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 |
Clutch fluid | Inspect sight glass | X | X | X | X | X | X | X | X | X | X | X | 2 |
Front master cylinder banjo bolt | Check torque | X | X | X | X | X | X | 1, 3, 4 | |||||
Clutch and front brake: reservoir cover screw | Check torque | X | X | X | X | X | X | 1, 3, 4 | |||||
Steering head bearings | Adjust | X | X | X | 3 | ||||||||
Lubricate | X | 3, 5 | |||||||||||
Lower fork bracket pinch bolt | Check torque | X | X | X | X | X | X | 1, 3, 6 | |||||
Upper fork bracket pinch bolt | Check torque | X | X | X | X | X | X | 1, 3, 6 | |||||
Throttle controls | Check, adjust and lubricate | X | X | X | X | X | X | X | X | X | X | X | 3 |
Hand controls: upper and lower switch housing screws | Check torque | X | X | X | X | X | X | 1, 3, 4 | |||||
Clutch lever handlebar clamp screws | Check torque | X | X | X | X | X | X | 1, 3, 4 | |||||
Master cylinder handlebar clamp screws | Check torque | X | X | X | X | X | X | 1, 3, 4 | |||||
Air cleaner | Inspect, service as required | X | X | X | X | X | X | X | X | X | X | 7 | |
Valve lash | Inspect, adjust if necessary | X | X | X | 3, 8 | ||||||||
Spark plugs | Replace | X | 9 | ||||||||||
Cooling system | Inspect; check clamps for tightness, check coolant freeze point | X | X | X | X | X | X | X | X | X | X | X | |
Coolant | Replace every 48,000 km (30000 mi) | 3 | |||||||||||
Radiator | Clean | X | X | X | X | X | X | X | X | X | X | X | |
Engine oil and filter | Replace | X | X | X | X | X | X | X | X | X | X | X | 1, 7 |
Oil lines and brake system | Inspect for leaks, contact or abrasion | X | X | X | X | X | X | X | X | X | X | X | 1, 3 |
Fuel lines and fittings | Inspect for leaks, contact or abrasion | X | X | X | X | X | X | X | X | X | X | X | 1, 3 |
Rear brake fluid | Inspect sight glass | X | X | X | X | X | X | X | X | X | X | X | 2 |
Reservoir cover screw, rear | Check torque | X | X | X | X | X | X | 1, 3, 4 | |||||
Brake pads and discs | Inspect for wear | X | X | X | X | X | X | X | X | X | X | X | |
Front axle nut | Check torque | X | X | X | X | X | X | 1, 3, 4 | |||||
Rear master cylinder banjo bolt | Check torque | X | X | X | X | X | X | 1, 3, 4 | |||||
Jiffy stand | Inspect and lubricate | X | X | X | X | X | X | X | X | X | X | X | 3, 7 |
Brake and clutch controls | Check, adjust and lubricate | X | X | X | X | X | X | X | X | X | X | X | |
Rear tire | 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 | 3 |
Rear axle nut | Check torque | X | X | X | X | X | X | 1, 3, 4 | |||||
Shock absorber bolts, upper and lower | Check torque | X | X | X | X | X | X | 1, 3, 6 | |||||
Lower frame rail fasteners | Check torque | X | X | X | X | X | X | 1, 3, 4 | |||||
Pivot shaft nut | Check torque | X | X | X | X | X | X | 1, 3, 6 | |||||
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, 7 |
Battery | Check battery, terminal torque and clean connections annually. | 1 | |||||||||||
Front fork | Rebuild | X | 3, 10 | ||||||||||
Fuel filter element | Replace every 160,000 km (100000 mi) | 3 | |||||||||||
Road test | Verify component and system functions | X | X | X | X | X | X | X | X | X | X | X | |
NOTES: | 1. Perform annually or at specified intervals, whichever comes
first. 2. Replace DOT 4 hydraulic brake fluid and flush system every two
years. 3. Should be performed by an authorized Harley-Davidson dealer, unless you
have the proper tools, service data and are mechanically qualified. 4. 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. 5. Disassemble, inspect and lubricate every 48,000 km (30000 mi). 6. Attempt to turn fastener using a torque wrench set to the minimum
torque specification for that fastener. If fastener does not rotate,
fastener torque has been maintained. No further attention is necessary. If
fastener moves, clean all locking material from threaded hole. Replace
fastener with a new one or clean original fastener threads and apply
appropriate locking agent (see appropriate procedure). Install fastener.
Tighten to specification. 7. 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). 8. Could vary with frequency of operation and riding style. 9. Perform every two years or at specified intervals, whichever comes
first. 10. Disassemble, inspect, rebuild forks and replace fork oil every 80,000 km (50000 mi). |
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) |