Harley Davidson Service Manual Touring Models 2006, harley
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2006 TOURING MODELS
SERVICE MANUAL
ELECTRICAL DIAGNOSTICS
Part Number 99483-06
Part Number 99497-06
Section 1: Maintenance
Section 2: Chassis
Section 3: Engine
Section 4: Fuel System
Section 5: Starter
Section 6: Drive
Section 7: Transmission
Section 8: Electrical
Section 9: Fuel Injection
Appendix
Section 1: Starting & Charging
Section 2: Instruments
Section 3: TSM & TSSM
Section 4: Engine Management
Section 5: Engine Management (EFI)
Section 6: Sound System
Section 7: Cruise Control
Section 8: Wiring
FLHTCUSE SERVICE SUPPLEMENT
Part Number 99500-06
Section 1: Maintenance
Section 2: Chassis
Section 3: Engine
Section 4: Fuel System
Section 5: Starter
Section 6: Drive
Section 7: Transmission
Section 8: Electrical
Section 9: Fuel Injection (No content)
Appendix
MAINTENANCE
1
Table Of Contents
SUBJECT
PAGE NO.
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3 Engine Oil/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.4 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.6 Wheel Spokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.7 Primary Chain/Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.8 Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.9 Transmission Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.10 Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.11 Throttle Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.12 Enrichener Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.13 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.14 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
1.15 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
1.16 Engine Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
1.17 Front Fork Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
1.18 Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
1.19 Critical Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
1.20 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
1.21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
-2
HOME
GENERAL
1.1
REPAIR NOTES
Disassembly and Assembly
General maintenance practices are given in this section. All
special tools and torque values are noted at the point of use
and all required parts or materials can be found in the appro-
priate PARTS CATALOG.
Always assemble or disassemble one part at a time. Do not
work on two assemblies simultaneously. Be sure to make all
necessary adjustments. Recheck your work when finished.
Be sure that everything is done.
Safety
Operate the motorcycle to perform any final check or adjust-
ments. If all is correct, the motorcycle is ready to go back to
the customer.
Safety is always the most important consideration when per-
forming any job. Be sure you have a complete understanding
of the task to be performed. Use common sense. Use the
proper tools. Don’t just do the job – do the job safely.
Checking Torques on Fasteners with Lock
Patches
To check the torque on a fastener that has a lock patch:
Removing Parts
1. Set the torque wrench for the lowest setting in the speci-
fied torque range.
Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. A hoist
and adjustable lifting beam or sling are needed to remove
some parts. The lengths of chains or cables from the hoist to
the part should be equal and parallel, and should be posi-
tioned directly over the center of the part. Be sure that no
obstructions will interfere with the lifting operation. Never
leave a part suspended in mid-air.
2. Attempt to tighten fastener to set torque. If fastener does
not move and lowest setting is satisfied (torque wrench
clicks), then the proper torque has been maintained.
REPAIR AND REPLACEMENT
Always use blocking or proper stands to support the part that
has been hoisted. If a part cannot be removed, verify that all
bolts and attaching hardware have been removed. Check to
see if any parts are in the way of the part being removed.
PROCEDURES
Hardware and Threaded Parts
When removing hoses, wiring or tubes, always tag each part
to ensure proper installation.
Install helical thread inserts when inside threads in castings
are stripped, damaged or not capable of withstanding speci-
fied torque.
Cleaning
Replace bolts, nuts, studs, washers, spacers and small com-
mon hardware if missing or in any way damaged. Clean up or
repair minor thread damage with a suitable tap or die.
If you intend to reuse parts, follow good shop practice and
thoroughly clean the parts before assembly. Keep all dirt out
of parts; the unit will perform better and last longer. Seals, fil-
ters and covers are used in this motorcycle to keep out envi-
ronmental dirt and dust. These items must be kept in good
condition to ensure satisfactory operation.
Replace all damaged or missing lubrication fittings.
Use Teflon tape on pipe fitting threads.
Clean and inspect all parts as they are removed. Be sure all
holes and passages are clean and open. After cleaning,
cover all parts with clean lint-free cloth, paper or other mate-
rial. Be sure the part is clean when it is installed.
Wiring, Hoses and Lines
Replace hoses, clamps, electrical wiring, electrical switches
or fuel lines if they do not meet specifications.
Always clean around lines or covers before they are
removed. Plug, tape or cap holes and openings to keep out
dirt, dust and debris.
Instruments and Gauges
Always verify cleanliness of blind holes before assembly.
Tightening screws with dirt, water or oil in the holes can
cause castings to crack or break.
Replace broken or defective instruments and gauges.
Replace dials and glass that are so scratched or discolored
that reading is difficult.
HOME
Bearings
Seals should not be removed unless necessary. Only remove
seals if required to gain access to other parts or if seal dam-
age or wear dictates replacement.
Leaking oil or grease usually means that a seal is damaged.
Replace leaking seals to prevent overheated bearings.
Always discard seals after removal. Do not use the same
seal twice.
Anti-friction bearings must be handled in a special way. To
keep out dirt and abrasives, cover the bearings as soon as
they are removed from the package.
Wash bearings in a non-flammable cleaning solution. Knock
out packed lubricant inside by tapping the bearing against a
wooden block. Wash bearings again. Cover bearings with
clean material after setting them down to dry. Never use com-
pressed air to dry bearings.
O-Rings (Preformed Packings)
Coat bearings with clean oil. Wrap bearings in clean paper.
Always discard O-rings after removal. Replace with new O-
rings. To prevent leaks, lubricate the O-rings before installa-
tion. Apply the same type of lubricant as that being sealed.
Be sure that all gasket, O-ring and seal mating surfaces are
thoroughly clean before installation.
Be sure that the chamfered side of the bearing always faces
the shoulder (when bearings installed against shoulders).
Lubricate bearings and all metal contact surfaces before
pressing into place. Only apply pressure on the part of the
bearing that makes direct contact with the mating part.
Gears
Always use the proper tools and fixtures for removing and
installing bearings.
Always check gears for damaged or worn teeth.
Remove burrs and rough spots with a honing stone or crocus
cloth before installation. Lubricate mating surfaces before
pressing gears on shafts.
Bearings do not usually need to be removed. Only remove
bearings if necessary.
Bushings
Shafts
Do not remove a bushing unless damaged, excessively worn
or loose in its bore. Press out bushings that must be
replaced.
If a shaft does not come out easily, check that all nuts, bolts
or retaining rings have been removed. Check to see if other
parts are in the way before using force.
When pressing or driving bushings, be sure to apply pres-
sure in line with the bushing bore. Use a bearing/bushing
driver or a bar with a smooth, flat end. Never use a hammer
to drive bushings.
Shafts fitted to tapered splines should be very tight. If shafts
are not tight, disassemble and inspect tapered splines. Dis-
card parts that are worn. Be sure tapered splines are clean,
dry and free of burrs before putting them in place. Press mat-
ing parts together tightly.
Clean all rust from the machined surfaces of new parts.
Inspect the bushing and the mated part for oil holes. Be sure
all oil holes are properly aligned.
Part Replacement
Gaskets
Always replace worn or damaged parts with new parts.
Always discard gaskets after removal. Replace with new gas-
kets. Never use the same gasket twice (unless instructed
otherwise). Be sure that gasket holes match up with holes in
the mating part.
CLEANING
If a gasket must be made, be sure to cut holes that match up
with the mating part. Serious damage can occur if any flange
holes are blocked by the gasket. Use material that is the right
type and thickness.
Part Protection
Before cleaning, protect rubber parts (such as hoses, boots
and electrical insulation) from cleaning solutions. Use a
grease-proof barrier material. Remove the rubber part if it
cannot be properly protected.
Lip Type Seals
Cleaning Process
Lip seals are used to seal oil or grease and are usually
installed with the sealing lip facing the contained lubricant.
Seal orientation, however, may vary under different applica-
tions.
Any cleaning method may be used as long as it does not
result in parts damage. Thorough cleaning is necessary for
proper parts inspection. Strip rusted paint areas to bare
metal before repainting.
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