Harley Davidson Softail 2006 2007 2008 2009 Service Manual

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WARNINGS AND CAUTIONS
Statements in this service manual preceded by the following words are of special significance.

PRODUCT REFERENCES

AWARNING ADANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. AWARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (00119a) ACAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (00139a) CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage (00140a) 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 performing 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 specific
service methods, which could damage the motorcycle or render it unsafe, are stated in this Service Manual. However, please remember that these warnings are not all-inclusive. Inadequate safety precautions could result in death or serious injury. 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-Davidson 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. Wear eye protection when using hammers, arbor or hydraulic presses, gear pullers, spring compressors, slide hammers and similar tools. Be especially cautious when using pulling, pressing or compressing equipment. The forces involved can cause parts to fly outward wi
th considerable force, possibly resulting in death or serious injury. Follow the directions listed on all products. Carefully read all labels, warnings and cautions before use. Inadequate safety precautions could result in death or serious injury.
When reference is made in this Service Manual to a specific brand name product , tool or instrument, an equivalent product , tool or instrument may be substituted.

Kent-Moore Products
All tools mentioned in this manual with an "HD", "J" or "8 " preface must be ordered through:

Kent-Moore SPX Corporation 28635 Mound Road Warren , Michigan USA 48092-3499

Sealing and Threadlocking Products
LOCTITE PRODUCTS

CONTENTS
All photographs, illustrations and procedures may not necessarily depict the most current model or component, but are based on the latest production information available at the time of publication. Since product improvement is our continual goal, HarleyDavidson reserves the right to change specifications, equipment or designs at any time without notice and without incurring obligation .

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TABLE OF CONTENTS
Page No. Page No.

SECTION 1-MAINTENANCE
1.1 General
Servicing a New Motorcycle Safe Operating Maintenance Shop Practices Repair Notes Safety Remov ing Parts Cleaning Disassembly and Assembly Repair and Replacement Procedures Hardware and Threaded Parts Threadl ock ing Agents Wiring, Hoses and Lines Instruments and Gauges Bearings Bushings Exhaust System Leakage Gaskets Lip Type Seals O-Rings (Prefo rmed Packings) Gears Shafts Part Replacement Cleaning Part Protectio n Cleaning Process Rust or Corrosion Remova l Tool Safety Air Tools Wrenches Pliers/Cutters/Prybars Hammers Punches /Chisels Screwdrivers Ratchets and Hand les Sockets Storage Units

1.5 Battery Maintenance .
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1-13
1-13 1-13 1-14 1-14 1-15 1-15

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

General Battery Electro lyte Antidotes (table) Disconnection and Removal. Installation and Connect ion Inspection Storage

1.6 Brakes
Fluid Inspection Rear Brake Pedal Pedal Height Pedal Lubricati on Pedal Pad

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1-16
1-16 1-17 1-17 1-17 1-17

1.7 Bleeding Brakes
General Procedure

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1-18
1-18 1-18

1.8 Brake Pads and Discs
Inspection Brake Pads Brake Disc Thickness Brake Disc Lateral Runout and Warpage Brake Pad Replaceme nt Rear Brake Caliper Front Brake Caliper: All But FLSTSC

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1-19
1-19 1-19 1-19 1-19 1-20 1-20 1-22

1.9 Tires and Wheels
Tires Tire Pressures (table) Tire Replacement Whee l Bearings Whee l Spokes

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1-23
1-23 1-23 1-24 1-24 1-24

1.10 Primary Chain
General

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1-25
1-25

1.11 Primary Chaincase Lubricant .
Chang ing Lubricant .

1-26
1-26

1.12 CIutch
Adjustment

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1-28
1-28

1.2 Fuel and Oil
Fuel Gasoline Blends Engine Oil Winter Lubrication

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1-5
1-5 1-5 1-5 1-5

1.13 Transmission Lubricant
Changing Lubricant

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1-30
1-30

1.14 Rear Belt Deflection
Inspection Rear Belt Deflection (Table) Adjustment

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1-31
1-31 1-31 1-32

1.3 Maintenance Schedule
First Schedu led Maintenance

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1-6
1-6

1.4 Engine Oil and Filter
Checking and Adding Oil Type of Oil Checking Oil Level Recommended Oil Grades (table) Changi ng Oil and Filter

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1-11
1-11 1-11 1-11 1-11 1-12

1.15 Rear Belt and Sprockets
Genera l Cleaning Inspection Sprockets Rear Belt Drive Belt Wear Analysis (table)

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1-33
1-33 1-33 1-33 1-33 1-33 1-34

1.16 Suspension Adjustments
Rear Shock Preload

1-35
1-35
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1.17 Steering Head Bearings: All But FLSTSC .
Adjustment Bearing Adjustment (Fall-away) Lubrication . .. .

1.29 Troubleshooting 1-36
1-36 1-36 1-36

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1-55
1-55 1-55 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

1.18 Steering Head Bearings: FLSTSC
General Lubrication Adjustment Adjustment

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1-37
1-37 1-37 1-37 1-38

1.19 Rocker Bearings: FLSTSC
Inspection

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1-39
1-39

1.20 Front Fork Oil
Replacing Fork Oil.

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1-41
1-41

1.21 Spark Plugs
Inspection

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1-43
1-43

1.22 Air Cleaner Filter
Removal Installation

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1-44
1-44 1-45

1.23 Cable and Chassis Lubrication
General Cables and Hand Levers Jiffy Stand . . .

1-46
1-46 1-46 1-46

1.24 Throttle Cables
Cable Inspection, Lubrication and Adjustment.. Inspection and Lubrication Adjustment

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1-47
1-47 1-47 1-48

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 Tank .. Engine Uses Too Much Oil Or Smokes Excessively Engine Leaks Oil From Cases, Push Rods, Hoses Low Oil Pressure . High Oil Pressure .. Electrical System . Alternator Does Not Charge .. Alternat or 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 Hold Normally .

1.25 Engine Mounts
Inspection

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1-49
1-49

SECTION 2-CHASSIS
2.1 Specifications
Tires Tire Fitment, Tubeless Cast Wheels (table) Tire Fitment, Laced Wheels (table) Tire Pressure, All Models (table)

1.26 Headlamp Alignment

1-50
1-50 1-51 1-51 1-51 1-51

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2-1
2-2 2-2 2-2 2-3

Inspection .................................................................. Adjustment.. .................. FLSTSC Models FLSTC/FLSTF/FLSTN/FXST/FXSTB/FXSTC Models FXSTD Models ......................................................

1.27 Critical Fasteners
Inspection Critical Fasteners (table)

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1-52
1-52 1-52

2.2 Torque Values 2.3 Vehicle Identification Number (V.I.N.)
General

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2-4 2-7
2-7

1.28 Storage
General Removal From Storage

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1-53
1-53 1-54

2.4 Front Wheel: All But FLSTSCIFXSTD
Removal Disassembly Disc Wheel. Laced Wheel Cleaning and Inspection Assemb ly Disc Wheel Laced Wheel Installation

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2-9
2-9 2-9 2-9 2-9 2-11 2-11 2-11 2-11 2-11

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