2015 Harley Davidson Softail Motorcycle Service Manual

Description

This Official 2015 Harley Davidson Softails Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2015 Harley-Davidson Softail motorcycles.

Table of Contents

Maintenance
Chassis
Engine
Fuel System
Drive
Transmission
Electrical
Appendix A Connector Repair
Appendix B Wiring
Appendix C ABS
Appendix D Conversions
Appendix E Glossary

Index of Topics

A
Acronyms and Abbreviations
Active Exhaust Module
General
Installation
Repair
Active Exhuast Module
Removal
Air Cleaner
Backplate Assembly: HDI Models
Installation
Removal
Air Cleaner Filter
Installation
Removal
Alignment
Axle
Checking
Alternator
Installation
Removal
Anniversary Badging
Assembling Motorcycle After Service
Procedure
Autofuse Electrical Connector
Assembly
Disassembly
Automatic Compression Release (ACR)
Installation
Removal
Auxiliary Lamps: FLSTC/FLSTN
Adjustment: FLSTC/FLSTN Models
Auxiliary Lamp Bulb
FLSTC Models
FLSTN Models
B
Battery
Charging
Cleaning
Inspection
Maintenance
Storage
Voltmeter Test
Battery Cables
Routing Procedure
Routing Procedure
Battery Maintenance
Disconnection and Removal
Belt Guard/Debris Deflector
Installation
Removal
Body Control Module (BCM)
Configuration
General
Body Control Module (BCM): All But FXSB
Installation
Removal
Body Control Module (BCM): FXSB
Installation
Removal
Bosch Compact 11M Connector
Bottom End Overhaul: Assembly
Counterbalancer Assembly
Crankcase
Bottom End Overhaul: Disassembly
Counterbalancer Assembly
Crankcase
Bottom End Overhaul (Assembly)
Cam Support Plate and Cover
Bottom End Overhaul (Disassembly)
Cam Support Plate
Bottom End Service
Engine in Chassis (Cam Compartment Service)
Engine Removed (Flywheel Compartment Service or Complete Engine Overhaul)
Brake Line
Front HCU-to-Front Caliper
Front Master Cylinder-to-Front HCU
Rear HCU to Rear Caliper
Rear Master Cylinder to Rear HCU
Brake Line Routing, Rear
Brake Lines
Inspection
Brake Pads and Discs
Brake Pad Replacement
Inspection
Brakes
Bleeding
Fluid Inspection
Rear Brake Pedal: Pedal Height
Rear Brake Pedal: Pedal Lubrication
Rear Brake Pedal: Pedal Pad
Breather Assembly
Cleaning and Inspection
Disassembly
Operation
Bulb Requirements
General
c
Cable and Chassis Lubrication
Jiffy Stand
Steering Head Bearings
Cam Support Plate
Cam Needle Bearings
Camshafts
Cleaning and Inspection
Installation
Oil Pressure Relief Valve
Removal
Capacities
Engine Oil (Table)
Engine Oil (Table)
Fuel (Table)
Fuel (Table)
Low Fuel Level (Table)
Low Fuel Level (Table)
Primary Chaincase (Table)
Primary Chaincase (Table)
Transmission (Table)
Transmission (Table)
Carrying Capacity
Cleaning
Bearings
Cleaning Process
Part Protection
Rust or Corrosion Removal
Clutch
Adjustment
Clutch Pack and Bearing
Clutch Pack Only
Removal and Installation
Clutch Hand Control
Installation
Removal
Clutch Release Cover
Assembly and Installation
Cleaning and Inspection
Clutch Switch
Replacement
Compression Test
Connectors
Autofuse Unsealed
Bosch Compact 11M
Connector Number
Delphi 100W Micro-Pack Sealed
Delphi 150 Metri-Pack Sealed
Delphi 280 Metri-Pack Unsealed
Delphi 480 Metri-Pack Unsealed
Delphi 630 Metri-Pack Unsealed
Delphi 800 Metri-Pack Sealed
Delphi GT 150 Sealed
Delphi GT 280 Sealed
Delphi Micro 64 Sealed
Description
Deutsch DTM Sealed Mini
Deutsch DTM Sealed Solid Barrel
Deutsch DT Sealed
Function
JAE MX19 Sealed
Location Table
Metri-Pack Terminal Crimps
Molex CMC Sealed
Molex MX 150 Sealed
Repair Instruction
Sealed Splice
Tyco 070 Multilock Unsealed
Tyco GET 64 Sealed Connector
Tyco MCP
Console: FXS
Console: FXS
Conversions
Fluid
Length
Torque
Counterbalancer Assembly
Cleaning, Inspection and Repair
Crankcase
Cleaning and Inspection
Cylinder Studs
Left Crankcase Half
Pipe Plugs and Oil Fittings
Right Crankcase Half
Sprocket Shaft Bearing Inner Race
Crank Position Sensor (CKP)
Installation
Removal
Crankshaft Runout, Measuring
Crankshaft Installed
Crankshaft Removed
Critical Fasteners
Cylinder
Boring and Honing
Cleaning
Deglazing
Inspection
Cylinder Head
Assembly
Cleaning
Disassembly
Inspection
Inspection: Tapered Keepers
Inspection: Valve Guides
Inspection: Valves
Inspection: Valve Seats
Inspection: Valve Springs
Valve and Seat Refacing
Valve Guide Installation
Valve Guide Removal
D
Delphi 100W Sealed Connector
Repair
Delphi 150 Metri-Pack Connector
Repair
Delphi 280 Metri-Pack Unsealed Connectors
Delphi 480 Metri-Pack Unsealed Connector
Repair
Delphi 630 Metri-Pack Unsealed Connector
Delphi 800 Metri-Pack Sealed Connectors
Repair
Delphi GT 150 Sealed Connector
Repair
Delphi GT 280 Sealed Connector
Delphi Micro-64 Sealed Connector
Repair
Deutsch Connector
Crimping Standard Terminals
Deutsch DTM Sealed Mini Connector
Crimping Terminals
Deutsch DTM Sealed Solid Barrel Connector
Crimping Terminals
Deutsch DT Sealed Connector
Repair
Drive Assembly
Starter Motor
Drive Belt
Cleaning
Inspection
Installation
Removal
Drive Belt and Sprockets
Adjusting Belt Deflection
Checking Belt Deflection
Inspection
Drive Components
Installation
Removal
E
Electrical Panel
General
Electrical Panel:AII But FXSB
Installation
Electrical Panel: All But FXSB
Removal
Electronic Control Module
General
Electronic Control Module: All But FXSB
Installation
Removal
Electronic Control Module: FXSB
Installation
Removal
Electronic Control Unit (ECU): All But FXSB
Installation
Removal
Electronic Control Unit (ECU): FXSB
Installation
Removal
Engine
Compression Test
Symptoms For Engine Repair
Engine Oil
Capacity (Table)
Capacity (Table)
Recommended Engine Oils
Winter Lubrication
Engine Oil and Filter
Changing Oil and Filter
Checking and Adding Oil: Checking Oil Level
Checking and Adding Oil: Type of Oil
Engine Oil Flow
Bottom End
Chain Guide Bracket
Oil Feed
Oil Return
Top End
Engine Temperature Sensor (ET)
Installation
Removal
Evaporative Emissions Control
Charcoal Canister
Hose Routing/Replacement
Purge Solenoid
Exhaust System
Exhaust System Leak Check
Leakage Repair Procedures
Exhaust System: FLSTC, FXST, FXSB
Installation
Mufflers
Removal
Exhaust System: FLSTN, FLSTF/B, FLS, FXS
Installation
Mufflers
Removal
F
Fluid Conversions
Fluids and Lubricants
Disposal and Recycling
Flywheel/Connecting Rod
General
Inspection
FOB
Assignment
Battery Replacement
Footboards and Footrests
Passenger Footrests
Rider Footboards
DirJrvr
Fork Lock
Installation
Removal
Front Brake Caliper
Assembly
Cleaning, Inspection and Repair
Disassembly
Installation
Removal
Front Brake Master Cylinder
Assembly and Installation
Assembly and Installation
Cleaning and Inspection
General
Removal and Disassembly
Front Brake Switch
Replacement
Front Fender
Installation
Removal
Front Fork Oil
Replacing Fork Oil
Front Forks
Assembly
Cleaning and Inspection
Disassembly
General
Installation
Removal
Front HCU-to-Front Caliper
Removal and Installation
Front Master Cylinder-to-Front HCU
Removal and Installation
Front Wheel
Assembly: Disc Wheel
Assembly: Laced Wheel
Cleaning and Inspection
Disassembly: Disc Wheel
Disassembly: Laced Wheel
Installation
Removal
Fuel
Capacities (Table)
Capacities (Table)
Gasoline Blends
Low Fuel Level (Table)
Low Fuel Level (Table)
Recommended Fuel
Fuel Gauge
General
Installation
Removal
Fuel Injectors
Installation
Removal
Fuel Pressure Test
Testing
Fuel Pump/Fuel Gauge Sending Unit
Installation
Fuel Pump/Fuel Guage Sending Unit
Disassembly/Assembly
General
Fuel Supply Line
Disconnect
Purge
Fuel Tank
Cleaning and Inspection
General
Installation
Removal
Fuse Block Repair
Fuses
Installation
Removal
G
Glossary
Acronyms and Abbreviations
H
Handlebars
Installation
Lower Clamps
Handlebars: FLSTC/FLSTN
Installation
Removal
Handlebars: FLSTF
Removal
Handlebars: FLSTF/B
Installation
Handlebars: FXS
Handlebars: FXS
Handlebar Switch Assembly, Left
Installation
Removal
Handlebar Switch Assembly, Right
Installation
Removal
Handlebar Switches
General
Repair Procedures
Headlamp
Adjustment
Alignment
Assembly Removal and Installation
Bulb Removal and Installation
Bulbs (Table)
General
Horn
Inspection
Horn: All But FXS/B
Removal and Installation
Horn: FXS/B
Removal and Installation
Hydraulic Control Unit (Front)
Installation
Removal
Hydraulic Control Unit (Rear)
Installation
Removal
I
Idle Air Control
Installation
Removal
Ignition/Light Switch
Ignition/Light Switch: All But FXS/B
Removal and Installation
Ignition/Light Switch: FXS/B
Removal and Installation
Ignition Coil
Installation
Removal
Indicator Lamp: FXSB
Installation
Removal
Indicator Lamps: All But FXS
General
Indicator Lamps: All But FXS/B
Installation
Removal
Indicator Lamps: FXS
Installation
Removal
Induction Module
Installation
Removal
Installing engine in chassis
Procedure
Intake Air Temperature Senor (IAT)
Installation
Intake Air Temperature Sensor (IAT)
Removal
Intake Leak Test
Leak Tester: Parts List
Leak Tester: Tester Adjustment
Leak Tester: Tester Assembly
Procedure
J
JAE MX19 Sealed Connectors
Crimping Terminals
Crimping Terminals
Housings
Installing Terminals
Removing Terminals
Jiffy Stand
Cleaning
Installation
Removal
Sensor (HDI Models)
L
Laced Wheel Rim Offset
License Plate Bracket
Front – India Only
Light Bulbs (Table)
LOCTITE
Luggage Rack: FLSTN
Removal/Installation
M
Main Drive Gear and Bearing
Cleaning and Inspection
Installation
Needle Bearing Replacement
Removal
Maintenance
Brake Line Inspection (Table)
Recommended Engine Oils
Transmission Lubricant Change
Main Wiring Harness
Installation
Removal
Manifold Absolute Pressure Sensor (MAP)
Installation
Removal
Medallions
Metric System
Metri-Pack Terminal Crimps
Molex CMC Sealed Connectors
Crimping Terminals
Housings
Installing Terminals
Removing Terminals
Molex MX 150 Sealed Connector
Repair
Terminal Crimps
N
Neutral Switch
General
Installation
Removal
O
Oil
Oil Pressure
Indicator Lamp
Testing
Oil Pressure Relief Valve
Remove, Inspect, and Install
Oil Pressure Switch
General
Installation
Removal
Oil Pump
Cleaning and Inspection
Installation
Operation
Removal
Oil Tank
Installation
Installation
Removal and Disassembly
Removal and Disassembly
Oxygen Sensor
Installation
Removal
P
Personal Identification Number (PIN)
Changing the PIN
Modifying an Existing PIN
Piston
Assembly
Cleaning
Disassembly
Inspection
Primary Chain
Automatic Chain Adjuster
Primary Chaincase
Changing Lubricant
Installation
Lubricant Capacity (Table)
Lubricant Capacity (Table)
Mainshaft Bearing and Lip Seal
Primary Chaincase Cover
Installation
Removal
Primary Chaincase Housing
Inspection
Mainshaft Bearing Inner Race
Removal
Purge Solenoid
Evaporative Emissions Control
Pushrods, Lifters and Covers
Assembly
Cleaning and Inspection
Disassembly
Lifter Inspection
R
Rear Brake Caliper
Assembly
Cleaning, Inspection and Repair
Disassembly
Installation
Removal
Rear Brake Master Cylinder
Assembly
Cleaning and Inspection
Disassembly
Installation
Removal
Rear Electrical Panel: FXSB
Installation
Removal
Rear Fender
Installation
Removal
Rear Fender: FLSTC
Installation
Removal
Rear Fender: FLSTF
Installation
Removal
Rear Fender: FLSTN
Assembly
Disassembly
Installation
Removal
Rear Fender: FXS
Installation
Removal
Rear Fender: FXST
Installation
Removal
Rear Fender Wire Conduit
Installation
Rear Fork
Cleaning and Inspection
Installation
Pivot Bearing Replacement
Removal
Rear HCU-to-Rear Caliper
Removal and Installation
Rear Master Cylinder-to-Rear HCU
Removal and Installation
Rear Shock Absorbers
General
Installation
Removal
Rear stop lamp Switch
General
Rear Stop Lamp Switch
Installation
Removal
Rear Wheel
Assembly
Cleaning and Inspection
Disassembly
Installation
Removal
Removing Engine From Chassis
Procedure
Repair and Replacement Procedures
Bearings
Bushings
Gaskets
Gears
Hardware and Threaded Parts
Lip Type Seals
O-Rings
Part Replacement
Shafts
Threadlocking Agents
Wiring, Hoses and Lines
Rocker Arms
Install Bushings
Remove Bushings
Shaft to Bushing
Shaft to Support Plate
Rocker Arm Support Plate
Disassembly
Inspection
s
Saddlebags: FLSTC
Installation
Removal
Safe Operating Maintenance
Saree Guard
Left Side
Right Side
Sealed Splice Connectors
Sealed Wheel Bearings
Installation
Removal
Seat: FLSTN/FLSTF/FLSTC
Removal/Installation
Seat/Strap Retention Unit
Replacement
Seats: FXS/FXST
Installation
Seats: FXST
Removal
Security Siren: All But FXSB
Installation
Removal
Security Siren: FXSB
Installation
Removal
Serialized Badges
Service Bulletins
Service Preparation
Service Wear Limits
Engine
Transmission
Servicing a New Motorcycle
Shift Lever
Replacement
Shift Linkage
Adjustment
Shifter Rod
Shock Absorber
Disposal
Shock Absorbers
Adjustment
Shop Practices
Checking Torques
Cleaning
Disassembly and Assembly
Disposal and Recycling
Magnetic Parts Trays
Removing Parts
Safety
Sidecar Configuration
Solenoid
Long Post Contact
Plunger
Short Post Contact
Spark Plug Cables
General
Inspection
Installation
Spark Plugs
Cleaning
Inspection
Installation
Removal
Specifications
Dimensions (Table)
Drive
Engine
Fuel System
Height (Table)
Length (Table)
Tires (Table)
Tires (Table)
Transmission
Weight (Table)
Width (Table)
Speedometer
General
Speedometer: All But FXS/B
Installation
Removal
Speedometer: FXS
Installation
Removal
Speedometer: FXSB
Installation
Removal
Spokes
Adjustment
SPX Kent-Moore
Starter
Drive Assembly
Installation
Removal
Solenoid
Steer Head Bearings
Adjustment
Adjustment
Lubrication
Steering Head
Assembly
Disassembly
Inspection: All Models
Installation
Removal
Steering Head Bearing Race Removal
Steering Head Bearings
Adjustment
Storage
Placing In Storage
Removal from Storage
Stripping Motorcycle for Service
Procedure
Switch Assembly, Handlebar, Left
Installation
Removal
Switch Assembly, Handlebar, Right
Installation
Removal
T
Tail Lamp
Bulb (Table)
Tail Lamp: All But FLSTN
Base Replacement
Bulb Replacement
General
Tail Lamp: FLSTN
Bulb Replacement
Tail Lamp Replacement
Tank Emblems
Throttle Cables
Inspection, Lubrication and Adjustment
Throttle Control
Assembly/Installation
Cleaning and Inspection
Removal/Disassembly
Throttle Position Sensor (TP)
General
Installation
Removal
Tire Replacement
Inspection
When To Replace
Tires
Checking Runout
Cleaning, Inspection and Repair
Installation
Pressure (Table)
Pressure (Table)
Removal
Specifications (Table)
Specifications (Table)
Wear Bar Indicators
Wheel Balancing
Tool Safety
Air Tools
Hammers
Pliers/Cutters/Pry bars
Punches/Chisels
Ratchets and Handles
Screwdrivers
Sockets
Storage Units
Wrenches
Top End Overhaul
Cylinder
Disassembly
Pushrods, Lifters and Covers
Top End Overhaul: Assembly
Breather Assembly
Piston
Rocker Arm Support Plate
Top End Overhaul: Disassembly
Cylinder
Cylinder Head
Piston
Pushrods, Lifters and Covers
Rocker Arm Support Plate
Rocker Covers
Top End Service
Engine in Chassis
Engine Removed from Chassis
Torque Conversion
Trademarks
Harley-Davidson
Referenced Products
Transmission
Assembly
Changing Lubricant
Checking Lubricant Level
Cleaning and Inspection
Disassembly
Lubricant Capacity (Table)
Lubricant Capacity (Table)
Theory of Operation
Transmission Assembly
Installation
Removal
Transmission Case
Assembly
Cleaning and Inspection
Disassembly
Installation
Removal
Transmission Clutch Release Cover
Removal and Disassembly
Transmission Sprocket
Cleaning and Inspection
Installation
Removal
Troubleshooting
Brakes
Compression Test
Cylinder Leakdown Test
Diagnosing Smoking Engine or High Oil
Consumption
Diagnosing Valve Train Noise
Electrical System
Engine
Handling
Lubrication System
Transmission
Truing Laced Wheels
Lateral Runout
Radial Runout
TSSM/HFSM Maintenance
FOB Battery
Turn Signals
Bulbs (Table)
Turn Signals/Running Lights
Bulb Replacement: Bullet Style
Bulb Replacement: Flat Lens Style
Lamp Replacement
Tyco 070 Multilock Unsealed Connector
Repair
Tyco GET 64 Sealed Connector
Crimping Terminals
Tyco MCP Connectors
Crimping Terminals
Installing Terminals
Removing Large Socket Terminals
Removing Small Socket Terminals
V
VIN
Vehicle Identification Number
Vapor Valve
Removal and Installation
Vehicle Identification Number (VIN)
Vehicle Speed Sensor (VSS)
General
Installation
Removal
Voltage Regulator
Installation
Removal
W
Weight Limits (Table)
Wheel Bearings
Check End Play
Wheel Lacing
Angle Flange Hub
Wheel Runout
Checking
Lateral
Radial
Wheels
Balancing
Laced Wheel Rim Offset
Spokes
Truing Laced Wheels
Weights
Wheel Bearings
Wheel Speed Sensor (Front)
Installation
Removal
Wheel Speed Sensor (Rear)
Installation
Removal
Windshield: FLSTC
Installation
Removal
Winter Lubrication
Wiring
Color Codes
Diagram Symbols
Wiring Diagram List