This manual provides general descriptions for accomplishing service and repair work with tested, efective tehniques. Following them will help assure reliability. Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing.
Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting, disassembling and assembling and servicing which cover procedures, precautions, factory specifications and allowable limits.
These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components. Appropiate service methods and correct repair procedures are esential for the safe, reliabe operation of all motor vehicles as well as the personal safety of the individual carrying out the work.
The illustrations in this manual are used to highlight the fundamental principles and procedures of basic interventions. In order to perform the work efficiently and to avoid costly mistakes, read the text and thoroughly familiarise yourself with procedures before starting work.
All work should be performed with great care and in a clean working area with adequate lighting. Please peruse and utilize this manual for Harley Davidson FLSTFI Fat Boy fully to ensurea complete repair work for satisfying you or your customers by keeping their vehicle in optimum condition. All information, illustration and specifications contained in this manual are based on the latest product information avaiable at the time of publication approval.
The specification, maintenance and other information for the components are included, and diagnostic information has also been added where necessary. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type part number fastener as removed. Do not allow problems to develop. Rectify all problems as soon as possible immediately if safety related. Follow the procedures in this manual carefully and completely.
Do not take short cuts. Keep complete records of all maintenance and repairs with dates and any new parts installed. The descriptions are brief but precise and are supported by photographs, notes, drawings and schematics, as well as exploded and sectional drawings.
This manual also contains information about adjusting work and valuable reference data for such adjustment values. To perform all repairs listed in this manual, a complete set of standard tools, as well as the special tools and fixtures shown and listed are necessary.
No special emphasis is put on replacing sealing components as we assume that these items are replaced during any repair. Unless specific values are given, all threaded connections should be tightened according to the required tightening torques listed on torque charts. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. The work can only be carried out if the owner has the necessary hand and special service tools to complete the job.
If ends of shifter cam are pitted or grooved, replace the shifter cam and bearings. Install new bearings in support blocks by pressing on the side of the bearing with letters stamped on it. Stamped side of bearing should face outward when support block is installed on cam.
Inspect shifter cam 4 for cracks or wear and replace if necessary. Inspect neutral indicator switch in top cover. Depress plunger.
It should spring back without binding. The switch is a non-repairable item and must be replaced if damaged. Assemble shifter cam components if necessary. Place a bearing 2 inside left support block 5 by pressing on the side of the bearing with letters stamped on it.
This side should face out. When installing new retaining ring verify the tab is on the right side and opening is towards bottom when you are looking at the end of the shifter drum.
Secure bearing by installing a new retaining ring 1 with the beveled side facing out. Place assembly on shifter cam and install a new small retaining ring 6. Place a bearing 2 inside right support block by pressing on the side of the bearing with letters stamped on it.
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