ITEM SERVICED | 1000 MI 1600 KM | 5000 MI 8000 KM | 10000 MI 16000 KM | 15000 MI 24000 KM | 20000 MI 32000 KM | 25000 MI 40000 KM | 30000 MI 48000 KM | 35000 MI 56000 KM | 40000 MI 64000 KM | 45000 MI 72000 KM | 50000 MI 80000 KM | NOTES |
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Check operation of electrical equipment and switches | X | X | X | X | X | X | X | X | X | X | X | |
Check front tire pressure, inspect tread | X | X | X | X | X | X | X | X | X | X | X | 1 |
Inspect front brake fluid sight glass | X | X | X | X | X | X | X | X | X | X | X | 2, 3 |
Inspect clutch fluid sight glass (hydraulic operated) | X | X | X | X | X | X | X | X | X | X | X | 2, 4 |
Check front brake and hydraulic clutch reservoir cover screw torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Check hand control fastener switch housing screw torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Check clutch lever handlebar clamp screw torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Check front brake handlebar clamp screw torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Inspect, lubricate and adjust steering head bearings | X | X | 5, 7 | |||||||||
Check hydraulic steering damper for leaks, smooth damper action and mounting fastener torque | X | X | X | X | X | X | X | X | X | X | X | 8 |
Inspect air cleaner, service as required | X | X | X | X | X | X | X | X | X | X | 9 | |
Replace engine oil and filter | X | X | X | X | X | X | X | X | X | X | X | 1, 9 |
Check engine coolant level, freeze point, inspect for leaks | X | X | X | X | X | X | X | X | X | X | X | |
Replace coolant every 48,000 km (30,000 mi) | 5 | |||||||||||
Clean radiators | X | X | X | X | X | X | X | X | X | X | X | |
Replace primary chaincase lubricant | X | X | X | X | X | X | 9 | |||||
Replace transmission lubricant | X | X | X | 9 | ||||||||
Check right front engine mount end cap screw torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Check engine mount to front crankcase screw torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Engine stabilizer link screw torque including bracket to head screws | X | X | X | X | X | X | 1, 5, 6 | |||||
Inspect oil lines and brake system for leaks, contact or abrasion | X | X | X | X | X | X | X | X | X | X | X | 1, 5 |
Inspect fuel lines and fittings for leaks, contact or abrasion | X | X | X | X | X | X | X | X | X | X | X | 1, 5 |
Inspect rear brake fluid sight glass | X | X | X | X | X | X | X | X | X | X | X | 2, 3 |
Inspect brake pads and discs for wear | X | X | X | X | X | X | X | X | X | X | X | |
Check front brake and clutch master cylinder banjo bolt torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Check front circuit manifold banjo bolt torque (12 mm) | X | X | X | X | X | X | 1, 5, 6 | |||||
Check front caliper banjo bolt torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Check rear master cylinder banjo bolt torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Check rear caliper banjo bolt torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Check rear circuit manifold banjo bolt torque (10 mm) | X | X | X | X | X | X | 1, 5, 6 | |||||
Check, adjust and lubricate (with HARLEY LUBE) brake and clutch controls | X | X | X | X | X | X | X | X | X | X | X | 5 |
Inspect and adjust parking brake | X | X | X | X | X | X | X | X | X | X | X | 5 |
Check rear tire pressure, inspect tread | X | X | X | X | X | X | X | X | X | X | X | 1 |
Inspect and adjust drive belt and sprockets | X | X | X | X | X | X | X | X | X | X | X | 5 |
Inspect rear sprocket isolators for wear | X | X | 5 | |||||||||
Check rear lug nut torque | X | X | X | X | X | X | 1, 5, 6, 10 | |||||
Check rear fork pivot shaft nut torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Check air suspension pressure, operation and leakage | X | X | X | X | X | X | X | X | X | X | X | 1, 5, 9 |
Inspect exhaust system for leaks, cracks and loose, or missing fasteners or exhaust shields | X | X | X | X | X | X | X | X | X | X | X | 1, 9 |
Check battery, terminal torque and clean connections annually. | 1 | |||||||||||
Lubricate battery terminals with ELECTRICAL CONTACT LUBRICANT annually. | 1 | |||||||||||
Replace spark plugs every two years or every 48,000 km (30,000 mi), whichever comes first. | ||||||||||||
Lubricate Fuel door hinge and latch with HARLEY LUBE | X | X | X | X | X | X | X | X | X | X | X | |
Rebuild front forks | X | 5, 11 | ||||||||||
Replace fuel filter element every 160,000 km (100,000 mi). | 5, 9 | |||||||||||
Road test to verify component and system functions | X | X | X | X | X | X | X | X | X | X | X | 12 |
NOTES: | 1. Perform annually or at specified intervals, whichever comes first. 2. Replace DOT 4 hydraulic fluid and flush system every two years. 3. Brake fluid level will drop as brake pads wear. 4. Clutch fluid level will rise as clutch wears. 5. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified. 6. For torque instructions, see Shop Practices in the service manual. 7. Disassemble, inspect, lubricate and adjust every 40,000 km (25,000 mi). 8. Replace or have rebuilt at 80,000 km (50,000 mi). 9. Perform maintenance more frequently in severe riding conditions such as extreme temperatures, dusty environments, mountainous or rough roads, long storage conditions, short runs, heavy stop/go traffic or poor fuel quality. 10. Always check lug nut torque within 805–1,610 km (500–1,000 mi) after wheel installation. 11. Disassemble, inspect, rebuild forks and replace fork oil every 80,000 km (50,000 mi). 12. Check reverse operation at each service interval. |
SERVICE MILE INTERVAL | DATE | DEALER NUMBER | TECHNICIAN NAME | TECHNICIAN SIGNATURE |
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1,600 km (1,000 mi) | ||||
8,000 km (5,000 mi) | ||||
16,000 km (10,000 mi) | ||||
24,000 km (15,000 mi) | ||||
32,000 km (20,000 mi) | ||||
40,000 km (25,000 mi) | ||||
48,000 km (30,000 mi) | ||||
56,000 km (35,000 mi) | ||||
64,000 km (40,000 mi) | ||||
72,000 km (45,000 mi) | ||||
80,000 km (50,000 mi) |