2011 HD CVO FLHTCUSE6 Model Service Manual Supplement 99500-11

2011 Harley-Davidson FLHTCUSE6
Model Service Manual Supplement

99500-11
©2010 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

2011 Harley-Davidson
FLHTCUSE6 Model Service
Manual Supplement
©2010 H-D.
ALL RIGHTS RESERVED
99500-11
Printed in the U.S.A.
VISIT THE HARLEY-DAVIDSON WEB SITE

http://www.harley-davidson.com
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2011 Harley-Davidson FLHTCUSE6 Model Service Manual Supplement (99500-11)

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NOTES
ABOUT THIS MANUAL
GENERAL PREPARATION FOR SERVICE
This service manual supplement has been designed to be used
with the current service manual and has been prepared with
two purposes in mind. First, it will acquaint the user with the
Stop the engine when refueling or servicing the fuel
construction of the Harley-Davidson product and assist in the
system. Do not smoke or allow open flame or sparks near
performance of basic maintenance and repair. Second, it will
gasoline. Gasoline is extremely flammable and highly
introduce to the professional Harley-Davidson Technician the
explosive, which could result in death or serious injury.
latest field-tested and factory-approved major repair methods.
(00002a)
We sincerely believe that this service manual supplement will
make your association with Harley-Davidson products more Good preparation is very important for efficient service work.
pleasant and profitable. A clean work area at the start of each job will allow you to
perform the repair as easily and quickly as possible, and will
NOTE
reduce the incidence of misplaced tools and parts. A motorcycle
This service manual supplement provides information unique that is excessively dirty should be cleaned before work starts.
to this model motorcycle. Any information not presented in this Cleaning will occasionally uncover sources of trouble. Tools,
supplement can be found in the appropriate service manual or instruments and any parts needed for the job should be
electrical diagnostic manual. Refer to Table i-1. gathered before work is started. Interrupting a job to locate
tools or parts is a distraction and causes needless delay.
Table i-1. Relevant Model Year Publications NOTES
PUBLICATION PART NUMBER • To avoid unnecessary disassembly, carefully read all rel-
Touring Models Service Manual 99483-11 ative service information before repair work is started.
Touring Models Electrical Diagnostic 99497-11 • In figure legends, the number which follows the name of
Manual a part indicates the quantity necessary for one complete
assembly.
HOW TO USE YOUR SERVICE MANUAL • When servicing a vehicle equipped with the Harley-Dav-
SUPPLEMENT idson Smart Security System (H-DSSS), you must first
FOREWORD
disarm the security system. Either keep the fob in close
Use the TABLE OF CONTENTS (which follows this FORE-
proximity to the vehicle, or use Digital Technician II to
WORD) and the INDEX (at the back of this manual) to quickly
disable the security system while the vehicle is being ser-
locate subjects. Sections and topics in this manual are
viced and re-enable the system after service is completed.
sequentially numbered for easy navigation.
SERVICE BULLETINS
NO. CHAPTER
In addition to the information presented in this service manual
1 Maintenance
supplement and the appropriate service manual, Harley-Dav-
2 Chassis idson Motor Company will periodically issue Service Bulletins
3 Engine to Harley-Davidson dealers. Service bulletins cover interim
engineering changes and supplementary information. Consult
4 Fuel System the service bulletins to keep your product knowledge current
5 Drive and complete.
6 Transmission USE GENUINE REPLACEMENT PARTS
7 Electrical
A Appendix A Wiring
B Appendix B Glossary Harley-Davidson parts and accessories are designed for
Harley-Davidson motorcycles. Using non-Harley-Davidson
For example, a cross-reference shown as 2.1 SPECIFICA- parts or accessories can adversely affect performance,
TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC- stability or handling, which could result in death or serious
ATIONS. injury. (00001b)
If the subject you seek is not in this supplement, refer to the To achieve satisfactory and lasting repairs, carefully follow the
corresponding chapter in the appropriate service manual. service manual instructions and use only genuine Harley-
Check the title page located in the front of each chapter to find Davidson replacement parts. Behind the emblem bearing the
the subject. words GENUINE HARLEY-DAVIDSON stand more than 100
For quick and easy reference, all pages contain a chapter years of design, research, manufacturing, testing and inspecting
number followed by a page number. For example, page 3-5 experience. This is your assurance that the parts you are using
refers to page 5 in chapter 3. will fit right, operate properly and last longer.
In figure legends, the number following the name of a part WARNINGS AND CAUTIONS
indicates the quantity necessary for one complete assembly.
Statements in this manual preceded by the following words
are of special significance.
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.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious Kent-Moore Products
injury. (00119a)
All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX Kent-Moore. For ordering
information or product returns, warranty or otherwise, visit
CAUTION indicates a potentially hazardous situation which, www.spx.com.
if not avoided, may result in minor or moderate injury. Loctite Sealing and Threadlocking Products
(00139a)
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, please contact Loctite
NOTICE indicates a potentially hazardous situation which, Corp. at www.loctite.com.
if not avoided, may result in property damage. (00140b)
PRODUCT REGISTERED MARKS
NOTE Apple, Alcantara S.p.A., Allen, Amp Multilock, Bluetooth,
Refers to important information, and is placed in italic type. It Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E.
is recommended that you take special notice of these items. Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod,
Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Magnaflux,
Proper service and repair is important for the safe, reliable Marson Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin,
operation of all mechanical products. The service procedures MPZ, Mulitilock, nano, NGK, Novus, Packard, Pirelli, Permatex,
recommended and described in this manual are effective Philips, PJ1, Pozidriv, Robinair, S100, Sems, Snap-on, Teflon,
methods for performing service operations. Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch,
Velcro, X-Acto, XM Satellite Radio, and zūmo are among the
trademarks of their respective owners.
Always wear proper eye protection when using hammers, H-D MICHIGAN, INC. TRADEMARK
arbor or hydraulic presses, gear pullers, spring com- INFORMATION
pressors, slide hammers and similar tools. Flying parts
could result in death or serious injury. (00496b) Harley, Harley-Davidson, H-D, Bar & Shield, Cross Bones,
Digital Tech, Digital Technician, Digital Technician II, Dyna,
Some of these service operations require the use of tools
Electra Glide, Evolution, Fat Bob, Fat Boy, Glaze, Gloss, H-D,
specially designed for the purpose. These special tools should
H-Dnet.com, HD, Harley, Harley-Davidson, Heritage Softail,
be used when and as recommended. It is important to note
Low Rider, Night Rod, Nightster, Night Train, Profile, Revolu-
that some warnings against the use of specific service methods,
tion, Road Glide, Road King, Road Tech, Rocker, Softail,
which could damage the motorcycle or render it unsafe, are
Sportster, Street Glide, Street Rod, Sun Ray, Sunwash, Tech
stated in this manual. However, remember that these warnings
Link, Twin Cam 88, Twin Cam 88B, Twin Cam 96, Twin Cam
are not all-inclusive. Inadequate safety precautions could result
96B, Twin Cam 103, Twin Cam 103B, Twin Cam 110, Twin
in death or serious injury.
Cam 110B, Tour-Pak, Screamin' Eagle, Softail, Super Glide,
Since Harley-Davidson could not possibly know, evaluate or SYN3, Ultra Classic, V-Rod, VRSC and Harley-Davidson
advise the service trade of all possible ways in which service Genuine Motor Parts and Genuine Motor Accessories are
might be performed, or of the possible hazardous con- among the trademarks of H-D Michigan, Inc.
sequences of each method, we have not undertaken any such
broad evaluation. Accordingly, anyone who uses a service CONTENTS
procedure or tool which is not recommended by Harley-Dav- All photographs, illustrations and procedures may not neces-
idson must first thoroughly satisfy himself that neither his nor sarily depict the most current model or component, but are
the operator's safety will be jeopardized as a result. Failure to based on the latest production information available at the time
do so could result in death or serious injury. of publication.
PRODUCT REFERENCES Since product improvement is our continual goal, Harley-Dav-
idson reserves the right to change specifications, equipment
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 2.6 FRONT AXLE COVERS
Replacement.....................................................................2-12
1.1 FASTENER TORQUE VALUES
2.7 LOWER TRIPLE CLAMP COVER
Fastener Torque Values in this Chapter..............................1-1
Replacement.....................................................................2-13
1.2 SCHEDULED MAINTENANCE
2.8 HANDLEBARS
General...............................................................................1-2
Removal............................................................................2-14
1.3 BULB REQUIREMENTS Disassembly.....................................................................2-15
Assembly..........................................................................2-15
General...............................................................................1-4
Pull Wire Leads.........................................................2-15
Install Switch Housings.............................................2-16
1.4 AIR FILTER ELEMENT
Install Connector Housings.......................................2-17
Removal..............................................................................1-5 Installing Handlebars........................................................2-18
Installation...........................................................................1-5 Clamp Handlebars to Risers.....................................2-18
Assemble Brake Controls..........................................2-18
1.5 HYDRAULIC CLUTCH FLUID Assemble Clutch Controls.........................................2-19
General...............................................................................1-6 Returning to Service.........................................................2-20
Fluid Inspection...................................................................1-6
2.9 HANDGRIPS
1.6 ENGINE LUBRICATION SYSTEM General.............................................................................2-21
General...............................................................................1-7 Preparing Motorcycle........................................................2-21
Separating Connectors.....................................................2-21
1.7 CRITICAL FASTENERS Replacing Handgrips........................................................2-21
Inspection...........................................................................1-8 Remove Left Handgrip..............................................2-21
Checking Torques on Fasteners..................................1-8 Install Left Handgrip...................................................2-22
Remove Right Handgrip............................................2-23
TABLE OF CONTENTS
CHASSIS Install Right Handgrip................................................2-23
Mating Connectors............................................................2-24
Returning to Service.........................................................2-24
Fastener Torque Values in this Chapter..............................2-1 2.10 CLUTCH MASTER CYLINDER AND
RESERVOIR
2.2 SPECIFICATIONS: CHASSIS
General.............................................................................2-25
General...............................................................................2-3 Removal............................................................................2-25
Disassembly.....................................................................2-26
2.3 VEHICLE IDENTIFICATION NUMBER Assembly..........................................................................2-26
(V.I.N.) Installation.........................................................................2-26
Vehicle Identification Number (VIN)....................................2-4
General........................................................................2-4 2.11 CLUTCH HAND LEVER
Location.......................................................................2-4 Removal............................................................................2-28
Abbreviated VIN..........................................................2-4 Installation.........................................................................2-28
2.4 FOOTBOARDS AND CONTROLS 2.12 CLUTCH FLUID LINE

Rider Footboards................................................................2-6 Removal............................................................................2-29
Removal......................................................................2-6 Installation.........................................................................2-29
Installation...................................................................2-6
Disassembly................................................................2-6 2.13 BLEEDING CLUTCH FLUID LINE
Assembly.....................................................................2-6 Draining and Filling...........................................................2-31
Shift Levers.........................................................................2-7 Bleed Clutch Master Cylinder...........................................2-32
Replace Pegs..............................................................2-7 Bleed Fluid Line and Actuator..........................................2-32
Replace Heel-Toe Shift Levers....................................2-7 Return Motorcycle to Service...........................................2-32
Rear Brake Pedal Pad........................................................2-7
Adjustable Passenger Footboards.....................................2-7 2.14 SEAT
Remove.......................................................................2-7
General.............................................................................2-33
Disassemble................................................................2-7
Removal............................................................................2-33
Assemble.....................................................................2-8
Cleaning and Inspection...................................................2-34
Install...........................................................................2-9
Installation.........................................................................2-34
Adjust...........................................................................2-9
2.5 HIGHWAY PEGS 2.15 RIDER BACKREST

Removal............................................................................2-35
Disassembly.....................................................................2-10
Installation.........................................................................2-35
Removing Clamp..............................................................2-10
Adjusting Tilt Angle...........................................................2-35
Installing Clamp................................................................2-10
Adjusting Front to Rear.....................................................2-35
Assembly..........................................................................2-10
III
TABLE OF CONTENTS
2.16 PASSENGER BACKREST Replacing Valve Guides....................................................3-12
Removal....................................................................3-12
Repair...............................................................................2-37
Installation.................................................................3-13
Assembly..........................................................................3-16
2.17 TOUR-PAK
Installation.........................................................................3-18
Removal............................................................................2-38
Installation.........................................................................2-39 3.6 PISTONS
Luggage Rack...................................................................2-39
General.............................................................................3-19
Removal....................................................................2-39
Measuring Piston..............................................................3-19
Installation.................................................................2-39
3.7 BORING AND HONING CYLINDERS
2.18 SADDLEBAGS
Inspection.........................................................................3-20
Removal............................................................................2-40
Cylinder Bore Finished Size.............................................3-21
Installation.........................................................................2-40
Piston Orientation.............................................................3-22
2.19 SADDLEBAGS LATCH 3.8 CRANKCASE ASSEMBLY
Removal............................................................................2-41
General.............................................................................3-23
Installation.........................................................................2-41
Assembly..........................................................................3-23
2.20 SADDLEBAG SUPPORTS 3.9 OIL COOLER
Removal............................................................................2-42
Oil Cooler Operation.........................................................3-25
Installation.........................................................................2-42
Removal............................................................................3-25
Installation.........................................................................3-25
2.21 AIR DEFLECTORS
Mid-Frame Air Deflectors..................................................2-43 3.10 OIL COOLER ADAPTER
Removal....................................................................2-43
Removal............................................................................3-26
Installation.................................................................2-43
Disassembly.....................................................................3-26
Assembly..........................................................................3-26
2.22 MUFFLER END CAP
Installation.........................................................................3-26
Replacement.....................................................................2-44
FUEL SYSTEM
ENGINE
4.2 AIR CLEANER BACKPLATE ASSEMBLY
3.2 SPECIFICATIONS: ENGINE
Removal..............................................................................4-2
General...............................................................................3-2 Installation...........................................................................4-2
Manufacturing Tolerances..................................................3-2
DRIVE
3.3 SERVICE WEAR LIMITS
General...............................................................................3-4 5.1 FASTENER TORQUE VALUES
3.4 TROUBLESHOOTING Fastener Torque Values in this Chapter..............................5-1
Compression Test...............................................................3-6 5.2 SPECIFICATIONS: DRIVE
Cylinder Leakdown Test......................................................3-6
General...............................................................................5-2
3.5 CYLINDER HEAD
5.3 CLUTCH RELEASE BEARING AND
General...............................................................................3-8
Removal..............................................................................3-8 PUSHROD
Determining Service...........................................................3-8 Removal..............................................................................5-3
Disassembly.......................................................................3-8 Installation...........................................................................5-3
Cleaning..............................................................................3-9 Measure Release Plate Movement.............................5-3
Inspection.........................................................................3-11 Install Clutch Inspection Cover....................................5-3
Cylinder Head............................................................3-11
Valve Guides.............................................................3-11 TRANSMISSION
Valves........................................................................3-11
Valve Springs.............................................................3-11 6.1 FASTENER TORQUE VALUES
Tapered Keepers.......................................................3-11
Valve Seats................................................................3-11 Fastener Torque Values in this Chapter..............................6-1
IV TABLE OF CONTENTS
TABLE OF CONTENTS
6.2 SPECIFICATIONS: TRANSMISSION Controls.....................................................................7-15
Warm-Up...................................................................7-15
General...............................................................................6-2
Automatic Shut-Off....................................................7-15
Diagnostics.......................................................................7-15
6.3 CLUTCH RELEASE COVER
Diagnostic Tips..........................................................7-15
Removal..............................................................................6-3 Connector Information...............................................7-15
Installation...........................................................................6-3 Heated Seat Inoperative...................................................7-16
Fill and Bleed......................................................................6-4 1. P&A Fuse Test.......................................................7-16
2. Heated Seat Circuit Test........................................7-16
6.4 SECONDARY CLUTCH ACTUATOR 3. Heated Seat Ground Circuit Test...........................7-16
Replacement.......................................................................6-5 4. Heated Seat Current Draw Test............................7-16
5. Heated Seat Passenger Pillion Current Draw
ELECTRICAL Test............................................................................7-16
6. Heated Seat Wire Test..........................................7-16
7.1 FASTENER TORQUE VALUES 7. Heated Seat Circuit Short to Ground Test.............7-16
Fastener Torque Values in this Chapter..............................7-1 7.8 HEATED HANDGRIPS

7.2 ELECTRICAL PROTECTION General.............................................................................7-17
Connector Information...............................................7-17
Fuses and Relays...............................................................7-2 Heated Handgrips Inoperative..........................................7-18
1. Heated Grips Fuse Test.........................................7-18
7.3 HEADLAMP 2. Current Draw Test..................................................7-18
General...............................................................................7-3 3. Power Supply Test.................................................7-18
Removal..............................................................................7-3 4. Accessory Power Supply Test...............................7-18
Installation...........................................................................7-4 5. Heated Grips Ground Circuit Test.........................7-18
6. Heated Grip Circuit Short to Ground Test..............7-18
7.4 AUXILIARY LAMPS AND BRACKETS 7. Heated Grips Continuity Test.................................7-18
Removing Lamps................................................................7-6 8. Heated Grips Test..................................................7-18
Removing Lamp Bracket....................................................7-7 9. Left Heated Grip Continuity Test...........................7-18
Installing Lamp Bracket......................................................7-7
Installing Lamps..................................................................7-7 7.9 IGNITION/FORK LOCK KNOB
Final Assembly............................................................7-7 Power Lock Ignition Knob.................................................7-19
Replacing Bulb....................................................................7-8 Removal....................................................................7-19
Installation.................................................................7-20
7.5 FRONT TURN SIGNALS
Removal............................................................................7-10 7.10 FAIRING CAP AND SWITCHES
Installation.........................................................................7-10 Removal............................................................................7-21
Installation.........................................................................7-21
7.6 TOUR-PAK LIGHTING
Wrap-Around Lights..........................................................7-11 7.11 DTC P1655, P1656
Removal....................................................................7-11 Description and Operation................................................7-23
Installation.................................................................7-11 Connector Information...............................................7-23
Interior Lamp.....................................................................7-11 DTC P1655.......................................................................7-25
Tour-Pak Lamps................................................................7-11 1. Front ACR Test......................................................7-25
Interior and Saddlebag Lamps Diagnostics......................7-12 2. Rear ACR Test.......................................................7-25
Description and Operation.........................................7-12 3. Rear ACR Control Circuit Test...............................7-25
Connector Information...............................................7-12 4. Front ACR Control Circuit Short to Ground Test....7-25
Lamps Inoperative............................................................7-13 5. Rear ACR Control Circuit Short to Ground Test.....7-25
1. Lamp Test..............................................................7-13 6. Shorted ACR Test..................................................7-25
2. Interior Lamp Power Test......................................7-13 7. ACR Supply Circuit Open Test..............................7-25
3. Radio Memory Fuses Test.....................................7-14 8. ACR Control Circuit Continuity Test......................7-25
4. Power Wire Continuity Test...................................7-14 DTC P1656.......................................................................7-26
5. Ground Wire Continuity Test.................................7-14 1. Front ACR Test......................................................7-26
6. Right Saddlebag Lamp Power (R/BK) Test...........7-14 2. Rear ACR Control Circuit Test...............................7-26
7. Right Saddlebag Lamp Power (W/BK) Test..........7-14 3. Rear ACR Test.......................................................7-26
8. Right Saddlebag Lamp Ground Test.....................7-14 4. Front ACR Control Circuit Test..............................7-26
9. Left Saddlebag Lamp Power (R) Test...................7-14
10. Left Saddlebag Lamp Power (W) Test.................7-14 7.12 PASSENGER HEADSET RECEPTACLE
11. Left Saddlebag Lamp Ground Test......................7-14 Repair...............................................................................7-27
Replace Weather Cap...............................................7-27
7.7 HEATED SEAT
General.............................................................................7-15
TABLE OF CONTENTS V
TABLE OF CONTENTS
7.13 XM SATELLITE RADIO DTC U1306 Infotainment Bus Lost Communication with NIM
Module..............................................................................7-37
General.............................................................................7-28
1. NIM Voltage Test...................................................7-37
XM Antenna......................................................................7-28
2. Battery Circuit Open Test......................................7-37
Remove.....................................................................7-28
3. Ground Circuit Open Test......................................7-37
Installation.................................................................7-28
4. NIM CAN Test........................................................7-37
XM Module........................................................................7-28
Removal....................................................................7-28 7.15 RADIO SOFTWARE UPDATE
Installation.................................................................7-28
Activation..........................................................................7-29 General.............................................................................7-38
XM Radio Diagnostics......................................................7-29 Updating Receiver Software.............................................7-38
Description and Operation.........................................7-29
Connector Information...............................................7-29
7.16 ADVANCED AUDIO RADIO
Symptom 12: No or Low Audio from XM or XM Removal............................................................................7-39
Inoperative........................................................................7-30 Installation.........................................................................7-39
1. XM Radio Operation Test......................................7-30
2. XM Audio Voltage Output Test..............................7-30 7.17 ADVANCED AUDIO AMPLIFIER
3. XM Audio Output Continuity Test..........................7-30 General.............................................................................7-40
4. XM Audio Output Short to Ground Test.................7-30 Removal............................................................................7-40
5. XM Audio Output Wires Shorted Together Test.....7-31 Installation.........................................................................7-40
6. XM Audio Output Shorted to Voltage Test.............7-31
7. XM Module Power Test.........................................7-31 7.18 GARAGE DOOR OPENER
8. XM Module CAN Voltage Test...............................7-31 Transmitter........................................................................7-42
9. XM Module CAN Continuity Test...........................7-31 Removal....................................................................7-42
10. XM Module Power/Ground Bus Continuity Test...7-31 Installation.................................................................7-42
Symptom 13: No or Intermittent Reception on XM Receiver............................................................................7-42
Module..............................................................................7-31 Installation.................................................................7-42
1. XM Antenna Power Test .......................................7-31 Remote Control Garage Door Opener..............................7-43
2. XM Antenna Resistance Test................................7-32 FCC Notices..............................................................7-43
DTC U1313 Infotainment Bus Lost Communication with XM Program the Receiver and Transmitter.....................7-43
Module..............................................................................7-32 Garage Door Opener Diagnostics....................................7-43
1. XM Module Voltage Test........................................7-32 Description and Operation.........................................7-43
2. XM Module Ground Test........................................7-32 Connector Information...............................................7-43
3. XM Module CAN Test............................................7-32 Garage Door Opener Inoperative.....................................7-44
4. XM Module CAN Test............................................7-32 1. Garage Door Opener Transmitter Test..................7-44
2. Fuse Test...............................................................7-44
7.14 ROAD TECH ZŪMO 660 GPS 3. Garage Door Opener Power Test..........................7-44
Mount and Harness..........................................................7-33 4. Low Beam Wire Test..............................................7-44
Removal....................................................................7-33 5. High Beam Wire Test.............................................7-44
Installation.................................................................7-33 6. Ground Wire Test...................................................7-45
Navigation Interface Module.............................................7-34 7. Garage Door Opener Receiver Test .....................7-45
Removal....................................................................7-34 8. Garage Door Opener Reprogramming Test..........7-45
Installation.................................................................7-34
Zūmo - GPS Diagnostics..................................................7-34 7.19 TWIST GRIP SENSOR (TGS)
Description and Operation.........................................7-34 Removal............................................................................7-46
Connector Information...............................................7-35 Installation.........................................................................7-46
No Vehicle Power To Unit.................................................7-35
1. On Vehicle, Zūmo Unit Test...................................7-35 7.20 POWER LOCKS
2. GPS Fuse Test......................................................7-35
Power Lock Lockset: Tour-Pak.........................................7-48
3. Power Circuit Test..................................................7-35
Removal....................................................................7-48
4. Ground Circuit Test................................................7-36
Installation.................................................................7-48
5. Off Vehicle, Zūmo Unit Test...................................7-36
Actuator: Tour-Pak............................................................7-48
No Sound Through Radio.................................................7-36
Removal....................................................................7-48
1. Off Vehicle, Zūmo Unit Test...................................7-36
Assembly...................................................................7-49
2. On Vehicle, Zūmo Unit Test...................................7-36
Power Locks: Saddlebags................................................7-49
3. Audio Jack Test.....................................................7-36
Removal....................................................................7-49
4. NIM Audio (+) Short to Power Test........................7-36
Installation.................................................................7-49
5. NIM Audio (-) Short to Power Test.........................7-36
Actuator: Saddlebag.........................................................7-50
6. NIM Audio (+) Continuity Test................................7-36
Disassembly..............................................................7-50
7. NIM Audio (-) Continuity Test................................7-36
Assembly...................................................................7-51
8. NIM Audio (+) Short to Ground Test......................7-37
Power Lock Module..........................................................7-51
9. NIM Audio (-) Short to Ground Test.......................7-37
Removal....................................................................7-51
VI TABLE OF CONTENTS
TABLE OF CONTENTS
Installation.................................................................7-51 Remove.....................................................................7-58
Power Lock Fob Programming.........................................7-51 Install.........................................................................7-58
Entering Program Mode............................................7-51 Replace Battery.........................................................7-58
Program Mode...........................................................7-52 Troubleshooting................................................................7-59
Replacing the Battery................................................7-52
Power Lock Diagnostics...................................................7-52 7.22 ULTRA CRUISE CONTROL
Description and Operation.........................................7-52 General.............................................................................7-60
Connector Information...............................................7-53 Diagnostics.......................................................................7-60
Power Locks Inoperative..................................................7-54 Entering ECM Diagnostic Mode................................7-60
1. System Test...........................................................7-54 Leaving ECM Diagnostic Mode.................................7-60
2. Power Lock Switch Test........................................7-54
3. Power Lock Fob Battery Test................................7-54 APPENDIX A WIRING
4. Actuator Test..........................................................7-54
5. Cam and Cylinder Test..........................................7-54
6. Power Lock Module Voltage Test..........................7-54
A.1 CONNECTORS
7. Power Lock Fuse Test...........................................7-54 Connectors.........................................................................A-1
8. Ground Circuit Test................................................7-54 Function and Location.................................................A-1
9. Lock Signal Short to Voltage Test..........................7-54 Place and Color...........................................................A-1
10. Lock Signal Short to Ground Test........................7-54 Connector Number......................................................A-1
11. Unlock Signal Short to Voltage Test.....................7-55 Repair Instructions......................................................A-1
12. Unlock Signal Short to Ground Test....................7-55
13. Lock Signal Open Test........................................7-55 A.2 WIRING DIAGRAMS
14. Unlock Signal Open Test.....................................7-55 Wiring Diagram Information................................................A-2
Power Locks Fairing Switch Inoperative...........................7-55 Wire Color Codes........................................................A-2
1. Instrument Fuse Test.............................................7-55 Wiring Diagram Symbols............................................A-2
2. Power Circuit Test..................................................7-55 Wiring Diagrams.................................................................A-4
3. Power Lock Switch Unlock Test............................7-55
4. Unlock Input Circuit Test........................................7-55 APPENDIX B GLOSSARY
5. Power Lock Switch Lock Test................................7-56
6. Lock Input Circuit Test...........................................7-56
B.1 GLOSSARY
7.21 HARLEY-DAVIDSON SMART SECURITY Acronyms and Abbreviations.............................................B-1
SYSTEM
REFERENCE MATERIAL
General.............................................................................7-57
HFSM Module...................................................................7-57
Removal....................................................................7-57
TOOLS...........................................................I
Installation.................................................................7-57
HFSM Antenna.................................................................7-57 TORQUE VALUES.......................................III
Removal....................................................................7-57
Installation.................................................................7-57 INDEX.........................................................VII
Smart Siren.......................................................................7-58
TABLE OF CONTENTS VII

NOTES
VIII TABLE OF CONTENTS

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
1.1 FASTENER TORQUE VALUES.................................................................................................1-1
1.2 SCHEDULED MAINTENANCE..................................................................................................1-2
1.3 BULB REQUIREMENTS............................................................................................................1-4
1.4 AIR FILTER ELEMENT..............................................................................................................1-5
1.5 HYDRAULIC CLUTCH FLUID...................................................................................................1-6
1.6 ENGINE LUBRICATION SYSTEM............................................................................................1-7
1.7 CRITICAL FASTENERS............................................................................................................1-8
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

Air cleaner cover screw 36-60 in-lbs 4.0-6.8 Nm 1.4 AIR FILTER ELEMENT, Installation
Air cleaner insert screw 27-32 in-lbs 3.1-3.6 Nm 1.4 AIR FILTER ELEMENT, Installation
Air filter element screws 55-60 in-lbs 6.2-6.8 Nm 1.4 AIR FILTER ELEMENT, Installation
2011 FLHTCUSE6 Service Supplement: Maintenance 1-1

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SCHEDULED MAINTENANCE 1.2

GENERAL Refer to Table 1-1. In addition to this supplement, see the
service manual for service procedures.
The scheduled maintenance table in this section lists the
maintenance requirements for this Touring family CVO model.
Table 1-1. Regular Service Intervals: 2011 FLHTCUSE6

ITEM SERVICED PROCEDURE 1000 MI 5000 MI 10000 MI 15000 MI 20000 MI 25000 MI 30000 MI 35000 MI 40000 MI 45000 MI 50000 MI NOTES
1600 KM 8000 KM 16000 KM 24000 KM 32000 KM 40000 KM 48000 KM 56000 KM 64000 KM 72000 KM 80000 KM
Engine oil and filter Replace X X X X X X X X X X X

Oil lines and brake Inspect for leaks, X X X X X X X X X X X 1, 3
system contact or abrasion
Air cleaner Inspect, service as X X X X X X X X X X
required
Tires Check pressure, X X X X X X X X X X X
inspect tread
Primary chaincase Replace X X X X X X
lubricant
Transmission lub- Replace X X X
ricant
Clutch fluid Check level and X X X X X X X X X X X 4
condition
Drive belt and Inspect, adjust belt X X X X X X X X X X X 1
sprockets
Compensator Inspect for wear 5
sprocket isolators
Brake and clutch Check and lub- X X X X X X X X X X X 1
controls ricate
Jiffy stand Inspect and lub- X X X X X X X X X X X 1
ricate
Fuel lines and fit- Inspect for leaks, X X X X X X X X X X X 1, 3
tings contact or abrasion
Fuel tank filter Replace X X 1
Brake fluid Inspect sight glass X X X X X X X X X X X 4
Brake pads and Inspect for wear X X X X X X X X X X X
discs
Spark plugs Inspect X X X X X X X X
Replace X X
Electrical equip- Check operation X X X X X X X X X X X
ment and switches
Front fork oil Replace X 1, 6
Steering head Lubricate X X X X X
bearings
Adjust X X 1, 2
Air suspension Check pressure, X X X X X X X X X X X 1
operation and
leakage
Windshield bush- Inspect X X X X X 1
ings (if applicable)
Fuel door, Tour- Lubricate hinges X X X X X X X X X X X
Pak, saddlebags (if and latches
equipped)
Critical fasteners Check tightness X X X X X X 1
Battery Check battery and 3
clean connections
Exhaust system Inspect for leaks, X X X X X X X X X X X 3
cracks, and loose
or missing
fasteners or heat
shields
1-2 2011 FLHTCUSE6 Service Supplement: Maintenance

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Table 1-1. Regular Service Intervals: 2011 FLHTCUSE6

ITEM SERVICED PROCEDURE 1000 MI 5000 MI 10000 MI 15000 MI 20000 MI 25000 MI 30000 MI 35000 MI 40000 MI 45000 MI 50000 MI NOTES
1600 KM 8000 KM 16000 KM 24000 KM 32000 KM 40000 KM 48000 KM 56000 KM 64000 KM 72000 KM 80000 KM
Road test Verify component X X X X X X X X X X X

and system func-
tions
NOTES: 1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified.
2. Disassemble, lubricate and inspect every 50,000 miles (80,000 kilometers).
3. Perform annually or at specified intervals, whichever comes first.
4. Change D.O.T. 4 hydraulic brake/clutch fluid and flush system every two years.
5. Perform at each rear tire change.
6. Replace fork oil and inspect every 50,000 miles (80,000 kilometers).

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BULB REQUIREMENTS 1.3

GENERAL
Table 1-2. Bulb Chart
LAMP DESCRIPTION BULBS CURRENT HARLEY-DAVIDSON

(ALL LAMPS 12 VOLT) REQUIRED DRAW PART NUMBER
AMPERAGE
Headlamp Headlamp - high (domestic) 1 5.1 67717-01
Headlamp - low (domestic) 1 4.3 68881-01
Headlamp - (international) 1 4.58/5.0 68329-03
Position lamp international 1 0.32 53436-97
Tail and stop Tail lamp 1 0.59 68167-04
lamp Stop lamp 1 2.10 68167-04
Tail lamp international 1 0.59 68167-04
Stop lamp international 1 2.10 68167-04
Turn signal lamp Front/running 2 2.25/0.59 69331-02
Front international 2 1.75 68163-84
Rear 2 2.25 69330-02
Rear international 2 1.75 68163-84
Auxiliary lighting License plate lamp international 1 0.37 53436-97
Tour-Pak side lamps* N/A 0.14 53788-06 (right side)
0.14 53789-06 (left side)
Tour-Pak wrap-around lamps* N/A 0.036 54136-10 (right side)
0.036 54135-10 (left side)
0.015 54137-10 (center)
Tour-Pak interior light* N/A 0.036 54332-04B
Saddlebag interior light* N/A 0.036 54333-04A
Auxiliary lamps 2 2.1 68453-05
Auxiliary lamps international 2 2.7 68851-98
Instrument panel High beam indicator 1 0.15 Instrument panel is illuminated with
lamps Oil pressure indicator 1 0.15 LEDs. Replace the entire assembly
upon failure.
Neutral indicator 1 0.15
Turn signal indicator 2 0.08
Gauge lamps Speedometer* N/A N/A N/A
Tachometer* N/A N/A N/A
Voltmeter 1 0.24 67454-04
Oil pressure 1 0.24 67454-04
Air temperature 1 0.24 67454-04
Fuel 1 0.24 67454-04
Items with * Illuminated with LEDs. Replace individual unit upon failure.

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AIR FILTER ELEMENT 1.4

REMOVAL INSTALLATION
NOTE 1. See Figure 1-1. Install air filter element (6).
For air filter element cleaning information, see the service 2. Apply LOCTITE 242 (blue) to air filter element fasteners.
manual. Install fasteners and tighten to 55-60 in-lbs (6.2-6.8 Nm).
1. See Figure 1-1. Remove fasteners (1) and air cleaner 3. Install air cleaner cover (4) and fastener (3). Tighten
insert (2). fastener to 36-60 in-lbs (4.0-6.8 Nm).
2. Remove fastener (3) and air cleaner cover (4). 4. Install air cleaner insert (2) and fasteners (1). Tighten
3. Remove fasteners (5) and air filter element (6). fasteners to 27-32 in-lbs (3.1-3.6 Nm).
sm06284
6
5
4
2
1
1. Air cleaner insert fastener (2)

2. Air cleaner insert
3. Air cleaner cover fastener
4. Air cleaner cover
5. Air filter element fastener (3)
6. Air filter element
Figure 1-1. Air Cleaner Cover

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HYDRAULIC CLUTCH FLUID 1.5

GENERAL 1. Position vehicle on a flat, level surface. Turn handlebar
so master cylinder is level.
The clutch is hydraulically actuated. The hand lever actuated
master cylinder creates pressure in the clutch fluid line that 2. See Figure 1-2. View reservoir sight glass and verify fluid
activates a secondary clutch actuator mounted in the clutch presence. Fluid level should be above the MIN line on the
release cover. The secondary clutch actuator piston extends sight glass.
and contacts a pushrod to disengage the clutch. NOTE
Do NOT overfill clutch reservoir. Clutch fluid volume in reservoir
increases with clutch wear and can damage seals causing
damage to clutch system.
D.O.T. 4 hydraulic brake fluid is used in the hydraulic
clutch. Do not use other types of fluids as they are not 3. If fluid level is below the MIN line on the sight glass:
compatible and could cause equipment damage. (00353a) a. Check for fluid leaks in hydraulic clutch system.
b. Remove reservoir cover and verify fluid level. If fluid
level is below FILL LEVEL on ledge in reservoir, add
D.O.T. 4 brake fluid will damage painted and body panel HARLEY-DAVIDSON D.O.T. 4 HYDRAULIC BRAKE
surfaces it comes in contact with. Always use caution and FLUID (Part No. 99953-99A). Do not exceed FILL
protect surfaces from spills whenever brake work is per- LEVEL. Replace cover. See 2.13 BLEEDING
formed. Failure to comply can result in cosmetic damage. CLUTCH FLUID LINE.
(00239b)
Do not wipe any spilled brake fluid off of finished surfaces. om01531
Always flush the affected components with clear (not soapy)
water.
Direct contact of D.O.T. 4 brake fluid with eyes can cause

irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
FLUID INSPECTION
Check fluid level in clutch master cylinder reservoir.
Figure 1-2. Clutch Reservoir Sight Glass
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)

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ENGINE LUBRICATION SYSTEM 1.6

GENERAL If it is necessary to add oil to bring the fill level to FULL on the
dipstick and SYN3 is not available, the first choice would be
to add H-D 360 SAE 20W50 to the SYN3 for engine lubrication.
Although H-D 360 is compatible with SYN3, we suggest the
Prolonged or repeated contact with used motor oil may mixture of the fluids be changed as soon as possible.
be harmful to skin and could cause skin cancer. Promptly If H-D 360 is not available, the second choice would be to add
wash affected areas with soap and water. (00358b) an oil certified for diesel engines. Acceptable diesel engine oil
designations include: CH-4, CI-4 and CJ-4. The preferred vis-
cosities for the diesel engine oils, in descending order are:
20W50, 15W40 and 10W40.
If swallowed, do not induce vomiting. Contact a physician
immediately. In case of contact with eyes, immediately We again suggest the mixture of the fluids be changed as soon
flush with water. Contact a physician if irritation persists. as possible. At the first opportunity, see a Harley-Davidson
(00357c) dealer to change back to 100 percent Harley-Davidson oil. DO
NOT add diesel engine oil to the primary chaincase or trans-
mission.
Refer to Table 1-3. To switch lubricant to H-D 360, completely
Do not switch lubricant brands indiscriminately because drain the SYN3 before filling with H-D 360. A residual amount
some lubricants interact chemically when mixed. Use of of fluid will remain. It is not required to flush out the residual
inferior lubricants can damage the engine. (00184a) fluid.
Screamin' Eagle SYN3 Synthetic Motorcycle Lubricant is
provided for engine lubrication.
Table 1-3. Recommended Oil Grades
HARLEY- VISCOSITY HARLEY- LOWEST COLD

DAVIDSON TYPE DAVIDSON AMBIENT WEATHER
RATING TEMPERATURE STARTS
BELOW
50 °F (10 °C)
Screamin' Eagle SYN3 Synthetic Motorcycle SAE 20W50 HD 360 Above 40 °F (4 °C) Excellent
Lubricant
H.D. Multi-Grade SAE 10W40 HD 360 Below 40 °F (4 °C) Excellent
Screamin' Eagle Synthetic Blend Motorcycle Engine SAE 20W50 HD 360 Above 40 °F (4 °C) Good
Oil
H.D. Multi-Grade SAE 20W50 HD 360 Above 40 °F (4 °C) Good
H.D. Regular Heavy SAE 50 HD 360 Above 60 °F (16 °C) Poor
H.D. Extra Heavy SAE 60 HD 360 Above 80 °F (27 °C) Poor

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CRITICAL FASTENERS 1.7

INSPECTION Checking Torques on Fasteners
Inspect critical fasteners at the scheduled service intervals. 1. Refer to Table 1-4. Attempt to turn the fastener using a
Replace any fasteners that are damaged or missing. torque wrench set to the minimum torque specification for
that fastener.
a. If the fastener does not rotate, the fastener torque
has been maintained. No further attention is neces-
sary at this time.
b. If the fastener rotates, remove it to determine if it has
a locking agent.
c. If it has a locking agent, 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).
d. Install and tighten the fastener to specification.
2. If the fastener does not have a locking agent, install and

tighten to specification.
Table 1-4. Critical Fasteners
SYSTEM FASTENER TORQUE

Axle Front axle nut 60-65 ft-lbs 81.3-88.1 Nm
Rear axle cone nut 95-105 ft-lbs 129-142 Nm
Brakes Brake caliper banjo bolts 17-19 ft-lbs 23.0-25.8 Nm
Master cylinder banjo bolts 12.5-14.5 ft-lbs 17.0-19.7 Nm
ABS module banjo bolts 12.5-14.5 ft-lbs 17.0-19.7 Nm
Front brake disc screws 16-24 ft-lbs 21.7-32.5 Nm
Rear brake disc screws 30-45 ft-lbs 40.7-61.0 Nm
Front master cylinder reservoir cover screws 8-10 in-lbs 0.9-1.1 Nm
Rear master cylinder reservoir cover screws 12-15 in-lbs 1.4-1.7 Nm
Rear master cylinder to frame screws 126-150 in-lbs 14.2-16.9 Nm
Front brake caliper mounting screws 28-38 ft-lbs 38.0-51.5 Nm
Rear brake caliper to caliper bracket screws 43-48 ft-lbs 58.3-65.1 Nm
Brake caliper pad pin 75-102 in-lbs 8.5-11.5 Nm
Front forks Axle holder nuts 132-180 in-lbs 14.9-20.4 Nm
Hand controls Clutch master cylinder/handlebar clamp screws 72-84 in-lbs 8.1-9.5 Nm
Brake master cylinder/handlebar clamp screws 72-84 in-lbs 8.1-9.5 Nm
Upper/lower switch housing screws 35-45 in-lbs 4.0-5.1 Nm
Rear fork pivot shaft Screws 50-55 ft-lbs 67.8-74.5 Nm
Rear fork bracket bolts 55-65 ft-lbs 74.6-88.1 Nm
Other Rear frame bolts 40-50 ft-lbs 54.2-67.8 Nm
Engine Stabilizer link bracket to cylinder head bolts 30-35 ft-lbs 40.7-47.5 Nm
Top stabilizer link to engine stabilizer bracket bolt See ENGINE MOUNTS in the service manual.
Top stabilizer link to frame weldment bolt
Engine to front engine mounting bracket bolts
Front engine mount bolts
Engine to transmission bolts 34-39 ft-lbs 46.1-52.9 Nm

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Table 1-4. Critical Fasteners
SYSTEM FASTENER TORQUE

Clutch Banjo bolt 12.5-14.5 ft-lbs 16.9-19.7 Nm
Clutch fluid line flare nut 72-120 in-lbs 8.1-13.6 Nm
Secondary actuator bleeder valve 12-15 in-lbs 1.4-1.7 Nm
Reservoir cover screws 8-10 in-lbs 0.9-1.1 Nm

NOTES

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
2.2 SPECIFICATIONS: CHASSIS....................................................................................................2-3
2.3 VEHICLE IDENTIFICATION NUMBER (V.I.N.)..........................................................................2-4
2.4 FOOTBOARDS AND CONTROLS............................................................................................2-6
2.5 HIGHWAY PEGS.....................................................................................................................2-10
2.6 FRONT AXLE COVERS..........................................................................................................2-12
2.7 LOWER TRIPLE CLAMP COVER...........................................................................................2-13
2.8 HANDLEBARS.........................................................................................................................2-14
2.9 HANDGRIPS............................................................................................................................2-21
2.10 CLUTCH MASTER CYLINDER AND RESERVOIR..............................................................2-25
2.11 CLUTCH HAND LEVER.........................................................................................................2-28
2.12 CLUTCH FLUID LINE............................................................................................................2-29
2.13 BLEEDING CLUTCH FLUID LINE.........................................................................................2-31
2.14 SEAT......................................................................................................................................2-33
2.15 RIDER BACKREST...............................................................................................................2-35
2.16 PASSENGER BACKREST....................................................................................................2-37
2.17 TOUR-PAK.............................................................................................................................2-38
2.18 SADDLEBAGS.......................................................................................................................2-40
2.19 SADDLEBAGS LATCH..........................................................................................................2-41
2.20 SADDLEBAG SUPPORTS....................................................................................................2-42
CHASSIS
2.21 AIR DEFLECTORS................................................................................................................2-43
2.22 MUFFLER END CAP.............................................................................................................2-44
NOTES
HOME

CHAPTER
in this chapter.

Air deflector bolts 25-35 in-lbs 2.8-4.0 Nm 2.21 AIR DEFLECTORS, Mid-Frame Air Deflectors
Brake pedal cover screws 15-19 ft-lbs 20.3-25.8 Nm 2.4 FOOTBOARDS AND CONTROLS, Rear Brake
Pedal Pad
Clutch actuator bleeder valve 12-15 in-lbs 1.4-1.7 Nm 2.10 CLUTCH MASTER CYLINDER AND
RESERVOIR, Installation
Clutch actuator bleeder valve 12-15 in-lbs 1.4-1.7 Nm 2.13 BLEEDING CLUTCH FLUID LINE, Return
Motorcycle to Service
Clutch fluid line clamp bolt 96-120 in-lbs 10.8-13.6 Nm 2.12 CLUTCH FLUID LINE, Installation
Clutch fluid line flare nut 72-120 in-lbs 8.1-13.6 Nm 2.13 BLEEDING CLUTCH FLUID LINE, Draining
and Filling
Clutch fluid line flare nut 72-120 in-lbs 8.1-13.6 Nm 2.13 BLEEDING CLUTCH FLUID LINE, Return
Clutch master cylinder banjo bolt 12.5-14.5 ft-lbs 16.9-19.7 Nm 2.10 CLUTCH MASTER CYLINDER AND
Clutch master cylinder banjo bolt 12.5-14.5 ft-lbs 16.9-19.7 Nm 2.13 BLEEDING CLUTCH FLUID LINE, Return
Clutch master cylinder clamp fastener 72-84 in-lbs 8.1-9.5 Nm 2.8 HANDLEBARS, Installing Handlebars
Clutch master cylinder clamp fastener 72-84 in-lbs 8.1-9.5 Nm 2.9 HANDGRIPS, Replacing Handgrips
Clutch master cylinder clamp fastener 72-84 in-lbs 8.1-9.5 Nm 2.10 CLUTCH MASTER CYLINDER AND
Clutch reservoir cover screws 8-10 in-lbs 0.9-1.1 Nm 2.10 CLUTCH MASTER CYLINDER AND
Clutch reservoir cover screws 8-10 in-lbs 0.9-1.1 Nm 2.13 BLEEDING CLUTCH FLUID LINE, Return
Engine guard bolt 15-20 ft-lbs 20.3-27.1 Nm 2.12 CLUTCH FLUID LINE, Installation
Front axle cover set screw 60-84 in-lbs 6.8-9.5 Nm 2.6 FRONT AXLE COVERS, Replacement/LOC-
TITE 262 THREADLOCKER (red)
Front brake master cylinder clamp 72-108 in-lbs 8.1-12.2 Nm 2.8 HANDLEBARS, Installing Handlebars
fastener
Front brake master cylinder clamp 72-108 in-lbs 8.1-12.2 Nm 2.9 HANDGRIPS, Replacing Handgrips
fastener
Handlebar switch housing screw 35-45 in-lbs 4.0-5.1 Nm 2.8 HANDLEBARS, Installing Handlebars
Handlebar switch housing screw 35-45 in-lbs 4.0-5.1 Nm 2.9 HANDGRIPS, Replacing Handgrips
Handlebar switch housing screw 35-45 in-lbs 4.0-5.1 Nm 2.10 CLUTCH MASTER CYLINDER AND
Handlebar top clamp fasteners 16-20 ft-lbs 20.3-27.1 Nm 2.8 HANDLEBARS, Installing Handlebars
Highway peg end screw 19 ft-lbs 26 Nm 2.5 HIGHWAY PEGS, Assembly/LOCTITE 243
THREADLOCKER (blue)
Highway peg mounting screws 14 ft-lbs 19 Nm 2.5 HIGHWAY PEGS, Installing Clamp
Highway peg nut 14-19 ft-lbs 19-25 Nm 2.5 HIGHWAY PEGS, Assembly
2011 FLHTCUSE6 Service Supplement: Chassis 2-1

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Muffler end cap fasteners 84-108 in-lbs 9.5-12.2 Nm 2.22 MUFFLER END CAP, Replacement
Muffler head shield clamps 20-40 in-lbs 2.3-4.5 Nm 2.22 MUFFLER END CAP, Replacement
Passenger footboard bracket screw 30-35 ft-lbs 41-47 Nm 2.4 FOOTBOARDS AND CONTROLS, Adjustable
Passenger Footboards
Passenger footboard lower adjustment 25-30 ft-lbs 34-40 Nm 2.4 FOOTBOARDS AND CONTROLS, Adjustable
bolt Passenger Footboards
Passenger footboard upper adjustment 25-30 ft-lbs 34-40 Nm 2.4 FOOTBOARDS AND CONTROLS, Adjustable
Rider backrest bracket 60-96 in-lbs 6.8-10.8 Nm 2.15 RIDER BACKREST, Adjusting Front to Rear
Rider backrest bracket support strap 132-180 in-lbs 15-20 Nm 2.15 RIDER BACKREST, Adjusting Front to Rear
Rider backrest mounting bracket screw 60-96 in-lbs 6.8-10.8 Nm 2.15 RIDER BACKREST, Adjusting Front to Rear
Rider footboard bracket socket screws 36-42 ft-lbs 48.8-57.0 Nm 2.4 FOOTBOARDS AND CONTROLS, Rider
Footboards
Rider footboard pivot bolt nut 60-80 in-lbs 6.8-9.0 Nm 2.4 FOOTBOARDS AND CONTROLS, Rider
Footboards
Saddlebag filler strip screw 15-20 ft-lbs 20.4-27.1 Nm 2.20 SADDLEBAG SUPPORTS, Installation
Saddlebag filler strip-to-lower fender 15-20 ft-lbs 20.4-27.1 Nm 2.20 SADDLEBAG SUPPORTS, Installation
support screw
Saddlebag inner screws 25 in-lbs 2.8 Nm 2.19 SADDLEBAGS LATCH, Installation
Shift lever clamp screws 18-22 ft-lbs 25-29 Nm 2.4 FOOTBOARDS AND CONTROLS, Shift Levers
Shift lever peg fastener 14-16 ft-lbs 19-21 Nm 2.4 FOOTBOARDS AND CONTROLS, Shift Levers
Speaker box mounting screws 25-35 in-lbs 2.8-4.0 Nm 2.17 TOUR-PAK, Installation
Tour-Pak luggage rack fastener 60-84 in-lbs 6.8-9.5 Nm 2.17 TOUR-PAK, Luggage Rack
Tour-Pak mounting bolts 96-120 in-lbs 10.8-13.6 Nm 2.17 TOUR-PAK, Installation
Triple clamp cover backside fasteners 70-110 in-lbs 7.9-12.4 Nm 2.7 LOWER TRIPLE CLAMP COVER, Replace-
ment
Triple clamp lower fastener 120-180 in-lbs 13.6-20.4 Nm 2.7 LOWER TRIPLE CLAMP COVER, Replace-
ment
2-2 2011 FLHTCUSE6 Service Supplement: Chassis

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SPECIFICATIONS: CHASSIS 2.2

GENERAL
Table 2-2. Weights
Table 2-1. Dimensions ITEM LB. KG

Weight as shipped from 895 406.0
ITEM IN. MM
factory
Wheel base 63.5 1613
GVWR 1360 616.9
Overall length 98.8 2510
GAWR front 500 226.8
Overall width 34.8 884
GAWR rear 927 420.5
Road clearance 5.1 130
Overall height 57.0 1448 Table 2-3. Capacities
Saddle height* 27.8 706
ITEM U.S. LITERS
*With 180 lb. (81.7 kg) rider on seat.
Fuel tank (total) 6 gal 22.7
NOTE Oil tank with filter 4.0 quarts 3.78 L
Gross Vehicle Weight Rating (GVWR) (maximum allowable Transmission (approximate) 32 fl. oz. 946 mL
loaded vehicle weight) and corresponding Gross Axle Weight Primary (drained) 38 fl. oz. 1100 mL
Ratings (GAWR) are listed on a label located on the right side
front downtube. Primary (cover removed) 45 fl. oz. 1330 mL
Front Fork* VOLUME HEIGHT
OZ ML IN. MM
10.78 317 4.92 125
* Front fork is functionally identical to FLHTCU. See Touring
Models Service Manual for appropriate front fork service
procedures.
Table 2-4. Tires
MOUNT SIZE APPROVED TIRE PRESSURE (COLD)

psi kPa
Front 17 in Dunlop D408F 130/80B17 36 248
Rear 16 in Dunlop D407 180/65B16 40 276

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VEHICLE IDENTIFICATION NUMBER (V.I.N.) 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 2-5.
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,
1
a printed VIN label (2) is also attached to the left front down-
tube.
Abbreviated VIN 2
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
om01538
1 2 3 4 5 6 7 8 9 10
1 HD 1 PR 8 1 7 B B 111000
Figure 2-2. Typical Harley-Davidson V.I.N.: 2011 FLHTCUSE6 Models
Table 2-5. Harley-Davidson V.I.N. Breakdown: 2011 FLHTCUSE6 Models
POSITION DESCRIPTION POSSIBLE VALUES

1 Market designation 1=Originally manufactured for sale within the United States
5=Originally manufactured for sale outside of the United States
2 Manufacturer HD=Harley-Davidson
3 Motorcycle type 1=Heavyweight motorcycle (901 cc or larger)
4 Model PR=CVO Ultra Classic® Electra Glide®
5 Engine type 8=110 cu. in. (1803 cc) air-cooled, fuel-injected

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Table 2-5. Harley-Davidson V.I.N. Breakdown: 2011 FLHTCUSE6 Models
POSITION DESCRIPTION POSSIBLE VALUES

6 Introduction date/ Normal Introduction Mid-year or Special Introduction
Calibration recognition 1=Domestic 2, 4=Domestic
3=California 5, 6=California
A=Canada B=Canada
C=HDI D=HDI
E=Japan F=Japan
G=Australia H=Australia
J=Brazil K=Brazil
L=Asia Pacific M=Asia Pacific
N=India P=India
7 V.I.N. check digit Can be 0-9 or X
8 Model year B=2011
9 Assembly plant B=York, PA U.S.A.
10 Sequential number Varies

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FOOTBOARDS AND CONTROLS 2.4

RIDER FOOTBOARDS 1. If removing left side footboard, raise motorcycle using a
suitable lift to remove weight from jiffy stand.
Removal 2. See Figure 2-3. Remove fasteners (5, 7).
3. Remove footboard and bracket assembly from motorcycle.
When lifting a motorcycle using a jack, be sure jack con- Installation

tacts both lower frame tubes where down tubes and lower 1. See Figure 2-3. Install footboard and bracket assembly
frame tubes converge. Never lift by jacking on cross- and secure with fasteners (5, 7).
members, oil pan or other housings. Failure to comply can
cause serious damage resulting in the need to perform 2. Tighten fasteners to 36-42 ft-lbs (48.8-57.0 Nm).
major repair work. (00586c)
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1 3 4
6 5
5
7
9
8
10
2
7
11
1. Rubber pad 7. Fastener, front bracket

2. Footboard 8. Right forward bracket
3. Pivot screw nut (2) 9. Left rear bracket
4. Pivot screw (2) 10. Jiffy stand bracket
5. Fastener, rear bracket 11. Left forward bracket
6. Right rear bracket
Figure 2-3. Rider Footboards (Typical) (Quantities shown are for each footboard)
Disassembly Assembly
NOTE 1. See Figure 2-3. Place footboard into position between
If only replacing the rubber pad, refer to step 1 below and then brackets and install pivot screws (4) so that the nuts (3)
steps 3-4 under ASSEMBLY. will be on the inboard side.
1. Tilt footboard upward. From bottom of footboard, use a 2. Install nuts (3) onto pivot screws and tighten to 60-80 in-
large flat blade screwdriver to push four rubber anchors lbs (6.8-9.0 Nm).
on pad up through holes in footboard. 3. Moisten four rubber anchors on bottom of new pad (1)
2. See Figure 2-3. Remove nuts (3) and pivot screws (4) with soapy water.
from underside of footboard.
3. Remove footboard from brackets.

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4. Place pad into position on footboard. From bottom of REAR BRAKE PEDAL PAD
footboard, use pliers to pull rubber anchors through holes
in footboard. NOTE
See the service manual for procedures to remove and install
SHIFT LEVERS the foot brake lever or linkage.
Replace Pegs 1. See Figure 2-5. Remove fastener (5) and offset washer
1. See Figure 2-4. Remove fastener (6). Remove shift lever (4). Remove brake pedal cover (3) and pad (2).
peg assembly and sleeve (4). 2. Assemble chrome cover and rubber pad to foot brake
2. Remove rubber pad (7) from chrome housing (5) if pedal. Secure with fastener (5). Tighten to 15-19 ft-lbs
necessary. (20.3-25.8 Nm).
3. Assemble chrome housing (5) over rubber pad (7).

sm06120
4. Insert sleeve (4) and fasten to shift lever with fastener (6).
5. Rotate pegs for rider posture and tighten fastener to 14- 3
16 ft-lbs (19-21 Nm).
Replace Heel-Toe Shift Levers

1. Mark location of levers relative to splined shaft using a 2
permanent marker.
2. See Figure 2-4. Remove clamp screws (8) from both levers
(3, 9). 1
3. Pull shift levers and spacer (2) off splined shaft (1).
4. Align marks made during disassembly and position shift 4
levers on splined shaft, or adjust for rider comfort.
5. Install and tighten clamp screws to 18-22 ft-lbs (25-29
Nm). 5
sm03963a 1. Foot brake lever

6
2. Rubber pad
5 3. Chrome cover
4. Offset washer
5. Fastener
4
Figure 2-5. Rear Brake Pedal
7
3 8 ADJUSTABLE PASSENGER FOOTBOARDS
2 Remove
1 9 1. See Figure 2-6. Remove the upper (1) adjustment bolt,
wave spring and the footboard assembly.
2. Remove the lower adjustment bolt (3), wave spring and
1. Splined shaft the rotating arm (2).
2. Spacer
3. Heel shift lever 3. Remove screw and lockwasher to remove footboard
4. Sleeve bracket from rear fork pivot bracket.
5. Chrome housing
6. Fastener
Disassemble
7. Rubber pad 1. See Figure 2-7. Pivot support 90 degrees to access and
8. Clamp screw back set screw out of insert.
9. Toe shift lever
2. Pull the insert out of the footboard.
Figure 2-4. Shift Levers and Pegs
3. Press the pivot pins into the center cavity and remove.
NOTE
With the support and the footboard base at 90 degrees,
squeeze the support against the footboard to release tension
on the pins. It maybe necessary to tap the pins with a brass
drift.

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4. Retain ball and spring from hole in support. NOTE

To slide the pins in the lugs, squeeze the support against the
footboard to compress the spring and relieve the tension on
sm03955
the pins. It maybe necessary to tap the pins in place with a
brass drift.
4. See Figure 2-9. Release the support and footboard to hold
the pins centered in the lugs of the footboard.
5. See Figure 2-10. With soapy water, moisten rubber beads
(1) and rubber sockets (2) on new insert.
1
6. Position in footboard and press on insert until beads have
engaged footboard pins and footboard pins have engaged
insert sockets.
sm03957
2
3 2
1. Upper adjustment bolt

2. Rotating arm
3. Lower adjustment bolt 1
Figure 2-6. Passenger Footboard Adjustment Bolts 3
sm03956
1. Spring
2. Hole
3. Ball
Figure 2-8. Support and Footboard
sm03958
Figure 2-7. Insert Set Screw
Assemble
1. See Figure 2-8. Place spring (1) into hole (2) in support
and place ball (3) on top of spring.
2. Orient the support to the footboard to fit the rotating arm.
Mate the support to the floorboard to capture the ball and
spring.
3. Install pivot pins from the outboard side. Center the pins
in lugs of footboard. Figure 2-9. Centered Pin

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NOTE
sm03961
Passenger footboards can be installed in one of three positions.
1 To move footboards to a new position, remove plastic plugs
from holes in rear fork pivot bracket as necessary.
2 1 2. Install screw and lockwasher. Tighten to 30-35 ft-lbs (41-
47 Nm).
3. Install rotating arm and lower adjustment bolt with wave
spring.
4. Install footboard assembly with upper adjustment bolt and
wave spring.
Adjust
1. Raise the footboard and loosen the lower adjustment bolt
1
enough to rotate the rotating arm. Rotate arm to desired
footboard height.
2 NOTE
Passenger footboards may adjusted to one of five positions.
1
2. Tighten lower adjustment bolt to 25-30 ft-lbs (34-40 Nm).
1. Rubber beads 3. Loosen upper adjustment bolt enough to allow footboard
2. Rubber sockets mount to be rotated.
Figure 2-10. Footboard and New Insert NOTE
The horizontal position of tilt of the footboard may be further
adjusted for passenger comfort.
Install
4. Move footboard mount to desired footboard horizontal
1. Insert locating pin of footboard bracket into hole in rear position or tilt.
fork pivot bracket.
5. Tighten upper adjustment bolt to 25-30 ft-lbs (34-40 Nm).

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HIGHWAY PEGS 2.5

DISASSEMBLY NOTES
1. See Figure 2-11. Remove the end screw (11) and slide • See Figure 2-13. Match the flair (1) of the clamp bracket
the chrome housing (1) off the mounting peg (9). to the bevel (2) of the mount bracket.
2. Push the rubber pad (10) out of the chrome housing. • Orient the highway pegs so that the pivot screw and the
two bracket clamp fasteners face forward and the decor-
3. Remove the pivot screw (3), washer (2) and decorative ative nut faces the rider.
nut (7).
• Do not position the highway pegs so that the mounting
4. Remove the mounting peg and the spring washer (8). brackets contact the lower fairings.
Save the spring washer.
ASSEMBLY
REMOVING CLAMP
1. See Figure 2-11. Apply LOCTITE 243 THREADLOCKER
1. See Figure 2-11. Remove the clamp screws (4). (blue) to the end threads of the pivot screw (3).
2. Separate the clamp bracket (6) from the mount bracket 2. With the square edge of spring washer (8) facing the slot,
(5) to remove the highway peg from the engine guard. hold the spring washer to the pivot hole of the mounting
peg (9).
sm06117 3. Orient the round edge of the pivot flat upward and install
4 5 with the pivot screw (3), washer (2) and nut (7). Tighten
to 14-19 ft-lbs (19-25 Nm).
3 6
4. Fit the rubber pad (10) to the chrome housing (1) and
squeeze the rubber pad into the housing.
2 5. Slide the chrome housing and rubber pad onto the

mounting peg.
1 8 6. Apply LOCTITE 243 THREADLOCKER (blue) to end screw
(11).
7
9 7. See Figure 2-12. For rider posture, rotate footpeg
approximately 40 degrees (3) from horizontal. Tighten end
screw to 19 ft-lbs (26 Nm).
11 10
1. Chrome housing
2. Washer
3. Pivot screw
4. Clamp screws (2)
5. Mount bracket
6. Clamp bracket
7. Nut
8. Spring washer
9. Mounting peg
10. Rubber pad
11. End screw
Figure 2-11. Highway Peg
INSTALLING CLAMP
1. See Figure 2-12. Use a grease pencil to draw a line (1)
on engine guard 6.5 in. (165 mm) from top of upper rail.
2. Clamp the brackets to the engine guard just below the line
with the brackets at a 25 degrees angle rearward (2).
3. Tighten the clamp screws to 14 ft-lbs (19 Nm).
4. Remove grease pencil mark.

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sm03966 sm03967
o
25
2
o
25
1
2
3 1
o
40
1. Clamp flair
2. Mount bevel
Figure 2-13. Clamp and Mount Brackets
1. 6.5 in. (165 mm)

2. 25 degrees
3. 40 degrees
Figure 2-12. Highway Peg Mounting

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FRONT AXLE COVERS 2.6

REPLACEMENT
sm03968
1. See Figure 2-14. Loosen but do not remove set screw
under cover. Remove cover.
2. Remove set screws from cover.
3. Liberally apply LOCTITE 262 THREADLOCKER (red) to
threads of set screw.
4. Orient cover over axle end so that set screw is on the
bottom and will tighten down against a flat on the axle nut.
5. Install and tighten set screw to 60-84 in-lbs (6.8-9.5 Nm).
6. Repeat for opposite side.
Figure 2-14. Front Axle Cover Set Screw

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LOWER TRIPLE CLAMP COVER 2.7

REPLACEMENT
1. See Figure 2-15. Loosen but do not remove the two screws
sm03969
1
(1) on the backside of the lower triple clamp cover (3). 2
2. Remove screw (4) through brake line manifold on bottom
of triple clamp cover. 3
3. Remove two loosened screws (1) with washers (2) and 5
remove cover.
4. To replace cover, fit cover inside bottom of nacelle and
around lower triple clamp (5). Hold in place.
5. Install screws (1) and washers (2). Tighten finger-tight
only. Install screw (4) through brake line manifold and
cover. Tighten finger-tight only. Verify that cover is snug
against rear surface of lower triple clamp.
4
NOTE
Plastic plugs in locator holes in rear surface of triple clamp can
cause interference with cover. Verify that center plug has been 1. Screw (2)
removed. 2. Washer (2)
6. Tighten screws (1) to 70-110 in-lbs (7.9-12.4 Nm). 3. Lower triple clamp cover
4. Screw
7. Tighten screw (4) to 120-180 in-lbs (13.6-20.4 Nm). 5. Lower triple clamp
8. Verify that brake line does not rub on cover. Adjust line or Figure 2-15. Lower Triple Clamp Cover
cover as necessary.

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HANDLEBARS 2.8
REMOVAL 2. Remove ignition/fork lock knob. If equipped with power
lock ignition knob, see 7.9 IGNITION/FORK LOCK KNOB.
3. Remove outer fairing and fairing cap. See service manual.
To prevent accidental vehicle start-up, which could cause 4. See Figure 2-16. Separate handlebar switch connectors
death or serious injury, remove main fuse before pro- [24] (1) and [22] (2). Separate heated handgrip power
ceeding. (00251b) harness connector [189] (3). Disengage connector hous-
ings from locating pins. Separate twist grip sensor (TGS)
1. Remove left saddlebag, left side cover and main fuse. connector [204] (5).
sm03970b
2 5
1
4 3
1. Left handlebar switch connector [24]

2. Right handlebar switch connector [22]
3. Handgrip heater power connector [189]
4. Handgrip heater interconnect [206]
5. Twist grip sensor connector [204]
Figure 2-16. Handlebar Control Connector Locations
5. See Figure 2-17. Squeeze front brake lever and insert a 7. Protect chrome and painted surfaces and tie master cyl-
5/32 in. (4 mm) thick cardboard insert (2) between front inder, reservoir and brake line out of the way.
brake lever and lever bracket.
8. Remove fasteners and washers securing handlebar clamp
to clutch lever bracket.
9. Protect chrome and painted surfaces and tie master cyl-
Do not remove or install the master cylinder assembly inder, reservoir and clutch fluid line out of the way.
without first positioning a 5/32-inch (4 mm) thick insert
10. Remove advanced audio radio assembly. See
between the brake lever and lever bracket. Removing or
7.16 ADVANCED AUDIO RADIO.
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and NOTE
plunger on the front stoplight switch. (00324a) Mark position of handlebar to maintain rider preference after
6. Remove fasteners securing handlebar clamp to master installation.
cylinder and front brake lever.

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11. Remove upper handlebar clamp and remove handlebar 9. See Figure 2-19. Lightly lubricate conduits and tape with
with wire harnesses from motorcycle. glass cleaner.
NOTE 10. Gently pull twist grip sensor (TGS) out of handlebar, along
If handlebar rubber mounts require service, see service manual. with the right handgrip heater harness.
11. Gently pull left handgrip out of handlebar, along with left
sm04667
handgrip heater harness.
12. Pull left and right switch control harnesses through
handlebar.
1
13. Unwrap electrical tape and wire from terminals.
14. Repair or replace switches and socket wires as necessary.
See the service manual for handlebar switch repair pro-
2 cedures.
sm04670
1. Groove
2. 5/32 in. (4 mm) thick cardboard insert 1
Figure 2-17. Cardboard Insert 2
DISASSEMBLY 5
3 4
1. See Figure 2-18. Cut and discard cable straps.
2. Separate heated handgrip interconnect harness connector
[206] (4). 1. LH switch control connector [24] (gray)
3. Remove terminals and wire leads from handlebar switch 2. Boot (2)
connectors [22, 24] and twist grip sensor (TGS) connector 3. Heated handgrip power connector [189]
[204]. See service manual for service procedures. 4. Heated handgrip interconnect connector [206]
5. RH switch control connector [22] (black)
4. Remove terminals and wire leads from heated handgrip 6. Twist grip sensor connector [204]
power connector [189] (3) and interconnect harness con-
nector [206] (4). See the service manual for service pro- Figure 2-18. Handlebar Harness Assembly
cedures.
5. Slide boots (2) off switch control wiring harnesses. Save ASSEMBLY
boots for assembly.
Pull Wire Leads
6. Wrap terminal ends of each wiring harness tightly in elec-
trical tape to protect terminals from damage as harness NOTES
is removed from handlebar. • If mechanics wire remains in handlebars, attach wire lead
NOTES bundles and pull mechanic's wire to draw wire leads back
• Forming too large a bulge with electrical tape at end of through handlebars. and out center of handlebar. Carefully
wiring harness can make it difficult to extract harness from remove mechanic's wire to avoid damage to terminals.
handlebar. • Liquid glass cleaner may be used to aid in pulling wires
• Option: Attach mechanic's wire to the terminal/wire leads. through conduit.
After drawing the leads through the handlebar, remove • Make sure grommets are in place in oval holes near each
the tape and leads. Leave the mechanic's wire in the end of handlebar before feeding harnesses into handlebar.
handlebar for installation.
• It is best to pull all the harnesses for one end of handlebar
7. Remove fasteners securing left and right switch control at a time. However, if you wish to pull only one harness
housing halves to handlebar.
NOTE
To release twist grip, a slight tug may be necessary.
8. Pull right grip off end of handlebar.

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at a time, pull smaller harnesses first, then larger har-

sm03974
nesses.
• As you pull on wire leaders, assist the process by gently
feeding harnesses into handlebar at other end.
• If resistance is felt, do not pull too hard on wire leader as
this may damage wires and/or terminals, or dislodge leader
from harness.
1. Cut five lengths of mechanic's wire, each approximately
3 ft (91.4 cm) long. These will be used as harness wire
leaders.
2. Feed two wire leaders through grommeted hole near left
end of handlebar and one wire leader through left end of
handlebar tube.
3. Feed one wire leader through grommeted hole near right
end of handlebar and one wire leader through right end
of handlebar tube.
4. Extract ends of all wire leaders through center hole. Secure
leaders at center hole so they cannot be accidentally pulled Figure 2-19. Wire Leader through Grommet at Hand Grip
back through handlebar. End of Handlebar
5. Make sure grommets are installed in oval holes near each
end of handlebar.
6. Secure each wire leader to its harness at ends of sm03976
handlebar as follows. Neatly wrap socket terminals and
wires of each harness with a few twists of the leader wire:
a. Left side: Attach wire leader extending from left end
of handlebar tube to left handgrip interconnect har-
ness. Attach other two wire leaders (extending from
grommeted hole near left end of handlebar), one to
left switch control harness and the other to left hand-
grip power harness.
b. Right side: Tape right handgrip interconnect harness
terminals to TGS harnesses. Attach wire leader
extending from right end of handlebar tube to TGS
harness. Attach other wire leader (extending from
grommeted hole near right end of handlebar) to right
switch control harness.
7. Wrap wires and terminals of each harness tightly with

electrical tape to protect wires and terminals when
installing harnesses in handlebar.
Figure 2-20. Wire Leader through Center of Handlebar
Grommets in each of the wiring holes in the handlebar Install Switch Housings
must remain in position after routing the wiring through
the handlebar. Operation without the grommets in place 1. See Figure 2-21 and Figure 2-22. Orient wires in switch-
can damage wires, causing a short circuit which could housings:
result in death or serious injury. (00416d) a. Right hand side: the RUN and STOP wires are
8. Lubricate wire conduits with glass cleaner. Grasp end of wrapped over the front of the handlebar, back and
wire leader and gently pull wire bundles through grommets into the handlebar through the grommet. Make sure
and handlebar ends to the handlebar center hole. Pull the wires run outboard of the clamping post cast into
harnesses until left heated handgrip and TGS are fully the inside of the lower housing.
seated on ends of handlebar, and no excess slack exists b. Left hand side: the HORN and HI/LO BEAM wires are
in switch control harnesses. also wrapped over the front of the handlebar, back
and into the handlebar through the grommet. Make
sure the wires run inboard of the clamping post cast
into the inside of the lower housing.

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2. Loosely install left and right switch housings onto

sm03978
handlebar and over inboard ends of heated handgrips.
3. Gently pull on wire leaders to remove any excess slack in
harnesses. Unwrap tape and mechanic's wire.
4. See Figure 2-18. Secure wire harnesses at exit from center 2
of handlebar with cable strap. 1
5. Install boot (2) on each switch control harness. Secure
with cable strap.
6. Fit wire seal into back of Deutsch socket housings. See 4
APPENDIX B DEUTSCH ELECTRICAL CONNECTORS 3
in the service manual. 5
sm03977
1. Right turn signal control and wiring

2. Cruise control switch
3. Mode select switch
4. Lower bracket
5. Clamping post
Figure 2-22. Wiring in Lower Right Hand Control Housing
Install Connector Housings

1. Following color codes in Table 2-6, Table 2-7 and
Table 2-8, insert terminals into numbered chambers in
connector housings.
NOTE
See the service manual for connector assembly guidelines.
2. Gently tug on wire ends to verify that all terminals are
locked.
3. See Figure 2-18. Mate handgrip interconnect harness
connectors [206]. Secure interconnect harness connector
assembly (4) to right hand switch control harness with
cable strap.
Figure 2-21. Run/Stop Switch Wiring in Upper Right Hand 4. Pull slack from harnesses and secure together with a cable
Control Housing strap where harnesses exit center of handlebar.

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1. Set handlebar on lower clamps and loosely install upper

Table 2-6. Handlebar Switch Connectors handlebar clamp and fasteners. Position wires so they exit
under radio to front of vehicle from between risers.
LH CONNECTOR [24] RH CONNECTOR [22]
(16-WAY, GRAY) (12-WAY, BLACK)
WIRE COLOR CAVITY NO. WIRE COLOR CAVITY NO.
O/W 1 O/W 1 Using excessive force to adjust handlebar can result in
damage to handlebar or clamp. (00444b)
Y 2 R/BE 2
2. Center handlebar laterally (sideways) in clamps.
BE 3 GY 3
W 4 W/BK 4 3. Snug front fasteners until upper clamp contacts lower
clamps.
W/V 5 W/BN 5
4. Position handlebar for rider comfort.
BK/R 6 BK/R 6
V/BK 7 BN/W 7 5. See Figure 2-23. In sequence shown, tighten fasteners to
16-20 ft-lbs (20.3-27.1 Nm).
BN/BK 8 GY/W 8
6. Route wire harness and mate left [24] and right [22] con-
PK/W 9 PK/W 9
nector socket and pin housings.
GN/BE 10 V/BK 10
7. See Figure 2-16. Mate heater and TGS connectors to main
GY/GN 11 W/BE 11 harness.
BK 12 BE/BK 12
8. Secure with cable straps as necessary.
V/BK 13 - -
O/BK 14 - -
sm04495
- 15 - -
- 16 - - 4 1
3
Table 2-7. Left Heated Hand Grip Connectors
INTERCONNECT [206] MAIN POWER [189]

(2-WAY, BLACK) (3-WAY, BLACK)
2
BK 1 O/W A
W 2 R B
- - BK C
Table 2-8. Twist Grip Sensor (TGS) Connectors
INTERCONNECT [206] TGS [204]

WIRE CAVITY WIRE CONDUIT CAVITY
COLOR NO. COLOR COLOR NO.
BK 1 BK Y 1 Figure 2-23. Handlebar Top Clamp Torque Sequence
W 2 W Y 2
- - R Y 3 Assemble Brake Controls
- - BK BK 4 1. Remove right switch housing fasteners.
- - W BK 5 2. Install throttle control grip and connect heated handgrip
- - R BK 6 connector to twist grip sensor. See 2.9 HANDGRIPS.
INSTALLING HANDLEBARS
Clamp Handlebars to Risers Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
Improperly aligned handlebars or components can contact in place may result in damage to the rubber boot and
the fuel tank when turned to the left or right. Contact with plunger on the front stoplight switch. (00324a)
the fuel tank can cause cosmetic damage. (00372b)

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3. Assemble switch housing halves to handlebar and brake

sm04496a
lever bracket:
a. Position upper switch housing so wire conduit wraps
around outside of handlebar and sets in clearance at
bottom of handlebar.
b. Verify that wires will not be pinched when fasteners
are tightened. 2
c. Verify that throttle works freely.
1
d. Install switch housing fasteners.
4. Loosely assemble handlebar clamp to front brake control

lever bracket master cylinder and reservoir:
2
a. Engage tab on switch with notch at top of brake lever
bracket.
b. Alternately tighten housing and bracket fasteners until
all components fit and wires route without interference.
Fasteners should only be snug.
c. Verify housing and bracket clamp are tight against
handgrip shoulder/edge of bar. 1. Clamping surface
2. Range marks
5. See Figure 2-24. The assembly can be rotated slightly Figure 2-24. Right Hand Control Assembly to Handlebar
for rider comfort. However, the clamp mating surface (1)
must be positioned between the two range marks (2) on
the bottom of the handlebar. Assemble Clutch Controls
1. Remove loosely installed switch control housing fasteners.
2. Loosely assemble clutch master cylinder/reservoir and
Control wiring is routed inside handlebar and may be clamp to handlebar. Alternately tighten fasteners until
pinched or cut if controls are rotated too far. Electrical clamp is snug to bracket.
damage to control wiring can result. (00571b)
3. Install switch housing:
6. Squeeze front brake lever and remove cardboard insert
between brake lever and bracket. a. Position upper switch housing so wire conduit wraps
around front of handlebar.
7. Tighten control lever clamps beginning with top fastener
to 72-108 in-lbs (8.1-12.2 Nm). The gap, if any must be b. Verify wires will not be pinched when fasteners are
at clearance flat on handlebar. tightened.
8. Tighten switch housing halves beginning with bottom c. Position upper switch housing so wire conduit sets in
fastener to 35-45 in-lbs (4.0-5.1 Nm). Rear gap, if any, clearance at bottom of handlebar, and upper harness
should be tighter. will not be pinched when fasteners are tightened.
d. Engage lower switch housing tab with notch in clutch
master cylinder/reservoir.
4. Install but do not tighten switch housing fasteners.

5. See Figure 2-25. The switch housing and clutch master
cylinder assembly can be rotated slightly for rider comfort.
However, the clamp mating surface (1) must be positioned
between the two range marks (2) on the bottom of the
handlebar.
Control wiring is routed inside handlebar and may be

pinched or cut if controls are rotated too far. Electrical
damage to control wiring can result. (00571b)
6. Tighten clutch master cylinder/reservoir clamp beginning
with top fastener to 72-84 in-lbs (8.1-9.5 Nm). Top gap,
if any, must be at handlebar clearance.

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7. Tighten turn signal and cruise control housings beginning 2. With motorcycle upright and with front fork pointed straight
with bottom fastener to 35-45 in-lbs (4.0-5.1 Nm). Rear ahead, adjust mirrors.
gap, if any, should be tighter.
NOTE
Adjust mirrors so a small portion of riders' shoulder is visible
sm03982b in each mirror. This visually establishes the distance of vehicles
to rear of motorcycle.
3. Install outer fairing and fairing cap according to procedure
in service manual.
4. Install ignition/fork lock knob. If equipped with power lock
1 ignition knob, see 7.9 IGNITION/FORK LOCK KNOB.
5. Install main fuse, left side cover and left saddlebag.
2
6. Test clutch lever and front brake lever for pressure and
operation.
7. Test for correct throttle operation.
2 8. Verify brake and clutch fluid line routing.
Be sure that all lights and switches operate properly before

operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
1. Clamping surface
2. Range marks 9. Turn ignition/light key switch to IGNITION and test switches
for operation.
Figure 2-25. Left Hand Control Assembly to Handlebar
RETURNING TO SERVICE After repairing the brake system, test brakes at low speed.
1. Verify routing of wire conduits, brake line and clutch fluid If brakes are not operating properly, testing at high speeds
line. See 2.12 CLUTCH FLUID LINE and FRONT BRAKE can cause loss of control, which could result in death or
LINE in the service manual. serious injury. (00289a)
10. Apply brake lever to test stop lamp.

HOME
HANDGRIPS 2.9
GENERAL 8. See Figure 2-27. Slide handgrip off end of handlebar.
Grasp handgrip interconnect (2) and power (1) harnesses
For electrical diagnostics, see 7.8 HEATED HANDGRIPS. and gently pull harness leads from handlebar.
PREPARING MOTORCYCLE NOTES
1. Remove main fuse. • See Figure 2-27. Note that power harness (1) feeds from
same hole in handlebar as switch control harnesses.
2. Remove ignition/fork lock knob. See 7.9 IGNITION/FORK
Handgrip interconnect harness (2) feeds from end of
LOCK KNOB.
handlebar.
3. Remove outer fairing and fairing cap. See service manual.
• Only pull far enough so that harness is completely free of
NOTE handlebar. Make sure free end of wire leader is still pro-
truding from center hole in handlebar.
It is not necessary to remove the handlebars from the motor-
cycle to replace the handgrips.
sm04670
SEPARATING CONNECTORS
1. See Figure 2-26. Cut cable straps. 6
2. Unplug interconnect harness connector [206] (4).
3. Left handgrip: Unplug power connector [189] (3).
1
4. Right handgrip: Unplug TGS connector [204] (6).
2
REPLACING HANDGRIPS
NOTES
5
• Left Handgrip: Remove terminals and wire leads from 3 4
the handgrip interconnect [206B] connector and the power
harness connector [189].
• Right Handgrip: No harnesses need to be removed to 1. LH switch control connector [24] (gray)
replace the right handgrip. For twist grip sensor (TGS) 2. Boot (2)
replacement, see 7.19 TWIST GRIP SENSOR (TGS). 3. Heated handgrip power connector [189]
4. Heated handgrip interconnect connector [206]
Remove Left Handgrip
5. RH switch control connector [22] (black)
1. Remove radio, CB and XM satellite components as an 6. Twist grip sensor connector [204]
assembly. See 7.16 ADVANCED AUDIO RADIO.
Figure 2-26. Handlebar Harness Assembly
2. Remove terminals and wire leads from connectors [206]
and [189]. See service manual for connector service
guidelines.
3. Attach a leader made of mechanic's wire, approximately sm03986
3 ft (91.4 cm) long, to each harness. Neatly wrap two or 2

three turns of leader around terminals and wire leads of
the harnesses, and wrap junction with electrical tape,
covering terminals and end of wire leader.
4. Bend free end of each wire leader into an "L" shape to
prevent leader from being pulled too far into the handlebar.
5. Remove clutch master cylinder assembly and suspend
out of the way. 1
6. Remove fasteners securing left switch housing to
handlebar. Carefully separate housings from handlebar.
7. Apply glass cleaner to harnesses to act as a lubricant.
1. Power harness
NOTE
2. Handgrip interconnect harness
When pulling harness leads, gently feed opposite end of har-
ness leads and mechanic's wire into center hole of handlebar. Figure 2-27. LH Heated Handgrip

HOME
Install Left Handgrip sm03988
1. Attach wire leaders to leads of new harnesses. Make sure

electrical tape wrap extends over end of harness conduit.
2. Lubricate wire harness conduits with glass cleaner.
3
3. Grasp end of each wire leader and carefully pull harnesses

through handlebar.
NOTE 1
Feed harnesses into handlebar with one hand as you pull on
the leaders with the other.
4. Slide handgrip onto end of handlebar and pull slack from
wiring harnesses.
5. Remove electrical tape and wire leaders from harnesses.
6. Refer to Table 2-9. Match wire lead color to cavity number
and insert wire lead terminals into connector housing 2
cavities.
1. Rim of handgrip
NOTE 2. Switch housing grooves
For DEUTSCH connector service, see service manual. 3. Power harness
7. Orient wires in switch-housings. The horn and HI/LO beam Figure 2-28. Mounting LH Handgrip
wires are also wrapped over the front of the handlebar,
and into the handlebar through the grommet. Make sure
the wires run inboard of the clamping post cast into the
inside of the lower housing. sm03989
8. See Figure 2-28. Install switch housings onto handlebar

and over inboard end of handgrip. Make sure rim (1) of
handgrip fits into grooves (2) in switch housings. Loosely
install fasteners.
9. See Figure 2-29. Orient handgrip so that power harness
fits in notch in lower switch housing groove. Be careful not
to pinch harness.
NOTE
Control wiring is routed inside the handlebar and may be
pinched or cut if controls are rotated too far.
10. See Figure 2-30. Install clutch master cylinder. Align for
operator comfort with clamping surface (1) located within
the range marks (2) stamped into the handlebar. Beginning Figure 2-29. Notch for Power Harness
with upper fastener, tighten fasteners to 72-84 in-lbs (8.1-
9.5 Nm).
11. Install radio, CB and XM satellite components as an
assembly. See 7.16 ADVANCED AUDIO RADIO.
12. Tighten switch housing fasteners to 35-45 in-lbs (4.0-5.1
Nm).
Table 2-9. Left Heated Hand Grip Connectors
INTERCONNECT [206] MAIN POWER [189]

BK 1 O/W A
W 2 R B
- - BK C

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sm03982b sm04667
1
2
2
2
1. Groove
2. 5/32 in. (4 mm) thick cardboard insert
Figure 2-31. Cardboard Insert
1. Clamping surface
2. Range marks Install Right Handgrip
Figure 2-30. Left Hand Control Assembly to Handlebar 1. See Figure 2-32. Verify twist grip sensor is properly
installed in end of handlebar.
2. Remove end cap (1) from handgrip.
Remove Right Handgrip
3. Press handgrip onto twist grip sensor and handlebar until
it is seated. Rotate handgrip to verify proper engagement.
4. Using needle nose pliers, reach through the hole in the
Do not remove or install the master cylinder assembly end of the handgrip and insert prongs of connector (2) into
without first positioning a 5/32-inch (4 mm) thick insert connector holes (3) located in end of twist grip sensor.
between the brake lever and lever bracket. Removing or Install end cap (1).
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a) sm04677
1. See Figure 2-31. Squeeze front brake lever and insert a

5/32 in. (4 mm) thick cardboard insert between front brake
lever and lever bracket.
2. Remove master cylinder and front brake lever and suspend 3
out of the way.
3. Remove fasteners securing right switch control housing
halves to handlebar. 1
NOTE 2
To remove the throttle handgrip, a slight tug may be necessary.
4. Separate switch housings and pull handgrip off end of
handlebar.
1. End cap
2. Heated grip connector
3. Receptacle in TGS
Figure 2-32. Right Handgrip Heater Connector

HOME
5. Assemble right switch control housing halves:

sm04496a
a. Position upper switch housing so wire conduit wraps
around outside of handlebar and sets in clearance at
bottom of handlebar.
b. Verify that wires will not be pinched when fasteners
are tightened.
c. Install switch housing fasteners finger tight. 2
d. Verify that throttle works freely. 1
6. Loosely install front brake master cylinder and reservoir:
a. Engage tab on switch with notch at top of brake lever
bracket. 2
b. Tighten housing and bracket fasteners until all com-
ponents fit and wires route without interference.
Fasteners should only be snug.
NOTE
Control wiring is routed inside the handlebar and may be
pinched or cut if controls are rotated too far. 1. Clamping surface
7. Tighten switch housing fasteners beginning with bottom 2. Range marks
fastener. Rear gap, if any, should be tighter. Figure 2-33. Right Hand Control Assembly to Handlebar
a. Push handgrip inboard compressing spring action of
TGS. Hold switch housing outboard against grip.
b. See Figure 2-33. Adjust brake master cylinder
MATING CONNECTORS
assembly for rider comfort. Make sure assembly is 1. Mate heated handgrip power connector [189] housings
positioned so that clamp mating surface (1) is located and interconnect harness connector [206] housings.
in area between range marks (2).
2. Install handgrip interconnect harness cable strap and
c. Hold switch housing outboard against grip. harness bundle cable strap.
d. While holding switch housing in place, release hand- RETURNING TO SERVICE
grip and tighten switch housing screws to 35-45 in-
lbs (4.0-5.1 Nm). 1. Install fairing cap and outer fairing. See service manual.
e. Release handgrip and verify free rotation and slight 2. Install ignition/fork lock knob. If equipped with power lock
inboard-outboard free play. ignition knob, see 7.9 IGNITION/FORK LOCK KNOB.
8. Tighten master cylinder clamp beginning with top fastener 3. Install main fuse, left sidecover and left saddlebag.
to 72-108 in-lbs (8.1-12.2 Nm). The gap, if any must be
at clearance flat on handlebar.
9. Squeeze front brake lever and remove cardboard insert. Be sure that all lights and switches operate properly before
Check operation of brake light while squeezing brake lever. operating motorcycle. Low visibility of rider can result in
10. Verify throttle operates freely. death or serious injury. (00316a)
4. Test heated handgrips and handlebar switches for opera-
tion.

HOME
CLUTCH MASTER CYLINDER AND RESERVOIR 2.10

GENERAL
The clutch is hydraulically actuated. Squeezing the clutch hand
lever causes the clutch master cylinder to apply pressure via Be sure no clutch fluid gets on tires, wheels or brakes
the clutch fluid in the clutch line to the secondary clutch actuator when draining fluid. Traction can be adversely affected,
mounted in the clutch release cover. The secondary clutch which could result in loss of control and death or serious
actuator piston extends and contacts the clutch release bearing injury. (00295a)
which disengages the clutch.
A bleeder valve at the secondary clutch actuator is used to
bleed air from the clutch line. D.O.T. 4 HYDRAULIC BRAKE D.O.T. 4 brake fluid will damage painted and body panel
FLUID (Part No. 99953-99A) is used in the clutch system and surfaces it comes in contact with. Always use caution and
is referred to as clutch fluid in this manual. protect surfaces from spills whenever brake work is per-
Check the clutch fluid level in the clutch fluid reservoir on left formed. Failure to comply can result in cosmetic damage.
handlebar. If the sight glass is dark, the fluid level in the (00239b)
reservoir is above the sight glass prism and the reservoir is Do not wipe any spilled brake fluid off of finished surfaces.
full. If the sight glass appears clear, the fluid level is below the Always flush the affected components with water (not soapy).
sight glass prism and the fluid level should be checked. Clutch
fluid should be level with the internal shelf marked FILL LEVEL NOTE
with the motorcycle upright and the gasket surface level. Place a large cup under the banjo fitting. Hydraulic fluid will
begin draining from the reservoir as the banjo bolt is removed.
4. Slowly loosen banjo bolt (9) and allow clutch fluid from
reservoir to drain into cup.
D.O.T. 4 hydraulic brake fluid is used in the hydraulic
clutch. Do not use other types of fluids as they are not NOTE
compatible and could cause equipment damage. (00353a) Dispose of clutch fluid in accordance with local regulations.
NOTE 5. Remove banjo bolt (9) and two steel/rubber washers (8).
Discard steel/rubber washers.
Clutch fluid volume in reservoir actually increases with clutch
wear. Do NOT overfill clutch reservoir. NOTE
To prevent the rest of the clutch fluid from draining from the
REMOVAL clutch line and secondary clutch actuator, support the banjo
1. Loosen left handlebar switch housing fasteners. fitting and clutch fluid line upright.
6. Remove master cylinder clamp screws and remove clutch
master cylinder/reservoir assembly.

2. See Figure 2-34. Loosen, but do not remove, fasteners
(1) that secure handlebar clamp to clutch master cyl-
inder/reservoir.
3. Loosen both cover screws (2) to relieve pressure in master
cylinder/reservoir.
Direct contact of D.O.T. 4 brake fluid with eyes can cause

irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

HOME
4. See Figure 2-34. If necessary, push the sight glass (10)

sm06888
2 3 into the reservoir to remove. Remove and discard O-ring
4 (11).
5
1
11 Use denatured alcohol to clean clutch system components.
Do not use mineral-based solvents (such as gasoline or
10 paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause clutch failure, which could result in death or serious
7 injury. (00296a)
9 8 6
5. Inspect the cover, sight glass, and gasket for cuts, tears
or general deterioration.
1. Clamp screw ASSEMBLY
2. Cover screws
3. Cover 1. See Figure 2-34. If removed, install sight glass (10) using
4. Pivot pin a new O-ring (11) lubricated with brake fluid or brake cyl-
5. Bushing inder assembly lubricant.
6. Clutch hand lever assembly 2. Install cover with new gasket on master cylinder/reservoir,
7. Retaining ring but do not tighten screws.
8. Steel/rubber washers
9. Banjo bolt
10. Sight glass
11. O-ring Wear safety glasses or goggles when removing or
Figure 2-34. Clutch Master Cylinder/Reservoir installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
DISASSEMBLY 3. Install clutch hand lever, pivot pin, and a new retaining
ring.
INSTALLATION
1. See Figure 2-35. Attach master cylinder/reservoir to
handlebar. Orient lever to rider position, with clamping
surface joint (1) within range marks (2) in handlebar.
Tighten clamp fasteners to 72-84 in-lbs (8.1-9.5 Nm).
NOTE
The master cylinder internal components cannot be serviced 2. Tighten handlebar switch housing screws to 35-45 in-lbs
individually. If a failure of the master cylinder piston assembly (4.0-5.1 Nm).
occurs, the master cylinder/reservoir assembly must be
replaced.
1. Remove master cylinder cover and gasket. Turn housing Avoid leakage. Be sure gaskets, banjo bolt(s) and clutch
upside down to remove remaining clutch fluid from reser- line are clean and undamaged before assembly. (00329a)
voir.
3. Attach banjo fitting to master cylinder using new
steel/rubber washers. Tighten banjo bolt finger tight.
Wear safety glasses or goggles when removing or

installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause D.O.T. 4 brake fluid will damage painted and body panel
serious eye injury. (00312a) surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
2. See Figure 2-34. Remove retaining ring (7) from pivot pin formed. Failure to comply can result in cosmetic damage.
(4). (00239b)
NOTE 4. Fill reservoir with D.O.T. 4 HYDRAULIC BRAKE FLUID
To remove piston spring load from the pivot pin, gently force (Part No. 99953-99A).
the clutch lever toward the piston (as if operating the clutch).
5. Loosen bleeder valve and allow fluid to fill clutch line until
3. Remove pivot pin (4) and clutch lever. a steady flow of clutch fluid flows from bleeder valve.
Finger tighten bleeder valve.

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6. Bleed clutch line. See 2.13 BLEEDING CLUTCH FLUID

sm04496a
LINE.
7. Verify that fluid level in clutch fluid reservoir is at FILL
LEVEL with motorcycle upright and gasket surface level.
NOTE
wear. Do NOT overfill clutch reservoir. 2
8. Verify operation by squeezing clutch hand lever.
1
9. Tighten fasteners as follows:
a. Banjo bolt to 12.5-14.5 ft-lbs (16.9-19.7 Nm).
b. Bleeder screw to 12-15 in-lbs (1.4-1.7 Nm). 2
c. Reservoir cover screws to 8-10 in-lbs (0.9-1.1 Nm).
10. Test clutch operation.
1. Clamping surface
2. Range marks
Figure 2-35. Right Hand Control Assembly to Handlebar

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CLUTCH HAND LEVER 2.11

1. See Figure 2-36. Lightly grease pivot bushing (5) and
install into clutch hand lever pivot hole. Position bushing
until it is flush with both sides of lever.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro- NOTE
ceeding. (00251b) If the clutch master cylinder/reservoir is full of clutch fluid under
pressure, it may be necessary to apply force to the hydraulic
1. Remove the main fuse.
piston in order to align the clutch hand lever and to allow the
pivot pin to be inserted.
2. Orient clutch lever in lever mounting bracket. Insert pivot
Wear safety glasses or goggles when removing or pin (2) from top.
installing retaining rings. Retaining rings can slip from the
serious eye injury. (00312a)
2. See Figure 2-36. Remove the retaining ring (1) from the Wear safety glasses or goggles when removing or
pivot pin (2). installing retaining rings. Retaining rings can slip from the
3. Remove pivot pin and lever. serious eye injury. (00312a)
4. Remove pivot bushing (5). 3. Install new retaining ring (1).
NOTE 4. Install main fuse.
Roller pin (3), bushing cups (4), anti-rattle spring and screw
5. Verify clutch lever operation.
(6) are only available as part of the replacement handle kit and
not serviced separately.
sm06889
2
5
1
3
4
6
1. Retaining ring
2. Pivot pin
3. Roller pin
4. Bushing cups
5. Pivot bushing
6. Anti-rattle spring and screw
Figure 2-36. Clutch Hand Lever

HOME
CLUTCH FLUID LINE 2.12

REMOVAL 2. Loosely secure line to clutch master cylinder using banjo
bolt and new washers.
1. Remove outer fairing. See the service manual for pro-
cedure.
sm03996a
3
Be sure no clutch fluid gets on tires, wheels or brakes
when adding fluid. Traction can be adversely affected, 2
which could result in loss of control and death or serious
injury. (00294a)
D.O.T. 4 brake fluid will damage painted and body panel 1

surfaces it comes in contact with. Always use caution and
formed. Failure to comply can result in cosmetic damage.
(00239b) 1. Flare nut
2. Clutch fluid line
NOTE 3. Clutch release cover
Never wipe spilled brake fluid off finished surfaces. Always
Figure 2-37. Clutch Flare Nut and Fluid Line
flush the affected components with plenty of clear water without
soap.
2. Loosen the clutch master cylinder/reservoir cover.
sm03997
3. See Figure 2-37. Place a suitable container under clutch
release cover (3).
NOTE
Make a note of the locations of all cable straps that secure the
brake line, for reference during assembly.
4. Loosen flare nut (1) and allow clutch fluid to drain.
5. Remove flare nut from clutch release cover.
NOTE
Dispose of clutch fluid in accordance with local regulations.
6. See Figure 2-38. Remove and discard O-ring.
NOTE
Clutch fluid line O-ring may remain inside the clutch release
cover. Use a non-metallic pick to remove old O-ring and other
debris.
7. See Figure 2-39. Remove banjo bolt (5) and two washers
(4). Discard washers.
8. See Figure 2-40. Carefully pull banjo fitting end of clutch
fluid line out through inner fairing grommet.
9. See Figure 2-41. Remove two clamps along right side
frame down tube. Figure 2-38. Clutch Fluid Line O-ring
10. See Figure 2-42. Cut cable strap securing clutch fluid line
to brake line. 3. See Figure 2-41. Route clutch fluid line down right side
11. Note line routing and remove clutch fluid line. frame tube, behind rear master cylinder and above foot-
board mounting bracket, to clutch release cover.
INSTALLATION 4. Install new O-ring on end of clutch fluid line.
1. See Figure 2-40. Route clutch fluid line through fairing
5. Install flare nut to clutch release cover and finger tighten.
grommet retracing original path of line.

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6. See Figure 2-42. Secure clutch fluid line at original loca-

sm04000b
tions along lower frame tube using new cable straps. Verify
there is no contact with the exhaust system or any other
items that might result in damage.
7. See Figure 2-41. Secure line with two clamps along right
side frame down tube and tighten fasteners.
a. Engine guard bolt to 15-20 ft-lbs (20.3-27.1 Nm).
b. Clutch fluid line clamp bolt to 96-120 in-lbs (10.8-13.6
Nm).
8. Fill and bleed clutch fluid system. See 2.13 BLEEDING

CLUTCH FLUID LINE.
sm04675
4
1
Figure 2-41. Clamp Locations on Frame Down Tube
(typical)
2
5 3
sm04001a
1. Clutch lever
2. Clutch master cylinder/reservoir
3. Clutch fluid line assembly
4. Banjo bolt washer (2)
5. Banjo bolt
Figure 2-39. Clutch Master Cylinder Assembly and Fluid
Line
sm03999 Figure 2-42. Cable Strap Location Around Clutch Fluid

Line
Figure 2-40. Clutch Fluid Line Inner Fairing Grommet

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BLEEDING CLUTCH FLUID LINE 2.13

DRAINING AND FILLING 9. Fill clutch master cylinder/reservoir with D.O.T. 4
HYDRAULIC BRAKE FLUID (Part No. 99953-99A). Initial
fluid level should not exceed FILL LEVEL with reservoir
in a level position.
Be sure no clutch fluid gets on tires, wheels or brakes NOTE
when adding fluid. Traction can be adversely affected, The shelf life of a bottle of unopened D.O.T. 4 HYDRAULIC
which could result in loss of control and death or serious BRAKE FLUID is one year. The shelf life of an uncontaminated
injury. (00294a) bottle that has been resealed is one week.
10. Bleed master cylinder. See 2.13 BLEEDING CLUTCH
FLUID LINE, Bleed Clutch Master Cylinder.
Direct contact of D.O.T. 4 brake fluid with eyes can cause 11. Bleed clutch fluid line and secondary actuator. See
irritation. Avoid eye contact. In case of eye contact flush 2.13 BLEEDING CLUTCH FLUID LINE, Bleed Fluid Line
with large amounts of water and get medical attention. and Actuator.
tion. Use in well ventilated area. KEEP OUT OF REACH OF sm03946
CHILDREN. (00240a)
D.O.T. 4 brake fluid will damage painted and body panel

formed. Failure to comply can result in cosmetic damage.
(00239b)
Do not wipe any spilled brake fluid off of finished surfaces.
Always flush the affected components with water (not soapy).
Do not allow dirt or debris to enter the master cylinder Figure 2-43. Actuator Bleeder Valve
1. Cover exhaust with towel and place a suitable pan under
sm03996a
clutch release cover to catch excess clutch fluid.
3
2. See Figure 2-43. Remove plastic cap and loosen bleeder
valve.
3. Run hose from bleeder valve to pan. 2
4. Loosen the clutch master cylinder/reservoir cover.
5. Allow clutch fluid to drain into pan.
6. See Figure 2-44. Remove flare nut (1) on outside of the
clutch release cover. Discard O-ring and drain fluid line
1
(2) into pan.
NOTE
Dispose of clutch fluid in accordance with local regulations.
1. Flare nut
7. Hand tighten valve and replace cap. 2. Clutch fluid line
3. Clutch release cover
8. Install clutch line flare nut with a new O-ring and tighten
to 72-120 in-lbs (8.1-13.6 Nm). Figure 2-44. Clutch Flare Nut and Fluid Line
NOTE
When filling an empty clutch fluid line, a Snap-on Basic Vacuum
Brake Bleeder with a fitting that mates to the secondary actu-
ator bleeder valve can be used to initially draw the fluid down
the clutch line.

HOME
BLEED CLUTCH MASTER CYLINDER 4. Fill reservoir to FILL LEVEL and repeat the previous step
three times or more until only a steady flow of clutch fluid
NOTE escapes banjo fitting and fluid level in reservoir is at FILL
Clutch fluid volume in reservoir actually increases with clutch LEVEL with motorcycle in an upright position.
wear. Do NOT overfill clutch reservoir.
BLEED FLUID LINE AND ACTUATOR
1. Stand motorcycle upright. Turn handlebars to level reser-
voir. 1. While holding reservoir cover in place:
a. Pump clutch hand lever 5 times.
2. Add D.O.T. 4 HYDRAULIC BRAKE FLUID (Part No.
99953-99A) to clutch master cylinder/reservoir. Initial fluid b. Hold clutch hand lever against handlebar.
level should not exceed FILL LEVEL with reservoir in a
c. Run hose from bleeder valve to suitable container.
level position.
d. Loosen actuator bleeder valve.
NOTE
e. Watch bleeder valve for air bubbles.
The shelf life of a bottle of unopened D.O.T. 4 HYDRAULIC
BRAKE FLUID is one year. The shelf life of an uncontaminated f. Tighten bleeder valve.
bottle that has been resealed is one week.
g. Release clutch hand lever.
NOTE
D.O.T. 4 brake fluid will damage painted and body panel
wear. Do NOT overfill clutch reservoir.
protect surfaces from spills whenever brake work is per- 2. With reservoir level, fill reservoir to FILL LEVEL and repeat
formed. Failure to comply can result in cosmetic damage. the previous step three times or more until only a steady
(00239b) flow of clutch fluid escapes bleeder valve and fluid level
in reservoir is at FILL LEVEL with motorcycle in an upright
Do not wipe any spilled brake fluid off of finished surfaces.
position.
Always flush the affected components with water (not soapy).
NOTE RETURN MOTORCYCLE TO SERVICE
Loosen banjo bolt only enough to allow air bubbles to escape. 1. Test pressure by squeezing clutch hand lever.
Clutch fluid under pressure can squirt a steady stream several
feet. 2. Tighten fasteners as follows:
a. Clutch master cylinder banjo bolt to 12.5-14.5 ft-lbs
3. While holding reservoir cover in place:
(16.9-19.7 Nm).
a. Pump clutch hand lever 5 times.
b. Clutch line flare nut to 72-120 in-lbs (8.1-13.6 Nm).
b. Hold clutch hand lever against handlebar.
c. Actuator bleeder valve to 12-15 in-lbs (1.4-1.7 Nm).
c. Hold shop towel under fitting and loosen master cyl-
inder banjo bolt. d. Reservoir cover screws to 8-10 in-lbs (0.9-1.1 Nm).
d. Watch banjo fitting for air bubbles. 3. Remove hose from bleeder valve and replace protective
cap.
e. Retighten banjo fitting.
4. Test ride motorcycle. Incorrect pressure or fluid level can
f. Release hand lever.
cause a dragging clutch or hard shifting.

HOME
SEAT 2.14
GENERAL
sm05893
This model is equipped with a heated seat. Individual controls,
mounted on left side of seat, provide warmth to the rider seat
and passenger pillion separately. For electrical diagnostics,
see 7.7 HEATED SEAT.
NOTE
Heater elements are not serviceable. If heater fails, seat must
be replaced.
REMOVAL 1
1. Remove rider backrest. See 2.15 RIDER BACKREST.
2. Remove left saddlebag. See 2.18 SADDLEBAGS.
3. See Figure 2-45. Remove fastener with flat washer holding
one side of passenger grabstrap.
4. Remove screw securing seat mounting bracket to rear
fender.
5. See Figure 2-46. Slide seat backward to free slot (1) on
bottom front of seat from tongue on rear fuel tank bracket.
6. See Figure 2-47. Disconnect seat heater harness con-
nector [191]. Remove seat.
sm05891 2
1. Seat bottom slot

2. Fuel tank rear bracket tongue
Figure 2-46. Seat Mounting
sm04121a
Figure 2-45. Seat Strap Bracket Screw
Figure 2-47. Heated Seat Connector [191]

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CLEANING AND INSPECTION INSTALLATION

1. See Figure 2-47. Set seat on frame. Plug in seat heater
harness connector [191]. Tuck harness down into frame
cavity. Make sure harness will not be pinched between
Do not use bleach or detergents containing bleach on
seat pan and vehicle frame.
saddlebags, seats, tank panels or painted surfaces. Doing
so can result in equipment damage. (00229a) 2. See Figure 2-46. Slide seat forward until tongue (2)
engages slot (1) in seat.
• Do not use ordinary soap to clean leather. It could dry
or remove the oils from the leather. 3. Push seat forward until retention screw can be installed
• Use ONLY a good quality saddle soap to clean leather. in fender and tighten securely.
Be sure to rinse saddle soap off thoroughly before
treating leather.
• Never try to dry leather quickly, using artificial means. After installing seat, pull upward on seat to be sure it is
Always let leather dry naturally at room temperature. locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
NOTE serious injury. (00070b)
Harley-Davidson Leather Dressing (Part No. 98261-91V) has 4. Pull up on seat to verify that it is properly secured.
been tested and approved for materials used in the seat used
on this motorcycle. 5. See Figure 2-45. Install passenger grabstrap to left
saddlebag mounting bracket.
1. Inspect seat, wiring harness and connector for wear or
damage. 6. Install left saddlebag.
2. Clean underside of pillion and seat. Clean fender and 7. Install rider backrest.
frame mounting surfaces.

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RIDER BACKREST 2.15

REMOVAL
sm04006
1. See Figure 2-48. Spread the seat covering at the base of
the backrest to expose the two spring loaded support arms.
2. Squeeze together the spring loaded support arms.
3. Pull upward to remove the backrest from the mounting
bracket.
1
INSTALLATION
1. See Figure 2-49. Spread the seat covering (1) to expose
the backrest mounting bracket (2). 2
2. Squeeze together the two spring loaded support arms on
the backrest.
3. Insert the support arms into the mounting bracket.
Vertical Adjustment: For rider comfort, move the backrest
up or down to select one of the three sets of vertical
adjustment holes.
1. Seat covering
4. Release to lock the backrest in the bracket. 2. Backrest mounting bracket
5. Test to verify the backrest is secured into the bracket. Figure 2-49. Mounting Bracket Through Seat
om00428
ADJUSTING TILT ANGLE
3 1. See Figure 2-50. Insert a 3/16 in. hex wrench through the
tilt angle adjustment access hole.
2. Engage the hex screw and tighten to tilt the backrest for-
ward, or loosen to tilt the backrest backward.
1
ADJUSTING FRONT TO REAR
1. Remove backrest and seat.
2. See Figure 2-51. Loosen, but do not remove, screw (3) at
base of support strap.
2 3. Remove screw and nut (4). Pivot support strap (2) out of
the way.
4. Remove nuts (5) and lift mounting bracket (1) off threaded
studs.
1. Support arms
5. With the large nylon washers in place, reposition bracket
2. Spring
in selected pair of horizontal adjustment holes (6).
3. Tilt adjustment eyelet
6. Install nuts and tighten to 60-96 in-lbs (6.8-10.8 Nm).
Figure 2-48. Rider Backrest Installation
7. Install screw and nut (4). Tighten to 132-180 in-lbs (15-
20 Nm).
8. Tighten support strap fastener (3) to 60-96 in-lbs (6.8-
10.8 Nm).
After installing seat, pull upward on seat to be sure it is

locked in position. While riding, a loose seat can shift
serious injury. (00070b)
9. Install seat.

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10. Make sure backrest fits properly and can be installed cor-
sm04009a
rectly in mounting holes in backrest mounting bracket.
1
sm04008
3
5
4
2
6
1. Backrest mounting bracket
2. Support strap
3. Screw
4. Screw and nut
5. Nut (2)
Figure 2-50. Adjust Rider Backrest Tilt Angle (Typical) 6. Horizontal adjustment holes
Figure 2-51. Backrest Mounting Bracket

HOME
PASSENGER BACKREST 2.16

REPAIR destroyed when the knob is removed. Never install a used
knob. Always install a new knob.
See the service manual for removal and installation of the
backrest assembly. Pull or pry the knob off. Push a new knob on the shaft until the
retainer clips engage. Pull lightly on the knob to verify the knob
NOTE is securely installed.
The only service component available for the lumbar backrest
is the knob. The retainer clips molded into the knob will be

HOME
TOUR-PAK 2.17
REMOVAL
sm04010b
NOTE
1
The following procedure is best performed with the aid of an
assistant. 9
8
1. Remove seat. See 2.14 SEAT.
2. Open Tour-Pak and remove bottom liner. 5
3. See Figure 2-52. Separate the following connections and
release cables from clips (3, 6): 6
10
a. Tour-Pak power lock connector [213T] (1).
7
b. CB antenna connector [104] (2). 4
c. AM/FM/WB antenna cable connector [29] (5).
2 3
d. Interior light harness connector [190] (7).
e. Tour-Pak lights harness connector [12] (9)
f. Power outlet (10).
4. Pull right side grommet (4) into Tour-Pak and remove from
CB antenna cable. Feed CB antenna cable through hole
in Tour-Pak. 1. Power lock connector [213T]
2. CB antenna connector [104]
5. Pull left side grommet (8) into Tour-Pak and remove from
3. Clip
harnesses.
4. Right exit hole grommet
6. Feed main harness including antenna cable, power lock 5. AM/FM/WB antenna cable connector [29]
connectors and lighting connectors through hole in Tour- 6. Clip
Pak. 7. Interior light connector [190]
8. Left exit hole grommet
7. Release rear headset receptacle from bracket at bottom
9. Tour-Pak lights connector
of left side speaker box.
10. Power outlet connector
8. See Figure 2-53. Either disconnect the rear speaker con- Figure 2-52. Tour-Pak Connections
nectors (see ADVANCED AUDIO SYSTEM in the Service
Manual) or remove three fasteners (1) and flat washers
to release each speaker box (2).
NOTE
Make note of which set of locating holes are used to mount
Tour-Pak.
9. Remove four screws and lock washers (4) from inside
Tour-Pak. Be sure to have a firm grasp on the Tour-Pak
as the screws are removed. Remove Tour-Pak.

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9. Feed main harness including Tour-Pak lights harness,

sm05812a
4 1 interior light harness, power locks harness and antenna
cable through hole in Tour-pak. Capture conduit in
grommet (8). Install grommet in hole with the larger OD
3 facing inside.
10. Connect Tour-pak lights connector (9), interior lights con-
nector (7), power outlet connector (10), power locks con-
nector (1) and antenna cable connector (5).
11. Capture cable and harnesses in two adhesive clips (6).
12. Install molded liner and map pouch in Tour-Pak.
2 After installing seat, pull upward on seat to be sure it is

13. Install saddlebags and seat.
LUGGAGE RACK
1. Speaker box fasteners
2. Speakers Removal
3. Ground ring terminal
1. Remove upper liner from Tour-Pak cover.
4. Screws and lock washers (4)
Figure 2-53. Tour-Pak Mounting Screws NOTE
Hold the luggage rack while removing four fasteners and
washers.
INSTALLATION 2. Remove four fasteners securing luggage rack to Tour-Pak
cover.
1. Place Tour-Pak on luggage rack and open lid.
2. See Figure 2-53. Install four screws (4) from inside Tour- Installation
Pak. Install radio antenna ground ring terminal (3) under 1. Place a flat washer and nylon washer on the hollow screw.
lock washer of left-rear screw. Apply a small amount of silicone sealant on the threads
3. In a crosswise pattern, tighten screws to 96-120 in-lbs and also to the surface where the nylon washer will contact
(10.8-13.6 Nm). the Tour-Pak lid.
4. If removed, install speaker boxes and secure with NOTE

fasteners and flat washers (1). Tighten fasteners to 25-35 The left-rear screw is hollow to provide a path for accessory
in-lbs (2.8-4.0 Nm). light wires, and uses larger washers.
2. Verify the mounting pads are in place on the legs of the
5. Connect speaker connectors.
luggage rack. Hold luggage rack in place and apply a small
6. See Figure 2-52. Pass CB antenna cable through hole in bead of silicone sealant around the studs where they pass
Tour-Pak. Capture cable in grommet. Install grommet (4) through the inside of the cover.
in hole with the larger OD facing inside.
3. Install nylon washers, flat washers and nuts.
7. Connect CB antenna cable connector (2). Capture cable
4. Install the hollow screw and washers in left-rear location.
in adhesive clips (3).
5. Tighten fasteners in a criss-cross pattern to 60-84 in-lbs
8. Capture rear headset receptacle in bracket at bottom of
(6.8-9.5 Nm).
left side speaker box.
6. Install liner in Tour-Pak cover.

HOME
SADDLEBAGS 2.18
REMOVAL 3. Align the bail head studs with the support bracket holes
and push the studs into the bracket while turning 1/4 turn
NOTE clockwise.
To prevent dropping saddlebags and damaging finish, hold
saddlebag while removing bail head studs.
sm06182
1. Open saddlebag lid and turn bail head studs 1/4 turn
counterclockwise. Remove studs and washers.
NOTE
International models do not have the bail and will require a flat
bladed screwdriver to remove the saddlebag fasteners.
2. See Figure 2-54. Tilt saddlebag away from motorcycle
and separate the electrical connector for the power lock.
INSTALLATION
1. Carefully place saddlebag in position on lower support
rail.
2. See Figure 2-54. Mate the power lock connector housings.
Figure 2-54. Power Lock Connector

HOME
SADDLEBAGS LATCH 2.19

REMOVAL
sm04019
1. Remove main fuse.
2. Open saddlebag and lift out felt liner.
3. Remove the two screws from the check strap and the latch
3 4
cover.
4. See Figure 2-55. Loosen the lock nut (1) on the cable end
and remove the barrel and cable from the inner cam arm
(2).
5. See Figure 2-56. Remove the e-clip (1).
6. Remove the spacer (2), spring (3), inner cam (4) and outer
cam (5).
7. See Figure 2-55. Remove the two inner screws (3) to 2
remove the cam plate (4).
INSTALLATION 1
1. Install the cam plate and finger tighten the two inner
screws.
2. See Figure 2-56. Push the outer cam through the hole in
the saddlebag and cam plate. Align the inner cam to the
square stock of the outer cam. 1. Lock nut
2. Inner cam arm
3. Slide the small end of the spring over the square stock of 3. Inner screws
the outer cam. Press the spring in place with the spacer. 4. Cam plate
4. Secure the assembly with the e-clip. Figure 2-55. Saddle Bag Cam Plate (Cover and Inner Liner
Removed)
5. Fit the barrel to the cam arm and tighten the lock nut on
the cable end.
6. Tighten the two inner screws to 25 in-lbs (2.8 Nm).
sm04020
7. Replace the latch cover and tighten the screws to the point 3
where the tether fabric begins to wrinkle.
8. Replace felt liner. 1
9. Replace maxi-fuse.
4 2
1. E-clip
2. Spacer
3. Spring
4. Inner cam
5. Outer cam
Figure 2-56. Latch Component Alignment

HOME
SADDLEBAG SUPPORTS 2.20

REMOVAL
sm06157
1. Remove saddlebags. See 2.18 SADDLEBAGS.
2. See Figure 2-57. Remove two screws (4), washers (3)
1 2
and nuts (2) securing saddlebag filler strip (1) to saddlebag
3
support.
3. Remove lower screw (5) and locknut (6). Remove filler
strip.
4
4. If necessary, see service manual to remove and install
the saddlebag supports.
INSTALLATION 5
6
1. If removed, install saddlebag support. See the service
manual for procedure. 1. Filler
2. See Figure 2-57. Install saddlebag filler strip (1) with two 2. Nut (2)
screws (4), washers (3) and nuts (2). Tighten to 15-20 ft- 3. Washer(2)
lbs (20.4-27.1 Nm). 4. Screw (2)
5. Screw
3. Install screw (5) and locknut (6). Tighten to 15-20 ft-lbs 6. Locknut
(20.4-27.1 Nm).
Figure 2-57. Filler Strip
4. Install the saddlebags. See 2.18 SADDLEBAGS.

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AIR DEFLECTORS 2.21

MID-FRAME AIR DEFLECTORS
sm05959
Removal
1. See Figure 2-58. Release spark plug wire from retainer 1
4
(3) (left deflector only). 3
2
2. Remove bolts (5) and washers (4).
5
3. Remove deflector (6) from frame.
Installation
1. See Figure 2-58. Verify clip nut (2) is installed in frame
hole. 6
2. Install left air deflector (6) with washers (4) and bolts (5). 7 4
Tighten bolts to 25-35 in-lbs (2.8-4.0 Nm).
5
3. Secure spark plug wire in retainer (3).
1. Right air deflector

2. Clip nut (2)
3. Rear spark plug wire retainer
4. Washer (4)
5. Bolt (4)
6. Left air deflector
7. Clinch nut (2)
Figure 2-58. Air Deflectors

HOME
MUFFLER END CAP 2.22

REPLACEMENT
sm05061a
1. Let motorcycle cool.
2. Loosen three clamps on muffler heat shield (2) and rotate
heat shield to access all three Torx fasteners.
3. See Figure 2-59. Loosen and remove three fasteners (1)
holding muffler end cap. 1
2
4. Remove end cap.
5. If necessary, remove and replace clip nut ring and clip
nuts.
6. Install clip nut ring and clip nuts in end cap.
7. Rotate fit to fastener holes in end cap and muffler. Install 1
and tighten fasteners to 84-108 in-lbs (9.5-12.2 Nm).
1
8. Return heat shield to original orientation and tighten three

clamps to 20-40 in-lbs (2.3-4.5 Nm).
1. Fastener (3)
2. Heat shield
Figure 2-59. Muffler End Cap Fastener Locations

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
3.2 SPECIFICATIONS: ENGINE......................................................................................................3-2
3.3 SERVICE WEAR LIMITS...........................................................................................................3-4
3.4 TROUBLESHOOTING...............................................................................................................3-6
3.5 CYLINDER HEAD......................................................................................................................3-8
3.6 PISTONS.................................................................................................................................3-19
3.7 BORING AND HONING CYLINDERS.....................................................................................3-20
3.8 CRANKCASE ASSEMBLY......................................................................................................3-23
3.9 OIL COOLER...........................................................................................................................3-25
3.10 OIL COOLER ADAPTER.......................................................................................................3-26
ENGINE
NOTES
HOME

CHAPTER
in this chapter.

Automatic compression release (ACR) 132-180 in-lbs 14.9-20.3 Nm 3.5 CYLINDER HEAD, Assembly/Apply three
equally spaced dots of LOCTITE 246 THREAD-
LOCKER MEDIUM STRENGTH/HIGH TEMPER-
ATURE around lower third of threads
Crankcase bolts, final 15-19 ft-lbs 20.3-25.8 Nm 3.8 CRANKCASE ASSEMBLY, Assembly
Crankcase bolts, initial 120 in-lbs 13.6 Nm 3.8 CRANKCASE ASSEMBLY, Assembly
Cylinder bolts, final torque 15-17 ft-lbs plus 20.3-23.1 Nm 3.7 BORING AND HONING CYLINDERS, Inspec-
90 degrees plus 90 degrees tion/See procedure for properly marking bolts
before turning 90 degrees.
Cylinder bolts, initial torque 120-144 in-lbs 13.6-16.3 Nm 3.7 BORING AND HONING CYLINDERS, Inspec-
tion
Oil cooler adapter inspection cover 90-120 in-lbs 10.2-13.6 Nm 3.10 OIL COOLER ADAPTER, Assembly/Apply 1
drop LOCTITE 246 THREADLOCKER MEDIUM
STRENGH/HIGH TEMPERATURE to the fasteners
Oil cooler mounting screws 20-22 ft-lbs 27.1-29.8 Nm 3.9 OIL COOLER, Installation
Oil filter adapter 18-22 ft-lbs 24.4-29.8 Nm 3.10 OIL COOLER ADAPTER, Installation
Spark plug 12-18 ft-lbs 16.3-24.4 Nm 3.4 TROUBLESHOOTING, Compression Test
2011 FLHTCUSE6 Service Supplement: Engine 3-1

HOME
SPECIFICATIONS: ENGINE 3.2

GENERAL
Table 3-3. Rocker Arms Specifications
NOTE
ROCKER ARMS IN. MM
This chapter provides unique information for models equipped
with Twin-Cam 110™ engines. Shaft fit in bushing (loose) 0.0005-0.0020 0.013-0.051
End clearance 0.003-0.013 0.08-0.33
Table 3-1. Engine: Twin-Cam 110™ Bushing fit in rocker arm (tight) 0.002-0.004 0.051-0.102
ITEM SPECIFICATION
Number of cylinders 2 Table 3-4. Rocker Arm Shaft Specifications
Type 4-cycle, 45 degree ROCKER ARM SHAFTS IN. MM

V-Type, air cooled Shaft fit in rocker arm support 0.0007-0.0022 0.018-0.056
Bore 4.000 in. (101.60 mm) plate (loose)
Stroke 4.375 in. (111.13 mm)
Piston displacement (approx.) 110 cu. in. (1800 cc) Table 3-5. Hydraulic Lifter Specifications
Compression ratio 9.15:1 HYDRAULIC IN MM
Cam system Twin cams, chain driven with LIFTERS
hydraulic tensioners Fit in crankcase 0.0009-0.0026 0.002-0.066
Max. sustained engine speed 5500 RPM (loose)
Idle speed 1000 RPM ± 50

Table 3-6. Cylinder Heads
Table 3-2. Oiling System ITEM IN. MM
ITEM SPECIFICATION Valve guide in head 0.0020-0.0033 0.051-0.084

(tight)
Oil tank capacity 4 qt (3.78 L)
with filter Intake valve seat in 0.004-0.0055 0.102-0.140
head (tight)
Preferred oil SYN3 20W50 (Part No. 99824-03/00QT
quart) Exhaust valve seat 0.004-0.0055 0.102-0.140
in head (tight)
Pump Twin gerotor, dual scavenge, crank
mounted and driven, internal oil pump, Head gasket sur- 0.0-0.006 0.0-0.0152
dry sump face (flatness)
Pressure 30-38 psi (207-262 kN/m2) at 2000 RPM

and normal operating temperature of 230 Table 3-7. Valves
°F (110 °C)
ITEM IN. MM
Filtration 5 micron media, filtered between pump
Fit in guide (intake 0.0011-0.0029 0.028-0.074
and engine
and exhaust)
Cooling Thermostat controlled oil cooler
Seat width 0.034-0.062 0.86-1.57
MANUFACTURING TOLERANCES Stem protrusion 1.990-2.024 50.55-51.41
from cylinder head
Refer to the Twin-Cam 96™ specifications in the service boss
manual for any specification not shown in the following tables.
Table 3-8. Valve Springs Specifications
ITEM PRESSURE DIMENSION

Closed 175 lbs (79 kg) 1.800 in (45.7 mm)
Open 432 lbs (196 kg) 1.250 in. (31.8 mm)
Free length n/a 2.210 in (56.1 mm)
3-2 2011 FLHTCUSE6 Service Supplement: Engine

HOME
Table 3-9. Pistons Table 3-11. Flywheel Specifications
ITEM IN. MM FLYWHEELS IN. MM

Fit in cylinder 0.0018-0.0027 0.046-0.069 Runout (shaft measured 0.000-0.010 0.0-0.254
Piston pin fit (loose) 0.0005-0.0009 0.013-0.023 in case)
Ring end gap: Runout (measured in 0.000-0.004 0.0-0.102

truing stand)
Top compression ring 0.016-0.024 0.406-0.610
End play 0.003-0.013 0.076-0.330
2nd compression ring 0.014-0.022 0.356-0.559
Oil control ring 0.010-0.030 0.254-0.762 Table 3-12. Crankshaft/Sprocket Shaft Bearing
Ring side clearance: Specifications
Top compression ring 0.00098-0.0024 0.025-0.061 CRANK- IN. MM
2nd compression ring 0.00098-0.0024 0.025-0.061 SHAFT/SPROCKET
SHAFT BEARINGS
Oil control ring 0.002-0.004 0.051-0.102
Roller bearing fit (loose) 0.0002-0.0015 0.005-0.038
Table 3-10. Connecting Rods Bearing fit in crankcase 0.0038-0.0054 0.097-0.137

(tight)
ITEM IN. MM
Bearing inner race on 0.0004-0.0014 0.010-0.036
Piston pin fit (loose) 0.0006-0.0012 0.015-0.030 crankshaft (tight)
Side play between fly- 0.005-0.015 0.13-0.38
wheels
Connecting rod to 0.0004-0.0017 0.0102-0.0432
crankpin (loose)

HOME
SERVICE WEAR LIMITS 3.3

GENERAL
Table 3-17. Cylinder Bore
Wear limits can be used as a guide when deciding whether to
reuse engine parts. Replace used parts whenever the following ITEM REPLACE IF WEAR EXCEEDS
wear limits are exceeded. IN. MM
NOTE Standard 4.002 101.65
Refer to the Twin-Cam 96™ specifications in the service 0.005 in. oversize 4.007 101.78
manual for any specification not shown in the following tables. 0.010 in. oversize 4.012 101.90
Table 3-13. Rocker Arm/Rocker Arm Shaft

Table 3-18. Pistons
ROCKER ARM/ROCKER REPLACE IF WEAR EXCEEDS
ARM SHAFT ITEM REPLACE IF
IN. MM WEAR EXCEEDS
Shaft fit in bushing (loose) 0.0035 0.089 IN. MM
End clearance 0.025 0.635 Fit in cylinder (loose) 0.003 0.076
Shaft fit in rocker arm 0.0035 0.089 Piston pin fit (loose) 0.0009 0.023
support (loose)
Ring end gap Top compression 0.034 0.864
2nd compression 0.032 0.813
Table 3-14. Hydraulic Lifters
Oil control ring rails 0.030 0.762
ITEM REPLACE IF WEAR EXCEEDS
Ring side clearance Top compression 0.0032 0.081
IN. MM
2nd compression 0.0032 0.081
Fit in crankcase 0.003 0.08
Oil control ring rails 0.004 0.102
Roller fit 0.0015 0.038
Roller end clearance 0.015 0.38 Table 3-19. Flywheel
FLYWHEEL REPLACE IF WEAR EXCEEDS

Table 3-15. Cylinder Heads
IN. MM
ITEM REPLACE IF
Runout (shaft measured 0.012 0.305
IN. MM in case)
Valve guide (tight) Less than 0.002 Less than 0.051 Runout (measured in 0.005 0.127
(intake and truing stand)
exhaust)
End play 0.013 0.330
Intake seat (tight) Less than 0.004 Less than 0.102
Exhaust seat (tight) Less than 0.004 Less than 0.102 Table 3-20. Crankshaft Roller Bearing
Head warpage Greater than 0.006 Greater than 0.152
ITEM REPLACE IF
IN. MM
Table 3-16. Cylinder
Roller bearing fit (loose) More than More than
CYLINDER REPLACE IF WEAR EXCEEDS 0.0015 0.038
IN. MM Crankshaft runout More than More than
Taper 0.002 0.051 0.003 0.076
Out of round 0.002 0.051 Bearing fit in crankcase (tight) Less than Less than
0.0038 0.097
Warpage of gasket sur- 0.006 0.152
faces: top Inner race on crankshaft (tight) Less than Less than
0.0004 0.010
Warpage of gasket or O- 0.004 0.102
ring surfaces: base

HOME
Table 3-21. Breather Assembly
BREATHER ASSEMBLY REPLACE IF WEAR

EXCEEDS
IN. MM
Breather cover warpage 0.005 0.13
Breather baffle warpage 0.005 0.13

HOME
TROUBLESHOOTING 3.4
COMPRESSION TEST 17. Install the spark plugs and tighten to 12-18 ft-lbs (16.3-
24.4 Nm). Connect spark plug wires.
PART NUMBER TOOL NAME
HD-33223-1 CYLINDER COMPRESSION GAUGE Table 3-22. Compression Specifications
A compression test can help determine the source of cylinder ACR STATUS PSI kPa
leakage. Use CYLINDER COMPRESSION GAUGE (Part System relay installed 130-170 896-1173
No. HD-33223-1) with a screw-in type adapter.
System relay removed 200-220 1379-1517
NOTE
All Twin-Cam engines use a 12 mm adapter with the compres-
Table 3-23. Compression Test Results
sion gauge.
1. Operate engine to normal operating temperature. TEST RESULTS DIAGNOSIS
Compression low on first stroke, -Readings that are con-
2. Disconnect spark plug wires, clean around plug base and
tends to build on the following siderably higher during
remove plugs.
strokes, but does not reach specific- the test after oil was
3. Remove air cleaner cover and filter. ation. Readings improve consider- injected, indicates worn
ably when oil is added to cylinder. piston rings.
4. Disconnect TCA connector [211] from the induction Results are similar with ACR discon-
module. nected. Inject approximately 1/2 oz.
NOTE (15 ml) engine oil into cylinder and
Never use a metal object to hold the throttle plate open. repeat the compression tests.
Damage to the throttle plate or throat of the induction module Compression low on first stroke, -Damaged intake or
may result. does not build up much on following exhaust valve
strokes. Does not improve consider- -Leaky cylinder head
5. Insert a 0.75 in. (19 mm) diameter by approximately 12
ably with the addition of oil. Results gasket
in. (305 mm) long wooden or nylon dowel to hold the
are similar with ACR disconnected. -ACR valve stuck open
throttle valve open.
-Incorrect push rod
6. Connect compression tester to front cylinder per manufac- length
turer's instructions. Compression builds quickly to near -Faulty ACR solenoid or
7. Make sure transmission is in neutral. Crank engine con- maximum specification. Similar circuit
tinuously through 5-7 full compression strokes. reading with ACR disconnected.
8. Note gauge readings at the end of the first and last com- CYLINDER LEAKDOWN TEST
pression strokes. Record test results.
9. Remove system relay from fuse block to disable ACR and
repeat test. See 7.2 ELECTRICAL PROTECTION. HD-35667-A CYLINDER LEAKDOWN TESTER
10. Install system relay. NOTE

On vehicles with automatic compression release (ACR), make
11. Repeat tests on rear cylinder with and without the system
sure the ACRs are closed for this test. Either perform the test
relay installed.
with the ignition/light switch in the off position or with the system
12. Hold throttle valve open and remove dowel. Connect TCA relay removed.
connector [211] when tests are complete.
The cylinder leakdown test will pinpoint engine problems
13. Removal of the system relay may set diagnostic trouble including leaking valves, worn, damaged or stuck piston rings
codes. Clear codes when test is complete. and blown head gaskets. The cylinder leakage tester applies
compressed air to the cylinder at a controlled pressure and
14. Assemble the air cleaner.
volume and measures the percent of leakage from the cylinder.
15. Refer to Table 3-22. If the final readings are within specific- Use the CYLINDER LEAKDOWN TESTER (Part No. HD-
ations and do not indicate more than a 10% variance 35667-A) and follow the specific instructions supplied with the
between cylinders, compression is considered normal. If tester.
compression does not meet specifications, refer to
Table 3-23 for possible causes. The following are some general instructions that apply to
Harley-Davidson V-twin engines:
16. If readings do not meet specifications, inject approximately
1/2 oz. (15 ml) engine oil into each cylinder and repeat 1. Run engine until it reaches normal operating temperature.
the compression tests on both cylinders. Readings that 2. Stop engine. Clean dirt from around spark plugs and
are considerably higher during the second test indicate remove the spark plugs.
worn piston rings.

HOME
NOTE test results. With a soap solution (applied around all tester fit-
Never use a metal object to hold the throttle plate open. tings), connect the cylinder leakdown tester to the compressed
Damage to the throttle plate or throat of the induction module air source and look for any bubbles that would indicate leakage
may result. from the tester.
3. Remove the air cleaner and set the throttle to the wide 6. Following the manufacturer's instructions, perform a cyl-
open position. On models having electronic throttle control, inder leakage test on the front cylinder. Make a note of
open the throttle plate by hand and insert a wooden or the percent of leakage. Leakage greater than 10% indic-
plastic dowel approximately 0.75 in. (19 mm) diameter by ates internal engine problems.
approximately 12 in. (305 mm) long to hold the throttle
7. Listen for air leaks at throttle body intake, exhaust pipe,
valve open.
and head gasket. Air escaping through the throttle body
4. The piston in the cylinder being tested must be at top dead indicates a leaking intake valve. Air escaping through the
center of compression stroke (both valves closed) during exhaust pipe indicates a leaking exhaust valve.
the test.
NOTE
5. To keep the engine from turning over when air pressure If air is escaping through valves, verify that piston is still at TDC
is applied to the cylinder, engage transmission in highest or check for correct push rod length.
gear and lock the rear brake.
8. Repeat procedure on rear cylinder.
NOTE
NOTE
Before performing the cylinder leakdown test, verify that the
After installing spark plugs, be sure that throttle plate is in the
tester itself is free from leakage to obtain the most accurate
closed position before starting the engine.

HOME
CYLINDER HEAD 3.5

GENERAL
sm04037
For service wear limits, refer to Table 3-15.
REMOVAL
See the service manual for removal of cylinder heads.
NOTE
Separate ACR connectors from the rear [203R] and front [203F]
cylinder heads when removing the heads from the cylinders.
DETERMINING SERVICE
Check cylinder head condition to determine if reconditioning
is necessary.
1. Raise valve ports of cylinder head to strong light source.
If light is visible around edges of seats, proceed to
3.5 CYLINDER HEAD, Disassembly to recondition cylinder
head.
2. One at a time, fill each port with solvent. Wait ten full
seconds and then check for leakage into combustion
chamber. If solvent leakage is evident, proceed to
3.5 CYLINDER HEAD, Disassembly to recondition cylinder
head.
Figure 3-2. Spring/Valve Stack and ACR

sm04036
DISASSEMBLY
HD-34736-B VALVE SPRING COMPRESSOR
HD-39786 CYLINDER HEAD HOLDING FIXTURE
HD-48498-A ACR SOLENOID SOCKET
1. Remove the ACR using the ACR SOLENOID

SOCKET (Part No. HD-48498-A). See service manual.
2. See Figure 3-3. Obtain the CYLINDER HEAD HOLDING
FIXTURE (Part No. HD-39786) and proceed as follows:
a. Thread the 12 mm end of the tool into the spark plug
hole of the cylinder head.
b. See Figure 3-4. Clamp tool in vise at a 45 degree
angle (or one that offers a comfortable working posi-
tion).
3. See Figure 3-5. Obtain the VALVE SPRING COM-

Figure 3-1. Combustion Chamber PRESSOR (Part No. HD-34736-B) and proceed as follows:
a. Place tool over cylinder head so that the blunt end is
centered on the valve head and adapter at end of
forcing screw is seated on the valve spring retainer.
b. Rotate forcing screw to compress valve springs.
c. If spring retainer has not separated from tapered
keepers, give head of tool a sharp tap with a soft
mallet. Using magnetic rod or small screwdriver,
remove the keepers from the valve stem groove.
d. Rotate forcing screw to release the valve spring
compression.

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4. Remove the spring retainer and inner and outer valve

sm02495
springs.
5. Slide the valve from the valve guide.
6. Using pliers, twist and remove the valve guide seal from
the top of the valve guide. Discard the valve guide seal. 2
7. Remove the spring seat from the cylinder head.
8. Mark the bottom of the valve "F(ront)" or "R(ear)" to
indicate the cylinder head from which it was removed.
Also, separate and tag tapered keepers, valve springs,
spring retainers, retaining rings and spring seats so that
they are installed on the same valve at time of assembly. 1
9. Repeat to remove the other valve.
2
10. Release the cylinder head holding fixture from the vise
and then remove the tool from the spark plug hole.
sm04038
2
1
1. Holding fixture
2. Compressor
1. 14 mm end Figure 3-5. Valve Spring Compressor (Part No. HD-34736-B)

2. 12 mm end
Figure 3-3. Cylinder Head Holding Fixture (Part No. CLEANING
HD-39786-A)
1. Remove old gasket material from cylinder head. Gasket
material left on sealing surfaces will cause leaks.
2. Remove all carbon deposits from combustion chamber
sm04039 and machined surfaces of cylinder head. Exercise caution
to avoid removing any metal material. For best results,
use an air tool with a worn wire brush. Scraping may result
in scratches or nicks.
3. To soften stubborn deposits, soak the cylinder head in a
chemical solution, such as GUNK HYDRO-SEAL or other
carbon and gum dissolving agent. Repeat last step as
necessary.
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)
4. Thoroughly clean the cylinder head, spring retainers,
tapered keepers, valves, inner and outer valve springs
and spring seats in a non-volatile cleaning solution or
solvent. Follow up with a thorough wash in hot soapy
Figure 3-4. Install Cylinder Head Holding Fixture in Vise water. Blow dry with compressed air.

HOME
NOTES
• If bead blasting is used, use walnut shells or other soft
cleaning materials.
Do not use glass or sand to bead blast surfaces exposed
to engine oil. Blasting materials can lodge in pores of the • Be aware that bead blasting materials may also enter
casting. Heat expansion releases this material which can threaded holes adversely affecting fastener engagement
contaminate oil resulting in engine damage. (00534b) and torque indication. Carefully cover all threaded holes
if bead blasting is employed.
sm04040
2 22
3 23
1 5 24
4
14
9 25
6
27 24 16
7
10
8
11 21
19
20
21 15
12
26 17
13
18
1. Automatic compression release (ACR) 15. Cylinder

2. Tapered keepers 16. Ring dowel
3. Spring retainer 17. O-ring seal
4. Outer spring 18. Cylinder stud
5. Inner spring 19. Piston
6. Valve guide seal 20. Piston pin
7. Spring seat 21. Circlip (2)
8. Valve guide 22. Top compression ring
9. Cylinder head bolt, short (2) 23. Second compression ring
10. Cylinder head bolt, long (2) 24. Oil rail
11. Cylinder head 25. Oil rail spacer
12. Valve seat 26. Nameplate
13. Valve 27. Retaining ring
14. Cylinder head gasket
Figure 3-6. Cylinder Head/Cylinder/Piston Assemblies (Exploded View)

HOME
INSPECTION Valves
PART NUMBER TOOL NAME 1. Replace the valve if there is evidence of burning or
cracking.
HD-34723 VALVE GUIDE HONE
2. Inspect the end of the valve stem for pitting or uneven
HD-34751 VALVE GUIDE CLEANING BRUSH
wear. Replace the valve if either of these conditions are
HD-48627 CYLINDER TORQUE PLATES found.
HD-96796-47 VALVE SPRING TESTER 3. Inspect for burrs around the valve stem keeper groove.
Remove burrs with a fine tooth file if found.
Cylinder Head
4. To determine if the valve stem is excessively worn, see
1. Check for scratches and nicks on all gasket sealing sur-
VALVE GUIDES above.
faces.
2. With the combustion chamber side facing upward, set a Valve Springs
straightedge diagonally across the length of the cylinder 1. Inspect springs for broken or discolored coils. Replace
head intersecting the upper and lower corners of the springs if either of these conditions are found.
gasket surface. Slide a feeler gauge beneath the
straightedge to check the head for warpage. Checking the 2. Set the intake and exhaust valve springs on a level surface
opposite diagonal, repeat the procedure to verify that the and use a straightedge to check for proper squareness
gasket surface is flat (especially if a head gasket was and height.
blown). Discard the head if any low spot is 0.006 in. (0.15 3. Check free length of inner and outer springs using a dial
mm) or greater. vernier caliper or load test with the VALVE SPRING
NOTE TESTER (Part No. HD-96796-47). Replace springs if free
For good results, use one of the CYLINDER TORQUE length or compression force do not meet specifications.
PLATES (Part No. HD-48627) in lieu of the straightedge. Lay See 3.2 SPECIFICATIONS: ENGINE.
the upper plate flat on the machined surface of the head. As
Tapered Keepers
a preliminary check, see if the plate rocks from side to side. A
head on which the plate rocks is immediately suspect. Insert 1. Inspect parts for damage or rust pits. Replace as neces-
a feeler gauge between the plate and head at various locations sary.
to see if warpage exceeds above specification.
2. Inspect inboard side of tapered keepers for excessive
3. Verify that oil passageways are open and clean. wear. Upraised center must be pronounced and fit snugly
in valve stem groove. Place keepers into groove and verify
Valve Guides that they grip tightly without sliding.
1. Inspect external surfaces for cracks (particularly the com-
bustion chamber side). Replace the guide if any cracks
Valve Seats
are found. 1. Inspect seats for cracking, chipping or burning. Replace
seats if any evidence of these conditions are found.
2. To verify cleanliness of valve guides, lightly hone using
the VALVE GUIDE HONE (Part No. HD-34723) and then 2. Check seats for recession by measuring valve stem pro-
scrub with the VALVE GUIDE CLEANING BRUSH (Part trusion.
No. HD-34751) to remove any dust or debris. Polish the
valve stem with fine emery cloth or steel wool to remove
carbon buildup, and then check valve stem to guide
clearance as follows:
a. Carefully measure the inside diameter of the valve
guide using an inside ball micrometer.
b. Measure the outside diameter of the valve stem with
an outside micrometer.
c. The clearance is the difference between the two
measurements. The valve stem and/or guide are
excessively worn if the clearance exceeds the limits
shown in Table 3-24. To determine if the guide is
excessively worn and must be replaced, repeat
measurements using a new valve.
Table 3-24. Service Wear Limits
VALVE VALVE STEM TO GUIDE CLEARANCE

Intake 0.0038 in. (0.0965 mm)
Exhaust 0.0038 in. (0.0965 mm)

HOME
REPLACING VALVE GUIDES sm04193

HD-34740 VALVE GUIDE AND VALVE GUIDE
SEAL HANDLE
1
HD-39782-A CYLINDER HEAD SUPPORT STAND
HD-39786 CYLINDER HEAD HOLDING FIXTURE
HD-39847 RATCHETING TAP HANDLE
HD-39932 VALVE GUIDE REAMER
HD-39964 REAMER LUBRICANT
HD-46583 VALVE GUIDE INSTALLER
Removal
3
1. See Figure 3-7. Obtain the CYLINDER HEAD SUPPORT 2
STAND (Part No. HD-39782-A) and proceed as follows:
a. Insert sleeve of intake or exhaust seat adapter into 1. Intake seat adapter
tube at top of support stand. 2. Exhaust seat adapter
3. Cylinder head support stand
b. Position cylinder head so that valve seat is centered
on seat adapter. Support stand ensures that valve Figure 3-7. Cylinder Head Support Stand (HD-39782-A)
guide and seat are perpendicular. If perpendicularity
is not achieved, the cylinder head valve guide bore
will be damaged during the press procedure.
sm04041
NOTE
Do not press out the valve guide from the bottom of the cylinder
head. Carbon buildup on the combustion chamber side of the
guide can deeply gouge the cylinder head bore diminishing Figure 3-8. Valve Guide & Valve Guide Seal Handle
the likelihood of achieving the proper interference fit and pos- (HD-34740)
sibly requiring replacement of the cylinder head casting.
2. See Figure 3-8. At the top of the cylinder head, insert
VALVE GUIDE AND VALVE GUIDE SEAL HANDLE (Part
No. HD-34740) into valve guide bore until stopped by sm02498
shoulder.
3. See Figure 3-9. Center valve guide driver under ram of
arbor press. Apply pressure until valve guide drops free 1
of cylinder head. Discard the valve guide.
1. Valve guide driver

2. Cylinder head stand
Figure 3-9. Remove Valve Guide

HOME
Installation sm02299
1. Check valve guide to valve bore clearance.

a. Measure the outside diameter of a new standard valve
guide. 1
b. Measure the cylinder head valve guide bore. The 2
valve guide should be 0.0020-0.0033 in. (0.051-0.084
mm) larger than the bore.
NOTE
Since some material is typically removed when the guide is
pressed out, it is normal to go to the next larger valve guide
1
for the proper interference fit.
2. See Figure 3-7 and Figure 3-10. Obtain the CYLINDER
HEAD SUPPORT STAND (Part No. HD-39782-A), VALVE
GUIDE AND VALVE GUIDE SEAL HANDLE (Part No. HD- 2
34740) and VALVE GUIDE INSTALLER (Part No. HD-
46583). Proceed as follows:
a. See Figure 3-10. Insert sleeve of intake or exhaust
seat adapter into tube at top of support stand. Position
cylinder head so that valve seat is centered on seat
adapter.
NOTE
Support stand ensures that valve guide and seat are per-
pendicular. If perpendicularity is not achieved, cylinder
head valve guide bore will be damaged during the press
procedure.
3
b. Apply petroleum jelly to lightly lubricate external sur-
faces of valve guide. Spread lubricant so that thin film
covers entire surface area.
c. At top of cylinder head, start valve guide into bore. 1. Valve guide driver
2. Valve guide installer sleeve
d. Place installer sleeve over valve guide, and then insert
3. Cylinder head stand
tapered end of valve guide driver into installer sleeve.
Figure 3-10. Install Valve Guide
e. Center valve guide driver under ram of arbor press
and apply pressure only until valve guide is started
in bore and then back off ram slightly to allow guide 3. See Figure 3-3. Obtain the CYLINDER HEAD HOLDING
to center itself. FIXTURE (Part No. HD-39786) and proceed as follows:
f. Verify that support stand and driver are square. Center a. Thread the 12 mm end of the tool into the spark plug
driver under ram and press valve guide further into hole of the cylinder head.
bore, but then back off ram again to allow valve guide
to find center. b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).
g. Repeat previous step and then apply pressure to
driver until installer sleeve contacts machined area NOTES
of cylinder head. • Valve guides must be reamed to within 0.0005-0.0001 in.
(0.013-0.0025 mm) of finished size.
NOTE
• For best results, do not push on reamer or apply pressure
Always back off ram to allow the valve guide to find center.
to the reamer handle. While excessive pressure results in
Pressing guide into cylinder head in one stroke can bend driver,
a rough cut, bore will be tapered if pressure is not centrally
break guide, distort cylinder head casting and/or damage cyl-
applied.
inder head valve guide bore.
• Never back reamer out of valve guide or bore will be
damaged.
4. See Figure 3-11. Obtain the VALVE GUIDE REAMER (Part
No. HD-39932), RATCHETING TAP HANDLE (Part

HOME
No. HD-39847) and REAMER LUBRICANT (Part No. HD-

sm04043
39964). Proceed as follows:
a. Install tap handle (2) on reamer (1).
b. Apply a liberal amount of reamer lubricant to valve
guide bore and bit of reamer. Start bit of reamer into
bore at top of cylinder head.
c. See Figure 3-12. Placing thumb on drive socket of
RATCHETING TAP HANDLE (Part No. HD-39847),
apply slight pressure on reamer while rotating in a
clockwise direction. Squirt additional lubricant onto
reamer and into guide as necessary.
d. Continue rotating RATCHETING TAP HANDLE (Part
No. HD-39847) until entire bit has passed through
valve guide bore and shank of reamer rotates freely.
e. Remove tap handle from reamer, and carefully pulling
on bit, draw shaft of reamer out combustion chamber
side of valve guide.
NOTE Figure 3-12. Ream Valve Guide Bore

Abrasive particles can damage machined surfaces and plug
oil passageways possibly resulting in engine failure.
6. See Figure 3-13. Clean valve guide bore with the VALVE
5. Direct compressed air into the valve guide bore to remove
GUIDE CLEANING BRUSH (HD-34751).
any metal shavings or debris.
7. See Figure 3-14. Obtain the 8 mm VALVE GUIDE FLEX
HONE (HD-34723) and REAMER LUBRICANT (Part
sm04042
No. HD-39964). Proceed as follows:
a. Install hone in a high speed electric drill.
b. Apply reamer lubricant to finishing stones of hone and
valve guide bore.
1
c. Start finishing stones of hone into bore.
d. See Figure 3-15. Activating the drill, move the entire
length of the finishing stone arrangement forward and
backward through the bore for 10 to 12 complete
strokes. Work for a crosshatch pattern of approxim-
ately 60 degrees.
2 NOTE
Abrasive particles can damage machined surfaces and plug
1. Valve guide reamer oil passageways possibly resulting in engine failure.
2. Ratcheting tap handle 8. See Figure 3-13. Direct compressed air into the valve
Figure 3-11. Valve Guide Reamer and Ratcheting Tap guide bore to remove any debris and then clean with the
Handle VALVE GUIDE CLEANING BRUSH (Part No. HD-34751).
NOTE
Always verify valve stem to valve guide clearance after honing,
since a worn reamer may cut the bore undersize.
9. Measure the inside diameter of the valve guide with an
inside ball micrometer. Measure the outside diameter of
the valve stem with an outside micrometer. The valve stem
may be excessively worn or the valve guide bore undercut
if the clearance is not within the limits (low end preferable)
shown in Table 3-25.
10. Using cleaning solvent, thoroughly clean valve guide bore.
Scrub valve guide bore with the VALVE GUIDE CLEANING
BRUSH (Part No. HD-34751).

HOME
sm04046
Table 3-25. New Parts Limits
VALVE VALVE STEM TO GUIDE CLEARANCE

Intake 0.0011-0.0029 in. (0.028-0.074 mm)
Exhaust 0.0011-0.0029 in. (0.028-0.074 mm)
NOTE
For best results, use a thin engine oil and clean valve guide
bore with the type of swabs or patches found in gun cleaning
kits. Continue to wipe bore until clean cloth shows no evidence
of dirt or debris.
Compressed air can pierce the skin and flying debris from
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
Figure 3-15. Hone Valve Guide Bore
11. Clean valves, cylinder head and valve seats in solvent.
Follow up with a thorough wash in hot soapy water. Blow
dry with low pressure compressed air. sm04047
sm04044
Figure 3-13. Valve Guide Cleaning Brush
sm04045
Figure 3-14. 8mm Valve Guide Flex Hone

Figure 3-16. Scrub Valve Guide Bore

HOME
ASSEMBLY capsule and down valve stem until contact is made with
top of valve guide. Remove capsule from valve stem tip.
HD-34736-B VALVE SPRING COMPRESSOR sm04048
HD-34740 VALVE GUIDE AND VALVE GUIDE
SEAL HANDLE
HD-39786 CYLINDER HEAD HOLDING FIXTURE 1
HD-48644 VALVE GUIDE SEAL INSTALLER
1. Obtain the CYLINDER HEAD HOLDING FIXTURE (Part

No. HD-39786) and proceed as follows:
a. Thread the 12 mm end of the tool into the spark plug
hole of the cylinder head.
2
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).
2. Slide spring seat over valve guide until it contacts the

machined area on the cylinder head casting. Use a little
grease to hold the spring seat in position, if necessary.
NOTE 1. Plastic capsule
At the time of disassembly, all parts should have been marked 2. Spring seat
or tagged so that they are installed on the same valve (and in
the same head). Figure 3-17. Install Plastic Capsule on Valve Stem
3. Run the VALVE GUIDE CLEANING BRUSH (Part No. HD-

34751) through the valve guide bore to verify cleanliness.
4. Using TORCO MPZ or another suitable product, apply a sm04049
liberal amount of engine assembly lube to valve stem.

5. From the bottom of the cylinder head, insert the valve stem
into the valve guide.
1
6. To distribute the assembly lube evenly around the valve
stem and guide, hand spin the valve as it is installed. Work
the valve back and forth in the bore to verify that it slides
smoothly and seats properly.
7. Remove the valve and apply a second coat of assembly
lube to the valve stem. Install the valve in the valve guide. 2
8. Retract the valve so that the stem is not visible above the
top of the valve guide.
9. Using isopropyl alcohol or other suitable degreaser, thor-
oughly clean external surface of valve guide until com-
pletely free of grease and oil.
1. Plastic capsule
2. Valve guide seal
Failure to install plastic capsule can cause the valve stem
Figure 3-18. Install Valve Guide Seal
seal to catch the edge of the valve stem keeper groove.
The resulting damage can cause leakage around the valve
stem, excessive oil consumption and valve sticking.
(00535b)
10. See Figure 3-17. Push on head of valve until it contacts
the valve seat. Placing finger at head of valve to keep
valve seated, slide plastic capsule over valve stem tip and
keeper groove.
11. See Figure 3-18. Apply a very thin film of clean H-D 20W50
engine oil to capsule. Slide new valve guide seal over

HOME
12. See Figure 3-19. Obtain the VALVE GUIDE SEAL

sm04052
INSTALLER (Part No. HD-48644) and proceed as follows: 1
a. Slide the installer tool over the valve guide seal using
valve stem as pilot. The tool bore allows insertion of
the valve stem, while the counterbore fits over the
valve guide seal.
b. See Figure 3-20. Using a small hammer, gently tap 2
the end of the tool until it lightly bottoms on the
installed spring seat. For best results, brace the cyl-
inder head to prevent movement during seal installa-
tion.
NOTES
• Repeated blows on installer after seal is in place will cause
3
seal distortion resulting in leakage around the valve stem, 4
excessive oil consumption and valve sticking.
5
• See Figure 3-21. If an arbor press is the preferred method
of valve guide seal installation, use the VALVE GUIDE
SEAL INSTALLER (Part No. HD-48644) with the VALVE
GUIDE AND VALVE GUIDE SEAL HANDLE (Part No. HD-
34740).
• Do NOT remove valve after seal is installed. Removing
the valve after seal installation will cause the valve guide
seal to catch the edge of the valve stem keeper groove.
The resulting damage will lead to leakage around the valve
stem, excessive oil consumption and valve sticking.
6
sm04051
1. Valve guide & valve guide seal handle
2. Valve guide seal installer
3. Valve guide seal
4. Valve
Figure 3-19. Valve Guide Seal Installer 5. Valve guide
6. Valve seat
Figure 3-21. Using Arbor Press to Install Valve Guide Seal
sm04052
13. Apply a liberal amount of assembly lube to valve stem tip

and keeper groove.
14. Install the inner and outer valve springs over the valve
guide. Fit the spring retainer on top of the inner and outer
valves springs. Like the spring seat, the smaller diameter
flange fits inside the inner valve spring. The larger diameter
flange separates the inner and outer springs.
Figure 3-20. Seat Valve Guide Seal

HOME
15. Obtain the VALVE SPRING COMPRESSOR (Part No. HD- 16. Tap the end of the valve stem once or twice with a soft
34736-B) and proceed as follows: mallet to make sure that tapered keepers are tightly seated
a. Place tool over cylinder head so that the blunt end is in the valve stem groove.
centered on the valve head and adapter at end of 17. Repeat all previous steps to install the other valve compon-
forcing screw is seated on the valve spring retainer. ents.
b. Rotate forcing screw to compress valve springs. 18. Verify that the copper seal washer is in place on the ACR.
c. With the tapered side down, fit the keepers into the 19. Apply three equally spaced dots of LOCTITE 246
valve stem groove. For best results, apply a dab of THREADLOCKER MEDIUM STRENGTH/HIGH TEMPER-
grease to the inboard side of the keepers before ATURE around the lower third of the threads. Tighten to
installation and use a magnetic rod for easy place- 132-180 in-lbs (14.9-20.3 Nm). See the service manual.
ment.
20. Release the cylinder head holding fixture from the vise
d. Arranging tapered keepers so that the gaps are evenly and then remove the tool from the spark plug hole.
spaced, turn forcing screw to release valve spring
compression. 21. Cover the cylinder head to protect it from dust and dirt
until time of installation.
NOTE
Over-compressing the valve spring can damage the valve guide INSTALLATION
seal resulting in leakage around the valve stem, excessive oil See service manual for cylinder head installation procedure.
consumption and valve sticking.

HOME
PISTONS 3.6
GENERAL
sm04055
See Figure 3-22. Though Twin Cam 110 pistons differ from
Twin Cam 96 in specification and appearance, piston service
procedures are the same except for measuring the nominal
diameter. See the appropriate procedures in the service manual
for repair. For service wear limits, refer to Table 3-18.
MEASURING PISTON
1. Allow the piston to cool to room temperature.
2. See Figure 3-23. With a pencil or marker, mark the piston
on each side of the skirt across the thrust faces (perpen-
dicular to the piston pin bore) 0.394 in. (10 mm) from the
bottom edge.
NOTE
Set the piston skirt down on a level table and use a rule to
measure 0.394 in. (10 mm) high on the skirt.
3. Using a micrometer at the marks, measure the nominal
diameter of the piston.
4. Use a dial bore gauge to measure the piston ring travel
zone in the cylinder bore. See the service manual for Figure 3-22. Twin-Cam 110 Piston
procedure.
5. Replace piston and/or cylinder if running clearance
exceeds 0.003 in. (0.076 mm).
sm04056
Figure 3-23. 0.394 in. (10 mm)

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BORING AND HONING CYLINDERS 3.7

INSPECTION
sm02506
3
HD-48627 CYLINDER TORQUE PLATES
TA360 SNAP-ON TORQUE ANGLE GAUGE
NOTE
Failure to use cylinder torque plates can produce measure-
ments that vary by as much as 0.001 in. (0.025 mm), possibly
resulting in the use of parts that are not suitable for service.
1. See Figure 3-24. To simulate an assembled cylinder for 2
accurately measuring cylinder taper and out-of-round 4 1
conditions, as well as for boring, honing or deglazing,
1. Bolts
obtain the CYLINDER TORQUE PLATES (Part No. HD-
2. Lower plate
48627). Install the torque plates as follows:
3. Upper plate
a. Remove O-ring seal from cylinder sleeve, if installed. 4. Vise grip step
b. Place used head gasket over two dowel pins at top Figure 3-24. Cylinder Torque Plates
of cylinder.
c. Install brass jaws or shop towels around teeth of vise
to prevent damage to tool. Clamp stepped side of NOTE
lower plate in vise with the simulated split line Maximum cylinder wear occurs at the very top of top ring travel.
(machined strip) facing away. Minimum wear occurs below ring travel. Failure to measure
d. See Figure 3-25. Lightly oil threads and shoulders of the cylinder at these points may result in a faulty decision
four bolts (1) with clean H-D 20W50 engine oil. Slide regarding the suitability of the cylinder for continued use.
four bolts all the way through holes of lower plate (2) 2. See Figure 3-27. Using an inside micrometer or dial bore
until washers contact outboard side. gauge, check cylinder bore for out-of round and taper.
e. Slide cylinder down bolts with the indent in the cooling Proceed as follows:
fins facing upward. a. At the top of the piston ring travel zone, starting about
0.50 in. (12.70 mm) or from the top of the cylinder,
f. With the two dowel pins and head gasket in place, measure the cylinder diameter at two locations; par-
align holes in upper plate with ends of bolts. Blind allel and perpendicular to the crankshaft. Record the
holes in upper plate accommodate dowel pins in cyl- readings.
inder. Alternately tighten four bolts into upper plate in
a crosswise pattern until finger tight. b. Repeat the two measurements at the center of the
piston ring travel zone.
g. See Figure 3-26. Tighten the bolts to 120-144 in-lbs
(13.6-16.3 Nm) in the sequence shown. c. Repeat the measurements again at the bottom of the
bore at a point below the piston ring travel zone.
h. Following the same sequence, tighten each bolt to
15-17 ft-lbs plus 90 degrees (20.3-23.1 Nm plus 90 d. Rebore the cylinder if the parallel and perpendicular
degrees). measurements at either the top, middle or bottom of
the bore vary by more than 0.002 in. (0.051 mm).
i. Using a grease pencil, mark a straight line on one of This indicates an out-of-round condition.
the bolts continuing the line over onto the lower plate.
Repeat step for remaining three bolts. e. Rebore the cylinder if the top, middle and bottom bore
diameters either parallel or perpendicular to the
j. Using the marks as a guide, turn each bolt 1/4 turn crankshaft vary by more than 0.002 in. (0.051 mm).
or 90 degrees. Be sure to tighten the bolts in the This indicates excessive taper.
sequence shown.
NOTE 3. Continue with cylinder service.
For best results, obtain SNAP-ON TORQUE ANGLE a. If cylinders are not scuffed or scored and are not worn
GAUGE (Part No. TA360). beyond the service limits, see Deglazing Cylinder in
the service manual.
k. For purposes of inspection, remove the assembly
from the vise and place on bench top. b. If cylinders are worn beyond the service limits, then
they must be rebored and/or honed to accept the next
standard oversize piston. See 3.7 BORING AND
HONING CYLINDERS, Cylinder Bore Finished Size.

HOME
sm02530 sm02532
2
1
1. Bolt (4)
2. Lower plate
3. Vise
Figure 3-25. Attaching Cylinder Torque Plates
Figure 3-27. Measure for Out-of-Round and Taper
sm02531
3 CYLINDER BORE FINISHED SIZE
4 1. For cylinder removal, cleaning, inspection, boring and
honing and installation, see CYLINDER in the service
manual.
2. Refer to Table 3-26. Bore the cylinder to 0.003 in. (0.08
mm) under the desired finished size. See BORING and
HONING CYLINDER in the service manual.
2
1
An incorrect cross hatch pattern or too fine a hone will
result in insufficient oil retention and possible piston
seizure and/or high oil consumption. (00538b)
3. Hone the cylinder to its finished size using a 280 grit rigid
hone followed by a 240 grit flexible ball hone. Honing must
be done with the torque plates attached. All honing must
Figure 3-26. Cylinder Torque Plate Bolt Sequence be done from the bottom (crankcase end) of the cylinder.
Work for a 60 degree crosshatch pattern.
4. Stop frequently to examine the cylinder bore and/or take
measurements. Remember, a precise 60 degree
crosshatch pattern in the piston travel area is important.
Failure to remove all abrasive particles may result in pre-

mature cylinder, piston and ring wear and engine failure.
(00537b) .
5. Thoroughly wash the cylinder bore with liquid dish soap
and warm water to remove all abrasive particles and
residual grit. Continue cleaning until a clean cloth shows
no evidence or dirt or debris.

HOME
6. Immediately apply a thin film of clean engine oil to a clean

sm04057
white paper towel and thoroughly wipe the inside of the
cylinder to prevent the cylinder bore from rusting.
NOTE
After wiping the cylinder with a clean, oiled paper towel, the
towel will be dark with contamination. Repeat this process
using a new lightly oiled paper towel each time until the towel
remains white. The cylinder is now clean.
7. With the cylinder at room temperature, check the piston
clearance in the cylinder in which the piston will run. See
INSPECTION under PISTON in service manual.
8. For cylinder installation, see CYLINDER in service manual.
PISTON ORIENTATION
See Figure 3-28. When replacing a piston, orient the piston so
that the etched arrow on the top of the piston faces forward.
Figure 3-28. Piston Orientation Arrow (arrow points to front
of engine)
Table 3-26. Oversize Pistons and Cylinder Bores, Twin Cam 110™
PISTON CYLINDER BORE FINISHED SIZE

TYPE SIZE MINIMUM MAXIMUM
Standard STD 4.0000 in. (101.6 mm) 4.0005 in. (101.613 mm)
Oversize 0.005 in. (0.13 mm) 4.0050 in. (101.727 mm) 4.0055 in. (101.740 mm)
0.010 in. (0.25 mm) 4.0100 in. (101.854 mm) 4.0105 in. (101.867 mm)

HOME
CRANKCASE ASSEMBLY 3.8

GENERAL
sm04059
With the exception of the top center crankcase bolt, crankcase
service is identical to original equipment. See the service
1
manual for complete procedure.
ASSEMBLY 1
HD-39361-B SPROCKET SHAFT OIL SEAL
INSTALLER 2
HD-42326-B CRANKSHAFT GUIDE
HD-97225-55C SPROCKET SHAFT BEARING
INSTALLER
1. Install left crankcase half in engine stand so that the split

line face is vertical.
2. See Figure 3-29. To prevent damage to the sprocket shaft
(roller) bearing, slide CRANKSHAFT GUIDE (Part No. HD-
42326-B) over end of sprocket shaft.
3
3. Slide flywheel assembly into left case half and remove
tool.
4. Tip crankcase in engine stand so that flywheel pinion shaft
is pointing straight up.
5. Apply a bead of High-Performance Sealant (gray), (Part
No. HD-99650-02) approximately 0.056 in. (1.4 mm) wide
to the split line face.
4
6. To prevent damage to the crankshaft (roller) bearing, slide
CRANKSHAFT GUIDE (Part No. HD-42326-B) over end
of crankshaft until it contacts shoulder on shaft.
7. See Figure 3-30. Slide right crankcase half over end of 2
crankshaft and mate case halves. Remove tool. 5
sm04058
1. Water pipe insulation

2. Crankshaft guide
3. Left crankcase
4. Crankshaft bearing
5. Right crankcase
Figure 3-30. Crankshaft Guide
Figure 3-29. Crankshaft Guide

NOTE
See Figure 3-31. The center upper bolt (1) is longer than the
remaining eight crankcase bolts.
8. See Figure 3-31. Install nine crankcase bolts:
a. Finger-tighten each crankcase bolt.
b. In sequence shown, tighten the crankcase bolts to
120 in-lbs (13.6 Nm).
c. In sequence shown, final-tighten each bolt to 15-19
ft-lbs (20.3-25.8 Nm).

HOME
9. Rotate crankcase in the engine stand so that the stator

sm04061
mount flange is facing upward.
10. Slide thrust washer over sprocket shaft with "THIS SIDE
OUT" facing out (and the chamfer inboard), or if using OE
part without markings, orient as required to preserve
existing wear pattern.
11. To install new oil seal into bearing bore, obtain pilot,
bearing, large flat washer and handle from SPROCKET
SHAFT BEARING INSTALLER (Part No. HD-97225-55C)
and proceed as follows: Figure 3-32. Sprocket Shaft Oil Seal Installer
a. Verify that seal lip garter springs are in place on both
sides of new seal.
b. With the lettering facing out, slide oil seal onto
sprocket shaft until it contacts bearing bore. sm02348
c. Thread pilot onto sprocket shaft until contact is made

with shoulder.
d. See Figure 3-32. Slide SPROCKET SHAFT OIL SEAL
INSTALLER (Part No. HD-39361-B) over pilot until it
contacts oil seal.
e. Slide bearing and large flat washer over pilot until
contact is made with seal installer.
f. Thread handle onto pilot shaft.
g. See Figure 3-33. Rotate handle until oil seal installer
makes firm contact with crankcase.
h. Remove seal installer tools from sprocket shaft.
12. Slide sprocket shaft spacer over end of sprocket shaft and
push into oil seal until seated against bearing race.
sm04060
1
4
5
8
7 Figure 3-33. Sprocket Shaft Oil Seal Installer
2
3
9 6
Figure 3-31. Crankcase Torque Sequence (left side)

HOME
OIL COOLER 3.9

OIL COOLER OPERATION INSTALLATION
NOTE PART NUMBER TOOL NAME
The following information pertains only to models with Twin HD-97087-65B HOSE CLAMP PLIERS
Cam 103™ or larger engines equipped with an oil cooler.
1. See Figure 3-34. If replacing the hoses, place new hose
The flow of oil to the cooler is controlled by a thermostat in an
clamps (2) on the oil cooler end of the hoses.
adapter located between the oil filter and the filter mount.
2. Push the supply and return hoses onto the fittings of the
Under pressure from the crankcase, engine oil flows from the
oil cooler.
crankcase oil filter mount into a passage in the oil cooler
adapter. The thermostat is located between the supply and 3. Align the hoses as necessary and use HOSE CLAMP
return ports of the adapter and consists of a temperature PLIERS (Part No. HD-97087-65B) to tighten the hose
sensitive element compressed between a spring and a threaded clamps.
plug.
4. Secure cooler to frame and tighten screws (1) to 20-22 ft-
When the engine oil temperature is below 200 °F (93 °C), an lbs (27.1-29.8 Nm).
open thermostat allows the largest percentage of engine oil in
the supply port to pass through to the return port and then to 5. Place clamps (5) on hoses and install the oil hoses into
the oil filter. A smaller percentage flows through the oil cooler. the fittings of the oil cooler adapter. Secure clamps on
hoses at oil cooler adapter.
When oil temperature exceeds 200 °F (93 °C), the thermostat
closes and all the oil flows through the supply hose to the oil 6. Check the condition of grommets (11) and replace as
cooler. necessary. Install cover (4), upper latches first, then push
down and back to engage lower pins into grommets.
The oil circulates through the finned tubes of the cooler to dis-
sipate heat and returns to the oil cooler adapter through a 7. Check oil level and add oil as required.
return hose.
8. After running engine, inspect oil cooler hose fittings for
The oil is then filtered before returning to the crankcase. leaks.
NOTE
Regardless of whether the thermostat is closed or open, oil is sm06159c
always pressurized in the oil cooler adapter, the oil cooler 9

supply hose, the oil cooler and the oil return hose. 8 10
At every service interval, the oil cooler fins should be checked
for dirt and debris. 7
REMOVAL
5
PART NUMBER TOOL NAME 3
HD-97087-65B HOSE CLAMP PLIERS
6
1. Cover the front fender to protect finish.

2
2. Place a container under the motorcycle to catch excess
oil.
NOTE 1
Dispose of oil in accordance with local regulations. 11 4
3. See Figure 3-34. Pull out on the bottom of the oil cooler
cover (4) to disengage the lower retaining pins, then pull
up and remove cover from oil cooler. 1. Screw (2)
2. Clamp (2)
4. Remove screws (1) securing the oil cooler (3) to the frame. 3. Oil cooler
5. Slide clamps (5) down the oil hoses (6, 7) and disconnect 4. Cover
hoses from the oil cooler adapter (8). 5. Hose clamp (2)
6. Return oil hose
6. Remove the oil cooler. 7. Supply oil hose
7. Inspect oil cooler for dirt, debris and damage. 8. Oil cooler adapter
9. Oil filter adapter
8. If removing the hoses from the oil cooler, use HOSE 10. Oil filter
CLAMP PLIERS (Part No. HD-97087-65B) to cut clamps 11. Grommet (2)
(2) on the supply and return hoses.
Figure 3-34. Oil Cooler

HOME
OIL COOLER ADAPTER 3.10

REMOVAL
sm04065
HD-42311 OIL FILTER WRENCH 3
NOTE
The following information pertains only to models with Twin
Cam 103™ or larger engines equipped with an oil cooler.
1. Place a container under motorcycle to catch excess oil.
2. Bend a cardboard funnel and fit to motorcycle to route
fluid away from regulator and oil cooler toward the con-
tainer. 1
3. Use OIL FILTER WRENCH (Part No. HD-42311) to
remove the oil filter.
4. Remove the clamps from the oil hoses at the adapter. 2
5. See Figure 3-35. Remove the oil filter adapter (1).
6. Remove the oil cooler adapter (2) with the gasket (3).
1. Inspection cover
DISASSEMBLY 2. Gasket
3. Positioning bosses
1. See Figure 3-36. Inspect the crankcase mating surface
and, if necessary, remove any old gasket material. Figure 3-36. Oil Cooler Adapter
2. Remove the inspection cover (1) and gasket.
3. Remove the two oil cooler line fittings. ASSEMBLY
NOTE 1. Install the inspection passage cover and new gasket.
Replace the oil cooler adapter if the thermostat is not func-
2. Clean all residual oil and threadlocking compound from
tioning.
the threaded holes and screws.
4. Clean the oil filter mount surface of old filter gasket
3. Apply one drop LOCTITE 246 THREADLOCKER MEDIUM
material.
STRENGTH/HIGH TEMPERATURE to the fasteners and
5. Clean the oil passages in solvent. tighten to 90-120 in-lbs (10.2-13.6 Nm).
6. Inspect the oil passages and the oil cooler mount. 4. See Figure 3-37. Install the supply (1) and return (2) port
oil line fittings.
a. Finger tighten.
sm04064a 3
b. From finger tight, turn 2-3 more turns.
2
INSTALLATION
1. See Figure 3-36. Match the positioning bosses (3) on the
oil cooler adapter to the oil filter mount.
1 NOTE
The oil cooler adapter will only fit in one location.
2. Clean all residual oil and threadlocking compound from
the threaded hole in the crankcase and threads of the oil
filter adapter.
3. Apply LOCTITE 246 THREADLOCKER MEDIUM
1. Oil filter adapter STRENGTH/HIGH TEMPERATURE to the threads of the
2. Oil cooler adapter oil filter adapter.
3. Gasket
NOTE
Figure 3-35. Oil Cooler Adapter Exercise care when starting oil filter adapter to prevent cross-
threading.

HOME
4. Hold oil cooler adapter in place and install the oil filter
sm04066
adapter with the internal hex facing outward. Tighten to
18-22 ft-lbs (24.4-29.8 Nm).
5. Install the oil hoses and clamps. 1
6. Install a new oil filter.
2
Oil level cannot be accurately measured on a cold engine.

For pre-ride inspection, with motorcycle leaning on jiffy
stand on level ground, oil should register on dipstick
between arrows when engine is cold. Do not add oil to
bring the level to the FULL mark on a COLD engine.
(00185a)
7. Perform an oil level COLD CHECK.
NOTE
Add only enough oil to bring the level between the two arrows
on the dipstick.
3
Do not operate the engine when the oil level is below the 1. Supply port
add mark on the dipstick at operating temperature. Engine 2. Return port
damage will result. (00187b) 3. Oil filter gasket surface
8. Start engine and check for oil leaks. Figure 3-37. Oil Line Fittings on Adapter
9. When at operating temperature, perform an oil level HOT

CHECK.

NOTES

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
4.2 AIR CLEANER BACKPLATE ASSEMBLY.................................................................................4-2
FUEL SYSTEM
NOTES
HOME

CHAPTER
in this chapter.

Air cleaner breather bolts 22-24 ft-lbs 29.8-32.5 Nm 4.2 AIR CLEANER BACKPLATE
ASSEMBLY, Installation
Air cleaner studs 55-60 in-lbs 6.2-6.8 Nm 4.2 AIR CLEANER BACKPLATE
2011 FLHTCUSE6 Service Supplement: Fuel System 4-1

HOME
AIR CLEANER BACKPLATE ASSEMBLY 4.2

REMOVAL 7. Install air cleaner element. See 1.4 AIR FILTER ELE-
MENT.
1. Remove air cleaner element. See 1.4 AIR FILTER ELE-
MENT.
sm06303
2. See Figure 4-1. Remove breather bolts (2) and O-rings 3 4
(3). Discard O-rings.
3. Remove air cleaner studs (1).
4. Remove air cleaner backing plate (4), gasket (5) and O- 2
rings. Discard gaskets and O-rings.
INSTALLATION
1. See Figure 4-1. Position new gasket (5) and two new O- 5
rings (3) on air cleaner backing plate (4).
1
2. Place air cleaner backing plate into position over throttle
body.
3. Install but do not tighten air cleaner studs (1) into throttle
body. 1. Air cleaner stud (3)
2. Breather bolts (2)
4. Place new O-rings on breather bolts (2). Install, but do 3. O-ring (4)
not tighten, breather bolts into cylinders. 4. Air cleaner backing plate
5. Tighten air cleaner studs to 55-60 in-lbs (6.2-6.8 Nm). 5. Gasket
6. Tighten breather bolts to 22-24 ft-lbs (29.8-32.5 Nm). Figure 4-1. Air Cleaner Backing Plate
4-2 2011 FLHTCUSE6 Service Supplement: Fuel System

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
5.2 SPECIFICATIONS: DRIVE........................................................................................................5-2
5.3 CLUTCH RELEASE BEARING AND PUSHROD......................................................................5-3
DRIVE
NOTES
HOME

CHAPTER
in this chapter.

Clutch inspection cover 84-108 in-lbs 9.5-12.2 Nm 5.3 CLUTCH RELEASE BEARING AND
PUSHROD, Installation
2011 FLHTCUSE6 Service Supplement: Drive 5-1

HOME
SPECIFICATIONS: DRIVE 5.2

GENERAL
Table 5-3. Drive Ratios
Table 5-1. Primary Chaincase Lubricant GEAR TRANSMISSION OVERALL

1 3.34 9.593
ITEM DRY FILL WET FILL
2 2.31 6.650
Amount 45 oz (1.32 l) 38 oz (1.12 l)
3 1.72 4.938
Part No. SYN3 20W50 (Part No. 99824-03/00QT
quart) 4 1.39 4.000
5 1.18 3.407
NOTES
6 1.00 2.875
• A dry fill is required any time the primary cover has been
removed and replaced.
NOTES
• A wet fill is required when the primary chain case lubricant • Transmission gear ratios indicate the number of mainshaft
has only been drained through the primary drain plug. revolutions required to drive the output sprocket one
revolution.
Table 5-2. Sprocket Teeth • Overall gear ratios indicate the number of engine revolu-
DRIVE ITEM NUMBER OF tions required to drive the rear wheel one revolution.
TEETH
Primary Engine 34
Clutch 46
Final Transmission 32
Rear wheel 68
5-2 2011 FLHTCUSE6 Service Supplement: Drive

HOME
CLUTCH RELEASE BEARING AND PUSHROD 5.3

REMOVAL
sm04072

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
1. Remove seat.
2. Remove negative cable from battery. 5
2
3. See Figure 5-1. To access clutch release bearing, remove
clutch inspection cover. 4
4. See Figure 5-2. Remove bearing plate retaining ring (1).
5. Pull out release bearing plate (3) with release bearing (4)
and push rod (5). 3
6. Remove push rod retainer (2).
7. Press release bearing out of bearing plate. 1
INSTALLATION
1. Bearing plate retaining ring
1. See Figure 5-2. Pressing on the outer race, press a new 2. Push rod retainer
release bearing (4) into bearing plate (3). 3. Release bearing plate
2. Assemble push rod (5) to bearing. 4. Release bearing
5. Push rod
3. Snap in push rod retainer (2).
Figure 5-2. Push Rod and Release Bearing
4. Slide push rod and clutch release bearing assembly
through clutch pack to secondary clutch actuator.
5. Snap in bearing plate retaining ring (1). Measure Release Plate Movement
1. Attach the standoff of a dial indicator to one of the 1/4-20
NOTE clutch-inspection (derby) cover mounting holes, or use a
Before installing clutch inspection cover check push rod and magnetic base and dial indicator mounted suitably. Posi-
release plate movement as follows. tion the indicator anvil (rod) to the end of the push rod.
sm04071
Insufficient clutch-release plate movement can lead to

difficulty or inability to shift, causing loss of control, which
could result in death or serious injury. (00345a)
2. Actuate the clutch lever to measure the axial movement
of the push rod and the clutch-release plate assembly.
The axial movement must be at least 0.080 in. (2.03 mm).
NOTE
Proper bleeding of the system will typically yield plate move-
ment of greater than 0.080 in. (2.03 mm). If clutch release plate
movement is less than 0.080 in. (2.03 mm), the system must
be bled and plate movement measured again.
Install Clutch Inspection Cover

Figure 5-1. Clutch Release Bearing 1. Thoroughly clean all gasket material from clutch inspection
cover and mating surface on primary cover.
2. See Figure 5-3. Install clutch inspection cover with new
gasket. Make sure the correct side of the gasket faces the
clutch inspection cover. In sequence shown, tighten
fasteners to 84-108 in-lbs (9.5-12.2 Nm).
2011 FLHTCUSE6 Service Supplement: Drive 5-3

HOME
3. Connect negative (-) battery cable to battery.

sm04073

causing loss of control, which could result in death or 1
serious injury. (00070b) 4 3
4. Install seat.
2 5
Figure 5-3. Clutch Inspection Cover Torque Sequence
5-4 2011 FLHTCUSE6 Service Supplement: Drive

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
6.2 SPECIFICATIONS: TRANSMISSION........................................................................................6-2
6.3 CLUTCH RELEASE COVER.....................................................................................................6-3
6.4 SECONDARY CLUTCH ACTUATOR........................................................................................6-5
TRANSMISSION
NOTES
HOME

CHAPTER
in this chapter.

Clutch fluid line flare nut 72-120 in-lbs 8.1-13.6 Nm 6.3 CLUTCH RELEASE COVER, Installation
Clutch release cover screw 84-132 in-lbs 11.6-18.2 Nm 6.3 CLUTCH RELEASE COVER, Installation
Filler plug and dipstick 25-75 in-lbs 2.8-8.5 Nm 6.3 CLUTCH RELEASE COVER, Fill and Bleed
Transmission drain plug 14-21 ft-lbs 19.0-28.5 Nm 6.3 CLUTCH RELEASE COVER, Fill and Bleed
2011 FLHTCUSE6 Service Supplement: Transmission 6-1

HOME
SPECIFICATIONS: TRANSMISSION 6.2

GENERAL
Table 6-2. Transmission Gear Ratios
Table 6-1. Transmission Data GEAR GEAR RATIO

First (low) 3.34
ITEM DATA
Second 2.31
Type 6-speed Cruise Drive™
forward - constant mesh Third 1.72
SYN3 20W50 Quart Part No. 99824-03/00QT Fourth 1.39
Capacity 32 oz. (946 ml) Fifth 1.19
Sixth (high) 1.00
NOTE
Transmission gear ratios indicate the number of mainshaft
revolutions required to drive the output sprocket one revolution.
6-2 2011 FLHTCUSE6 Service Supplement: Transmission

HOME
CLUTCH RELEASE COVER 6.3

REMOVAL
sm04074
1. Remove filler plug and dipstick.
2. Place a suitable container under transmission. Remove
magnetic drain plug at bottom right of oil pan and drain 1 1
transmission lubricant.
3. Remove seat.
2

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
4. Remove negative battery cable.
5. To access the clutch release cover assembly, remove
right side exhaust system. See the service manual.
6. Place a pan under clutch release cover. Remove cap and 1. Hole for locating dowel
open bleeder valve. Loosen flare nut and allow clutch fluid 2. Secondary clutch actuator
to drain.
Figure 6-1. Inside Clutch Release Cover
7. Remove clutch fluid line from cover and drain line. See
2.13 BLEEDING CLUTCH FLUID LINE.
NOTE INSTALLATION
Dispose of clutch fluid in accordance with local regulations. 1. See Figure 6-2. Place a new clutch release gasket (2) on
8. See Figure 6-3. Discard O-ring on end of clutch fluid line. locating dowels (1) and position clutch release cover on
transmission side door.
NOTE
Clutch fluid line O-ring may stick to inside of clutch release 2. Install fasteners with the two short fasteners at the top of
cover. Use a non-metallic pick to remove old O-ring and other the release cover. Tighten fasteners to 84-132 in-lbs
debris. (11.6-18.2 Nm).
9. Remove clutch release cover fasteners, cover and gasket. 3. See Figure 6-3. Install a new clutch fluid line O-ring on
the end of the clutch fluid line.
10. Clean and inspect clutch release cover. Clean with dena-
tured alcohol or D.O.T. 4 HYDRAULIC BRAKE FLUID 4. Install clutch fluid line flare nut to clutch release cover.
(Part No. 99953-99A) only. Tighten to 72-120 in-lbs (8.1-13.6 Nm).
NOTE
If required, replace locating dowels in transmission side door. sm04075
11. See Figure 6-1. Disassemble and inspect secondary clutch

actuator (2). Rebuild if required. See 6.4 SECONDARY 1
1
CLUTCH ACTUATOR. 2
1. Locating dowels
2. Gasket
Figure 6-2. Transmission Side Door

HOME
sm04076
FILL AND BLEED
1. Fill clutch reservoir and bleed clutch fluid system. See
2.13 BLEEDING CLUTCH FLUID LINE.
2. Inspect O-ring on transmission lubricant drain plug and
replace as necessary. Install drain plug and tighten to 14-
21 ft-lbs (19.0-28.5 Nm).
3. Fill the transmission with 32 oz. (946 ml) of transmission
lubricant or until the lubricant level on the dipstick of the
filler plug is at the F (FULL) mark with the motorcycle level
and upright and the filler plug resting on the threads. Use
only Screamin' Eagle SYN3 Synthetic Motorcycle Lub-
ricant.
4. Inspect the filler plug and dipstick O-ring and install filler
plug/dipstick. Tighten the plug to 25-75 in-lbs (2.8-8.5
Nm).
5. Install exhaust system. See the service manual.
6. Install negative battery cable.

Figure 6-3. Clutch Fluid Line O-ring locked in position. While riding, a loose seat can shift
7. Install seat.

HOME
SECONDARY CLUTCH ACTUATOR 6.4

REPLACEMENT 6. While pushing piston into actuator bore, use a wooden
tooth pick or the end of a cable strap to prevent primary
1. Remove the clutch release cover. See 6.3 CLUTCH cup from rolling over.
RELEASE COVER.
7. Install the clutch release cover. See 6.3 CLUTCH
RELEASE COVER.
Compressed air can pierce the skin and flying debris from sm04077
safety glasses when working with compressed air. Never 1
use your hand to check for air leaks or to determine air 2
2. Remove piston.
a. Install bleeder valve if removed. 3
b. Support on a wooden block and apply low pressure
compressed air to clutch fluid line hole to remove
piston from cover bore.
3. See Figure 6-4. Remove the piston and spring. Discard

spring and piston assembly.
Avoid leakage. Prevent damage to piston or piston bore.

Use non-metallic tools when servicing clutch actuator.
(00328a)
4. Lubricate new piston assembly and piston bore with the 1. Piston
service kit lubricant. 2. Primary cup
3. Spring
5. Install new spring.
Figure 6-4. Secondary Clutch Actuator Components

NOTES

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
7.2 ELECTRICAL PROTECTION....................................................................................................7-2
7.3 HEADLAMP...............................................................................................................................7-3
7.4 AUXILIARY LAMPS AND BRACKETS......................................................................................7-6
7.5 FRONT TURN SIGNALS.........................................................................................................7-10
7.6 TOUR-PAK LIGHTING.............................................................................................................7-11
7.7 HEATED SEAT.........................................................................................................................7-15
7.8 HEATED HANDGRIPS............................................................................................................7-17
7.9 IGNITION/FORK LOCK KNOB................................................................................................7-19
7.10 FAIRING CAP AND SWITCHES............................................................................................7-21
7.11 DTC P1655, P1656................................................................................................................7-23
7.12 PASSENGER HEADSET RECEPTACLE..............................................................................7-27
7.13 XM SATELLITE RADIO.........................................................................................................7-28
7.14 ROAD TECH ZŪMO 660 GPS...............................................................................................7-33
7.15 RADIO SOFTWARE UPDATE...............................................................................................7-38
7.16 ADVANCED AUDIO RADIO..................................................................................................7-39
7.17 ADVANCED AUDIO AMPLIFIER...........................................................................................7-40
7.18 GARAGE DOOR OPENER....................................................................................................7-42
ELECTRICAL
7.19 TWIST GRIP SENSOR (TGS)...............................................................................................7-46
7.20 POWER LOCKS....................................................................................................................7-48
7.21 HARLEY-DAVIDSON SMART SECURITY SYSTEM............................................................7-57
7.22 ULTRA CRUISE CONTROL..................................................................................................7-60
NOTES
HOME

CHAPTER
in this chapter.

Amplifier fasteners 96-108 in-lbs 10.8-12.2 Nm 7.17 ADVANCED AUDIO AMPLIFIER, Installation
Auxiliary lamp/turn signal bracket screw 15-20 ft-lbs 20.3-27.1 Nm 7.4 AUXILIARY LAMPS AND
BRACKETS, Installing Lamp Bracket
Dash pad screws 20-25 in-lbs 2.3-2.8 Nm 7.14 ROAD TECH ZŪMO 660 GPS, Mount and
Harness
Door opener mount bracket screw 35-45 in-lbs 3.9-5.1 Nm 7.18 GARAGE DOOR OPENER, Transmitter
Fairing cap screws 25-30 in-lbs 2.8-3.4 Nm 7.10 FAIRING CAP AND SWITCHES, Installation
GPS unit bracket screw 20-25 in-lbs 2.3-2.8 Nm 7.14 ROAD TECH ZŪMO 660 GPS, Mount and
Harness
GPS unit cradle screw 14-20 in-lbs 1.6-2.3 Nm 7.14 ROAD TECH ZŪMO 660 GPS, Mount and
Harness
Headlamp door screw 9-18 in-lbs 1.0-2.0 Nm 7.3 HEADLAMP, Installation
Headlamp retaining ring screw 23-28 in-lbs 2.6-3.2 Nm 7.3 HEADLAMP, Installation
Ignition/lights switch nut 85-115 in-lbs 9.6-13.0 Nm 7.9 IGNITION/FORK LOCK KNOB, Power Lock
Ignition Knob
Latch hook nut, Tour-Pak 25-35 in-lbs 2.8-4.0 Nm 7.20 POWER LOCKS, Power Lock Lockset: Tour-
Pak
Lockset retaining nut, Tour-Pak 30-45 in-lbs 3.4-5.1 Nm 7.20 POWER LOCKS, Power Lock Lockset: Tour-
Pak
Power lock module bracket fastener 30-50 in-lbs 3.4-5.6 Nm 7.20 POWER LOCKS, Power Lock Module
Power lock module fastener 20-40 in-lbs 2.3-4.5 Nm 7.20 POWER LOCKS, Power Lock Module
Radio chassis mounting screws 35-45 in-lbs 4.0-5.1 Nm 7.16 ADVANCED AUDIO RADIO, Installation
Saddlebag lamp nuts 22 in-lbs 2.5 Nm 7.6 TOUR-PAK LIGHTING, Tour-Pak Lamps
Saddlebag latch cover screws 25 in-lbs 2.8 Nm 7.20 POWER LOCKS, Power Locks: Saddlebags
Turn signal bracket screw 96-120 in-lbs 10.8-13.6 Nm 7.5 FRONT TURN SIGNALS, Installation
Wrap-around Tour-Pak Light flange nuts 15 in-lbs 1.7 Nm 7.6 TOUR-PAK LIGHTING, Wrap-Around Lights
Wrap-around Tour-Pak Light screws 12 in-lbs 1.3 Nm 7.6 TOUR-PAK LIGHTING, Wrap-Around Lights
2011 FLHTCUSE6 Service Supplement: Electrical 7-1

HOME
ELECTRICAL PROTECTION 7.2

FUSES AND RELAYS The main fuse is also located in the left electrical caddy.
The fuse and relay block is located in the left electrical caddy,
under the left side cover. See Figure 7-1 for fuse assignments.
om01166b
1 2 3 4
5 6 7 8
11
10 13 26
9 12
14 15 16
17
19 20
18
21 22
23 24 25
1. Brake (15 amp) 10. System relay 19. Headlamp (15 amp)
2. Accessory (15 amp) 11. Power lock (15 amp) 20. Lights (15 amp)
3. P&A (15 amp) 12. GPS (2 amp) 21. Heated grips (5 amp)
4. Radio power (15 amp) 13. Start relay 22. Spare (15 amp)
5. Radio memory (15 amp) 14. P&A ignition (2 amp max) 23. ABS (30 amp)
6. Battery (15 amp) 15. Instruments (15 amp) 24. Amplifier (30 amp)
7. ECM power (15 amp) 16. Ignition (15 amp) 25. Spare (30 amp)
8. Power outlet (15 amp) 17. Lighting relay 26. Main fuse (40 amp)
9. Fuel pump (15 amp) 18. Brake relay
Figure 7-1. Fuses
7-2 2011 FLHTCUSE6 Service Supplement: Electrical

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HEADLAMP 7.3
GENERAL
ed01579
See Figure 7-2. The headlamp assembly used on domestic
models contains two headlamp bulbs: a low beam bulb (1) and
2
a separate high beam bulb (2). See the service manual for
repair of the headlamp used on international models.
REMOVAL
1. Place a clean shop cloth or fender protector over front
fender.
2. See Figure 7-3. Remove screw (1). Pull straight out gently
on bottom of headlamp door (2). When bottom of door
clears headlamp lens, lift up on door slightly and remove
from vehicle.
3. See Figure 7-4. Support glass headlamp shell (2) and
remove three screws (1). Remove retaining ring (3). Lay
headlamp shell on fender protector.
4. See Figure 7-5. Pinch latches (4) together and remove
connectors from headlamp bulbs.
NOTE
See Figure 7-6. Sockets on back of headlamp shell are part 1
of bulb assemblies.
1. Screw
2. Headlamp door
Figure 7-3. Headlamp Door
Handle bulb carefully and wear eye protection. Bulb con-
tains gas under pressure, which, if not handled carefully,
could cause serious eye injury. (00062b)
5. Turn bulb socket counterclockwise approximately 1/8 turn ed01580
and pull straight out to remove bulb. Discard bulb.
1 3
ed01578
2
1
1
1
2
1. Screw (3)
2. Headlamp shell
3. Retaining ring
1. Low beam bulb Figure 7-4. Headlamp Mounting
2. High beam bulb
Figure 7-2. Headlamp Assembly

HOME
1. Install new bulb(s) into headlamp shell.

ed01581
a. Insert bulb into appropriate hole in shell with bulb
socket pointing at the approximate 4 o'clock position.
b. Turn bulb clockwise to lock in place.
3
2. Mate connectors to bulb sockets.
4 3. See Figure 7-7. Position headlamp shell into mounting

4 ring (1). Hold in place with retaining ring (2). Secure
retaining ring with three screws (3). Tighten to 23-28 in-
lbs (2.6-3.2 Nm).
4. See Figure 7-8. Make sure rubber gasket (2) is in place
in headlamp door (1) and not deformed or damaged. Make
2 sure gasket springs (3) are holding gasket in place. Make
sure top spring (4) is in place and located at top center of
door.
5. Install headlamp door.
a. Fit square-shaped portion of top spring into slot at top
1
of backplate.
b. Carefully press door down around headlamp lens.
When correctly installed, equal amounts of gasket
1. Headlamp shell should be visible between door and headlamp shell.
2. Low beam harness connector [38LOB]
3. High beam harness connector [38HIB] 6. Secure door at bottom with screw. Tighten to 9-18 in-lbs
4. Latch (2 per connector) (1.0-2.0 Nm).
Figure 7-5. Headlamp Bulb Connectors 7. Check headlamp alignment. See service manual for pro-
cedure.
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ed01582
3
1. Mounting ring
2. Retaining ring
Figure 7-6. Headlamp Bulb
3. Screw (3)
Figure 7-7. Headlamp Support
INSTALLATION
Never touch the quartz bulb. Fingerprints will etch the

glass and decrease bulb life. Handle the bulb with paper
or a clean, dry cloth. Failure to do so could result in bulb
damage. (00210b)
NOTE
Low beam is upper bulb (green label). High beam is lower bulb
(yellow label).

HOME
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1 2
1. Headlamp door
2. Rubber gasket
3. Gasket spring (2)
4. Top spring
Figure 7-8. Headlamp Door Assembly

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AUXILIARY LAMPS AND BRACKETS 7.4

REMOVING LAMPS
1. Remove outer fairing. See service manual.
2. Separate turn signal/auxiliary lamp connector [31] hous-
ings.
3. See Figure 7-9. Remove GY/BK wire terminal (9) from
socket housing (10). See service manual for procedures.
Refer to Table 7-1.
4. Remove cable straps from conduit.
5. Attach a chaser wire or string to the terminal of the GY/BK
wire lead.
NOTE
Use a flare nut socket (SNAP-ON Part No. FRX181) to remove
and install auxiliary lamps.
6. See Figure 7-9. Remove nut (1), lockwasher (2) and clamp
block (3).
7. Remove auxiliary lamp assembly (4) and rubber isolator
(5) from bracket (6) while slowly pulling wire through con-
duit and bracket.

HOME
8. Separate chaser wire from GY/BK wire and leave in place REMOVING LAMP BRACKET
for installation.
1. Remove turn signal assembly. See 7.5 FRONT TURN
SIGNALS.
Table 7-1. Turn Signal/Auxiliary Lamp Connector [31]
2. See Figure 7-9. Remove two screws (7) and washers (8).
Left Side [31LA] Right Side [31RA]
3. Remove bracket from motorcycle.
WIRE TERMINAL WIRE TERMINAL
COLOR COLOR INSTALLING LAMP BRACKET
GY/BK 4 GY/BK 4
1. Align bracket with mounting holes on front fork assembly.
2. Install washers and screws.
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3. Tighten screws to 15-20 ft-lbs (20.3-27.1 Nm).
4. Install turn signal assembly. See 7.5 FRONT TURN SIG-
NALS.
INSTALLING LAMPS
1. Thread rubber isolator onto wire and over mounting stud.
4
2. Using chaser wire used during removal, pull wire lead
through bracket and up through conduit to the connector
[31].
9 NOTE
10
Liquid glass cleaner may be used to aid in pulling wires through
conduit.
8 3. Position rubber isolator and auxiliary lamp assembly onto
7 auxiliary lamp bracket.
4. Install clamp block, lockwasher and nut.
5. See Figure 7-10. Orient lamps straight ahead and hori-
zontal. Finger-tighten nut.
NOTE
Align the lamps and tighten the nut to the specified torque
before operating the motorcycle.
5 6. Install terminal into appropriate cavity of socket housing.

6
NOTE
3 See service manual for wire lead terminal service procedures.
7. Mate connector halves of auxiliary lamp connector.
2 8. Proceed to Final Assembly.
1
Final Assembly
1. Install turn signal assembly. See 7.5 FRONT TURN SIG-
NALS.
2. Install outer fairing and align lamps. See service manual.
1. Nut
2. Lockwasher
3. Clamp block
4. Lamp assembly
5. Rubber isolator
6. Bracket
7. Bracket screws (2)
8. Washers (2)
9. Socket terminal
10. Socket housing
Figure 7-9. Auxiliary Lamps and Brackets

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ed01587 ed01590
6
7
4
3
5 2
8
1. Bulb reflector
Figure 7-10. Headlamp and Auxiliary Lamps
2. Bezel ring screw
3. Bezel
4. Lamp housing
REPLACING BULB 5. Connector
1. See Figure 7-11. Holding bulb reflector (1) in place, loosen 6. Bulb assembly
screw (2) from nut (8) enough to remove bezel ring (3) 7. Nesting ring
from lamp housing (4). 8. Nut
NOTE Figure 7-11. Auxiliary Lamp Assembly

See Figure 7-12. Socket on back of reflector is part of bulb
assembly.
ed01591
Handle bulb carefully and wear eye protection. Bulb con-

tains gas under pressure, which, if not handled carefully,
could cause serious eye injury. (00062b)
2. See Figure 7-11. Unplug connector (5) from socket on
back of bulb reflector. This socket is part of bulb assembly
(6).
3. Remove nesting ring (7) from reflector.
4. See Figure 7-12. Hold reflector so that socket is facing
you. Grasp socket, turn counterclockwise (1) approximately
1/8 turn and remove bulb assembly from reflector. Discard 2 1
bulb assembly.
1. Loosen
2. Tighten
Figure 7-12. Replacing Bulb in Reflector
Never touch the quartz bulb. Fingerprints will etch the

glass and decrease bulb life. Handle the bulb with paper
or a clean, dry cloth. Failure to do so could result in bulb
damage. (00210b)
5. Install new bulb assembly into reflector housing, being
careful not to touch glass bulb. Turn assembly approxim-
ately 1/8 turn clockwise (2) to secure.
6. See Figure 7-14. Place nesting ring (2) onto reflector (1)
so that concave surface of nesting ring faces away from
reflector, nesting ring index tab (5) is at the bottom, and
reflector index tabs (3) fit inside nesting ring slots (4).

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7. Plug connector into socket in reflector.

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8. Mount reflector into lamp housing, fit bezel ring onto 4
assembly and secure with screw and nut. 2
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3
Figure 7-13. Auxiliary Lamp Bulb/Pin Housing

1 5
1. Reflector
2. Nesting ring
3. Reflector index tab (2)
4. Nesting ring slot (2)
5. Nesting ring index tab
Figure 7-14. Assembling Reflector and Nesting Ring

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FRONT TURN SIGNALS 7.5

1. Remove outer fairing. See service manual. 1. Lay old turn signal lamp next to new turn signal lamp and
cut wires to length.
2. Separate turn signal/auxiliary lamp connector.
2. One at a time, push wire leads through mounting bracket.
3. See Figure 7-15. Remove the three turn signal terminals
and leads (1) from the connector housing. 3. Secure chaser wire or string to wire leads and pull wires
through conduit.
NOTE
See service manual for wire lead and terminal service proced- NOTE
ures. Liquid glass cleaner may be used to aid in pulling wires through
conduit.
4. Remove cable straps from conduit.
4. Install fastener to secure turn signal assembly and stand
5. Cut off the terminals.
off to mounting bracket.
6. Secure chaser wire or string to end of wires.
5. Strip 3/16 in. (4.8 mm) of insulation off new lamp wires
7. Support the turn signal assembly (2) and stand-off (3) and crimp on new socket terminals.
while removing fastener (4) and washer (5) to release turn
NOTE
signal from mounting bracket (6).
See service manual for wire lead and terminal service proced-
8. Pull turn signal wires through conduit and through hole in ures.
mounting bracket. 6. Refer to Table 7-2. Matching wire lead color to cavity
number, install socket terminals into housing.
ed01594 7. Mate pin and socket halves of turn signal connector.
8. Install new wire wraps around conduit.
4 9. Point turn signal lens forward and tighten fastener to 96-

120 in-lbs (10.8-13.6 Nm).
Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
6 (00478b)
10. Turn ignition/light key switch to IGNITION and test for
proper operation.
11. Install outer fairing. See service manual.
3 Table 7-2. Turn Signal/Auxiliary Lamp Connector [31]

1
Left Side [31LA] Right Side [31RA]
WIRE TERMINAL WIRE TERMINAL
COLOR COLOR
2 BE (DOM) 1 BE (DOM) 1
V 2 V 2
BK 3 BK 3
GY/BK 4 GY/BK 4
(aux lamp) (aux lamp)
1. Turn signal leads

2. Turn signal assembly
3. Stand-off
4. Fastener
5. Washer
6. Mounting bracket
Figure 7-15. Turn Signal Assembly

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TOUR-PAK LIGHTING 7.6

WRAP-AROUND LIGHTS 2. Install large flat washer and ring terminal onto antenna
connector (1). Install nut and tighten securely.
Removal 3. Connect radio antenna cable.
NOTE
4. Install flat washer, ring terminal, and nut (with tooth
The wrap-around light uses LED-type lamps. Failure of a seg- washer) onto CB antenna stud (4). Tighten nut securely.
ment will require replacement of that segment.
5. Install remaining flange nuts (3) and tighten to 15 in-lbs
1. Remove molded liner with map pouch from Tour-Pak. (1.7 Nm).
2. Remove both antenna masts. 6. Install two screws (5) in each side and tighten to 12 in-lbs
3. See Figure 7-16. Separate connector (2) and remove ter- (1.3 Nm).
minals from housing. See MOLEX CONNECTORS in the 7. Install terminals in connector housing. Refer to Table 7-3.
service manual.
8. Install both antenna masts.
4. Remove nut, tooth washer and ring terminal from CB
antenna stud (4). 9. Install molded liner and map pouch.
5. Disconnect radio antenna cable connector and remove

nut, ring terminal and large flat washer from radio antenna Table 7-3. Wrap-Around Lamp Connector [12-6]
connector (1). CAVITY NO. ASSIGNMENT WIRE COLOR
6. Remove two screws (5) from each side. 1 Tail, right V
7. Remove seven flange nuts (3). Remove lamp assembly 2 Tail, center V
from Tour-Pak. 3 Stop BE
4 Tail, left V
sm06734
5 Ground, right BK
1
6 Ground, center BK
7 Plug -
8 Ground, left BK
2
5 INTERIOR LAMP
1. Separate three lamp harness connectors from Tour-Pak
lighting harness and saddlebag lamps.
3 2. Remove Tour-Pak lock assembly and remove lamp/bracket
assembly. See 7.20 POWER LOCKS, Power Lock
Lockset: Tour-Pak.
3. Install Tour-Pak lock assembly and new lamp/bracket
assembly.
4. Secure lamp harness in anchor clips on cover and mate
three connectors.
4 5. Install upper Tour-Pak liner.
1. Radio antenna stud

TOUR-PAK LAMPS
2. Wrap-around lamp connector 1. Remove lower Tour-Pak liner.
3. Flange nut (7)
4. CB radio antenna stud 2. See Figure 7-17. Separate connector (1) and remove ter-
5. Screws (4) minals from connector housing.
Figure 7-16. Wrap-Around Light 3. Remove harness from anchor clip (2).
4. Remove nuts from hollow studs (3) and remove lamp from
Tour-Pak.
Installation
5. Install lamp and secure with nuts. Tighten nuts to 22 in-
1. See Figure 7-16. Feed lamp harnesses through hole into lbs (2.5 Nm).
Tour-Pak. Install lamp assembly and secure with center
flange nut (3). 6. Install terminals in connector housing (1) and mate con-
nector.

HOME
7. Secure harness in anchor clip (2). INTERIOR AND SADDLEBAG LAMPS

8. Install lower Tour-Pak liner. DIAGNOSTICS
9. Verify lamp operation. Description and Operation
The Tour-Pak lighting system is a LED system that has three
Table 7-4. Saddlebag Lamp Connector parts, the interior lamp and two saddlebag lamps. The lamps
CAVITY WIRE COLOR are turned ON and OFF by pressing the center of the lamp's
lens.
1 Red
Interior lamp: The interior lamp is located in the inside cover
2 White of the Tour-Pak. The interior lamp is the main component of
3 Black the three. It receives the power from the radio memory fuse
and transfers that power to the saddlebag lamps through its
circuit board.
sm06753
Saddlebag lamps: The saddlebag lamps are located on the
underside of the Tour-Pak above the saddlebag. The saddlebag
lamps receive their power from the interior lamp assembly
1 which consists of two power wires. One is to power the circuit
2 board and the other is to power the lamps. Each saddlebag
lamp can be replaced separately.
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
3 the harness test kit terminal probes, see A.1 CONNECTORS.
1. Connector
2. Anchor clip
3. Hollow studs
Figure 7-17. Saddlebag Lamps

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em00908
Fuse Block
[64-1]
Radio Memory
Fuse
15A
Battery R 2A 2B R/O
BK
R/O
BK
1 2 [190A]
1 2 [190B]
GND 1
BK
R
R Interior
BK
Lamp
W/BK
R/BK
R
W/BK
R/BK
BK
BK
W
R
1 2 3 [190A-L] 3 2 1 [190A-R]
1 2 3 [190B-L] 3 2 1 [190B-R]
BK
BK
W
W
R
Left R Right
Saddlebag Saddlebag
Lamp Lamp
Figure 7-18. Tour-Pak Lamp Circuit
LAMPS INOPERATIVE 2. Are all lamps inoperative?

a. Yes. Go to Test 2.
b. No. Interior lamp only. Replace the Tour-Pak light
HD-41404-C HARNESS CONNECTOR TEST KIT
assembly.
c. No. Right saddlebag lamp only. Go to Test 6.
Table 7-5. Lamps Inoperative Diagnostic Faults
d. No. Left saddlebag lamp only. Go to Test 9.
POSSIBLE CAUSES
Power circuit open 2. Interior Lamp Power Test
Ground circuit open 1. Disconnect Tour-Pak lights [190].
Lamp module malfunction 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), test for voltage between [190A] terminals 1 and
1. Lamp Test 2.
1. Turn the interior lamp and both saddlebag lamps ON.
3. Is battery voltage present?
a. Yes. Replace the Tour-Pak light assembly.
b. No. Go to Test 3.

HOME
3. Radio Memory Fuses Test 2. Is battery voltage present?
1. Verify that the radio memory fuse is good. a. Yes. Go to Test 8.
2. Is fuse good? b. No. Replace the Tour-Pak light assembly.
a. Yes. Go to Test 4. 8. Right Saddlebag Lamp Ground Test

b. No. Replace radio memory fuse and repair short to 1. Test for continuity between [190A-R] terminal 3 and
ground on (R/O) wire. (5041) ground.
4. Power Wire Continuity Test 2. Is continuity present?
1. Test for continuity between [190A] terminal 2 and fuse a. Yes. Replace the right saddlebag lamp assembly.
block [64-1] socket terminal 2B. b. No. Replace the Tour-Pak light assembly.
2. Is continuity present?
9. Left Saddlebag Lamp Power (R) Test
1. Disconnect right saddlebag lamp [190-L].
b. No. Repair open in (R/O) wire. (5041)
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
5. Ground Wire Continuity Test 41404-C), test for voltage between [190A-L] terminal 1
and ground.
1. Test for continuity between [190A] terminal 1 and ground.
a. Yes. Intermittent problem. Perform wiggle test. See
the electrical diagnostic manual. Monitor both the b. No. Replace the Tour-Pak light assembly.
(R/O) wire and (BK) wire for open wire.
10. Left Saddlebag Lamp Power (W) Test
b. No. Repair open in (BK) wire. (5041)
1. Test for voltage between [190A-L] terminal 2 and ground.
6. Right Saddlebag Lamp Power (R/BK) Test 2. Is battery voltage present?
1. Disconnect right saddlebag lamp [190-R]. a. Yes. Go to Test 11.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD- b. No. Replace the Tour-Pak light assembly.
41404-C), test for voltage between [190A-R] terminal 1
and ground. 11. Left Saddlebag Lamp Ground Test
3. Is battery voltage present? 1. Test for continuity between [190A-L] terminal 3 and
a. Yes. Go to Test 7. ground.
b. No. Replace the Tour-Pak light assembly. 2. Is continuity present?

a. Yes. Replace the left saddlebag lamp assembly.
7. Right Saddlebag Lamp Power (W/BK) Test
b. No. Replace the Tour-Pak light assembly.
1. Test for voltage between [190A-R] terminal 2 and ground.

HOME
HEATED SEAT 7.7

GENERAL
sm04121a
Controls
See Figure 7-19. The heated seat is controlled by three-position
rocker switches on the left side of the seat. The front switch
controls the rider seat and the rear switch controls the pas-
senger pillion.
• High Heat: Rock the switch at the top for high heat.
• OFF: The OFF position is in the middle.
• Low Heat: Rock the switch at the bottom for low heat.
See Figure 7-20. To remove and install a heated seat, see
2.14 SEAT.
Warm-Up
For safety, after the seat is turned on, 8-10 minutes of warm-
up is required before heat is noticed. Press down on the seat
with your hand to check for heat.
Figure 7-20. Heated Seat Connector [191]
Automatic Shut-Off
For safety concerns, the heated seat is designed to shut-off
automatically after one hour of continuous use. The seat can
DIAGNOSTICS
be turned back on immediately after auto shut-off has occurred, PART NUMBER TOOL NAME
with no harm to the system. To reactivate the heated seat, the
seat switch must be turned OFF and then switched back to the HD-41404-C HARNESS CONNECTOR TEST KIT
desired setting.
Diagnostic Tips
NOTE
If the seat temperature does not change after 8-10 minute
Running a hand over the seat may not detect any change in warm-up period, test the seat continuity using HARNESS
temperature. The heat has to permeate a layer of foam pad- CONNECTOR TEST KIT (Part No. HD-41404-C) and a multi-
ding. Always press down on the seat to check for heat. meter.
Refer to diagnostic procedures that follow for troubleshooting.
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the harness test kit terminal probes, see A.1 CONNECTORS.
Figure 7-19. Heated Seat Rocker Switches

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em00449
3. Heated Seat Ground Circuit Test
1. Test for voltage between [191A] terminal 3 and ground.
a. Yes. Repair open in (BK) ground wire. (5041)
BK
b. No. Repair open in (O/R) wire. (5041)
GND 1A [33A]
[33B] 1 2 3 4. Heated Seat Current Draw Test
R/GY
1. Remove the P&A fuse.
[64-1] 2. Connect [191].
P&A 15A
O/R 1F 1E R/GY 3. Place the heated seat switch for the rider seat in the high
position.
41404-C) and a multimeter, measure the current through
O/R
BK
the P&A fuse.

1 2 3 4 [191A]
[191B] NOTE
When checking current draw, use the 10 Amp maximum fused
terminal on the multimeter and switch the selector to DC Amps.
If during the tests the multimeter shows 0 Amps, check the
multimeter fuse and the terminal location of the meter leads.
Figure 7-21. Heated Seat Circuit 5. Does the current draw increase to 1.5-3.0 Amps?
HEATED SEAT INOPERATIVE b. No. Replace the heated seat assembly. (2506)
5. Heated Seat Passenger Pillion Current
HD-41404-C HARNESS CONNECTOR TEST KIT Draw Test
1. Turn off the rider heated seat.
Table 7-6. Heated Seat Inoperative Diagnostic Faults
2. Place the passenger pillion heated seat in the high posi-
POSSIBLE CAUSES tion.
Open in ground circuit
3. Measure the current through the P&A fuse.
Open in power circuit
4. Does the current draw increase to 0.75-2.0 Amps?
Short to ground in power circuit
a. Yes. System operating properly.
Heated seat malfunction
b. No. Replace the heated seat assembly. (2506)
1. P&A Fuse Test
6. Heated Seat Wire Test
1. Inspect the P&A fuse.
1. Disconnect heated seat [191].
2. Is the fuse good?
2. Inspect seat power harness for pinched or frayed wires.
3. Are any wires pinched or frayed?
a. Yes. Repair wire(s).
2. Heated Seat Circuit Test b. No. Go to Test 7.
1. Install P&A fuse.
7. Heated Seat Circuit Short to Ground Test
2. Disconnect heated seat [191A].
3. Turn IGN ON. 41404-C) and a multimeter, test for continuity between
4. Using HARNESS CONNECTOR TEST KIT (Part No. HD- [191A] terminals 3 and 4.
41404-C) and a multimeter, test for voltage between [191A] 2. Is continuity present?
terminals 3 and 4.
a. Yes. Repair short to ground in (O/R) wire. (5401)
b. No. Replace heated seat assembly and P&A fuse.
a. Yes. Go to Test 4. (2506)

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HEATED HANDGRIPS 7.8

GENERAL
ed01597
See Figure 7-22. The heated handgrips are controlled by the
rotating switch located at the end of the left handgrip. The
switch can be turned from an OFF position through 6 increas-
ingly warm settings. To remove and install a heated handgrip,
see 2.9 HANDGRIPS for service procedures.
2
1
P
T
T
Figure 7-22. Heated Handgrip Control Switch
em00450
[206B] [206A]
BK 1 1 BK
BK/W 2 2 W
[33A]
[33B] 1 2 3
O/W
BK
R/GY
R
[189B] A B C
[189A] A B C
O/W
BK
R
64-1 Accessory
15A
O/W 1D 1C R/GY
BK
GND 1
64-2 Heated
Grips
5A
R 3D 3C R/GY
Figure 7-23. Heated Handgrip Circuit

HOME
HEATED HANDGRIPS INOPERATIVE 4. Accessory Power Supply Test

PART NUMBER TOOL NAME 1. Test for voltage between [189A] terminal A and ground.
HD-41404-C HARNESS CONNECTOR TEST KIT 2. Is battery voltage present?

Table 7-7. Heated Handgrips Inoperative Diagnostic Faults b. No. Repair open in (O/W) wire. (5041)
POSSIBLE CAUSES
5. Heated Grips Ground Circuit Test
Open in the ground circuit
1. Test for continuity between [189A] terminal C and ground.
Open in the power circuit
Short to ground in the power circuit
Right heated grip malfunction
b. No. Repair open in (BK) wire. (5041)
Left heated grip malfunction
1. Heated Grips Fuse Test 6. Heated Grip Circuit Short to Ground Test
1. Inspect the heated grips and accessory fuses. 1. Disconnect the heated handgrips to main harness [189].
2. Are the fuses good? 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between
a. Yes. Go to Test 2. [189A] terminal B and ground.
b. No. Heated grips fuse. Go to Test 6. 3. Is continuity present?
c. No. Accessory fuse. Replace fuse and repair circuit a. Yes. Repair short to ground in (R) wire. (5041)
accordingly. If problem is still present, then continue
with tests. Go to Test 2. b. No. Go to Test 7.
2. Current Draw Test 7. Heated Grips Continuity Test

1. Remove heated grips fuse. 1. Test for continuity between [189B] terminal B and ground.
2. Turn the IGN ON. 2. Is continuity present?

3. With the heated handgrips off, using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404-C) and a multi- b. No. Intermittent concern. Perform Wiggle Test.
meter, measure the current draw across [64-2B] socket
terminal 3C and terminal 3D. 8. Heated Grips Test
4. Turn the heated handgrips control to the maximum setting 1. Disconnect the heated handgrip interconnect [206].
while watching the current draw. 2. Test for continuity between [189B] terminal B and ground.
5. Does the current draw increase to approximately 3 Amps 3. Is continuity present?
above the original reading?
a. Yes. Replace left heated handgrip. See the service
a. Yes. System functioning normally. manual. (6553)
b. No. Go to Test 3. b. No. Replace right heated handgrip. See the service
manual. (6554)
3. Power Supply Test
1. Install the heated grips fuse. 9. Left Heated Grip Continuity Test
2. Disconnect the heated handgrips to main harness [189]. 1. Connect [189].
3. Turn IGN ON. 2. Disconnect the heated handgrip interconnect [206].
4. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 3. With IGN ON turn heated hand grips to HIGH position.
41404-C) and a multimeter, test for voltage between [189A] 4. Test for voltage between [206B] terminals 1 and 2.
terminal B and ground.
5. Is voltage present?
a. Yes. Replace right heated hand grip. See service
a. Yes. Go to Test 4. manual. (6554)
b. No. Repair open in (R) wire. (5041) b. No. Replace left heated hand grip. See service
manual. (6553)

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IGNITION/FORK LOCK KNOB 7.9

POWER LOCK IGNITION KNOB
sm06828
Removal 1
2. Remove headlight assembly. If switch is to be removed,
remove outer fairing instead. See service manual. 2
3. See Figure 7-24. Separate connector (1).
4. Secure chaser wire or string to power lock knob harness.
5. Release the ignition switch knob:
a. Insert the ignition switch key and turn to the
ACCESSORY position. Leave the key installed.
b. Turn the key counterclockwise while pressing button
on bottom of knob to release knob.
1. Connector
c. Lift knob until shaft clears switch. 2. Radio chassis
NOTE Figure 7-24. Power Lock Knob Connector (Typical)
See the service manual for more detailed instructions.
6. See Figure 7-25. Remove nut (3). Pull collar (4) and spacer
(5) off switch.
sm06840
7. Lift the switch plate (6) to pull tabs from slots in left and 1
right speedometer/tachometer housings.. 2 3 4 5
6
8. Remove knob (1), spring (2), nut (3), collar (4), spacer (5)
and switch plate (6) together from motorcycle while pulling
knob harness up through notch in inner left and right
speedometer/tachometer housings.. When connector exits,
remove chaser wire or string.
NOTE
Removal of all components (2-6) require removal of the con-
nector housing.
9. Remove components from harness as necessary:
a. Remove terminals from connector housing.
1. Knob
b. Remove spacer (5), collar (4), nut (3), spring (2) and 2. Spring
switch plate (6) from shaft of ignition knob and har- 3. Nut
ness. 4. Collar
5. Spacer
NOTE
6. Switch plate
No components within the power lock knob are service-
able. Figure 7-25. Power Lock Ignition Knob (Typical)
10. Remove the ignition/lights key switch as outlined in the

service manual.

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sm06846
Table 7-8. Power Lock Ignition Knob
1 WIRE COLOR TERMINAL
GN 1
2 BE 2
3
3. Install spacer (5) and switch plate (6) over harness.
4
4. Secure chaser wire or string to locking knob harness. Feed
5 harness into notch in left and right speedometer/tacho-
meter housings. while pulling chaser wire or string.
5. Install switch plate on left and right speedometer/tacho-
meter housings..
6. Install spacer (5), collar (4), and secure with nut (3).
Tighten nut to 85-115 in-lbs (9.6-13.0 Nm).
1. Knob
7. Install ignition switch knob:
2. Spring
3. Nut a. Rotate key counterclockwise to the UNLOCK position.
4. Collar NOTE
5. Spacer Route the wiring harness down through notch in inner left
Figure 7-26. Component Orientation and right speedometer/tachometer housings. while
inserting knob shaft into switch. Gently pull the wire
through as the knob is inserted to prevent the harness
Installation from bunching, resulting in possible wear damage.
1. Install the ignition/lights key switch as outlined in the ser- b. b. With the knob pointing toward the ACCESSORY
vice manual. position, insert shaft into switch assembly while gently
pulling the harness through.
NOTE
See Figure 7-26. It is important that the following components c. Hold the knob down and turn key clockwise. An aud-
be installed with the correct orientation. ible "click" should be heard when knob and switch
are properly engaged.
2. See Figure 7-25. If removed, install components on har-
ness and shaft: d. Rotate knob through all four switch positions to verify
proper operation. If the knob does not install properly,
a. Place spring (2), nut (3) and collar (4) over shaft of
proceed as outlined in the service manual.
knob, passing the harness through the center of the
spring and nut, and through the square hole in the 8. See Figure 7-24. Route the wiring harness under left fairing
collar. bracket and mate connector (1) halves. Secure connector
b. Verify components are properly oriented. Install ter- to bottom of radio chassis (2) using a new anchored cable
minals in connector housing. Refer to Table 7-8. strap.
9. Install headlight assembly or outer fairing. See the service
manual.
10. Install main fuse.
11. Test power lock knob operation.

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FAIRING CAP AND SWITCHES 7.10

REMOVAL 4. Gently spread the ends to remove the fairing cap, with
switches, from the steering head.
1. Remove the ignition switch knob, and the switch position
plate. See service manual. If equipped with ignition knob 5. Cut cable straps and remove switches (3, 5, 6, 7) or and/or
power lock see 7.9 IGNITION/FORK LOCK KNOB. wire leads as required. See service manual.
2. Remove the two T-27 Torx screws (with flat washers) to NOTE
release the fairing cap. The CRUISE/SPOT switch controller (4) is fixed to the fairing
cap with double sided tape. To remove, pry the controller off
3. See Figure 7-27. With the forks turned to the left fork stop, the fairing.
separate the 12-place Multilock connector [105] (1) and
the 3-place Multilock connector [212] (2).
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2
4
3 5 6 7
1
1. 12-place Multilock connector [105B]
2. 3-place Multilock connector [212B]
3. CRUISE/SPOT switch
4. CRUISE/SPOT controller
5. SPKR switch
6. Power lock switch
7. ACC switch
Figure 7-27. Inner Fairing Cap
INSTALLATION 4. Install new cable straps.
1. Replace switches as required. See service manual for 5. Fit the rubber grommets to the ends of the faring cap.
procedures. 6. With the forks turned to the left fork stop, spread the fairing
NOTE cap over the steering head and ignition switch/fork lock.
Clean the fairing surface under the CRUISE/SPOT controller NOTE
with isopropyl alcohol and use double sided tape to fix the The grommets should capture the handlebar.
controller to the faring.
7. Mate connectors [105] (1) and [212] (2).
2. Replace connector terminals and wire leads as required.
See the service manual. 8. Install and alternately tighten the Torx screws to 25-30 in-
lbs (2.8-3.4 Nm).
3. Install wire terminals into the connector housings as
required. Refer to Table 7-9 and Table 7-10.

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9. Install position plate and switch knob. See service manual

for procedures. If equipped with ignition knob power lock Table 7-10. Main Harness Connector [212]
see 7.9 IGNITION/FORK LOCK KNOB.
SWITCH WIRE COLOR TERMINAL
Power lock GN/BK 1
Table 7-9. Interconnect Harness [105]
Power lock O/R 2
SWITCH WIRE COLOR TERMINAL
Power lock BE/BK 3
CRUISE/SPOT BK 8
CRUISE/SPOT GY/BK 7
CRUISE/SPOT Y 6
CRUISE/SPOT R/GN 5
CRUISE/SPOT O/V 4
SPKR BK/GN 12
SPKR BN/O 11
SPKR V/O 10
SPKR O/BE 9
ACC BK 3
ACC O 2
ACC O/R 1

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DTC P1655, P1656 7.11

DESCRIPTION AND OPERATION
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See Figure 7-28. The Automatic Compression Release (ACR)
is opened and closed by the ECM to assist starting.
See Figure 7-29. When open, compressed gases are released
through the exhaust port.
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2 3
1
Figure 7-29. ACR in Head
1. Rear ACR [203R] diagram(s) and diagnostic procedure(s), including the color of
2. TMAP [80] the harness test kit terminal probes, see A.1 CONNECTORS.
3. Front ACR [203F]
Figure 7-28. Between Cylinders Right Side

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em00905
To Front ACR Rear ACR

Fuel Pump
[203AF] 2 1 2 1 [203AR]
O/GY
[203BF] 2 1 2 1 [203BR]
V/GY
V/GY
Y/GN
Y/GN
TGS
[224A] 6 5 4 3 21
O/GY
[224B] 6 5 4 3 21
ET
TCA
GY
BN
BE
BK
Sensor
R
V
V/GY
4B
Y/GN
Fuel
Pump [211A] 1 2 3 4 5 6 [204A] 6 5 4 3 21 [90A] A B
Fuse TMAP
15A [211B] 1 2 3 4 5 6 [204B] 6 5 4 3 2 1 [90B] A B
4A
Sensor
BK/W
BN/O
BK/GY
BE/GN
BK/W
R/W
PK/Y
BK/W
BN/O
BK/O
BN/R
V/Y
BN/V
BK/PK
[80A]
Y/GN
1 2 3 4
System [80B] 1 2 3 4
Relay
R/W
V/W
BK/GY
LGN/Y
87 5 4C Y/GN
30 3 3D BE/GY
86
85 To 15A
ECM Fuse
Ignition Coil [83A] [83B]
Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O
[65B] [65A]
[84A] [84B]
BN/O A A
Front Fuel A A Y/GN W/GN B B VSS
Injector B B W/Y
BK/Y C C
[85A] [85B]
Rear Fuel A A Y/GN BK/BN 4

Injector B B GN/GY
PK/O 3 Front
[95A] [95B] GN/W 2 HO2S
Y/GN 1
B B GY/Y
A A Y/GN [138A]
Purge Solenoid
(Optional)
BK/BN 4
Rear
PK/GN 3
To 15A 2
HO2S
GN/W
Exhaust Y/GN 1 (BK)
Control Fuse
[137A]
1 LGN/R
Active 2 BK
Exhaust 3 V/O
(HDI Only) 4 V/BE
BK
R
[179B]
GN/GY
PK/GN
BE/GN
BK/GN
GY/BE
BK/GY
BK/BN
LGN/Y
BK/PK
GN/W
W/GN
BK/W
BN/O
Y/GN
V/GY
GY/Y
BK/O
BN/R
BE/O
PK/O
BN/V
V/BE
PK/Y
Y/BE
BK/Y
R/W
V/W
W/Y
V/O
V/Y
BK
2 1 [79A]
R
Right
[78B] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73 GND 2 2 1 [79B]
[78A] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73
HO2S Return
Purge Solenoid
Exhaust Actuator
Rear Fuel Injector
TMAP Sensor Input
Throttle Actuator Control HI

Throttle Actuator Control LO
O2 Heater Ground
Ion Sense
TPS 2
TPS 1
TGS 2
CKP Sensor
Rear HO2 Sensor
ET Sensor
Rear Ignition Coil
TGS 1
5V Sensor Ground 1
5V Sensor Ground 2
CKP Sensor (+)
Ground
ACR Ground
Front Fuel Injector
Front Ignition Coil
Front HO2 Sensor

Exhaust Feedback
5V Sensor Power 1
12V Power
5V Sensor Power 2
Vehicle Speed Input
Vehicle Speed Ground

IAT Sensor
CKP
Sensor
ECM
Figure 7-30. EFI Simplified Schematic

HOME
DTC P1655 4. Is continuity present?

b. No. Replace the ECM. See the service manual. (7080)
HD-34730-2D FUEL INJECTOR TEST LIGHT
HD-41404-C HARNESS CONNECTOR TEST KIT 5. Rear ACR Control Circuit Short to Ground
HD-48637 BREAKOUT BOX Test
1. Disconnect rear ACR [203RB].
Table 7-11. DTC P1655 Diagnostic Faults
2. Test for continuity between [203FB] terminal 2 and ground.
POSSIBLE CAUSES
ACR solenoid malfunction a. Yes. Repair short to ground in (V/GY) wire. (5041)
Open in ACR control circuit
b. No. Replace front and rear ACR solenoids. See the
Open in system relay circuit service manual. (7078)
ECM malfunction
Short to ground in ACR control circuit
6. Shorted ACR Test
1. Disconnect rear ACR [203RB].
1. Front ACR Test 2. Crank engine for 5 seconds.
1. Disconnect front ACR [203F].
3. Does the test light flash on and off?
2. Connect FUEL INJECTOR TEST LIGHT (Part No. HD- a. Yes. Replace front and rear ACR solenoids. See the
34730-2D). service manual. (7078)
3. Crank engine for 5 seconds. b. No. Go to Test 7.
7. ACR Supply Circuit Open Test
1. Disconnect the test light.
b. No, test light stays on steady. Go to Test 4.
2. While cranking the engine, test for voltage between
c. No, did not stay on steady. Go to Test 6.
[203FB] terminal 1 and ground.
2. Rear ACR Test 3. Is battery voltage present?
1. Disconnect rear ACR [203R]. a. Yes. Go to Test 8.
2. Connect FUEL INJECTOR TEST LIGHT (Part No. HD- b. No. Repair open in (Y/GN) wire. (5041)
34730-2D).
8. ACR Control Circuit Continuity Test
3. Crank engine for 5 seconds.
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
4. Does the test light flash on and off? 48637) between wire harness [78B] and ECM [78A] leaving
a. Yes. Replace front and rear ACR solenoids. See the [78A] disconnected.
service manual. (7078)
b. No. Go to Test 3. 41404-C) and a multimeter, test for continuity between
breakout box terminal 19 and [203FB] terminal 2.
3. Rear ACR Control Circuit Test 3. Is continuity present?
1. While cranking the engine, test for voltage between a. Yes. Replace the ECM. See the service manual.
[203RB] terminal 1 and ground. (7080)
2. Is battery voltage present? b. No. Repair open in (V/GY) wire. (5041)
a. Yes. Repair open between [203RB] and [78] (V/GY)
wire. (5041)
b. No. Repair open in (Y/GN) wire. (5041)
4. Front ACR Control Circuit Short to

Ground Test
1. Turn IGN OFF.
2. Disconnect ECM [78].
3. Test for continuity between [203FB] terminal 2 and ground.

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DTC P1656 meter, test for measure voltage between [203FB] terminal
2 and ground.
3. Is voltage greater than 1.0V?
HD-34730-2D FUEL INJECTOR TEST LIGHT
a. Yes. Repair short to voltage between [203FB] terminal
HD-41404-C HARNESS CONNECTOR TEST KIT 2 and [78B] terminal 19 (5041).
b. No. Replace front and rear ACR solenoids. See the
Table 7-12. DTC P1656 Diagnostic Faults service manual. (7078)
POSSIBLE CAUSES
3. Rear ACR Test
Short to voltage in ACR control circuit
1. Disconnect rear ACR [203R].
ACR solenoid malfunction
ECM malfunction
1. Front ACR Test a. Yes. Replace front and rear ACR solenoids. See the
1. Disconnect front ACR [203F]. service manual. (7078)
2. Connect FUEL INJECTOR TEST LIGHT (Part No. HD- b. No. Go to Test 4.
34730-2D).
4. Front ACR Control Circuit Test
1. Disconnect fuel injector test light.
2. While cranking the engine, using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404-C) and a multi-
b. No. Go to Test 3. meter, test for voltage between [203FB] terminal 2 and
ground.
2. Rear ACR Control Circuit Test 3. Is voltage greater than 1.0V?
1. Disconnect rear ACR [203R]. a. Yes. Repair short to voltage between [203FB] terminal
2. While cranking the engine, using HARNESS CON- 2 and ECM [78B] terminal 19. (5041)
NECTOR TEST KIT (Part No. HD-41404-C) and a multi- b. No. Replace the ECM. See the service manual. (7080)

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PASSENGER HEADSET RECEPTACLE 7.12

REPAIR
ed01600
The passenger headset receptacle can not be replaced separ-
ately. The entire audio harness must be replaced in the event
of a failure. See AUDIO HARNESS in the service manual.
Replace Weather Cap

1. See Figure 7-31 and Figure 7-32. Use a spanner, punch,
or small screwdriver to loosen the retaining ring.
2. Remove ring and weather cap.
3. Install new weather cap and verify the boss engages the
notch in the housing.
4. Install retaining ring and tighten securely.
ed01599
Figure 7-32. Retaining Ring
Figure 7-31. Passenger Headset Receptacle

HOME
XM SATELLITE RADIO 7.13

GENERAL NOTE
After installing the antenna, avoid contact with or movement
See Figure 7-33. The XM Satellite Radio module (1) mounted of the antenna for 20 minutes.
on the AM/FM/WB receiver. The antenna (2) is also mounted
inside the fairing. 2. See Figure 7-33. Mate XM radio antenna connector (4) to
the module.
The XM module is attached to the receiver with a screw (5)
and connected to the main wiring harness through a connector 3. Bundle and tuck antenna lead (3) under instrument har-
[185] (6). The antenna connector [185C] (4) connects the ness.
module to the antenna. The antenna lead is bundled (3) and 4. Install outer fairing.
tucked under a wire harness conduit.
sm06991a
2 3
ed01603
1 4
6 5
1. XM satellite radio module

2. Antenna Figure 7-34. Antenna Connector [185C] Release Latch
3. Antenna wire bundle
4. XM antenna connector
5. Screw, module mounting XM MODULE
6. Module harness connector
Removal
Figure 7-33. XM Radio Module and Connections
XM ANTENNA
3. See Figure 7-33. Separate XM module harness connector
Remove (6).
1. Remove main fuse. 4. Separate the XM antenna connector (4) from the module.
2. Remove outer fairing. See service manual for procedure. 5. Remove the mounting screw (5).
3. See Figure 7-33. Separate the antenna connector (4) from 6. Pull the module straight forward.
the XM radio module.
Installation
4. Pry the antenna (2) from the mounting bracket.
1. See Figure 7-35. Slide XM satellite radio module in on top
Installation of AM/FM/WB radio so that locating pins on the back of
the module engage the grommet holes.
1. Install antenna:
a. Clean the inscribed area on the top of the antenna 2. See Figure 7-33. Install bracket mounting screw (5) and
bracket with isopropyl alcohol. Allow to dry. tighten securely.
b. Remove adhesive backing from the antenna. 3. Mate XM module harness connector (6) housings.
c. With the wire lead toward the receiver, center the 4. Mate antenna connector (4) to the module.
antenna over the inscription. Press and hold for 60 NOTE
seconds. To verify operation, it may be necessary to transfer (activate)
service for the replacement radio ID.
5. Install outer fairing. See service manual.

HOME

ed01606
ed01605
1
Figure 7-35. XM Radio Module Grommet Holes 4
ACTIVATION
1. See Figure 7-36. With the AM/FM/WB receiver ON, 1. XM satellite radio band
repeatedly press and release the MODE SEL switch on 2. Channel 1 (XM preview channel)
the right hand grip to cycle through to XM (1) in the LCD. 3. Channel 0 (XM ID channel)
2. Verify that channel 1, the XM Satellite Radio Preview 4. XM satellite ID
channel is playing and displayed in the LCD (2). 5. Activation phone number
3. Tilt and release the MODE SEL switch DN to change the Figure 7-36. XM Satellite Radio Activation Displays
channel to 0 (3). Record the 8-digit XM satellite ID (4)
before calling the activation phone number (5) to activate
service. XM RADIO DIAGNOSTICS
NOTE Description and Operation
After activation, play channel 1 on Advanced Audio XM Satellite
XM unit is mounted in the fairing and is powered by the radio
Radio for at least one hour to acquire all the XM Satellite
memory fuse. It is used along with the XM antenna to receive
Channels.
XM radio stations. It communicates with the audio system
through the radio CAN bus circuit. The XM unit has a left and
right input to the radio for independent left and right speaker
signals.

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2. Turn radio ON.

em00909
3. Does XM icon appear on radio display when moving
[28A] [28B] through the bands with two or more signal bars present?
Radio
XM Left 7 7 W a. Yes, "Check Antenna" or "No Signal" appears on
CAN + 13 13 Y/O radio display. See 7.13 XM SATELLITE RADIO,
CAN - 14 14 Y/V Symptom 13: No or Intermittent Reception on XM
XM Shield 18 18 BK Module.
XM Right 30 30 R
From b. Yes, icon appears with no error message. Go to
Radio Test 2.
Memory
Fuse
c. No. Go to Test 7.
[6B] [6A]
2. XM Audio Voltage Output Test
R/O 3 3 R/O
1. Connect ADVANCED AUDIO SYSTEM BREAKOUT
Y/O 4 4
BOX (Part No. HD-47918) between radio [28A] and radio
Y/V 5 5
BK/GN 6 6 BK/GN
harness [28B].
2. With radio ON and XM active, measure voltage on
breakout box [28] terminals 30 and 18 (right channel) and
GND 2 between terminals 7 and 18 (left channel).
XM Module
XM Right 6 6 R 3. Is varying AC voltage (0-1.5V) present when XM is active?
XM Left 7 7 W a. Yes. Replace radio. See the service manual. (6103)
XM Shield 8 8 BK
Battery 9 9 R/O b. No. Go to Test 3.
Ground 10 10 BK/GN
CAN + 11 11 Y/O 3. XM Audio Output Continuity Test
CAN - 12 12 Y/V
1. Turn radio off.
[185A] [185B] 2. Disconnect XM radio [185].
3. Disconnect radio [28A] from breakout box.
Figure 7-37. XM Module Circuit
41404-C), test for continuity between the following:
SYMPTOM 12: NO OR LOW AUDIO FROM a. Breakout box [28B] terminal 18 and XM [185B] ter-
XM OR XM INOPERATIVE minal 8
PART NUMBER TOOL NAME b. Breakout box [28B] terminal 7 and XM [185B] terminal
7
c. Breakout box [28B] terminal 30 and XM [185B] ter-
HD-42682 BREAKOUT BOX
minal 6
HD-45325 JUMPER HARNESS
HD-47918 ADVANCED AUDIO SYSTEM
BREAKOUT BOX a. Yes. Connect XM module. Go to Test 4.
b. No. Repair open on (R), (BK) or (W) wire between
Table 7-13. Symptom 12: No or Low Audio from XM or XM radio harness [28B] and XM [185B]. (5041)
Inoperative Diagnostic Faults
4. XM Audio Output Short to Ground Test
POSSIBLE CAUSES
1. Test for continuity between the following:
XM module malfunction
a. Breakout box [28B] terminal 18 and XM [185B] ter-
Antenna malfunction minal 8
Satellite unavailable b. Breakout box [28B] terminal 7 and XM [185B] terminal
7
1. XM Radio Operation Test
c. Breakout box [28B] terminal 30 and XM [185B] ter-
NOTE minal 6
XM radio is not available in all areas. For additional information
or to verify a particular region supports XM radio, refer to
www.xmradio.com.
1. Locate vehicle in an open area with line of site to southern
sky.

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2. Is continuity present? 2. Is voltage between 4-6V?

a. Yes. Repair short to ground on (R), (BK) or (W) wire a. Yes. Inspect [185] for damaged, pushed back or cor-
in radio harness to XM [185B]. Installed modules may roded terminals. Repair as required. If connections
also be shorted to ground internally. Disconnect XM are okay, replace XM module. (6126)
module while observing multimeter. If disconnecting
XM module causes multimeter to indicate infinity,
replace XM module. (6157)
9. XM Module CAN Continuity Test
BOX (Part No. HD-47918) between radio [28A] and radio
5. XM Audio Output Wires Shorted Together harness [28B].
Test
2. Test for continuity between the following:
1. Disconnect breakout box from radio [28A].
a. Radio breakout box [28] terminal 13 and XM breakout
2. Test for continuity between the following: box (black) terminal 11.
a. Breakout box [28] terminals 18 and 7 b. Radio breakout box [28] terminal 14 and XM breakout
b. Breakout box [28] terminal 7 and 30 box (black) terminal 12.
c. Breakout box [28] terminal 30 and 18 3. Is continuity present?

a. Yes. Replace radio. See the service manual. (6103)
a. Yes. Repair short between (R), (BK) or (W) wires in b. No. Repair open on (Y/O) or (Y/V) wires. (6128)
radio harness. Installed modules may also be shorted
internally. Disconnect XM module while observing 10. XM Module Power/Ground Bus
multimeter. If disconnecting XM module causes mul- Continuity Test
timeter to indicate infinity, replace XM module. (5041)
b. No. Go to Test 6. BOX (Part No. HD-47918) between radio [27A] and har-
ness [27B].
6. XM Audio Output Shorted to Voltage Test 2. With radio on, test for voltage between breakout box ter-
1. Connect breakout box to radio [28A]. minal 10 and ground.
2. Test for voltage between the following: 3. Is battery voltage present?
a. Breakout box [28] terminal 18 and ground. a. Yes. Repair open (R/O) wire between XM [185B] and
radio memory fuse. (6129)
b. Breakout box [28] terminal 7 and ground.
b. No. Repair open (BK/GN) wire between XM [185B]
c. Breakout box [28] terminal 30 and ground.
and ground. (6129)
3. Is voltage greater than 8V?
SYMPTOM 13: NO OR INTERMITTENT
a. Yes. Repair short to voltage on (R), (BK) or (W) wires.
Installed modules may also be shorted internally. RECEPTION ON XM MODULE
Disconnect XM module while observing multimeter.
If disconnecting XM module causes multimeter to
indicate normal voltage, replace XM module. (5041) HD-41404-C HARNESS CONNECTOR TEST KIT
b. No. Replace XM module. (6128) Before proceeding with this test, verify the vehicle is located
in an open area with line of sight to the southern sky and all
7. XM Module Power Test metal objects obstructing a properly installed antenna are
removed.
1. Install BREAKOUT BOX (Part No. HD-42682) and
JUMPER HARNESS (Part No. HD-45325) to XM [185B].
Table 7-14. Symptom 13: No or Intermittent Reception on
2. With IGN ON, measure voltage between XM breakout box XM Module Diagnostic Faults
(black) terminals 9 and 10.
POSSIBLE CAUSES
XM module malfunction
Antenna malfunction
b. No. Inspect [185] for damaged, pushed back or cor-
roded terminals. Repair as required, then continue Satellite unavailable
testing. Go to Test 10.
1. XM Antenna Power Test
8. XM Module CAN Voltage Test 1. Disconnect XM antenna from XM module and turn IGN
ON.
1. Measure voltage between XM breakout box (black) ter-
minals 11 and 12.

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2. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 1. XM Module Voltage Test
41404-C), measure the voltage at XM antenna connector
on back of XM module between center conductor and 1. Disconnect XM module [185].
radio case. 2. With IGN ON, and using the HARNESS CONNECTOR
3. Is voltage 4.25-4.75V? TEST KIT (Part No. HD-41404-C), measure voltage
between [185B] terminals 9 and 10.
b. No. Replace XM module. (6126)
2. XM Antenna Resistance Test b. No. Go to Test 2.
1. Turn IGN OFF.
2. XM Module Ground Test
2. Measure the resistance between XM antenna cable con-
nector center conductor and antenna cable shield. 1. Measure voltage between [185B] terminal 9 and ground.
3. Is resistance between 35-55 Ohms? 2. Is battery voltage present?

a. Yes. Replace XM module. (6126) a. Yes. Repair open in (BK/GN) ground wire. (5041)
b. No. Replace antenna. (6146) b. No. Repair open in (R/O) wire. (5041)
DTC U1313 INFOTAINMENT BUS LOST 3. XM Module CAN Test

COMMUNICATION WITH XM MODULE 1. Measure voltage between XM [185B] terminals 11 and
12.
2. Is voltage between 3.85-5.0V?
a. Yes. Replace XM module. (6626)
Table 7-15. DTC U1313 Infotainment BUS Lost
Communication with XM Module Diagnostic Faults
4. XM Module CAN Test
POSSIBLE CAUSES
1. Measure voltage between XM [185B] terminals 12 and
Open in power wire ground.
Open in ground wire 2. Is voltage between 3.85-5.0V?
XM module malfunction a. Yes. Repair open in (Y/O) wire. (5041)
Open in CAN circuit b. No. Repair open in (Y/V) wire. (5041)

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ROAD TECH ZŪMO 660 GPS 7.14

MOUNT AND HARNESS
sm06854
Removal 6
4
1. Remove outer fairing. See the service manual. 3 5
2. See Figure 7-39. Remove cable straps (8). 2
3. See Figure 7-38. Remove screws (1) securing cradle (2)
to mount (4). Allow cradle to hang from harness.
1
4. Hold nuts (6) and retainer (5) and remove screws (3).
5. Remove mount (4), retainer and nuts. Allow to hang by
harness.
6. Remove two screws and washers securing dash pad to
inner fairing. Remove dash pad.
7
7. See Figure 7-39. Disconnect harness and remove cradle
assembly from vehicle.
a. Separate GPS audio jack (6).
1. Screw (4)
b. Separate power connector (7). 2. Cradle
NOTE 3. Screw (2)
Note harness routing and anchor points during removal. 4. Mount
5. Retainer
c. Cut cable straps as needed and pull harness out 6. Lock nut (2)
through dash and dash pad. 7. T-bushing (4)
Installation Figure 7-38. GPS Unit Mount
1. See Figure 7-38. Route harness through dash pad and

inner fairing.
2. Install dash pad and tighten screws to 20-25 in-lbs (2.3-
2.8 Nm).
3. Secure mount with screws, nuts and retainer. Tighten
screws to 20-25 in-lbs (2.3-2.8 Nm).
NOTE
Verify that the T-bushings (7) are inserted into the rubber isol-
ators.
4. Secure cradle and tighten screws to 14-20 in-lbs (1.6-2.3
Nm).
5. See Figure 7-39. Route harness behind instrument overlay
harness (3) and down next to brace (2).
6. Mate GPS audio jack (6) and power connector (7).
7. Gather harnesses and secure as noted during removal
using new cable straps (8).
8. Install outer fairing. See the service manual.

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sm06992a
NAVIGATION INTERFACE MODULE
1 Removal
2 2. Remove outer fairing. See the service manual.
3. See Figure 7-39. Separate NIM connector (5).
3 4. Separate GPS audio jack (6).
5. Pry NIM (4) from the inner fairing.
Installation
1. Install NIM:
a. Use isopropyl alcohol to clean the mounting area on
the inner fairing. Allow to dry.
8 4 b. Remove adhesive backing from NIM.
c. With the wire lead toward the bottom, press and hold
5 NIM for 60 seconds. Avoid contact with or movement
of the NIM for 20 minutes.
2. See Figure 7-39. Mate the NIM connector (5) and audio
jack (6).
7
6 3. Install outer fairing. See service manual for procedure.
ZŪMO - GPS DIAGNOSTICS

Description and Operation
1. GPS harness Zūmo is a GPS system that is integrated into the audio system.
2. Brace, inner fairing The zūmo unit attaches to a fairing mounted cradle and com-
3. Instrument overlay harness municates with the radio using the radio CAN lines through the
4. Navigation interface module (NIM) navigation interface module (NIM). The NIM also enables the
5. NIM connector GPS sound to play through the radio speakers when the Zūmo
6. GPS 660 audio jack is selected on the radio. The unit is powered and charged by
7. GPS power connector the GPS fuse and capable of communicating with a bluetooth
8. Cable strap enabled phone. Refer to Table 7-16.
Figure 7-39. GPS Harness Routing
Table 7-16. Zūmo Troubleshooting
Problem Solution
Never receives satellite signals. Take unit out of parking garages and away from tall buildings and trees. Remain
stationary for several minutes.
Does not charge on vehicle. Check the accessory fuse.
Ensure that the unit is receiving battery voltage with IGN ON.
Zūmo can only charge between 32 °F and 113 °F (0 °C and 45 °C). If the unit is placed
in direct sunlight or in a hot environment, it cannot charge.
Clear all user data. Press and hold on the lower-right corner of the units screen while it is turning on.
Keep pressed until the message appears. Touch Yes to clear all user data.
Locked up/frozen. If the units screen stops functioning, turn off, then turn on the unit. If this does not
help, press the Power button and hold it for 8 seconds. Turn on the unit again. The
unit should operate normally.
Touchscreen is not responding properly. Turn off the unit. Hold your finger on the screen and then press and hold the Power
button. Hold until the calibration screen appears. Follow on-screen instructions.
Battery gauge does not seem accurate. Allow the unit to fully discharge, and then fully charge it (without interrupting the charge
cycle).

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Table 7-16. Zūmo Troubleshooting
Problem Solution
Phone will not connect to zūmo unit. Touch Tools > Settings > Bluetooth. Verify that the Bluetooth field is set to Enabled.
Ensure your phone is turned on and is less than 33 feet (about 10 meters) away from
your zūmo unit.
Go to www.garmin.com/bluetooth for more help.
Cannot receive traffic information. Verify that you are in a coverage area. You must be in a coverage area to get the
traffic information for that area.
Verify that the FM TMC Traffic receiver is connected to the power connector on the
cradle and also a proper connection at [272].
Connector Information NO VEHICLE POWER TO UNIT

For additional information about the connectors in the following PART NUMBER TOOL NAME
the harness test kit terminal probes, see A.1 CONNECTORS. HD-41404-C HARNESS CONNECTOR TEST KIT
em00892 64-1 Fuse Table 7-17. No Vehicle Power to Unit Diagnostic Faults
GPS 2A Block
Ignition R/GY POSSIBLE CAUSES
4E 4F
Switch
Open in power circuit
O/W
BK
[275A-2] [275B-2]
Short to ground in power circuit
2 1 [272B]
2 1 [272A] Open in ground circuit
GPS cradle
GPS Input
BK
R
NIM Zūmo unit

Audio +
Ground
Battery
Audio -
CAN +
CAN -
GPS
Cradle
NOTE
BK/GN
BK/BE
R/BE
Zūmo unit's battery must be fully charged.

R/O
Y/O
Y/V
6 5 4 3 2 1 [275A-1] From
Radio
1. On Vehicle, Zūmo Unit Test
6 5 4 3 2 1 [275B-1] Memory 1. With zūmo unit OFF, install unit onto vehicle.
Fuse
BK/GN
R/O
Y/O
R/BE
Y/V
BK/BE
2. Turn IGN ON.

[6B] [6A]
R/O
3. Does unit automatically turn ON?

BK/GN
R/O 3 3 R/O
Y/O 4 4
a. Yes. No problem found.
Y/V 5 5
BK/GN 6 6 BK/GN b. No. Go to Test 2.
BK/GN
BK/GN
BK/BE
R/BE
2. GPS Fuse Test

R/O
R/O
Y/O
Y/V
4 13 14 27 [28B] 10 11 19 20 [27B] 1. Verify GPS fuse is good.

6 13 14 27 [28A] 10 11 19 20 [27A]
2. Is fuse good?
CAN -
Battery
Battery
CAN +
Ground
Ground
NIM Audio +
NIM Audio -
Radio
b. No. Replace GPS fuse and repair short to ground on
(O/W) wire. (5041)
Figure 7-40. Zūmo Circuit
3. Power Circuit Test
1. Turn IGN OFF.
2. Disconnect zūmo [272].
3. With IGN ON, and using HARNESS CONNECTOR TEST
KIT (Part No. HD-41404-C) and multimeter, test for battery
voltage at [272B] terminal 1 (O/W) wire.

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4. Is battery voltage present? 4. Does unit automatically turn ON?

a. Yes. Go to Test 4. a. Yes. Go to Test 3.
b. No. Repair open in (O/W) wire. (5041) b. No. See 7.14 ROAD TECH ZŪMO 660 GPS, No
Vehicle Power To Unit.
4. Ground Circuit Test
1. Turn IGN OFF.
3. Audio Jack Test
1. Disconnect audio jack [275].
2. Test for continuity between [272B] terminal 2 (BK) wire
and ground. 2. Install head phones into [275B-2].
3. Is continuity present? 3. With zūmo operating, can sound be heard through head
a. Yes. Go to Test 5. phones?
b. No. Repair open in (BK) ground wire. (5041)
b. No. Replace the GPS cradle. See service manual.
5. Off Vehicle, Zūmo Unit Test (6184)
1. Remove zūmo unit from vehicle.
4. NIM Audio (+) Short to Power Test
2. Turn unit ON.
1. Turn IGN OFF.
3. Does unit turn ON?
2. Install radio ADVANCED AUDIO SYSTEM BREAKOUT
a. Yes. Replace GPS cradle. See service manual. (6184) BOX (Part No. HD-47918) between radio [28A] and har-
b. No. Send zūmo unit in for repair. ness [28B].
3. Remove zūmo from GPS cradle.
NO SOUND THROUGH RADIO
4. Turn IGN and radio ON.
5. Test for voltage between breakout box terminal 4 and
HD-47918 ADVANCED AUDIO SYSTEM ground.
BREAKOUT BOX
6. Is voltage present?
a. Yes. Repair short to voltage in (R/BE) wire. (5041)
Table 7-18. No Sound Through Radio Diagnostic Faults
POSSIBLE CAUSES
GPS cradle 5. NIM Audio (-) Short to Power Test
Zūmo unit 1. Test for voltage between breakout box terminal 27 and
NIM malfunction ground.
Short to voltage in circuits 2. Is voltage present?

Short to ground in circuits a. Yes. Repair short to voltage in (BK/BE) wire. (5041)
Open circuits b. No. Go to Test 6.
NOTE 6. NIM Audio (+) Continuity Test

All radio DTCs must be addressed before further testing. Zūmo 1. Turn IGN OFF.
unit's battery must be fully charged.
2. Disconnect NIM [275].
1. Off Vehicle, Zūmo Unit Test 3. Disconnect ADVANCED AUDIO SYSTEM BREAKOUT
1. With the unit removed from the vehicle, turn unit ON and BOX (Part No. HD-47918) from radio [28A], leaving har-
volume to high. ness [28B] connected.
2. Does the unit have sound? 4. Test for continuity between breakout box terminals 4 and
a. Yes. Go to Test 2. NIM [275B-1] terminal 1.
b. No. Send zūmo unit in for repair. 5. Is continuity present?

2. On Vehicle, Zūmo Unit Test b. No. Repair open in (R/BE) wire. (5041)
1. Turn unit OFF.
7. NIM Audio (-) Continuity Test
2. Install unit onto vehicle.
1. Test for continuity between breakout box terminals 27 and
3. Turn IGN ON. NIM [275B-] terminal 2.

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2. Is continuity present? 2. Disconnect NIM [275].

a. Yes. Go to Test 8. 3. Turn IGN and radio ON.
b. No. Repair open in (BK/BE) wire. (5041) 4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), test for voltage between [275B-1] terminals 3
8. NIM Audio (+) Short to Ground Test and 4.
1. Test for continuity between breakout box terminals 4 and 5. Is battery voltage present?
ground.
a. Yes. Repair short to ground in (R/BE) wire. (5041)
b. No. Go to Test 9. 2. Battery Circuit Open Test
1. Turn IGN OFF.
9. NIM Audio (-) Short to Ground Test
2. Install radio ADVANCED AUDIO SYSTEM BREAKOUT
1. Test for continuity between breakout box terminals 27 and BOX (Part No. HD-47918) between radio [27A] and har-
ground. ness [27B].
2. Is continuity present? 3. Test for continuity between breakout box terminals 20 and
a. Yes. Repair short to ground in (BK/BE) wire. (5041) [275B-1] terminal 3.
b. No. Replace NIM. See service manual. (6162) 4. Is continuity present?
DTC U1306 INFOTAINMENT BUS LOST
b. No. Repair open in (R/O) wire. (5041)
COMMUNICATION WITH NIM MODULE
PART NUMBER TOOL NAME 3. Ground Circuit Open Test
HD-41404-C HARNESS CONNECTOR TEST KIT 1. Test for continuity between breakout box terminals 19 and
[275B-1] terminal 4.
HD-47918 ADVANCED AUDIO SYSTEM
BREAKOUT BOX 2. Is continuity present?
a. Yes. Replace radio. See service manual. (6101)
Table 7-19. DTC U1306 Infotainment Bus Lost b. No. Repair open in (BK/GN) wire. (5041)
Communication with NIM Module Diagnostic Faults
POSSIBLE CAUSES 4. NIM CAN Test

Radio malfunction 1. With IGN ON measure voltage between [275B-1] terminals
5 and 6.
NIM malfunction
Module shorted to ground or voltage 2. Is voltage between 3.85-5.0V?
a. Yes. Replace NIM. See the service manual. (6162)
Open circuits
b. No. Repair open in (Y/O) wire between [275B-1] ter-
1. NIM Voltage Test minal 5 and [28B] terminal 13, or (Y/V) between
[275B-1] terminal 6 and [28B] terminal 14. (5041)
1. Turn IGN OFF.

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RADIO SOFTWARE UPDATE 7.15

GENERAL UPDATING RECEIVER SOFTWARE
The Advanced Audio receiver software will need to be updated NOTE
after replacing the GPS navigation module or the receiver Eject any CD. Leave the CD door open while the updated
module. The software will also need to be updated after receipt software is being installed.
of software revisions.
The latest software updates as well as installation instructions
can be found at http://www.harley-dav-
idson.com/cp/moar/en/software.asp. The updated software file
must be written to a CD which is then used to install the new
software.

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ADVANCED AUDIO RADIO 7.16

REMOVAL
ed01615
NOTE
AM/FM/WB radio, CB transceiver and XM Satellite Radio
module may all be removed as a unit.
1. See Figure 7-41. Separate antenna connectors (2, 3, 4).
2. Separate module connectors:
a. Separate XM module 12-pin connector [185] (1).
b. Separate CB transceiver 12-pin connector [184] (5). 1
c. Remove AM/FM/WB radio 23-pin connector [27] (7)
and 35-pin connector [28] (6) from receiver.
3. Remove cable strap securing ignition switch harness to

bottom of radio chassis.
4. Remove cable strap securing ignition knob power lock 2
connector to bottom of radio chassis.
5. See Figure 7-42. Remove four screws with captive
washers (1), two on either side of radio chassis.
NOTE
Both screws on each side may be reached through tool access
slot (2). 1. Screw with captive washer (4)
6. Remove advanced audio sound system assembly by 2. Tool access slot
pulling straight forward and lifting up slightly after radio Figure 7-42. Sound System Mounting
bezel clears fairing.
7. If necessary, remove the CB and XM satellite modules.
INSTALLATION
1. If removed, install the CB and XM satellite modules.
sm06994a
2. See Figure 7-42. Slide sound system assembly into place

in fairing.
3. Secure with four screws with captive washers (1), two on
3 either side of radio chassis. Tighten to 35-45 in-lbs (4.0-
2 4 5.1 Nm).
4. Push ignition switch harness cable strap mount into hole
in bottom of radio chassis.
5. Push ignition knob power lock connector cable strap mount
into hole in bottom of radio chassis.
5
1 6. See Figure 7-41. Mate advanced audio system connectors
7 6 (1, 5, 6, 7) to modules.
7. Plug in antenna connectors (2, 3, 4).
1. XM module 12-pin connector [185]
2. XM antenna connector [185]
3. CB antenna connector [50]
4. AM/FM/WB antenna connector [51]
5. CB transceiver 12-pin connector [184]
6. AM/FM/WB radio 35-pin connector [28]
7. AM/FM/WB radio 23-pin connector [27]
Figure 7-41. Advanced Audio Connectors

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ADVANCED AUDIO AMPLIFIER 7.17

GENERAL 5. Install Tour-Pak. See 2.17 TOUR-PAK.
The Advanced Audio High-Output Amplifier is located under 6. See Figure 7-44. Install new cable straps securing Tour-
the Tour-Pak. Pak wiring to Tour-Pak support.
REMOVAL 7. Insert passenger headset socket into clip.
1. Turn ignition switch OFF. 8. Test sound system for proper operation.
NOTE
sm06191
See Figure 7-43. Under the connector, use a flat blade screw-
driver to pull the latch down to release the connector [149].
2. See Figure 7-45. Unplug wiring harness connector [149]
from amplifier. 1
2
3. Place a clean shop towel on the seat.
4. Cut cable straps (2) securing Tour-Pak wiring to Tour-Pak
support.
5. Remove passenger headset socket from clip.
6. While leaving wiring attached, remove Tour-Pak and place
on seat. See 2.17 TOUR-PAK.
7. To protect finish, place a clean shop towel between the
fender and amplifier. 1. Amplifier connector
2. Cable strap
8. See Figure 7-45. Remove fasteners (5) and washers (4)
from amplifier bracket (1). Figure 7-44. Amplifier Connector
9. Remove amplifier bracket from Tour-Pak support (2).
10. Slide amplifier out right side of motorcycle.
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Figure 7-43. Connector [149] Release Latch
INSTALLATION
1. See Figure 7-45. Install amplifier (3) into position in Tour-
Pak support (2).
2. Place amplifier bracket (1) on Tour-Pak support. Place
amplifier over amplifier bracket (1) studs.
3. Secure amplifier with washers (4) and fasteners (5) and
tighten to 96-108 in-lbs (10.8-12.2 Nm).
4. Plug wiring harness connector [149] into amplifier socket.

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sm06187
4 3
1. Amplifier bracket
2. Tour-Pak support
3. Amplifier
4. Washer
5. Fastener
Figure 7-45. Amplifier Components

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GARAGE DOOR OPENER 7.18

TRANSMITTER 2. Find an unswitched 110V power outlet in garage that is
located either highest in the garage, or closest to front of
Removal garage, or both. Locate the Harley-Davidson remote-con-
trol garage door opener receiver here.
NOTE
With some brands of garage door opener systems, it may be
3. See Figure 7-46. Disconnect wiring harness connector necessary to plug in the Harley-Davidson receiver at a location
[132+] (3). some distance away from the door opener. If the Harley-Dav-
idson receiver is plugged in too close to the original opener
4. Remove transmitter from mount bracket.
receiver, effective transmission range may be significantly
5. If necessary, remove screw (2) and remove mount bracket. reduced on both systems.
Installation 3. Find two garage door activation switch terminals at one

of these locations:
1. See Figure 7-46. If removed, install mount bracket and
a. The existing wall-mounted, hard wired garage door
tighten screw (2) to 35-45 in-lbs (3.9-5.1 Nm).
opener button.
NOTE
b. The garage door drive unit to which the garage door
Be certain to apply pressure to adhesive tape when installing
opener button is connected.
transmitter.
2. Clean surface with isopropyl alcohol and allow to dry. 4. Fasten stripped end of Harley-Davidson garage door
Apply new transmitter. opener receiver wires to door-opener terminals that
activate door opener drive unit. Refer to door-opener
3. Mate connector (3). manufacturer's documentation for terminal locations and
4. Verify transmitter function by checking that the LED light connections.
on transmitter blinks when the high-low beam switch is NOTE
activated. Do not remove original wires from original connections on the
5. Install outer fairing. See service manual. door-opener button or on drive-unit terminals.
6. Install main fuse. 5. Assemble and install garage door opener button in its ori-
ginal location.
6. Route the plug end of the Harley-Davidson garage door
sm07005a
opener wires to the Harley-Davidson garage door opener
receiver location.
7. See Figure 7-47. Plug connector on Harley-Davidson
garage door opener receiver wires into the receptacle (1)
back of Harley-Davidson garage door opener receiver.
8. Plug garage door opener receiver into selected power
1 2
outlet.
9. Plug power cord from garage door drive unit into power
outlet.
10. Press wall-mounted garage door opener button to test
button operation.
1. Transmitter
2. Screw (not visible)
3. Connector [132+]
Figure 7-46. Garage Door Opener Transmitter
RECEIVER
Installation
1. Unplug power cord from garage door drive unit to prevent
door activation during installation.

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1. Check that a red light is visible on the front of the Harley-

ed01622
Davidson garage door opener receiver, indicating power
to the receiver.
1 2. See Figure 7-47. Press and hold the Set button (3) on the
¨
Harley-Davidson garage door opener receiver. The LED
(2) blinks continuously while the Set button is pressed.
2 3. Set the motorcycle ignition switch to IGN. Switch the

headlamp beam switch using one of these sequences:
a. Starting from Low beam, switch High, then Low.
3 b. Starting from High beam, switch Low, then High.
NOTE
When the receiver receives a signal from the transmitter, the
LED on the transmitter turns off.
1. Wire connector/plug receptacle
4. Release the Set button on the receiver.
2. LED
3. Set button
Figure 7-47. Garage Door Opener Receiver
REMOTE CONTROL GARAGE DOOR death or serious injury. (00316a)
OPENER NOTE
Clear all obstructions away from between the transmitter and
FCC Notices receiver before testing the operation of the garage door opener.
NOTE 5. Test the garage door opener, high beam, and low beam
Changes or modifications to this unit not expressly approved headlamp operation.
by the manufacturer could void the user's authority to operate
NOTE
the equipment.
When the transmitter is activated by toggling the headlamp
This equipment has been tested and found to comply with the switch, the red LED on the transmitter illuminates for one
limits for Class B digital devices pursuant to Part 15, Subpart second to indicate that the transmitter is functioning correctly.
B of the FCC Rules. These limits are designed to provide
6. Turn the motorcycle ignition switch OFF.
reasonable protection against harmful interference in a resid-
ential environment. GARAGE DOOR OPENER DIAGNOSTICS
This equipment generates, uses, and can radiate radio fre-
quency energy, and if not installed and used in accordance Description and Operation
with the instruction manual, may cause harmful interference The garage door opener has two main components, the garage
to radio communications. However, there is no guarantee that door opener transmitter and the garage door opener receiver.
interference will not occur in a particular installation. Both of these components work as an additional unit to the
If this equipment does cause harmful interference to radio or existing automatic garage door opener.
television reception, which can be determined by turning the Transmitter: Located on the vehicle, the transmitter is powered
equipment off and on, the user is encouraged to try to correct through the P&A fuse. It receives input from the headlamp
the interference by one or more of the following measures. switch. When the headlamp switch is toggled to LO-HI-LO or
• Reorient or relocate the receiving antenna. HI-LO-HI the transmitter sees that action and sends a RF signal
to garage door opener receiver.
• Increase the distance between the equipment and the
receiver. Receiver: Located usually in or around the customers garage
and powered through an 110V power outlet. The receiver col-
• Connect the equipment to an outlet on a circuit different lects the RF signal from the transmitter and activates the
from that to which the receiver is connected. garage door opener motor. The receiver is connected directly
• Consult the dealer or an experienced radio/TV technician to the motor through a cable that is connected to the garage
for help. door activation switch terminals located on the motor.
Program the Receiver and Transmitter Connector Information

The receiver must be programmed to receive the transmitter For additional information about the connectors in the following
frequency. This process may require two people, depending diagram(s) and diagnostic procedure(s), including the color of
on how far apart the receiver and transmitter are during the the harness test kit terminal probes, see A.1 CONNECTORS.
programming process.

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em00904 Low Beam

[38L]
BK 1
Y 2 Headlamp
[38A]
BK 1
W 2
[38B] [38A]
[38H]
W 1 1 W High Beam
W
See
Fairing Y 2 2 Y
Harness
BK
BK 3 3 BK
O/R 1 1 O/W Power

Y 2 2 Y LO Beam Garage
W 3 3 W HI Beam Door Opener
BK 4 4 BK Ground
P And A [278A] [278B]

O/R
Fuse
Figure 7-48. Garage Door Opener Circuit
GARAGE DOOR OPENER INOPERATIVE 2. Fuse Test

PART NUMBER TOOL NAME 1. Verify that the P&A fuse is good.
HD-41404-C HARNESS CONNECTOR TEST KIT 2. Is fuse good?

Table 7-20. Garage Door Opener Inoperative Diagnostic b. No. Replace fuse and repair circuit accordingly. If
Faults problem is still present, then continue tests. Go to
Test 3. (5041)
POSSIBLE CAUSES
Open P&A fuse 3. Garage Door Opener Power Test
Open in garage door opener circuit 1. Turn IGN OFF, disconnect garage door opener transmitter
Transmitter malfunction [278].
Receiver malfunction 2. Turn IGN ON.
Improper receiver wiring 3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
Insufficient receiver to opener spacing 41404-C) and multimeter, test for battery voltage at [278A]
terminal 1 (O/R) wire.
Programming malfunction
NOTES a. Yes. Go to Test 4.
• The garage door opener receiver is necessary to complete b. No. Repair open in (O/R) wire. (5041)
the diagnostics in the test procedures 7 and 8.
• Verify that the entire vehicle's lighting is working properly 4. Low Beam Wire Test
before proceeding with the diagnostics. 1. With the headlamp switch in the LO position.
1. Garage Door Opener Transmitter Test 2. Test for battery voltage at [278A] terminal 2 (Y) wire.
1. With IGN ON, monitor the garage door opener transmitter 3. Is battery voltage present?
and toggle the headlamp switch to LO-HI-LO or HI-LO-HI.
2. Does LED on the transmitter flash when headlamp switch
b. No. Repair open in (Y) wire. (5041)
is toggled?
a. Yes. Go to Test 7. 5. High Beam Wire Test
b. No. Go to Test 2. 1. With the headlamp switch in the HI position.

HOME
2. Test for battery voltage at [278A] terminal 3 (W) wire. 3. Does LED on the receiver flash one time when switch is
toggled?
a. Yes. Verification of the receiver being properly wired
and sufficient spacing to the existing garage door is
b. No. Repair open in (W) wire. (5041) needed. See 7.18 GARAGE DOOR OPENER,
Receiver.
6. Ground Wire Test b. No. Go to Test 8.
1. Turn IGN OFF.
2. Test for continuity between [278A] terminal 4 and ground.
8. Garage Door Opener Reprogramming Test
1. Unplug the receiver from the 110V power outlet.
a. Yes. Replace the garage door opener transmitter and 2. Wait 10 seconds.
receiver. 3. Press and hold the program button on the receiver. While
b. No. Repair open between [278A] terminal 4 and holding the button down, plug the receiver into the 110V
ground. (5041) power outlet. The red LED will flash rapidly.
4. Release the program button. The receiver is now reset,
7. Garage Door Opener Receiver Test and all memory is erased.
1. Plug the garage door opener receiver into 110V power 5. Re-program the receiver. See 7.18 GARAGE DOOR
outlet. OPENER, Remote Control Garage Door Opener.
2. With IGN ON, monitor the receiver and toggle the head- 6. With IGN ON, monitor the receiver and toggle the head-
lamp switch to LO-HI-LO or HI-LO-HI. lamp switch to LO-HI-LO or HI-LO-HI.
7. Does LED on the receiver flash one time when switch is
toggled?
a. Yes. System is now working correctly.
b. No. Replace garage door opener receiver. (6415)

HOME
TWIST GRIP SENSOR (TGS) 7.19

REMOVAL 4. Remove cable straps as necessary.
NOTE 5. See Figure 7-49. Separate right handlebar switch con-

nector [22] (2), handgrip heater interconnect connector
The twist grip sensor also contains the leads for the handgrip
[206] (4) and twist grip sensor (TGS) connector [204] (5).
heater.
6. Remove the right handgrip. See 2.9 HANDGRIPS,
Replacing Handgrips.
7. Pull the twist grip sensor and harness out of the handlebar
3. Remove advanced audio radio, XM radio and CB radio along with the right handlebar switch harnesses. See
as an assembly to gain access to center of handlebar. 2.8 HANDLEBARS, Disassembly.
See 7.16 ADVANCED AUDIO RADIO.
sm03970b
2 5
1
4 3
1. Left handlebar switch connector [24]

2. Right handlebar switch connector [22]
3. Handgrip heater power connector [189]
4. Handgrip heater interconnect [206]
5. Twist grip sensor connector [204]
Figure 7-49. Handlebar Control Connector Locations
INSTALLATION 3. See Figure 7-49. Mate connectors (2, 4, 5). Secure inter-
connect harness connector assembly to right switch control
1. Carefully pull harnesses through handlebar and assemble harness with cable strap.
connectors. See 2.8 HANDLEBARS, Assembly.
4. Install advanced audio radio assembly. See
NOTE 7.16 ADVANCED AUDIO RADIO.
Do not pull the switch housings so far inboard as to cause the
throttle grip to bind or drag on the handlebar. Rotate the throttle 5. Install main fuse.
grip to verify that it freely returns to the idle position. 6. Install outer fairing.
2. Install the right handgrip. See 2.9 HANDGRIPS, Replacing
Handgrips.

HOME
7. Turn the ignition/light key switch to IGNITION and apply

brake lever to test operation of brake lamp.
death or serious injury. (00316a)

HOME
POWER LOCKS 7.20

POWER LOCK LOCKSET: TOUR-PAK
ed01632
Removal
2. Remove the felt liner from Tour-Pak cover.
2
3. See Figure 7-50. Remove the fastener (1) holding the latch
cover in place.
4. See Figure 7-51. Remove retaining ring (1) and disconnect 1
cable end from latch.
5. Remove nut and washer (2).
6. Remove latch components (3).
7. Remove nut (4) and remove lockset from cover.
Installation
1. See Figure 7-51. Insert the lockset and install nut (4).
Tighten to 30-45 in-lbs (3.4-5.1 Nm). 3
2. Install latch components (3) and secure with nut and
washer (2). Tighten to 25-35 in-lbs (2.8-4.0 Nm).
3. Connect cable end to latch hook and retain with retaining
ring (1).
4
4. See Figure 7-50. Install the latch cover and secure with
fastener (1).
5. Install felt liner.
6. Install main fuse and test power lock operation.
1. Retaining ring
ed01631
2. Nut and washer
3. Latch components
4. Nut
Figure 7-51. Tour-Pak Lockset
ACTUATOR: TOUR-PAK
Removal
NOTE
2
The actuator and/or cable can be replaced without removing
1 the protective box from the Tour-Pak.
1. Fastener
2. Latch cover 2. Remove upper and lower felt liners.
Figure 7-50. Tour-Pak Latch Cover 3. Separate the connector [213T] located in the Tour-Pak
bottom.
4. Remove the cover from the latch assembly.
5. Remove two fasteners and remove the actuator box cover.
NOTE
To prevent locking the Tour-Pak without a release mechanism,
do not close the Tour-Pak cover until repairs are complete.
6. See Figure 7-52. Remove harness from retaining clips (1).

HOME
7. Remove retaining ring (2) securing cable to latch

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assembly. 2
8. Loosen jamnut (3) from each end of cable. Remove cable 1 6
from latch bracket and actuator box slots.
9. Pull the actuator (4) off of its thin plastic mounting studs
while disengaging the harness and grommet (5) from the
actuator box.
10. Remove the fastener and locknut (6) from the end of the
actuator to remove the cable.
3
11. If necessary, remove the actuator box (7) from the inside 5 4 7
wall of the Tour-Pak cover.
Assembly
NOTE 1. Harness retaining clip
Be certain to apply pressure to adhesive tape when installing 2. Retaining ring, latch
actuator box. 3. Jamnuts
4. Actuator
1. If removed, attach the actuator box to the inside of Tour- 5. Harness and grommet
Pak cover: 6. Fastener and locknut
a. See Figure 7-52. Clean mounting surface of Tour-Pak 7. Actuator box
with isopropyl alcohol. Allow to dry.
Figure 7-52. Tour-Pak Power Lock Actuator
b. Use double sided tape and mount actuator box (7) to
inside wall of Tour-Pak cover.
POWER LOCKS: SADDLEBAGS
2. Assemble the cable to the end of the actuator with fastener
and locknut (6). Tighten securely. Removal
3. Slide the actuator (4) over the plastic mounting studs. 1. Remove the main fuse.
4. Press the harness and grommet (5) into the slot in the 2. Open the saddlebag and lift out the felt liner.
box.
3. Separate the power lock connector [213] and remove the
5. Slide the cable into the slots in the box and latch bracket. saddlebag.
Tighten the jamnuts (3) securely.
4. Remove the wire terminals from the connector housing
6. Install the actuator box cover. and pull the wire leads through the cord grip exit hole in
the side of the saddlebag.
7. Connect the cable to the latch assembly and secure with
retaining ring (2). NOTES
8. Route harness through retainers (1) and mate connector • Squeeze the cord grip together on the inside of the
[213T] to harness connector located in Tour-Pak bottom. saddlebag and push the cord grip out.
9. Install latch cover. • See APPENDIX B DEUTSCH ELECTRICAL CON-
NECTORS in the service manual for connector service
10. Install felt liners. procedures.
11. Install the main fuse and test power lock operation. 5. Remove the two screws from the check strap and the latch
cover.
6. See Figure 7-53. Loosen the lock nut on the cable end
and remove the cable ball end from the latch inner cam.
If the inner cam and latch require service, see
2.19 SADDLEBAGS LATCH for procedures.
7. Remove harness from the retaining clips.
8. Remove the actuator box and harness from the bottom of
saddlebag.
Installation
1. Clean inside mounting surface of saddlebag with isopropyl
alcohol. Allow to dry.
2. Use double sided tape to fix box to mounting surface.

HOME
3. Slip barrel end of cable into saddlebag locking arm.

ed01635
Assemble cable into slot on bracket. Tighten locknut.
4. Thread wire leads through exit hole in side of saddlebag
and under harness retaining clips. Replace clips if neces-
sary.
5. See Figure 7-55. Snap cord grip over the wire lead conduit
and press the small end of the cord grip into exit hole from
the outside of saddlebag.
6. Install terminals in connector housing. The cavity numbers
are embossed on the sides of the connector. Refer to
Table 7-21.
NOTE
See APPENDIX B DEUTSCH ELECTRICAL CONNECTORS
in the service manual for connector service procedures.
7. Mate power lock connector [213] halves while installing
the saddlebag.
8. Install latch cover. Tighten screws to 25 in-lbs (2.8 Nm).
9. Install felt liner.
10. Install the main fuse and test power lock.
Figure 7-54. Actuator Box
Table 7-21. Connectors [213R] and [213L]
TERMINAL WIRE LEAD COLOR

1 GN ed01636
2 BE
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Figure 7-55. Cord Grip
ACTUATOR: SADDLEBAG
Figure 7-53. Cable Ball End in Inner Cam
Disassembly
NOTE
The actuator and/or cable can be replaced without removing
the protective box from the saddlebag.
1. To remove the actuator assembly from a saddlebag, see
7.20 POWER LOCKS, Power Locks: Saddlebags.
2. Remove two fasteners to open the actuator box cover.
3. Loosen the cable jamnut.
4. Pull the actuator off from its thin plastic mounting studs
and slide the grommet and wire leads out of the slot in the
box.

HOME
5. Remove the screw and locknut from the end of the actuator
ed01637
to remove the cable and elbow.
Assembly
1. Fasten the cable eyelet over the actuator with the screw
and tighten the locknut.
2. Orient the actuator to the cable and grommet slots in the
box, and slide the actuator over the plastic mounting studs.
3. Press the wire lead grommet into the slot in the box. 3
4. Install the cable elbow in the slot in the box and tighten
the locknut.
5. Install the cover with two fasteners.
6. Install the power lock assembly into the saddlebag. See
7.20 POWER LOCKS, Power Locks: Saddlebags. 4
POWER LOCK MODULE

See Figure 7-56. The lock module is located inside the outer 2 1
fairing and attached to the right fairing bracket.
Removal
1. Remove the main fuse. 1. Power lock module
2. Fastener
2. Remove outer fairing. See the service manual. 3. Fastener
3. Disconnect harness connector from module (1). 4. Module bracket
4. Remove fastener (2). Remove module. Figure 7-56. Power Lock Module
5. If necessary, remove fastener (3) and remove bracket (4).
Installation POWER LOCK FOB PROGRAMMING

1. If removed, install bracket (4) and tighten fastener (3) to Entering Program Mode
30-50 in-lbs (3.4-5.6 Nm). Read all directions first.
2. Install module and tighten fastener (2) to 20-40 in-lbs (2.3- NOTE
4.5 Nm).
To program a fob, it is necessary to put the receiver on the
3. Install connector to module (1). motorcycle into program mode.
4. Install outer fairing and connect main fuse. 1. Turn ignition knob to IGNITION.
NOTE NOTES
If the power lock module is replaced, it must be programmed • Verify that both saddlebags and the Tour-Pak power locks
to the fobs. are functioning correctly when using the saddlebag/Tour-
Pak lock switch.
5. New power lock module must be programmed to operate
with the fobs. See 7.20 POWER LOCKS, Power Lock Fob • Leave the Tour-Pak lid open during programming to see
Programming. the Tour-Pak power lock hook move during lock and unlock
events.
2. See Figure 7-59. Press UNLOCK on the saddlebag/Tour-
Pak lock switch to set locks to the unlocked position. Wait
5 seconds.
3. Press LOCK once on the saddlebag/Tour-Pak lock switch.
4. Press UNLOCK on the saddlebag/Tour-Pak lock switch 3
times in a row.
5. Press LOCK on the saddlebag/Tour-Pak lock switch 3
times in a row.
6. Press and hold UNLOCK for 5 seconds. After 5 seconds,
the actuators will cycle the locks to locked then back to
unlocked. Release the switch. The receiver is now begin-
ning its program cycle.

HOME
7. Wait 11 more seconds. The actuators will once again cycle

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to lock then back to unlock. The receiver is now in program
mode.
2
Program Mode
NOTE
Pressing lock or unlock on the saddlebag/Tour-Pak lock switch
during program mode will cause program mode to end.
1. See Figure 7-57. Press and release the LOCK button on
fob number 1 repeatedly until you hear the actuators lock.
Verify the fob is programmed by pressing UNLOCK.
2. After fob number 1 is programmed, wait 5 seconds until
the actuators cycle to lock then back to unlock. Now pro- 1
gram fob number 2.
1. Thumbnail slot
3. Repeat previous steps to program fob number 2.
2. Battery
4. The receiver will remain in program mode for 30 seconds.
Figure 7-58. Power Lock Fob Battery
Repeat steps 1 and 2 to program any other fobs.
5. To exit program mode, perform one of the following:
a. Wait 30 seconds. Replacing the Battery
1. See Figure 7-58. Slowly turn a thin screwdriver blade in
b. Press lock or unlock on the saddlebag/Tour-Pak lock
the thumbnail slot (1) on the side of the fob to separate
switch.
the two halves.
c. Remove power lock fuse.
2. Remove the battery (2) and discard.
NOTE
ed01639 Dispose of old battery in accordance with local regulations.
1 2
3. Install a new battery (Panasonic 2032 or equivalent) with
the positive (+) side facing up.
4. Align the two halves of the fob and snap together.
ed01638
88.7 FM1 101.1

91.3 91.3 MHz 90.7
95.5 CB
INT 12:27SCAN More
3
CRUISE SPKR ACC
SPOT
1. Lock
2. Unlock
3. Key
Figure 7-57. Power Lock Fob
Figure 7-59. Saddlebag/Tour-Pak Lock Switch
POWER LOCK DIAGNOSTICS

Description and Operation
The power lock module is powered through the power locks
fuse. It receives input from the power lock switch. The power
lock switch is powered through the P&A fuse. When the power
lock switch is pressed to the lock position, the power lock
module sends a signal through the lock signal circuit locking
the saddle bags and Tour-Pak. When the power lock switch is

HOME
pressed to the unlock position, the power lock module sends Connector Information
a signal through the unlock signal circuit unlocking the saddle
bags and Tour-Pak. The power lock module functions the same For additional information about the connectors in the following
way when the fob buttons are activated. diagram(s) and diagnostic procedure(s), including the color of
em00894 Fuse
64-2 64-1
Block
1E 2G
Instrs Fuse Power Locks

15A 15A
1F 2H
R/V
O
Power Lock
Switch [212B] [212A]
GN/BK 1 1 GN/BK
R/V 2 2 O
BE/BK 3 3 BE/BK
Power Locks Module GN/W 1 Ignition Knob Lock

Battery power 1 1 R/V BE/W 2 [213KB]
Lock input 2 2 BE/BK
Unlock input 3 3 GN/BK
[213KA]
Lock Signal 6 6 BE/W

Unlock Signal 7 7 GN/W GN/W 1 Right Saddlebag Lock
Power Ground 8 8 BK BE/W 2 [213RB]
[231A] [231B] [213RA]
GN/W 1 Left Saddlebag Lock

BE/W 2 [213LB]
[213LA]
GN/W 1 Tour-Pak Lock

GND 1A BE/W 2 [213TB]
[213TA]
Figure 7-60. Power Locks Circuit

HOME
POWER LOCKS INOPERATIVE 3. Are the actuators functioning?

5. Cam and Cylinder Test
Table 7-22. Power Locks Inoperative Diagnostic Faults
1. Watch the cam as the power locks are operated.
POSSIBLE CAUSES 2. Does the cam rotate inside the saddlebag or Tour-Pak
Lock cylinder malfunction when the actuator is powered?
Latch cam malfunction a. Yes. Replace the lock cylinder. (6221)
Actuator cable malfunction b. No. Replace the latch cam and/or actuator cable.
Power lock module malfunction (6220)
Power lock fob malfunction 6. Power Lock Module Voltage Test

Open in lock signal circuit
1. Turn IGN OFF.
Short to ground in lock signal circuit
2. Disconnect power lock module [231].
Short to voltage in lock signal circuit
3. Turn IGN ON. Using HARNESS CONNECTOR TEST
Open in unlock signal circuit
KIT (Part No. HD-41404-C) and a multimeter, test for
Short to ground in unlock signal circuit voltage between [231B] terminal 1 (R/V) wire and ground.
Short to voltage in unlock signal circuit 4. Is battery voltage present?
Short to ground in power circuit a. Yes. Go to Test 8.
Open in power circuit b. No. Go to Test 7.
Open in lock input circuit
Open in unlock input circuit 7. Power Lock Fuse Test
1. Inspect the power lock fuse.
1. System Test
2. Is the fuse good?
1. With the fob, operate the power locks.
a. Yes. Repair open in (R/V) wire. (5041)
2. Where is the issue located?
b. No. Repair short to ground in (R/V) and replace power
a. Saddle bags, Tour-Pak. Go to Test 4. lock fuse, verify repair. (5041)
b. Power ignition knob lock. Go to Test 13.
8. Ground Circuit Test
c. Multiple locks. Go to Test 2.
1. Test for continuity between [231B] terminal 8 (BK) wire
and ground.
2. Power Lock Switch Test
1. Turn IGN ON. 2. Is continuity present?
2. Operate the power locks using the power lock switch.
b. No. Repair open in (BK) ground wire. (5041)
3. Do the actuators function?
a. Yes. Go to Test 3. 9. Lock Signal Short to Voltage Test
b. No. Go to Test 6. 1. With IGN ON.
2. Test for voltage between [231B] terminal 6 (BE/W) wire
3. Power Lock Fob Battery Test
and ground.
1. Measure the voltage of the power lock fob battery.
2. Does the battery measure approximately 2.9V? a. Yes. Repair short to voltage in (BE/W) wire. (5041)
a. Yes. Replace the power lock fob and repeat test 1
and 2. (6232) If power lock fob has been replaced in b. No. Go to Test 10.
a prior test replace the power lock module. (6223)
10. Lock Signal Short to Ground Test
b. No. Replace the power lock fob battery. (6233)
1. Test for continuity between [231B] terminal 6 (BE/W) wire
and ground.
4. Actuator Test
1. Turn IGN ON. 2. Is continuity present?
a. Yes. Repair short to ground in (BE/W) wire. (5041)
2. Watch the actuators as the power locks are operated.

HOME
11. Unlock Signal Short to Voltage Test POWER LOCKS FAIRING SWITCH
1. Test for voltage between [231B] terminal 7 (GN/W) wire INOPERATIVE
and ground.
a. Yes. Repair short to voltage in (GN/W) wire. (5041)
b. No. Go to Test 12. Table 7-23. Power Locks Fairing Switch Inoperative
Diagnostic Faults
12. Unlock Signal Short to Ground Test
POSSIBLE CAUSES
1. Test for continuity between [231B] terminal 7 (GN/W) wire
and ground. Power lock module malfunction
Open in lock signal circuit
Short to ground in lock signal circuit
a. Yes. Repair short to ground in (GN/W) wire. (5041)
Short to voltage in lock signal circuit
Open in unlock signal circuit
13. Lock Signal Open Test Short to ground in unlock signal circuit
1. Turn IGN OFF. Short to voltage in unlock signal circuit
2. Disconnect power lock module [231]. Short to ground in power circuit
3. Disconnect inoperative lock [213RA], [213LA], [213KA] or Open in power circuit

[213TA]. Open in lock input circuit
4. Using HARNESS CONNECTOR TEST KIT (Part No. HD- Open in unlock input circuit
41404-C) and a multimeter, test for continuity between Fairing lock switch malfunction
[231B] terminal 6 (BE/W) wire and inoperative lock terminal
2 (BE/W) wire. 1. Instrument Fuse Test
5. Is continuity present? 1. Inspect the INSTRS fuse.
a. Yes. Go to Test 14. 2. Is the fuse good?
b. No. Repair open in (BE/W) wire. (5041) a. Yes. Go to Test 2.
b. No. Repair short to ground in (O) wire and replace
14. Unlock Signal Open Test
INSTRS fuse, verify repair. (5041)
1. Test for continuity between [231B] terminal 7 (GN/W) wire
and inoperative lock terminal 1 (GN/W) wire. 2. Power Circuit Test
2. Is continuity present? 1. Disconnect power lock switch [212].
a. Yes. Only one lock inoperative. Replace the inoper- 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
ative power lock actuator. 41404-C) and a multimeter, test for voltage between [212A]
b. Yes. All locks inoperative. Replace the power lock terminal 2 and ground.
module. 3. Is battery voltage present?
c. No. Repair open in (GN/W) wire. (5041) a. Yes. Go to Test 3.
b. No. Repair open in (O) wire. (5041)
3. Power Lock Switch Unlock Test

1. Jumper [212A] terminals 1 and 2 together.
2. Do the actuators unlock?
4. Unlock Input Circuit Test

1. Disconnect power locks module [231].
2. Test for continuity between [212A] terminal 1 and [231B]
terminal 3.

HOME
3. Is continuity present? 6. Lock Input Circuit Test

a. Yes. Replace the power locks module. (6223) 1. Disconnect power locks module [231].
b. No. Repair open in (GN/BK) wire. (5041) 2. Test for continuity between [212A] terminal 3 and [231B]
terminal 2.
5. Power Lock Switch Lock Test
1. Jumper [212A] terminals 2 and 3 together.
a. Yes. Replace the power locks module. (6223)
2. Do the actuators lock?
b. No. Repair open in (BE/BK) wire. (5041)
a. Yes. Replace the power lock switch. (6228)

HOME
HARLEY-DAVIDSON SMART SECURITY SYSTEM 7.21

GENERAL
sm06107a
The Smart Security System includes:
2
• Hands-Free Fob
• Hands-Free Antenna
1
• Hands-Free Security Module (HFSM)
3
• Smart Security Siren
HFSM MODULE 4
5
Removal
1. With the ignition key ON and the security fob present,
remove the main fuse.
2. Remove right saddlebag and right side cover. 1. Rear wheel speed sensor connector
3. See Figure 7-61. Release rear ABS wheel speed sensor 2. Upper retainer
connector (1) from battery tray. 3. TSM/HFSM connector
4. HFSM antenna jumper harness connector
NOTE 5. Oxygen sensor connectors
It is not necessary to disconnect or remove the oxygen sensor
connectors (5) from the upper retainer (2). Figure 7-61. TSM/HFSM Module
4. Pull out on bottom of module to release from retainer in

battery tray. HFSM ANTENNA
5. Remove module from upper retainer (2) and disconnect
TSM/HFSM connector (3) and HFSM antenna jumper
Removal
harness connector (4). 1. Remove seat.
Installation 2. See Figure 7-62. Release HFSM antenna (2) from top
caddy.
1. If removed, route the jumper harness in its original location.
3. Disconnect HFSM antenna jumper harness.
2. See Figure 7-61. Connect TSM/HFSM connector (3) and
HFSM antenna jumper harness connector (4). 4. If necessary, remove HFSM antenna jumper harness as
follows:
3. Install module into upper retainer (2) and push bottom of
a. Remove HFSM module and disconnect antenna
module until it is secure in the retainer on the battery tray.
jumper harness. See 7.21 HARLEY-DAVIDSON
4. Secure rear wheel speed sensor connector (1) to retainer. SMART SECURITY SYSTEM, HFSM Module.
5. Install right side cover and saddlebag. b. Cut cable strap retaining jumper harness and main
harness to rear downtube.
c. Remove jumper harness through right side opening.
Installation
death or serious injury. (00316a) 1. Install HFSM antenna jumper harness as follows:
6. Install main fuse and test all turn signal functions. Test all a. Feed jumper harness down ahead of battery tray and
security system functions,. out through right side opening.
b. Route jumper harness under ABS mounting area of
battery tray to the TSM/HFSM module.
c. Connect jumper harness connector to HFSM module
and install HFSM module. See 7.21 HARLEY-DAV-
IDSON SMART SECURITY SYSTEM, HFSM Module.
d. Secure antenna harness and main harness to down
tube using a new cable strap.
2. See Figure 7-62. Connect HFSM antenna (2) to jumper

harness.

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3. Engage groove on HFSM antenna on tongue at front of

sm06174a
top caddy.
2
1
4. Install seat.
2
5. Test all security system functions.
3
sm05698
1
1. Connector [142]
2. Retainers
3. Smart Siren
4 Figure 7-63. Electrical Caddy and Smart Siren

5
Replace Battery
NOTES
2
3 • The siren's internal 9 Volt battery is rechargeable and does
not need to be replaced on a regular basis. Battery life
3 under normal conditions is approximately three to six
years.
1. Purge solenoid
• The internal siren battery may not charge if the vehicle's
2. HFSM antenna
battery is less than 12.5 Volts.
3. Cable straps
4. Fastener 1. Disarm system and remove siren. See procedure above.
5. Hold-down (not visible)
2. See Figure 7-64. Insert a small flathead screwdriver or
Figure 7-62. Top Caddy pick between the case and cover at a 45 degree angle.
Slowly twist the blade to pop off the cover.
3. Replace battery by removing old battery from polarized
SMART SIREN battery clip.
Remove 4. Install a new 9 Volt nickel metal hydride battery.
1. Remove the left saddlebag and the left side cover. NOTE
2. With the smart security system disarmed, remove the main Only a nickel metal hydride 9 Volt battery should be used in
fuse. the siren.
3. See Figure 7-63. Separate connector [142] (1). 5. See Figure 7-65. Reinstall battery cover:
a. Carefully install the rubber seal (1) around the edge
4. Release retainers (2) and remove smart siren (3).
of the siren.
Install b. Fold the foam padding (2) over the battery.
1. Push the smart siren into place in the electrical caddy and c. Snap cover (3) into place.
verify retainers are latched.
2. Mate connector [142] to the smart siren. 6. Install siren and check operation. If siren is working prop-
erly and is in the chirp mode, it will respond with two chirps
3. Install the main fuse. on arming.
4. Install the side cover.
5. Check operation. If siren is working properly and is in the
chirp mode, it will respond with two chirps on arming.

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ed02057 ed01645
3 4
1
3
6
5 2
1. Catch (2)
2. Slot (2)
3. Cover
4. 9-Volt battery
5. Rubber seal
6. Connector [142]
Figure 7-64. Open Siren Battery Cover
1. Seal
2. Foam padding
3. Cover
Figure 7-65. Replace Battery Cover
TROUBLESHOOTING
The HFSM will disarm the security system when the HFSS fob
is in the rider's pocket and the rider is within arm's length of
the center of the vehicle. The system may not disarm the
security system if the distance between the HFSS fob and the
vehicle-mounted antenna is less than 4 in. (102 mm). This may
occur if the rider places the HFSS fob on the seat and then
attempts to move the vehicle or disarm the security system. If
this occurs the rider should move the security fob a few inches
away from the seat to allow the system to disarm.
See the electrical diagnostic manual for service instructions.

HOME
ULTRA CRUISE CONTROL 7.22

GENERAL DIAGNOSTICS
See Figure 7-66 The cruise control on this model functions Entering cruise control diagnostics is different from other FL
similarly to the standard FL with an important difference. The models. Normally the ECM requires the simultaneous actuation
CRUISE/SPOT controller used on this model is a momentary of the cruise enable and set switches. The latching relay
switch that triggers a latching relay to send power to the ECM. associated with the CRUISE/SPOT switch adds a time delay
. to the ECM causing the ECM to fail entering diagnostic mode.
Entering ECM Diagnostic Mode

em00448
Perform the following steps to enter the ECM diagnostic mode:
1. Place RUN/STOP switch OFF.
2. Turn ignition switch to IGN.
3. Momentarily press the CRUISE switch.
4. Press and hold the cruise SET switch.
BN/O
BK/GN
GN/BK
O/R
O/BE
V/O
R/V
BE/BK
BK
O
5. Place RUN/STOP switch ON.
GY/BK
The ignition switch powers the slow-acting cruise switch

R/GN
O/V
BK
latching relay causing the relay to close before the power is

applied to the ECM by the RUN/STOP switch. In this way, the
ECM sees both inputs simultaneously as the ECM powers up.
Leaving ECM Diagnostic Mode

To leave the diagnostic mode, turn the ignition switch off, and
then on again.
GN/BK
BK/GN
GY/BK
BE/BK
R/GN
BN/O
O/BE
O/R
R/V
V/O
O/V
BK
BK
O
Y
12 1110 9 8 7 6 5 4 3 2 1 [105B] 1 2 3 [212B]

To Fairing Harness To Main Harness
[105A] [212A]
Figure 7-66. Fairing Switches

TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
A.1 CONNECTORS.........................................................................................................................A-1
A.2 WIRING DIAGRAMS.................................................................................................................A-2
APPENDIX A WIRING
NOTES
HOME
CONNECTORS A.1
CONNECTORS Connector Number
Function and Location On wiring diagrams and in service/repair instructions, con-
nectors are identified by a number in brackets.
Refer to Table A-1. On the motorcycle, a connector can be
identified by its function and location. The connectors in the Repair Instructions
table are not found in the service manual. The repair instructions in the service manual are by connector
Place and Color type.
The place (number of wire cavities of a housing) and color of

the connector can also aid identification.
Table A-1. Connector Locations
NO. DESCRIPTION TYPE TERMINAL LOCATION

PROBE
COLOR
[6] Audio 16-place Molex MX 150 Sealed Inside outer fairing
(BK)
[149] Audio amplifier 23-place Amp Gray Under Tour-Pak
[185] XM satellite antenna 1-place Deutsch Inside outer fairing, on XM module
[188] Amplifier 2-place Deutsch DTP Sealed Under seat
(BK)
[189] Heated hand grip to main har- 3-place Deutsch DT Sealed Black Inside outer fairing
ness (BK)
[190] Interior lamp 2-place Tyco 070 Multilock Brown Inside Tour-Pak
Unsealed (BK)
[190-R] Right saddlebag lamp 2-place Yeonho 025 YST Inside Tour-Pak
[190-L] Left saddlebag lamp 2-place Yeonho 025 YST Inside Tour-Pak
[191] Heated seat 2-place Deutsch DT Sealed Brown Under seat
(BK)
[212] Power lock switch 3-place Tyco 070 Multilock Gray Fairing cap
Unsealed (BK)
[213K] Ignition knob lock 2-place Tyco 040 Unsealed Gray Inside outer fairing, under radio
[213L] Saddlebag lock (LH) 2-place Tyco 040 Unsealed Brown Inside LH saddlebag
[213R] Saddlebag lock (RH) 2-place Tyco 040 Unsealed Brown Inside RH saddlebag
[213T] Tour-Pak lock 2-place Tyco 040 Unsealed Brown Inside Tour-Pak cover liner
[231] Power lock module 8-place Deutsch DT Sealed Black Inside outer fairing
(GY)
[272] GPS-zūmo 2-place Tyco Superseal 1.5 Gray Inside outer fairing
Sealed (BK)
[275-1] NIM 6-place Deutsch DTM Sealed Brown Inside outer fairing
(BK)
[275-2] NIM 1-place audio jack locking (BK) Inside outer fairing
2011 FLHTCUSE6 Service Supplement: Appendix A Wiring A-1

HOME
WIRING DIAGRAMS A.2

WIRING DIAGRAM INFORMATION
ed03175
Wire Color Codes 5
Wire traces on wiring diagrams are labeled with alpha codes.
Refer to Table A-2. 3 4 6
For Solid Color Wires: See Figure A-1. The alpha code
identifies wire color.
1 2 7
For Striped Wires: The code is written with a slash (/) between
GN/Y
W
the solid color code and the stripe code. For example, a trace
labeled GN/Y is a green wire with a yellow stripe. 8
[21A] 1 2
Wiring Diagram Symbols [21B] 1 2
See Figure A-1. On wiring diagrams and in service/repair 9
GN/Y
instructions, connectors are identified by a number in brackets
[ ]. The letter inside the brackets identifies whether the housing 10
is a socket or pin housing. 1 2
A=Pin: The letter A and the pin symbol after a connector
number identifies the pin side of the terminal connectors. 13 11
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-
lowing: 1. Connector number
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
Wire break: The wire breaks are used to show option variances 5. Socket symbol
or page breaks. 6. Pin symbol
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 2011 FLHTCUSE6 Service Supplement: Appendix A Wiring

HOME
ed03176 Table A-2. Wire Color Codes
ALPHA CODE WIRE COLOR

1 A C E G J BE Blue
2
15 3
15 4
15 5
15
1 BK Black
6
15 7
15 8
15 9
15
BN Brown
64-1 2
10 11
15
12 GN Green
3
13 GY Gray
15 14
4 B D F H LGN Light Green
27 O Orange
A C E
15 16
15 17
15 PK Pink
18
R Red
19 20
15 21
15
64-2 TN Tan
22 23
15
3
V Violet
24
30 25 26
30 W White
4 B D F H
Y Yellow
1. Fuse block [64-1]

2. Brake
3. Accessory
4. P&A
5. Radio
6. Radio memory
7. Battery
8. ECM power
9. Power outlet
10. System relay
11. Power lock
12. Start relay
13. Fuel pump
14. GPS
15. P&A IGN (2 Amp max)
16. Instruments
17. Ignition
18. Lighting relay
19. Brake relay
20. Headlamp
21. Lights
22. Heated grips
23. Spare
24. ABS
25. Amplifier
26. Spare
27. Fuse block [64-2]
Figure A-2. Fuse Block and Socket Terminals
2011 FLHTCUSE6 Service Supplement: Appendix A Wiring A-3

HOME
WIRING DIAGRAMS
Wiring Diagram List

DIAGRAM LOCATION
Main Harness (1 of 2): 2011 FLHTCUSE6 Figure A-3
Main Harness (2 of 2): 2011 FLHTCUSE6 Figure A-4
Fairing Harness: 2011 FLHTCUSE6 Figure A-5
Lighting, Garage Door Opener: 2011 FLHTCUSE6 Figure A-6
Starting and Charging System: 2011 FLHTCUSE6 Figure A-7
Indicators, Fairing Switches, Handlebar Switches, ABS: 2011 FLHTCUSE6 Figure A-8
Audio Overlay Harness: 2011 FLHTCUSE6 Figure A-9
A-4 2011 FLHTCUSE6 Service Supplement: Appendix A Wiring

et00437 See
Indicators, Main Power
TSM/TSSM/HFSM At Starter Voltage B+ Ignition
Fairing Switches, Start Main Fuse
Battery 1 1 Handlebar Solenoid [BATT] 40A Regulator Connector Switch
BN/GY A B C D [141A]
Ignition 2 2 Switches, ABS Fuel
Ground
GY [128B] [5B] [77B] [160B] [33B]
I I 1 2 3
Signal
A B N P
Power
Serial Data Link 3 3 LGN/V Pump
A B C D [141B]
Neutral Switch 4 4 TN
R/BN
GY
PK/BN
R/BE
R/V
LGN/V
BK
GN
R/GY
BK
R/BK
BK
R
R
R
Left Turn Feed 5 5 V
Y/W
O/GY
BK/GN
BK
Right Turn Feed 6 6 BN Fuel Pump 1 2 3 [142A]
R
Right Turn SW Input 7 7 W/BN
Left Turn SW Input 8 8 W/V Assembly In Tank
Start Relay Control 9 9 A B C [142B]
TN/GN
Clutch Switch 10 10 BK/R Fuel Tank
BN/GY
BK/GN
LGN/BN
BK/GN
Alarm Signal 11 11 LGN/BN
O/GY
Ground 12 12 BK/GN Harness
Y/W
64-1
BK
Cruse/Brake 15A
O/V 1B 1A
[30A] [30B] 1 2 3 4 [13B] Accessory 15A
(GY) See Lighting, O/W 1D 1C R/GY
Garage Door 1 2 3 4 [13A]
P&A 15A
Opener Power Outlet
Y/W
O/GY
BK/GN
R/BE
BK
See Main Harness (2 Of 2)
O/R 1F 1E R/GY
[190A] 1 2 [258B]
GN/O 1 2 Radio Power/Siren 15A
O/BE 1H 1G R/GY
BN/BE
BK
R/O
BK
BK/GN
BE/BK GN 4G 5 87
W/BE
R/GN R/GY 3H 3 30 Start
Relay
TN/GN 3G 2 85
LGN/V BK/R 4H 1 86
GY
Y/GN R/O Radio Memory 15A
BE/GY R/O 2B 2A R
W/BK Battery 15A
BN/GY 2D 2C R
ECM Power 15A
16 BE/BK BK BE/GY 2F 2E R
15 R/GN LH GND BE/GY Power Outlet 15A
14 W/BE Stud
13 LGN/V BN/BE 2H 2G R/GY
(Dirty) BK
11 W/V
10 W/BN
[GND 1]
9 O/BE Y/GN 4C 5 87
8 BN System
7 V BE/GY 3D 3 30 Relay
6 W/BK GN/O
5 O/W 3C 2 85
4 O/R W/BK 4D 1 86
3 GY
Power Locks 15A
1 O
R/V 3F 3E R
[1B] RT GND [GND 2]
See Fuel Pump 15A
[2B] Stud BK/GN
Fairing O/GY 4B 4A Y/GN
(Clean) BK/GN
Harness 12 BK/GN
11 BK/R GPS 2A
10 TN O/W 4F 4E R/GY
9 GN/Y
8 BN/GN
7 O P&A IGN 2A MAX 64-2
6 Y/BK 1B 1A
5 Y/W INSTRS 15A
4 BN/GY
3 O 1D 1C R/BK
BE
2 BK/R Ignition 15A
1 R/BN GY 1F 1E
BK Headlamp 15A
D
C BK/GN BE 2D 2C
B BE Lights 15A
A R/O BE 2F 2E
[15B]
87 5 2G
87A 4
Oil D
Lighting 30 3 1J R
Pressure C Relay
B BN/GN 85 2 2J BK
Sender A GN/Y 86 1 1G R/BK
[139B]
PK/BN
O/W
O/V 3A 5 87
Y/BK
Battery Power 1 1 R/V

BK
TN
BK
Lock Input 2 2 BE/BK Horn R/Y 2B 3 30 Brake

Power Unlock Input 3 3 GN/BK B A 1 2 Relay
Locks 2 R/BE 2A 2 85
GN/BK
BE/BK
BK 3B 1 86
Module Lock Signal 6 6 BE/W
Unlock Signal 7 7 GN/W
O
Heated Grips 5A
Power Ground 8 8 BK 1
Neutral Rear (BK) R 3D 3C R/GY
R/Y
O/W
O/R
R/Y
[122]
R/Y
BK
BE
BK
BN
BK
BE
[231A] [231B] [212A] 1 2 3
Switch Stop Light [4A]
O
[12B]
V
[7A] ABS 30A
[212B] 1 2 3 [131] Switch 1 2 3 4 3 2 1 1 2 3 5 6 7 R/V 4B 4A R
O/W
BK
[121] AMP 30A
R
ACC See
GN/BK
[189A]
BE/BK
See R 4D 4C R/GY
R/V
Connector
GN/W
GN/W
GN/W
GN/W
BK/GN
BE/W
BE/W
BE/W
BE/W
Lighting, Lighting, A B C
O/W
Garage
O/R
Garage
BK
BK
R
Door Door See Indicators,
1 2 [213RA] [213LA] 1 2 [213KA]
1 2 1 2 [213TA] Opener Opener Fairing Switches, 2 1 [188B]
[272B] 1 2 [191A] 1 2 3 4
1 2 [213RB] [213LB] 1 2 [213KB]
1 2 1 2 [213TB] Handlebar
To To Switches, See Audio
Right Saddle Left Saddle Ignition Knob Tour-Pak Power Lock GPS Heated ABS Overlay
Bag Lock Bag Lock Lock Lock Switch Seat Harness
Figure A-3. Main Harness (1 of 2): 2011 FLHTCUSE6

Figure A-3. Figure A-3.
Main Harness (1 of 2): 2011 FLHTCUSE6 Main Harness (1 of 2): 2011 FLHTCUSE6
et00438 Yellow Tubing
R Ignition
1 2 3 4 5 6
W Coil
Twist Grip BK
Sensor R
W
Rear Front
BK Fuel Fuel CKP
Injector Injector TMAP
Black Tubing Sensor TCA
ET
Ion Sense
Coil Front
Coil Rear
Sensor
BK
BK
W
W
R
Power
DLC [204A] 1 2 3 4 5 6 1 2 [79A]
[85A] A B A B [84A]
[90A] [83A] A B C D
[91A] 1 2 3 4 [204B] 1 2 3 4 5 6
[85B] [84B] 1 2 3 4 [80A] 6 5 4 3 2 1 [211A] 1 2 [79B]
A B A B
(GY) [83B] A B C D [80B]
BK/W
BN/O
[211B]
R/W
BK
BE/GN
R
BK/GY
BK/GN
1 2 3 4
GY
V/Y
LGN/V
6 5 4 3 2 1
Y/GN
W/Y
A B
Y/GN
GN/GY
Y/GN
BE/O
Y/BE
GY/BE
R/W
V/W
BK/W
BK/GY
BN/O
LGN/Y
BN/R
BK/O
BN/V
BK/PK
[90B] A B
ECM [78A] [78B]
BK/W
PK/Y
18 18 BK
ACR 19 19 V/GY
Purge Solenoid 20 20 GY/Y
Cruise/Set/Coast 22 22 BE/BK BE/BK

Rear Injector 23 23 GN/GY
TMAP Sensor Input 24 24 V/W
Brake Switch 25 25 R/BE R/BE
System Relay Enable 27 27 GN/O GN/O

Front Injector 28 28 W/Y
Twist Grip High 29 29 BK/O
Twist Grip Low 30 30 BK/PK
Heated O2 GND 31 31 GN/W
BK/GN
Ion Sense 33 33 GY/BE
Cruise Resume/Accelerate 34 34 W/BE W/BE
Cruise Enable 35 35 R/GN R/GN
Throttle Pos. Sensor 2 36 36 BN/R
Throttle Pos Sensor 1 37 37 BN/V
Twist Grip Sensor 2 39 39 V/Y

Vehicle Speed Input 40 40 W/GN LGN/V
See Main Harness (1 Of 2)

Crank Position Sensor (-) 43 43 +BK
GY
Rear O2 Sensor (Unheated) 46 46 PK/GN
O2 Sensor Ground 48 48 BK/BN
Intake Air Temperature 49 49 LGN/Y
5V Sensor Power 1 50 50 BN/O
Engine Temperature 51 51 PK/Y
Twisted 12 V Power 52 52 Y/GN Y/GN
Pair
Rear Coil 53 53 Y/BE
Front Coil 54 54 BE/O
Jiffy Stand Sensor 56 56 GN/BN

57 57 BK
Twist Grip Sensor 1 59 59 BE/GN
5V Sensor Ground 1 61 61 BK/W

5V Sensor Ground 2 62 62 BK/GY
Crank Position Sensor (+) 63 63 R
Vehicle Speed Ground 64 64 BK/Y
Front O2 Sensor (Unheated) 66 66 PK/O

5V Sensor Power 2 68 68 R/W
Serial Data 69 69 LGN/V
12V Battery 71 71 BE/GY BE/GY

12V Run/Stop Switch 72 72 W/BK W/BK
Ground 73 73 BK/GN
GN/BN
PK/GN
BK/GN
BK/BN
BK/BN
GN/W
GN/W
W/GN
Y/GN
Y/GN
Y/GN
BN/O
BN/O
Y/GN
Y/GN
GY/Y
PK/O
V/GY
V/GY
BK/Y
B A [95B] 1 2 3 4 [138B] 1 2 3 4 [137B] [65B] 1 2 3 [133B] 1 2 3 [203FB] 1 2 1 2 [203RB]
Purge Front Rear VSS JSS Front Rear
Solenoid HO2S HO2S (HDI Only) ACR ACR
Figure A-4. Main Harness (2 of 2): 2011 FLHTCUSE6

Main Harness (2 of 2): 2011 FLHTCUSE6 Main Harness (2 of 2): 2011 FLHTCUSE6
et00439 See Indicators, See Indicators,
[278B]
Fairing Switches, Fairing Switches, Oil Air
Ground Handlebar Handlebar Fuel Voltmeter Pressure Temperature
1 O/R
2 Y To Fork Switches, ABS Switches, ABS [116A] [110A] [112A] [114A]
3 W Bracket [21A] 1 2 3 4 5 6 7 12 11 10 9 8 7 6 5 4 3 2 1 [105A] [116B] [110B] [112B] [114B]
See 4 BK
Lighting, [GND3] (BK) (BK)
O/W
R/GN
GN/Y
W
O/R
GY/BK
BK
BN
BN/O
O
TN
BK
O/BE
V/O
V
BK
BK
1 2 1 2 1 2 1 2
Garage + S S S
BK
1 W + S + +
Door 1 3 [117A] 1 3 [111A] 1 3 [113A] 1 3 [115A]
Opener Hi Beam 2 2 2 2
2 Y
Lo Beam [117B] [111B] [113B] [115B]
BN/GN
O
BK
BK
Y/W
O
BK
BK
O
BK
BK
BE/V
BK
BK
O
3 BK
GND
HDI Only [38B]
(BK)
[29B] BK [107B] [107A]
O/W
BE/V 1 1
[22B] 2 2 TEMP Signal
BK Ground
3 3
Right Hand 1 O/W
2 R/BE Air
Controls 3 GY Temperature
See 4 W/BK Sensor
Indicators, 5 W/BN [1A]
6 BK/R
Fairing 7 BN/W
Switches, 8 GY/W BE/BK 16
Handlebar 9 PK/W R/GN 15
Switches, ABS 10 V/BK W/BE 14
11 W/BE LGN/V 13
12 BE/BK
W/V 11
W/BN 10
[24B] O/BE 9
BN 8
V 7
W/BK 6
14 O/BK O/W 5
Left Hand 13 V/BK O/R 4
Controls 12 BK/GN GY 3
11 GY/GN O 1
See 10 GN/BE
Indicators, 9 PK/W
Fairing 8 BN/BK [2A]
Switches, 7 BK/R See
6 Y/BK Main Harness
Handlebar 5 W/V BK/GN 12
Switches, ABS 4 W BK/R 11 (1 Of 2)
3 BE TN 10
2 Y GN/Y 9
1 O/W BN/GN 8
O 7
Y/BK 6
[27B] Y/W 5
BN/GY 4
BE 3
1 LGN/BK BK/R 2
2 BE/Y R/BE 1
3 PK/W
4 GY/W
5 V/BK
6 BN/W
BK D
7 O/BK BK/GN C
8 BN/BK
BE B
9 LGN/V R/O A
10 R/O
To Radio 11 BK/GN
BN/GY
LGN/V
BK/GN
BK/GN
BN/GY
12
LGN/V
O/BE [15A]
O/W
Y/W
13
BK
BK
O/W
BN/O
O
15 V/GY
O
16 W/O
17 LGN/W [39B] 1 2 5 6 7 8 9 11
[108B] 1 2 5 6 7
18
(BK) (GY)
GY/R [39A]
19 BK/GN 1 2 5 6 7 8 9 11 [108A] 1 2 5 6 7
20 R/O
Reset Switch
Ignition
Trip Odometer-
Accessory
Serial Data
Battery
Ground
Fuel Level
Tri p Switch
Accessory
Serial Data
Battery
Ground
Ignition
21 V/O
22 GY/GN
23 GN/BE
[34B]
Right Front LGN/BK O/R
BK
BK
O/W
GY/BK
GY/BK
Speaker GY/R
BE
BN
BK
BE
BK
BK
BE
V
[32A] BK
[35B] RPM x 100
2 1 [32B] 4 3 2 1 [31RA] 4 3 2 1 [31LA]
Left Front LGN/W [132B] [132A]
Speaker Trip Odometer
W/O Front Fender RH Front LH Front Reset Switch Cigar
LGN/BK
LGN/BK
LGN/W
LGN/W
BK/GN
Tip Lamp Turn Signal Turn Signal Lighter

GY/R
GY/R
[154A]
V/GY
BE/Y
W/O
W/O
R/O
[6A] 16 15 14 13 10 9 8 7 6 3 2 1
Speedometer Tachometer
See Audio Overlay Harness
Figure A-5. Fairing Harness: 2011 FLHTCUSE6

Fairing Harness: 2011 FLHTCUSE6 Fairing Harness: 2011 FLHTCUSE6
et00440 See
Low Beam [7B] 1 2 3 4 5 6 7 8 Main Harness
Headlamp Detail [38L] Rear Lighting
(1 Of 2)
O/W
R/Y
BN
BK
BE
V
Right Rear
BK 1 V/BN Directional
Y 2 Headlamp Lamp
BK
[38A]
BK 1
W 2
[38B] [38A]
BK
[38H] Tail Lamp
R/Y
W 1 1 W High Beam O/W
O/W
R/Y
W BE/W
BN
BK
BE
V
See Brake Light
Fairing Y 2 2 Y 6 5 4 3 2 1 [94B]
Harness
BK 6 5 4 3 2 1
[94A]
BK 3 3 BK [19B]
V/BN 1 1 [19A]
BK License
BK 2 2
BK Plate Lamp
Running Light (DOM )
1 1 1 [18B] [18A] (HDI Only)
O/R O/W
Y 2 2 Y 2 Garage
W 3 3 W 3 Door Opener V/BN 1 1
4 4 4 2 2 Running Light (HDI)
BK BK BK
4 4
BK 1 1 3
[278A] [278B] 2 2
3
P And A 2 2
O/R BK 3 3 1
Fuse 1
[45B] [45A] [93A] [93B]
V/BN Left Rear

Direction
BK Lamp
Left Or Right BK
Directionals, V
And DOM BE
Running Lamps
Tour-Pak Tour-Pak Lighting
See LED
Main Harness Wrap Around
(1 Of 2) Tour-Pak Right Side Lights
Marker Lights
3 2 1 [12B] Interior Lamp
BK
R/Y
BK
BE
BE
BE 1 1 BE W
BE 2 2 BE R
Left Or Right Tail [12-2A] 1 2 R/Y 3 3 R/Y R/Y
AUX Lamps Right
W/BK
R/BK
BK
R
[12-2B] 1 2 BE 4 4 BE
BK 5 5 BK
BE Saddlebag
Lamp
BK 6 6 BK BK
BE
BK
Stop BK 8 8 BK
[73LB] BK BE R/BK 1 1 R
[73RB] [12-6B] [12-6A] BK
GY/BK
W/BK 2 2 W
BK 3 3 BK
[190A-R] [190B-R]
Left
Saddlebag
Lamp
BE
BK
[12-3B] 1 2
[12-3A] 1 2 R 1 1 R
W 2 2 W
BK 3 3 BK
GY/BK
BE
BK
Note: [190A-L] [190B-L]

V
BK
R
The Same Directional/AUX Lamp ASSY Tour-Pak Left Side
Are Used On Both Left And Right Sides. [31LB] 1 2 3 4
Marker Lights [190B] 1 2
[31RB]
See See
Fairing Main Harness
Harness (1 Of 2)
Figure A-6. Lighting, Garage Door Opener: 2011 FLHTCUSE6

Lighting, Garage Door Opener: 2011 FLHTCUSE6 Lighting, Garage Door Opener: 2011 FLHTCUSE6
et00441
[208A] [208B]
[209B] [209A]
HFSM Stator
Receive Antenna 1 1 Y/BK [77B] [77A] [47A] [47B]
Xmit Antenna A 2 2 O/Y O/Y 1 Xmit Antenna A
Xmit Antenna B 3 3 BK BK 2 Xmit Antenna B 2
Unused 4 4 BK BK
BK BK
TSM/TSSM/HFSM 1 DC AC BK BK
BK
BK
Battery 1 1 BN/GY
Ignition 2 2 GY
Neutral Switch 4 4 TN Main Fuse
40A
Start Relay Control 9 9 TN/GN
Clutch Switch 10 10 BK/R
BK
Ground 12 12 BK/GN
[5B]
[30A] [30B] B A
R
Right Hand Battery
R
R
Controls Red
Band
Main Fuse
BK
BK
BK
[78A] [78B] 40A
R
R
BK
[128B] Red
[128A] Band
ECM GN [5B]
Engine Stop Switch Engine Stop Switch 72 72 W/BK
A B Left
Start Switch GND 1 Powertrain
BK
BK/GN Starter Dirty Grounds
R
R
(Black) BK Battery Starter
[22A] [22B] (Black)
[1A] [1B]
GY 3 3 GY GY 3 3 GY Left [33B] [33A]

Right
W/BK 4 4 W/BK W/BK 6 6 W/BK GND 2 GND 1
BK/R 6 6 BK/R Clean Dirty R 2 B+
ACC
R/GY 1 ACC
Ignition
OFF
Switch
R/BK 3 IGN IGN
64-1B
GN 4G 5 87
Clutch
Lockout R/GY 3H 3 30 Start
Switch TN/GN 3G 2 85 Relay
BK/R 4H 1 86
(Gray) (Gray)
[24A] [24B] [2A] [2B] Battery 15A
BN/GY 2D 2C R
BK/GN 12 12 BK/GN
BK/R 7 7 BK/R BK/R 11 11 BK/R
BK/R 2 2 BK/R
BK 12 12 BK/GN 64-2B
Ignition 15A
GY 1F 1E R/BK
GY
[2A] [2B] 87 5 2G
Left Hand Lighting 30 3 1J R

Controls Relay
TN 10 10 TN 85 2 2J BK
86 1 1G R/BK
TN
[21A] 7
(BK)
[21B] 7 6 Left GND 1
Dirty
O
TN
BK
TN
Neutral B A [131]
TN Neutral
O
Switch
Figure A-7. Starting and Charging System: 2011 FLHTCUSE6

Starting and Charging System: 2011 FLHTCUSE6 Starting and Charging System: 2011 FLHTCUSE6
et00398
Right Hand
See Fairing Controls
Harness
1 2 3 4 5 6 7 [21B] ABS
Module [166A] [166B]
(BK) Radio Function Switch
GN/Y
BN
BK
TN
O
V
Right Directional Switch ECU/Solenoid Ground 1 1 BK
Engine Off/Run Switch Rear Brake Input 3 3 PK/BN

Indicator
Lamps Start Switch
Rear Wheel Speed (-) 7 7 BE/V
Cruise Set/Resume Switch Rear Wheel Speed (+) 8 8 BE/BN
BN Right Datalink 9 9 LGN/V
BK Turn ECU/Solenoid Power 10 10 R/V
Motor Ground 11 11 BK
Oil Front Brake Input 13 13 R/BN

GN/Y
O Pressure
Stop Lamp Switch Front Wheel Speed (+) 17 17 BK/BE
TN Front Wheel Speed (-) 18 18 BK/V
Neutral [22A] Ignition Wake-Up 19 19 GY
O
O/W 1 Motor Power 20 20 R/V
R/Y 2
W High GY 3
W/BK 4
BK Beam W/BN 5 See
BK
Fairing
W
BK/R 6
Left BN/W 7 Harness 4 4 R/BE
V
1 2 [206A] GY/W 8 ABS
BK Turn 3 3 R/BE
PK/W 9 Diode 2 2 R/BN
1 2 [206B] V/BK 10 Pack 1 1 PK/BN
W/BE 11
BE/BK 12
BK/W
BK
[201A] [201B]
O/W A See
R B Main Harness
BK C (1 Of 2)
SPKR ACC
PK/BN
LGN/V
CRUISE
[189B]
R/BN
R/BE
R/V
SPOT
GY
BK
O/BK 14
V/BK 13 See
BK 12 Main Harness
GY/GN 11 (1 Of 2)
BE/BN
BK/BE
BK/V
BE/V
GN/BE 10
PK/W 9 See
BN/BK 8 Fairing
BK/R 7
Y/BK 6 Harness
BN/O
BK/GN
O/BE
V/O
W/V 5 [168B]
GN/BK
O/R
R/V
BE/BK
BK
W 4 [167B] A B A B
BE 3 [167A] A B A B [168A]
Y 2
GY/BK
O/W 1
BK
R/GN
R
O/V
BK
BK
R
Y
[24A]
Clutch
Lockout Switch
PTT & SQ
Horn Switch
Front Rear
GN/BK
Headlamp Hi/Lo Switch

BE/BK
WSS WSS
BK/GN
GY/BK
R/GN
BN/O
O/BE
R/V
O/R
V/O
O/V
Left Directional Switch

BK
BK
O
Y
[105B] 12 1110 9 8 7 6 5 4 3 2 1 [212B] 1 2 3 Radio Audio Control
See See
Fairing Harness Main Harness
(1 Of 2)
Left Hand
Controls
Figure A-8. Indicators, Fairing Switches, Handlebar Switches, ABS: 2011 FLHTCUSE6
Indicators, Fairing Switches, Handlebar Switches, ABS: 2011 Indicators, Fairing Switches, Handlebar Switches, ABS: 2011
FLHTCUSE6 FLHTCUSE6
et00442 To To
NIM Speaker Speaker
[36B] [37B]
NIM Audio +
NIM Audio -
Ground
Battery
CAN +
CAN -
Right Rear Left Rear
GN
LGN/BN
W/BN
BN
DOWN
+VOL
MODE
-VOL
PTT
Speaker Speaker
UP
Controls Controls
BK/GN
BK/BE
R/BE
[76B]
R/O
Y/O
Y/V
LGN/BN
BK 1
GY/W
GY/W
W/BN
PK/W
PK/W
O/BK
O/BK
V/BK
V/BK
1 2 3 4 5 6 [275A] Y/BK 2 Passenger
GN
BN
GY/Y 3 Headset
1 2 3 4 5 6 [275B] (BK) (BK) R 4
[41B] 1 2 3 4 5 6 [42B] 1 2 3 4 5 6 GY/O 5
R/O
BK/GN
Y/O
R/BE
BK/BE
Y/V
BK 8
Twisted [41A] 1 2 3 4 5 6 [42A] 1 2 3 4 5 6
[28A] [28B] Pair
GY/W
GY/W
BN/W
W/BN
PK/W
PK/W
GN
O/BK
LGN/BN
BN
V/BK
V/BK
Radio [184A]
CB/GMRS Audio + 3 3 R
NIM Audio + 4 4 R/BE R 1
LR HDSET SPKR + 5 5 GY/O BK 2
LF HDSET SPKR + 6 6 Y/W R 4
XM Left 7 7 W BK 5 Ultra CB
Front MIC + 9 9 R R/O 9
Rear MIC + 10 10 R BK/GN 10
RR2 11 11 V/BK Y/O 11
RC4 12 12 BN/W Y/V 12
CAN + 13 13 Y/O
CAN - 14 14 Y/V
L SDCAR HDSET SPKR + 15 15 GN/V
R SDCAR HDSET SPKR + 16 16 GY/BK
HDSET SPKR - (Shared) 17 17 Y/BK
XM Shield 18 18 BK
MIC - (Shared) 20 20 BK
MIC Shield - (Shield) 21 21 BK
MIC SUM Out - 22 22 BK
RR1 23 23 GY/W
CB/GMRS Audio SHLD 26 26 BK
NIM Audio - 27 27 BK/BE
RR HDSET SPKR + 28 28 GY/Y [188A]
RF HDSET SPKR + 29 29 Y/R
XM Right 30 30 R See Main
SDCAR MIC In + 32 32 W BK 2
MIC SUM Out + 33 33 R R 1 Harness
RR0 (RR CNTL Matrix) 34 34 PK/W (1 Of 2)
RC3 (RR CNTL Matrix) 35 35 O/BK
[6B]
Twisted
Pair Y/GY 1
BE/Y 2
R/O 3
Y/O 4
Y/V 5
BK/GN 6 See
GY/R 7 Fairing
LGN/BK 8
9
Harness
W/O
[53B] LGN/W 10
GY/R 13
LGN/BK 14
1 W W/O 15
2 GN/V LGN/W 16
3 GY/BK
4 BK/GN
Front/Sidecar 5 Y/GY
Intercom 6 BE/Y Twisted [149B] [149A]
7 Y/BK Pair Amplifier
8 Y/W
9 Y/R Y/O 1 1 CAN +
10 R Y/V 2 2 CAN -
11 R 3 3 Battery
BK
R R 4 4 Battery
12 BK
GY/R 6 6 Right Front Out +
W/O 7 7 Left Front Out +
6 R BN 8 8 Left Rear Out +
7 W
8 BK LGN/W 11 11 Left Front In -
XM 9 R/O
LGN/BK 12 12 Right Front In -
10 BK/GN LGN/BK 13 13 Right Front Out -
11 Y/O LGN/W 14 14 Left Front Out -
12 Y/V W/BN 15 15 Left Rear Out -
[185B] W/O 18 18 Left Front In +

GY/R
GY/R 19 19 Right Front In +
BK 20 20 Ground
BK BK 21 21 Ground
GN 22 22 Right Rear Out +
LGN/BN 23 23 Right Rear Out -
Twisted Twisted
Pair Pair
Figure A-9. Audio Overlay Harness: 2011 FLHTCUSE6

Audio Overlay Harness: 2011 FLHTCUSE6 Audio Overlay Harness: 2011 FLHTCUSE6
TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
B.1 GLOSSARY...............................................................................................................................B-1
APPENDIX B GLOSSARY
NOTES
HOME
GLOSSARY B.1
ACRONYMS AND ABBREVIATIONS
Table B-1. Acronyms and Abbreviations
ACRONYM OR ABBREVIATION DESCRIPTION

A Amperes
ABS Anti-lock braking system
Ah Ampere-hour
AC Alternating current
ACC Accessory position on ignition switch
ACR Automatic compression release
AIS Active Intake Solenoid
AGM Absorbed glass mat (battery)
AWG American wire gauge
B+ Battery voltage
bar Bar
BAS Bank angle sensor
BCM Body control module
BTDC Before top dead center
°C Celsius (Centigrade)
CA California
CAL Calibration
CAN Controller area network
cc Cubic centimeters
cm Centimeters
cm3 Cubic centimeters
CCA Cold cranking amps
CKP Crankshaft position
cm Centimeter
CCW Counterclockwise
CW Clockwise
DC Direct current
DLC Data link connector
DOM Domestic
DTC Diagnostic trouble code
DOT Department of Transportation
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
ET Engine temperature
EVAP Evaporative emissions control system
°F Fahrenheit
2011 FLHTCUSE6 Service Supplement: Appendix B Glossary B-1

HOME

FPS Fuel pressure sensor
ft Foot
ft-lbs Foot pounds
fl oz Fluid ounce
g Gram
gal Gallon
GAWR Gross axle weight rating
GPS Global positioning system
GND Ground (electrical)
GVWR Gross vehicle weight rating
HCU Hydraulic control unit
HDI Harley-Davidson International
H-DSSS Harley-Davidson smart security system
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
in-lbs Inch pounds
JSS Jiffy stand sensor
kg Kilogram
km Kilometer
kPa Kilopascal
km/h Kilometers per hour
kW Kilowatt
L Liter
lb Pounds
LCD Liquid crystal display
LED Light emitting diode
LHCM Left hand control module
mA Milliampere
MAP Manifold absolute pressure
max Maximum
mi Mile
min Minimum
B-2 2011 FLHTCUSE6 Service Supplement: Appendix B Glossary

HOME

mL Milliliter
mm Millimeter
mph Miles per hour
ms Millisecond
Nm Newton-meter
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
psi Pounds per square inch
PWM signal Pulse width modulated signal
qt Quart
RCM Reverse control module
RES Reserve mark on fuel supply valve
RHCM Right hand control module
rpm Revolutions per minute
s Seconds
SCFH Cubic feet per hour at standard conditions
SPDO Speedometer
TCA Throttle control actuator
TDC Top dead center
TGS Twist grip sensor
TMAP Intake air temperature/manifold absolute pressure
TPS Throttle position sensor
TSM Turn signal module
TSSM Turn signal/security module
V Volt
VAC Volts of alternating current
VDC Volts of direct current
VIN Vehicle identification number
VSS Vehicle speed sensor
W Watt
WSS Wheel speed sensor
2011 FLHTCUSE6 Service Supplement: Appendix B Glossary B-3

NOTES
B-4 2011 FLHTCUSE6 Service Supplement: Appendix B Glossary

Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-33223-1 CYLINDER COMPRESSION GAUGE 3.4 TROUBLESHOOTING, Compression Test
HD-34723 VALVE GUIDE HONE 3.5 CYLINDER HEAD, Inspection
HD-34730-2D FUEL INJECTOR TEST LIGHT 7.11 DTC P1655, P1656, DTC P1655
HD-34730-2D FUEL INJECTOR TEST LIGHT 7.11 DTC P1655, P1656, DTC P1656
HD-34736-B VALVE SPRING COMPRESSOR 3.5 CYLINDER HEAD, Disassembly
HD-34736-B VALVE SPRING COMPRESSOR 3.5 CYLINDER HEAD, Assembly
HD-34740 VALVE GUIDE AND VALVE GUIDE SEAL 3.5 CYLINDER HEAD, Replacing Valve Guides
HANDLE
HD-34740 VALVE GUIDE AND VALVE GUIDE SEAL 3.5 CYLINDER HEAD, Replacing Valve Guides
HANDLE
HD-34740 VALVE GUIDE AND VALVE GUIDE SEAL 3.5 CYLINDER HEAD, Assembly
HANDLE
HD-34751 VALVE GUIDE CLEANING BRUSH 3.5 CYLINDER HEAD, Inspection
HD-34751 VALVE GUIDE CLEANING BRUSH 3.5 CYLINDER HEAD, Replacing Valve Guides
HD-34751 VALVE GUIDE CLEANING BRUSH 3.5 CYLINDER HEAD, Assembly
HD-35667-A CYLINDER LEAKDOWN TESTER 3.4 TROUBLESHOOTING, Cylinder Leakdown Test
HD-39361-B SPROCKET SHAFT OIL SEAL INSTALLER 3.8 CRANKCASE ASSEMBLY, Assembly
HD-39782-A CYLINDER HEAD SUPPORT STAND 3.5 CYLINDER HEAD, Replacing Valve Guides
HD-39782-A CYLINDER HEAD SUPPORT STAND 3.5 CYLINDER HEAD, Replacing Valve Guides
HD-39786 CYLINDER HEAD HOLDING FIXTURE 3.5 CYLINDER HEAD, Disassembly
HD-39786 CYLINDER HEAD HOLDING FIXTURE 3.5 CYLINDER HEAD, Replacing Valve Guides
TOOLS
HD-39786 CYLINDER HEAD HOLDING FIXTURE 3.5 CYLINDER HEAD, Assembly
HD-39847 RATCHETING TAP HANDLE 3.5 CYLINDER HEAD, Replacing Valve Guides
HD-39847 RATCHETING TAP HANDLE 3.5 CYLINDER HEAD, Replacing Valve Guides
HD-39932 VALVE GUIDE REAMER 3.5 CYLINDER HEAD, Replacing Valve Guides
HD-39964 REAMER LUBRICANT 3.5 CYLINDER HEAD, Replacing Valve Guides
HD-39964 REAMER LUBRICANT 3.5 CYLINDER HEAD, Replacing Valve Guides
HD-41404-C HARNESS CONNECTOR TEST KIT 7.6 TOUR-PAK LIGHTING, Lamps Inoperative
HD-41404-C HARNESS CONNECTOR TEST KIT 7.11 DTC P1655, P1656, DTC P1655
HD-41404-C HARNESS CONNECTOR TEST KIT 7.11 DTC P1655, P1656, DTC P1656
HD-41404-C HARNESS CONNECTOR TEST KIT 7.13 XM SATELLITE RADIO, Symptom 12: No or Low
Audio from XM or XM Inoperative
HD-41404-C HARNESS CONNECTOR TEST KIT 7.13 XM SATELLITE RADIO, Symptom 13: No or Inter-
mittent Reception on XM Module
HD-41404-C HARNESS CONNECTOR TEST KIT 7.14 ROAD TECH ZŪMO 660 GPS, DTC U1306
Infotainment Bus Lost Communication with NIM Module
HD-41404-C HARNESS CONNECTOR TEST KIT 7.18 GARAGE DOOR OPENER, Garage Door Opener
Inoperative
HD-42311 OIL FILTER WRENCH 3.10 OIL COOLER ADAPTER, Removal
HD-42326-B CRANKSHAFT GUIDE 3.8 CRANKCASE ASSEMBLY, Assembly
HD-42682 BREAKOUT BOX 7.13 XM SATELLITE RADIO, Symptom 12: No or Low
HD-45325 JUMPER HARNESS 7.13 XM SATELLITE RADIO, Symptom 12: No or Low
HD-46583 VALVE GUIDE INSTALLER 3.5 CYLINDER HEAD, Replacing Valve Guides
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 7.13 XM SATELLITE RADIO, Symptom 12: No or Low
BOX Audio from XM or XM Inoperative
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 7.13 XM SATELLITE RADIO, Symptom 12: No or Low
BOX Audio from XM or XM Inoperative
I
Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 7.14 ROAD TECH ZŪMO 660 GPS, No Sound Through
BOX Radio
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 7.14 ROAD TECH ZŪMO 660 GPS, DTC U1306
BOX Infotainment Bus Lost Communication with NIM Module
HD-48498-A ACR SOLENOID SOCKET 3.5 CYLINDER HEAD, Disassembly
HD-48627 CYLINDER TORQUE PLATES 3.5 CYLINDER HEAD, Inspection
HD-48627 CYLINDER TORQUE PLATES 3.7 BORING AND HONING CYLINDERS, Inspection
HD-48637 BREAKOUT BOX 7.11 DTC P1655, P1656, DTC P1655
HD-48644 VALVE GUIDE SEAL INSTALLER 3.5 CYLINDER HEAD, Assembly
HD-96796-47 VALVE SPRING TESTER 3.5 CYLINDER HEAD, Inspection
HD-97087-65B HOSE CLAMP PLIERS 3.9 OIL COOLER, Removal
HD-97225-55C SPROCKET SHAFT BEARING INSTALLER 3.8 CRANKCASE ASSEMBLY, Assembly
TA360 SNAP-ON TORQUE ANGLE GAUGE 3.7 BORING AND HONING CYLINDERS, Inspection
II TOOLS
2011 Harley-Davidson FLHTCUSE6 Model Service
Manual Supplement
Air cleaner breather bolts 22-24 ft-lbs 29.8-32.5 Nm 4.2 AIR CLEANER BACKPLATE
Air cleaner cover screw 36-60 in-lbs 4.0-6.8 Nm 1.4 AIR FILTER ELEMENT, Installation
Air cleaner insert screw 27-32 in-lbs 3.1-3.6 Nm 1.4 AIR FILTER ELEMENT, Installation
Air cleaner studs 55-60 in-lbs 6.2-6.8 Nm 4.2 AIR CLEANER BACKPLATE
Air deflector bolts 25-35 in-lbs 2.8-4.0 Nm 2.21 AIR DEFLECTORS, Mid-Frame Air Deflectors
Air filter element screws 55-60 in-lbs 6.2-6.8 Nm 1.4 AIR FILTER ELEMENT, Installation
Amplifier fasteners 96-108 in-lbs 10.8-12.2 Nm 7.17 ADVANCED AUDIO AMPLIFIER, Installation
Automatic compression release (ACR) 132-180 in-lbs 14.9-20.3 Nm 3.5 CYLINDER HEAD, Assembly/Apply three
equally spaced dots of LOCTITE 246 THREAD-
LOCKER MEDIUM STRENGTH/HIGH TEMPER-
ATURE around lower third of threads
Auxiliary lamp/turn signal bracket screw 15-20 ft-lbs 20.3-27.1 Nm 7.4 AUXILIARY LAMPS AND
BRACKETS, Installing Lamp Bracket
Brake pedal cover screws 15-19 ft-lbs 20.3-25.8 Nm 2.4 FOOTBOARDS AND CONTROLS, Rear Brake
Pedal Pad
Clutch actuator bleeder valve 12-15 in-lbs 1.4-1.7 Nm 2.10 CLUTCH MASTER CYLINDER AND
TORQUE VALUES
Clutch actuator bleeder valve 12-15 in-lbs 1.4-1.7 Nm 2.13 BLEEDING CLUTCH FLUID LINE, Return
Clutch fluid line clamp bolt 96-120 in-lbs 10.8-13.6 Nm 2.12 CLUTCH FLUID LINE, Installation
Clutch fluid line flare nut 72-120 in-lbs 8.1-13.6 Nm 2.13 BLEEDING CLUTCH FLUID LINE, Draining
and Filling
Clutch fluid line flare nut 72-120 in-lbs 8.1-13.6 Nm 2.13 BLEEDING CLUTCH FLUID LINE, Return
Clutch fluid line flare nut 72-120 in-lbs 8.1-13.6 Nm 6.3 CLUTCH RELEASE COVER, Installation
Clutch inspection cover 84-108 in-lbs 9.5-12.2 Nm 5.3 CLUTCH RELEASE BEARING AND
PUSHROD, Installation
Clutch master cylinder banjo bolt 12.5-14.5 ft-lbs 16.9-19.7 Nm 2.10 CLUTCH MASTER CYLINDER AND
Clutch master cylinder banjo bolt 12.5-14.5 ft-lbs 16.9-19.7 Nm 2.13 BLEEDING CLUTCH FLUID LINE, Return
Clutch master cylinder clamp fastener 72-84 in-lbs 8.1-9.5 Nm 2.8 HANDLEBARS, Installing Handlebars
Clutch master cylinder clamp fastener 72-84 in-lbs 8.1-9.5 Nm 2.9 HANDGRIPS, Replacing Handgrips
Clutch master cylinder clamp fastener 72-84 in-lbs 8.1-9.5 Nm 2.10 CLUTCH MASTER CYLINDER AND
Clutch release cover screw 84-132 in-lbs 11.6-18.2 Nm 6.3 CLUTCH RELEASE COVER, Installation
Clutch reservoir cover screws 8-10 in-lbs 0.9-1.1 Nm 2.10 CLUTCH MASTER CYLINDER AND
Clutch reservoir cover screws 8-10 in-lbs 0.9-1.1 Nm 2.13 BLEEDING CLUTCH FLUID LINE, Return
Crankcase bolts, final 15-19 ft-lbs 20.3-25.8 Nm 3.8 CRANKCASE ASSEMBLY, Assembly
Crankcase bolts, initial 120 in-lbs 13.6 Nm 3.8 CRANKCASE ASSEMBLY, Assembly
Cylinder bolts, final torque 15-17 ft-lbs plus 20.3-23.1 Nm 3.7 BORING AND HONING CYLINDERS, Inspec-
90 degrees plus 90 degrees tion/See procedure for properly marking bolts
before turning 90 degrees.
Cylinder bolts, initial torque 120-144 in-lbs 13.6-16.3 Nm 3.7 BORING AND HONING CYLINDERS, Inspec-
tion
III
Manual Supplement
Dash pad screws 20-25 in-lbs 2.3-2.8 Nm 7.14 ROAD TECH ZŪMO 660 GPS, Mount and
Harness
Door opener mount bracket screw 35-45 in-lbs 3.9-5.1 Nm 7.18 GARAGE DOOR OPENER, Transmitter
Engine guard bolt 15-20 ft-lbs 20.3-27.1 Nm 2.12 CLUTCH FLUID LINE, Installation
Fairing cap screws 25-30 in-lbs 2.8-3.4 Nm 7.10 FAIRING CAP AND SWITCHES, Installation
Filler plug and dipstick 25-75 in-lbs 2.8-8.5 Nm 6.3 CLUTCH RELEASE COVER, Fill and Bleed
Front axle cover set screw 60-84 in-lbs 6.8-9.5 Nm 2.6 FRONT AXLE COVERS, Replacement/LOC-
TITE 262 THREADLOCKER (red)
Front brake master cylinder clamp 72-108 in-lbs 8.1-12.2 Nm 2.8 HANDLEBARS, Installing Handlebars
fastener
Front brake master cylinder clamp 72-108 in-lbs 8.1-12.2 Nm 2.9 HANDGRIPS, Replacing Handgrips
fastener
GPS unit bracket screw 20-25 in-lbs 2.3-2.8 Nm 7.14 ROAD TECH ZŪMO 660 GPS, Mount and
Harness
GPS unit cradle screw 14-20 in-lbs 1.6-2.3 Nm 7.14 ROAD TECH ZŪMO 660 GPS, Mount and
Harness
Handlebar switch housing screw 35-45 in-lbs 4.0-5.1 Nm 2.10 CLUTCH MASTER CYLINDER AND
Handlebar top clamp fasteners 16-20 ft-lbs 20.3-27.1 Nm 2.8 HANDLEBARS, Installing Handlebars
Headlamp door screw 9-18 in-lbs 1.0-2.0 Nm 7.3 HEADLAMP, Installation
Headlamp retaining ring screw 23-28 in-lbs 2.6-3.2 Nm 7.3 HEADLAMP, Installation
Highway peg end screw 19 ft-lbs 26 Nm 2.5 HIGHWAY PEGS, Assembly/LOCTITE 243
THREADLOCKER (blue)
Highway peg mounting screws 14 ft-lbs 19 Nm 2.5 HIGHWAY PEGS, Installing Clamp
Highway peg nut 14-19 ft-lbs 19-25 Nm 2.5 HIGHWAY PEGS, Assembly
Ignition/lights switch nut 85-115 in-lbs 9.6-13.0 Nm 7.9 IGNITION/FORK LOCK KNOB, Power Lock
Ignition Knob
Latch hook nut, Tour-Pak 25-35 in-lbs 2.8-4.0 Nm 7.20 POWER LOCKS, Power Lock Lockset: Tour-
Pak
Lockset retaining nut, Tour-Pak 30-45 in-lbs 3.4-5.1 Nm 7.20 POWER LOCKS, Power Lock Lockset: Tour-
Pak
Muffler end cap fasteners 84-108 in-lbs 9.5-12.2 Nm 2.22 MUFFLER END CAP, Replacement
Muffler head shield clamps 20-40 in-lbs 2.3-4.5 Nm 2.22 MUFFLER END CAP, Replacement
Oil cooler adapter inspection cover 90-120 in-lbs 10.2-13.6 Nm 3.10 OIL COOLER ADAPTER, Assembly/Apply 1
drop LOCTITE 246 THREADLOCKER MEDIUM
STRENGH/HIGH TEMPERATURE to the fasteners
Oil cooler mounting screws 20-22 ft-lbs 27.1-29.8 Nm 3.9 OIL COOLER, Installation
Oil filter adapter 18-22 ft-lbs 24.4-29.8 Nm 3.10 OIL COOLER ADAPTER, Installation
Passenger footboard bracket screw 30-35 ft-lbs 41-47 Nm 2.4 FOOTBOARDS AND CONTROLS, Adjustable
Passenger Footboards
IV TORQUE VALUES
Manual Supplement
Passenger footboard lower adjustment 25-30 ft-lbs 34-40 Nm 2.4 FOOTBOARDS AND CONTROLS, Adjustable
Passenger footboard upper adjustment 25-30 ft-lbs 34-40 Nm 2.4 FOOTBOARDS AND CONTROLS, Adjustable
Power lock module bracket fastener 30-50 in-lbs 3.4-5.6 Nm 7.20 POWER LOCKS, Power Lock Module
Power lock module fastener 20-40 in-lbs 2.3-4.5 Nm 7.20 POWER LOCKS, Power Lock Module
Radio chassis mounting screws 35-45 in-lbs 4.0-5.1 Nm 7.16 ADVANCED AUDIO RADIO, Installation
Rider backrest bracket 60-96 in-lbs 6.8-10.8 Nm 2.15 RIDER BACKREST, Adjusting Front to Rear
Rider backrest bracket support strap 132-180 in-lbs 15-20 Nm 2.15 RIDER BACKREST, Adjusting Front to Rear
Rider backrest mounting bracket screw 60-96 in-lbs 6.8-10.8 Nm 2.15 RIDER BACKREST, Adjusting Front to Rear
Rider footboard bracket socket screws 36-42 ft-lbs 48.8-57.0 Nm 2.4 FOOTBOARDS AND CONTROLS, Rider
Footboards
Rider footboard pivot bolt nut 60-80 in-lbs 6.8-9.0 Nm 2.4 FOOTBOARDS AND CONTROLS, Rider
Footboards
Saddlebag filler strip screw 15-20 ft-lbs 20.4-27.1 Nm 2.20 SADDLEBAG SUPPORTS, Installation
Saddlebag filler strip-to-lower fender 15-20 ft-lbs 20.4-27.1 Nm 2.20 SADDLEBAG SUPPORTS, Installation
support screw
Saddlebag inner screws 25 in-lbs 2.8 Nm 2.19 SADDLEBAGS LATCH, Installation
Saddlebag lamp nuts 22 in-lbs 2.5 Nm 7.6 TOUR-PAK LIGHTING, Tour-Pak Lamps
Saddlebag latch cover screws 25 in-lbs 2.8 Nm 7.20 POWER LOCKS, Power Locks: Saddlebags
Shift lever clamp screws 18-22 ft-lbs 25-29 Nm 2.4 FOOTBOARDS AND CONTROLS, Shift Levers
Shift lever peg fastener 14-16 ft-lbs 19-21 Nm 2.4 FOOTBOARDS AND CONTROLS, Shift Levers
Spark plug 12-18 ft-lbs 16.3-24.4 Nm 3.4 TROUBLESHOOTING, Compression Test
Speaker box mounting screws 25-35 in-lbs 2.8-4.0 Nm 2.17 TOUR-PAK, Installation
Tour-Pak luggage rack fastener 60-84 in-lbs 6.8-9.5 Nm 2.17 TOUR-PAK, Luggage Rack
Tour-Pak mounting bolts 96-120 in-lbs 10.8-13.6 Nm 2.17 TOUR-PAK, Installation
Transmission drain plug 14-21 ft-lbs 19.0-28.5 Nm 6.3 CLUTCH RELEASE COVER, Fill and Bleed
Triple clamp cover backside fasteners 70-110 in-lbs 7.9-12.4 Nm 2.7 LOWER TRIPLE CLAMP COVER, Replace-
ment
Triple clamp lower fastener 120-180 in-lbs 13.6-20.4 Nm 2.7 LOWER TRIPLE CLAMP COVER, Replace-
ment
Turn signal bracket screw 96-120 in-lbs 10.8-13.6 Nm 7.5 FRONT TURN SIGNALS, Installation
Wrap-around Tour-Pak Light flange nuts 15 in-lbs 1.7 Nm 7.6 TOUR-PAK LIGHTING, Wrap-Around Lights
Wrap-around Tour-Pak Light screws 12 in-lbs 1.3 Nm 7.6 TOUR-PAK LIGHTING, Wrap-Around Lights
TORQUE VALUES V
NOTES
VI TORQUE VALUES
Cylinder
A Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Advanced Audio Amplifier Cylinder Heads
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Advanced Audio Radio Determining Service. . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Headset Receptacle Repair. . . . . . . . . . . . . . . . . . . 7-27 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Software Update. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Software Update. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Air Cleaner Assembly Replacing Valve Guides. . . . . . . . . . . . . . . . . . . . . . 3-12
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Air Cleaner Assembly (All but Japan) D
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Dash Pad
Air Cleaner Filter Removal and installation. . . . . . . . . . . . . . . . . . . . . 7-33
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Drive
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Automatic Compression Release (ACR) DTC Priority Table
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 DTC P1655. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Auxiliary Lamps and Brackets DTC P1656. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Installing Lamp Bracket. . . . . . . . . . . . . . . . . . . . . . . 7-7 DTC U1306. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Installing Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 DTC U1313. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Removing Lamp Bracket. . . . . . . . . . . . . . . . . . . . . . 7-7
Removing Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
E
Replacing Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Electrical Protection
Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
B Engine
Bleeding Clutch Fluid Line Compression Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Bleed Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . 2-32 Engine Lubrication
Draining and Filling. . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Boring and Honing Cylinders
Cylinder Bore Finished Size. . . . . . . . . . . . . . . . . . . 3-21
F
INDEX
Piston Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Fairing Cap and Switches
Bulb Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Footboards and Controls
C Adjustable Passenger Footboards. . . . . . . . . . . . . . . 2-7
Clutch Actuator Shift Levers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Foreword
Clutch Fluid Line Important General Information. . . . . . . . . . . . . . . . . . . i-I
Bleed Fluid Line and Actuator. . . . . . . . . . . . . . . . . 2-32 Front Axle Covers
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 Front Turn Signal
Return Motorcycle to Service. . . . . . . . . . . . . . . . . . 2-32 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Clutch Hand Lever Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
G
Clutch Master Cylinder/Reservoir Garage Door Opener
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Clutch Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Remote Control Garage Door Opener. . . . . . . . . . . 7-43
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Garage Door Opener Diagnostics. . . . . . . . . . . . . . . . . . 7-43
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Glossary
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . B-1
Clutch Release Bearing and Push Rod GPS Navigation
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Dash Mount Installation. . . . . . . . . . . . . . . . . . . . . . 7-33
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Dash Mount Removal. . . . . . . . . . . . . . . . . . . . . . . . 7-33
Clutch Release Cover Navigation interface module (NIM). . . . . . . . . . . . . . 7-34
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 H
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Compression Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Handgrips
Connectors Replacing Handgrips. . . . . . . . . . . . . . . . . . . . . . . . 2-21
Function and Location. . . . . . . . . . . . . . . . . . . . . . . . A-1 Replacing Left Handgrip. . . . . . . . . . . . . . . . . . . . . . 2-21
Crankcase Assembly Replacing Right Handgrip. . . . . . . . . . . . . . . . . . . . 2-23
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Handlebars
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Critical Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
VII
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Power Lock Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Power Locks
Returning to Service. . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Actuator: Saddlebag. . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Headlamp Actuator: Tour-Pak. . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Lockset: Tour-Pak. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Power Locks: Saddlebags. . . . . . . . . . . . . . . . . . . . 7-49
Heated Handgrips
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
R
Heated Seat Radio
Automatic Shut-Off. . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Warm-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Rider Backrest
HFSM Antenna Adjusting Front to Rear. . . . . . . . . . . . . . . . . . . . . . 2-35
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 Adjusting Tilt Angle. . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Highway Pegs Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 S
Installing Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Removing Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Saddlebag Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Hydraulic Clutch Fluid Saddlebag Latch
Clutch Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
I Saddlebags
Ignition/Light Key Switch and Fork Lock Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Power Lock Ignition Knob Installation. . . . . . . . . . . 7-20 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Power Lock Ignition Knob Removal. . . . . . . . . . . . . 7-19 Saddlebag Supports
Interior Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
L Seat
Light Bulbs Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 2-34
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Loctite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Lower Triple Clamp Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Secondary Clutch Actuator
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
M Service Bulletins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-I
Maintenance Schedule Service Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-I
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Smart Security System
Mid-Frame Air Deflectors. . . . . . . . . . . . . . . . . . . . . . . . . 2-43 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
Muffler End Cap HFSM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Smart Siren. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
N Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
Specifications
Navigation Interface Module Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Engine Tolerances. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
O Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
SPX Kent-Moore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Oil Cooler
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 T
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Tour-Pak
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Oil Cooler Adapter Interior Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Luggage Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Saddlebag Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
P Wrap-Around Lights. . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Trademarks
Passenger Backrest
Harley-Davidson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Referenced Products. . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Pistons
Troubleshooting
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Compression Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Measuring Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
VIII INDEX
Cylinder Leakdown Test. . . . . . . . . . . . . . . . . . . . . . . 3-6
TSM/HFSM
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
Turn Signal
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Twist Grip Sensor
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46
V
VIN
Vehicle Identification Number. . . . . . . . . . . . . . . . . . . 2-4
W
Wiring Diagram Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . A-2
X
XM Radio Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
XM Satellite Radio
Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
XM Antenna. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
XM Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Z
Zūmo - GPS Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Zūmo Navigation
Navigation interface module (NIM). . . . . . . . . . . . . . 7-34
Zūmo Navigation Unit
Mount Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Mount Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
INDEX IX
NOTES
X INDEX

2011 HD CVO FLHTCUSE6 Model Service Manual Supplement 99500-11

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2011 HD CVO FLHTCUSE6 Model Service Manual Supplement 99500-11

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2011 Harley-Davidson FLHTCUSE6

Model Service Manual Supplement

Harley-Davidson Motor Company

Printed in the U.S.A.

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2011 Harley-Davidson FLHTCUSE6 Model Service Manual Supplement (99500-11)

2.4 FOOTBOARDS AND CONTROLS 2.12 CLUTCH FLUID LINE

2.5 HIGHWAY PEGS 2.15 RIDER BACKREST

Fastener Torque Values in this Chapter..............................7-1 7.8 HEATED HANDGRIPS

TABLE OF CONTENTS VII

VIII TABLE OF CONTENTS

FASTENER TORQUE VALUES 1.1

FASTENER TORQUE VALUE NOTES

2011 FLHTCUSE6 Service Supplement: Maintenance 1-1

SCHEDULED MAINTENANCE 1.2

Table 1-1. Regular Service Intervals: 2011 FLHTCUSE6

Engine oil and filter Replace X X X X X X X X X X X

1-2 2011 FLHTCUSE6 Service Supplement: Maintenance

Table 1-1. Regular Service Intervals: 2011 FLHTCUSE6

Road test Verify component X X X X X X X X X X X

2011 FLHTCUSE6 Service Supplement: Maintenance 1-3

BULB REQUIREMENTS 1.3

LAMP DESCRIPTION BULBS CURRENT HARLEY-DAVIDSON

1-4 2011 FLHTCUSE6 Service Supplement: Maintenance

AIR FILTER ELEMENT 1.4

1. Air cleaner insert fastener (2)

2011 FLHTCUSE6 Service Supplement: Maintenance 1-5

HYDRAULIC CLUTCH FLUID 1.5

Direct contact of D.O.T. 4 brake fluid with eyes can cause

Figure 1-2. Clutch Reservoir Sight Glass

Do not allow dirt or debris to enter the master cylinder

1-6 2011 FLHTCUSE6 Service Supplement: Maintenance

ENGINE LUBRICATION SYSTEM 1.6

Table 1-3. Recommended Oil Grades

HARLEY- VISCOSITY HARLEY- LOWEST COLD

2011 FLHTCUSE6 Service Supplement: Maintenance 1-7

CRITICAL FASTENERS 1.7

2. If the fastener does not have a locking agent, install and

Table 1-4. Critical Fasteners

SYSTEM FASTENER TORQUE

1-8 2011 FLHTCUSE6 Service Supplement: Maintenance

Table 1-4. Critical Fasteners

SYSTEM FASTENER TORQUE

2011 FLHTCUSE6 Service Supplement: Maintenance 1-9

1-10 2011 FLHTCUSE6 Service Supplement: Maintenance

FASTENER TORQUE VALUES 2.1

FASTENER TORQUE VALUE NOTES

2011 FLHTCUSE6 Service Supplement: Chassis 2-1

FASTENER TORQUE VALUE NOTES

2-2 2011 FLHTCUSE6 Service Supplement: Chassis

SPECIFICATIONS: CHASSIS 2.2

Table 2-1. Dimensions ITEM LB. KG

Table 2-4. Tires

MOUNT SIZE APPROVED TIRE PRESSURE (COLD)

2011 FLHTCUSE6 Service Supplement: Chassis 2-3

VEHICLE IDENTIFICATION NUMBER (V.I.N.) 2.3

Table 2-5. Harley-Davidson V.I.N. Breakdown: 2011 FLHTCUSE6 Models

POSITION DESCRIPTION POSSIBLE VALUES

2-4 2011 FLHTCUSE6 Service Supplement: Chassis

Table 2-5. Harley-Davidson V.I.N. Breakdown: 2011 FLHTCUSE6 Models

POSITION DESCRIPTION POSSIBLE VALUES

2011 FLHTCUSE6 Service Supplement: Chassis 2-5