Harley Davidson Service Manual Softail 2007 (Part 1), harley
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11
21
I
MAINTENANCE
I
CHASSIS
31
2007
I
ENGINE
SOFTAIL
SERVICE
41
I
FUEL SYSTEM
MANUAL
51
I
ELECTRIC STARTER
The information in this Service Manual applies
to all 2007 Softail@models.
61
I
DRIVE
71
I
TRANSMISSION
©
2006
HARLEY-DAVIDSON MOTOR COMPANY
All RIGHTS RESERVED
PART NO. 99482-07
sl
Printed in the U.S.A.
I
ELECTRICAL
I
APPENDIX
I
I
VISIT THE HARLEY-DAVIDSON WEB SITE
I
INDEX
CMI- 5M -
03107
fl't1i;
r
•
l1E:.
••
 FOREWORD
GENERAL
PREPARATION FOR SERVICE
This Service Manual has been prepared with two purposes in
mind. First, it will acquaint the user with the construction of
the Harley-Davidson product and assist in the performance of
basic maintenance and repair. Secondly, it will introduce to
the professional Harley-Davidson Technician the latest field-
tested and factory-approved major repair methods. We sin-
cerely believe that this Service Manual will make your associ-
ation
AWARNING
Stop the engine when refueling or servicing the fuel sys-
tem. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
Good preparation is very important for efficient service work.
A clean work area at the start of each job will allow you to per-
form the repair as easily and quickly as possible, and will
reduce the incidence of misplaced tools and parts. A motorcy-
cle that is excessively dirty should be cleaned before work
starts. Cleaning will occasionally uncover sources of trouble.
Tools, instruments and any parts needed for the job should be
gathered before work is started. Interrupting a job to locate
tools or parts is a distraction and causes needless delay. See
APPENDIX A-TOOLS for equipment required for special ser-
vice work.
with
Harley-Davidson
products
more
pleasant
and
profitable.
HOW TO USE
YOUR SERVICE MANUAL
Information is arranged as follows:
•
Section 1-Maintenance
NOTE
•
Section 2-Ghassis
•
To avoid unnecessary disassembly, carefully read all rel-
ative service information before repair work
is
started.
•
Section 3-Engine
•
In figure legends, the number which follows the name of
a
part indicates the quantity necessary for one complete
assembly.
•
Section 4-Fuel System
•
Section 5-Electric Starter
SERVICE BULLETINS
•
Section 6-Drive
•
Section 7-Transmission
In addition to the information presented in this Service
Manual, Harley-Davidson Motor Company will periodically
issue Service Bulletins to Harley dealers. Service Bulletins
cover interim engineering changes and supplementary infor-
mation.
•
Section 8-Electrical
•
Appendix A-Tools
•
Appendix B-Wiring
USE GENUINE
REPLACEMENT PARTS
•
Appendix G-Metric Conversions
•
Appendix D-Glossary
Use the TABLE OF CONTENTS following this FOREWORD
or the INDEX at the back of the book to find the desired sub-
ject.
AWARNING
When replacement parts are required, use only genuine
Harley-Davidson parts or parts with equivalent character-
istics (which include type , strength and material). Failure
to do so may result in product malfunction. This could
result in death or serious injury.
To ensure satisfactory and lasting repairs, carefully follow the
Service Manual instructions and use only genuine Harley-
Davidson replacement parts. Behind the emblem bearing the
words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturing, testing and
inspecting experience. This is your assurance that the parts
you are using will fit right, operate properly and last longer
Note that each manual section contains sequentially num-
bered topics. The numbering system allows quick cross refer-
ences throughout the document.
For example, the sixth topic (BRAKES) in section one (MAIN-
TENANCE) could be referred to as:
1.6 BRAKES
This cross reference directs the reader to section 1
(MAINTENANCE) and topic 6 (BRAKES).
i.
 WARNINGS AND CAUTIONS
PRODUCT REFERENCES
Statements in this service manual preceded by the following
words are of special significance.
AWARNING
ADANGER
Follow the directions listed on all products. Carefully
read all labels, warnings and cautions before use. Inade-
quate safety precautions could result in death or serious
injury.
DANGER indicates an imminently hazardous situation
which, if
not
avoided, will result in
death
or
serious
injury.
When reference is made in this Service Manual to a specific
brand
AWARNING
name
product ,
tool
or
instrument,
an
equivalent
product , tool or instrument may be substituted.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury. (00119a)
Kent-Moore Products
ACAUTION
All tools mentioned in this manual with an "HD", "J" or "8 "
preface must be ordered through:
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. (00139a)
Kent-Moore
SPX Corporation
28635 Mound Road
Warren , Michigan USA 48092-3499
CAUTION
CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage (00140a)
Sealing and Threadlocking Products
LOCTITE PRODUCTS
AWARNING
•
Proper service and repair is important for the safe ,
reliable operation of all mechanical products. The
service procedures recommended and described in
this Service Manual are effective methods for per-
forming service operations. Some of these service
operations require the use of tools specially
designed for the purpose. These special tools should
be used when and as recommended. It is important
to note that some warnings against the use of spe-
cific service methods, which could damage the
motorcycle or render it unsafe, are stated in this Ser-
vice Manual. However, please remember that these
warnings are not all-inclusive. Inadequate safety pre-
cautions could result in death or serious injury.
Some procedures in this Serv ice Manual call for the use of
Loctite® products. If you have any questions regarding Loctite
product usage or retailer/wholesaler locations , please contact
Loctite Corp. at www.loctite.com.
CONTENTS
All photographs, illustrations and procedures may not neces-
sarily depict the most current model or component, but are
based on the latest production information available at the
time of publication.
•
Since Harley-Davidson could not possibly know,
evaluate or advise the service trade of all possible
ways in which service might be performed, or of the
possible hazardous consequences of each method,
we have not undertaken any such broad evaluation.
Accordingly, anyone who uses a service procedure
or tool which is not recommended by Harley-David-
son must first thoroughly satisfy himself that neither
his nor the operator's safety will be jeopardized as a
result. This could result in death or serious injury.
Since product improvement is our continual goal, Harley-
Davidson reserves the right to change specifications, equip-
ment or designs at any time without notice and without incur-
ring obligation .
•
Wear eye protection when using hammers, arbor or
hydraulic presses, gear pullers, spring compressors,
slide hammers and similar tools. Be especially cau-
tious when using pulling, pressing or compressing
equipment. The forces involved can cause parts to
fly outward with considerable force, possibly result-
ing in death or serious injury.
ii.
 TABLE OF CONTENTS
Page No.
Page No.
SECTION 1-MAINTENANCE
1-13
1-13
1-13
1-14
1-14
1-15
1-15
1-16
1-16
1-17
1-17
1-17
1-17
1.5 Battery Maintenance
.
General
.
Battery Electro lyte Antidotes (table)
.
1.1 General
.
1-1
1-1
1-1
1-1
1-1
1-1
1-1
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-4
1-4
1-4
1-4
1-4
1-4
1-4
Disconnection and Removal.
.
Servicing a New Motorcycle
.
Installation and Connect ion
.
Safe Operating Maintenance
..
Inspection
..
Shop Practices
.
Storage
..
Repair Notes
.
1.6 Brakes
.
Safety
.
Fluid Inspection
.
Remov ing Parts
.
Rear Brake Pedal
.
Cleaning
.
Pedal Height
.
Disassembly and Assembly
..
Pedal Lubricati on
.
Repair and Replacement Procedures
..
Pedal Pad
.
Hardware and Threaded Parts
..
Threadl ock ing Agents
..
1.7 Bleeding Brakes
..
1-18
1-18
1-18
Wiring, Hoses and Lines
..
General
.
Instruments and Gauges
..
Procedure
.
Bearings
.
Bushings
.
1.8 Brake Pads and Discs
..
1-19
1-19
1-19
1-19
1-19
1-20
1-20
1-22
Exhaust System Leakage
..
Inspecti on
.
Gaskets
.
Brake Pads
.
Lip Type Seals
.
Brake Disc Thickness
..
O-Rings (Prefo rmed Packings)
..
Brake Disc Lateral Runout and Warpage
:
Gears
.
Brake Pad Replaceme nt
.
Shafts
.
Rear Brake Caliper
..
Part Replacement
.
Front Brake Caliper: All But FLSTSC
..
Cleaning
.
Part Protectio n
.
1.9 Tires and Wheels
..
1-23
1-23
1-23
1-24
1-24
1-24
1-25
1-25
Cleaning Process
.
Tires
.
Rust or Corrosion Remova l
.
Tire Pressures (table)
.
Tool Safety
.
Tire Replacement
.
Air Tools
..
Whee l Bearings
.
Wrenches
..
Whee l Spokes
.
Pliers/Cutters/Prybars
.
1.10 Primary Chain
.
Hammers
.
Punches /Chisels
.
General
.
Screwdrivers
.
1.11 Primary Chaincase Lubricant
.
1-26
1-26
Ratchets and Hand les
..
Sockets
.
Chang ing Lubricant
.
Storage Units
.
1.12 CIutch
.
1-28
1-28
1-30
1-30
1.2 Fuel and Oil
.
1-5
1-5
1-5
1-5
1-5
1-6
1-6
1-11
1-11
1-11
1-11
1-11
1-12
Adjustment
.
Fuel
.
1.13 Transmission Lubricant
.
Gasoline Blends
.
Changing Lubricant
.
Engine Oil
.
Winter Lubrication
.
1.14 Rear Belt Deflection
.
1-31
1-31
1-31
1-32
1-33
1-33
1-33
1-33
1-33
1-33
1-34
1.3 Maintenance Schedule
.
Inspection
.
Rear Belt Deflection (Table)
..
First Schedu led Maintenance
..
Adjustment
..
1.4 Engine Oil and Filter
..
1.15 Rear Belt and Sprockets
.
Checking and Adding Oil
..
Genera l
..
Type of Oil
..
Cleaning
.
Checking Oil Level
.
Inspection
.
Recommended Oil Grades (table)
..
Sprockets
.
Changi ng Oil and Filter
.
Rear Belt
.
Drive Belt Wear Analysis (table)
..
1.16 Suspension Adjustments
1-35
Rear Shock Preload
1-35
iii
Page
No.
Page
No.
1.17 Steering Head Bearings: All But
FLSTSC
1.29 Troubleshooting
.
1-55
1-55
1-55
.
1-36
1-36
1-36
1-36
General
..
Engine
.
Adjustment
.
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 Tank ..
Engine Uses Too Much Oil Or Smokes Excessively
Engine Leaks Oil From Cases, Push Rods, Hoses
Low Oil Pressure
Bearing Adjustment (Fall-away)
..
1-55
1-55
1-55
1-55
1-56
1-56
1-56
1-56
1-56
1-56
1-56
1-56
1-56
1-56
1-57
1-57
1-57
1-57
1-57
1-57
1-57
1-57
1-57
1-57
1-57
1-57
1-58
1-58
1-58
1-58
Lubrication
.
1.18 Steering Head Bearings:
FLSTSC
.
1-37
1-37
1-37
1-37
1-38
General
..
Lubrication
.
Adjustment
.
Adjustment
.
1.19 Rocker Bearings: FLSTSC
.
1-39
1-39
1-41
1-41
1-43
1-43
1-44
1-44
1-45
Inspection
.
1.20 Front Fork Oil
.
Replacing Fork Oil.
.
.
1.21 Spark Plugs
.
High Oil Pressure
..
Inspection
.
Electrical System
.
Alternator Does Not Charge
..
1.22 Air Cleaner Filter
.
Alternat or Charge Rate Is Below Normal.
.
Removal
.
Speedometer Operates Erratically
..
Installation
..
Transmission
..
Shifts Hard
.-
..
1.23 Cable and Chassis Lubrication
General
1-46
1-46
1-46
1-46
Jumps Out Of Gear
.
.
Clutch Slips
.
Cables and Hand Levers
.
Clutch Drags Or Does Not Release
.
Jiffy Stand
.
Clutch Chatters
.
1.24 Throttle Cables
.
1-47
1-47
1-47
1-48
1-49
1-49
Handling
.
Irregularities
..
Cable Inspection, Lubrication and Adjustment..
..
Brakes
.
Inspection and Lubrication
.
Brake Does Not Hold Normally
.
Adjustment
..
1.25 Engine Mounts
.
SECTION 2-CHASSIS
Inspection
.
1.26 Headlamp Alignment 1-50
Inspection .................................................................. 1-50
Adjustment.. .................. 1-51
FLSTSC Models 1-51
FLSTC/FLSTF/FLSTN/FXST/FXSTB/FXSTC Models 1-51
FXSTD Models ......................................................
2-1
2-2
2-2
2-2
2-3
2-4
2.1 Specifications
.
Tires
..
Tire Fitment, Tubeless Cast Wheels (table)
.
Tire Fitment, Laced Wheels (table)
..
Tire Pressure, All Models (table)
.
1-51
2.2 Torque Values
.
1.27 Critical Fasteners
.
1-52
1-52
1-52
2.3 Vehicle Identification
Number (V.I.N.)
Inspection
.
Critical Fasteners (table)
.
.
2-7
2-7
General
..
1.28 Storage
.
1-53
1-53
1-54
General
..
2.4 Front Wheel: All But
FLSTSCIFXSTD
Removal From Storage
.
.
2-9
2-9
2-9
2-9
2-9
2-11
2-11
2-11
2-11
2-11
Removal
.
Disassembly
.
Disc Wheel.
..
Laced Wheel
.
Cleaning and Inspection
.
Assemb ly
.
Disc Wheel
.
Laced Wheel
.
Installation
.
iv
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