2024 Harley-Davidson FLTRK, FLHRXS, FLHTK Models – 94001161 (Preview)
2024 FLTRK, FLHRXS, FLHTK MODELS SERVICE MANUAL #94001161
FOREWORD
GENERAL
MANUAL LAYOUT
HOW TO USE THIS SERVICE MANUAL
PREPARATION FOR SERVICE
USE GENUINE REPLACEMENT PARTS
SHOP PRACTICES
CLEANING
DISPOSAL AND RECYCLING
TOOLS AND MATERIALS
PRODUCT REGISTERED MARKS
H-D U.S.A., LLC TRADEMARK INFORMATION
CONTENTS
TABLE OF CONTENTS
SAFETY
1.1 SAFETY
MAINTENANCE
2.1 FASTENER TORQUE VALUES
2.2 GENERAL
2.3 MAINTENANCE SCHEDULE
2.4 FUEL AND OIL
2.5 REPLACE ENGINE OIL AND FILTER
2.6 REPLACE PRIMARY CHAINCASE LUBRICANT
2.7 REPLACE TRANSMISSION LUBRICANT
2.8 INSPECT TIRES AND WHEELS
2.9 LUBRICATE CABLES AND CHASSIS
2.10 INSPECT BRAKES
2.11 CHECK AND REPLACE BRAKE FLUID
2.12 CHECK AND ADJUST CLUTCH
2.13 REBUILD FRONT FORK AND REPLACE OIL
2.14 ADJUST AND LUBRICATE STEERING HEAD BEARINGS
2.15 INSPECT RADIATOR AND COOLANT
2.16 INSPECT FUEL LINES AND FITTINGS
2.17 INSPECT AND LUBRICATE JIFFY STAND
2.18 INSPECT AND ADJUST DRIVE BELT AND SPROCKETS
2.19 INSPECT REAR SPROCKET ISOLATOR
2.20 ADJUST SUSPENSION
2.21 INSPECT EXHAUST SYSTEM
2.22 INSPECT AIRFILTER
2.23 INSPECT BATTERY
2.24 CLEAN, INSPECT, REPLACE SPARK PLUGS
2.25 STORAGE
2.26 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 CHECKING AND TRUING WHEELS
3.7 REAR WHEEL COMPENSATOR
3.8 SEALED WHEEL BEARINGS
3.9 TIRE PRESSURE MONITORING SYSTEM (TPMS)
3.10 TIRES
3.11 ELECTRONIC CHASSIS CONTROL
3.12 FRONT BRAKE MASTER CYLINDER
3.13 FRONT BRAKE CALIPER
3.14 REAR BRAKE MASTER CYLINDER
3.15 REAR BRAKE CALIPER
3.16 PARKING BRAKE ASSEMBLY
3.17 BRAKE LINES
3.18 ABS MODU LE
3.19 BLEED BRAKES
3.20 LEFT SIDE COVER
3.21 RIGHT SIDE COVER
3.22 FRONT FORK
3.23 STEERING HEAD/FORK STEM AND BRACKET ASSEMBLY
3.24 REAR FORK
3.25 BELT GUARDS
3.26 REAR SHOCK ABSORBERS
3.27 CLUTCH CONTROL
3.28 HEADLAMP NACELLE
3.29 FAIRING: FORK MOUNTED
3.30 FAIRING: FRAME MOUNTED
3.31 FAIRING LOWERS
3.32 ENGINE GUARD
3.33 AIR DEFLECTORS
3.34 WINDSHIELD
3.35 HAND GRIPS
3.36 HANDLEBAR
3.37 MIRRORS
3.38 FRONT FENDER
3.39 REAR FENDER
3.40 REAR FENDER WIRE CONDUIT
3.41 REAR LICENSE PLATE BRACKET
3.42 RIDER FOOTRESTS
3.43 PASSENGER FOOTRESTS
3.44 JIFFY STAND
3.45 SEAT
3.46 REAR FRAME
3.47 TOUR-PAK
3.48 TOUR-PAK SUPPORT
3.49 SADDLEBAGS
3.50 SADDLEBAG SUPPORTS
3.51 MEDALLIONS, BADGES, TANK EMBLEMS AND ADHESIVE STRIPS
ENGINE
4.1 FASTENER TORQUE VALUES
4.2 SPECIFICATIONS
4.3 ENGINE OIL FLOW
4.4 OIL PUMP OPERATION
4.5 BREATHER OPERATION
4.6 OIL PRESSURE
4.7 TROUBLESHOOTING
4.8 CRIMP CLAMPS
4.9 OIL COOLER
4.10 OIL CHECK VALVE
4.11 OIL COOLANT LINES
4.12 FRONT ENGINE MOUNT
4.13 UPPER ROCKER COVERS
4.14 BREATHERS
4.15 LOWER ROCKER COVERS
4.16 ROCKER ARMS
4.17 PUSHRODS, LIFTERS AND COVERS
4.18 CYLINDER HEADS
4.19 CYLINDERS
4.20 PISTONS
4.21 CAM COMPARTMENT AND COMPONENTS
4.22 OIL PUMP
4.23 REPLACE ENGINE
4.24 CRANKCASE
4.25 FLYWHEEL AND CONNECTING RODS
4.26 OIL PAN
DRIVE AND TRANSMISSION
5.1 FASTENER TORQUE VALUES
5.2 SPECIFICATIONS
5.3 TRANSMISSION OPERATION
5.4 DRIVE BELT
5.5 SHIFTER LINKAGE
5.6 CLUTCH RELEASE COVER
5.7 CLUTCH RELEASE PUSH ROD COMPONENTS
5.8 PRIMARY CHAINCASE COVER
5.9 DRIVE COMPONENTS
5.10 CLUTCH
5.11 PRIMARY CHAINCASE HOUSING
5.12 TRANSMISSION SPROCKET
5.13 TRANSMISSION
5.14 MAIN DRIVE GEAR AND BEARING
5.15 TRANSMISSION CASE
FUEL AND EXHAUST
6.1 FASTENER TORQUE VALUES
6.2 SPECIFICATIONS
6.3 AIR CLEANER BACKPLATE ASSEMBLY
6.4 CONSOLE
6.5 FUEL PRESSURE TEST
6.6 PURGE FUEL LINE
6.7 FUEL LINE
6.8 FUEL TANK
6.9 FUEL TANK TOP PLATE
6.10 FUEL LEVEL SENDER
6.11 FUEL PUMP
6.12 VENT TUBE
6.13 VAPOR VALVE
6.14 TEMPERATURE MANIFOLD ABSOLUTE P RESSURE (TMAP) SENSOR
6.15 TWIST GRIP SENSOR (TGS)
6.16 FUEL INJECTORS
6.17 INDUCTION MODULE
6.18 INTAKE LEAK TEST
6.19 HEATED OXYGEN SENSORS ( HO2S)
6.20 MUFFLERS
6.21 EXHAUST SYSTEM
6.22 PURGE SOLENOID: EVAPORATIVE EMISSIONS
6.23 CHARCOAL CANISTER: EVAPORATIVE EMISSIONS
6.24 PURGE LINES : EVAPORATIVE EMISSIONS
COOLING SYSTEM
7.1 FASTEN ER TORQUE VALUES
7.2 SPECIFICATIONS
7.3 COOLANT FLOW
7.4 DIAGNOSE AND TEST
7.5 COOLANT
7.6 COOLANT PUMP
7.7 COOLANT OVERFLOW TANK
7.8 COOLANT HOSES
7.9 ENGINE COOLANT TEMPERATURE (ECT) SENSOR
7.10 RADIATOR
ELECTRICAL
8.1 FASTENER TORQUE VALUES
8.2 SPECIFICATIONS
8.3 FUSES AND RELAYS
8.4 POWER DISCONNECT
8.5 FAIRING POWER OUTLET
8.6 STARTER
8.7 ALTERNATOR
8.8 VOLTAGE REGULATOR
8.9 IGNITION SWITC H
8.10 SPARK PLUG CABLES
8.11 IGNITION COIL
8.12 LEFT HAND CONTROL MODULE (LHCM)
8.13 RIGHT HAND CONTROL MODULE (RHCM)
8.14 ACCESSORY SWITCHES
8.15 INSTRUMENT MOD U LE (IM)
8.16 INDICATOR LAMPS
8.17 FAIRING GAUGES
8.18 FUEL LEVEL GAUGE
8.19 OIL PRESSURE SWITCH
8.20 NEUTRAL INDICATOR SWITCH
8.21 HORN
8.22 HEADLAMP
8.23 AUXILIARY LAMPS
8.24 FRONT TURN SIGNAL LAMPS
8.25 REAR TURN SIGNAL LAMPS
8.26 TAIL LAMP
8.27 REAR FENDER TIP LAMP
8.28 TOUR-PAK LIGHTING
8.29 REAR STOPLAMP SWITCH
8.30 LICENSE PLATE LAMP
8.31 RADIO
8.32 FRONT SPEAKERS
8.33 REAR SPEAKERS
8.34 PASSENGER AUDIO CONTROLS
8.35 RIDER HEADSET CONNECTOR
8.36 HIDDEN ANTENNA
8.37 GPS ANTENNA
8.38 ANTENNA CABLES
8.39 ELECTRONIC CONTROL MODULE (ECM)
8.40 BODY CONTROL MODULE (BCM)
8.41 SECURITY SYSTEM ACTIVATION
8.42 PERSONAL IDENTIFICATION NUMBER (PIN)
8.43 SECURITY SYSTEM MAINTENANCE
8.44 SECURITY SIREN
8.45 SECURITY SYSTEM ANTENNA
8.46 COOLING FAN
8.47 AMBIENT AIR TEMPERATURE SENSOR
8.48 CRANKSHAFT POSITION SENSOR (CKP)
8.49 ENGINE TEMPERATURE (ET) SENSOR
8.50 KNOCK SENSOR (KS)
8.51 AUTOMATIC COMPRESSION RELEASE (ACR)
8.52 VEHICLE SPEED SENSOR (VSS)
8.53 FRONT WHEEL SPEED SENSOR (WSS)
8.54 REAR WHEEL SPEED SENSOR (WSS)
8.55 INERTIAL MEASUREMENT UNIT (IMU)
8.56 JIFFY STAND SENSOR (JSS)
8.57 WIRE TROUGH
8.58 TOP CADDY
8.59 LEFT SIDE CADDY
8.60 RIGHT SIDE CADDY
8.61 LOWER BACKBONE CADDY
8.62 BATTERY TRAY
8.63 TOUR-PAK WIRE HARNESS
8.64 FAIRING WIRE HARNESS
8.65 MAIN WIRE HARNESS
REFERENCE
A.1 GLOSSARY
A.2 METRIC CONVERSION
A.3 FLUID CONVERSION
TOOLS
TORQUE VALUES
INDEX
WIRING DIAGRAMS
A1. WIRING DIAGRAMS
WIRING DIAGRAM LIST
Battery Power Distribution: FLH with Fairing
Battery Power Distribution: FLT
Battery Power Distribution without Fairing
Ignition and ACC: FLH
Ignition and ACC: FLT
Sensor Grounds: FLH
Sensor Grounds: FLT
Ground Circuit: FLH
Ground Circuit: FLT
Front Lighting and Hand Controls
Fairing Harness: FLH
Main Harness FLH (1 of 3) (with Fairing)
Main Harness FLH (2 of 3) (with Fairing)
Main Harness FLH (3 of 3) (with Fairing)
Main Harness FLHX (1 of 3) (Non-ABS with Fairing)
Main Harness FLHX (2 of 3) (Non-ABS with Fairing)
Main Harness FLHX (3 of 3) (Non-ABS with Fairing)
Fairing Harness: FLT
Main Harness FLT (1 of 3) (with Fairing)
Main Harness FLT (2 of 3) (with Fairing)
Main Harness FLT (3 of 3) (with Fairing)
Main Harness FLTR (1 of 3) (Non-ABS with Fairing)
Main Harness FLTR (2 of 3) (Non-ABS with Fairing)
Main Harness FLTR (3 of 3) (Non-ABS with Fairing)
Main Harness (1 of 3) (without Fairing)
Main Harness (2 of 3) (without Fairing)
Main Harness (3 of 3) (without Fairing)
Main Harness FLHR (1 of 3) (Non-ABS without Fairing)
Main Harness FLHR (2 of 3) (Non-ABS without Fairing)
Main Harness FLHR (3 of 3) (Non-ABS without Fairing)
Rear Lighting
OE Radio (Except FLHX/S, FLT)
OE Radio (No Tour-Pak)
BOOM!: Radio with 1 Amp
BOOM!: Radio with 2 Amps (1 of 2)
BOOM!: Radio with 2 Amps (2 of 2)
BOOM!: Radio with 4 Amps (1 of 4), Front Amp
BOOM!: Radio with 4 Amps (2 of 4), Left Saddlebag Amp
BOOM!: Radio with 4 Amps (3 of 4), Right Saddlebag Amp
BOOM!: Radio with 4 Amps (4 of 4), Tour-Pak Amp
Rockford Fosgate: Primary Amplifier with 2 Speakers
Rockford Fosgate: 4 Speakers – Saddlebags or 6 Speakers – Secondary Amplifier, Saddlebags & Tour-Pak
Rockford Fosgate: 6 Speakers – Fairings & Saddlebags or 6 Speakers Tour-Pak & Lower Fai rings
Rockford Fosgate: 8 Speakers – Saddlebags, Lower Fairings & Tour-Pak
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