2025 Harley-Davidson FLHX, FLHXU, FLTRX Models 94001277 (Preview)
Foreword
Table of Contents
1 Safety
1.1 SAFETY
Safety
Safety Messages
Customer Safety
Personal Protection
Tool Safety
Product Safety
Hazardous Materials
Electrical Systems
2 Maintenance
2.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
2.2 GENERAL
Servicing a New Motorcycle
Secure the Motorcycle for Service
Set Motorcycle Upright
Raise Front or Rear Wheel for Service
2.3 MAINTENANCE SCHEDULE
General
Regular Service Intervals
2.4 FUEL AND OIL
Fuel
Gasoline Blends
Engine Lubrication
Winter Lubrication
2.5 REPLACE ENGINE OIL AND FILTER
Check Engine Oil Level
Oil Level Cold Check
Oil Level Hot Check
Change Oil and Oil Filter
2.6 REPLACE PRIMARY CHAINCASE LUBRICANT
Change Primary Chaincase Lubricant
2.7 REPLACE TRANSMISSION LUBRICANT
Check Transmission Lubricant
Change Transmission Lubricant
2.8 INSPECT TIRES AND WHEELS
General
Tire Pressure
Inspecting Tires
Tires
When to Replace Tires
Wheel Bearings
2.9 LUBRICATE CABLES AND CHASSIS
General
Lubrication Points
2.10 INSPECT BRAKES
Inspect
Brake Pads
Brake Disc
Replace Front Brake Pads
Remove
Install
Replace Rear Brake Pads
Remove
Install
2.11 CHECK AND REPLACE BRAKE FLUID
Check Brake Fluid Level
Drain and Replace Fluid
Inspect Brake Lines
2.12 CHECK AND ADJUST CLUTCH
Check and Adjust
Clutch Cable Only Check
Adjust
Proper Button Engagement
2.13 REBUILD FRONT FORK AND REPLACE OIL
Rebuild and Replace Fork Oil
2.14 ADJUST AND LUBRICATE STEERING HEAD BEARINGS
Check and Adjust
Measure Swing-Back
Adjust Swing-Back
Lubricate
2.15 INSPECT RADIATOR AND COOLANT
General
Clean Radiator
Inspect
Check Coolant Level
Check Freeze Point
Check for leaks
Drain and Fill Cooling System
2.16 INSPECT FUEL LINES AND FITTINGS
Inspect
2.17 INSPECT AND LUBRICATE JIFFY STAND
Inspect and Lubricate
2.18 INSPECT AND ADJUST DRIVE BELT AND SPROCKETS
Inspect
General
Cleaning
Sprockets
Drive Belt
Measure Drive Belt Deflection
Adjust Belt
Prepare
Adjust
Assemble
Complete
2.19 INSPECT REAR SPROCKET ISOLATOR
Inspect
2.20 ADJUST SUSPENSION
Adjust Shock Absorber
Preload Adjustment
Damping Adjustment (If equipped)
2.21 INSPECT EXHAUST SYSTEM
Leak Check
2.22 INSPECT AIR FILTER
Remove
Clean and Inspect
Install
2.23 CLEAN AND INSPECT BREATHER HOSE
Clean and Inspect
2.24 INSPECT BATTERY
Prepare
Remove
Install
Clean and Inspect
Voltage Test
Storage
Complete
2.25 CLEAN, INSPECT, REPLACE SPARK PLUGS
Prepare
Remove
Clean and Inspect
Install
Complete
2.26 STORAGE
Place in Storage
Remove from Storage
2.27 TROUBLESHOOTING
General
Engine
Starter Motor Does Not Operate or Does Not Turn Engine Over
Engine Turns Over But Does Not Start
Starts Hard
Starts But Runs Irregularly or Misses
A Spark Plug Fouls Repeatedly
Pre-Ignition or Detonation (Knocks or Pings)
Overheating
Valve Train Noise
Excessive Vibration
Check Engine Light Illuminates During Operation
Lubrication System
Oil Does Not Return To Oil Reservoir
Engine Uses Too Much Oil Or Smokes Excessively
Engine Leaks Oil From Cases, Pushrods, Hoses, Etc.
Low Oil Pressure
High Oil Pressure
Electrical System
Alternator Does Not Charge
Alternator Charge Rate Is Below Normal
Speedometer Operates Erratically
Transmission
Shifts Hard
Jumps Out Of Gear
Clutch Slips
Clutch Drags Or Does Not Release
Clutch Chatters
Handling
Irregularities
Brakes
Brake Does Not Hold Normally
3 Chassis
3.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
3.2 SPECIFICATIONS
Chassis
Chassis Specifications
Tire Specifications
3.3 VEHICLE IDENTIFICATION NUMBER (VIN)
Vehicle Identification Number (VIN)
General
Location
Abbreviated VIN
3.4 FRONT WHEEL
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
3.5 REAR WHEEL
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
3.6 CHECKING AND TRUING WHEELS
General
Checking Wheel Runout
Checking Radial Runout
Checking Lateral Runout
3.7 REAR WHEEL COMPENSATOR
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
3.8 SEALED WHEEL BEARINGS
Prepare
Inspect
Remove
Install
Complete
3.9 TIRE PRESSURE MONITORING SYSTEM (TPMS)
General
General
Prepare
Remove
Install
Install Sensor
Complete
3.10 TIRES
General
Prepare
Remove
Tubeless-Type With TPMS
Clean, Inspect and Repair
Install
Tubeless-Type With TPMS
Check Tire Runout
Lateral Runout
Radial Runout
Balance
Static versus Dynamic
Weights
Complete
3.11 ELECTRONIC CHASSIS CONTROL
Rider Enhancements
Linked Braking with Anti-Lock Brake System (ABS)
Cornering Rider Safety Enhancement Components
Traction Control System (TCS)
Drag-Torque Slip Control System (DSCS)
Vehicle Hold Control (VHC)
3.12 FRONT BRAKE MASTER CYLINDER
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
3.13 FRONT BRAKE CALIPER
Prepare
Remove
Remove Caliper to Remove Front Wheel or Replacing Brake Pads
Remove Caliper for Service
Install
Install Caliper After Service
Install Caliper after Installing Front Wheel or Brake Pad Replacement
Complete
3.14 REAR BRAKE MASTER CYLINDER
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
3.15 REAR BRAKE CALIPER
Prepare
Remove
Remove Caliper to Remove Rear Wheel or Replacing Brake Pads
Remove Caliper for Service
Install
Install Caliper After Service
Install Caliper after Installing Rear Wheel or Brake Pad Replacement
Complete
3.16 BRAKE LINES
Brake Line: Front Master Cylinder to ABS Module
Prepare
Remove
Install
Complete
Brake Line: Front Caliper to ABS Module
Prepare
Remove
Install
Complete
Brake Line: Rear Master Cylinder to ABS Module
Prepare
Remove
Install
Complete
Brake Line: Rear Caliper to ABS Module
Prepare
Remove
Install
Complete
3.17 ABS MODULE
General
Reflex™ Linked Brakes With ABS Operation
Prepare
Remove
Install
Complete
3.18 BLEED BRAKES
Drain
Fill and Bleed
3.19 LEFT SIDE COVER
Prepare
Remove
Install
Complete
3.20 RIGHT SIDE COVER
Prepare
Remove
Install
Complete
3.21 FRONT FORK
Check For Oil Leak
Fork Oil Seals
Check Oil Leak
Prepare
Remove
Install
Disassemble
Initial Disassembly
Fork Drain
Complete Disassembly
Clean and Inspect
Assemble
Initial Assembly
Final Fill
Complete Assembly
Complete
3.22 STEERING HEAD/FORK STEM AND BRACKET ASSEMBLY
Prepare
Remove
Upper Fork Bracket
Lower Fork Bracket
Steering Head Bearings
Install
Steering Head Bearings
Lower Fork Bracket
Upper Fork Bracket
Complete
3.23 REAR FORK
Prepare
Remove
Install
Disassemble
Assemble
Complete
3.24 BELT GUARDS
Prepare
Remove
Install
Complete
3.25 REAR SHOCK ABSORBERS
Prepare
Remove
Right Rear Shock
Left Rear Shock
Clean and Inspect
Install
Right Rear Shock
Left Rear Shock
Disassemble
Remove Shock Adjuster Knob (shock mounted)
Remove Shock Adjuster Knob (remote mounted)
Assemble
Install Shock Adjuster Knob (shock mounted)
Install Shock Adjuster Knob (remote mounted)
Complete
3.26 CLUTCH CONTROL
Prepare
Remove
Clutch Cable Disconnect
Clutch Cable: Lower End
Clutch Cable: Upper End
Clutch Hand Control
Clean and Inspect
Install
Clutch Hand Control
Clutch Cable: Lower End
Clutch Cable: Upper End
Clutch Cable Connect
Disassemble
Lock Button
Housing
Clutch Lever
Assemble
Clutch Lever
Housing
Lock Button
Complete
3.27 FAIRING: FORK MOUNTED
Remove and Install: Windshield
Short Windshield
Tall Windshield
Remove and Install: Air Duct Bezel Assembly
Prepare
Remove
Install
Complete
Disassemble and Assemble: Air Duct Bezel Assembly
Disassemble
Assemble
Remove and Install: Air Duct Cover Assembly
Prepare
Remove
Install
Complete
Disassemble and Assemble: Air Duct Cover Assembly
Disassemble
Assemble
Remove and Install: Outer Fairing Shell
Prepare
Remove
Install
Complete
Dissemble and Assemble: Outer Fairing Shell
Prepare
Disassemble
Assemble
Complete
Remove and Install: Mirrors
Prepare
Remove
Install
Complete
Remove and Install: Upper Air Duct
Prepare
Remove
Install
Complete
Remove and Install: Air Deflector Assembly
Prepare
Remove
Install
Complete
Remove and Install: Air Deflector Wing
Remove
Install
Remove and Install: Headlamp Assembly
Prepare
Remove
Install
Complete
Remove and Install: Dash Panel
Prepare
Remove
Install
Complete
Detach Fairing For Service
Prepare
Detach
Attach
Complete
Remove and Install: Inner Fairing Shell
Prepare
Remove
Install
Complete
Remove and Install: Upper Support Bracket
Prepare
Remove
Install
Complete
Remove and Install: Media Tray
Remove
Install
Disassemble and Assemble: Media Tray
Replace Door
Replace Latch
Replace Bumper
Remove and Install: Media Compartment
Prepare
Complete
Disassemble and Assemble: Media Compartment
Replace Cable
Replace Spring and Spool
Replace Damper
Remove and Install: Speaker Enclosure
Prepare
Remove
Install
Complete
3.28 FAIRING: FRAME MOUNTED
Remove and Install: Windshield
Remove
Install
Remove and Install: Air Deflectors
Remove
Install
Remove and Install: Air Duct Cover and Air Duct Bezel
Prepare
Remove
Install
Remove and Install: Air Duct Vane Assembly
Prepare
Remove
Install
Complete
Disassemble and Assemble: Air Duct Vane Assembly
Remove
Install
Remove and Install: Outer Fairing Shell
Prepare
Remove
Install
Complete
Remove and Install: Lower Vents
Prepare
Remove
Install
Complete
Remove and Install: Nacelle
Remove
Install
Remove and Install: Inner Fairing Assembly
Prepare
Remove
Install
Complete
Disassemble and Assemble: Inner Fairing Assembly
Prepare
Disassemble
Assemble
Remove and Install: Mounting Bracket
Prepare
Remove
Install
Complete
Remove and Install: Fairing Supports
Prepare
Remove
Install
Complete
Remove and Install: Storage Compartment Doors and Hinges
Prepare
Remove
Install
Complete
Remove and Install: Storage Compartment Door Cosmetic Cover
Remove
Install
Remove and Install: Storage Compartments
Prepare
Remove
Install
Complete
Remove and Install: Media Cable
Prepare
Remove
Install
Complete
Remove and Install: Speaker Enclosure
Prepare
Remove
Install
Complete
3.29 FAIRING LOWERS
Prepare
Remove
RH Fairing Lower
LH Fairing Lower
Install
LH Fairing Lower
RH Fairing Lower
Disassemble
Storage Compartment Assembly
Storage Compartment Door Assembly
Lower Fairing Door Vent Assembly
Assemble
Lower Fairing Vent Assembly
Storage Compartment Door Assembly
Storage Compartment Assembly
Complete
3.30 RADIATOR SCREEN
Remove
Install
3.31 RADIATOR SHROUD
Remove
Install
Radiator Shroud Screen
Remove
Install
3.32 ENGINE GUARD
Prepare
Chopped Engine Guard
Engine Guard
Remove
Chopped Engine Guard
Engine Guard
Install
Chopped Engine Guard
Engine Guard
Complete
Chopped Engine Guard
Engine Guard
3.33 AIR DEFLECTORS
Frame Mounted Fairing
Remove
Install
Remove and Install: Air Deflector Wing
Remove
Install
Remove and Install: Mid Frame Deflectors
Remove
Install
3.34 HAND GRIPS
General
3.35 HANDLEBAR
Prepare
Remove and Install: Fork Mounted Fairing
Prepare
Remove
Install
Complete
Remove and Install: Frame Mounted Fairing
Prepare
Remove
Install
Complete
Remove and Install: Wire Harness
Prepare
Remove
Install
Complete
Disassemble and Assemble
Disassemble
Assemble
Complete
3.36 MIRRORS
Remove
Install
3.37 FRONT FENDER
Remove
Install
3.38 REAR FENDER
Prepare
Remove
Install
Disassemble
Assemble
Complete
3.39 REAR FENDER WIRE CONDUIT
Prepare
Remove
Install
Complete
3.40 REAR LICENSE PLATE BRACKET
Prepare
Remove
Install
Complete
3.41 RIDER FOOTRESTS
Prepare
Remove
Install
Disassemble
Assemble
Complete
3.42 PASSENGER FOOTRESTS
Remove
Install
Disassemble
Assemble
3.43 JIFFY STAND
Prepare
Remove
Jiffy Stand Sensor
Jiffy Stand Leg
Jiffy Stand Bracket
Install
Jiffy Stand Bracket
Jiffy Stand Leg
Jiffy Stand Sensor
Complete
3.44 SEAT
Remove
Remove Seat
Seat Retention Nut
Install
Install Seat
Seat Retention Nut
3.45 REAR FRAME
Prepare
Remove
Thread Repair
Install
Complete
3.46 TOUR-PAK
Prepare
Remove
Install
Disassemble and Assemble
TOUR-PAK BACKREST
TOUR-PAK RACK
TOUR-PAK LINER
HINGES
TOUR-PAK SEAL
TETHER
TOUR-PAK LOCK
LATCH HANDLE AND CATCH
GROUND PLATE/TRIM
Complete
3.47 TOUR-PAK SUPPORT
Prepare
Remove
Install
Disassemble
Assemble
Complete
3.48 SADDLEBAGS
Remove
Install
Disassemble
Lock
Face Plate
Strikes
Tether
Cover
Cover Seal
Hinge
Lever
Cushions
Assemble
Lock
Strikes
Cover
Cover Seal
Hinge
Tether
Lever
Cushions
3.49 SADDLEBAG SUPPORTS
Prepare
Remove
Saddlebag Support Insert.
Lower Saddlebag Support
Saddlebag Support Assembly
Install
Saddlebag Support Insert.
Lower Saddlebag Support
Saddlebag Support Assembly
Complete
3.50 MEDALLIONS, BADGES, TANK EMBLEMS AND ADHESIVE STRIPS
Remove
Install
4 Engine
4.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
4.2 SPECIFICATIONS
Engine
SERVICE WEAR LIMITS
4.3 ENGINE OIL FLOW
Operation
Internal Oil Distribution
4.4 OIL PUMP OPERATION
General
Operation
4.5 BREATHER OPERATION
General
4.6 OIL PRESSURE
Operation
Oil Pressure Check
4.7 TROUBLESHOOTING
Typical Symptoms
Typical Symptoms
Compression Test
Cylinder Leakdown Test
Measure Crankshaft Endplay
Measure Crankshaft Runout
Flywheel Assembly Installed
Flywheel Assembly Removed
Diagnose Valve Train Noise
Diagnose Smoking Engine or High Oil Consumption
Initail Tests
Check Before Cylinder Head Removal
Check After Cylinder Head Removal
4.8 CRIMP CLAMPS
Remove
Removal
Install
Installation
4.9 FRONT ENGINE MOUNT
Prepare
Remove and Install: Lower Front Engine Mount
Remove
Install
Remove and Install: Upper Front Engine Mount
Remove
Inspect
Install
Stabilizer Link Bracket
Complete
4.10 UPPER ROCKER COVERS
Prepare
Remove
Install
Complete
4.11 BREATHER
Prepare
Remove
Breather Hose
Breather Cover
Install
Breather Cover
Breather Hose
Complete
4.12 LOWER ROCKER COVERS
Prepare
Remove
Install
Complete
4.13 ROCKER ARMS
Prepare
Remove
Clean and Inspect
Install
Complete
4.14 PUSHRODS, LIFTERS AND COVERS
Prepare
Remove
Pushrods
Pushrod Covers
Lifters
Clean and Inspect
Inspect Lifters
Assemble Pushrod Cover
Install
Lifters
Pushrod Covers
Pushrods
Complete
4.15 CYLINDER HEADS
Prepare
Remove
Clean
Install
Disassemble
Clean and Inspect
Cylinder Head
Valve Guides
Valves and Valve Seats
Valve Springs
Tapered Keepers
Valve Seats
Valve and Seat Repair
Assemble
Complete
4.16 CYLINDERS
Prepare
Remove
Install
Clean and Inspect
Deglaze Cylinder
Complete
4.17 PISTONS
Prepare
Remove
Install
Disassemble
Clean and Inspect
Clean
Inspect
Check Piston Ring Gap
Assemble
Complete
4.18 CAM COMPARTMENT AND COMPONENTS
Prepare
Remove and Install: Camshaft Cover
Remove
Install
Remove
Camshaft Drive
Camshaft
Inspect Cam Component
Camshaft
Cam Support Plate
Cam Drive Components
Install
Camshaft
Camshaft Drive
Complete
Camshaft Needle Bearings
Remove
Install
4.19 OIL PUMP
Prepare
Remove
Disassemble and Inspect
Assemble
Install
Complete
4.20 REPLACE ENGINE
Prepare
Prepare
Remove
Remove
Install
Install
Complete
Complete
4.21 CRANKCASE
Prepare
Disassemble
Clean and Inspect
Assemble
Repair Right Crankcase Half
Remove Main Bearing
Install Main Bearing
Remove Balancer Bearing
Install Balancer Bearing
Remove Piston Jets
Install Piston Jets
Repair Left Crankcase Half
Remove Main Bearing
Install Main Bearing
Remove Balancer Bearing
Install Balancer Bearing
Sprocket Shaft Bearing Inner Race
Remove
Install
Cylinder Studs
Remove
Install
Plugs and Oil Fittings
Remove
Install
Complete
4.22 FLYWHEEL AND CONNECTING RODS
Symptoms
Overview
No Oil Pressure
Vibration
Prepare
Inspect
Complete
4.23 OIL PAN
Prepare
Remove
Install
Complete
5 Drive and Transmission
5.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
5.2 SPECIFICATIONS
Drive Specifications
Transmission Specifications
SERVICE WEAR LIMITS
5.3 TRANSMISSION OPERATION
Power Flow
Neutral
First Gear
Second Gear
Third Gear
Fourth Gear
Fifth Gear
Sixth Gear
5.4 DRIVE BELT
Prepare
Remove
Install
Complete
5.5 SHIFTER LINKAGE
Shifter Rod
Remove
Install
Adjustment
Foot Shift Lever
Remove
Install
Shifter Rod Lever, Front
Remove
Install
Shifter Rod Lever, Rear
Remove
Install
5.6 CLUTCH RELEASE COVER
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
5.7 CLUTCH RELEASE PUSH ROD COMPONENTS
Prepare
Remove
Right Side
Left Side
Install
Left Side
Right Side
Complete
5.8 PRIMARY CHAINCASE COVER
Prepare
Remove
Install
Complete
5.9 DRIVE COMPONENTS
Prepare
Remove
Install
Complete
5.10 CLUTCH
Prepare
Disassemble and Assemble: Clutch Pack
Disassemble
Clean and Inspect
Assemble
Disassemble and Assemble: Hub
Disassemble
Assemble
Complete
5.11 PRIMARY CHAINCASE HOUSING
Prepare
Remove
Inspect
Install
Mainshaft Bearing and Seal
Remove
Install
Mainshaft Bearing Inner Race
Remove
Install
Shifter Shaft Bushing
Vent Hose
Remove
Install
Complete
5.12 TRANSMISSION SPROCKET
Prepare
Remove
Clean and Inspect
Install
Complete
5.13 TRANSMISSION
Prepare
Remove
Install
Disassemble
Remove Shift Cam and Shifter Forks
Remove Mainshaft
Remove Countershaft
Remove Bearing Housing Bearings
Clean and Inspect
Assemble
Install Bearing Housing Bearings
Install Countershaft
Install Mainshaft
Install Shifter Cam/Shifter Forks
Complete
5.14 MAIN DRIVE GEAR AND BEARING
Prepare
Remove
Clean and Inspect
Install
Replace Needle Bearings
Remove
Install
Replace Mainshaft Seal
Remove
Install
Complete
5.15 TRANSMISSION CASE
Prepare
Remove
Install
Disassemble
Remove Shifter Pawl Lever
Remove Transmission Plug
Clean and Inspect
Assemble
Install Transmission plug
Install Countershaft Needle Bearing
Install Shifter Pawl Lever
Complete
6 Fuel and Exhaust
6.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
6.2 SPECIFICATIONS
Specifications
6.3 AIR CLEANER BACKPLATE ASSEMBLY
Remove
Install
6.4 CONSOLE
Prepare
Remove
Install
Complete
6.5 FUEL PRESSURE TEST
Prepare
Test
6.6 PURGE FUEL LINE
Purge
6.7 FUEL LINE
Prepare
Remove
Install
Complete
6.8 FUEL INLET
Prepare
Remove
Install
Complete
6.9 FUEL TANK
Prepare
Remove
Install
Complete
6.10 FUEL PUMP
Prepare
Remove
Clean and Inspect
Install
Disassemble
Quick Connector
Level sender
Pressure Regulator
Filters
Assemble
Filter
Pressure Regulator
Level Sender
Quick Connector
Complete
6.11 DRAIN LINE
Prepare
Remove
Install
Complete
6.12 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE (TMAP) SENSOR
Prepare
Remove
Install
Complete
6.13 TWIST GRIP SENSOR (TGS)
Prepare
Remove
Install
Complete
6.14 FUEL INJECTORS
Prepare
Remove
Install
Complete
6.15 INDUCTION MODULE
Prepare
Remove
Install
Disassemble
Throttle Body
Flange Adapters
Intake Manifold
Assemble
Intake Manifold
Throttle Body
Flange Adapters
Complete
6.16 INTAKE LEAK TEST
Leak Tester
Parts List
Tester Assembly
Tester Adjustment
Procedure
6.17 HEATED OXYGEN SENSORS (HO2S)
Prepare
Remove
Front HO2 Sensor
Rear HO2 Sensor
Crossover HO2 Sensor (if equipped)
Install
Front HO2 Sensor
Rear HO2 Sensor
Crossover HO2 Sensor (if equipped)
Complete
6.18 MUFFLERS
Prepare
Remove
Install
Complete
6.19 EXHAUST SYSTEM
Prepare
Remove
Install
Complete
6.20 PURGE SOLENOID: EVAPORATIVE EMISSIONS
Prepare
Remove
Install
Complete
6.21 CHARCOAL CANISTER: EVAPORATIVE EMISSIONS
Prepare
Remove
Install
Complete
6.22 PURGE LINES: EVAPORATIVE EMISSIONS
Prepare
Remove
Install
Complete
7 Cooling System
7.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
7.2 SPECIFICATIONS
General
7.3 COOLANT FLOW
Operation
Engine Below Operating Temperature
Coolant Flow with Engine at Operating Temperature
Coolant Reservoir
7.4 DIAGNOSE AND TEST
Troubleshooting
TROUBLESHOOTING
Pressure Cap Test
PRESSURE CAP TEST
System Pressure Test
SYSTEM PRESSURE TEST
Freeze Point Test
FREEZE POINT TEST
Leak Detection Dye Test
LEAK DETECTION DYE TEST
Gasket Leak Test
GASKET LEAK TEST
7.5 COOLANT
Check Coolant Level
Drain and Fill Cooling System
Drain
Fill/Bleed Coolant System
7.6 COOLANT PUMP
Prepare
Remove
Install
Complete
7.7 COOLANT RESERVOIR
Prepare
Remove
Install
Complete
7.8 COOLANT HOSES
Prepare
Remove
Install
Complete
7.9 ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Prepare
Remove
Install
Complete
7.10 RADIATOR
Prepare
Remove
Install
Complete
8 Electrical
8.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
8.2 SPECIFICATIONS
Specifications
8.3 FUSES AND RELAYS
Prepare
Remove
Main Fuse
Fuses and Relays
Install
Fuses and Relays
Main Fuse
Complete
8.4 POWER DISCONNECT
Main Fuse
Remove Main Fuse
Install Main Fuse
Negative Battery Cable
Disconnect Negative Battery Cable
Connect Negative Battery Cable
8.5 STARTER
Prepare
Remove
Install
Complete
8.6 ALTERNATOR
Prepare
Remove
Install
Complete
8.7 VOLTAGE REGULATOR
Prepare
Remove
Install
Complete
8.8 SPARK PLUG CABLES
Prepare
Remove
Install
Complete
8.9 IGNITION COIL
Prepare
Remove
Install
Complete
8.10 LEFT HAND CONTROL MODULE (LHCM)
Prepare
Remove
Remove
Install
Assemble
Install
Clutch Switch Replacement
Remove
Install
Complete
8.11 RIGHT HAND CONTROL MODULE (RHCM)
Prepare
Remove
Remove
Disassemble
Install
Assemble
Install
Front Brake Switch Replacement
Remove
Install
Complete
8.12 IFCU DISPLAY
Prepare
Remove
Install
Complete
8.13 FORK LOCK
Prepare
Remove
Install
Complete
8.14 OIL PRESSURE SWITCH
Prepare
Remove
Install
Complete
8.15 HORN
Prepare
Remove
Install
Complete
8.16 HEADLAMP
Prepare
Remove and Install: Single Headlamp
Remove
Disassembly
Assemble
Install
Remove and Install: Dual Headlamp
Remove
Install
Align
Prepare
Check Alignment
Adjust
Fork Mounted Fairing
Frame Mounted Fairing
Complete
8.17 FRONT TURN SIGNAL LAMPS
Prepare
Single Headlamp
Dual Headlamp
Remove
Install
Complete
Single Headlamp
8.18 REAR TURN SIGNAL LAMPS
General
8.19 TAIL LAMP
Bulb Replacement
Prepare
Remove
Install
Complete
8.20 REAR STOPLAMP SWITCH
Prepare
Remove
Install
Complete
8.21 LICENSE PLATE LAMP
Prepare
Remove
Install
Complete
8.22 AUDIO AMPLIFIER
Prepare
Remove
Install
Complete
8.23 FRONT SPEAKERS
Prepare
Remove and Install: Fork Mounted Fairing
Remove
Install
Remove and Install: Frame Mounted Fairing
Remove
Install
Complete
8.24 HIDDEN ANTENNA
Prepare
Remove
Install
Complete
8.25 GPS ANTENNA
Prepare
Remove
Install
Complete
8.26 ELECTRONIC CONTROL MODULE (ECM)
Prepare
Remove
Install
Complete
8.27 BODY CONTROL MODULE (BCM)
Prepare
Remove
Install
Complete
8.28 SECURITY SYSTEM ACTIVATION
Activation
Fob Assignment
8.29 PERSONAL IDENTIFICATION NUMBER (PIN)
Changing the PIN
Changing the PIN
Touch Screen Entry
8.30 SECURITY SYSTEM MAINTENANCE
Service Mode
Transport Mode
To Enter Transport Mode
To Exit Transport Mode
Fob Battery
Battery Replacement Schedule
Battery Replacement
8.31 SECURITY SYSTEM ANTENNA
Prepare
Remove
Install
Complete
8.32 COOLING FAN
Prepare
Remove
Install
Complete
8.33 AMBIENT AIR TEMPERATURE SENSOR
Remove
Install
8.34 CRANKSHAFT POSITION SENSOR (CKP)
Prepare
Remove
Install
Complete
8.35 CAMSHAFT TIMING SENSOR
Prepare
Remove
Install
Complete
8.36 ENGINE TEMPERATURE (ET) SENSOR
Prepare
Remove
Install
Complete
8.37 KNOCK SENSOR (KS)
Prepare
Remove
Install
Complete
8.38 AUTOMATIC COMPRESSION RELEASE (ACR)
Prepare
Remove
Install
Complete
8.39 GEAR POSITION SENSOR
Prepare
Remove
Install
Complete
8.40 FRONT WHEEL SPEED SENSOR (WSS)
Prepare
Remove
Fork mounted fairing
Frame mounted fairing
Install
Fork mounted fairing
Frame mounted fairing
Complete
8.41 REAR WHEEL SPEED SENSOR (WSS)
Prepare
Remove
Install
Complete
8.42 INERTIAL MEASUREMENT UNIT (IMU)
Prepare
Remove
Install
Complete
8.43 JIFFY STAND SENSOR (JSS)
Prepare
Remove
Install
Complete
8.44 WIRE TROUGH
Prepare
Remove
Install
Complete
8.45 TOP CADDY
Prepare
Remove
Install
Complete
8.46 LEFT SIDE CADDY
Prepare
Remove
Install
Complete
8.47 RIGHT SIDE CADDY
Prepare
Remove
Install
Complete
8.48 LOWER BACKBONE CADDY
Prepare
Remove
Install
Complete
8.49 BATTERY TRAY
Prepare
Remove
Install
Complete
8.50 FAIRING WIRE HARNESS
Prepare
Remove and Install: Fork Mounted Fairing
Remove
Install
Remove and Install: Frame Mounted Fairing
Remove
Install
Complete
8.51 MAIN WIRE HARNESS
Prepare
Remove and Install: Fork Mounted Fairing
Remove
Install
Remove and Install: Frame Mounted Fairing
Remove
Install
Remove and Install: Common Components
Remove
Install
Complete
A Reference
A.1 GLOSSARY
Acronyms and Abbreviations
A.2 METRIC CONVERSION
Conversion Table
A.3 FLUID CONVERSION
United States System
Metric System
British Imperial System
A.4 TORQUE CONVERSION
United States System
Metric System
TOOLS
Torque Values
Index
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