service repair manual

2. Chapter One
1 General Information
Chapter Two
2 Troubleshooting
Chapter Three
3 Periodic Lubrication, Maintenance & Tune-up
Chapter Four
4 Engine
Chapter Five
5 Clutch and Primary Drive
Chapter Six
6 Transmission
Chapter Seven
7 Fuel, Exhaust & Emission Control Systems
Chapter Eight
8 Electrical System
Chapter Nine
9 Wheels, Hubs & Tires
Chapter Ten
10 Front Suspension & Steering (Models with Telescopic Front Forks)
Chapter Eleven
11 Front Suspension & Steering (Springer Front Fork)
Chapter Twelve
12 Rear Suspension
Chapter Thirteen
13 Brakes
Chapter Fourteen
14 Body
Chapter Fifteen
15 Supplement
Chapter Sixteen
16 Index
Chapter Seventeen
17 Wiring Diagrams

3. CHAPTER ONE
GENERAL INFORMATION
This detailed and comprehensive manual covers the
Harley-Davidson FLST and FXST Softail Series of mo-
torcycles equipped with the Twin Cam 88B, 95B and
103B engines.
The text provides complete information on mainte-
nance, tune-up, repair and overhaul. Hundreds of original
photographs and illustrations created during the complete
disassembly of the motorcycle guide the reader through
every job. All procedures are in step-by-step form and de-
signed for the reader who may be working on the motor-
cycle for the first time.
MANUAL ORGANIZATION
A shop manual is a tool and as in all service manuals,
the chapters are thumb tabbed for easy reference. Main
headings are listed in the table of contents and the index.
Frequently used specifications and capacities from the ta-
bles at the end of each individual chapter are listed in the
Quick Reference Data section at the front of the manual.
Specifications and capacities are provided in U.S. stan-
dard and metric units of measure.
During some of the procedures there will be refer-
ences to headings in other chapters or sections of the man-
ual. When a specific heading is called out it in a step it will
be italicized as it appears in the manual. If a sub-heading
is indicated as being “in this section” it is located within
the same main heading. For example, the sub-heading
Handling Gasoline Safely is located within the main
heading SAFETY.
This chapter provides general information on shop
safety, tools and their usage, service fundamentals and
shop supplies. Tables 1-12, at the end of the chapter, list
the following:
Table 1 lists model designation.
Table 2 lists general dimensions.
Table 3 lists motorcycle weight.
Table 4 lists motorcycle weight ratings.
Table 5 lists fuel tank capacity.
Table 6 lists decimal and metric equivalents.
Table 7 lists general torque specifications.
Table 8 lists conversion formulas.
Table 9 lists technical abbreviations.
Table 10 lists American tap and drill sizes.
Table 11 lists Metric tap and drill sizes.
Table 12 lists special tools and their part numbers.
Chapter Two provides methods for quick and accurate
diagnosis of problems. Troubleshooting procedures pres-
1
NOTE: Refer to the Supplement
at the back of this manual for
information unique to 2004-2005
models, including
Screamin’
Eagle models.

4. ent typical symptoms and logical methods to pinpoint and
repair the problem.
Chapter Three explains all routine maintenance neces-
sary to keep the motorcycle running well. Chapter Three
also includes recommended tune-up procedures, eliminat-
ing the need to constantly consult other chapters on the
various assemblies.
Subsequent chapters describe specific systems such as
engine, transmission, clutch, drive system, fuel and ex-
haust systems, suspension and brakes. Each disassembly,
repair and assembly procedure is given in step-by-step
form.
WARNINGS, CAUTIONS AND NOTES
The terms, WARNING, CAUTION and NOTE have
specific meanings in this manual.
A WARNING emphasizes areas where injury or even
death could result from negligence. Mechanical damage
may also occur. WARNINGS are to be taken seriously.
A CAUTION emphasizes areas where equipment dam-
age could occur. Disregarding a CAUTION could cause
permanent mechanical damage, though injury is unlikely.
ANOTE provides additional information to make a step
or procedure easier or clearer. Disregarding a NOTE
could cause inconvenience, but would not cause equip-
ment damage or personal injury.
SAFETY
Professional mechanics can work for years and never
sustain a serious injury or mishap. Follow these guide-
lines and practice common sense to safely service the mo-
torcycle.
1. Do not operate the motorcycle in an enclosed area. The
exhaust gasses contain carbon monoxide, an odorless,
colorless and tasteless poisonous gas. Carbon monoxide
levels build quickly in small enclosed areas and can cause
unconsciousness and death in a short time. Make sure the
work area is properly ventilated or operate the motorcycle
outside.
2. Never use gasoline or extremely flammable liquid to
clean parts. Refer to Cleaning Parts and Handling Gaso-
line Safely in this chapter.
3. Never smoke or use a torch in the vicinity of flamma-
ble liquids, such as gasoline or cleaning solvent.
4. Before welding or brazing on the motorcycle, remove
the fuel tank, carburetor and shocks to a safe distance at
least 50 ft. (15 m) away.
5. Use the correct type and size of tools to avoid damag-
ing fasteners.
6. Keep tools clean and in good condition. Replace or re-
pair worn or damaged equipment.
7. When loosening a tight fastener, be guided by what
would happen if the tool slips.
8. When replacing fasteners, make sure the new fasteners
are the same size and strength as the original ones.
9. Keep the work area clean and organized.
10. Wear eye protection anytime the safety of the eyes is
in question. This includes procedures involving drilling,
grinding, hammering, compressed air and chemicals.
11. Wear the correct clothing for the job. Tie up or cover
long hair so it can not get caught in moving equipment.
12. Do not carry sharp tools in clothing pockets.
13. Always have an approved fire extinguisher available.
Make sure it is rated for gasoline (Class B) and electrical
(Class C) fires.
14. Do not use compressed air to clean clothes, the mo-
torcycle or the work area. Debris may be blown into the
eyes or skin. Never direct compressed air at anyone. Do
not allow children to use or play with any compressed air
equipment.
15. When using compressed air to dry rotating parts, hold
the part so it cannot rotate. Do not allow the force of the air
to spin the part. The air jet is capable of rotating parts at
extreme speed. The part may be damaged or disintegrate
and cause serious injury.
16. Do not inhale the dust created by brake pad and clutch
wear. These particles may contain asbestos. In addition,
some types of insulating materials and gaskets may con-
tain asbestos. Inhaling asbestos particles is hazardous to
health.
17. Never work on the motorcycle while someone is
working under it.
18. When placing the motorcycle on a stand, make sure it
is secure before walking away.
Handling Gasoline Safely
Gasoline is a volatile flammable liquid and is one of the
most dangerous items in the shop. Because gasoline is
used so often, many people forget that it is hazardous.
Only use gasoline as fuel for gasoline internal combustion
engines. When working on a motorcycle, keep in mind
that gasoline is always present in the fuel tank, fuel line
and carburetor. To avoid a disastrous accident when work-
ing around the fuel system, carefully observe the follow-
ing precautions:
1. Never use gasoline to clean parts. See Parts Cleaning
in this section.
2. When working on the fuel system, work outside or in a
well-ventilated area.
2 CHAPTER ONE

5. 3. Do not add fuel to the fuel tank or service the fuel sys-
tem while the motorcycle is near open flames, sparks or
where someone is smoking. Gasoline vapor is heavier
than air, it collects in low areas and is more easily ignited
than liquid gasoline.
4. Allow the engine to cool completely before working
on any fuel system component.
5. When draining the carburetor, catch the fuel in a plas-
tic container and pour it into an approved gasoline storage
devise.
6. Do not store gasoline in glass containers. If the glass
breaks, a serious explosion or fire may occur.
7. Immediately wipe up spilled gasoline with rags. Store
the rags in a metal container with a lid until they can be
properly disposed of, or place them outside in a safe place
for the fuel to evaporate.
8. Do not pour water onto a gasoline fire. Water spreads
the fire and makes it more difficult to put out. Use a class
B, BC or ABC fire extinguisher to extinguish the fire.
9. Always turn off the engine before refueling. Do not
spill fuel onto the engine or exhaust system. Do not over-
fill the fuel tank. Leave an air space at the top of the tank
to allow room for the fuel to expand due to temperature
fluctuations.
Parts Cleaning
Cleaning parts is one of the more tedious and difficult
service jobs performed in the home garage. There are
many types of chemical cleaners and solvents available
for shop use. Most are poisonous and extremely flamma-
ble. To prevent chemical exposure, vapor buildup, fire and
serious injury, note the following:
1. Read and observe the entire product label before using
any chemical. Always know what type of chemical is be-
ing used and whether it is poisonous and/or flammable.
2. Do not use more than one type of cleaning solvent at a
time. When mixing chemicals, measure the proper
amounts according to the manufacturer.
3. Work in a well-ventilated area.
4. Wear chemical-resistant gloves.
5. Wear safety glasses.
6. Wear a vapor respirator if the instructions call for it.
7. Wash hands and arms thoroughly after cleaning parts.
8. Keep chemical products away from children and pets.
9. Thoroughly clean all oil, grease and cleaner residue
from any part that must be heated.
10. Use a nylon brush when cleaning parts. Metal brushes
may cause a spark.
11. When using a parts washer, only use the solvent rec-
ommended by the manufacturer. Make sure the parts
washer is equipped with a metal lid that will lower in case
of fire.
Warning Labels
Most manufacturers attach information and warning la-
bels to the motorcycle. These labels contain instructions
that are important to personal safety when operating, ser-
vicing, transporting and storing the motorcycle. Refer to
the owner’s manual for the description and location of la-
bels. Order replacement labels from the manufacturer if
they are missing or damaged.
SERIAL NUMBERS
Serial numbers are stamped on various locations on the
frame, engine, transmission and carburetor. Record these
numbers in the Quick Reference Data section in the front
of the manual. Have these numbers available when order-
ing parts.
The frame serial number (Figure 1) is stamped on the
right side of the frame down tube.
The VIN number label (Figure 2) is located just below
the frame number on the right side frame down tube.
The engine serial number is stamped on a pad on the left
side of the crankcase (Figure 3) and the right side of the
crankcase (Figure 4).
The transmission serial number (Figure 5) is stamped
on a pad on the right side of the transmission case next to
the side door.
The carburetor serial number (Figure 6) is located on
the side of the carburetor body next to the accelerator
pump linkage. There is no serial number for the fuel injec-
tion module.
Table 1 lists model designation.
GENERAL INFORMATION 3 1
1

6. FASTENERS
Proper fastener selection and installation is important to
ensure the motorcycle operates as designed and can be
serviced efficiently. The choice of original equipment fas-
teners is not arrived at by chance. Make sure that replace-
ment fasteners meet all the same requirements as the
originals.
Threaded Fasteners
Threaded fasteners secure most of the components on
the motorcycle. Most are tightened by turning them clock-
wise (right-hand threads). If the normal rotation of the
component being tightened would loosen the fastener, it
may have left-hand threads. If a left-hand threaded fas-
tener is used, it is noted in the text.
Two dimensions are required to match the threads of the
fastener: the number of threads in a given distance and the
outside diameter of the threads.
CAUTION
There are a variety of Metric and American
fasteners used on the engine and chassis.
Do not interchange fasteners of the incor-
rect type as the component along with the
fastener may be damaged.
Two systems are currently used to specify threaded fas-
tener dimensions: the U.S. Standard system and the metric
system (Figure 7). Pay particular attention when working
with unidentified fasteners; mismatching thread types can
damage threads.
NOTE
To ensure the fastener threads are not mis-
matched or cross-threaded, start all fasten-
ers by hand. If a fastener is hard to start or
turn, determine the cause before tightening
with a wrench.
The length (L, Figure 8), diameter (D) and distance be-
tween thread crests (pitch) (T) classify metric screws and
bolts. A typical bolt may be identified by the numbers,
8—1.25 × 130. This indicates the bolt has diameter of 8 mm,
the distance between thread crests is 1.25 mm and the length
is 130 mm. Always measure bolt length as shown in Figure
8 to avoid purchasing replacements of the wrong length.
If a number is located on the top of the fastener, (Figure 8)
this indicates the strength of the fastener. The higher the
number, the stronger the fastener. Generally, unnumbered
fasteners are the weakest.
Many screws, bolts and studs are combined with nuts to
secure particular components. To indicate the size of a
4 CHAPTER ONE
3
4
5
2

7. nut, manufacturers specify the internal diameter and the
thread pitch.
The measurement across two flats on a nut or bolt indi-
cates the wrench size.
WARNING
Do not install fasteners with a strength clas-
sification lower than what was originally in-
stalled by the manufacturer. Doing so may
cause equipment failure and/or damage.
Torque Specifications
The materials used in the manufacture of the motorcy-
cle may be subjected to uneven stresses if the fasteners of
the various subassemblies are not installed and tightened
correctly. Fasteners that are improperly installed or work
loose can cause extensive damage. It is essential to use an
accurate torque wrench, described in this chapter, with the
torque specifications in this manual.
Specifications for torque are provided in Newton-me-
ters (N•m), foot-pounds (ft.-lb.) and inch-pounds (in.-lb.).
Refer to Table 7 for general torque specifications. To use
Table 7, first determine the size of the fastener as de-
scribed in Threaded Fasteners in this section. Torque
specifications for specific components are at the end of
the appropriate chapters. Torque wrenches are covered in
the Basic Tools section.
Self-Locking Fasteners
Several types of bolts, screws and nuts incorporate a
system that creates interference between the two fasten-
ers. Interference is achieved in various ways. The most
common type is the nylon insert nut and a dry adhesive
coating on the threads of a bolt.
Self-locking fasteners offer greater holding strength
than standard fasteners, which improves their resistance
to vibration. Most self-locking fasteners cannot be reused.
The materials used to form the lock become distorted after
the initial installation and removal. It is a good practice to
discard and replace self-locking fasteners after their re-
moval. Do not replace self-locking fasteners with stan-
dard fasteners.
Washers
There are two basic types of washers: flat washers and
lockwashers. Flat washers are simple discs with a hole to
fit a screw or bolt. Lockwashers are used to prevent a fas-
tener from working loose. Washers can be used as spacers
and seals, or to help distribute fastener load and to prevent
the fastener from damaging the component.
As with fasteners, when replacing washers, make sure
the replacement washers are of the same design and qual-
ity.
GENERAL INFORMATION 5 1
7
8
U.S. Standard Metric
60° 60°
Grade marking
T
-9.8 D
L
6

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9. Cotter Pins
A cotter pin is a split metal pin inserted into a hole or
slot to prevent a fastener from loosening. In certain appli-
cations, such as the rear axle on an ATV or motorcycle, the
fastener must be secured in this way. For these applica-
tions, a cotter pin and castellated (slotted) nut is used.
To use a cotter pin, first make sure the diameter is cor-
rect for the hole in the fastener. After correctly tightening
the fastener and aligning the holes, insert the cotter pin
through the hole and bend the ends over the fastener (Fig-
ure 9). Unless instructed to do so, never loosen a torqued
fastener to align the holes. If the holes do not align, tighten
the fastener just enough to achieve alignment.
Cotter pins are available in various diameters and
lengths. Measure length from the bottom of the head to the
tip of the shortest pin.
Snap Rings and E-clips
Snap rings (Figure 10) are circular-shaped metal re-
taining clips. They are required to secure parts and gears
in place on parts such as shafts, pins or rods. External type
snap rings are used to retain items on shafts. Internal type
snap rings secure parts within housing bores. In some ap-
plications, in addition to securing the component(s), snap
rings of varying thickness also determine endplay. These
are usually called selective snap rings.
Two basic types of snap rings are used: machined and
stamped snap rings. Machined snap rings (Figure 11) can
be installed in either direction, since both faces have sharp
edges. Stamped snap rings (Figure 12) are manufactured
with a sharp edge and a round edge. When installing a
stamped snap ring in a thrust application, install the sharp
edge facing away from the part producing the thrust.
Remove E-clips with a flat blade screwdriver by prying
between the shaft and E-clip. To install an E-clip, center it
over the shaft groove and push or tap it into place.
Observe the following when installing snap rings:
1. Remove and install snap rings with snap ring pliers.
See Snap Ring Pliers in this chapter.
2. In some applications, it may be necessary to replace
snap rings after removing them.
3. Compress or expand snap rings only enough to install
them. If overly expanded, they lose their retaining ability.
4. After installing a snap ring, make sure it seats com-
pletely.
5. Wear eye protection when removing and installing
snap rings.
SHOP SUPPLIES
Lubricants and Fluids
Periodic lubrication helps ensure a long service life for
any type of equipment. Using the correct type of lubricant
is as important as performing the lubrication service, al-
though in an emergency the wrong type is better than
none. The following section describes the types of lubri-
cants most often required. Make sure to follow the manu-
facturer’s recommendations for lubricant types.
6 CHAPTER ONE
9
10
Internal snap ring Plain circlip
Correct installation
of cotter pin
External snap ring E-clip

10. Engine oils
Engine oil is classified by two standards: the American
Petroleum Institute (API) service classification and the
Society of Automotive Engineers (SAE) viscosity rating.
This information is on the oil container label. Two letters
indicate the API service classification. The number or se-
quence of numbers and letter (10W-40 for example) is the
oil’s viscosity rating. The API service classification and
the SAE viscosity index are not indications of oil quality.
The service classification indicates that the oil meets
specific lubrication standards. The first letter in the classi-
fication (S) indicates that the oil is for gasoline engines.
The second letter indicates the standard the oil satisfies.
Always use an oil with a classification recommended
by the manufacturer. Using an oil with a different classifi-
cation can cause engine damage.
Viscosity is an indication of the oil’s thickness. Thin
oils have a lower number while thick oils have a higher
number. Engine oils fall into the 5- to 50-weight range for
single-grade oils.
Most manufacturers recommend multigrade oil. These
oils perform efficiently across a wide range of operating
conditions. Multigrade oils are identified by a (W) after
the first number, which indicates the low-temperature vis-
cosity.
Engine oils are most commonly mineral (petroleum)
based; however, synthetic and semi-synthetic types are
used more frequently. When selecting engine oil, follow
the manufacturer’s recommendation for type, classifica-
tion and viscosity.
Greases
Grease is lubricating oil with thickening agents added
to it. The National Lubricating Grease Institute (NLGI)
grades grease. Grades range from No. 000 to No. 6, with
No. 6 being the thickest. Typical multipurpose grease is
NLGI No. 2. For specific applications, manufacturers
may recommend water-resistant type grease or one with
an additive such as molybdenum disulfide (MoS2).
Brake fluid
Brake fluid is the hydraulic fluid used to transmit hy-
draulic pressure (force) to the wheel brakes. Brake fluid is
classified by the Department of Transportation (DOT).
Current designations for brake fluid are DOT 3, DOT 4
and DOT 5. This classification appears on the fluid con-
tainer.
Each type of brake fluid has its own definite character-
istics. The Harley-Davidson Softail uses the silicone
based DOT 5 brake fluid. Do not intermix DOT 3 or DOT
4 with DOT 5 type brake fluid as this may cause brake
system failure since the DOT 5 brake fluid is not compati-
ble with other brake fluids. When adding brake fluid, only
use the fluid recommended by the manufacturer.
Brake fluid will damage any plastic, painted or plated
surface it contacts. Use extreme care when working with
brake fluid and clean up spills immediately with soap and
water.
Hydraulic brake systems require clean and moisture-
free brake fluid. Never reuse brake fluid. Keep containers
and reservoirs properly sealed.
WARNING
Never put a mineral-based (petroleum) oil
into the brake system. Mineral oil will cause
rubber parts in the system to swell and
GENERAL INFORMATION 7 1
11
12
Rounded edges
Sharp edges
Full support
areas
Directions
of thrust
Direction of thrust

11. break apart, resulting in complete brake
failure.
Cleaners, Degreasers and Solvents
Many chemicals are available to remove oil, grease and
other residue from the motorcycle. Before using cleaning
solvents, consider how they will be used and disposed of,
particularly if they are not water-soluble. Local ordi-
nances may require special procedures for the disposal of
many types of cleaning chemicals. Refer to Safety and
Parts Cleaning in this chapter for more information on
their use.
To clean brake system components, use brake parts
cleaner. Petroleum-based products will damage brake sys-
tem seals. Brake parts cleaner leaves no residue. Use elec-
trical contact cleaner to clean electrical connections and
components without leaving any residue. Carburetor
cleaner is a powerful solvent used to remove fuel deposits
and varnish from fuel system components. Use this
cleaner carefully, as it may damage finishes.
Generally, degreasers are strong cleaners used to re-
move heavy accumulations of grease from engine and
frame components.
Most solvents are designed to be used in a parts wash-
ing cabinet for individual component cleaning. For safety,
use only nonflammable or high flash point solvents.
Gasket Sealant
Sealants are used with a gasket or seal and are occasion-
ally used alone. Follow the manufacturer’s recommenda-
tion when using sealants. Use extreme care when
choosing a sealant different from the type originally rec-
ommended. Choose sealants based on their resistance to
heat and various fluids, and their sealing capabilities.
One of the most common sealants is RTV, or room tem-
perature vulcanizing sealant. This sealant cures at room
temperature over a specific time period. This allows the
repositioning of components without damaging gaskets.
Moisture in the air causes the RTV sealant to cure. Al-
ways install the tube cap as soon as possible after applying
RTV sealant. RTV sealant has a limited shelf life and will
not cure properly if the shelf life has expired. Keep partial
tubes sealed and discard them if they have surpassed the
expiration date.
Applying RTV sealant
Clean all old gasket residue from the mating surfaces.
Remove all gasket material from blind threaded holes; it
can cause inaccurate bolt torque. Spray the mating sur-
faces with aerosol parts cleaner and wipe with a lint-free
cloth. The area must be clean for the sealant to adhere.
Apply RTV sealant in a continuous bead 2-3 mm
(0.08-0.12 in.) thick. Circle all the fastener holes unless
otherwise specified. Do not allow any sealant to enter
these holes. Assemble and tighten the fasteners to the
specified torque within the time frame recommended by
the RTV sealant manufacturer.
Gasket Remover
Aerosol gasket remover can help remove stubborn gas-
kets. This product can speed up the removal process and
prevent damage to the mating surface that may be caused
by using a scraping tool. Most of these types of products
are very caustic. Follow the gasket remover manufac-
turer’s instructions for use.
Threadlocking Compound
Athreadlocking compound is a fluid applied to the threads
of fasteners. After the fastener is tightened, the fluid dries
and becomes a solid filler between the threads. This makes it
difficult for the fastener to work loose from vibration, or heat
expansion and contraction. Some threadlocking compounds
also provide a seal against fluid leakage.
Before applying threadlocking compound, remove any
old compound from both thread areas and clean them with
aerosol parts cleaner. Use the compound sparingly. Ex-
cess fluid can run into adjoining parts.
Threadlocking compounds are available in different
strengths. Follow the particular manufacturer’s recommen-
dations regarding compound selection. Anumber of manu-
facturers offer a wide range of threadlocking compounds
for various strength, temperature and repair applications.
8 CHAPTER ONE
13

12. BASIC TOOLS
Most of the procedures in this manual can be carried out
with simple hand tools and test equipment familiar to the
home mechanic. Always use the correct tools for the job at
hand. Keep tools organized and clean. Store them in a tool
chest with related tools organized together.
Some of the procedures in this manual specify special
tools. In most cases, the tool is illustrated in use.
Well-equipped mechanics may be able to substitute simi-
lar tools or fabricate a suitable replacement. In some
cases, specialized equipment or expertise may make it im-
practical for the home mechanic to attempt the procedure.
Such operations are identified in the text with the recom-
mendation to have a dealership or specialist perform the
task. It may be less expensive to have a professional per-
form these jobs, especially when considering the cost of
the equipment.
Quality tools are essential. The best are constructed of
high-strength alloy steel. These tools are light, easy to use
and resistant to wear. Their working surface is devoid of
sharp edges and the tool is carefully polished. They have
an easy-to-clean finish and are comfortable to use. Qual-
ity tools are a good investment.
When purchasing tools to perform the procedures cov-
ered in this manual, consider the tool’s potential frequency
of use. If starting a tool kit, consider purchasing a basic tool
set (Figure 13) from a large tool supplier. These sets are
available in many tool combinations and offer substantial
savings when compared to individually purchased tools.
As work experience grows and tasks become more compli-
cated, specialized tools can be added.
The models covered in this manual use both U.S. Stan-
dard and metric fasteners. Make sure the correct type of
tool is used.
Screwdrivers
Screwdrivers of various lengths and types are manda-
tory for the simplest tool kit. The two basic types are the
slotted tip (flat blade) and the Phillips tip. These are avail-
able in sets that often include an assortment of tip sizes
and shaft lengths.
As with all tools, use a screwdriver designed for the job.
Make sure the size of the tip conforms to the size and
shape of the fastener. Use them only for driving screws.
Never use a screwdriver for prying or chiseling metal. Re-
pair or replace worn or damaged screwdrivers. A worn tip
may damage the fastener, making it difficult to remove.
Torx Drivers
Many of the components on the Harley-Davidson models
covered in this manual are secured with internal Torx fasten-
ers. These fasteners require specific Torx drivers for removal
and installation. These fasteners reduce cam-out and fastener
damage, and allow high torque transmission due to the com-
plete enclosure of the driver within the fastener.
Torx screwdrivers in individual sizes, or screwdrivers that
accept various bit sizes are available. However, the most
practical application is a Torx bit set that accepts various
drive types and sizes. A typical set contains T-10 through
T40 bits that accept 1/4 and 3/8 in. drive attachments.
Wrenches
Open-end, box-end and combination wrenches (Figure
14) are available in a variety of types and sizes.
The number stamped on the wrench refers to the dis-
tance between the work areas. This size must match the
size of the fastener head.
The box-end wrench is an excellent tool because it grips
the fastener on all sides. This reduces the chance of the
tool slipping. The box-end wrench is designed with either
a 6- or 12-point opening. For stubborn or damaged fasten-
ers, the 6-point provides superior holding ability by con-
tacting the fastener across a wider area at all six edges. For
general use, the 12-point works well. It allows the wrench
to be removed and reinstalled without moving the handle
over such a wide arc.
An open-end wrench is fast and works best in areas with
limited overhead access. It contacts the fastener at only
two points, and is subject to slipping under heavy force, or
if the tool or fastener is worn. A box-end wrench is pre-
ferred in most instances, especially when breaking a fas-
tener loose and applying the final tightness to a fastener.
GENERAL INFORMATION 9 1
14

13. The combination wrench has a box-end on one end and
an open-end on the other. This combination makes it a
very convenient tool.
Adjustable Wrenches
An adjustable wrench or Crescent wrench (Figure 15)
can fit nearly any nut or bolt head that has clear access
around its entire perimeter. Adjustable wrenches are best
used as a backup wrench to keep a large nut or bolt from
turning while the other end is being loosened or tightened
with a box-end or socket wrench.
Adjustable wrenches contact the fastener at only two
points, which makes them more subject to slipping off the
fastener. The fact that one jaw is adjustable and may
loosen only aggravates this shortcoming. Make certain
the solid jaw is the one transmitting the force.
Socket Wrenches, Ratchets and Handles
Sockets that attach to a ratchet handle (Figure 16) are
available with 6-point (A, Figure 17) or 12-point (B)
openings and different drive sizes. The drive size indi-
cates the size of the square hole that accepts the ratchet
handle. The number stamped on the socket is the size of
the work area and must match the fastener head.
As with wrenches, a 6-point socket provides superior
holding ability, while a 12-point socket needs to be moved
only half as far to reposition it on the fastener.
Sockets are designated for either hand or impact use.
Impact sockets are made of thicker material for more du-
rability. Compare the size and wall thickness of a 19-mm
hand socket (A, Figure 18) and the 19-mm impact socket
(B). Use impact sockets when using an impact driver or
air tools. Use hand sockets with hand-driven attachments.
WARNING
Do not use hand sockets with air or impact
tools as they may shatter and cause injury.
Always wear eye protection when using im-
pact or air tools.
Various handles are available for sockets. The speed
handle is used for fast operation. Flexible ratchet heads in
varying lengths allow the socket to be turned with varying
force, and at odd angles. Extension bars allow the socket
setup to reach difficult areas. The ratchet is the most ver-
satile. It allows the user to install or remove the nut with-
out removing the socket.
Sockets combined with any number of drivers make
them undoubtedly the fastest, safest and most convenient
tool for fastener removal and installation.
10 CHAPTER ONE
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17
18
15

14. Impact Driver
An impact driver provides extra force for removing fas-
teners by converting the impact of a hammer into a turn-
ing motion. This makes it possible to remove stubborn
fasteners without damaging them. Impact drivers and in-
terchangeable bits (Figure 19) are available from most
tool suppliers. When using a socket with an impact driver,
make sure the socket is designed for impact use. Refer to
Socket Wrenches, Ratchets and Handles in this section.
WARNING
Do not use hand sockets with air or impact
tools as they may shatter and cause injury.
Always wear eye protection when using im-
pact or air tools.
Allen Wrenches
Allen or setscrew wrenches (Figure 20) are used on fas-
teners with hexagonal recesses in the fastener head. These
wrenches are available in L-shaped bar, socket and T-han-
dle types. Most motorcycles are equipped with metric fas-
teners. Allen bolts are sometimes called socket bolts.
Torque Wrenches
A torque wrench (Figure 21) is used with a socket,
torque adapter or similar extension to tighten a fastener to a
measured torque. Torque wrenches come in several drive
sizes (1/4, 3/8, ½ and 3/4) and have various methods of
reading the torque value. The drive size indicates the size of
the square drive that accepts the socket, adapter or exten-
sion. Common methods of reading the torque value are the
deflecting beam, the dial indicator and the audible click .
When choosing a torque wrench, consider the torque
range, drive size and accuracy. The torque specifications
in this manual indicate the range required.
A torque wrench is a precision tool that must be properly
cared for to remain accurate. Store torque wrenches in cases
or separate padded drawers within a toolbox. Follow the
manufacturer’s instructions for their care and calibration.
Torque Adapters
Torque adapters or extensions extend or reduce the
reach of a torque wrench. The torque adapter shown in
Figure 22 is used to tighten a fastener that cannot be
reached due to the size of the torque wrench head, drive
and socket. If a torque adapter changes the effective lever
length (Figure 23), the torque reading on the wrench will
not equal the actual torque applied to the fastener. It is nec-
GENERAL INFORMATION 11 1
19
20
21
22

15. essary to recalibrate the torque setting on the wrench to com-
pensate for the change of lever length. When a torque adapter
is used at a right angle to the drive head, calibration is not re-
quired since the effective length has not changed.
To recalculate a torque reading when using a torque
adapter, use the following formula and refer to Figure 23.
TW = TA ×L
L + A
TW is the torque setting or dial reading on the wrench.
TA is the torque specification and the actual amount of
torque that will be applied to the fastener.
A is the amount that the adapter increases (or in some
cases reduces) the effective lever length as measured
along the centerline of the torque wrench.
L is the lever length of the wrench as measured from the
center of the drive to the center of the grip.
The effective length is the sum of L and A.
Example:
TA = 20 ft.-lb.
A = 3 in.
L = 14 in.
TW = 20 ×14 = 280 = 16.5 ft. lb.
14 + 3 17
12 CHAPTER ONE
23
L
A
L
L
A
L + A = Effective length
L = Effective length
No calculation needed
L
HOW TO MEASURE TORQUE WRENCH EFFECTIVE LENGTH