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 interva
|