm 2.22 BODY, Installation/Apply LOCTITE 243
SEALANT (blue).
Body attachment screws (outside trunk) 23-28 ft-lbs 31.2-38.0 Nm 2.22 BODY, Installation/Apply LOCTITE 243
SEALANT (blue).
Brake caliper, front, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.8 FRONT BRAKE CALIPERS, Installation
Brake caliper, front, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.11 BRAKE LINES, Front Brake Lines
Brake caliper, front, mounting screws 28-38 ft-lbs 37.9-51.5 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
Replacement
V
Supplement
Brake caliper, front, mounting screws 28-38 ft-lbs 37.9-51.5 Nm 2.8 FRONT BRAKE CALIPERS, Installation/metric
Brake caliper, front, pad pin 23-27 ft-lbs 31.2-36.6 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
Replacement
Brake caliper, rear, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.10 REAR BRAKE CALIPERS, Installation
Brake caliper, rear, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.11 BRAKE LINES, Rear Brake Line
Brake caliper, rear, mount bushing bolts 32-36 ft-lbs 43.4-48.8 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
Replacement
Brake caliper, rear, mount bushing bolts 32-36 ft-lbs 43.4-48.8 Nm 2.10 REAR BRAKE CALIPERS, Installation
Brake caliper, rear, mounting bracket 41-45 ft-lbs 55.6-61.0 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
screws Replacement/Apply LOCTITE MEDIUM
243 (blue) to screws.
Brake caliper, rear, mounting bracket 41-45 ft-lbs 55.6-61.0 Nm 2.10 REAR BRAKE CALIPERS, Installation/Use
screws Loctite Medium Strength Threadlocker 243 (blue)
Brake caliper bleeder valve, front 80-100 in-lbs 9.0-11.3 Nm 1.6 BRAKES, Brake Fluid Replacement
Brake caliper bleeder valve, front 80-100 in-lbs 9.0-11.3 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
Replacement
Brake caliper bleeder valve, front 80-100 in-lbs 9.0-11.3 Nm 2.12 BLEEDING BRAKES, Procedure
Brake caliper bleeder valve, rear 31-33 in-lbs 3.5-3.7 Nm 1.6 BRAKES, Brake Fluid Replacement
Brake caliper bleeder valve, rear 31-33 in-lbs 3.5-3.7 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
Replacement
Brake caliper bleeder valve, rear 31-33 in-lbs 3.5-3.7 Nm 2.12 BLEEDING BRAKES, Procedure
Brake line, rear, tee locknut 59-63 in-lbs 6.7-7.1 Nm 2.11 BRAKE LINES, Rear Brake Line
Brake line, rear, tee locknut 59-63 in-lbs 6.7-7.1 Nm 2.27 REAR FORK, Installation/Use new locknut
Brake line P-clamp screw 80-100 in-lbs 9.0-11.3 Nm 2.11 BRAKE LINES, Rear Brake Line
Brake manifold, rear circuit, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.11 BRAKE LINES, Front Brake Lines
Brake manifold, rear circuit, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.11 BRAKE LINES, Rear Brake Line
Brake manifold mounting screw 96-120 in-lbs 10.8-13.6 Nm 2.11 BRAKE LINES, Front Brake Lines
Brake master cylinder, front, banjo bolt 17-22 ft-lbs 23.1-29.8 Nm 2.11 BRAKE LINES, Front Brake Lines
Brake master cylinder, front, clamp 60-80 in-lbs 6.8-9.0 Nm 2.7 FRONT BRAKE MASTER CYL-
screws INDER, Assembly
Brake master cylinder, rear, banjo bolt 27-29 ft-lbs 36.6-39.3 Nm 2.9 REAR BRAKE MASTER CYL-
Brake master cylinder, rear, banjo bolt 27-29 ft-lbs 36.6-39.3 Nm 2.11 BRAKE LINES, Rear Brake Line
Brake master cylinder, rear, mounting 30-40 ft-lbs 40.7-54.2 Nm 2.9 REAR BRAKE MASTER CYL-
bracket nut INDER/PEDAL, Installation/Apply LOCTITE 243
SEALANT (blue).
Brake master cylinder, rear, mounting 126-150 in-lbs 14.2-16.9 Nm 2.9 REAR BRAKE MASTER CYL-
bracket screws INDER/PEDAL, Installation
Brake master cylinder cover screws, 6-8 in-lbs 0.7-0.9 Nm 1.6 BRAKES, Brake Fluid Replacement
VI TORQUE VALUES
Supplement
Brake master cylinder cover screws, 6-8 in-lbs 0.7-0.9 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
FLRT, rear reservoir Replacement
Brake master cylinder cover screws, 6-8 in-lbs 0.7-0.9 Nm 2.12 BLEEDING BRAKES, Procedure
Brake master cylinder reservoir cover 6-8 in-lbs 0.7-0.9 Nm 1.6 BRAKES, Brake Fluid Replacement
Brake master cylinder reservoir cover 6-8 in-lbs 0.7-0.9 Nm 1.7 BRAKE PADS AND DISCS, Brake Pad
screws, front reservoir Replacement
Brake master cylinder reservoir cover 6-8 in-lbs 0.7-0.9 Nm 2.12 BLEEDING BRAKES, Procedure
Brake pedal shaft locknut 15-20 ft-lbs 20.3-27.1 Nm 2.9 REAR BRAKE MASTER CYL-
Brake reaction plate screws 40-45 ft-lbs 54.2-61.0 Nm 5.4 AXLE, Installation
Clutch line P-clamp 40-48 in-lbs 4.5-5.4 Nm 2.15 CLUTCH FLUID LINE: FLRT, Line Replace-
ment
Clutch line P-clamp 40-48 in-lbs 4.5-5.4 Nm 2.31 HEADLAMP NACELLE, Installation
Clutch master cylinder clamp screws 60-80 in-lbs 6.8-9.0 Nm 2.14 CLUTCH MASTER CYLINDER AND
RESERVOIR, Assembly
Clutch reservoir cover screws 6-8 in-lbs 0.7-0.9 Nm 1.10 HYDRAULIC CLUTCH FLUID, Fluid Inspec-
tion
Clutch reservoir cover screws 6-8 in-lbs 0.7-0.9 Nm 2.14 CLUTCH MASTER CYLINDER AND
RESERVOIR, Assembly
Differential assembly screws 65-70 ft-lbs 88.1-94.9 Nm 5.5 AXLE HOUSING/DIFFEREN-
TIAL, Assembly/Use new screws
Differential bearing cap screws 39-44 ft-lbs 52.9-59.7 Nm 5.5 AXLE HOUSING/DIFFERENTIAL, Installation
Engine mount end cap screws, front 42-48 ft-lbs 56.9-65.0 Nm 2.11 BRAKE LINES, Rear Brake Line
Engine stabilizer bracket screws 30-35 ft-lbs 40.7-47.5 Nm 2.33 ENGINE STABILIZER, Stabilizer Link/Apply
LOCTITE 272 HIGH STRENGTH/HIGH TEMPER-
ATURE THREADLOCKER AND SEALANT
(red/orange) to threads
Fairing double studs 120-180 in-lbs 13.6-20.3 Nm 2.32 STEERING DAMPER ASSEMBLY, Installation
Fender, rear, screws 108-132 in-lbs 12.2-14.9 Nm 2.23 REAR FENDERS, Installation/Apply LOCTITE
SEALANT (blue).
Frame connection bracket screws 41-45 ft-lbs 55.6-61.0 Nm 2.25 INTERMEDIATE FRAME, Assembly
Front axle nut 70-75 ft-lbs 94.9-101.7 Nm 2.4 FRONT WHEEL, Installation
Front axle pinch screw (metric) 18-22 ft-lbs 24.4-29.8 Nm 2.4 FRONT WHEEL, Installation
Ground strap to forward stud (inside 14-17 ft-lbs 19.0-23.1 Nm 2.22 BODY, Installation
trunk)
Ground strap to upper stud: FLHTCUTG 96-120 in-lbs 10.8-13.5 Nm 2.22 BODY, Assembly: FLHTCUTG
Handlebar cover screws: FLRT 10-20 in-lbs 1.1-2.3 Nm 2.31 HEADLAMP NACELLE, Installation
Headlamp bracket nuts, HDI 120-150 in-lbs 13.6-16.9 Nm 7.5 FRONT LIGHTING: HDI, Lamps Bracket
Headlamp cover bracket screws 22-32 in-lbs 2.5-3.6 Nm 7.5 FRONT LIGHTING: HDI, General
Headlamp cover screw 9-18 in-lbs 1.0-2.0 Nm 7.5 FRONT LIGHTING: HDI, General
TORQUE VALUES VII

Supplement
Headlamp horizontal adjustment screw: 30-35 ft-lbs 40.7-47.5 Nm 1.17 HEADLAMP ALIGNMENT, Headlamp: FLRT
FLRT
Headlamp mounting screw: FLRT 30-35 ft-lbs 40.7-47.5 Nm 2.31 HEADLAMP NACELLE, Installation
Headlamp nacelle acorn nuts 96-132 in-lbs 10.8-14.9 Nm 2.31 HEADLAMP NACELLE, Installation
Headlamp nacelle top cover screws 84-120 in-lbs 9.5-13.5 Nm 2.31 HEADLAMP NACELLE, Installation
Headlamp nut: HDI Models 20-24 ft-lbs 27.1-32.5 Nm 1.17 HEADLAMP ALIGNMENT, FLHTCUTG HDI
Dual LED Headlamps
Headlamp ring screw, HDI 9-14 in-lbs 1.0-1.6 Nm 7.5 FRONT LIGHTING: HDI, Headlamp Bulb
Replacement: FLHTCUTG HDI
Headlamp vertical adjustment screw: 35-45 ft-lbs 47.5-61.0 Nm 1.17 HEADLAMP ALIGNMENT, Headlamp: FLRT
FLRT
Intermediate frame screws 40-45 ft-lbs 54.2-61.0 Nm 2.25 INTERMEDIATE FRAME, Installation
Left electrical caddy screw 72-96 in-lbs 8.1-10.9 Nm 2.25 INTERMEDIATE FRAME, Installation
License plate bracket screws: 18-30 in-lbs 2.0-3.4 Nm 2.17 TRUNK DOOR: FLHTCUTG, Assembly/Use
FLHTCUTG LOCTITE 243 MEDIUM STRENGTH THREAD-
License plate lamp housing locknuts: 60-72 in-lbs 6.8-8.1 Nm 7.7 LICENSE PLATE LAMPS/BRACKET:
FLHTCUTG FLHTCUTG, Installation/Use new locknuts
License plate lamp screws: FLHTCUTG 9-12 in-lbs 1.0-1.4 Nm 7.7 LICENSE PLATE LAMPS/BRACKET:
Lug nuts 90-100 ft-lbs 122.0-135.6 Nm 1.11 DRIVE BELT, Setting Deflection/Always check
lug nut torque within 500-1000 mi (805-1610 km)
after wheel installation.
Lug nuts 90-100 ft-lbs 122.0-135.6 Nm 2.6 REAR WHEELS, Installation/Always check lug
nut torque within 500-1000 mi (805-1610 km) after
wheel installation.
Muffler bracket screws 14-18 in-lbs 19.0-24.4 Nm 2.24 REAR FRAME, Installation
Panhard rod clevis screw 55-60 ft-lbs 74.6-81.4 Nm 2.30 PANHARD ROD, Installation
Panhard rod clevis screw 55-60 ft-lbs 74.6-81.4 Nm 2.30 PANHARD ROD, Adjustment
Panhard rod locknut 55-60 ft-lbs 74.6-81.4 Nm 2.30 PANHARD ROD, Installation
Parking brake cable anchor bracket 41-45 ft-lbs 55.6-61.0 Nm 2.13 PARKING BRAKE ASSEMBLY, Cables
screws
Parking brake pawl locknut 60-96 in-lbs 6.8-10.8 Nm 2.13 PARKING BRAKE ASSEMBLY, Pedal
Assembly
Parking brake pedal bracket screws 36-42 ft-lbs 48.8-56.9 Nm 2.13 PARKING BRAKE ASSEMBLY, Pedal
Assembly
Parking brake pedal locknut 15-20 ft-lbs 20.3-27.1 Nm 2.13 PARKING BRAKE ASSEMBLY, Pedal
Assembly
Parking brake sensor jamnut 30-35 in-lbs 3.4-4.0 Nm 2.13 PARKING BRAKE ASSEMBLY, Parking Brake
Sensor
Passenger grab handles: FLRT 96-120 in-lbs 10.8-13.6 Nm 2.22 BODY, Assembly: FLRT
Passenger grab handle screws: FLRT 96-120 in-lbs 10.8-13.6 Nm 2.22 BODY, Passenger Grab Handles: FLRT
VIII TORQUE VALUES

Supplement
Passenger handrail screws 60-96 in-lbs 6.8-10.9 Nm 2.25 INTERMEDIATE FRAME, Assembly
Pinch block screws 41-45 ft-lbs 55.6-61.0 Nm 1.11 DRIVE BELT, Setting Deflection/Use LOCTITE
SEALANT (blue)
Pinch block screws 41-45 ft-lbs 55.6-61.0 Nm 2.29 SHOCK ABSORBERS, Installation/Use
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm 7.11 REVERSE CONTROL SYSTEM, Reverse
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm 7.12 REVERSE JUMPER CABLES/WIRES, RCM
Lead
RCM solenoid screws 32-40 in-lbs 3.6-4.5 Nm 7.11 REVERSE CONTROL SYSTEM, Reverse
Rear fork bracket bolts 55-65 ft-lbs 74.6-88.1 Nm 2.27 REAR FORK, Installation/Apply two drops of
LOCKER AND SEALANT (blue) to threads
Rear fork pivot shaft locknut 50 ft-lbs + 180 67.8 Nm + 180 2.27 REAR FORK, Installation/Always use new
degrees addi- degrees addi- locknuts and cup washers
Rear frame screws 41-45 ft-lbs 55.6-61.0 Nm 2.24 REAR FRAME, Installation/ Use LOCTITE
SEALANT (red)
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Vehicle
Reverse circuit breaker screw 32-40 in-lbs 3.6-4.5 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Reverse motor bracket screws 39-44 ft-lbs 52.9-59.7 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
Reverse motor screws 39-44 ft-lbs 52.9-59.7 Nm 7.12 REVERSE JUMPER
Reverse motor screws 39-44 ft-lbs 52.9-59.7 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
Reverse motor solenoid energizer lead 24-30 in-lbs 2.7-3.4 Nm 7.12 REVERSE JUMPER CABLES/WIRES, RCM
nut Solenoid to Reverse Motor Solenoid Energizer
Lead
TORQUE VALUES IX
Supplement
Reverse motor solenoid energizer lead 24-30 in-lbs 2.7-3.4 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
nut tion
Reverse motor solenoid power lead nut 60-84 in-lbs 6.8-9.5 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Reverse motor solenoid power lead nut 60-84 in-lbs 6.8-9.5 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
tion
Reverse motor solenoid screws 70 in-lbs 7.9 Nm 7.13 REVERSE MOTOR AND
BRACKET, Assembly
Right caddy to battery tray screw 36-40 in-lbs 4.1-4.5 Nm 7.3 BATTERY TRAY, Installation
Ring gear screws 22-26 ft-lbs 29.8-35.3 Nm 5.5 AXLE HOUSING/DIFFERENTIAL, Assembly
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 2.24 REAR FRAME, Installation/Use LOCTITE 262
HIGH STRENGTH THREADLOCKER AND
SEALANT (red)
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 2.29 SHOCK ABSORBERS, Installation/Use
LOCTITE 262 HIGH STRENGTH THREAD-
LOCKER AND SEALANT (red)
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 2.30 PANHARD ROD, Adjustment/Use LOCTITE
SEALANT (red)
Solenoid to reverse motor jumper nut 45 in-lbs 5.1 Nm 7.13 REVERSE MOTOR AND
BRACKET, Assembly
Starter mounting screws 25-27 ft-lbs 33.9-36.6 Nm 7.12 REVERSE JUMPER
Starter solenoid post nut 70-90 in-lbs 7.9-10.2 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Vehicle
Steering damper acorn nut 16-20 ft-lbs 21.7-27.1 Nm 2.32 STEERING DAMPER ASSEMBLY, Installation
Steering damper bracket to frame screw: 22-28 ft-lbs 29.8-38.0 Nm 2.32 STEERING DAMPER ASSEMBLY, Installation
FLRT
Steering damper locknut 16-20 ft-lbs 21.7-27.1 Nm 2.32 STEERING DAMPER ASSEMBLY, Installation
Steering damper side bracket acorn nuts: 120-180 in-lbs 13.6-20.3 Nm 2.32 STEERING DAMPER ASSEMBLY, Installa-
FLHTCUTG tion/ These also retain the auxiliary/fog/HDI head-
lamp brackets.
Steering damper side bracket to fork 20-25 ft-lbs 27.1-33.9 Nm 2.32 STEERING DAMPER ASSEMBLY, Installation
bracket screws: FLRT
Stop lamp switch, rear 12-15 ft-lbs 16.3-20.3 Nm 2.11 BRAKE LINES, Rear Brake Line/Use
LOCTITE 565 THREAD SEALANT
Tail lamp/turn signal base screw 36-48 in-lbs 4.1-5.4 Nm 7.6 TAIL LAMPS/REAR TURN SIGNALS, Installa-
Tail lamp/turn signal bracket screw, HDI 36-48 in-lbs 4.1-5.4 Nm 7.6 TAIL LAMPS/REAR TURN SIGNALS, Installa-
tion
tion
X TORQUE VALUES
Supplement
Tail lamp/turn signal screws 21-24 in-lbs 2.4-2.7 Nm 7.8 REAR LIGHTS HARNESS:
Tail lamp/turn signal screws 21-24 in-lbs 2.4-2.7 Nm 7.9 REAR LIGHTS HARNESS: FLRT, Installation
Tail lamp bracket: FLRT 72-96 in-lbs 8.1-10.8 Nm 2.23 REAR FENDERS, Installation
Transmission dipstick 25-75 in-lbs 2.8-8.5 Nm 1.5 LUBRICANTS, Checking Transmission Lub-
ricant Level
Transmission ground post nut 66-114 in-lbs 7.5-12.9 Nm 7.12 REVERSE JUMPER
Trunk bulkhead cover screws 72-96 in-lbs 8.1-10.8 Nm 2.22 BODY, Assembly: FLRT
Trunk door cover screws: FLHTCUTG 30-54 in-lbs 3.4-6.1 Nm 2.17 TRUNK DOOR: FLHTCUTG, Installation
Trunk door cover screws: FLHTCUTG 30-54 in-lbs 3.4-6.1 Nm 7.7 LICENSE PLATE LAMPS/BRACKET:
Trunk door cover screws: FLHTCUTG 30-54 in-lbs 3.4-6.1 Nm 7.8 REAR LIGHTS HARNESS:
Trunk door hinge cover screws: FLRT 25-35 in-lbs 2.8-3.9 Nm 2.19 TRUNK DOOR: FLRT, Repair
Trunk door hinge locknuts: FLHTCUTG 60-84 in-lbs 6.8-9.5 Nm 2.17 TRUNK DOOR: FLHTCUTG, Installation/Use
new locknuts
Trunk door hinge screws: FLHTCUTG 48-72 in-lbs 5.4-8.1 Nm 2.17 TRUNK DOOR: FLHTCUTG, Assembly/Use
Trunk door hinge to body screws: FLRT 72-96 in-lbs 8.1-11.0 Nm 2.19 TRUNK DOOR: FLRT, Repair
Trunk door hinge to door screws: FLRT 72-96 in-lbs 8.1-11.0 Nm 2.19 TRUNK DOOR: FLRT, Repair
Trunk door lanyard screws: FLHTCUTG 48-72 in-lbs 5.4-8.1 Nm 2.17 TRUNK DOOR: FLHTCUTG, Installation
Latch Assembly
Latch Assembly
Trunk door latch housing screws: 48-60 in-lbs 5.4-6.8 Nm 2.18 TRUNK DOOR LOCKSET: FLHTCUTG, Latch
FLHTCUTG Assembly
Trunk door latch mechanism screws: 8-10 in-lbs 0.9-1.1 Nm 2.18 TRUNK DOOR LOCKSET: FLHTCUTG, Latch
FLHTCUTG Assembly
Trunk door latch pin bracket screws: 48-72 in-lbs 5.4-8.1 Nm 2.17 TRUNK DOOR: FLHTCUTG, Installation
FLHTCUTG
Trunk door latch pin jamnut: FLHTCUTG 48-72 in-lbs 5.4-8.1 Nm 2.17 TRUNK DOOR: FLHTCUTG, Assembly
Trunk door latch pin jamnut: FLHTCUTG 48-72 in-lbs 5.4-8.1 Nm 2.18 TRUNK DOOR LOCKSET: FLHTCUTG, Latch
Pin
Trunk door lock housing nuts: 9-11 in-lbs 1.0-1.2 Nm 2.18 TRUNK DOOR LOCKSET: FLHTCUTG, Latch
FLHTCUTG Assembly
Trunk door striker pin: FLRT 35-40 ft-lbs 47.0-54.0 Nm 2.19 TRUNK DOOR: FLRT, Repair
Trunk door striker pin: FLRT 35-40 ft-lbs 47.0-54.0 Nm 2.19 TRUNK DOOR: FLRT, Adjust Trunk Door
Trunk door striker screws: FLRT 72-96 in-lbs 8.1-11.0 Nm 2.19 TRUNK DOOR: FLRT, Repair
TORQUE VALUES XI
Supplement
Trunk door tether reel screws: FLRT 72-96 in-lbs 8.1-10.8 Nm 2.22 BODY, Assembly: FLRT
Trunk door tether to door screws: FLRT 16-22 in-lbs 1.8-2.5 Nm 2.19 TRUNK DOOR: FLRT, Repair
Trunk latch cover screws: FLRT 20-25 in-lbs 2.3-2.8 Nm 2.20 TRUNK DOOR LOCKSET: FLRT, Lock and
Latch Assembly
Trunk latch housing cover screw: 25-28 in-lbs 2.8-3.2 Nm 2.18 TRUNK DOOR LOCKSET:
FLHTCUTG FLHTCUTG, Lockset
Latch Assembly
Latch Assembly
Trunk lock knob nut: FLRT 13-16 ft-lbs 17.6-21.7 Nm 2.20 TRUNK DOOR LOCKSET: FLRT, Lock and
Latch Assembly
Turn signal, front, lamp to bracket screw 12-16 ft-lbs 16.3-21.7 Nm 7.4 FRONT LIGHTING, Front Turn Signal Lamp:
FLRT
Turn signal lamp, front, mounting screw, 96-131 in-lbs 10.9-14.8 Nm 7.5 FRONT LIGHTING: HDI, Turn Signal Lamps
HDI
Upper handlebar clamp fastener, rear: 16-20 ft-lbs 21.7-27.1 Nm 2.16 HANDLEBAR, Adjustment: FLRT
all models
Wheel center cap clamp screw 72-96 in-lbs 8.1-10.9 Nm 2.6 REAR WHEELS, Installation/Use LOCTITE
SEALANT (blue)
XII TORQUE VALUES

Bulb Replacement
A Headlamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . . . . B-4 Specifications (Table). . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Air Suspension
Recommended Pressure (Table). . . . . . . . . . . . . . . 1-26 C
Alignment Clutch Fluid Line: FLRT
Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Axle Clutch Master Cylinder
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 2-30
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Clutch Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Axle Housing Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Connectors
Lateral Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 End Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-29
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Conversions
Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
B Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Bank Angle Sensor Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63 Covers: HDI
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Battery Tray D
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Diagnostics
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 BAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Bleeding Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Rear Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Body Reverse Motor System. . . . . . . . . . . . . . . . . . . . . . . 7-31
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 Differential
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Threaded Insert Replacement. . . . . . . . . . . . . . . . . 2-47 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Body: FLHTCUTG Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Drive Belt
INDEX
Trunk Door Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 Checking and Adjusting Deflection. . . . . . . . . . . . . . 1-23
Body: FLRT Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Passenger Grab Handles. . . . . . . . . . . . . . . . . . . . . 2-46
E
Trunk Door Hinge. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 Engine
Trunk Door Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 General Specifications: Twin Cam 103. . . . . . . . . . . 3-1
Brake Caliper, Front Engine Oil Level
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Cold Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Hot Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Brake Caliper, Rear Engine Stabilizer
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
Brake Lines Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
Front Caliper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 F
Front Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . 2-18
Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Fender, Rear
Brake Master Cylinder, Front Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 2-11 Fluid Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Foreword
Brake Master Cylinder, Rear Important General Information. . . . . . . . . . . . . . . . . . . i-I
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Fork, Rear
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 2-15 Disassembly/Assembly. . . . . . . . . . . . . . . . . . . . . . 2-58
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Fork Oil
Reservior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Checking and Filling. . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Brake Pads and Discs Forks, Front
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Front Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Brakes Front Lighting: HDI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Bleeding. . . . . . . . . . . . . . . . . . . . . See Bleeding Brakes Front Wheel
Fluid Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
XIII
Parking Brake
G Adjustment, Wheels off the Ground. . . . . . . . . . . . . 1-20
Glossary Adjustment, Wheels on the Ground. . . . . . . . . . . . . 1-20
Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . B-4 Cable replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
H Magnet Replacement. . . . . . . . . . . . . . . . . . . . . . . . 2-27
Pedal Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Handlebar Pedal Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Adjustment: FLRT. . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Pedal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Pedal Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Headlamp Pedal Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31 Sensor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Adjustment: HDI. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . 2-27
Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31 Parking Brake Lamp Diagnostics. . . . . . . . . . . . . . . . . . 7-48
Alignment: HDI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 R
FLHTCUTG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Rear Air Suspension
Repair, FLRT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Headlamp, HDI Rear Frame
Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Headlamp Housing, HDI Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Rear Lights Harness: FLHTCUTG
Headlamp Nacelle: FLRT Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65 Rear Lights Harness: FLRT
High Beam Indicator Lamp Diagnostics. . . . . . . . . . . . . 7-49 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Hydraulic Clutch Fluid Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Clutch Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Rear Tire
I Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Indicator Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45 Rear Wheel
Indicator Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Initial Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Intermediate Frame Reverse Control System
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 RCM Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 RCM Solenoid Replacement. . . . . . . . . . . . . . . . . . 7-20
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 Reverse Circuit Breaker Replacement. . . . . . . . . . . 7-21
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Isolator, Rear Sprocket Reverse Jumper Cables/Wires. . . . . . . . . . . . . . . . . . . . 7-23
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Circuit Breaker to RCM Solenoid Jumper. . . . . . . . 7-23
L Circuit Breaker to Reverse Motor Solenoid Jumper. . 7-24
RCM Solenoid to Reverse Motor Solenoid Jumper. . 7-23
License Plate Lamp/Bracket: FLHTCUTG
Reverse Motor to Battery Ground Jumper. . . . . . . . 7-25
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Reverse Motor/Bracket
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Lifting Vehicle
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Jacking Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Reverse Motor Solenoid
Light Bulbs (Table). . . . . . . . . . . . . . . See Bulb Replacement
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
LOCTITE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
M Solenoid Hold-In Test. . . . . . . . . . . . . . . . . . . . . . . . 7-43
Maintenance Solenoid Pull-In Test. . . . . . . . . . . . . . . . . . . . . . . . . 7-43
Brake Line Inspection (Table). . . . . . . . . . . . . . . . . . 1-16 Solenoid Return Test. . . . . . . . . . . . . . . . . . . . . . . . 7-44
Headlamp Alignment. . . . . . . . . . . . . . . . . . . . . . . . 1-31 Reverse Motor System
Headlamp Bulb Replacement. . . . . . . . . . . . . . . . . . . 7-6 Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Metric System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Reverse Motor Current Draw Test. . . . . . . . . . . . . . 7-42
P S
Panhard Rod Service Bulletins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-I
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64 Service Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-I
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 Shock Absorbers
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
XIV INDEX
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II Trunk Door Lock Assembly: FLHTCUTG
Specifications Assembly/Installation. . . . . . . . . . . . . . . . . . . . . . . . 2-37
Engine, AC (008535). . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Removal/Disassembly. . . . . . . . . . . . . . . . . . . . . . . 2-37
Quick Reference Maintenance Chart (Table). . . . . . . 1-9 Trunk Door Lock Assembly: FLRT
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Starter Free Running Current Draw Test. . . . . . . . . . . . . 7-42 Trunk Door Seal: FLHTCUTG
Steering Damper Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67 Trunk Door Seal: FLRT
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Steering Head Bearings. . . . . . . . . . . . . . . . . . . . . . . . . 1-27 Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Suspension, Air Turn Signal Lamps, Front, HDI
Recommended Pressure (Table). . . . . . . . . . . . . . . 1-26 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
System Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
T V
Tail Lamp/Rear Turn Signals Vehicle Starter to Circuit Breaker Jumper
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Tail Lamp Bracket VIN
FLRT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Vehicle Identification Number. . . . . . . . . . . . . . . . . . . 2-6
Tires
Pressure (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
W
Torque Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Wiring Diagram Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Tour-Pak
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Trademarks
Harley-Davidson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Referenced Products. . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Transmission
Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Troubleshooting
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Reverse Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Trunk Door: FLHTCUTG
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Hinge Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Hinge Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Trunk Door: FLRT
Adjust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Trunk Door Latch Assembly: FLHTCUTG
Disassembly/Assembly. . . . . . . . . . . . . . . . . . . . . . 2-38
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Trunk Door Latch Pin: FLHTCUTG
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
INDEX XV
NOTES
XVI INDEX

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2015 Harley-Davidson Trike Models

Service Manual Supplement

Harley-Davidson Motor Company

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITE

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2015 Harley-Davidson Trike Models Service Manual Supplement (99601-15)

A Appendix A Wiring WARNINGS AND CAUTIONS

Read and follow warnings and directions on all products.

6.1 TRANSMISSION 7.8 REAR LIGHTS HARNESS: FLHTCUTG

ELECTRICAL 7.9 REAR LIGHTS HARNESS: FLRT

TABLE OF CONTENTS VII

VIII TABLE OF CONTENTS

FASTENER TORQUE VALUES 1.1

FASTENER TORQUE VALUE NOTES

2015 Trike Service Supplement Maintenance 1-1

FASTENER TORQUE VALUE NOTES

1-2 2015 Trike Service Supplement Maintenance

LIFTING MOTORCYCLE WITH A JACK 1.2

When lifting a motorcycle using a jack, be sure jack con-

2015 Trike Service Supplement Maintenance 1-3

BULB REQUIREMENTS 1.3

LAMP DESCRIPTION BULBS HARLEY-DAVIDSON

1-4 2015 Trike Service Supplement Maintenance

MAINTENANCE SCHEDULE 1.4

Table 1-2. Regular Service Intervals: 2015 Trike Models

2015 Trike Service Supplement Maintenance 1-5

Table 1-2. Regular Service Intervals: 2015 Trike Models

1-6 2015 Trike Service Supplement Maintenance

Table 1-2. Regular Service Intervals: 2015 Trike Models

Table 1-3. Quick Reference Maintenance and Torque Chart: Trike

ITEM SERVICED SPECIFICATION DATA

2015 Trike Service Supplement Maintenance 1-7

Table 1-3. Quick Reference Maintenance and Torque Chart: Trike

ITEM SERVICED SPECIFICATION DATA

1-8 2015 Trike Service Supplement Maintenance

Table 1-3. Quick Reference Maintenance and Torque Chart: Trike

ITEM SERVICED SPECIFICATION DATA

Table 1-4. Lubricants, Greases, Sealants

ITEM PART NUMBER PACKAGE

2015 Trike Service Supplement Maintenance 1-9

Table 1-4. Lubricants, Greases, Sealants

ITEM PART NUMBER PACKAGE

1-10 2015 Trike Service Supplement Maintenance

Oil Level Cold Check

Oil Level Hot Check

Do not allow hot oil level to fall below Add/Fill mark on

2015 Trike Service Supplement Maintenance 1-11

Table 1-5. Recommended Engine Oils

TYPE VISCOSITY RATING LOWEST AMBIENT COLD-WEATHER

CHECKING TRANSMISSION LUBRICANT

Check the transmission lubricant level with engine turned off

Table 1-6. Recommended Lubricant

1-12 2015 Trike Service Supplement Maintenance

1. Front circuit 7. Rear circuit manifold

2015 Trike Service Supplement Maintenance 1-13

BRAKE FLUID REPLACEMENT

A plugged or covered relief port can cause brake drag or

1-14 2015 Trike Service Supplement Maintenance

6. Operate vacuum bleeder while maintaining fluid level in

7. Repeat with each caliper following the sequence in

BRAKE LINES INSPECTION

Table 1-10. Brake Line Inspection