For complete service information also see:
Harley Davidson 2019 Set of Service And Diagnostic Manuals
Harley Davidson Touring Models 2018 Set of Diagnostic And Service Manuals
This PDF Service Manual has been created to inform Harley Davidson technicians about the construction of Harley Davidson products and the latest tested and approved maintenance and repair techniques.
Harley Davidson's service manual is intended for use by professional, qualified, and experienced technicians.
This service manual is organized into chapters, sections, and topics. Sections are laid out as follows: Prepare, Remove, Install, Disassemble, Clean/Inspect, Assemble, Complete.
This service repair manual is an electronic PDF book that will become your indispensable service assistant in matters of routine maintenance.
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Models covered:
TOURING MODELS
CONTENTS:
- SAFETY
- MAINTENANCE
- 2.1 FASTENER TORQUE VALUES
- 2.2 GENERAL
- 2.3 FUEL AND OIL
- 2.4 MAINTENANCE SCHEDULE
- 2.5 ENGINE OIL AND FILTER
- 2.6 AIR CLEANER ELEMENT
- 2.7 EXHAUST SYSTEM
- 2.8 COOLANT
- 2.9 TIRES AND WHEELS
- 2.10 PRIMARY CHAINCASE LUBRICANT
- 2.11 TRANSMISSION LUBRICANT
- 2.12 HYDRAULIC CLUTCH FLUID
- 2.13 BRAKES
- 2.14 BRAKE PADS AND DISCS
- 2.15 DRIVE BELT AND SPROCKETS
- 2.16 REAR SPROCKET ISOLATOR
- 2.17 CABLE AND CHASSIS LUBRICATION
- 2.18 SPARK PLUGS
- 2.19 STEERING HEAD BEARINGS
- 2.20 REAR SUSPENSION ADJUSTMENTS
- 2.21 BATTERY MAINTENANCE
- 2.22 HEADLAMP ALIGNMENT
- 2.23 STORAGE
- 2.24 TROUBLESHOOTING
- CHASSIS
- 3.1 FASTENER TORQUE VALUES
- 3.2 SPECIFICATIONS
- 3.3 VEHICLE IDENTIFICATION NUMBER (VIN)
- 3.4 FRONT WHEEL
- 3.5 REAR WHEEL
- 3.6 REAR WHEEL COMPENSATOR
- 3.7 WHEEL LACING: FRONT RIM
- 3.8 WHEEL LACING: 16 INCH REAR RIM
- 3.9 WHEEL RUNOUT
- 3.10 SEALED WHEEL BEARINGS
- 3.11 TIRES
- 3.12 FRONT BRAKE MASTER CYLINDER
- 3.13 FRONT BRAKE CALIPER
- 3.14 REAR BRAKE MASTER CYLINDER
- 3.15 REAR BRAKE CALIPER
- 3.16 BRAKE LINES
- 3.17 ABS MODULE
- 3.18 BLEED BRAKES
- 3.19 FRONT FORK
- 3.20 STEERING HEAD BEARINGS
- 3.21 REAR SUSPENSION
- 3.22 REAR FORK
- 3.23 CLUTCH MASTER CYLINDER AND RESERVOIR
- 3.24 HYDRAULIC CLUTCH HAND LEVER
- 3.25 CLUTCH FLUID LINE
- 3.26 BLEED CLUTCH CONTROL SYSTEM
- 3.27 HANDLEBAR
- 3.28 MIRRORS
- 3.29 SEAT
- 3.30 SADDLEBAGS
- 3.31 SADDLEBAG SERVICE
- 3.32 TOUR-PAK
- 3.33 TOUR-PAK SERVICE
- 3.34 TOUR-PAK BACKREST
- 3.35 FAIRING LOWERS AND ENGINE GUARD
- 3.36 OUTER FAIRING AND WINDSHIELD: FORK MOUNTED FAIRING MODELS
- 3.37 DASH PANEL: FORK MOUNTED FAIRING MODELS
- 3.38 INNER FAIRING: FORK MOUNTED FAIRING MODELS
- 3.39 INSTRUMENT BEZEL: FRAME MOUNTED FAIRING MODELS
- 3.40 INSTRUMENT NACELLE: FRAME MOUNTED FAIRING MODELS
- 3.41 OUTER FAIRING AND WINDSHIELD: FRAME MOUNTED FAIRING MODELD
- 3.42 INNER FAIRING: FRAME MOUNTED FAIRING MODELS
- 3.43 STORAGE COMPARTMENTS: FRAME MOUNTED FAIRING MODELS
- 3.44 AIR DEFLECTORS
- 3.45 WINDSHIELD: ROAD KING MODELS
- 3.46 HEADLAMP NACELLE: ROAD KING MODELS
- 3.47 FRONT FENDER
- 3.48 REAR FENDER
- 3.49 REAR FASCIA
- 3.50 REAR FRAME
- 3.51 FOOTBOARDS AND FOOTRESTS
- 3.52 JIFFY STAND
- 3.53 FRONT ENGINE MOUNT
- 3.54 MEDALLIONS, BADGES AND TANK EMBLEMS
- ENGINE
- 4.1 FASTENER TORQUE VALUES
- 4.2 SPECIFICATIONS
- 4.3 SERVICE WEAR LIMITS
- 4.4 ENGINE OIL FLOW
- 4.5 OIL PUMP OPERATION
- 4.6 BREATHER OPERATION
- 4.7 OIL PRESSURE
- 4.8 TROUBLESHOOTING
- 4.9 OIL COOLER AND DOWNTUBE
- 4.10 OIL COOLANT LINES
- 4.11 HOW TO USE THIS SECTION
- 4.12 PREPARE MOTORCYCLE FOR SERVICE
- 4.13 ASSEMBLE MOTORCYCLE AFTER SERVICE
- 4.14 TOP END SERVICE
- 4.15 CAM COMPARTMENT SERVICE
- 4.16 BOTTOM END SERVICE
- 4.17 REMOVE ENGINE
- 4.18 INSTALL ENGINE
- 4.19 UPPER ROCKER COVERS
- 4.20 LOWER ROCKER COVERS
- 4.21 BREATHERS
- 4.22 ROCKER ARMS
- 4.23 PUSHRODS, LIFTERS AND COVERS
- 4.24 CYLINDER HEAD
- 4.25 CYLINDERS
- 4.26 PISTONS
- 4.27 CAM COMPARTMENT AND COMPONENTS
- 4.28 OIL PUMP
- 4.29 CRANKCASE
- 4.30 FLYWHEEL AND CONNECTING RODS
- 4.31 OIL PAN
- FUEL SYSTEM
- 5.1 FASTENER TORQUE VALUES
- 5.2 SPECIFICATIONS: FUEL SYSTEM
- 5.3 FUEL PRESSURE TEST
- 5.4 INTAKE LEAK TEST
- 5.5 AIR CLENAER ASSEMBLY
- 5.6 FUEL TANK
- 5.7 FUEL TANK TOP PLATE
- 5.8 FUEL FILTER
- 5.9 FUEL PRESSURE REGULATOR
- 5.10 FUEL LEVEL SENDER
- 5.11 TWIST GRIP SENSOR (TGS)
- 5.12 INDUCTION MODULE
- 5.13 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP)
- 5.14 FUEL INJECTORS
- 5.15 HEATED OXYGEN SENSORS (HO2)
- 5.16 FUEL PUMP
- 5.17 EXHAUST SYSTEM
- 5.18 EVAPORATIVE EMISSIONS CONTROL SYSTEM
- COOLING SYSTEM
- 6.1 FASTENER TORQUE VALUES
- 6.2 SPECIFICATIONS: COOLING SYSTEM
- 6.3 COOLING SYSTEM OPERATION
- 6.4 TESTING AND DIAGNOSTICS
- 6.5 COOLING SYSTEM REPAIR
- DRIVE
- 7.1 FASTENER TORQUE VALUES
- 7.2 SPECIFICATIONS: DRIVE
- 7.3 PRIMARY CHAINCASE COVER
- 7.4 DRIVE COMPONENTS
- 7.5 PRIMARY CHAINCASE HOUSING
- 7.6 CLUTCH: ASSIST AND SLIP
- 7.7 HYDRAULIC CLUTCH RELEASE BEARING AND PUSHROD
- 7.8 TRANSMISSION SPROCKET
- 7.9 DRIVE BELT
- TRANSMISSION
- 8.1 FASTENER TORQUE VALUES
- 8.2 SPECIFICATIONS: TRANSMISSION
- 8.3 TRANSMISSION OPERATION
- 8.4 SHIFTER LINKAGE
- 8.5 TRANSMISSION SIDE COVERS
- 8.6 SECONDARY CLUTCH ACTUATOR
- 8.7 TRANSMISSION
- 8.8 MAIN DRIVE GEAR AND BEARING
- 8.9 TRANSMISSION CASE
- ELECTRICAL
- 9.1 FASTENER TORQUE VALUES
- 9.2 SPECIFICATIONS: ELECTRICAL
- 9.3 SYSTEM FUSES AND RELAYS
- 9.4 ELECTRONIC CONTROL MODULE (ECM)
- 9.5 BODY CONTROL MODULE (BCM)
- 9.6 ELECTRICAL CADDIES
- 9.7 IGNITION COIL AND SPARK PLUG CABLES
- 9.8 STARTER
- 9.9 HEADLAMP
- 9.10 AUXILIARY/FOG LAMPS AND BRACKETS
- 9.11 REAR LIGHTING
- 9.12 FENDER TIP LAMPS
- 9.13 TOUR-PAK LIGHTS
- 9.14 TURN SIGNAL LAMPS
- 9.15 IGNITION SWITCH AND FORK LOCK
- 9.16 ACCESSORY SWITCHES
- 9.17 CRANKSHAFT POSITION SENSOR (CKP)
- 9.18 KNOCK SENSOR (KS)
- 9.19 ENIGNE TEMPERATURE SENSOR (ET)
- 9.20 ENIGNE COOLANT TEMPERATURE SENSOR (ECT)
- 9.21 AUTOMATIC COMPRESSION RELEASE (ACR)
- 9.22 VOLTAGE REGULATOR
- 9.23 ALTERNATOR
- 9.24 VEHICLE SPEED SENSOR (VSS)
- 9.25 WHEEL SPEED SENSORS
- 9.26 NEUTRAL SWITCH
- 9.27 OIL PRESSURE SWITCH
- 9.28 STOP LAMP SWITCHES
- 9.29 HORN
- 9.30 FAIRING POWER OUTLET
- 9.31 GAUGES AND INSTRUMENTS: FAIRING MODELS
- 9.32 GAUGES AND INSTRUMENTS: ROAD KING MODELS
- 9.33 INDICATOR LAMPS: ROAD KING MODELS
- 9.34 BOOM! BOX INFOTAINMENT SYSTEM
- 9.35 ANTENNA CABLES
- 9.36 WIRE TROUGH
- 9.37 MAIN WIRING HARNESS
- 9.38 FAIRING HARNESS
- 9.39 HANDLERBAR SWITCH PACKS
- 9.40 SECURITY SYSTEM MAINTENANCE
- 9.41 PERSONAL IDENTIFICATION NUMBER (PIN)
- 9.42 SECURITY SYSTEM ACTUATION
- 9.43 SECURITY SIREN
- APPENDIX B REFERENCE
- B.1 METRIC CONVERSION
- B.2 FLUID CONVERSION
- B.3 TORQUE CONVERSION
- B.4 GLOSSARY
- REFERENCE MATERIAL
- TOOLS
- TORQUE VALUES
- INDEX
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