| Description | Part Number | Qty. |
|---|---|---|
| FAT JACK | HD-45968 | 1 |
| RESS REPLACEMENT KIT | HD-52734 | 1 |
| 1. | Stand motorcycle upright (not leaning on jiffy stand) on a level surface. See Maintenance → GENERAL. | |
| 2. | Remove top cover. See Chassis → TOP COVER. | |
| 3. | Remove rear cover. See Chassis → REAR COVER. | |
| 4. | Deactivate electrical system. See Electrical → POWER DISCONNECT. | |
| 5. | Disconnect negative battery cable. See Maintenance → INSPECT BATTERY. | |
| 6. | Install special tool. Special Tool: RESS REPLACEMENT KIT (HD-52734) a. Remove skid plate. See Electric Vehicle Powertrain (EVPT) → SKID PLATE. b. Install special baseplate. c. Install screws. Tighten. d. Support powertrain with Fat Jack. Special Tool: FAT JACK (HD-45968) | |
| 7. | Remove BCM. See Electrical → BODY CONTROL MODULE (BCM). | |
| 8. | Remove power receptacle assembly. See High-Voltage System → POWER RECEPTACLE (VEHICLE INLET). | |
| 9. | Remove tail section. See Chassis → TAIL SECTION. | |
| 10. | Remove fairing. See Chassis → FAIRING. | |
| 11. | Remove upper, middle and lower side covers. See Chassis → SIDE COVERS. | |
| 12. | Remove front cover. See Electric Vehicle Powertrain (EVPT) → FRONT COVER. | |
| 13. | Remove left and right footrest brackets. See Chassis → RIDER FOOTRESTS. | |
| 14. | NOTE Do Not separate brake lines from master cylinder. | |
| 15. | Remove sensor from jiffy stand. Let sensor hang until it is removed later in the procedure. See Electrical → JIFFY STAND SENSOR (JSS). | |
| 16. | Remove high-voltage cable cover. See Electric Vehicle Powertrain (EVPT) → HIGH-VOLTAGE CABLE COVER. | |
| 17. | Remove primary cover. See Electric Vehicle Powertrain (EVPT) → PRIMARY COVER. | |
| 18. | Remove lower belt guard. See Chassis → BELT GUARDS. | |
| 19. | Remove drive belt tensioner. See Electric Vehicle Powertrain (EVPT) → TENSIONER PULLEY AND IDLER SPROCKET. | |
| 20. | Detach rear shock absorber from RESS housing. a. Remove front screw from rear shock absorber. See Chassis → REAR SHOCK ABSORBER. | |
| 21. | NOTE Do Not separate brake lines from caliper. | |
| 22. | Remove P-clamp from rear caliper brake line to ABS module. See Brake Line: Rear Caliper to ABS Module in Chassis → BRAKE LINES. | |
| 23. | Disconnect connectors. a. Rear WSS. See Electrical → REAR WHEEL SPEED SENSOR (WSS). b. Rear wire harness. See Electrical → REAR WIRE HARNESS. | |
| 24. | Separate rear half of motorcycle from RESS. a. Remove rear fork pivot shaft. See Chassis → REAR FORK. b. Move rear half of motorcycle away from RESS. | |
| 25. | Remove upper P-clamp from EVPT breather. See Electric Vehicle Powertrain (EVPT) → BREATHER ASSEMBLY. | |
| 26. | Disconnect EVPT high-voltage connector. See Electric Vehicle Powertrain (EVPT) → POWERTRAIN. | |
| 27. | Detach front brake line manifold from under steering head. See Brake Line: Front Caliper to ABS Module in Chassis → BRAKE LINES. | |
| 28. | Remove antenna. See Electrical → SECURITY SYSTEM ANTENNA. | |
| 29. | Remove left frame grounds. See Electrical → MAIN WIRE HARNESS. a. Upper front: Two on left side of outer frame. b. Lower rear: One on left side of inner frame. | |
| 30. | Detach ABS module from RESS. a. Remove ABS module cover. See Chassis → ABS MODULE. b. Disconnect ABS module connector. c. Detach ABS module from battery housing. d. Disconnect brake switch connector. e. Detach brake lines from brackets, cable straps and clamps. See Chassis → BRAKE LINES. f. Move caliper, master cylinder, ABS module and brake lines toward front left of vehicle. Support items from handlebars. | |
| 31. | Remove IMU. See Electrical → INERTIAL MEASUREMENT UNIT (IMU). | |
| 32. | Disconnect TCU connector. See Electrical → TELEMETRY CONTROL UNIT (TCU). | |
| 33. | Remove AC in-line filter. See High-Voltage System → AC OBC IN-LINE FILTER. | |
| 34. | NOTE Do not disconnect coolant lines. a. Disconnect battery charger connectors. | |
| 35. | Remove coolant overflow hose from filler neck. See Cooling System → COOLANT HOSES. | |
| 36. | Remove screws from radiator mounting tabs. See Cooling System → RADIATOR. | |
| 37. | Disconnect front WSS connector. See Electrical → FRONT WHEEL SPEED SENSOR (WSS). | |
| 38. | Disconnect jiffy stand sensor connector. See Electrical → JIFFY STAND SENSOR (JSS). | |
| 39. | Disconnect twist grip sensor connector. See Electrical → TWIST GRIP SENSOR (TGS). | |
| 40. | Disconnect front wire harness. See Electrical → FRONT WIRE HARNESS. | |
| 41. | Remove coolant hose p-clamps from front of RESS. See Cooling System → COOLANT HOSES. | |
| 42. | Support front end and handlebar assembly. | |
| 43. | NOTE Make sure that the remaining assembly is properly supported. | |
| 44. | Remove lower main harness bracket from back of RESS. See Electrical → MAIN WIRE HARNESS. | |
| 45. | Remove main harness connectors from top and left-side of RESS. See Electrical → MAIN WIRE HARNESS. a. Top: BCM, BCM power, fuse, diagnostic link, antenna and charger. b. Left-side (upper main harness bracket): Headlamp, fork lock, hand control modules, turn signal lamps and charger power. c. Move harness off to the left side. | |
| 46. | Remove right frame. See Chassis → FRAME. | |
| 47. | Rotate battery charger, steering head and cooling system assembly away from RESS. Support components as required. | |
| 48. | Install straps to RESS. a. Locate straps in RESS kit. b. Install and route straps between EVPT and RESS. One in front and one in rear. c. Attach overhead lifting device to straps. d. Tighten slack in straps. | |
| 49. | Remove EVPT screws from RESS. See Electric Vehicle Powertrain (EVPT) → POWERTRAIN. | |
| 50. | Disconnect main harness Battery Disconnect Unit (BDU) connector from rear of RESS. See Electrical → MAIN WIRE HARNESS. | |
| 51. | Lift RESS away and set down in a secure location. | |
| 52. | Remove and transfer: a. Set screws from EVPT/RESS. b. Brackets. c. Clamps. d. Cable straps. Replace as needed. |