2025 Harley-Davidson Road King, Police, Trike Models 94001291 (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
Secure the Motorcycle 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
Tread
Wheel Bearings
2.9 LUBRICATE CABLES AND CHASSIS
General
Lubrication Points
2.10 INSPECT BRAKES
General
Linked Braking
Enhanced Chassis Controls
Traction Control
Inspect
FLHTP, FLHRXS, FLTRXP, FLHP
TRIKE
Replace Front Brake Pads
Remove
Install
Replace Rear Brake Pads
Remove
Install
Replace Rear Brake Pads
Prepare
Remove
Clean and Inspect
Install
Complete
2.11 CHECK AND REPLACE BRAKE FLUID
Check Brake Fluid Level
Drain and Replace Fluid
Inspect Brake Lines
2.12 ADJUST BRAKE LINKAGE
Adjust Parking Brake
Wheels on the Ground
Wheels off the Ground
2.13 CHECK AND ADJUST CLUTCH
Check and Adjust
Clutch Cable Only Check
Adjust
Proper Button Engagement
2.14 REBUILD FRONT FORK AND REPLACE OIL
Rebuild and Replace Fork Oil
2.15 ADJUST AND LUBRICATE STEERING HEAD BEARINGS
Check and Adjust
Measure Swing-Back
Adjust Swing-Back
Lubricate
2.16 INSPECT STEERING DAMPER
Inspect
2.17 INSPECT RADIATOR AND COOLANT
General
Clean Radiator
Inspect
Check Freeze Point
Check for leaks
Drain and Fill Cooling System
2.18 INSPECT FUEL LINES AND FITTINGS
Inspect
2.19 INSPECT AND LUBRICATE JIFFY STAND
Inspect and Lubricate
2.20 INSPECT AND ADJUST DRIVE BELT AND SPROCKETS
Inspect
General
Cleaning
Sprockets
Drive Belt
Measure Drive Belt Deflection
Adjust Belt
Prepare
Adjust
Assemble
Complete
Adjust Belt: Trike
Prepare
Adjust
Complete
2.21 INSPECT REAR SPROCKET ISOLATOR
Inspect
Inspect
2.22 ADJUST SUSPENSION
Adjust Shock Absorber
Two Wheel
Trike
2.23 INSPECT EXHAUST SYSTEM
Leak Check
2.24 INSPECT AIR FILTER
Remove
Standard
Oval
Clean and Inspect
Install
Standard
Oval
2.25 INSPECT BATTERY
Prepare
Remove
Install
Clean and Inspect
Voltage Test
Storage
Complete
2.26 CLEAN, INSPECT, REPLACE SPARK PLUGS
Prepare
Remove
Clean and Inspect
Install
Complete
2.27 STORAGE
Place in Storage
Remove from Storage
2.28 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 Operate Normally
Parking Brake Does Not Hold Normally
Reverse Motor
Reverse Motor Does Not Operate/Cannot Enable
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 AXLE COVERS
Remove
Install
3.5 FRONT WHEEL
Prepare
Remove
Install
Disassemble
Standard
Trike
Clean and Inspect
Assemble
Standard
Trike
Complete
3.6 REAR WHEEL
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
3.7 REAR WHEELS
Prepare
Remove
Install
Complete
3.8 CHECKING AND TRUING WHEELS
General
Checking Wheel Runout
Checking Radial Runout
Checking Lateral Runout
3.9 REAR WHEEL COMPENSATOR
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
3.10 SEALED WHEEL BEARINGS
Prepare
Inspect
Remove
Install
Complete
3.11 TIRE PRESSURE MONITORING SYSTEM (TPMS)
General
General
Prepare
Remove
Install
Install Sensor
Complete
3.12 TIRES
General
Prepare
Remove
Models With TPMS
Models Without TPMS
Clean, Inspect and Repair
Install
Tubeless-Type With TPMS
Tubeless-Type Without TPMS
Check Tire Runout
Lateral Runout
Radial Runout
Balance
Static versus Dynamic
Weights
Complete
3.13 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)
3.14 FRONT BRAKE MASTER CYLINDER
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
3.15 FRONT BRAKE CALIPER
Prepare
Remove
Install
Complete
3.16 REAR BRAKE MASTER CYLINDER
Remove and Install
Prepare
Remove
Install
Complete
Remove and Install: Trike
Prepare
Remove
Install
Complete
Disassemble and Assemble
Disassemble
Clean and inspect
Assemble
Disassemble and Assemble: Trike
Disassemble
Clean and Inspect
Assemble
3.17 REAR BRAKE CALIPER
Remove and Install
Prepare
Remove
Install
Complete
Remove and Install
Prepare
Remove
Install
Complete
3.18 PARKING BRAKE ASSEMBLY
Remove and Install: Pedal Assembly
Remove
Install
Disassemble and Inspection
Assemble
Pedal Mounting Bracket
Adjusting Parking Brake Sensor Gap
Parking Brake Sensor Replacement
Parking Brake Sensor Magnet
3.19 BRAKE LINES
Brake Line: Front Master Cylinder to ABS Module
Prepare
Remove
Install
Complete
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: Front Caliper to ABS Module
Prepare
Remove
Install
Complete
Brake Line: Rear Master Cylinder 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
Brake Line: Rear Caliper to ABS Module
Prepare
Remove
Install
Complete
3.20 ABS MODULE
General
Reflex™ Linked Brakes With ABS Operation
Remove and Install
Prepare
Remove
Install
Complete
Remove and Install
Prepare
Remove
Install
Complete
3.21 HIGH PRESSURE SENSOR
General
Prepare
Remove
Install
Complete
3.22 BRAKE SWITCH
Prepare
Remove
Install
Complete
3.23 BLEED BRAKES
Drain
Fill and Bleed
3.24 LEFT SIDE COVER
Prepare
Remove
Install
Complete
3.25 RIGHT SIDE COVER
Prepare
Remove
Install
Complete
3.26 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
3.27 STEERING HEAD/FORK STEM AND BRACKET ASSEMBLY
Prepare
Remove
Upper Fork Bracket
Lower Fork Bracket
Steering Head Bearings
Install
Upper Fork Bracket
Lower Fork Bracket
Steering Head Bearings
Complete
3.28 STEERING DAMPER ASSEMBLY
Remove
FLHTCUTG
FLRT/FLTRT
Install
FLHTCUTG
FLRT/FLTRT
3.29 REAR FORK
Prepare
Remove
Install
Disassemble
Remove Bearings
Disassemble Pivot Shaft/Mount
Assemble
Complete
3.30 Rear Fork: Trike
Prepare
Remove
Install
Disassemble
Remove Bearings
Disassemble Pivot Shaft/Mount
Assemble
Complete
3.31 LATERAL ALIGNMENT
Align
3.32 BELT GUARDS
Prepare
Remove
Debris Deflector
Install
Debris Deflector
Complete
3.33 REAR SHOCK ABSORBERS
Remove and Install
Prepare
Remove
Clean and Inspect
Install
Complete
Remove and Install
Prepare
Remove
Clean and Inspect
Install
Complete
Disassemble and Assemble: Rear Shock Adjuster
Remove Shock Absorber Knob
Install Shock Absorber Knob
3.34 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
3.35 HEADLAMP NACELLE
Remove and Install
Prepare
Remove
Install
Complete
Remove and Install
Prepare
Remove
Install
Complete
3.36 FAIRING: FORK MOUNTED
Remove and Install: Windshield
Prepare
Remove
Install
Complete
Remove and Install: Outer Fairing Shell
Prepare
Remove
Install
Complete
Remove and Install: Perimeter Trim
Prepare
Remove
Install
Complete
Remove and Install: Glovebox
Remove
Install
Remove and Install: Headlamp Assembly
Remove
Install
Remove and Install: Vent Bezel
Prepare
Remove
Install
Complete
Remove and Install: Dash Panel
Prepare
Remove
Install
Complete
Detach Fairing For Service
Prepare
Detach
Attach
Complete
Remove and Install: Fairing
Prepare
Remove
Install
Complete
Remove and Install: Inner Fairing Shell
Prepare
Remove
Install
Complete
Remove and Install: Vent
Cleaning
Prepare
Remove
Install
Complete
Disassemble and Assemble: Vent
Prepare
Disassemble
Assemble
Complete
Remove and Install: Upper Support Bracket
Prepare
Remove
Install
Complete
Remove and Install: Media Compartment
Prepare
Remove
Install
Complete
Disassemble and Assemble: Media Compartment
Replace Cable
Replace Cover
Replace Latch
3.37 FAIRING: FRAME MOUNTED
Remove and Install: Windshield
Remove
Install
Remove and Install: Upper Vent
Remove
Install
Cleaning Air Vent
Repair Button Mechanism
Remove and Install: Glovebox
Mic Jack
Remove and Install: Outer Fairing Shell
Remove
Install
Remove and Install: Lower Vents
Remove
Install
Remove and Install: Instrument Bezel
Remove
Install
Remove and Install: Instrument Nacelle
Remove
Install
Remove and Install: Inner Fairing Shell
Remove
Install
Remove and Install: Inner Fairing Shell
Remove
Install
Disassemble and Assemble: Inner Fairing Shell
Disassemble
Assemble
Remove and Install: Mounting Bracket
Remove
Install
Remove and Install: Radio Support Bracket
Prepare
Remove
Install
Complete
Remove and Install: Storage Compartment Doors and Hinges
Replace Storage Compartment Door
Replace Storage Compartment Door
Remove Storage Compartment Door/Hinge
Install Storage Compartment Door/Hinge
Remove and Install: Storage Compartments
Remove
Install
Remove and Install: Media Cable
Remove
Install
3.38 FAIRING LOWERS
Remove and Install: Air-Cooled
Remove
Install
Remove and Install: Twin-Cooled
Remove
Install
Disassemble and Assemble: Air-Cooled
Disassembly
Assembly
Disassemble and Assemble: Twin-Cooled
3.39 ENGINE GUARD
Prepare
Remove
Engine guard
Chopped engine guard
Install
Engine guard
Chopped engine guard
Complete
3.40 AIR DEFLECTORS
Remove and Install: Fork Mounted Fairing
Remove
Install
Remove and Install: Frame Mounted Fairing
Remove
Install
Remove and Install: Mid Frame Deflectors
Removal
Installation
3.41 WINDSHIELD
Remove
Install
Disassemble
Assemble
3.42 HAND GRIPS
Prepare
Remove and Install: Standard
Left Grip
Right Grip
Remove and Install: Heated
Remove Left Grip
Install Left Grip
Remove Right Grip
Install Right Grip
Complete
3.43 HANDLEBAR
General
Prepare
Remove and Install: Without Fairing
Remove
Install
Remove and Install: Fork Mounted Fairing
Remove
Install
Remove and Install: Frame Mounted Fairing
Remove
Install
Disassemble and Assemble
Disassemble
Assemble
Adjust
Road King Special (FLHRXS)
Trike
Complete
3.44 MIRRORS
Remove and Install: Handlebar Mount
Remove
Install
3.45 FRONT FENDER
Remove
Install
Disassemble
Assemble
3.46 REAR FENDER
Prepare
Remove
Install
Disassemble
Mounting Hardware
Stud Plate
Lights and Harnesses
Assemble
Mounting Hardware
Stud Plate
Lights and Harnesses
Complete
3.47 REAR FENDERS
Prepare
Remove
Install
Complete
3.48 REAR FENDER WIRE CONDUIT
Prepare
Remove
Install
Complete
3.49 REAR LICENSE PLATE BRACKET
Prepare
Remove
Install
Disassemble
Assemble
Complete
3.50 RIDER FOOTRESTS
Prepare
Remove
Install
Disassemble
Assemble
Complete
3.51 PASSENGER FOOTRESTS
Remove
Passenger Footboard
Passenger Footpeg: Standard
Replace Pad and Adjust Footpeg
Install
Passenger Footboard
Passenger Footpeg: Standard
Replace Pad and Adjust Footpeg
Disassemble
Passenger Footboard
Passenger Footpeg: Standard
Assemble
Passenger Footboard
Passenger Footpeg: Standard
3.52 JIFFY STAND
Prepare
Remove
Jiffy Stand Leg
Jiffy Stand Bracket
Install
Jiffy Stand Leg
Jiffy Stand Bracket
Complete
3.53 SEAT
Remove
Two-Up One-Piece Seat
Seat Retention Nut
Seat Bumper
Install
Two-Up One-Piece Seat
Seat Retention Nut
Seat Bumper
Remove and Install: Seat
Remove
Install
Disassemble
Assemble
3.54 INTERMEDIATE FRAME
Prepare
Remove
Install
Disassemble
Assemble
Complete
3.55 REAR FRAME
Prepare
Remove
Thread Repair
Install
Complete
3.56 REAR FRAME: TRIKE
Prepare
Remove
Install
Disassemble
Assemble
Complete
3.57 PANHARD ROD
Prepare
Remove
Install
Complete
Adjust
3.58 TRUNK DOOR
Remove and Install: Top Opening
Remove
Install
Remove and Install: Side Opening
Remove
Install
Disassemble and Assemble: Top Opening
Disassemble
Assemble
Lockset Remove and Disassemble
Lockset Install and Assemble
Remove Latch Assembly
Remove Lock Assembly
Install Lock Assembly
Latch Mechanism Replacement
Install Latch Mechanism
Remove Latch Pin
Install Latch Pin
Disassemble and Assemble: Side Opening
Trunk Door Hinge
Seal Inspection
Seal Replacement
Striker
Adjust Trunk Door
Remove Lockset Assembly
Install Lockset Assembly
Lock Cover
Latch Cover
Retractable Tether
3.59 BODY
Prepare
Remove
Install
Repair
Threaded Inserts
Disassemble
Tour-Pak Models
Non-Tour-Pak Models
Assemble
Tour-Pak Models
Non-Tour-Pak Models
Complete
3.60 TOUR-PAK
Prepare
Remove
Install
Adjust
Complete
3.61 TOUR-PAK SUPPORT
Prepare
Remove
Install
Disassemble
Assemble
Complete
3.62 SADDLEBAGS
Remove
Install
Disassemble
Lock
Strikes
Cover
Cover Seal
Hinge
Latch Assembly
Skid Plate (If equipped with extended bags)
Assemble
Lock
Strikes
Cover
Cover Seal
Hinge
Latch Assembly
Skid Plate
3.63 SADDLEBAG SUPPORTS
Prepare
Remove
Support
Install
Support
Complete
3.64 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: All
External Oil Distribution: Oil-Cooled Only
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
Crankshaft/Flywheel Installed
Crankshaft 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 OIL COOLER
Prepare
Remove
Downtube Assembly with Components
Install
Install Downtube Assembly
Disassemble
Without Cooling Fan
With Cooling Fan
Assemble
Without Cooling Fan
With Cooling Fan
Complete
4.10 OIL CHECK VALVE
Prepare
Remove
Install
Complete
4.11 OIL COOLANT LINES
Prepare
Remove
Install
Complete
4.12 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
4.13 UPPER ROCKER COVERS
Prepare
Remove
Install
Complete
4.14 BREATHERS
Prepare
Remove
Install
Complete
4.15 LOWER ROCKER COVERS
Prepare
Remove
Install
Complete
4.16 ROCKER ARMS
Prepare
Remove
Clean and Inspect
Install
Complete
4.17 PUSHRODS, LIFTERS AND COVERS
Prepare
Remove
Pushrods
Pushrod Covers
Lifters
Clean and Inspect
Inspect Lifters
Assemble Pushrod Cover
Install
Lifters
Pushrod Covers
Pushrods
Complete
4.18 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
4.19 CYLINDERS
Prepare
Remove
Install
Clean and Inspect
Deglaze Cylinder
Complete
4.20 PISTONS
Prepare
Remove
Install
Disassemble
Clean and Inspect
Clean
Inspect
Check Piston Ring Gap
Assemble
Complete
4.21 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
4.22 OIL PUMP
Prepare
Remove
Disassemble and Inspect
Assemble
Install
Complete
4.23 REPLACE ENGINE
Prepare
Prepare
Remove
Remove
Install
Install
Complete
Complete
4.24 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
4.25 FLYWHEEL AND CONNECTING RODS
Symptoms
Overview
No Oil Pressure
Vibration
Prepare
Inspect
Complete
4.26 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
Foot Shift Lever
Replace Pegs
Replace Heel-Toe Shift Levers
Shifter Rod Lever, Front
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 AXLE
Prepare
Remove
Install
Disassemble
Assemble
Complete
5.13 AXLE HOUSING/DIFFERENTIAL
Prepare
Remove
Install
Disassemble
Bearings
Sprocket
Ring Gear
Differential
Assemble
Differential
Ring Gear
Sprocket
Bearings
Complete
5.14 TRANSMISSION SPROCKET
Prepare
Remove
Clean and Inspect
Install
Complete
5.15 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
5.16 MAIN DRIVE GEAR AND BEARING
Prepare
Remove
Clean and Inspect
Install
Replace Needle Bearings
Remove
Install
Replace Mainshaft Seal
Remove
Install
Complete
5.17 TRANSMISSION CASE
Prepare
Remove
Install
Disassemble
Remove Shifter Pawl Lever
Remove Oil Return Tube/Cover
Clean and Inspect
Assemble
Install Oil Return Tube/Cover
Replace 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
Prepare
Remove
Standard
Oval
Install
Standard
Oval
Complete
6.4 CONSOLE
Prepare
Remove
Install
Complete
6.5 FUEL PRESSURE TEST
Prepare
Test
Complete
6.6 PURGE FUEL LINE
Purge
6.7 FUEL LINE
Prepare
Remove
Install
Complete
6.8 FUEL TANK
Prepare
Remove
Install
Disassemble and Assemble
Remove
Install
Complete
6.9 FUEL TANK TOP PLATE
Prepare
Remove
Install
Disassemble
Fuel Filter
Fuel Pressure Regulator
Assemble
Fuel Filter
Fuel Pressure Regulator
Complete
6.10 FUEL LEVEL SENDER
Prepare
Remove
Install
Complete
6.11 FUEL PUMP
Prepare
Remove
Clean and Inspect
Install
Disassemble
Assemble
Complete
6.12 VENT TUBE
Prepare
Remove
Install
Complete
6.13 VAPOR VALVE
Prepare
6.14 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE (TMAP) SENSOR
Prepare
Remove
Install
Complete
6.15 TWIST GRIP SENSOR (TGS)
Prepare
Remove
Install
Complete
6.16 FUEL INJECTORS
Prepare
Remove
Install
Complete
6.17 INDUCTION MODULE
Prepare
Remove
Install
Disassemble
Assemble
Complete
6.18 INTAKE LEAK TEST
Leak Tester
Parts List
Tester Assembly
Tester Adjustment
Procedure
6.19 HEATED OXYGEN SENSORS (HO2S)
Prepare
Remove
Rear HO2 Sensor
Front HO2 Sensor
Third HO2 Sensor (if equipped) Typical
Install
Front HO2 Sensor
Rear HO2 Sensor
Third HO2 Sensor (if equipped) Typical
Complete
6.20 MUFFLERS
Prepare
Remove
Install
Complete
6.21 EXHAUST SYSTEM
General
Prepare
Remove
Install
Complete
6.22 PURGE SOLENOID: EVAPORATIVE EMISSIONS
Prepare
Remove
Install
Complete
6.23 CHARCOAL CANISTER: EVAPORATIVE EMISSIONS
Prepare
Remove
Install
Complete
6.24 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
OPERATION
COOLANT FLOW
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 System
Power Fill and Bleed
Manual Fill and Bleed
7.6 COOLANT PUMP
Prepare
Remove
Install
Complete
7.7 COOLANT OVERFLOW TANK
Prepare
Remove
Install
Complete
7.8 COOLANT HOSES
Prepare
Remove and Install: Horizontal Tube
Remove
Install
Remove and Install: Coolant Hoses
Inlet Left and Right Coolant Hoses, Radiator to Horizontal Downtube
Outlet Coolant Hose, Left Radiator and Downtube
Inlet Coolant Hose, Right Radiator to Coolant Pump
Remove and Install: Coolant Lines
Remove
Inspect
Install
Remove and Install: Coolant Downtubes
Remove
Inspect
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 FAIRING POWER OUTLET
Prepare
Remove
Install
Complete
8.6 STARTER
Prepare
Remove
Install
Complete
8.7 ALTERNATOR
Prepare
Remove
Install
Complete
8.8 VOLTAGE REGULATOR
Prepare
Remove
Install
Complete
8.9 IGNITION SWITCH
Prepare
Remove and Install: Fairing Models
Remove
Install
Remove and Install: Non-Fairing Models
Remove
Install
Complete
8.10 SPARK PLUG CABLES
Prepare
Remove
Install
Complete
8.11 IGNITION COIL
Prepare
Remove
Install
Complete
8.12 LEFT HAND CONTROL MODULE (LHCM)
Prepare
Remove
Install
Switch Caps
Rocker Switch Caps
Cruise Switch Cap
Clutch Switch Replacement
Complete
8.13 RIGHT HAND CONTROL MODULE (RHCM)
Prepare
Remove
Install
Switch Caps
Rocker Switch Caps
Toggle and Joystick Caps
Front Brake Switch Replacement
Complete
8.14 HANDLEBAR SWITCHES
General
Siren and Air Horn Connector Configuration
8.15 ACCESSORY SWITCHES
Prepare
Remove and Install: Fork Mounted Fairing
Remove
Install
Remove and Install: Frame Mounted Fairing
Remove
Install
Remove and Install: Nacelle Mounted
Remove
Install
Complete
8.16 INSTRUMENT MODULE (IM)
Prepare
Remove
Fairing Models
Non-Fairing Models
Install
Fairing Models
Non-Fairing Models
Complete
8.17 INDICATOR LAMPS
Prepare
Remove
Install
Complete
8.18 FAIRING GAUGES
Prepare
Remove
Install
Complete
8.19 FUEL LEVEL GAUGE
Prepare
Remove
Install
Complete
8.20 OIL PRESSURE SWITCH
Prepare
Remove
Install
Complete
8.21 NEUTRAL INDICATOR SWITCH
Prepare
Remove
Install
Complete
8.22 HORN
Prepare
Remove
Horn Assembly with Bracket
Horn Assembly
Install
Horn Assembly with Bracket
Horn Assembly
Disassemble
Assemble
Complete
8.23 HEADLAMP
Bulb Replacement
Bulb Replacement: LED Type
Bulb Replacement: Halogen Type
Prepare
Remove and Install: Single Headlamp
Removal
Installation
Remove and Install: Dual Headlamp
Removal
Installation
Align
Adjust
HEADLAMP
AUXILIARY/FOG LAMPS
Complete
8.24 HEADLAMP
Remove and Install: Single Headlamp
Disassemble
Assemble
Headlamp Repair
Remove and Install: Dual Headlamp
Remove: Center Cover
Install: Center Cover
Remove: Dual LED
Install: Dual LED
Remove: Fairing Models Lamps Bracket
Install: Fairing Models Lamps Bracket
Remove: Non-Fairing Models Lamps Bracket
Install: Non-Fairing Models Lamps Bracket
Remove: Dual LED Headlamp Housing
Install: Dual LED Headlamp Housing
Align
Dual LED Headlamps
Non-Fairing Models, Single Headlamps
Adjust
Dual LED Headlamps
Non-Fairing Models, Single Headlamp
8.25 AUXILIARY LAMPS
Bulb Replacement
Remove
Install
Prepare
Remove
Lamp Housing with Bracket
Lamp Housing
Install
Lamp Housing
Lamp Housing with Bracket
Adjust
Complete
8.26 LED TURN SIGNAL BULBS
Remove
Install
8.27 FRONT TURN SIGNAL LAMPS
Bulb Replacement
Bullet Style
Prepare
Remove and Install: Handlebar Mount
Remove
Install
Remove and Install: Light Bar Mount
Remove
Install
Remove and Install: Single Headlamp
Remove: Incandescent
Install: Incandescent
Remove: LED
Install: LED
Remove and Install: Dual Headlamp
Remove: LED Front Turn Signal Lamps
Install: LED Front Turn Signal Lamps
Complete
8.28 REAR TURN SIGNAL LAMPS
General
Bulb Replacement
Prepare
Bullet Style
Flat Lens Style
Tour-Pak Style
Remove and Install: Bullet Style
Remove
Install
Lamp Repair
Remove Lamps Bracket Assembly
Install Lamps Bracket Assembly
Remove and Install: Flat Lens Style
Lightbar Assembly
Turn Signal Lamp
Remove
Install
Complete
Bullet Style
Flat Lens Style
8.29 TAIL LAMP
Remove and Install: Standard
Prepare
Remove
Install
Complete
Standard Tail Lamp
Bullet Style Lights
Remove and Install: Trike
Prepare
Remove
Install
Complete
8.30 REVERSE LAMPS
Prepare
Remove
Tour-Pak models:
Non-Tour-Pak models:
Install
Tour-Pak models:
Non-Tour-Pak models:
Complete
8.31 REAR FENDER TIP LAMP
Prepare
Remove and Install: Fascia Lamp
Remove
Install
Complete
8.32 TOUR-PAK LIGHTING
Prepare
Remove and Install: Side Lamps/Trim Strips
Remove
Install
Remove and Install: Wrap-Around Lamp
Remove
Repair
Install
Complete
8.33 REAR STOPLAMP SWITCH
Remove and Install
Prepare
Remove
Install
Complete
Remove and Install
Prepare
Remove
Install
Complete
8.34 LICENSE PLATE LAMP
General
Prepare
Remove
Lamp (Tour-Pak Models)
License Plate Bracket (Tour-Pak Models)
License Plate Lamps/Bracket (HDI Non-Tour-Pak Models)
Install
Lamp (Tour-Pak Models)
License Plate Bracket (Tour-Pak Models)
Lamps/License Plate Bracket (HDI Non-Tour-Pak Models)
Complete
8.35 RADIO
Prepare
Remove and Install: Fork Mounted Fairing
Remove
Install
Remove and Install: Frame Mounted Fairing
Remove
Install
Complete
8.36 FRONT SPEAKERS
Prepare
Remove and Install: Fork Mounted Fairing
Remove
Install
Speaker Grille
Remove and Install: Fork Mounted Fairing
Remove
Install
Remove and Install: Frame Mounted Fairing
Speaker Grille
Speaker
Speaker Enclosure
Complete
8.37 REAR SPEAKERS
Prepare
Remove
Speaker Only
Speaker and Enclosure
Install
Speaker Only
Speaker and Enclosure
Disassemble
Assemble
Complete
8.38 PASSENGER AUDIO CONTROLS
General
8.39 RIDER HEADSET CONNECTOR
Prepare
Remove
Install
Complete
8.40 HIDDEN ANTENNA
Prepare
Remove
Frame Mounted Fairing
Fork Mounted Fairing
Install
Frame Mounted Fairing
Fork Mounted Fairing
Complete
8.41 GPS ANTENNA
Prepare
Remove
Install
Complete
8.42 ANTENNA CABLES
Prepare
Remove and Install: Main Cable
Remove
Install
Remove and Install: Cable Extension (Models With Tour-Pak)
Remove
Install
Remove and Install: Cable Extension (Models Without Tour-Pak)
Remove
Install
Complete
8.43 ELECTRONIC CONTROL MODULE (ECM)
Prepare
Remove
Install
Complete
8.44 BODY CONTROL MODULE (BCM)
Prepare
Remove
Install
Complete
8.45 REVERSE CONTROL SYSTEM
Remove and Install: Reverse Switch
Remove and Install: Reverse Control Module (RCM)
Remove
Install
Remove and Install: Reverse Solenoid
Remove
Install
Remove and Install: Reverse Circuit Breaker
Remove
Install
8.46 REVERSE SYSTEM ELECTRICAL CABLES
Vehicle Starter to Circuit Breaker
Remove
Install
Circuit Breaker to Reverse Solenoid
Remove
Install
Circuit Breaker to Reverse Motor
Remove
Install
Reverse Solenoid to Reverse Motor
Remove
Install
Reverse Motor to Battery Ground
Remove
Install
8.47 REVERSE MOTOR
Prepare
Remove
Install
Disassemble
Disassemble
Assemble
Assemble
Complete
8.48 SECURITY SYSTEM ACTIVATION
Activation
Fob Assignment
8.49 PERSONAL IDENTIFICATION NUMBER (PIN)
General
Changing the PIN
Modifying an Existing PIN
8.50 SECURITY SYSTEM MAINTENANCE
Service Mode
Transport Mode
To Enter Transport Mode
To Exit Transport Mode
Fob Battery
Battery Replacement Schedule
Battery Replacement
Security Siren Battery
Battery Replacement Schedule
Battery Replacement
8.51 SECURITY SIREN
Prepare
Remove
Install
Complete
8.52 SECURITY SYSTEM ANTENNA
Prepare
Remove
Install
Complete
8.53 COOLING FAN
Prepare
Remove
Install
Complete
8.54 AMBIENT AIR TEMPERATURE SENSOR
Remove
Install
8.55 CRANKSHAFT POSITION SENSOR (CKP)
Prepare
Remove
Install
Complete
8.56 ENGINE TEMPERATURE (ET) SENSOR
Prepare
Remove
Install
Complete
8.57 KNOCK SENSOR (KS)
Prepare
Remove
Install
Complete
8.58 AUTOMATIC COMPRESSION RELEASE (ACR)
Prepare
Remove
Install
Complete
8.59 VEHICLE SPEED SENSOR (VSS)
Prepare
Remove
Install
Complete
8.60 FRONT WHEEL SPEED SENSOR (WSS)
Prepare
Prepare
Remove
Remove
Install
Installation
Complete
Complete
8.61 REAR WHEEL SPEED SENSOR (WSS)
Remove and Install: Standard Fork
Prepare
Remove
Install
Complete
Remove and Install: Trike
Prepare
Remove
Install
Complete
8.62 INERTIAL MEASUREMENT UNIT (IMU)
Remove and Install: Two-Wheel
Prepare
Remove
Install
Complete
Remove and Install: Trike
Prepare
Remove
Install
Complete
8.63 JIFFY STAND SENSOR (JSS)
Prepare
Remove
Install
Complete
8.64 WIRE TROUGH
Prepare
Remove
Install
Complete
8.65 TOP CADDY
Prepare
Remove
Install
Complete
8.66 LEFT SIDE CADDY
Prepare
Remove
Install
Complete
8.67 RIGHT SIDE CADDY
Prepare
Remove
Install
Complete
8.68 LOWER BACKBONE CADDY
Prepare
Remove
Install
Complete
8.69 BATTERY TRAY
Remove and Install: Two-Wheel
Prepare
Remove
Install
Complete
Remove and Install: Trike
Prepare
Remove
Install
Complete
8.70 TOUR-PAK WIRE HARNESS
Prepare
Remove
Install
Complete
8.71 FAIRING WIRE HARNESS
Prepare
Remove and Install: Fork Mounted Fairing
Remove
Install
Remove and Install: Frame Mounted Fairing
Remove
Install
Complete
8.72 REAR LIGHTS HARNESS
Prepare
Remove and Install: Top Opening Trunk
Remove
Install
Remove and Install: Side Opening Trunk
Remove
Install
8.73 MAIN WIRE HARNESS
Prepare
Remove and Install: Fork Mounted Fairing
Remove
Install
Remove and Install: Frame Mounted Fairing
Remove
Install
Remove and Install: Without 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
TOOLS
Torque Values
Index
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