ITEM SERVICED | PROCEDURE | 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 |
---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Electrical equipment and switches | Check operation | X | X | X | X | X | X | X | X | X | X | X | |
Front tire | Check pressure, inspect tread | X | X | X | X | X | X | X | X | X | X | X | 1 |
Front brake fluid | Inspect sight glass | X | X | X | X | X | X | X | X | X | X | X | 2, 3 |
Clutch (hydraulic operated) | Inspect sight glass | X | X | X | X | X | X | X | X | X | X | X | 2, 4 |
Reservoir cover screw: front brake and hydraulic clutch | Check torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Hand control fasteners | Check switch housing screw torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Check clutch 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 | ||||||
Steering head bearings | Disassemble, inspect, lubricate and adjust | X | X | 5, 7 | |||||||||
Hydraulic steering damper | Check for leaks smooth damper action, mounting fastener torque | X | X | X | X | X | X | X | X | X | X | X | 8 |
Air cleaner | Inspect, service as required | X | X | X | X | X | X | X | X | X | X | 9 | |
Engine oil and filter | Replace | X | X | X | X | X | X | X | X | X | X | X | 1, 9 |
Engine coolant | Check freeze point, inspect for leaks | X | X | X | X | X | X | X | X | X | X | X | |
Replace coolant | Replace every 48,000 km (30000 mi) | 5 | |||||||||||
Clean radiators | X | X | X | X | X | X | X | X | X | X | X | ||
Primary chaincase lubricant | Replace | X | X | X | X | X | X | 9 | |||||
Transmission lubricant | Replace | X | X | X | 9 | ||||||||
Right front engine mount end cap screws | Check torque | X | X | X | X | X | X | 1, 5, 10 | |||||
Engine mount to front crankcase screws | Check torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Engine stabilizer link screw torque including bracket to head
screws | Check torque | X | X | X | X | X | X | 1, 5, 10 | |||||
Oil lines and brake system | Inspect for leaks, contact or abrasion | X | X | X | X | X | X | X | X | X | X | X | 1, 5 |
Fuel lines and fittings | Inspect for leaks, contact or abrasion | X | X | X | X | X | X | X | X | X | X | X | 1, 5 |
Rear brake fluid | Inspect sight glass | X | X | X | X | X | X | X | X | X | X | X | 2, 3 |
Brake pads and discs | Inspect for wear | X | X | X | X | X | X | X | X | X | X | X | |
Front brake and clutch master cylinder banjo bolts | Check torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Front circuit manifold banjo bolt (12 mm) | Check Torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Front caliper banjo bolts | Check Torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Rear master cylinder banjo bolt | Check Torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Rear caliper banjo bolt | Check Torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Rear circuit manifold banjo bolt (10 mm) | Check Torque | X | X | X | X | X | X | 1, 5, 6 | |||||
Brake and clutch controls | Check, adjust and lubricate with HARLEY LUBE | X | X | X | X | X | X | X | X | X | X | X | 5 |
Parking brake | Inspect and adjust | X | X | X | X | X | X | X | X | X | X | X | 5 |
Rear tires | Check pressure, inspect tread | X | X | X | X | X | X | X | X | X | X | X | 1 |
Drive belt and sprockets | Inspect, adjust belt | X | X | X | X | X | X | X | X | X | X | X | 5 |
Rear sprocket isolators | Inspect for wear | X | X | 5 | |||||||||
Rear lug nuts | Check torque | X | X | X | X | X | X | 1, 5, 6, 11 | |||||
Rear fork | Check pivot shaft nut torque | X | X | X | X | X | X | 1, 5, 10 | |||||
Air suspension | Check pressure, operation and leakage | X | X | X | X | X | X | X | X | X | X | X | 1, 5, 9 |
Exhaust system | Inspect for leaks, cracks, and loose or missing fasteners or exhaust
shields | X | X | X | X | X | X | X | X | X | X | X | 1, 9 |
Battery Check battery and clean connections annually. | Battery terminal torque | Check annually | 1 | ||||||||||
Clean and lubricate terminals with ELECTRICAL CONTACT LUBRICANT | Perform annually | 1 | |||||||||||
Spark plugs | Replace every two years or every 30,000 mi (48,000 km), whichever comes first. | ||||||||||||
Fuel door | Lubricate hinge and latch with HARLEY LUBE | X | X | X | X | X | X | X | X | X | X | X | |
Front forks | Rebuild | X | 5, 12 | ||||||||||
Fuel filter element | Replace every 160,000 km (100000 mi). | 5 | |||||||||||
Road test | Verify component and system functions | X | X | X | X | X | X | X | X | X | X | X | 13 |
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. Attempt to turn the fastener using a torque wrench set to the minimum
torque specification for that fastener. If the fastener does not rotate, the
fastener torque has been maintained. No further attention is necessary. If
fastener moves, tighten to specification. 7. Disassemble, inspect, lubricate and adjust every 40,000 km (25000 mi). 8. Replace or have rebuilt at 80,000 km (50000 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. Attempt to turn the fastener using a torque wrench set to the minimum
torque specification for that fastener. If the fastener does not rotate, the
fastener torque has been maintained. No further attention is necessary. If
the fastener moves, clean all locking material from the threaded hole.
Replace the fastener with a new one or clean the original fastener threads
and apply the appropriate locking agent (see appropriate procedure). Install
fastener. Tighten to specification. 11. Always check lug nut torque within 805–1,610 km (500–1,000 mi) after wheel installation. 12. Disassemble, inspect, rebuild forks and replace fork oil every 80,000 km (50000 mi). 13. Check reverse operation at each service interval. |
SERVICE MILE INTERVAL | DATE | DEALER NUMBER | TECHNICIAN NAME | TECHNICIAN SIGNATURE |
---|---|---|---|---|
1,600 km (1000 mi) | ||||
8,000 km (5000 mi) | ||||
16,000 km (10000 mi) | ||||
24,000 km (15000 mi) | ||||
32,000 km (20000 mi) | ||||
40,000 km (25000 mi) | ||||
48,000 km (30000 mi) | ||||
56,000 km (35000 mi) | ||||
64,000 km (40000 mi) | ||||
72,000 km (45000 mi) | ||||
80,000 km (50000 mi) |