| Description | Part Number | Qty. |
|---|---|---|
| FAT JACK | HD-45968 | 1 |
| 1. | Stand motorcycle upright (not leaning on jiffy stand) on a level surface. See Maintenance → GENERAL. | |
| 2. | Remove seat and seat latch assembly. See Chassis → SEAT. | |
| 3. | Deactivate electrical system. See Electrical → POWER DISCONNECT. | |
| 4. | Remove battery. See Maintenance → INSPECT BATTERY. | |
| 5. | Remove top cover. See Chassis → TOP COVER. | |
| 6. | Remove rear cover. See Chassis → REAR COVER. | |
| 7. | Remove radiator, inlet side and lower motor covers. See Chassis → SIDE COVERS. | |
| 8. | Remove jiffy stand. See Electrical → JIFFY STAND SENSOR (JSS). | |
| 9. | Remove bottom pan. See Chassis → BOTTOM PAN. | |
| 10. | Position a fat jack or similar with a rag on top to protect Rechargeable Energy Storage System (RESS) under the boss on the bottom of the RESS. Raise jack until it contacts RESS. Special Tool: FAT JACK (HD-45968) | |
| 11. | Secure jack to motorcycle lift to prevent movement. | |
| 12. | Remove power receptacle connector. See High-Voltage System → VEHICLE INLET. NOTE Do not separate brake lines from master cylinder. | |
| 13. | Remove rear master cylinder from footrest. See Chassis → REAR BRAKE MASTER CYLINDER. | |
| 14. | Drain coolant. See Cooling System → COOLANT. | |
| 15. | Disconnect coolant pump connector. See Cooling System → COOLANT PUMP. | |
| 16. | Disconnect low voltage Power Electronics Unit (PEU) connector. | |
| 17. | Disconnect rear lighting bracket connector and five wire locators. See Chassis → REAR LIGHTING BRACKET. | |
| 18. | Remove splash guard. See Chassis → SPLASH GUARD. | |
| 19. | Disconnect rear wheel speed sensor connector. See Electrical → REAR WHEEL SPEED SENSOR (WSS). | |
| 20. | Remove rear master cylinder reservoir hose p-clamps. See Chassis → REAR BRAKE MASTER CYLINDER. | |
| 21. | Remove left and right footrest brackets. See Chassis → RIDER FOOTRESTS. | |
| 22. | Detach rear brake caliper. See Chassis → BRAKE LINES. NOTE Do not separate brake lines from caliper. | |
| 23. | Remove upper shock and front link screw. See Chassis → REAR SHOCK ABSORBER. | |
| 24. | Remove drive belt from front sprocket. See Electric Vehicle Powertrain (EVPT) → DRIVE BELT. | |
| 25. | Remove rear fork bearing caps. See Chassis → SWINGARM. | |
| 26. | Remove the rear fork as an assembly.Chassis → REAR BRAKE MASTER CYLINDER | |
| 27. | Remove rear shock cover. See Chassis → REAR SHOCK COVER. | |
| 28. | Position rear master cylinder reservoir aside. See Chassis → REAR BRAKE MASTER CYLINDER. | |
| 29. | Disconnect horn, Telematic Control Unit (TCU), fork lock, RESS, cooling fans and Universal Serial Bus (USB) port connectors. See Electrical → FRONT WIRE HARNESS. | |
| 30. | Remove front electrical caddy. See Electrical → FRONT ELECTRICAL CADDY. | |
| 31. | Remove tail sections screws and washers. See Chassis → TAIL SECTION. | |
| 32. | Remove tail section as an assembly. | |
| 33. | Remove P-clamp from rear caliper brake line to Anti-lock Braking System (ABS) module. See Chassis → BRAKE LINES → Brake Line: Rear Caliper to ABS Module. | |
| 34. | Detach ABS module from RESS. a. Detach ABS module from battery housing. See Chassis → ABS MODULE. b. Disconnect brake switch connector. c. Detach brake lines from brackets, cable straps and clamps. See Chassis → BRAKE LINES. | |
| 35. | Refer to High-Voltage System → RECHARGEABLE ENERGY STORAGE SYSTEM (RESS) → Install → Seat Bracket Tab. Remove screws (1) and seat bracket tab (2). | |
| 36. | Remove Inertial Measurement Unit (IMU). See Electrical → INERTIAL MEASUREMENT UNIT (IMU). | |
| 37. | Remove three-phase cover. See Electric Vehicle Powertrain (EVPT) → THREE-PHASE COVER. | |
| 38. | Remove radiator. See Cooling System → RADIATOR. | |
| 39. | Remove electric motor. See Electric Vehicle Powertrain (EVPT) → ELECTRIC MOTOR. | |
| 40. | Disconnect electric motor to coolant pump hose and battery charger to electric motor coolant hose. See Cooling System → COOLANT HOSES. | |
| 41. | Lock the front brake and secure the front suspension/fork assembly to prevent damage. | |
| 42. | Refer to High-Voltage System → RECHARGEABLE ENERGY STORAGE SYSTEM (RESS) → Install → RESS Assembly. Set up engine hoist (2) to the rear of the lift and extend arm (1) to its longest length. | |
| 43. | Move hoist as far forward as possible. Using chains with L-brackets (5), attach one bracket to each of the upper tail section bolt hole (3) using the factory bolt (6). If required, use several washers (4) to step the bracket out past the boss on the RESS case to prevent cosmetic damage. | |
| 44. | Use a ratchet strap (10) and route it across the front of the RESS (7), passing between two bosses on the case, then back up to the lift chain and rear chain. | |
| 45. | Start lifting with the engine hoist until the chain and strap are supporting the weight of the RESS. | |
| 46. | Using a second person remove the four bolts (12) from the steering head assembly (11) to the RESS. Have the helper brace the RESS. Once the bolts are removed start lowering the jack supporting the RESS and prepare for the RESS to swing back once it comes off the jack. Allow the RESS to swing back and hang from the hoist. | |
| 47. | Lower RESS to within a few inches of the lift table. | |
| 48. | Refer to High-Voltage System → RECHARGEABLE ENERGY STORAGE SYSTEM (RESS) → Install → RESS Assembly. Remove PEU high voltage cables from RESS. | |
| 49. | Remove the four bolts (8) from the PEU (9) and remove it from the RESS. |