Harley Davidson Touring Models 2006 Service Manual.pdf

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

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

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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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