2013 Harley-Davidson Trike Model

Service Manual Supplement

99601-13
©2012 H-D.
 IMPORTANT NOTICE

Harley-Davidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards
and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture.

To maintain the safety, dependability, and emission and noise control performance, it is essential that
the procedures, specifications and service instructions in this manual are followed.

Any substitution, alteration or adjustment of emission system and noise control components outside of
factory specifications may be prohibited by law.

Harley-Davidson Motor Company

2013 Harley-Davidson Trike
Model Service Manual
Supplement

©2012 H-D.
ALL RIGHTS RESERVED
99601-13

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITE

http://www.harley-davidson.com
Blank Text Here
 READER COMMENTS
Blank Text Here
The Harley-Davidson Service Communications Department maintains a continuous effort to improve the quality
and usefulness of its publications. To do this effectively, we need user feedback - your critical evaluation of
this manual.

Please comment on the completeness, accuracy, organization, usability, and readability of this manual.

Please list the page, item, and part number(s) of any errors you find in this manual.

Please tell us how we can improve this manual.

Occupation:

Name: Dealership:

Street: Department:

City: State: Zip:

2013 Harley-Davidson Trike Model Service Manual Supplement (99601-13)

Please clip out and mail to:
Service Communications Department
Harley-Davidson Motor Company
P.O. Box 653
Milwaukee, WI USA 53201
NOTES
ABOUT THIS MANUAL
GENERAL PREPARATION FOR SERVICE
This service manual supplement has been designed to be used
with the current service manual and has been prepared with PART NUMBER TOOL NAME
two purposes in mind. HD-48650 DIGITAL TECHNICIAN II
• It will acquaint the user with the construction of the Harley-
Davidson product and assist in the performance of basic
maintenance and repair.
• It will introduce to the professional Harley-Davidson Stop the engine when refueling or servicing the fuel
Technician the latest field-tested and factory-approved system. Do not smoke or allow open flame or sparks near
major repair methods. gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
We sincerely believe that this service manual supplement will (00002a)
make your association with Harley-Davidson products more
pleasant and profitable. Good preparation is very important for efficient service work.
Start each job with a clean work area. This will allow the repair
NOTE to proceed as smoothly as possible. It will also reduce the
This service manual supplement provides information unique incidence of misplaced tools and parts. Clean a motorcycle
to this model motorcycle. Any information not presented in this that is excessively dirty before work starts. Cleaning will occa-
supplement can be found in the appropriate service manual or sionally uncover sources of trouble. Gather any tools, instru-
electrical diagnostic manual. Refer to Table i-1. ments and any parts needed for the job before work begins.
Interrupting a job to locate tools or parts is a distraction and
causes needless delay.
Table i-1. Relevant Model Year Publications
NOTES
PUBLICATION PART NUMBER
• To avoid unnecessary disassembly, carefully read all
Touring Models Service Manual 99483-13 related service information before repair work begins.
Touring Models Electrical Diagnostic 99497-13
• In figure legends, the number which follows the name of

FOREWORD
Manual
a part indicates the quantity necessary for one complete
assembly.
HOW TO USE YOUR SERVICE MANUAL
SUPPLEMENT • When servicing a vehicle equipped with the Harley-Dav-
idson Smart Security System (H-DSSS), it must first be
Use the TABLE OF CONTENTS (which follows this FORE- disarmed. Keep the fob close to the vehicle or use
WORD) and the INDEX (at the back of this manual) to quickly DIGITAL TECHNICIAN II (Part No. HD-48650) to disable
locate subjects. Sections and topics in this manual are the system. Activate the system after service is completed.
sequentially numbered for easy navigation.
SERVICE BULLETINS
NO. CHAPTER
In addition to the information presented in this service manual
1 Maintenance supplement and the appropriate service manual, Harley-Dav-
2 Chassis idson Motor Company will periodically issue Service Bulletins
to Harley-Davidson dealers. Service bulletins cover interim
3 Engine engineering changes and supplementary information. Consult
4 Fuel System the service bulletins to keep your product knowledge current
and complete.
5 Drive
6 Transmission USE GENUINE REPLACEMENT PARTS
7 Electrical
A Appendix A Wiring
Harley-Davidson parts and accessories are designed for
For example, a cross-reference shown as 2.1 Harley-Davidson motorcycles. Using non-Harley-Davidson
SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 parts or accessories can adversely affect performance,
SPECIFICATIONS. stability or handling, which could result in death or serious
If the subject you seek is not in this supplement, refer to the injury. (00001b)
corresponding chapter in the appropriate service manual. To achieve satisfactory and lasting repairs, carefully follow the
Check the title page located in the front of each chapter to find service manual instructions and use only genuine Harley-
the subject. Davidson replacement parts. Behind the emblem bearing the
For quick and easy reference, all pages contain a chapter words GENUINE HARLEY-DAVIDSON stand more than 100
number followed by a page number. For example, page 3-5 years of design, research, manufacturing, testing and inspecting
refers to page 5 in chapter 3. experience. This is your assurance that the parts you are using
will fit right, operate properly and last longer.
In figure legends, the number following the name of a part
indicates the quantity necessary for one complete assembly.

I
WARNINGS AND CAUTIONS When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool
Statements in this manual preceded by the following words or instrument may be substituted.
are of special significance.
Kent-Moore Products
All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX Kent-Moore. For ordering
WARNING indicates a potentially hazardous situation information or product returns, warranty or otherwise, visit
which, if not avoided, could result in death or serious www.spx.com.
injury. (00119a)
LOCTITE Sealing and THREADLOCKING
Products
CAUTION indicates a potentially hazardous situation which, Some procedures in this manual call for the use of LOCTITE
if not avoided, may result in minor or moderate injury. products. If you have any questions regarding LOCTITE product
(00139a) usage or retailer/wholesaler locations, contact Loctite Corp. at
www.loctite.com.

PRODUCT REGISTERED MARKS

NOTICE indicates a potentially hazardous situation which, Apple, Alcantara S.p.A., Allen, Amp Multilock, Bluetooth,
if not avoided, may result in property damage. (00140b) Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E.
Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod,
NOTE Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Magnaflux,
Refers to important information, and is placed in italic type. It Marson Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin,
is recommended that you take special notice of these items. MPZ, Mulitilock, nano, NGK, Novus, Packard, Pirelli, Permatex,
Philips, PJ1, Pozidriv, Robinair, S100, Sems, Snap-on, Teflon,
Proper service and repair is important for the safe, reliable Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch,
operation of all mechanical products. The service procedures Velcro, X-Acto, XM Satellite Radio, and zumo are among the
recommended and described in this manual are effective trademarks of their respective owners.
methods for performing service operations.
H-D MICHIGAN, INC. TRADEMARK
INFORMATION
Always wear proper eye protection when using hammers, Bar & Shield, Cross Bones, Digital Tech, Digital Technician,
arbor or hydraulic presses, gear pullers, spring com- Digital Technician II, Dyna, Electra Glide, Evolution, Fat Bob,
pressors, slide hammers and similar tools. Flying parts Fat Boy, Forty-Eight, Glaze, Gloss, H-D, H-Dnet.com, Harley,
could result in death or serious injury. (00496b) Harley-Davidson, HD, Heritage Softail, Iron 883, Low Rider,
Night Rod, Nightster, Night Train, Profile, Revolution, Road
Some of these service operations require the use of tools
Glide, Road King, Road Tech, Rocker, Screamin' Eagle, Sev-
specially designed for the purpose. These special tools should
enty-Two, Softail, Sportster, Street Glide, Street Rod, Sun Ray,
be used when and as recommended. It is important to note
Sunwash, Super Glide, SuperLow, Switchback, SYN3, Tech-
that some warnings against the use of specific service methods,
Link, TechLink II, Tour-Pak, Twin Cam 88, Twin Cam 88B,
which could damage the motorcycle or render it unsafe, are
Twin Cam 96, Twin Cam 96B, Twin Cam 103, Twin Cam 103B,
stated in this manual. However, remember that these warnings
Twin Cam 110, Twin Cam 110B, Ultra Classic, V-Rod, VRSC,
are not all-inclusive. Inadequate safety precautions could result
XR1200X and Harley-Davidson Genuine Motor Parts and
in death or serious injury.
Genuine Motor Accessories are among the trademarks of H-
Since Harley-Davidson could not possibly know, evaluate or D Michigan, Inc.
advise the service trade of all possible ways in which service
might be performed, or of the possible hazardous con- CONTENTS
sequences of each method, we have not undertaken any such All photographs, illustrations and procedures may not neces-
broad evaluation. Accordingly, anyone who uses a service sarily depict the most current model or component, but are
procedure or tool which is not recommended by Harley-Dav- based on the latest production information available at the time
idson must first thoroughly satisfy himself that neither his nor of publication.
the operator's safety will be jeopardized as a result. Failure to
do so could result in death or serious injury. Since product improvement is our continual goal, Harley-Dav-
idson reserves the right to change specifications, equipment
PRODUCT REFERENCES or designs at any time without notice and without incurring
obligation.

Read and follow warnings and directions on all products.

Failure to follow warnings and directions can result in
death or serious injury. (00470b)

II FOREWORD
MAINTENANCE 1.17 TROUBLESHOOTING
General.............................................................................1-26
1.1 FASTENER TORQUE VALUES Engine...............................................................................1-26
Starter Motor Does Not Operate or Does Not Turn Engine
Fastener Torque Values in this Chapter..............................1-1
Over ..........................................................................1-26
Engine Turns Over But Does Not Start ....................1-26
1.2 LIFTING MOTORCYCLE WITH A JACK
Starts Hard................................................................1-26
Jacking Points.....................................................................1-2 Starts But Runs Irregularly or Misses .......................1-26
A Spark Plug Fouls Repeatedly................................1-27
1.3 BULB REQUIREMENTS Pre-Ignition or Detonation (Knocks or Pings)............1-27
General...............................................................................1-3 Overheating...............................................................1-27
Valve Train Noise.......................................................1-27
1.4 MAINTENANCE SCHEDULE Excessive Vibration...................................................1-27
General...............................................................................1-4 Check Engine Light Illuminates During Operation.....1-27
Lubrication System...........................................................1-27
1.5 LUBRICANTS Oil Does Not Return To Oil Reservoir........................1-27
Engine Uses Too Much Oil Or Smokes Excessively..1-27
Engine Oil Level..................................................................1-9
Engine Leaks Oil From Cases, Push Rods, Hoses,
Oil Level Cold Check...................................................1-9
Etc.............................................................................1-27
Oil Level Hot Check.....................................................1-9
Low Oil Pressure.......................................................1-28
Checking Transmission Lubricant Level...........................1-10
High Oil Pressure......................................................1-28
1.6 REAR BRAKES Electrical System..............................................................1-28
Alternator Does Not Charge......................................1-28
Fluid Inspection.................................................................1-11 Alternator Charge Rate Is Below Normal..................1-28
Brake Lines.......................................................................1-11 Speedometer Operates Erratically............................1-28
Transmission....................................................................1-28
1.7 REAR BRAKE PADS AND DISCS Shifts Hard.................................................................1-28

TABLE OF CONTENTS
Inspection.........................................................................1-12 Jumps Out Of Gear...................................................1-28
Brake Pads................................................................1-12 Clutch Slips................................................................1-28
Brake Disc Thickness................................................1-12 Clutch Drags Or Does Not Release..........................1-28
Brake Disc Lateral Runout........................................1-12 Clutch Chatters..........................................................1-28
Replacement.....................................................................1-12 Handling............................................................................1-28
Irregularities...............................................................1-28
1.8 REAR TIRES Brakes...............................................................................1-29
Inspection.........................................................................1-14 Brake Does Not Operate Normally............................1-29
Tire Pressure.............................................................1-14 Park Brake Does Not Hold Normally.........................1-29
Tire Wear ..................................................................1-14 Reverse Motor..................................................................1-29
Tire Replacement......................................................1-14 Reverse Motor Does Not Operate/Cannot Enable.....1-29
Tire Balancing............................................................1-14
CHASSIS
1.9 DRIVE BELT
Checking Drive Belt Deflection.........................................1-15 2.1 FASTENER TORQUE VALUES
Setting Deflection..............................................................1-15 Fastener Torque Values in this Chapter..............................2-1
1.10 REAR WHEEL COMPENSATOR 2.2 SPECIFICATIONS
Checking Isolator Wear....................................................1-17 General...............................................................................2-4
1.11 PARK BRAKE 2.3 VEHICLE IDENTIFICATION NUMBER
Adjustment........................................................................1-18 (VIN)
1.12 REAR SUSPENSION ADJUSTMENTS Vehicle Identification Number (VIN)....................................2-5
General........................................................................2-5
General.............................................................................1-20
Location.......................................................................2-5
1.13 STEERING HEAD BEARINGS Abbreviated VIN..........................................................2-5

Checking...........................................................................1-21 2.4 REAR WHEELS

1.14 STEERING DAMPER Removal..............................................................................2-7
Installation...........................................................................2-7
Inspection.........................................................................1-22
2.5 REAR BRAKE CALIPERS
1.15 FORK OIL
Removal..............................................................................2-8
Procedure.........................................................................1-23 Installation...........................................................................2-8
Repair.................................................................................2-9
1.16 CRITICAL FASTENERS Disassembly................................................................2-9
Inspection.........................................................................1-24 Assembly.....................................................................2-9
Checking Torques on Fasteners................................1-24

III
TABLE OF CONTENTS
2.6 REAR BRAKE MASTER Assembly..........................................................................2-29
Installation.........................................................................2-29
CYLINDER/PEDAL
General.............................................................................2-10 2.14 INTERMEDIATE FRAME
Removal............................................................................2-10 Removal............................................................................2-31
Disassembly.....................................................................2-11 Disassembly.....................................................................2-31
Cleaning and Inspection...................................................2-12 Assembly..........................................................................2-32
Assembly..........................................................................2-12 Installation.........................................................................2-32
Installation.........................................................................2-12
Rear Brake Line................................................................2-13 2.15 REAR FORK
Removal....................................................................2-13
Removal............................................................................2-34
Installation.................................................................2-13
Repair...............................................................................2-35
2.7 BLEEDING BRAKES Bearing Removal.......................................................2-35
Bearing Installation....................................................2-35
General.............................................................................2-15 Installation.........................................................................2-37
Procedure.........................................................................2-15
2.16 LATERAL ALIGNMENT
2.8 TRUNK DOOR
Procedure.........................................................................2-38
Removal............................................................................2-17
Disassembly.....................................................................2-18 2.17 PARK BRAKE ASSEMBLY
Assembly..........................................................................2-18
Cable Removal.................................................................2-39
Installation.........................................................................2-18
Handle Disassembly.........................................................2-39
2.9 TRUNK DOOR LOCKSET Assemble Handle..............................................................2-39
Cable Installation..............................................................2-42
Lockset.............................................................................2-19
Removal/Disassembly...............................................2-19 2.18 SHOCK ABSORBERS
Assembly/Installation.................................................2-19
Removal............................................................................2-43
Latch Assembly................................................................2-20
Installation.........................................................................2-43
Removal....................................................................2-20
Lock Assembly Removal...........................................2-20 2.19 PANHARD ROD
Lock Assembly Installation........................................2-20
Latch Mechanism Replacement................................2-21 Removal............................................................................2-44
Installation.................................................................2-21 Installation.........................................................................2-44
Latch Pin...........................................................................2-22 Adjustment........................................................................2-45
Removal....................................................................2-22
Installation.................................................................2-22 2.20 STEERING DAMPER ASSEMBLY
Removal............................................................................2-46
2.10 TOUR-PAK Installation.........................................................................2-46
Removal............................................................................2-23
Installation.........................................................................2-23 2.21 FRONT WHEEL
Removal............................................................................2-47
2.11 BODY Installation.........................................................................2-47
Removal............................................................................2-24
Disassembly.....................................................................2-24 2.22 FRONT FENDER
Repair...............................................................................2-24 Removal............................................................................2-48
Threaded Inserts.......................................................2-24 Installation.........................................................................2-48
Assembly..........................................................................2-25
Installation.........................................................................2-25 2.23 ENGINE STABILIZER
Trunk Door Seal................................................................2-26 Stabilizer Link...................................................................2-49
Inspection..................................................................2-26 Removal....................................................................2-49
Replacement.............................................................2-26 Installation.................................................................2-49
Bracket......................................................................2-49
2.12 REAR FENDERS
Removal............................................................................2-27 ENGINE
Disassembly.....................................................................2-27
Assembly..........................................................................2-27 3.1 SPECIFICATIONS: ENGINE
Installation.........................................................................2-27
General Specifications: Twin Cam 103™...........................3-1
2.13 REAR FRAME
Removal............................................................................2-29
Disassembly.....................................................................2-29

IV TABLE OF CONTENTS
 TABLE OF CONTENTS
FUEL SYSTEM Installation.........................................................................7-10

7.6 TAIL LAMPS/REAR TURN SIGNALS

4.1 FUEL SYSTEM Removal............................................................................7-12
No Unique Content.............................................................4-1 Installation.........................................................................7-12

DRIVE 7.7 TAIL LAMP/REAR TURN SIGNAL

CONVERTER MODULE
5.1 FASTENER TORQUE VALUES Removal............................................................................7-13
Fastener Torque Values in this Chapter..............................5-1 Installation.........................................................................7-13

5.2 AXLE 7.8 LICENSE PLATE LAMPS/BRACKET

Removal..............................................................................5-2 Removal............................................................................7-14
Disassembly.......................................................................5-2 Installation.........................................................................7-14
Assembly............................................................................5-3
Installation...........................................................................5-4 7.9 REAR LIGHTS HARNESS
Removal............................................................................7-15
5.3 AXLE HOUSING/DIFFERENTIAL Installation.........................................................................7-15
Removal..............................................................................5-5
Disassembly.......................................................................5-6 7.10 BANK ANGLE SENSOR (BAS)
Bearings......................................................................5-6 Removal............................................................................7-17
Sprocket......................................................................5-6 Installation.........................................................................7-17
Ring Gear....................................................................5-6
Differential...................................................................5-6 7.11 REVERSE CONTROL SYSTEM
Assembly............................................................................5-7 RCM Replacement...........................................................7-18
Differential...................................................................5-7 Removal....................................................................7-18
Ring Gear....................................................................5-7 Installation.................................................................7-18
Sprocket......................................................................5-7 Reverse Solenoid Replacement.......................................7-18
Bearings......................................................................5-7 Removal....................................................................7-18
Installation...........................................................................5-8 Installation.................................................................7-18
Circuit Breaker Replacement............................................7-19
5.4 DRIVE BELT REPLACEMENT Removal....................................................................7-19
Removal..............................................................................5-9 Installation.................................................................7-19
Installation...........................................................................5-9
7.12 REVERSE JUMPER CABLES/WIRES
TRANSMISSION General.............................................................................7-21
Vehicle Starter to Circuit Breaker Power Lead.................7-21
6.1 TRANSMISSION Removal....................................................................7-21
General...............................................................................6-1 Installation.................................................................7-21
Specifications......................................................................6-1 Circuit Breaker to RCM Solenoid......................................7-21
Removal....................................................................7-21
ELECTRICAL Installation.................................................................7-21
RCM Solenoid to Reverse Motor Solenoid Energizer
Lead..................................................................................7-21
7.1 FASTENER TORQUE VALUES Removal....................................................................7-21
Fastener Torque Values in this Chapter..............................7-1 Installation.................................................................7-22
Circuit Breaker to Reverse Motor Solenoid Power Lead...7-22
7.2 SYSTEM FUSES AND RELAYS Removal....................................................................7-22
General...............................................................................7-4 Installation.................................................................7-22
Reverse Motor to Battery Ground.....................................7-23
7.3 BATTERY TRAY Removal....................................................................7-23
Installation.................................................................7-23
Removal..............................................................................7-5
Installation...........................................................................7-5 7.13 REVERSE MOTOR AND BRACKET
7.4 AUXILIARY LAMPS Removal............................................................................7-24
Disassembly.....................................................................7-24
Removal..............................................................................7-6
Assembly..........................................................................7-25
Installation...........................................................................7-6
Installation.........................................................................7-25
7.5 FRONT TURN SIGNAL LAMPS
Removal..............................................................................7-9

TABLE OF CONTENTS V
TABLE OF CONTENTS
7.14 REVERSE SWITCHES 24. RCM Accessory Power Circuit Test.....................7-37
25. RCM Handlebar Switch Test...............................7-37
Removal............................................................................7-27
Installation.........................................................................7-27 7.16 REVERSE MOTOR TESTING
7.15 REVERSE MOTOR SYSTEM Testing Reverse Motor On Motorcycle.............................7-38
Reverse Motor Current Draw Test.............................7-38
DIAGNOSTICS Testing Reverse Motor on Bench.....................................7-38
Reverse Motor System.....................................................7-29 Free Running Current Draw Test...............................7-38
Operation...................................................................7-29 Reverse Motor Solenoid...................................................7-39
Diagnostic Tips..........................................................7-30 Solenoid Pull-In Test.........................................................7-39
Connector Information...............................................7-31 Solenoid Hold-In Test........................................................7-39
Reverse Enable Indicator Inoperative..............................7-33 Solenoid Return Test........................................................7-40
1. Reverse Enable Circuit Test..................................7-33
2. Reverse Enable Circuit Continuity Test.................7-33 7.17 REAR LIGHTING DIAGNOSTICS
Reverse Enable Indicator On At All Times.......................7-33 Rear Lighting....................................................................7-41
1. Reverse Enable Circuit Test..................................7-33 General......................................................................7-41
2. Reverse Enable Switch Test..................................7-33 Rear Running Lamps................................................7-41
3. Reverse Enable Short to Voltage Test...................7-33 Brake Lamps and Rear Turn Directionals.................7-41
4. Reverse Enable Short to Ground Test...................7-33 Diagnostics.......................................................................7-41
Reverse Motor Spins But Does Not Drive........................7-33 Diagnostic Tips..........................................................7-41
1. Ring Gear Test.......................................................7-33 Connector Information...............................................7-41
2. Reverse Motor Solenoid Test................................7-34 Brake Lamps Inoperative..................................................7-42
Reverse Motor Stalls or Spins Too Slowly........................7-34 1. Stop Lamp Operational Test..................................7-42
1. Circuit Breaker Test...............................................7-34 2. Rear Stop Lamp Switch Voltage Test....................7-42
2. Reverse Motor Solenoid Voltage Drop Test..........7-34 3. Rear Stop Lamp Switch Test.................................7-42
3. Reverse Motor Solenoid Circuit Test.....................7-34 4. Front Stop Lamp switch Voltage Test....................7-43
4. Circuit Breaker Voltage Drop Test.........................7-34 5. Front Stop Lamp Switch Test................................7-43
5. Vehicle Starter Test................................................7-34 6. Bulb Test................................................................7-43
6. Ground Circuit Test................................................7-34 7. Inoperative Lamp Voltage Test..............................7-43
7. Reverse Motor Current Draw On Vehicle Test......7-34 8. Inoperative Lamp Ground Circuit Test...................7-43
8. Reverse Motor Test...............................................7-34 9. Converter Module Test..........................................7-43
9. Reverse Motor Free Running Current Draw Test...7-34 10. Circuit Board Test................................................7-43
Reverse Motor Runs On...................................................7-35 11. Brake Fuse Test...................................................7-43
1. Reverse Solenoid Control Circuit Test...................7-35 12. Stop Lamp Circuit Voltage Test...........................7-43
2. RCM Solenoid Circuit Test....................................7-35 13. Stop Lamp Circuit Ground Test...........................7-43
3. Reverse Motor Solenoid Control Circuit Test........7-35 14. Brake Relay Switch Supply Circuit Test..............7-44
4. RCM Solenoid Control Circuit Test........................7-35 15. Brake Relay Coil Supply Circuit Test...................7-44
5. RCM Test...............................................................7-35 16. Brake Relay Coil Ground Circuit Test..................7-44
6. RCM Switch Test...................................................7-35 17. Brake Relay Test.................................................7-44
Reverse Motor Inoperative...............................................7-35
1. Enable Switch Function Test.................................7-35 7.18 BAS FUNCTION: DTCS B1151, B1152,
2. RCM Circuit Test....................................................7-36
3. Reverse Motor High Current Circuit Test...............7-36
AND B1153
4. Ground Circuit Test................................................7-36 General.............................................................................7-45
5. Reverse Motor Solenoid Test................................7-36 BAS Operation...........................................................7-45
6. Reverse Motor Control Circuit Test.......................7-36 BAS Restart...............................................................7-45
7. RCM Solenoid Control Circuit Test........................7-36 Bank Angle Sensor (BAS).........................................7-45
8. RCM Solenoid Ground Circuit Test.......................7-36 Diagnostics.......................................................................7-45
9. RCM Ground Circuit Test......................................7-36 Diagnostic Tips..........................................................7-45
10. RCM Solenoid Control Circuit Open Test............7-36 Connector Information...............................................7-45
11. RCM Test.............................................................7-36 DTC B1151.......................................................................7-46
12. RCM Drive Switch Circuit Test............................7-36 1. Signal Circuit Test..................................................7-46
13. Circuit Breaker Supply Voltage Test....................7-36 2. BAS Test................................................................7-46
14. Reverse Motor Solenoid Test..............................7-37 3. Siren Test...............................................................7-46
15. Reverse Motor Circuit Solenoid Test...................7-37 4. Wiggle Test............................................................7-46
16. Circuit Breaker Test.............................................7-37 DTC B1152, B1153...........................................................7-47
17. Neutral Circuit Test..............................................7-37 1. Signal Circuit Voltage Test.....................................7-47
18. Accessory Fuse Test...........................................7-37 2. BAS Connection Test............................................7-47
19. Accessory Circuit Open Test...............................7-37 3. Signal Circuit Open Test........................................7-47
20. Ground Circuit Open Test....................................7-37 4. Ground Circuit Open Test......................................7-47
21. Enable Switch Circuit Test...................................7-37 5. Ground Circuit Wiggle Test....................................7-47
22. Neutral Circuit Open Test....................................7-37 6. Ignition Circuit Open Test......................................7-47
23. RCM Ignition Power Test.....................................7-37 7. BAS Signal Voltage Test........................................7-47

VI TABLE OF CONTENTS
 TABLE OF CONTENTS
8. BAS Ground Circuit Test.......................................7-47 Wire Color Codes........................................................A-5
9. TSM/TSSM/HFSM Ground Circuit Test.................7-47 Wiring Diagram Symbols............................................A-5
10. BAS Ignition Circuit Test......................................7-48 Wiring Diagrams.................................................................A-7
11. Ignition Circuit Wiggle Test..................................7-48
12. TSM/TSSM/HFSM Test.......................................7-48 REFERENCE MATERIAL
APPENDIX A WIRING TOOLS...........................................................I
A.1 CONNECTORS TORQUE VALUES.......................................III
Connectors.........................................................................A-1
INDEX..........................................................XI
A.2 WIRING DIAGRAMS
Wiring Diagram Information................................................A-5

TABLE OF CONTENTS VII

NOTES

VIII TABLE OF CONTENTS

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
1.1 FASTENER TORQUE VALUES.................................................................................................1-1
1.2 LIFTING MOTORCYCLE WITH A JACK...................................................................................1-2
1.3 BULB REQUIREMENTS............................................................................................................1-3
1.4 MAINTENANCE SCHEDULE....................................................................................................1-4
1.5 LUBRICANTS............................................................................................................................1-9
1.6 REAR BRAKES.......................................................................................................................1-11
1.7 REAR BRAKE PADS AND DISCS...........................................................................................1-12
1.8 REAR TIRES...........................................................................................................................1-14
1.9 DRIVE BELT............................................................................................................................1-15
1.10 REAR WHEEL COMPENSATOR..........................................................................................1-17
1.11 PARK BRAKE.........................................................................................................................1-18
1.12 REAR SUSPENSION ADJUSTMENTS.................................................................................1-20
1.13 STEERING HEAD BEARINGS..............................................................................................1-21
1.14 STEERING DAMPER............................................................................................................1-22
1.15 FORK OIL..............................................................................................................................1-23
1.16 CRITICAL FASTENERS........................................................................................................1-24
1.17 TROUBLESHOOTING...........................................................................................................1-26

MAINTENANCE
NOTES
HOME

FASTENER TORQUE VALUES 1.1

FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.

FASTENER TORQUE VALUE NOTES

Air cleaner cover bracket screws 108-132 in-lbs 12.2-14.9 Nm 1.4 MAINTENANCE SCHEDULE, General
Air cleaner cover screw 36-60 in-lbs 4.1-6.8 Nm 1.4 MAINTENANCE SCHEDULE, General
Axle adjustment screw jamnut 15-25 ft-lbs 20.3-34.0 Nm 1.9 DRIVE BELT, Setting Deflection
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 1.4 MAINTENANCE SCHEDULE, General
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 1.9 DRIVE BELT, Setting Deflection
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 1.10 REAR WHEEL COMPENSATOR, Checking
Isolator Wear
Brake caliper, front, pad pin 75-102 in-lbs 8.5-11.5 Nm 1.4 MAINTENANCE SCHEDULE, General
Brake caliper, rear, mounting/pad pins 32-36 ft-lbs 43.4-48.8 Nm 1.4 MAINTENANCE SCHEDULE, General
Brake caliper, rear, mounting/pad pins 32-36 ft-lbs 43.4-48.8 Nm 1.7 REAR BRAKE PADS AND DISCS, Replace-
ment
Brake master cylinder, front, reservoir 10-12 in-lbs 1.1-1.4 Nm 1.4 MAINTENANCE SCHEDULE, General
cover screws
Brake master cylinder, rear, reservoir 6-8 in-lbs 0.7-0.9 Nm 1.4 MAINTENANCE SCHEDULE, General
cover screws
Brake master cylinder, rear, reservoir 6-8 in-lbs 0.7-0.9 Nm 1.7 REAR BRAKE PADS AND DISCS, Replace-
cover screws ment
Clutch adjuster screw locknut 72-120 in-lbs 8.1-13.6 Nm 1.4 MAINTENANCE SCHEDULE, General
Clutch inspection cover screws 84-108 in-lbs 9.5-12.2 Nm 1.4 MAINTENANCE SCHEDULE, General
Engine oil drain plug 14-21 ft-lbs 19.0-28.5 Nm 1.4 MAINTENANCE SCHEDULE, General
Handlebar switch housing screw 35-45 in-lbs 4.0-5.1 Nm 1.4 MAINTENANCE SCHEDULE, General
Lower fork bracket pinch bolts 70-75 ft-lbs 94.9-101.7 Nm 1.13 STEERING HEAD BEARINGS, Checking
Lower fork bracket pinch bolts 70-75 ft-lbs 94.9-101.7 Nm 1.15 FORK OIL, Procedure
Lug nuts 90-100 ft-lbs 122.0-135.6 Nm 1.9 DRIVE BELT, Setting Deflection/Always check
lug nut torque within 500-1000 mi (805-1610 km)
after wheel installation.
Park brake actuator shaft locknut 32-36 ft-lbs 43.4-48.8 Nm 1.11 PARK BRAKE, Adjustment/Use new locknut
Pinch block screws 41-45 ft-lbs 55.6-61.0 Nm 1.9 DRIVE BELT, Setting Deflection/Use LOCTITE
243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Primary chaincase drain plug 14-21 ft-lbs 19.0-28.5 Nm 1.4 MAINTENANCE SCHEDULE, General
Spark plug 12-18 ft-lbs 16.3-24.4 Nm 1.4 MAINTENANCE SCHEDULE, General
Top caddy screws 72-96 in-lbs 8.1-10.9 Nm 1.4 MAINTENANCE SCHEDULE, General
Transmission dipstick 25-75 in-lbs 2.8-8.5 Nm 1.4 MAINTENANCE SCHEDULE, General
Transmission dipstick 25-75 in-lbs 2.8-8.5 Nm 1.5 LUBRICANTS, Checking Transmission Lub-
ricant Level
Transmission drain plug 14-21 ft-lbs 19.0-28.5 Nm 1.4 MAINTENANCE SCHEDULE, General

2013 Trike Service Supplement: Maintenance 1-1

HOME

LIFTING MOTORCYCLE WITH A JACK 1.2

JACKING POINTS sm06445

When lifting a motorcycle using a jack, be sure jack con-

tacts both lower frame tubes where down tubes and lower
frame tubes converge. Never lift by jacking on cross-
members, oil pan or other housings. Failure to comply can
cause serious damage resulting in the need to perform
major repair work. (00586c)

NOTES
• Never use differential housing as lifting point.
• Set the park brake and block the wheels as necessary to
prevent the vehicle from rolling.
• Lift against the forgings where the down tubes and lower
frame tubes join. Figure 1-1. Jack Placement Under Front
Because the balance point is toward the rear of the motorcycle,
special consideration must be made when lifting with a jack
for service. sm06448

See Figure 1-1. When lifting the front to remove the front tire
or check steering head bearings, etc., engage the parking
brake. Place the jack under the forward portion of the frame,
approximately centered under the crankshaft, and be sure it
contacts the frame tube forgings on both sides.
See Figure 1-2. When lifting the rear of the motorcycle, secure
the front tire in a wheel vise and secure front end to the
motorcycle lift using straps. Place the jack under the rear por-
tion of the frame, approximately centered under the clutch
cover, and be sure it contacts the frame tube forgings on both
sides.
Alternatively, each rear wheel can be raised by placing a jack
under the left or right side of the axle.

Figure 1-2. Jack Placement Under Rear

1-2 2013 Trike Service Supplement: Maintenance

HOME

BULB REQUIREMENTS 1.3

GENERAL
Table 1-1. Bulb Chart

LAMP (ALL LAMPS 12 VOLT) BULBS CURRENT DRAW HARLEY-DAVIDSON

REQUIRED AMPERAGE PART NUMBER
Headlamp 1 4.58/5.0 68329-03
Tail/stop/rear turn signal lamp 2 0.59/2.10 68167-04
Front turn signal lamp 2 0.59/2.25 69331-02
Tour-Pak tail/stop lamps 2 0.59/2.10 68168-89A
Fender tip lamps 1 0.30 68193-95
Auxiliary lamps 2 2.1 68453-05
Instrument panel lamps* High beam indicator Instrument panel is illuminated with LEDs. Replace entire assembly upon
Oil pressure indicator failure.

Neutral indicator
Turn signal indicator
License plate lamp 2 0.35 52441-95
Reverse enable lamp* Illuminated with an LED. Replace entire assembly upon failure.
Tour-Pak side lamps* Illuminated with an LED. Replace entire assembly upon failure.
Gauge lamps Speedometer N/A N/A N/A
Tachometer N/A N/A N/A
Voltmeter 1 0.24 67445-00
Oil pressure indicator 1 0.24 67445-00
Air temperature gauge 1 0.24 67445-00
Fuel gauge 1 0.24 67445-00
Items with * Illuminated with LEDs. Replace entire assembly upon failure.

2013 Trike Service Supplement: Maintenance 1-3

HOME

MAINTENANCE SCHEDULE 1.4

GENERAL ures, just refer to the table for the recommended service
interval. To quickly reference or verify any specifications, see
FASTENER TORQUE VALUE Table 1-3.

Engine oil drain plug 14-21 ft-lbs 19.0-28.5 Nm If more detailed information is needed, turn to the sections
which follow for step-by-step instructions.
Primary chaincase drain plug 14-21 ft-lbs 19.0-28.5 Nm
Also, throughout this manual, you will be instructed to use
Clutch adjuster screw locknut 72-120 in-lbs 8.1-13.6 Nm
various lubricants, greases and sealants. Refer to Table 1-4
Clutch inspection cover 84-108 in-lbs 9.5-12.2 Nm for the correct part numbers of these items.
screws
NOTE
Transmission drain plug 14-21 ft-lbs 19.0-28.5 Nm
Grease is added to the differential during manufacturing and
Transmission dipstick 25-75 in-lbs 2.8-8.5 Nm will last the life of the motorcycle. Never add grease to the dif-
Brake master cylinder, front, 10-12 in-lbs 1.1-1.4 Nm ferential. Adding grease can cause the differential to be over-
reservoir cover screws filled resulting in damage to grease seals.

Brake master cylinder, rear, 6-8 in-lbs 0.7-0.9 Nm

reservoir cover screws
Brake caliper, front, pad pin 75-102 in-lbs 8.5-11.5 Nm
Brake caliper, rear, 32-36 ft-lbs 43.4-48.8 Nm
mounting/pad pins
Air cleaner cover bracket 108-132 12.2-14.9 Nm
screws in-lbs
Air cleaner cover screw 36-60 in-lbs 4.1-6.8 Nm
Handlebar switch housing 35-45 in-lbs 4.0-5.1 Nm
screw
Spark plug 12-18 ft-lbs 16.3-24.4 Nm
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
Top caddy screws 72-96 in-lbs 8.1-10.9 Nm

The table below lists the periodic maintenance requirements

for Trike model motorcycles. If you are familiar with the proced-

Table 1-2. Regular Service Intervals: 2013 Trike Models

ITEM SERVICED PROCEDURE 1000 MI 5000 MI 10000 15000 20000 25000 30000 35000 40000 45000 50000 NOTES
1600 KM 8000 KM MI MI MI MI MI MI MI MI MI
16000 24000 32000 40000 48000 56000 64000 72000 80000
KM KM KM KM KM KM KM KM KM
Engine oil and filter Replace X X X X X X X X X X X 3, 8
Oil lines and brake Inspect for leaks, X X X X X X X X X X X 1, 3
system contact or abrasion
Air cleaner Inspect, service as X X X X X X X X X X 8
required
Tires Check pressure, X X X X X X X X X X X 3
inspect tread
Primary chaincase Replace X X X X X X 8
lubricant
Transmission lub- Replace X X X 8
ricant
Clutch Check adjustment X X X X X X X X X X X 1, 8
Drive belt and Inspect, adjust belt X X X X X X X X X X X 1
sprocket(s)
Rear sprocket isol- Inspect for wear X X 1
ators
Brake and clutch Check and lub- X X X X X X X X X X X 1
controls ricate
Park brake Inspect, adjust X X X X X X X X X X X 1

1-4 2013 Trike Service Supplement: Maintenance

HOME

Table 1-2. Regular Service Intervals: 2013 Trike Models

ITEM SERVICED PROCEDURE 1000 MI 5000 MI 10000 15000 20000 25000 30000 35000 40000 45000 50000 NOTES
1600 KM 8000 KM MI MI MI MI MI MI MI MI MI
16000 24000 32000 40000 48000 56000 64000 72000 80000
KM KM KM KM KM KM KM KM KM
Fuel lines and fit- Inspect for leaks, X X X X X X X X X X X 1, 3
tings contact or abrasion
Fuel filter element Replace every 100,000 mi (160,000 km). 1
Brake fluid Inspect sight glass X X X X X X X X X X X 4
Brake pads and Inspect for wear X X X X X X X X X X X
discs
Spark plugs Replace X 9
Electrical equip- Check operation X X X X X X X X X X X
ment and switches
Front forks Rebuild X 1, 6
Steering head Lubricate X X X X X
bearings
Steering head Adjust X X 1, 2
bearings
Hydraulic steering Check for leaks, X X X X X X X X X X X 5
damper smooth damper
action, mounting
fastener torque
Air suspension Check pressure, X X X X X X X X X X X 1, 8
operation and
leakage
Fuel door, trunk, Lubricate hinges X X X X X X X X X X X
Tour-Pak (if and latches
equipped)
Critical fasteners Check tightness X X X X X X 1
Battery Check battery and clean connections annually.
Exhaust system Inspect for leaks, X X X X X X X X X X X 3, 8
cracks, and loose
or missing
fasteners or heat
shields
Road test Verify component X X X X X X X X X X X 7
and system func-
tions
NOTES: 1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified.
2. Disassemble, lubricate and inspect every 50,000 mi (80,000 km).
3. Perform annually or at specified intervals, whichever comes first.
4. Change DOT 4 hydraulic brake fluid and flush system every two years.
5. Replace or have rebuilt at 50,000 mi (80,000 km).
6. Disassemble, inspect, rebuild forks and replace fork oil every 50,000 mi (80,000 km).
7. Check reverse operation at each service interval.
8. 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).
9. Perform every two years or at specified intervals, whichever comes first.

Table 1-3. Quick Reference Maintenance Chart

ITEM SERVICED SPECIFICATION DATA

Engine oil and filter Drain plug torque 14-21 ft-lbs (19.0-28.5 Nm)
Oil capacity * 4 qt (3.8 L)
Filter Hand tighten 1/2-3/4 turn after gasket contact

2013 Trike Service Supplement: Maintenance 1-5

HOME

Table 1-3. Quick Reference Maintenance Chart

ITEM SERVICED SPECIFICATION DATA

Primary chain lubricant Lubricant type and capacity FORMULA+ TRANSMISSION AND PRIMARY
CHAINCASE LUBRICANT
or
SCREAMIN' EAGLE SYN3 FULL SYNTHETIC
MOTORCYCLE LUBRICANT 20W50
Wet: 38 oz (1.12 L)
Dry: 45 oz (1.33 L)
Primary chaincase drain plug torque 14-21 ft-lbs (19.0-28.5 Nm)
Clutch adjustment Adjuster screw free play 1/2-1 turn
Adjuster screw locknut torque 72-120 in-lbs (8.1-13.6 Nm)
Free play at hand lever 1/16-1/8 in (1.6-3.2 mm)
Clutch inspection cover torque 84-108 in-lbs (9.5-12.2 Nm)
Transmission lubricant Lubricant level Dipstick between FULL and ADD marks with filler
plug threaded in.
Lubricant type and capacity ** FORMULA+ TRANSMISSION AND PRIMARY
CHAINCASE LUBRICANT
or
SCREAMIN' EAGLE SYN3 FULL SYNTHETIC
MOTORCYCLE LUBRICANT 20W50
32 oz (0.95 L)
Transmission drain plug torque 14-21 ft-lbs (19.0-28.5 Nm)
Transmission dipstick torque 25-75 in-lbs (2.8-8.5 Nm)
Tire pressure and wear Pressure: solo rider or with passenger Front: 36 psi (248 kPa)
Rear: 26 psi (179 kPa)
Wear Replace if less than 1/32 in (0.8 mm) of tread pat-
tern
Brake fluid level (Check Type DOT 4 BRAKE FLUID
sight glass. If fluid is low, Fluid level - inspect sight glass. If not visible, Front: 0.20 in (5.0 mm)
remove reservoir cover remove cover (from top of master cylinder reservoir) Rear: 0.25 in (6.4 mm)
and re-check.)
Master cylinder reservoir cover screw torque Front: 10-12 in-lbs (1.1-1.4 Nm)
Rear: 6-8 in-lbs (0.7-0.9 Nm)
Brake pads and discs Minimum brake pad thickness Front: 0.016 in (0.4 mm)
Rear: 0.050 in (1.27 mm)
Brake caliper pad pin torque Front: 75-102 in-lbs (8.5-11.5 Nm)
Rear: 32-36 ft-lbs (43.4-48.8 Nm)
Minimum brake disc thickness Front: 0.180 in (4.5 mm)
Rear: 0.220 in (5.59 mm)
Maximum brake disc lateral runout and warpage 0.008 in (0.20 mm)
(front and rear)
Drive belt deflection Upward force applied at midpoint of bottom belt 10 lb. (4.5 kg)
strand
Deflection 3/8-7/16 in (9.5-11.1 mm)
Air cleaner Air cleaner cover bracket screw torque 108-132 in-lbs (12.2-14.9 Nm)
Air cleaner cover screw torque 36-60 in-lbs (4.1-6.8 Nm)
Air cleaner cover screw Threadlocker LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue)
Clutch cable Lubricant Harley® Lube
Handlebar switch housing screw torque 35-45 in-lbs (4.0-5.1 Nm)

1-6 2013 Trike Service Supplement: Maintenance

HOME

Table 1-3. Quick Reference Maintenance Chart

ITEM SERVICED SPECIFICATION DATA

Spark plugs Type HD-6R12
Gap 0.038-0.043 in (0.97-1.09 mm)
Torque 12-18 ft-lbs (16.3-24.4 Nm)
Front fork oil Amount 4.7 in (119 mm)
Type TYPE 'E' HYDRAULIC FORK OIL
Battery Terminal screw torque 60-70 in-lbs (6.8-7.9 Nm)
Top caddy screw torque 72-96 in-lbs (8.1-10.9 Nm)
* Capacity is approximate. When changing oil, initially add 3.5 qt (3.3 L). Run engine until warm. Check and fill as necessary.
** Capacity is approximate. When changing lubricant, initially add 28 oz (0.83 L). Check and fill as necessary.

Table 1-4. Lubricants, Greases, Sealants

ITEM PART NUMBER PACKAGE

3M 847 Adhesive 021200-19718 * 5 oz tube
3M General Purpose Adhesive Remover 15 oz. aerosol
Anti-Seize Lubricant 98960-97 1 oz squeeze tube
Big Piston Fork Oil (Sportster XR only) 62600029 16 oz bottle
CCI #20 Brake Grease 42830-05 squeeze packet (included in master cylinder
rebuild kit)
DOT 4 Brake Fluid 99953-99A 12 oz bottle
Dow Corning Moly 44 Grease 94674-99 2 cc packet
Electrical Contact Lubricant 99861-02 1 oz squeeze tube
Formula+ Transmission and Primary Chaincase 99851-05 1 qt bottle
Lubricant
G40M Brake Grease 42820-04 squeeze packet
Genuine Harley-Davidson Extended Life Antifreeze 99822-02 1 gal container
and Coolant (V-Rod only)
Genuine Harley-Davidson H-D 360 20W50 99816-2050/00QT 1 qt bottle
Motorcycle Oil
Harley-Davidson Adhesive (Griplock) 99839-95 10 g tube
Harley-Davidson High Performance Sealant - Gray 99650-02 1.9 oz squeeze tube
Harley-Davidson Leather Dressing 98261-91V 6 oz can
Harley-Davidson Seal Grease 11300005 1 oz tube
Harley® Lube 94968-09 1/4 oz needle dispenser
Hylomar Gasket and Thread Sealant 99653-85 3.5 oz tube
Loctite 222 Low Strength Threadlocker and Sealant (purple) 99811-97 6 mL tube
Loctite 243 Medium Strength Threadlocker and Sealant (blue) 99642-97 6 mL tube
11100005 50 mL bottle
Loctite 246 Medium Strength/High Temperature Threadlocker
(blue)
Loctite 262 High Strength Threadlocker and Sealant (red) 94759-99 6 mL tube
11100006 50 mL bottle
Loctite 411 Prism Instant Adhesive
Loctite 420 Super Bonder Adhesive
Loctite 565 Thread Sealant 99818-97 6 mL tube

2013 Trike Service Supplement: Maintenance 1-7

HOME

Table 1-4. Lubricants, Greases, Sealants

ITEM PART NUMBER PACKAGE

Loctite 770 Prism Primer
Loctite 7649 Cleaner/Primer 98968-99 1.75 oz bottle
RTV Silicone Sealer 99650-02 1.9 oz tube
Screamin' Eagle Assembly Lube 94971-09 4 oz bottle
Screamin' Eagle SYN3 Full Synthetic Motorcycle 99824-03/00QT 1 qt bottle
Lubricant 20W50
Special Purpose Grease 99857-97A 14 oz cartridge
Type "E" Hydraulic Fork Oil 62600026 16 oz bottle
Wheel Bearing Grease 99855-89 1 lb can
99856-92 14 oz cartridge
* Not a Harley-Davidson part number

1-8 2013 Trike Service Supplement: Maintenance

HOME

LUBRICANTS 1.5
ENGINE OIL LEVEL 2. Place motorcycle on level ground. Allow engine to idle for
1-2 minutes. Turn engine off.
3. See Figure 1-3. Remove filler plug/dipstick and wipe off
the dipstick. Insert the dipstick and tighten into the fill
Prolonged or repeated contact with used motor oil may spout.
be harmful to skin and could cause skin cancer. Promptly
wash affected areas with soap and water. (00358b) 4. See Figure 1-4. Remove filler plug/dipstick and check oil
level. Oil level must register between the ADD QT and
FULL HOT marks on the VEHICLE UPRIGHT gauge. If
oil level is at or below the ADD QT mark, add only enough
Do not overfill oil. Doing so can result in oil carryover to oil to bring the level to the FULL HOT mark. Do not overfill.
the air cleaner leading to equipment damage and/or 5. Start engine and carefully check for oil leaks around drain
equipment malfunction. (00190b) plug and oil filter.
Check engine oil level at each complete fuel refill. This motor-
cycle was originally equipped with GENUINE HARLEY-DAV- om01566
IDSON H-D 360 MOTORCYCLE OIL 20W50. H-D 360 is the
preferred oil under normal operating conditions. If operation
under extreme cold or heat are expected, refer to Table 1-5
for alternative choices. See the service manual for more
information.

Oil Level Cold Check

1. For pre-ride inspection, place motorcycle on level ground.
2. See Figure 1-3. Remove filler plug/dipstick and wipe off
the dipstick. Insert the dipstick and tighten into the fill
spout.
NOTE
Oil level on a cold engine should never be above the midway
point.
3. See Figure 1-4. Remove filler plug/dipstick and check oil
level. The correct oil level is midway (2) between the ADD
QT and FULL HOT marks on the VEHICLE UPRIGHT Figure 1-3. Engine Oil Filler Cap
gauge.

NOTE
sm06088
If oil level is at or below the ADD QT mark, add only enough
oil to bring the level midway (2) between the ADD QT and FULL
HOT marks. Never bring the level to the FULL HOT mark on
a cold engine.

Oil Level Hot Check

Do not allow hot oil level to fall below Add/Fill mark on

3
dipstick. Doing so can result in equipment damage and/or 2
equipment malfunction. (00189a)
1
NOTE
Perform engine oil level hot check only with engine at normal 1. ADD QT mark
operating temperature. 2. Cold check level
3. FULL HOT mark
1. Ride motorcycle until engine is at normal operating tem-
perature. Figure 1-4. Engine Oil Dipstick (VEHICLE UPRIGHT Gauge)

2013 Trike Service Supplement: Maintenance 1-9

HOME

Table 1-5. Recommended Engine Oils

TYPE VISCOSITY RATING LOWEST AMBIENT COLD WEATHER

TEMPERATURE STARTS BELOW
50 °F (10 °C)
Screamin' Eagle SYN 3 Full Synthetic SAE 20W50 HD 360 Above 30 °F (-1 °C) Excellent
Motorcycle Lubricant
Genuine Harley-Davidson H-D 360 SAE 20W50 HD 360 Above 40 °F (4 °C) Good
Motorcycle Oil
Genuine Harley-Davidson H-D 360 SAE 50 HD 360 Above 60 °F (16 °C) Poor
Motorcycle Oil
Genuine Harley-Davidson H-D 360 SAE 60 HD 360 Above 80 °F (27 °C) Poor
Motorcycle Oil
Genuine Harley-Davidson H-D 360 SAE 10W40 HD 360 Below 40 °F (4 °C) Excellent
Motorcycle Oil

CHECKING TRANSMISSION LUBRICANT

om01567
LEVEL
FASTENER TORQUE VALUE
Transmission dipstick 25-75 in-lbs 2.8-8.5 Nm

Check the transmission lubricant level with engine turned off

and motorcycle on level surface.
NOTE
Allow vehicle to rest for a few moments before checking lub-
ricant level. This will allow lubricant level to normalize.
1. See Figure 1-5. Remove transmission lubricant dipstick.
Wipe dipstick clean.
2. Thread dipstick into transmission finger tight.
3. See Figure 1-6. Remove dipstick and check lubricant level
on dipstick. If lubricant level is at or below the ADD mark
on the dipstick, add only enough lubricant to bring level Figure 1-5. Transmission Dipstick Location
to between ADD mark and FULL mark on dipstick.
4. Install dipstick. Tighten to 25-75 in-lbs (2.8-8.5 Nm).
om01041

Table 1-6. Recommended Lubricant

MODEL LUBRICANT REFILL

QTY. *
FORMULA+ TRANSMISSION AND 28 oz
PRIMARY CHAIN LUBRICANT (0.83 L)
or
SCREAMIN' EAGLE SYN3 FULL SYN- 2
THETIC MOTORCYCLE LUBRICANT 1
20W50
* Approximate. Check and add as needed to bring level within
specification.

1. Add
2. Full
Figure 1-6. Transmission Dipstick Lubricant Level

1-10 2013 Trike Service Supplement: Maintenance

HOME

REAR BRAKES 1.6

FLUID INSPECTION
sm06981
1. See Figure 1-7. Check fluid level in rear brake master
cylinder reservoir.
a. Position vehicle on a level surface.
b. View reservoir sight glass and verify fluid presence.
Sight glass should appear dark if fluid is present.

2. If sight glass is not dark, check brake system for fluid

leaks. Check that brake pads are properly installed and
not worn beyond service wear limits. Perform any neces-
sary repairs. See 1.7 REAR BRAKE PADS AND DISCS.
3. If sight glass is still not dark, remove cover and verify fluid
level. If necessary, add DOT 4 BRAKE FLUID to reservoir.
Replace cover. See 2.7 BLEEDING BRAKES.
4. Rear brake foot pedal must have a firm feel when applied.
If not, bleed system using only DOT 4 BRAKE FLUID. See
2.7 BLEEDING BRAKES.
Figure 1-7. Rear Master Cylinder Sight Glass

BRAKE LINES
Inspect brake lines for leaks, contact or abrasion. Refer to
Table 1-7.

Table 1-7. Brake Line Inspection

LINE TYPE INSPECTION REMEDY

Steel lines No marks OK/Monitor
Slight mark in paint or plating*
Copper colored-paint/plating worn off*
Silver colored base material-no noticeable feel of wear*
Silver colored base material-noticeable feel of wear* Replace
Brake fluid leak or other damage
Rubber hose No marks OK/Monitor
Slight dent or flattening of ribs*
Worn to bottom of ribs Replace
Brake fluid leak or other damage
Protective cover No marks OK/Monitor
(steel, rubber, plastic or braided) Slight dent in covering*

Slight dent or flattening of plastic covering*

Worn or cut-through covering-exposed brake line material Replace
Brake fluid leak or other damage
* If there is line contact, reposition the line. If base material is visible, prevent corrosion with touch-up paint.

2013 Trike Service Supplement: Maintenance 1-11

HOME

REAR BRAKE PADS AND DISCS 1.7

INSPECTION NOTE
Do not operate brake pedal with caliper removed or piston may
Check rear brake pads and discs: be forced out. This caliper can not be disassembled and would
• At every scheduled service interval. require replacement of the entire assembly.

• Whenever components are removed for service. 6. Remove cover from rear brake master cylinder reservoir.
NOTE
Brake Pads
Fluid level will rise as piston is pushed back into caliper, pos-
sibly overflowing the reservoir. Remove some fluid from the
reservoir if necessary.
Always replace brake pads in complete sets for correct 7. Push piston into caliper until fully seated.
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a) 8. Clean any debris from caliper bushing bores. Verify that
bushings (2) slide smoothly in caliper bores without rocking
Replace all rear brake pads (inner and outer of both left and or sticking.
right side calipers) if the friction material of any single pad is
worn to 0.050 in. (1.27 mm) or less above the backing plate. 9. Using grease supplied in brake pad kit, lubricate O-rings,
OD of bushings and pad pins in area that brake pads
Periodically check and adjust mechanical park brake for proper contact. Do not apply grease to threads of pad pins.
operation. Always adjust park brake whenever brake pads are
replaced. Always install new actuator shaft locknut (provided 10. Install new inner and outer pads in caliper. Install caliper
in brake pad service kit) whenever park brake is adjusted at on disc. Verify that friction material of both pads face disc.
the calipers. 11. Install new mounting/pad pins (1). Tighten to 32-36 ft-lbs
Inspect brake system for leaks and repair as necessary. Inspect (43.4-48.8 Nm).
brake lines and hoses for damage or wear.
12. Install new retaining rings (3).
Brake Disc Thickness
sm06456
Inspect brake disc surface condition. Replace disc if pitted,
grooved or scored.
Inspect brake disc for excessive wear. Replace disc if thickness 3
is 0.220 in. (5.59 mm) or less.

Brake Disc Lateral Runout 2

Inspect brake disc lateral runout and warpage. Replace disc 1 4
if either is greater than 0.008 in. (0.20 mm).

REPLACEMENT
FASTENER TORQUE VALUE 5
Brake caliper, rear, 32-36 ft-lbs 43.4-48.8 Nm
mounting/pad pins
Brake master cylinder, rear, 6-8 in-lbs 0.7-0.9 Nm 1. Mounting/pad pin (2)
reservoir cover screws 2. Bushing (2)
3. Retaining ring (2)
1. Remove rear wheels. See 2.4 REAR WHEELS. 4. Brake pads
5. O-rings (4)
2. Release park brake and loosen park brake adjustment.
See 1.11 PARK BRAKE. Figure 1-8. Rear Brake Caliper Assembly

Always replace brake pads in complete sets for correct

After servicing brakes and before moving motorcycle,
and safe brake operation. Improper brake operation could
pump brakes to build brake system pressure. Insufficient
result in death or serious injury. (00111a)
pressure can adversely affect brake performance, which
3. See Figure 1-8. Remove retaining rings (3) and discard. could result in death or serious injury. (00279a)
4. Use a ball-end hex key socket to remove mounting/pad 13. Press brake pedal several times to set pads to proper
pins (1) and discard. Remove caliper from disc. operating position within calipers.

5. Remove inner and outer pads (4) from caliper.

1-12 2013 Trike Service Supplement: Maintenance

HOME

14. Check level in rear brake master cylinder reservoir. Level 18. With the ignition/light key switch turned to IGNITION, apply
should be 1/4 ± 1/8 in. (6.35 ± 3.18 mm) below the gasket rear brakes to verify operation of brake lamp.
surface.
15. Install master cylinder reservoir cover. Tighten to 6-8 in-lbs
(0.7-0.9 Nm).
After repairing the brake system, test brakes at low speed.
NOTE If brakes are not operating properly, testing at high speeds
Always check lug nut torque within 500-1000 mi (805-1610 can cause loss of control, which could result in death or
km) after wheel installation. serious injury. (00289a)
16. Install rear wheels. See 2.4 REAR WHEELS. 19. Test ride motorcycle.
17. Adjust park brake. See 1.11 PARK BRAKE. NOTE
Avoid making hard stops for the first 100 mi (160 km) to allow
the new pads to become conditioned to the brake discs.

2013 Trike Service Supplement: Maintenance 1-13

HOME

REAR TIRES 1.8

INSPECTION Tire Balancing
Tire Pressure NOTES

Always maintain proper tire pressure as specified in Table 2-3. • The Trike rear wheel assemblies must be statically bal-
Do not load tires beyond GAWR specified in Table 2-2. anced within 0.5 oz (14 g).
Underinflated, over-inflated or overloaded tires can fail. • The maximum weight permitted to be added to a wheel
Check pressure when tire is cold. Refer to Table 2-3. assembly is 3.5 oz (99 g).
• Always check lug nut torque within 500-1000 mi (805-1610
Tire Wear km) after wheel installation.

om01351
Replace tire immediately with a Harley-Davidson specified
tire when wear bars become visible or only 1/32 in (0.8
mm) tread depth remains. Riding with a worn tire could
result in death or serious injury. (00090c)
Harley-Davidson tires are equipped with wear bars that run
horizontally across the tread. When a tire is worn to the point
that the wear bars are visible, or 1/32 in. (0.8 mm) tread depth
remains, the tire can:
• Be more easily damaged leading to tire failure.
• Provide reduced traction.
• Adversely affect stability and handling.
1. See Figure 1-9. Locate arrows on tire sidewalls. The
arrows point to location of tread wear bars.
NOTE
See Figure 1-10. Tread wear bars will be at the tread surface
when 1/32 in (0.8 mm) or less of tread remains. As wear may
be uneven, always replace the tire before any single tread wear Figure 1-9. Rear Tire Tread Wear Bar Indicator
bar is at the tread surface.
2. Also replace tire if any of the following conditions are
om01582
evident:
a. Tire cords or fabric are visible through cracked side-
wall.
b. Bumps, bulges or splits.
c. Punctures, cuts or other damage that cannot be
repaired.

Tire Replacement

Use only Harley-Davidson specified tires. See a Harley-

Davidson dealer. Using non-specified tires can adversely
affect stability, handling or braking, which could result in
death or serious injury. (00024b)
Refer to Table 2-3.
Figure 1-10. Dunlop Rear Tire Wear Bar Appearance

1-14 2013 Trike Service Supplement: Maintenance

HOME

DRIVE BELT 1.9

CHECKING DRIVE BELT DEFLECTION and compare with specifications in Table 1-8. Belt must
be adjusted if not within specification.
PART NUMBER TOOL NAME
Table 1-8. Belt Deflection
HD-35381A BELT TENSION GAUGE
MODELS INCHES MILLIMETERS
NOTE
All models 3/8-7/16 9.5-11.1
Always use BELT TENSION GAUGE (Part No. HD-35381A)
to measure belt deflection. Do not rely on "feel" as this can
result in belts that are under tensioned. Loose belts will fail due om00156
to "ratcheting" (jumping a tooth). 2
Check belt deflection: 1
• With transmission in neutral.
• At loosest spot in belt.
• With motorcycle at room temperature.
• With the rear wheels elevated or on the ground without
rider or luggage.

3
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery 4
cable before proceeding. (00048a)
1. Transmission sprocket
1. Disconnect battery negative cable. 2. Rear wheel sprocket
2. Slide O-ring on gauge toward 0 lbs (0 kg) mark. 3. 10 lbs (4.5 kg) of force
4. Amount of deflection
3. See Figure 1-11. Fit cradle against bottom of belt midway
between transmission sprocket and rear sprocket. Figure 1-11. Checking Belt Deflection

4. Push upward on knob until O-ring slides to the 10 lb (4.5

kg) mark on the tool and compare belt deflection to scale SETTING DEFLECTION
on debris deflector.
FASTENER TORQUE VALUE
5. Rotate rear wheels and measure deflection at several
locations around the belt. Select the loosest measurement Axle adjustment screw jamnut 15-25 ft-lbs 20.3-34.0 Nm
Pinch block screws 41-45 ft-lbs 55.6-61.0 Nm
Lug nuts 90-100 ft-lbs 122.0-135.6
Nm
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm

1. Remove rear wheels. See 2.4 REAR WHEELS.

2. See Figure 1-12. Loosen four pinch block bolts (1) on each
side.
3. Loosen jamnut (2) on both adjustment screws (3).
4. Check axle alignment before adjusting belt tension.
a. Verify the axle housing is tight against the head of
the adjustment screw (3). Use a scale or dial caliper
to measure the distance (4) from the face of the
adapter plate to the front of the axle housing on both
sides.
b. Distance (4) must be within 0.062 in (1.6 mm) on each
side. Turn the adjustment screws (3) until measure-
ment is within specification.

2013 Trike Service Supplement: Maintenance 1-15

HOME

5. Reduce or increase belt deflection by turning the adjust- 15. Connect battery negative cable. Tighten to 60-70 in-lbs
ment screw on each side in or out an equal number of (6.8-7.9 Nm).
turns .
6. Verify that firm contact is made with heads of adjustment
screws and check belt deflection. See 1.9 DRIVE BELT,
After installing seat, pull upward on seat to be sure it is
Checking Drive Belt Deflection.
locked in position. While riding, a loose seat can shift
7. Repeat steps until belt deflection is within specification. causing loss of control, which could result in death or
serious injury. (00070b)
8. Snug jamnut against rear of each adapter plate and again
check axle alignment measurement (4). Tighten jamnuts 16. Install seat.
to 15-25 ft-lbs (20.3-34.0 Nm).
sm06048
9. Remove one pinch block bolt (1) at a time and remove all
residual threadlocking compound from threaded hole in 4
pinch block. Use compressed air to blow out any debris.
10. If bolt is to be reused, remove all threadlocking compound
using a wire brush or wire wheel. Apply LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND SEALANT 1
(blue).
11. Install bolt with flat washer and tighten until snug.
12. Tighten all pinch block bolts in a crosswise pattern to 41-
45 ft-lbs (55.6-61.0 Nm).
2
3
13. Verify belt deflection. Rotate the rear tires a few rotations
by hand and verify the belt does not contact either the
battery tray or frame. If either is the case, adjust the rear
axle lateral alignment. See 2.16 LATERAL ALIGNMENT. 1. Pinch block bolts (4 each side)
2. Jamnut
14. Install rear wheels and tighten lug nuts in a crosswise 3. Adjustment screw
pattern to 90-100 ft-lbs (122.0-135.6 Nm). See 2.4 REAR 4. Measured distance
WHEELS.
Figure 1-12. Adjust Axle
NOTE
Always check lug nut torque within 500-1000 mi (805-1610
km) after wheel installation.

1-16 2013 Trike Service Supplement: Maintenance

HOME

REAR WHEEL COMPENSATOR 1.10

CHECKING ISOLATOR WEAR 11. Release park brake.

FASTENER TORQUE VALUE sm06149

Battery cable screw 60-70 in-lbs 6.8-7.9 Nm A

1. Remove seat.

To prevent accidental vehicle start-up, which could cause 2 1

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2. Disconnect battery negative cable.
NOTE
Although this procedure can be done with the vehicle on the
ground, it is easer to do with it raised on a lift.
3. Raise motorcycle on lift.
4. Set the parking brake.
5. Rotate rear drive sprocket forward by hand as far as pos-
sible and hold.
6. See Figure 1-13. Draw a horizontal line from the flat of a
B
ring gear tooth to the edge of the sprocket. Use a paint
pen or felt marker for best results.
7. Hold the ring gear and rotate sprocket rearward by hand
until sprocket stops and hold in place.
8. If the line on the sprocket moves further than the flat of
the next ring gear tooth, then freeplay is more than 4
degrees or 0.409 in. (10.4 mm) and isolators must be
replaced. See 5.3 AXLE HOUSING/DIFFERENTIAL for
removal and disassembly instructions.
9. Connect battery negative cable. Tighten to 60-70 in-lbs
(6.8-7.9 Nm).
3

After installing seat, pull upward on seat to be sure it is

locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or 1. Ring gear tooth paint mark
serious injury. (00070b) 2. Sprocket paint mark
3. Maximum freeplay
10. Install seat.
Figure 1-13. Check Isolator Wear, Reverse Equipped

2013 Trike Service Supplement: Maintenance 1-17

HOME

PARK BRAKE 1.11

ADJUSTMENT NOTE
The highest reading will occur before the handle reaches
FASTENER TORQUE VALUE the fully engaged position.

Park brake actuator shaft 32-36 ft-lbs 43.4-48.8 Nm c. Pull handle down toward ENGAGED position while
locknut taking note of highest reading on force gauge. Use
an arc that most closely resembles the natural motion
NOTE of the handle and stop when reading begins to
decrease.
For the 1000 mi (1600 km) service, see step 10 only. At all
other service intervals, as well as after replacement of the d. See Figure 1-14. If the highest reading is not within
brake pads, calipers, caliper cable brackets or park brake 40-45 lbs (177.9-200.1 N) of force, return park brake
cables, follow entire procedure. to OFF position, and loosen set screw (2). Turn knob
(1) clockwise to increase or counterclockwise to
1. Remove rear wheels. See 2.4 REAR WHEELS.
decrease force and recheck.
2. See Figure 1-14. Set the park brake lever to the disen-
e. Rotate knob until set screw (2) is aligned with gap (4)
gaged position. Loosen set screw (2) and turn adjustment
at front or rear of handle. Tighten set screw.
knob (1) counterclockwise as far as it will go.
3. See Figure 1-15. Disconnect spring (2) between actuator NOTE
arm (3) and cable bracket (1). Always check lug nut torque within 500-1000 mi (805-1610
km) after wheel installation.
4. Remove locknut (4) and actuator arm (3) from shaft.
11. Install rear wheels. See 2.4 REAR WHEELS.
5. Turn shaft into caliper by hand until contact is made with
back of piston. NOTE
Verify that park brake cables properly actuate brakes before
a. Right caliper shaft; rotate clockwise.
parking on a slope.
b. Left caliper shaft; rotate counterclockwise.
sm05531
NOTE
Do not force the shaft into the piston to align the splines. Brake
drag will occur and result in accelerated brake pad wear. 1
2
6. Install actuator arm, staying as close to lever stop (5) as
possible. If necessary, back out shaft one spline to engage
splines.
7. Install new locknut (4) onto shaft. Tighten to 32-36 ft-lbs
(43.4-48.8 Nm). 3
8. Install spring (2).
4
9. Repeat steps on other brake caliper.
10. Obtain digital force gauge or fish scale capable of meas-
uring at least 50 pounds, and proceed as follows: 1. Knob
a. See Figure 1-16. Move park brake to OFF position. 2. Set screw
3. Handle
b. See Figure 1-17. Install heavy cable strap (Part No.
4. Gap
11321 or Part No. 10325) between knurling on knob
and connect hook of force gauge. Figure 1-14. Park Brake

1-18 2013 Trike Service Supplement: Maintenance

HOME

sm06457 sm05530

4
5 2
1. Cable bracket 1. Off (disengaged)
2. Spring 2. Over center (engaged)
3. Actuator arm
4. Locknut Figure 1-16. Park Brake Positions
5. Lever stop
Figure 1-15. Park Brake Adjustment
sm05914

Figure 1-17. Check Park Brake Adjustment

2013 Trike Service Supplement: Maintenance 1-19

HOME

REAR SUSPENSION ADJUSTMENTS 1.12

GENERAL when loading vehicle. Do not pressurize system in excess of
50 psi (345 kPa).
PART NUMBER TOOL NAME
HD-34633A AIR SUSPENSION PUMP AND GAUGE
Do not exceed maximum air pressure for rear suspension.
See Figure 1-18. Adjust rear air suspension pressure by adding Air components fill rapidly. Therefore, use low air line
or removing air from the air valve located behind the right side pressure. Failure to do so may result in possible damage
cover. to components. (00165a)
NOTES
• Use a no-loss air gauge such as AIR SUSPENSION PUMP
AND GAUGE (Part No. HD-34633A) to check air pressure. Use caution when bleeding air from the suspension.
Check suspension pressure weekly if driven daily or before Moisture combined with lubricant may leak onto the rear
each trip if only used occasionally. wheel, tire and/or brake components and adversely affect
• Improper inflation of rear air suspension components also traction, which could result in death or serious injury.
can result in a reduction of available suspension travel, (00084a)
reduced rider comfort and possible damage to shock
absorbers. om01317b

Air pressure may be varied to suit load conditions, riding style

and personal comfort. Less initial pressure does not necessarily
result in a softer ride.

Do not exceed the motorcycle's Gross Vehicle Weight

Rating (GVWR) or Gross Axle Weight Rating (GAWR).
Exceeding these weight ratings can lead to component
failure and adversely affect stability, handling and perform-
ance, which could result in death or serious injury. (00016f)
Refer to Table 1-9 as a starting point in determining suitable
rear air suspension pressures. Do not exceed maximum GVWR
Figure 1-18. Rear Air Suspension Air Valve

Table 1-9. Rear Suspension Recommended Air Pressure

SHOCK LOAD TOTAL WEIGHT PRESSURE

PSI kPa
Solo rider up to 150 lb (68 kg) 5-10 34-69
150-200 lb (68-91 kg) 10-20 69-138
200-250 lb (91-113 kg) 20-30 138-206
250-300 lb (113-136 kg) 30-40 206-276
300 lb (136 kg) to maximum added weight allowed* 40-50 276-345
Solo rider with capacity luggage of 80 lb up to 150 lb (68 kg) 25-30 172-206
(36 kg) 150-200 lb (68-91 kg) 30-40 206-276
200-250 lb (91-113 kg) 40-50 276-345
250 lb (113 kg) to maximum added weight allowed* 50 345
Rider plus passenger All weights up to maximum added weight allowed* 50 345
Maximum loaded vehicle Maximum added weight allowed* 50 345
Do not exceed 50 psi (345 kPa) rear shock pressure.
*Refer to Table 2-2 for maximum added weight allowed on the motorcycle.

1-20 2013 Trike Service Supplement: Maintenance

HOME

STEERING HEAD BEARINGS 1.13

CHECKING 5. If clutch cable or main harness appears to be influencing
swing momentum, proceed as follows:
FASTENER TORQUE VALUE a. Clutch cable: Disconnect clutch cable at hand lever
Lower fork bracket pinch bolts 70-75 ft-lbs 94.9-101.7 and remove from inner fairing. See the service manual
Nm for details.
b. Main harness: Remove rivet and P-clamp to release
1. Verify that front end of motorcycle is in stock configuration. main harness from steering head.
Non-factory accessories can influence swing momentum.
c. Recheck steering head bearing swing-by.
2. Raise motorcycle so that front wheel is off the ground. See
1.2 LIFTING MOTORCYCLE WITH A JACK. 6. See adjustment procedure in the service manual to correct
a swing pattern. Tighten lower fork bracket pinch bolts to
3. Remove steering damper. See 2.20 STEERING DAMPER 70-75 ft-lbs (94.9-101.7 Nm).
ASSEMBLY.
7. Install steering damper. See 2.20 STEERING DAMPER
NOTE ASSEMBLY.
Any movement from full left toward center is considered swing.
8. Install clutch cable or main harness P-clamp, if removed.
4. See Figure 1-19. Turn handlebars until contact is made
with the left fork stop and then let go. The wheel should
stop in either the first or second swing.

sm06116a

1 2 3

1. Correct- wheel stops in first swing

2. Correct- wheel stops in second swing
3. Too loose- wheel stops in third swing
Figure 1-19. Check Steering Head Bearing Swing-by

2013 Trike Service Supplement: Maintenance 1-21

HOME

STEERING DAMPER 1.14

INSPECTION 3. Replace the steering damper if there is oil leakage or a
lack of damping at any point in the range. See
2.20 STEERING DAMPER ASSEMBLY.
NOTE
When lifting a motorcycle using a jack, be sure jack con- If the vehicle is out of warranty and the steering damper needs
tacts both lower frame tubes where down tubes and lower to be repaired, return to:
frame tubes converge. Never lift by jacking on cross-
members, oil pan or other housings. Failure to comply can Ohlins USA
cause serious damage resulting in the need to perform 703-C Old Spartanburg Road
major repair work. (00586c)
Hendersonville, NC 28792
1. Raise motorcycle so that front wheel is off the ground. See
1.2 LIFTING MOTORCYCLE WITH A JACK. 828-692-4525

2. Turn handlebars through the full range of motion at least Ohlins provides a complete rebuilding service for the steering
two cycles. Observe the action of the damper for even damper used on Trike models.
force throughout the range of motion.

1-22 2013 Trike Service Supplement: Maintenance

HOME

FORK OIL 1.15

PROCEDURE
sm02903

PART NUMBER TOOL NAME

HD-59000B FORK OIL LEVEL GAUGE 10
20
30
40
FASTENER TORQUE VALUE 50
mL
60
Lower fork bracket pinch bolts 70-75 ft-lbs 94.9-101.7
Nm

Fork oil change also requires rebuilding the forks. See the
service manual for complete disassembly and assembly pro-
cedures. Use the following specifications in place of the ones
in those procedures.

Figure 1-20. Fork Oil level Gauge

Incorrect amount of fork oil can adversely affect handling

and lead to loss of vehicle control, which could result in sm02904
death or serious injury. (00298a)
1. Inspect upper fork spring for damage or distortion. Replace
upper fork spring if free length is less than 20.1 in (510.5
mm). Replace rebound spring whenever upper fork spring
is replaced.
2. Pour slightly more than 11.8 oz (350 cc) of Harley-Dav-
idson TYPE "E" HYDRAULIC FORK OIL into fork tube.
3. Set FORK OIL LEVEL GAUGE (Part No. HD-59000B) to
measure 4.7 in (119 mm).
4. Assemble and install fork. See the service manual. Tighten
lower fork bracket pinch bolts to 70-75 ft-lbs (94.9-101.7
Nm).

Figure 1-21. Remove Excess Fork Oil

2013 Trike Service Supplement: Maintenance 1-23

HOME

CRITICAL FASTENERS 1.16

INSPECTION 1. Attempt to turn the fastener using a torque wrench set to
the minimum torque specification for that fastener. Refer
Checking Torques on Fasteners to Table 1-10.
Inspect critical fasteners at the scheduled service intervals. a. If the fastener does not rotate, the fastener torque
Replace any damaged or missing fasteners. has been maintained. No further attention is neces-
sary.
b. If the fastener rotates, remove it to determine if it has
a locking agent.
c. If it has a locking agent, 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 pro-
cedure).
d. Install fastener. Tighten to specification.

2. If the fastener does not have a locking agent, install

fastener. Tighten to specification.

Table 1-10. Critical Fasteners

SYSTEM FASTENER TORQUE

Hand controls Switch housing screws 35-45 in-lbs 4-5 Nm
Clutch lever bracket handlebar clamp screws 72-108 in-lbs 8.1-12.2 Nm
Master cylinder reservoir handlebar clamp 72-108 in-lbs 8.1-12.2 Nm
screws
Brakes Front caliper banjo bolts 17-19 ft-lbs 23-26 Nm
Rear caliper banjo bolts 20-22 ft-lbs 27.1-29.8 Nm
Front master cylinder banjo bolt 12.5-14.5 ft-lbs 17.0-19.7 Nm
Rear master cylinder banjo bolt 17-22 ft-lbs 23-30 Nm
Front brake disc screws 16-24 ft-lbs 22-33 Nm
Front master cylinder reservoir cover screws 10-12 in-lbs 1.1-1.4 Nm
Rear master cylinder reservoir cover screws 6-8 in-lbs 0.7-0.9 Nm
Rear master cylinder mounting bracket 126-150 in-lbs 14-17 Nm
screws
Front brake caliper mounting screws 28-38 ft-lbs 38-52 Nm
Rear brake caliper mounting bracket screws 41-45 ft-lbs 55.6-61.0 Nm
Front brake caliper pad pin 75-102 in-lbs 8.5-11.5 Nm
Rear brake caliper pad pin 32-36 ft-lbs 43.4-48.8 Nm
Axles Front axle nut 70-75 ft-lbs 94.9-101.7 Nm
Rear lug nuts* 90-100 ft-lbs 122.0-135.6 Nm
Front forks Front axle holder nuts 132-180 in-lbs 15-20 Nm
Pivot shaft Locknuts 50 ft-lbs 67.8 Nm
NOTE: Install new nuts and cup washers if either locknut
moves. Tighten using the torque-turn method as outlined
in 2.15 REAR FORK.
Rear fork bracket screws 55-65 ft-lbs 74.6-88.1 Nm

1-24 2013 Trike Service Supplement: Maintenance

HOME

Table 1-10. Critical Fasteners

SYSTEM FASTENER TORQUE

Other Steering damper nuts 16-20 ft-lbs 21.7-27.1 Nm
Transmission to engine bolts 34-39 ft-lbs 46-53 Nm
Engine mount bolts See the service manual
Engine stabilizer link (includes bracket-to- See 2.23 ENGINE STABILIZER.
head screws)
Intermediate frame screws 40-45 ft-lbs 54.2-61.0 Nm
* Always check lug nut torque within 500-1000 mi (805-1610 km) after wheel installation.

2013 Trike Service Supplement: Maintenance 1-25

HOME

TROUBLESHOOTING 1.17
GENERAL 9. Fuel filter clogged.
10. Sticking or damaged valve(s) or wrong length push rod(s).
11. Plugged fuel injectors.
The Troubleshooting section of this manual is a guide to
diagnose problems. Read the appropriate sections of this
Starts Hard
manual before performing any work. Improper repair and/or 1. Spark plugs in bad condition or have improper gap or are
maintenance could result in death or serious injury. partially fouled.
(00528b)
2. Spark plug cables in poor condition.
Use the symptoms listed for general troubleshooting. More
than one condition may be present at a time. Check all possible 3. Battery nearly discharged.
items to keep motorcycle in good operating condition. 4. Damaged wire or loose wire connection at one of the bat-
NOTE tery terminals, ignition coil or ECM connector.
See the electrical diagnostic manual for additional information. 5. Water or dirt in fuel system.

ENGINE 6. Intake air leak.

7. Fuel tank vent hose, filler cap vent or vapor valve plugged,
Starter Motor Does Not Operate or Does Not or fuel line closed off, restricting fuel flow.
Turn Engine Over
8. Engine lubricant too heavy (winter operation).
1. Ignition switch not in IGNITION position.
NOTE
2. Engine run switch in OFF position. For cold weather starts, always disengage clutch.
3. Discharged battery, loose or corroded connections 9. Ignition not functioning properly (possible sensor failure).
(solenoid chatters).
10. Faulty ignition coil.
4. Starter control circuit, relay, or solenoid faulty.
11. Valves sticking.
5. Electric starter shaft pinion gear not engaging or overrun-
ning clutch slipping. 12. Partially plugged fuel injector(s).

6. TSM/TSSM/HFSM Bank Angle Sensor tripped and igni- Starts But Runs Irregularly or Misses
tion/light key switch not cycled OFF then back to IGNI-
1. Spark plugs in poor condition or partially fouled.
TION.
2. Spark plug cables in poor condition and shorting or leaking.
7. Security system activated.
3. Spark plug gap too close or too wide.
8. Motorcycle in gear and clutch not pulled in.
4. Faulty ignition coil, ECM, or sensor.
9. Main fuse not in place.
5. Battery nearly discharged.
Engine Turns Over But Does Not Start
6. Damaged wire or loose connection at battery terminals,
1. Fuel tank empty. ignition coil or ECM connector.
2. Fouled spark plugs. 7. Intermittent short circuit due to damaged wire insulation.
3. Discharged battery, loose or damaged battery terminal 8. Water or dirt in fuel system.
connections.
9. Fuel tank vent system plugged.
4. Engine lubricant too heavy (winter operation).
10. Air leak at intake manifold or air cleaner.
NOTE
For cold weather starts, always disengage clutch. 11. Loose or dirty ECM connector.
5. Spark plug cables in bad condition and shorting, cable 12. Faulty Sensor(s): Temperature Manifold Absolute Pressure
connections loose or cables connected to incorrect cylin- (TMAP), Crank Position (CKP) or Oxygen (O2).
ders.
13. Incorrect valve timing.
6. Damaged wire or loose wire connection at ignition coil,
14. Weak or damaged valve springs.
battery, or ECM connector.
15. Damaged intake or exhaust valve.
7. Ignition timing incorrect due to faulty ignition coil, ECM or
sensors. 16. Partially plugged fuel injector(s).
8. Bank Angle Sensor tripped and ignition switch not cycled
OFF then back to IGNITION.

1-26 2013 Trike Service Supplement: Maintenance

HOME

A Spark Plug Fouls Repeatedly 7. Internal engine problem.

1. Fuel mixture too rich. 8. Damaged frame.

2. Incorrect spark plug for the kind of service. 9. Stabilizer links worn or loose, or stabilizer link brackets
loose or damaged.
3. Piston rings badly worn or damaged.
10. Isolators worn or isolator bolts loose or damaged.
4. Valve guides or seals badly worn.
11. Rubber mounts loose or worn.
Pre-Ignition or Detonation (Knocks or Pings)
12. Rear fork pivot shaft fasteners loose.
1. Fuel octane rating too low.
13. Front engine mounting bolts loose.
2. Faulty spark plugs.
Check Engine Light Illuminates During
3. Incorrect spark plug for the kind of service.
Operation
4. Excessive carbon deposit on piston head or in combustion
chamber. 1. Fault detected. See the electrical diagnostic manual for
more information.
5. Ignition timing advanced due to faulty sensor inputs (TMAP
and/or CKP). LUBRICATION SYSTEM
6. Ignition timing advanced due to ECM or sensors (CKP, Oil Does Not Return To Oil Reservoir
ET or TMAP) defective.
1. Oil reservoir empty.
7. Intake manifold vacuum leak.
2. Oil pump not functioning.
Overheating 3. Restricted oil lines or fittings.
1. Insufficient oil supply or oil not circulating.
4. Restricted oil filter.
2. Insufficient air flow over engine.
5. O-ring damaged or missing from oil pump/crankcase
3. Heavy carbon deposits. junction (also results in poor engine performance).

4. Ignition timing retarded due to defective ECM or faulty Engine Uses Too Much Oil Or Smokes
sensor(s) (TMAP and/or CKP).
Excessively
5. Leaking valve(s). 1. Oil reservoir overfilled.
Valve Train Noise 2. Restricted oil return line to oil reservoir.
1. Low oil pressure caused by oil feed pump not functioning 3. Restricted breather operation.
properly or oil passages obstructed.
4. Restricted oil filter.
2. Faulty hydraulic lifter(s).
5. Oil pump misaligned or in poor condition.
3. Bent push rod(s).
6. Piston rings badly worn or broken.
4. Incorrect push rod length.
7. Valve guides or seals worn or damaged.
5. Rocker arm binding on shaft.
8. O-ring damaged or missing from oil pump/crankcase
6. Valve sticking in guide. junction (also results in poor engine performance).
7. Chain tensioning spring or shoe worn. 9. Plugged crankcase scavenge port.
8. Cam(s), cam gear(s) or cam bushing(s) worn. 10. Oil diluted with gasoline.
9. Cam timing incorrect.
Engine Leaks Oil From Cases, Push Rods,
Excessive Vibration Hoses, Etc.
1. Wheels bent or damaged and/or tires worn or damaged. 1. Loose parts.
2. Engine/Transmission/Rear Wheel not aligned properly. 2. Imperfect seal at gaskets, push rod covers, washers, etc.
3. Primary chain badly worn or links tight as a result of 3. Restricted breather passages or hose to air cleaner.
insufficient lubrication or misalignment.
4. Restricted oil filter.
4. Engine to transmission mounting bolts loose.
5. Oil reservoir overfilled.
5. Upper engine mounting bracket loose/damaged or
6. Lower rocker housing gasket installed incorrectly (upside
mounting bracket pre-loaded.
down).
6. Ignition timing advanced due to faulty sensor inputs (TMAP
7. Restricted oil return line to oil reservoir.
and/or CKP)/poorly tuned engine.

2013 Trike Service Supplement: Maintenance 1-27

HOME

8. Porosity. Jumps Out Of Gear

Low Oil Pressure 1. Shifter rod improperly adjusted.
1. Oil reservoir underfilled. 2. Shifter drum (inside transmission) improperly adjusted or
damaged/worn.
2. Faulty low oil pressure switch.
3. Shifter engaging parts (inside transmission) badly worn
3. Oil pump O-ring damaged or missing.
and rounded.
4. Bypass valve stuck in open position.
4. Shifter forks bent.
5. Ball missing or leaking in cam support plate.
5. Damaged gears.
6. Worn oil pump gerotor(s).
Clutch Slips
7. Oil diluted with gasoline.
1. Clutch controls improperly adjusted.
High Oil Pressure 2. Insufficient clutch spring tension.
1. Oil reservoir overfilled.
3. Worn friction discs.
2. Bypass valve stuck in closed position.
Clutch Drags Or Does Not Release
ELECTRICAL SYSTEM 1. Lubricant level too high in primary chaincase.
NOTE 2. Clutch controls improperly adjusted.
For diagnostic information see the electrical diagnostic manual.
3. Primary chain badly misaligned or too tight.
Alternator Does Not Charge 4. Insufficient clutch spring tension.
1. Voltage regulator module not grounded. 5. Clutch discs warped.
2. Engine ground wire loose or damaged.
Clutch Chatters
3. Faulty voltage regulator module.
Friction discs or steel discs worn or warped.
4. Loose or damaged wires in charging circuit.
HANDLING
5. Faulty stator and/or rotor.
Irregularities
Alternator Charge Rate Is Below Normal
1. Improperly loaded motorcycle. Non-standard equipment
1. Weak or damaged battery. on the front end such as heavy radio receivers, extra
lighting equipment or luggage tends to cause unstable
2. Loose connections.
handling.
3. Faulty voltage regulator module.
2. Damaged tire(s) or improper front-rear tire combination.
4. Faulty stator and/or rotor.
3. Irregular or peaked front tire tread wear.
Speedometer Operates Erratically 4. Incorrect tire pressure.
1. Contaminated vehicle speed sensor (remove sensor and
5. Shock absorber not functioning normally.
clean off metal particles).
6. Incorrect air suspension pressure.
2. Loose connections.
7. Loose front wheel axle nuts or rear wheel lug nuts. Tighten
TRANSMISSION to recommended torque specification.
Shifts Hard 8. Excessive front wheel hub bearing play.
1. Primary chaincase overfilled with lubricant. 9. Rear axle out of alignment with frame and front wheel.
2. Clutch not fully disengaging. 10. Steering head bearings improperly adjusted. Correct
adjustment and replace pitted or worn bearings and races.
3. Transmission lubricant too heavy (winter operation).
11. Damaged or inoperative steering damper.
4. Shifter return spring (inside transmission) bent or broken.
12. Tire and wheel unbalanced.
5. Bent shifter rod.
13. Rims and tires out-of-round or eccentric with hub.
6. Shifter forks (inside transmission) sprung.
14. Rims and tires out-of-true sideways.
7. Corners worn off shifter clutch dog rings (inside transmis-
sion). 15. Rear fork pivot assembly: improperly tightened or
assembled, or loose/pitted or damaged pivot bearings.

1-28 2013 Trike Service Supplement: Maintenance

HOME

16. Engine mounts and/or stabilizer links loose, worn or 7. Brake fades due to heat build up - brake pads dragging
damaged. or excessive braking.
17. Uneven rear brake operation. 8. Brake fluid leak when under pressure.
18. Loose rear axle bearing cap bolts or bearing retainer nuts. Park Brake Does Not Hold Normally
BRAKES 1. Park brake requires adjustment.

Brake Does Not Operate Normally 2. Rear brake pads or discs worn. Replace parts and adjust
park brake.
1. Master cylinder reservoir low on fluid, system leaking or
pads worn. REVERSE MOTOR
2. Brake system contains air bubbles. Reverse Motor Does Not Operate/Cannot
3. Master cylinder or caliper piston seals worn or parts Enable
damaged. 1. Vehicle not started or vehicle not in neutral.
4. Brake pads contaminated with grease or oil. 2. Reverse motor circuit breaker open/tripped.
5. Brake pads or disc worn. 3. Open accessory fuse.
6. Brake drags: insufficient brake pedal or hand lever free-
play, caliper piston worn or damaged, or excessive brake
fluid in reservoir.

2013 Trike Service Supplement: Maintenance 1-29

NOTES

1-30 2013 Trike Service Supplement: Maintenance

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
2.1 FASTENER TORQUE VALUES.................................................................................................2-1
2.2 SPECIFICATIONS.....................................................................................................................2-4
2.3 VEHICLE IDENTIFICATION NUMBER (VIN)............................................................................2-5
2.4 REAR WHEELS.........................................................................................................................2-7
2.5 REAR BRAKE CALIPERS.........................................................................................................2-8
2.6 REAR BRAKE MASTER CYLINDER/PEDAL..........................................................................2-10
2.7 BLEEDING BRAKES...............................................................................................................2-15
2.8 TRUNK DOOR.........................................................................................................................2-17
2.9 TRUNK DOOR LOCKSET.......................................................................................................2-19
2.10 TOUR-PAK.............................................................................................................................2-23
2.11 BODY.....................................................................................................................................2-24
2.12 REAR FENDERS...................................................................................................................2-27
2.13 REAR FRAME.......................................................................................................................2-29
2.14 INTERMEDIATE FRAME.......................................................................................................2-31
2.15 REAR FORK..........................................................................................................................2-34
2.16 LATERAL ALIGNMENT.........................................................................................................2-38
2.17 PARK BRAKE ASSEMBLY....................................................................................................2-39
2.18 SHOCK ABSORBERS...........................................................................................................2-43
2.19 PANHARD ROD.....................................................................................................................2-44
2.20 STEERING DAMPER ASSEMBLY........................................................................................2-46

CHASSIS
2.21 FRONT WHEEL.....................................................................................................................2-47
2.22 FRONT FENDER...................................................................................................................2-48
2.23 ENGINE STABILIZER............................................................................................................2-49
NOTES
HOME

FASTENER TORQUE VALUES 2.1

FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.

FASTENER TORQUE VALUE NOTES

Air valve nut 12-15 in-lbs 1.4-1.7 Nm 2.14 INTERMEDIATE FRAME, Installation
Axle adapter plate screws 41-45 ft-lbs 55.6-61.0 Nm 2.16 LATERAL ALIGNMENT, Procedure/Use
LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue)
Axle adapter plate screws 41-45 ft-lbs 55.6-61.0 Nm 2.17 PARK BRAKE ASSEMBLY, Assemble
Handle/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
Bank angle sensor bracket screws 72-108 in-lbs 8.1-12.2 Nm 2.14 INTERMEDIATE FRAME, Assembly
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 2.4 REAR WHEELS, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 2.11 BODY, Installation
Battery tray screws 72-96 in-lbs 8.1-10.9 Nm 2.14 INTERMEDIATE FRAME, Installation
Body attachment screws (inside trunk) 14-17 ft-lbs 19.0-23.1 Nm 2.11 BODY, Installation/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue) on screws
Body attachment screws (outside trunk) 24-26 ft-lbs 32.5-35.3 Nm 2.11 BODY, Installation/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Brake caliper, rear, banjo bolt 17-19 ft-lbs 23.1-25.8 Nm 2.5 REAR BRAKE CALIPERS, Installation
Brake caliper, rear, banjo bolt 17-19 ft-lbs 23.1-25.8 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Rear Brake Line
Brake caliper, rear, cable bracket screws 132-156 in-lbs 14.9-17.6 Nm 2.5 REAR BRAKE CALIPERS, Repair
Brake caliper, rear, mounting bracket 41-45 ft-lbs 55.6-61.0 Nm 2.5 REAR BRAKE CALIPERS, Installation/Use
screws LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue)
Brake caliper, rear, mounting bracket 41-45 ft-lbs 55.6-61.0 Nm 2.5 REAR BRAKE CALIPERS, Repair/Use LOC-
screws TITE 243 MEDIUM STRENGTH THREADLOCKER
AND SEALANT (blue)
Brake caliper, rear, reaction bracket 41-45 ft-lbs 55.6-61.0 Nm 2.5 REAR BRAKE CALIPERS, Repair/Use LOC-
screws TITE 243 MEDIUM STRENGTH THREADLOCKER
AND SEALANT (blue)
Brake caliper bleeder valve 80-100 in-lbs 9.0-11.3 Nm 2.7 BLEEDING BRAKES, Procedure
Brake lamp switch, rear, bracket fastener 80-100 in-lbs 9.0-11.3 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Installation
Brake line, rear, tee locknut 59-63 in-lbs 6.7-7.1 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Rear Brake Line/Use new locknut

Brake line, rear, tee locknut 59-63 in-lbs 6.7-7.1 Nm 2.15 REAR FORK, Installation/Use new locknut
Brake master cylinder, front, reservoir 10-12 in-lbs 1.1-1.4 Nm 2.7 BLEEDING BRAKES, Procedure
cover screws
Brake master cylinder, rear, banjo bolt 17-22 ft-lbs 23.0-29.8 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Installation
Brake master cylinder, rear, banjo bolt 17-22 ft-lbs 23.0-29.8 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Rear Brake Line

2013 Trike Service Supplement: Chassis 2-1

HOME

FASTENER TORQUE VALUE NOTES

Brake master cylinder, rear, mounting 30-40 ft-lbs 40.7-54.2 Nm 2.6 REAR BRAKE MASTER CYL-
bracket nut INDER/PEDAL, Installation/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Brake master cylinder, rear, mounting 126-150 in-lbs 14.2-16.9 Nm 2.6 REAR BRAKE MASTER CYL-
bracket screws INDER/PEDAL, Installation
Brake master cylinder, rear, reservoir 6-8 in-lbs 0.7-0.9 Nm 2.7 BLEEDING BRAKES, Procedure
cover screws
Brake pedal shaft locknut 15-20 ft-lbs 20.3-27.1 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Installation
Engine mount, front, end cap fasteners 42-48 ft-lbs 48.8-54.2 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Rear Brake Line
Engine stabilizer bracket screws 30-35 ft-lbs 40.7-47.5 Nm 2.23 ENGINE STABILIZER, Stabilizer Link/Apply
LOCTITE 272 HIGH STRENGTH/HIGH TEMPER-
ATURE THREADLOCKER AND SEALANT
(red/orange) to threads
Engine stabilizer link screws 30-35 ft-lbs 40.7-47.5 Nm 2.23 ENGINE STABILIZER, Stabilizer Link
Engine stabilizer link screws 30-35 ft-lbs 40.7-47.5 Nm 2.23 ENGINE STABILIZER, Stabilizer Link
Fender, front, mount screws 24-28 ft-lbs 32.5-38.0 Nm 2.22 FRONT FENDER, Installation
Fender, front, side trim or skirt 10-15 in-lbs 1.1-1.7 Nm 2.22 FRONT FENDER, Installation
Fender, rear, screws 108-132 in-lbs 12.2-14.9 Nm 2.12 REAR FENDERS, Installation/Apply LOCTITE
243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue) to threads
Frame connection bracket screws 41-45 ft-lbs 55.6-61.0 Nm 2.14 INTERMEDIATE FRAME, Assembly
Front axle holder nuts 132-180 in-lbs 14.9-20.3 Nm 2.21 FRONT WHEEL, Installation
Front axle nut 70-75 ft-lbs 94.9-101.7 Nm 2.21 FRONT WHEEL, Installation
Ground strap to forward stud (inside 14-17 ft-lbs 19.0-23.1 Nm 2.11 BODY, Installation
trunk)
Ground strap to upper stud 96-120 in-lbs 10.8-13.5 Nm 2.11 BODY, Assembly
Handrail screws, passenger 60-96 in-lbs 6.8-10.9 Nm 2.14 INTERMEDIATE FRAME, Assembly
Intermediate frame screws 40-45 ft-lbs 54.2-61.0 Nm 2.14 INTERMEDIATE FRAME, Installation
Left electrical caddy screw 72-96 in-lbs 8.1-10.9 Nm 2.14 INTERMEDIATE FRAME, Installation
License plate bracket screws 18-30 in-lbs 2.0-3.4 Nm 2.8 TRUNK DOOR, Assembly/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Lug nuts 90-100 ft-lbs 122.0-135.6 Nm 2.4 REAR WHEELS, Installation/Always check lug
nut torque within 500-1000 mi (805-1610 km) after
wheel installation.
Muffler bracket screws 96-144 in-lbs 10.9-16.3 Nm 2.13 REAR FRAME, Installation
Panhard rod adjustment jamnut 20-30 ft-lbs 27.1-40.7 Nm 2.19 PANHARD ROD, Adjustment
Panhard rod adjustment jamnut 20-30 ft-lbs 27.1-40.7 Nm 2.19 PANHARD ROD, Adjustment
Panhard rod clevis screw 55-60 ft-lbs 74.6-81.4 Nm 2.19 PANHARD ROD, Installation
Panhard rod clevis screw 55-60 ft-lbs 74.6-81.4 Nm 2.19 PANHARD ROD, Adjustment
Panhard rod locknut 55-60 ft-lbs 74.6-81.4 Nm 2.19 PANHARD ROD, Installation
Park brake cable clamp nut 15-17 ft-lbs 20.3-23.1 Nm 2.17 PARK BRAKE ASSEMBLY, Assemble Handle
Park brake knob screw 10-15 in-lbs 1.1-1.7 Nm 2.17 PARK BRAKE ASSEMBLY, Assemble
Handle/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
Park brake mounting screws 15-17 ft-lbs 20.3-23.1 Nm 2.17 PARK BRAKE ASSEMBLY, Assemble Handle
P-clamp to pinch block screw 14-17 ft-lbs 19.0-23.1 Nm 2.17 PARK BRAKE ASSEMBLY, Cable Installation

2-2 2013 Trike Service Supplement: Chassis

HOME

FASTENER TORQUE VALUE NOTES

Pinch block screws 41-45 ft-lbs 55.6-61.0 Nm 2.18 SHOCK ABSORBERS, Installation/Use
LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue)
Rear fork bracket bolts 55-65 ft-lbs 74.6-88.1 Nm 2.15 REAR FORK, Installation/Apply two drops of
LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue) to threads
Rear fork pivot shaft locknut 50 ft-lbs + 180 67.8 Nm + 180 2.15 REAR FORK, Installation/Always use new
degrees addi- degrees addi- locknuts and cup washers
tional rotation tional rotation
Rear frame screws 41-45 ft-lbs 55.6-61.0 Nm 2.13 REAR FRAME, Installation/ Use LOCTITE
262 HIGH STRENGTH THREADLOCKER AND
SEALANT (red)
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 2.13 REAR FRAME, Installation/Use LOCTITE 262
HIGH STRENGTH THREADLOCKER AND
SEALANT (red)
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 2.18 SHOCK ABSORBERS, Installation/Use
LOCTITE 262 HIGH STRENGTH THREAD-
LOCKER AND SEALANT (red)
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 2.19 PANHARD ROD, Adjustment/Use LOCTITE
262 HIGH STRENGTH THREADLOCKER AND
SEALANT (red)
Steering damper acorn nut 16-20 ft-lbs 21.7-27.1 Nm 2.20 STEERING DAMPER ASSEMBLY, Installation
Steering damper bracket screw 16-20 ft-lbs 21.7-27.1 Nm 2.20 STEERING DAMPER ASSEMBLY, Installation
Steering damper locknut 16-20 ft-lbs 21.7-27.1 Nm 2.20 STEERING DAMPER ASSEMBLY, Installation
Steering damper side mounting bracket 15-20 ft-lbs 20.3-27.1 Nm 2.20 STEERING DAMPER ASSEMBLY, Installation
screws
Tail lamp/turn signal chrome base screw 36-48 in-lbs 4.1-5.4 Nm 2.12 REAR FENDERS, Assembly/Use LOCTITE
222 LOW STRENGTH THREADLOCKER AND
SEALANT (purple)
Tail lamp/turn signal lens screws 21-24 in-lbs 2.4-2.7 Nm 2.12 REAR FENDERS, Installation
Tour-Pak rack screws 60-84 in-lbs 6.8-9.5 Nm 2.10 TOUR-PAK, Installation/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Tour-Pak screws 60-84 in-lbs 6.8-9.5 Nm 2.10 TOUR-PAK, Installation/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Trunk door cover screws 30-54 in-lbs 3.4-6.1 Nm 2.8 TRUNK DOOR, Installation
Trunk door hinge locknuts 60-84 in-lbs 6.8-9.5 Nm 2.8 TRUNK DOOR, Installation/Use new locknuts
Trunk door hinge screws 48-72 in-lbs 5.4-8.1 Nm 2.8 TRUNK DOOR, Assembly/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Trunk door lanyard screws 48-72 in-lbs 5.4-8.1 Nm 2.8 TRUNK DOOR, Installation
Trunk door latch housing screws 48-60 in-lbs 5.4-6.8 Nm 2.9 TRUNK DOOR LOCKSET, Latch Assembly
Trunk door latch mechanism screws 8-10 in-lbs 0.9-1.1 Nm 2.9 TRUNK DOOR LOCKSET, Latch Assembly
Trunk door latch pin bracket screws 48-72 in-lbs 5.4-8.1 Nm 2.8 TRUNK DOOR, Installation
Trunk door latch pin jamnut 48-72 in-lbs 5.4-8.1 Nm 2.8 TRUNK DOOR, Assembly
Trunk door latch pin jamnut 48-72 in-lbs 5.4-8.1 Nm 2.9 TRUNK DOOR LOCKSET, Latch Pin
Trunk door lock housing nuts 9-11 in-lbs 1.0-1.2 Nm 2.9 TRUNK DOOR LOCKSET, Latch Assembly
Trunk latch housing cover screw 25-28 in-lbs 2.8-3.2 Nm 2.9 TRUNK DOOR LOCKSET, Lockset
Wheel center cap clamp screw 72-96 in-lbs 8.1-10.9 Nm 2.4 REAR WHEELS, Installation/Use LOCTITE
243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)

2013 Trike Service Supplement: Chassis 2-3

HOME

SPECIFICATIONS 2.2
GENERAL running weight. For example, a motorcycle with GVWR of 1200
lbs (544 kg) having a running weight of 800 lbs (363 kg), would
allow a maximum of an additional 400 lbs (181 kg) combined
Table 2-1. Dimensions weight of the rider, passenger, riding gear, cargo and installed
ITEM IN MM accessories.
Length 105.8 2687
Table 2-2. Weights
Overall Width 54.7 1389
ITEM LB KG
Overall Height 59.3 1506
Running weight* 1191 540.2
Wheelbase 66.6 1692
Maximum added weight 509 230.9
Ground clearance 4.7 119
allowed**
Saddle height* 27.1 688
GVWR 1700 771.1
*With 180 lb ( 81.7 kg) rider on seat.
GAWR front 500 226.8
GAWR rear 1200 544.3
* The total weight of the motorcycle as delivered with all
Do not exceed the motorcycle's Gross Vehicle Weight oil/fluids and approximately 90% of fuel.
Rating (GVWR) or Gross Axle Weight Rating (GAWR). ** The sum total weight of the rider, passenger, cargo, riding
Exceeding these weight ratings can lead to component gear and any accessories cannot exceed this weight.
failure and adversely affect stability, handling and perform-
ance, which could result in death or serious injury. (00016f)
• GVWR is the sum of the weight of the motorcycle,
accessories, and the maximum weight of the rider, pas- Use only Harley-Davidson specified tires. See a Harley-
senger and cargo that can be safely carried. Davidson dealer. Using non-specified tires can adversely
affect stability, handling or braking, which could result in
• GAWR is the maximum amount of weight that can be death or serious injury. (00024b)
safely carried on each axle.
• The GVWR and GAWR are shown on the information NOTE
label, located on the frame down tube. Harley-Davidson does not perform any testing with only
nitrogen in tires. Harley-Davidson neither recommends nor
The maximum additional weight allowed on the motorcycle
discourages the use of pure nitrogen to inflate tires.
equals the Gross Vehicle Weight Rating (GVWR) minus the

Table 2-3. Specified Tires

MOUNT SIZE SPECIFIED TIRE PRESSURE (COLD)

PSI kPa
Front 16 in. Dunlop D402F MT90B16 72H 36 248
Rear 15 in. Dunlop P205/65 R15 92T 26 179

2-4 2013 Trike Service Supplement: Chassis

HOME

VEHICLE IDENTIFICATION NUMBER (VIN) 2.3

VEHICLE IDENTIFICATION NUMBER (VIN) om01391

General
See Figure 2-2. A unique 17-digit serial or Vehicle Identification
Number (VIN) is assigned to each motorcycle. For a description
of each item in the VIN, refer to Table 2-4.

Location
See Figure 2-1. The full 17-digit VIN (1) is stamped on the right
side of the frame near the steering head. In some destinations,
a printed VIN label (2) is also attached to the front downtube.

Abbreviated VIN 2
1
An abbreviated VIN showing the vehicle model, engine type,
model year, and sequential number is stamped on the left side
of the crankcase between the engine cylinders.
NOTE
Always give the full 17-digit Vehicle Identification Number when
ordering parts or making any inquiry about your motorcycle.

1. Stamped VIN
2. VIN label
Figure 2-1. VIN Locations

2013 Trike Service Supplement: Chassis 2-5

HOME

om01283

1 2 3 4 5 6 7 8 9

1HD 1 MA M 1 3 D B 111000

Figure 2-2. Typical Harley-Davidson VIN: 2013 Trike Models

Table 2-4. Harley-Davidson VIN Breakdown: 2013 Trike Models

POSITION DESCRIPTION POSSIBLE VALUES

1 World manufacturer identifier 1HD=Originally manufactured for sale within the United States
5HD=Originally manufactured for sale outside of the United States
2 Motorcycle type 1=Heavyweight motorcycle (901 cc or larger)
3 Model MA=FLHTCUTG Tri Glide™ Ultra Classic®
MA=FLHTCUTG ANV Tri Glide™ Ultra Classic® 110th Anniversary Edition
4 Engine type M=Twin Cam 103, 1690 cc air-cooled, fuel-injected
5 Introduction date/ Normal Introduction Mid-year or Special Introduction
Configuration and calibration 1=Domestic (DOM) 2, 4=Domestic (DOM)
recognition 3=California (CAL) 5, 6=California (CAL)
A=Canada (CAN) B=Canada (CAN)
6 VIN check digit Can be 0-9 or X
7 Model year D=2013
8 Assembly plant B=York, PA U.S.A.
9 Sequential number Varies

2-6 2013 Trike Service Supplement: Chassis

HOME

REAR WHEELS 2.4

REMOVAL INSTALLATION
1. Remove seat.
FASTENER TORQUE VALUE
Wheel center cap clamp screw 72-96 in-lbs 8.1-10.9 Nm
Lug nuts 90-100 ft-lbs 122.0-135.6
To prevent accidental vehicle start-up, which could cause Nm
death or serious injury, disconnect negative (-) battery
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
cable before proceeding. (00048a)
2. Disconnect battery negative (-) cable. 1. If removed, install center caps. Apply LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND SEALANT
(blue) to center cap clamp screw. Install screw with flat
washer. Tighten to 72-96 in-lbs (8.1-10.9 Nm).
When lifting a motorcycle using a jack, be sure jack con-
tacts both lower frame tubes where down tubes and lower 2. Install wheel and tighten lug nuts to 90-100 ft-lbs (122.0-
frame tubes converge. Never lift by jacking on cross- 135.6 Nm) in a crosswise pattern.
members, oil pan or other housings. Failure to comply can NOTE
cause serious damage resulting in the need to perform Always check lug nut torque within 500-1000 mi (805-1610
major repair work. (00586c) km) after wheel installation.
3. Position jack to lift rear of motorcycle. See 1.2 LIFTING 3. Connect battery negative (-) cable. Tighten to 60-70 in-lbs
MOTORCYCLE WITH A JACK. (6.8-7.9 Nm).
4. Before lifting motorcycle, set park brake and loosen four
lug nuts in a crosswise pattern. Raise jack.
5. Remove lug nuts and pull wheel from axle flange studs. After installing seat, pull upward on seat to be sure it is
6. If necessary, remove center cap. locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
4. Install seat.

2013 Trike Service Supplement: Chassis 2-7

HOME

REAR BRAKE CALIPERS 2.5

REMOVAL sm06459a
NOTE 8
If only replacing brake pads, see 1.7 REAR BRAKE PADS
AND DISCS.
7
1. Remove rear wheel. See 2.4 REAR WHEELS. 4 6
2. Release park brake. 5
NOTE
See Figure 2-3. Wrap banjo fitting with piece of shop towel to
absorb any loss of brake fluid. 9
3
3. Remove banjo bolt (6) with two copper washers to release 10
brake line.
4. Disconnect spring (2). 2
5. Compress fingers on cable retainer (4) and remove cable
from bracket (3). 1
6. Remove end of cable from actuator lever (13).
7. If caliper is to be disassembled, loosen mounting/pad pins 11
(1) and locknut (14) before removing caliper assembly.
12
8. Remove two screws (7). Remove caliper assembly from 16
disc. 13
14 15

1. Mounting/pad pin
2. Spring
3. Cable bracket
4. Cable retainer
5. Screw (4)
6. Banjo bolt/bleeder valve
7. Screw (2)
8. Caliper reaction bracket
9. Retaining rings (2)
10. Caliper mounting bracket
11. Caliper assembly
12. Dust boot
13. Actuator lever
14. Locknut
15. Bushing (2)
16. O-ring (4)
Figure 2-3. Rear Brake Caliper Assembly

INSTALLATION
FASTENER TORQUE VALUE
Brake caliper, rear, mounting 41-45 ft-lbs 55.6-61.0 Nm
bracket screws
Brake caliper, rear, banjo bolt 17-19 ft-lbs 23.1-25.8 Nm

1. See Figure 2-3. Install caliper assembly with brake pads

onto disc.
2. Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue) to screws (7) and install.
Tighten to 41-45 ft-lbs (55.6-61.0 Nm).
3. If damaged or removed, install new cable retainer (4).

2-8 2013 Trike Service Supplement: Chassis

HOME

4. Install end of cable into actuator lever (13). 2. Remove locknut (14), actuator lever (13) and dust boot
(12).
5. Engage cable in bracket (3). Bend fingers on cable retainer
outward slightly to lock position of cable in bracket. 3. Remove retaining rings (9) and mounting/pad pins (1).
Discard all.
6. Start banjo bolt (6) with two new copper washers to install
brake line. Tighten to 17-19 ft-lbs (23.1-25.8 Nm). 4. Remove caliper from bracket (10) and remove brake pads.
7. Fill and bleed brake system. See 2.7 BLEEDING BRAKES. 5. Remove bushings (15) and O-rings (16) from caliper
housing.
8. Adjust park brake. See 1.11 PARK BRAKE.
NOTE
9. Install rear wheel. See 2.4 REAR WHEELS.
The axle shaft must be removed to remove caliper reaction
NOTE bracket (8). If caliper reaction bracket requires removal, see
Always check lug nut torque within 500-1000 mi (805-1610 5.2 AXLE.
km) after wheel installation. 6. If necessary, remove four screws to free reaction bracket
REPAIR (8) from axle housing.

Assembly
FASTENER TORQUE VALUE
1. See Figure 2-3. If removed, apply LOCTITE 243 MEDIUM
Brake caliper, rear, reaction 41-45 ft-lbs 55.6-61.0 Nm
STRENGTH THREADLOCKER AND SEALANT (blue) to
bracket screws
screws and fasten caliper reaction bracket (8) to axle
Brake caliper, rear, mounting 41-45 ft-lbs 55.6-61.0 Nm housing. Tighten to 41-45 ft-lbs (55.6-61.0 Nm) in a
bracket screws crosswise pattern. Install axle shaft. See 5.2 AXLE.
Brake caliper, rear, cable 132-156 14.9-17.6 Nm 2. Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
bracket screws in-lbs LOCKER AND SEALANT (blue) to screws (7). Secure
caliper mounting bracket (10) to caliper reaction bracket
Disassembly (8). Tighten to 41-45 ft-lbs (55.6-61.0 Nm).

NOTES 3. Install cable bracket (3) on caliper housing. Tighten screws

• The caliper housing contains no serviceable components. (5) to 132-156 in-lbs (14.9-17.6 Nm).
Replace the caliper assembly it is damaged or leaking. 4. Install dust boot (12), actuator lever (13) and locknut (14)
• The left and right caliper assemblies are unique from each Do not tighten locknut at this time.
other. Do not mix them if both are removed at the same 5. Install caliper and brake pads. See 2.5 REAR BRAKE
time. CALIPERS, Installation.
1. See Figure 2-3. Remove screws (5). Remove cable
bracket (3) from caliper housing.

2013 Trike Service Supplement: Chassis 2-9

HOME

REAR BRAKE MASTER CYLINDER/PEDAL 2.6

GENERAL NOTE
Wrap banjo fitting with piece of shop towel to absorb any loss
of brake fluid.
4. Remove banjo bolt (metric) to release brake line from
Direct contact of D.O.T. 4 brake fluid with eyes can cause master cylinder reservoir. Hold suitable container under
irritation. Avoid eye contact. In case of eye contact flush banjo bolt bore to allow reservoir to drain. Discard copper
with large amounts of water and get medical attention. washers.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten- 5. Using a clean shop cloth, wipe out any remaining fluid in
tion. Use in well ventilated area. KEEP OUT OF REACH OF the master cylinder reservoir.
CHILDREN. (00240a) 6. Move brake line to access mounting nut:
a. Cut two cable straps to free rear brake line from main
harness at top of lower frame tube. Release brake
line from two main harness conduit clips.
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and b. Remove screw securing brake lamp switch bracket.
protect surfaces from spills whenever brake work is per- Push on bracket to release locating tab from slot in
formed. Failure to comply can result in cosmetic damage. frame weldment.
(00239b)
c. Cut cable strap to free brake lamp switch wires and
main harness from lower frame tube. Remove ter-
minals from rear brake light switch spade contacts, if
Do not allow dirt or debris to enter the master cylinder necessary.
reservoir. Dirt or debris in the reservoir can cause improper
7. Remove nut to free brake pedal/master cylinder assembly
operation and equipment damage. (00205c)
from mounting bracket.
NOTE 8. Remove two fasteners securing mounting bracket to
Immediately wipe up any brake fluid spillage with a clean, dry, engine mount end cap.
soft cloth. Follow up by thoroughly wiping affected area with a 9. Remove mounting bracket from brake pedal/master cyl-
clean, damp, soft cloth (small spills) or washing with a large inder assembly.
quantity of soapy water (large spills).
10. Remove locknut with flat washer. Pull brake pedal/master
REMOVAL cylinder assembly from pedal shaft. Remove and discard
1. Remove right side rider footboard. See the service manual. O-ring on each side of brake pedal shaft bore.

2. Thoroughly clean the cover before removal. 11. See Figure 2-4. Remove cotter pin (4), flat washer (3) and
clevis pin (2) from brake pedal flange.
3. Remove cover from master cylinder reservoir.

2-10 2013 Trike Service Supplement: Chassis

HOME

sm06257

1 3
4

1. Brake pedal 4. Cotter pin

2. Clevis pin 5. Master cylinder reservoir
3. Flat washer
Figure 2-4. Rear Brake Pedal/Master Cylinder Assembly

DISASSEMBLY sm06462

NOTE 2
1
Do not disassemble the cartridge assembly. The cartridge
assembly components are not sold separately. Replace the 3 12
master cylinder assembly if leakage is evident. 11
4
1. Thoroughly clean exterior of master cylinder assembly 5 6
with denatured alcohol. 10
2. Stand master cylinder assembly upright on a clean shop 7
towel on the banjo sealing surface with reservoir over edge 8
9
of work surface.

Wear safety glasses or goggles when removing or

installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause 1. Retaining ring
serious eye injury. (00312a) 2. Large washer
3. Dust boot
3. See Figure 2-5. Push down and hold large flat washer (2) 4. Spring
and remove retaining ring (1). Discard retaining ring. 5. Retaining ring
4. Remove large flat washer (2), dust boot (3) and spring (4). 6. O-ring (2)
7. Cartridge assembly
5. Push on threaded end of cartridge assembly (7) to remove. 8. Slot
Use hand pressure only. Exercise caution to keep cartridge 9. Reservoir housing
assembly free of dirt and grease. 10. Gasket
6. If reservoir housing (9) is to be replaced, remove O-rings 11. Cover
(6) from cartridge assembly. 12. Screw (2)
Figure 2-5. Rear Master Cylinder

2013 Trike Service Supplement: Chassis 2-11

HOME

CLEANING AND INSPECTION 6. Install spring (4), dust boot (3), and large flat washer (2).
7. Push down on large flat washer and hold spring in a
compressed state. Install new retaining ring (1) in groove
of clevis.
Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or 8. Seat dust boot over lip on reservoir housing.
paint thinner), which will deteriorate rubber parts even 9. Rotate boot so that drain/air hole is at the bottom.
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious INSTALLATION
injury. (00291a)
1. Clean all metal parts, except the cartridge body assembly. FASTENER TORQUE VALUE
Dry with compressed air. Clean all rubber parts using Brake master cylinder, rear, 126-150 14.2-16.9 Nm
denatured alcohol. mounting bracket screws in-lbs
2. Inspect reservoir bore for scratches. Replace reservoir if Brake master cylinder, rear, 30-40 ft-lbs 40.7-54.2 Nm
scratches are present. mounting bracket nut
3. Check dust boot for damage. Replace as necessary. Brake pedal shaft locknut 15-20 ft-lbs 20.3-27.1 Nm

4. Inspect threads on cartridge body. Replace assembly if Brake master cylinder, rear, 17-22 ft-lbs 23.0-29.8 Nm
threads are damaged. banjo bolt
Brake lamp switch, rear, 80-100 in-lbs 9.0-11.3 Nm
5. Inspect spring for distortion, cracks or broken coils.
bracket fastener
Replace as necessary.
6. Clean O-ring grooves on cartridge body using a soft cotton 1. Install master cylinder assembly onto brake pedal flange.
cloth moistened with alcohol and allow to dry. Inspect Install clevis pin from the outboard side. Install flat washer
grooves for scratches. and cotter pin on clevis pin.
7. Inspect reservoir cover gasket for damage. Replace as 2. Apply a light coat of WHEEL BEARING GREASE to the
necessary: brake pedal shaft and bore and install new O-ring on each
a. From inboard side, push sight glass toward top of side of bore.
cover until free. 3. Install brake pedal/master cylinder assembly on the pedal
b. Pull rubber gasket from cover. shaft. Install flat washer and new locknut on pedal shaft.

c. Fit nipple of new gasket into hole of cover aligning 4. Insert threaded end of cartridge body through opening in
gasket and cover holes. mounting bracket. Apply LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT (blue) to
NOTE threads and start mounting nut.
Use a small quantity of clean brake fluid to lubricate sight
glass. 5. Secure mounting bracket to engine mount end cap.
Tighten to 126-150 in-lbs (14.2-16.9 Nm).
d. From bottom of gasket, push flat end of sight glass
through nipple until top of glass is flush with top of 6. Tighten mounting nut to 30-40 ft-lbs (40.7-54.2 Nm).
gasket. Verify that glass is square in bore. 7. Tighten brake pedal shaft locknut to 15-20 ft-lbs (20.3-27.1
Nm).
ASSEMBLY
8. Secure brake line to master cylinder with banjo bolt
1. See Figure 2-5. If O-rings (6) have been removed, lubricate (metric) and new copper washers. Tighten to 17-22 ft-lbs
new O-rings with DOT 4 BRAKE FLUID and carefully (23.0-29.8 Nm).
install in grooves on outside of cartridge assembly.
9. Complete installation of rear brake line:
2. Wipe bore of reservoir housing with DOT 4 BRAKE FLUID.
a. Install terminals onto rear brake lamp switch contacts
3. Verify large retaining ring (5) is installed on cartridge (polarity is not important). Install new cable strap to
assembly. secure rear brake lamp switch wires and main harness
to lower frame tube.
NOTE
Use hand pressure only to assemble cartridge into reservoir b. Secure brake lamp switch bracket to frame weldment.
housing. Tighten to 80-100 in-lbs (9.0-11.3 Nm).
4. Insert cartridge assembly into reservoir housing aligning c. Secure rear brake line in two main harness conduit
tab in housing bore with slot (8) on cartridge. Cartridge clips at top of lower frame tube. Install two new cable
assembly is fully installed when reservoir housing contacts straps adjacent to clips to secure brake line to main
large retaining ring (5). harness.
5. Stand master cylinder assembly upright on a clean shop 10. Fill and bleed brake system. See 2.7 BLEEDING BRAKES.
towel on the banjo sealing surface with reservoir over edge
of work surface. 11. Install rider footboard. See the service manual.

2-12 2013 Trike Service Supplement: Chassis

HOME

12. Install fairing lower. See the service manual.

sm06484

After repairing the brake system, test brakes at low speed.

If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
1
serious injury. (00289a)
13. Test ride motorcycle.

REAR BRAKE LINE

FASTENER TORQUE VALUE
Brake line, rear, tee locknut 59-63 in-lbs 6.7-7.1 Nm
Engine mount, front, end cap 42-48 ft-lbs 48.8-54.2 Nm
2
fasteners
Brake master cylinder, rear, 17-22 ft-lbs 23.0-29.8 Nm 1. Engine mount end cap
banjo bolt 2. Engine mount end cap fastener
Brake caliper, rear, banjo bolt 17-19 ft-lbs 23.1-25.8 Nm Figure 2-6. Engine mount end cap

Removal Installation
1. Remove side covers. 1. Route front section of brake line (with rubber sleeve)
2. Remove rear wheels. See 2.4 REAR WHEELS. downward at rear of transmission exhaust bracket.

3. Disconnect brake line from master cylinder. See 2.6 REAR 2. Route left caliper brake line through opening between oil
BRAKE MASTER CYLINDER/PEDAL, Removal. filler spout and pivot shaft mount, then across top of rear
fork to left side of motorcycle. Keep brake line below
4. See Figure 2-6. Support front of engine. Remove three reverse motor-to-battery ground cable.
fasteners (2) to remove rear master cylinder, pedal
assembly, right side rider footboard and engine mount end 3. Route right caliper brake line through same opening,
cap (1) as an assembly. Release brake line from lower pulling it rearward along inboard side of intermediate frame
frame tube. downtubes and outboard between fender and caliper cable
bracket.
5. Release brake line hoses from four cable clips at top of
rear fork. Rotate clips sideways to prevent hoses from re- 4. Install brake line tee onto rear fork stud with new locknut.
engaging. Tighten to 59-63 in-lbs (6.7-7.1 Nm).

6. Remove brake line tee from rear fork stud. 5. Start banjo bolt with new copper washers to secure brake
line to left and right calipers.
7. Remove TSM/HFSM from bracket at right side of battery
tray. Pull module and main harness conduit outboard. 6. Capture rear brake line hoses in four cable clips at top of
Allow to hang. rear fork.

8. Remove banjo bolts (metric) to release brake lines from 7. See Figure 2-6. Install rear master cylinder, brake pedal
calipers. Discard copper washers. assembly, right side rider footboard and engine mount end
cap (1) as an assembly. Secure with three fasteners (2).
9. Remove brake lines. Tighten to 42-48 ft-lbs (48.8-54.2 Nm). See the service
manual.
8. Connect brake line to master cylinder using new copper
washers. Tighten banjo bolt to 17-22 ft-lbs (23.0-29.8 Nm).
9. Tighten caliper banjo bolts to 17-19 ft-lbs (23.1-25.8 Nm).
10. Fill and bleed brake system. See 2.7 BLEEDING BRAKES.
11. Install rear wheels. See 2.4 REAR WHEELS.
NOTE
Always check lug nut torque within 500-1000 mi (805-1610
km) after wheel installation.
12. Install TSM/HFSM onto bracket at right side of battery tray.
13. Install side covers.
14. Install right fairing lower. See the service manual.

2013 Trike Service Supplement: Chassis 2-13

HOME

15. Test ride motorcycle to verify bleeding procedure.

After repairing the brake system, test brakes at low speed.

If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

2-14 2013 Trike Service Supplement: Chassis

HOME

BLEEDING BRAKES 2.7

GENERAL 1. Remove bleeder valve cap. Install end of clear plastic
tubing over bleeder valve and place free end in a clean
container.
2. Position vehicle or handlebar so master cylinder reservoir
Use denatured alcohol to clean brake system components. is level.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even NOTE
after assembly. Deterioration of these components can Protect paint from brake fluid spills. Wrap a clean shop cloth
cause brake failure, which could result in death or serious around the outside of the master cylinder reservoir.
injury. (00291a) 3. Remove cover from master cylinder reservoir.

Direct contact of D.O.T. 4 brake fluid with eyes can cause A plugged or covered relief port can cause brake drag or
irritation. Avoid eye contact. In case of eye contact flush lock-up, which could lead to loss of control, resulting in
with large amounts of water and get medical attention. death or serious injury. (00288a)
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten- 4. Refer to Table 2-5. Add brake fluid as necessary. Verify
tion. Use in well ventilated area. KEEP OUT OF REACH OF operation of the master cylinder relief port by actuating
CHILDREN. (00240a) the brake pedal or lever. A slight spurt of fluid will break
the surface.
5. Operate the brake lever or pedal to build hydraulic pres-
sure.
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and NOTE
protect surfaces from spills whenever brake work is per- Pay careful attention to the level of the fluid in the master cyl-
formed. Failure to comply can result in cosmetic damage. inder reservoir and add fluid before it empties to avoid drawing
(00239b) air into the brake lines.
6. While holding pressure with the brake lever or pedal:
a. Open bleeder valve about 3/4 turn.
Do not allow dirt or debris to enter the master cylinder b. Close bleeder valve as soon as the lever or pedal has
reservoir. Dirt or debris in the reservoir can cause improper moved full range of travel.
operation and equipment damage. (00205c)
c. Allow brake lever or pedal to return slowly to its
Front brake hand lever and rear brake foot pedal must have a released position.
firm feel when brakes are applied. If not, bleed system as
described. 7. Repeat steps until all air bubbles are purged and a solid
column of fluid is observed in the bleeder tube.
PROCEDURE
8. Tighten bleeder valve to specification. Install bleeder valve
PART NUMBER TOOL NAME cap.
SNAP-ON BB200A BASIC VACUUM BRAKE BLEEDER NOTE
If bleeding a dual caliper brake system, repeat steps to bleed
FASTENER TORQUE VALUE the second brake line and caliper.

Brake caliper bleeder valve 80-100 in-lbs 9.0-11.3 Nm 9. Check and fill reservoir to specified level.
Brake master cylinder, front, 10-12 in-lbs 1.1-1.4 Nm NOTE
reservoir cover screws Check master cylinder cover gasket bellows. Verify that the
Brake master cylinder, rear, 6-8 in-lbs 0.7-0.9 Nm master cylinder cover gasket bellows is not extended or brake
reservoir cover screws fluid will be ejected from the reservoir.
10. Refer to Table 2-6. Verify gasket and sealing surfaces are
NOTE free of debris. Install master cylinder reservoir cover:
If the brake system was completely drained, use the BASIC a. Front Master Cylinder Reservoir: Orient the cover
VACUUM BRAKE BLEEDER (Part No. Snap-On BB200A). with the vent holes facing the rear. Install cover
Refer to the instructions provided with the tool. If a vacuum screws and tighten to specification.
brake bleeder is not available, use the following procedure.
b. Rear Master Cylinder Reservoir: Install cover
screws and tighten to specification.

2013 Trike Service Supplement: Chassis 2-15

HOME

NOTE
Dispose of used brake fluid in accordance with local regula- Table 2-5. Fluid Level
tions.
ITEM SPECIFICATION
11. Verify stop lamp operation. Front reservoir MAX LEVEL boss
Rear reservoir 1/4 in (6.4 mm) below gasket surface

After repairing the brake system, test brakes at low speed. Table 2-6. Torque Specifications
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or FASTENER TORQUE VALUE
serious injury. (00289a) Brake caliper bleeder valve 80-100 in-lbs (9.0-11.3 Nm)
12. Test ride motorcycle. Repeat the bleeding procedure if Brake master cylinder, front, 10-12 in-lbs (1.1-1.4 Nm)
brakes feel spongy. reservoir cover screws
Brake master cylinder, rear, 6-8 in-lbs (0.7-0.9 Nm)
reservoir cover screws

2-16 2013 Trike Service Supplement: Chassis

HOME

TRUNK DOOR 2.8

REMOVAL 3. Disconnect license plate lamps connector (8) and trunk
light connector if equipped.
1. See Figure 2-7. Remove screw (1) to release lanyard (5)
from trunk door (both sides). 4. Release harness from retainer clips.

2. Remove screws (4) and remove trunk door cover. 5. Remove bottom trunk liner.
6. Remove locknuts with flat washers (6) from each hinge
and remove door.

sm06907

14
12
11

10 9

7
6

2
13

4
1. Screw, lanyard (4) 8. License plate lamp assembly with connector
2. Hinge (2) 9. Cover, license plate lamp
3. Threaded insert (2) 10. Contact pad, rubber
4. Screw, trunk door cover (4) 11. Bracket, license plate, top
5. Lanyard assembly (2) 12. Bracket, license plate, bottom
6. Locknuts with flat washers (4) 13. Hinge screws (3 each side)
7. Latch bracket screw (3) 14. Reflector
Figure 2-7. Trunk Door

2013 Trike Service Supplement: Chassis 2-17

HOME

DISASSEMBLY INSTALLATION
1. See Figure 2-7. Remove screws (13) to release hinge
FASTENER TORQUE VALUE
(both sides).
Trunk door hinge locknuts 60-84 in-lbs 6.8-9.5 Nm
2. Remove three screws (7) to release latch pin bracket.
Trunk door latch pin bracket 48-72 in-lbs 5.4-8.1 Nm
3. Remove license plate lamps/bracket (9, 10, 11, 12). See screws
7.8 LICENSE PLATE LAMPS/BRACKET.
Trunk door cover screws 30-54 in-lbs 3.4-6.1 Nm
4. Remove screws to release license plate bracket. Gently Trunk door lanyard screws 48-72 in-lbs 5.4-8.1 Nm
pull upper half of bracket to release adhesive pad (10)
from trunk door.
1. Install the hinges over the mounting studs. If equipped
ASSEMBLY with trunk light, also install the trunk light switch bracket
on the left forward stud.
FASTENER TORQUE VALUE 2. Secure hinges to stud plates in body with new locknuts
License plate bracket screws 18-30 in-lbs 2.0-3.4 Nm and flat washers. Tighten to 60-84 in-lbs (6.8-9.5 Nm).
Trunk door latch pin jamnut 48-72 in-lbs 5.4-8.1 Nm 3. Lubricate hinges with HARLEY® LUBE if necessary.
Trunk door hinge screws 48-72 in-lbs 5.4-8.1 Nm 4. Install bottom trunk liner.

1. Install license plate bracket: 5. Connect license plate lamps connector.

a. Install three screws into upper half of license plate 6. Capture rear lighting harness under retainer clips.
bracket and start into trunk door to properly locate
7. Adjust latch pin:
adhesive pad.
a. With latch pin bracket screws finger-tight, close and
b. Remove screws and apply LOCTITE 243 MEDIUM latch door to center the latch pin.
STRENGTH THREADLOCKER AND SEALANT (blue)
b. Open door and tighten screws to 48-72 in-lbs (5.4-
c. Secure upper and lower brackets with screws. 8.1 Nm).
d. Tighten to 18-30 in-lbs (2.0-3.4 Nm). c. Close and open door to verify operation. Adjust pin
bracket location or pin height if necessary.
2. Install license plate lamps/bracket. See 7.8 LICENSE
PLATE LAMPS/BRACKET. NOTE
3. Install latch pin bracket and loosely secure with three See Figure 2-9. Route rear lighting harness through gap in
screws approximately centered in each slot. Adjustment front left corner of trunk door cover.
will be made at a later time. 8. Install trunk door cover. Tighten to 30-54 in-lbs (3.4-6.1
Nm) in a crosswise pattern.
4. See Figure 2-8. If latch pin was removed, install and adjust
to 1.050 in (26.67 mm) from upper surface of bracket to 9. Twist lanyard 1/2 turn toward the door opening and secure
end of pin. Use a dial caliper to measure distance (2). to door with screw. Tighten to 48-72 in-lbs (5.4-8.1 Nm).
Repeat step on other side.
5. Hold latch pin and tighten jamnut to 48-72 in-lbs (5.4-8.1
Nm). 10. Verify that each lanyard rotates freely at both ends.
6. Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue) and install screws to sm06108a

secure each hinge to trunk door. Tighten to 48-72 in-lbs

(5.4-8.1 Nm) in a crosswise pattern.

sm06909

1
3
2

Figure 2-9. Trunk Door Cover

1. Surface of bracket
2. Adjustment dimension
3. Jamnut
Figure 2-8. Adjust Latch Pin

2-18 2013 Trike Service Supplement: Chassis

HOME

TRUNK DOOR LOCKSET 2.9

LOCKSET 7. See Figure 2-10. With the lockset compressed into the
lock mechanism, slide U-clip (5) into installed position.
When correctly installed the ends of the U-clip will protrude
PART NUMBER TOOL NAME
from opposite side of bezel.
HD-34736-B VALVE SPRING COMPRESSOR
8. Install latch cover with screws (7). Tighten to 25-28 in-lbs
(2.8-3.2 Nm).
FASTENER TORQUE VALUE
NOTE
Trunk latch housing cover 25-28 in-lbs 2.8-3.2 Nm
If water spray is directed at the lock for an extended time, water
screw
may enter through the lock tumblers.

Removal/Disassembly
sm06906
1. See Figure 2-10. Remove screws (7) and latch housing 2 3
cover (6). 1
2. Remove U-clip (5). Use a small screwdriver for best res-
ults.
3. Remove lockset (1) from bore. 4
4. Inspect foam seal (2) and remove from body if necessary. 5
5. If necessary, remove lock assembly from bezel:
a. See Figure 2-11. Press pin out of lock bezel.
b. Push lock assembly from bezel.
6

Assembly/Installation
1. Obtain new U-clip if bent or distorted.
NOTE
The pin retaining the lock assembly in the bezel is used during
8
7
manufacturing and is not necessary for repair. Installation is
optional. 1. Lockset assembly
2. Foam washer
2. See Figure 2-12. If the lockset is disassembled, inspect
3. O-ring
condition of the internal O-ring and replace if necessary.
4. Latch housing
Apply a light film of H-D ELECTRICAL CONTACT LUB-
5. U-clip
RICANT to O-ring and install lock assembly into bezel.
6. Latch housing cover
NOTE 7. Screw (2)
Always install the U-clip for the vehicle LEFT side. Bezel failure 8. Screw (4)
will result if installed from the right side.
Figure 2-10. Trunk Door Lock Assembly
3. See Figure 2-13. Start U-clip (1) into slots of lock assembly
from LEFT side and verify that both ends of U-clip are
visible. sm06155

4. Retract U-clip until bore is not obstructed.

5. See Figure 2-10. If removed, install new foam washer (2)
on lockset (1) with the adhesive side facing body. Remove
backing from foam seal and install lockset into body.
6. See Figure 2-14. Compress the lockset into the lock
mechanism to ease installation of U-clip.
a. Use VALVE SPRING COMPRESSOR (Part No. HD-
34736-B) (1) with the large adapter (3).
b. Install a 5/8 in. deep well socket (2) in the adapter to
press against the outer lockset bezel.
c. Turn the clamp screw only enough to install U-clip to
avoid over-tightening and possible damage to the lock
mechanism.
Figure 2-11. Push Pin Out

2013 Trike Service Supplement: Chassis 2-19

HOME

sm06598 sm06998

2 3

Figure 2-12. Install O-Ring

sm06153

1. Valve spring compressor

2. Socket
3. Large adapter
Figure 2-14. Install Trunk Lockset

LATCH ASSEMBLY
FASTENER TORQUE VALUE
1 Trunk door lock housing nuts 9-11 in-lbs 1.0-1.2 Nm
Trunk door latch mechanism 8-10 in-lbs 0.9-1.1 Nm
screws
Trunk door latch housing 48-60 in-lbs 5.4-6.8 Nm
screws

Removal
1. Remove lockset. See 2.9 TRUNK DOOR LOCKSET,
Lockset.
2. See Figure 2-10. Remove four screws (8) to release latch
housing (4) from body.
3. Remove O-ring (3).
2
Lock Assembly Removal
1. See Figure 2-15. Remove two screws (1) and nuts (5) to
1. Insert release lock assembly (2) from latch housing.
2. Retract
2. Disconnect lock arm from link (12). If necessary, remove
Figure 2-13. Install U-clip link from latch lever (11).

Lock Assembly Installation

1. If removed, attach latch link (12) to latch lever (11).
2. Engage arm of lock assembly to link.
3. Install lock assembly (2) into latch housing and secure
with two nuts (5) and screws (1). Tighten to 9-11 in-lbs
(1.0-1.2 Nm).
4. Verify operation of latch mechanism.

2-20 2013 Trike Service Supplement: Chassis

HOME

sm06908

3
2
1

7
6

11
10 9
12 8

1. Screw (2)
2. Lock assembly
3. Latch housing
4. Return spring
5. Nut (2)
6. Spring sleeve
7. Cover
8. Screw (2)
9. Screw (3)
10. Retainer plate
11. Latch lever
12. Latch link
Figure 2-15. Trunk Door Latch Assembly

Latch Mechanism Replacement Installation

1. See Figure 2-15. Disconnect return spring (4) and sleeve 1. See Figure 2-10. Use a small amount of grease to hold
(6). new O-ring (3) in place. Install latch housing assembly (4)
and secure with four screws (8). Tighten to 48-60 in-lbs
2. Remove three screws (9).
(5.4-6.8 Nm).
3. Remove retainer plate (10) and latch lever (11) from
2. Install lockset (1). See 2.9 TRUNK DOOR LOCKSET,
housing. Disconnect from link (12).
Lockset.
4. Connect latch lever to link (12).
3. Check and adjust trunk door. See 2.8 TRUNK DOOR,
NOTE Installation.
Screws (9) must be replaced with new. Do not use liquid
threadlocker or binding may occur.
5. Install latch lever (11) and retainer plate (10) and secure
with three new screws (9). Tighten to 8-10 in-lbs (0.9-1.1
Nm).
6. Install return spring (4).

2013 Trike Service Supplement: Chassis 2-21

HOME

LATCH PIN 4. Check door latch operation and adjust latch pin bracket
as necessary. See 2.8 TRUNK DOOR, Installation.
FASTENER TORQUE VALUE
sm06909
Trunk door latch pin jamnut 48-72 in-lbs 5.4-8.1 Nm

3 1
Removal 2
1. See Figure 2-16. Hold latch pin with a wrench and loosen
jamnut (3).
2. Remove latch pin and jamnut.

Installation
1. Install latch pin with jamnut.
1. Surface of bracket
2. See Figure 2-16. Adjust the latch pin to 1.050 in (26.67 2. Adjustment dimension
mm) from surface of latch bracket to end of pin. Use a dial 3. Jamnut
caliper to measure distance (2).
Figure 2-16. Adjust Latch Pin
3. Hold latch pin and tighten jamnut (3) to 48-72 in-lbs (5.4-
8.1 Nm).

2-22 2013 Trike Service Supplement: Chassis

HOME

TOUR-PAK 2.10
REMOVAL fasten rack to body. Tighten screws to 60-84 in-lbs (6.8-
9.5 Nm) in a crosswise pattern.
1. Remove Tour-Pak liner.
2. Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
2. Disconnect the following items on the left side of the Tour- LOCKER AND SEALANT (blue) and install four screws to
Pak: fasten Tour-Pak to rack. Tighten screws to 60-84 in-lbs
a. Tour-Pak light harness connector, 3 pin [12A] (6.8-9.5 Nm) in a crosswise pattern.
b. AM/FM radio antenna [51A], DIN connector and 3. Connect the following items on the left side of the Tour-
remove from spring Pak:
c. Left rear speaker connector, 6 pin [42B] a. Tour-Pak light harness connector, 3 pin [12A]
b. AM/FM radio antenna [51A], DIN connector (connect
3. Disconnect the following items on the right side of the to spring)
Tour-Pak:
a. CB antenna [50A] c. Left rear speaker connector, 6 pin [42B]

b. Right rear speaker connector 4. Connect the following items on the right side of the Tour-
Pak:
c. 6 pin [41B]
a. CB antenna [50A]
4. Remove four screws to release Tour-Pak from rack. b. Right rear speaker connector
5. Remove six screws to release rack from body. c. 6 pin [41B]
INSTALLATION 5. Install Tour-Pak liner.
FASTENER TORQUE VALUE
Tour-Pak rack screws 60-84 in-lbs 6.8-9.5 Nm
Tour-Pak screws 60-84 in-lbs 6.8-9.5 Nm

1. Apply LOCTITE 243 MEDIUM STRENGTH THREAD-

LOCKER AND SEALANT (blue) and install six screws to

2013 Trike Service Supplement: Chassis 2-23

HOME

BODY 2.11
REMOVAL REPAIR
1. Remove seat. Threaded Inserts
NOTE
Not all threaded inserts are serviceable. Refer to the parts
To prevent accidental vehicle start-up, which could cause catalog before continuing to be sure the damaged insert can
death or serious injury, disconnect negative (-) battery be replaced.
cable before proceeding. (00048a)
1. See Figure 2-17. Remove damaged insert. Thread in a
2. Disconnect battery negative (-) cable. bolt or tap and use pliers to pull insert from body.
3. Remove side covers. 2. Clean bonding area using isopropyl alcohol. Allow to dry
completely.
4. Remove trunk liners.
3. See Figure 2-18. Install new insert onto a bolt.
5. Tour-Pak Wiring:
a. Separate Tour-Pak light harness connector. 4. Thoroughly mix two-part epoxy that is recommended for
use on plastic. Roll insert in adhesive to apply adhesive
b. Disconnect AM/FM radio antenna. to insert.
c. Separate passenger audio connector and disconnect 5. See Figure 2-19. Tap insert into body until flush with sur-
from spring. face using a plastic hammer. Remove bolt.
d. Separate both rear speaker connectors. NOTE
e. Disconnect CB antenna. Do not use solvent to clean adhesive from threads or area
surrounding the insert. Weakening of the bond will result.
6. Disconnect rear lighting harness connector from tail 6. Carefully remove excess adhesive. If adhesive gets into
lamp/turn signal converter module located under seat. threads of insert, allow to cure and remove using a tap.
Separate trunk light connector if equipped.
7. Allow adhesive to cure at least 24 hours before applying
7. Remove four lower screws and washers (internal). torque.
NOTE
The left-front fastener is used as a ground stud. Remove sm07003a
locknut with two flat washers from front left ground stud and
remove ground strap.
8. Remove front fasteners and washers securing body to
intermediate frame (internal).
9. Remove two screws and washers to release front external
brackets from intermediate frame downtubes.
10. With assistance, lift body off rear frame.

DISASSEMBLY
1. Remove Tour-Pak and rack. See 2.10 TOUR-PAK.
2. Remove locknut with flat washer to release ground strap
from upper ground stud.
3. Remove rear fenders. See 2.12 REAR FENDERS.
Figure 2-17. Remove Insert
4. Remove rear lighting harness. See 7.9 REAR LIGHTS
HARNESS.
5. Remove trunk door. See 2.8 TRUNK DOOR.
6. Remove trunk door lockset and latch assembly. See
2.9 TRUNK DOOR LOCKSET.
7. Remove trunk door seal. See 2.11 BODY, Trunk Door
Seal.

2-24 2013 Trike Service Supplement: Chassis

HOME

sm07002a
INSTALLATION
FASTENER TORQUE VALUE
Body attachment screws 14-17 ft-lbs 19.0-23.1 Nm
(inside trunk)
Body attachment screws (out- 24-26 ft-lbs 32.5-35.3 Nm
side trunk)
Ground strap to forward stud 14-17 ft-lbs 19.0-23.1 Nm
(inside trunk)
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm

1. With assistance, set body onto rear frame.

NOTES
Figure 2-18. Apply Adhesive • Clean all residual locking residue form threaded fasteners.
• Start all screws before tightening any. If any screws are
misaligned or difficult to start, the rear frame may not be
sm07004a properly aligned. To align frame, loosen four intermediate-
to-rear frame screws on each side and move rear frame
until all body fasteners align.
• If rear frame was adjusted, clean all locking agent from
screws and threaded holes, and adjust the panhard rod
as outlined in 2.13 REAR FRAME.
2. Temporarily move the rear lighting harness to the left side
to prevent it from becoming trapped when securing the
body.
3. Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue) to all body fasteners.
Apply to the longer end of the ground stud on Tour-Pak
equipped models.
Figure 2-19. Install Insert
4. With assistance, set the body in place.
5. Start the front lower left screw first.
ASSEMBLY
6. Start longer end of ground stud to fasten left-front body to
FASTENER TORQUE VALUE intermediate frame.
Ground strap to upper stud 96-120 in-lbs 10.8-13.5 Nm 7. Start all remaining screws.
8. Tighten all internal screws to 14-17 ft-lbs (19.0-23.1 Nm).
1. Install rear fenders. See 2.12 REAR FENDERS.
9. Tighten two front (external) screws to 24-26 ft-lbs (32.5-
2. Install rear lighting harness. See 7.9 REAR LIGHTS
35.3 Nm).
HARNESS.
10. Position flat washer on each side of ground strap and
3. Install rack and Tour-Pak. See 2.10 TOUR-PAK.
install on left-front stud. Install new locknut and tighten to
4. Secure ground strap to upper ground stud with washer 14-17 ft-lbs (19.0-23.1 Nm).
and locknut. Tighten locknut to 96-120 in-lbs (10.8-13.5
11. Mate rear lighting harness to tail lamp/turn signal converter
Nm).
module. Mate trunk light harness connector.
5. Install trunk door seal. See 2.11 BODY, Trunk Door Seal.
12. Tour-Pak Wiring:
6. Install trunk door latch assembly and lockset. See a. Mate Tour-Pak light harness connector.
2.9 TRUNK DOOR LOCKSET.
b. Connect AM/FM radio antenna.
7. Install trunk door. See 2.8 TRUNK DOOR.
c. Mate passenger audio plug and connect to spring.
d. Mate both speaker connectors.
e. Connect CB antenna.

13. Install trunk liners.

14. Install side covers.

2013 Trike Service Supplement: Chassis 2-25

HOME

15. Connect battery negative (-) cable. Tighten screw to 60-70 4. Continue around the opening until the seal returns to the
in-lbs (6.8-7.9 Nm). point of beginning. Use care at the corners to prevent
bunching or kinking of the seal.
NOTE
Do not cut seal long. Doing so may cause seal to bunch
After installing seat, pull upward on seat to be sure it is
allowing a path of water intrusion.
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or 5. Cut the seal squarely so the ends mate tightly together
serious injury. (00070b) but do not cut long. A gap of up to 0.062 in (1.6 mm) is
allowed.
16. Install seat.
6. After the entire seal is initially installed, go back around
TRUNK DOOR SEAL the entire seal and press firmly in place to be sure it is
securely adhered. Visually inspect the seal contact.
PART NUMBER TOOL NAME
7. Check and adjust trunk door. See 2.8 TRUNK DOOR,
HD-25070 ROBINAIR HEAT GUN Installation.

Inspection sm06538

1. Inspect for accumulation of dirt, grime or debris. Clean 1

with warm soapy water, if necessary.
2. Inspect for damage or excessive wear. Replace if brittle,
cracked, torn or shredded.
3. Verify seal is adhered securely. Replace if seal is not
securely adhered at any point.

Replacement
NOTE
The use of ROBINAIR HEAT GUN (Part No. HD-25070) may
improve seal removal. 2
1. Remove old seal and all residual adhesive using 3M
GENERAL PURPOSE ADHESIVE REMOVER or equi- 1. Seal, trunk door (cut to fit)
valent. 2. Ends of seal
NOTE Figure 2-20. Trunk Door Seal
Do not touch the cleaned area with fingers after cleaning.
2. Thoroughly clean the surface around the door opening
using a clean cloth and isopropyl alcohol. sm06804
2 3
NOTE
Install the new seal with the holes toward the inside of the
opening. 1
3. See Figure 2-20. Beginning at the bottom middle of the
opening, peel back a few inches of backing material and
adhere the end (2) of the seal even with the edge of the
flange as shown in Figure 2-21. Work only a few inches
at a time.
NOTE
To prevent the possibility of water intrusion, be careful the seal
flows smoothly around each corner and does not bunch or kink
1. Trunk door seal
at the corners.
2. Hole
3. Edge of door opening flange
Figure 2-21. Cross Section of Gasket Placement

2-26 2013 Trike Service Supplement: Chassis

HOME

REAR FENDERS 2.12

REMOVAL ASSEMBLY
NOTE
FASTENER TORQUE VALUE
Rear fenders replacement does not require body removal.
Tail lamp/turn signal chrome 36-48 in-lbs 4.1-5.4 Nm
1. Remove rear wheel. See 2.4 REAR WHEELS. base screw
2. Remove screws to release tail lamp/turn signal lens.
1. Install circuit board onto pin housing. Install pin housing
3. See Figure 2-22. Disconnect tail lamp/turn signal connector into chrome base.
(1), 4-place Multilock.
2. See Figure 2-22. Apply LOCTITE 222 LOW STRENGTH
4. Disconnect rear lighting harness connector (2), 6-place THREADLOCKER AND SEALANT (purple) to screw (4).
Multilock. Feed socket housing through opening (3) to Fasten chrome base to fender bracket. Tighten to 36-48
inboard side of fender. in-lbs (4.1-5.4 Nm).
5. Release rear lighting harness from three adhesive clips 3. See Figure 2-23. Inspect adhesive rubber pads on side
in fender well. Feed harness through holes to underside of body. Replace if necessary.
of body.
4. Install new reflector, if necessary. Center reflector over
6. Remove six screws with flat washers to release fender rear axle and 0.25 in. (6.4 mm) above the bottom edge of
from body. the fender.

sm06105 sm06124a

4 2

3
1. Tail lamp/turn signal connector Figure 2-23. Install Fender Pads
2. Rear lighting harness connector
3. Opening INSTALLATION
4. Chrome base screw
Figure 2-22. Remove Lens From Chrome Base FASTENER TORQUE VALUE
Fender, rear, screws 108-132 12.2-14.9 Nm
in-lbs
DISASSEMBLY
Tail lamp/turn signal lens 21-24 in-lbs 2.4-2.7 Nm
1. See Figure 2-22. Remove screw (4) with flat washer to screws
release chrome base from fender bracket.
2. Remove pin housing and circuit board from chrome base. 1. Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
Remove circuit board from pin housing. LOCKER AND SEALANT (blue) to threads of six screws.
2. Install screws with flat washers to fasten fender to body.
Tighten to 108-132 in-lbs (12.2-14.9 Nm).
3. Route rear lighting harness through holes to inboard side
of fender. Capture harness in three adhesive clips in fender
well. Install new adhesive clips if damaged or missing.

2013 Trike Service Supplement: Chassis 2-27

HOME

4. See Figure 2-22. Route connector housing through NOTE

opening (3) to outboard side of fender. Mate rear lighting Always check lug nut torque within 500-1000 mi (805-1610
connector (2), 6-place Multilock. km) after wheel installation.
5. Mate tail lamp/turn signal connector (1), 4-place Multilock.
6. Secure tail lamp/turn signal lens with two screws. Tighten
to 21-24 in-lbs (2.4-2.7 Nm). Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
7. Install rear wheel. See 2.4 REAR WHEELS. death or serious injury. (00316a)
8. Test tail lamp/turn signal operation.

2-28 2013 Trike Service Supplement: Chassis

HOME

REAR FRAME 2.13

REMOVAL INSTALLATION
1. Remove body. See 2.11 BODY.
FASTENER TORQUE VALUE
2. Release both mufflers from mounting brackets. Rear frame screws 41-45 ft-lbs 55.6-61.0 Nm
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm
Muffler bracket screws 96-144 in-lbs 10.9-16.3 Nm
When lifting a motorcycle using a jack, be sure jack con-
tacts both lower frame tubes where down tubes and lower NOTE
frame tubes converge. Never lift by jacking on cross- Clean threadlocking compound from all fasteners and threaded
members, oil pan or other housings. Failure to comply can holes prior to assembly.
cause serious damage resulting in the need to perform
major repair work. (00586c) 1. See Figure 2-24. Install rear frame onto intermediate frame
bosses (4).
3. Place jack under frame, positioned to lift rear of motor-
cycle. See 1.2 LIFTING MOTORCYCLE WITH A JACK. 2. Apply LOCTITE 262 HIGH STRENGTH THREADLOCKER
Lift rear of motorcycle until rear tires are just touching. AND SEALANT (red) and start eight screws (3) with
washers. If reusing original rear frame, align marks made
4. See Figure 2-24. Remove upper shock screws from both
during removal.
sides.
3. If installing a new rear frame, side-to-side level of rear
5. Disconnect panhard rod from right side axle pinch block.
frame should be checked:
6. If rear frame is to be reused, make vertical and horizontal a. Set the vehicle on a flat level surface.
alignment marks between intermediate frame boss (4) and
rear frame (2) on each side. Remove eight screws with b. Set the front wheel straight forward.
washers to release rear frame from intermediate frame. c. Check the front wheel with an inclinometer on either
7. Remove rear frame from intermediate frame bosses. front brake disc to verify it is vertical.
NOTE
sm06125a Comparison of front to rear measurement is not critical.
4 3
The side-to-side measurement of the front pair of tabs or
rear pair is the important measurement.
2
d. See Figure 2-25. Measure the distance from the level
1 surface to the top of each body mounting tab.
e. Adjust rear frame until the side-to-side measurement
of either pair of tabs are within 0.125 in (3.17 mm) of
each other.

4. Tighten screws to 41-45 ft-lbs (55.6-61.0 Nm) in a cross-

wise pattern.

3 NOTE
The length of the panhard rod must be adjusted whenever a
1. Upper shock screw new rear frame is installed. If installing the original rear frame,
2. Rear frame the rod may not require adjustment. Verify adjustment and
3. Rear frame screw adjust as necessary. See 2.19 PANHARD ROD, Adjustment.
4. Intermediate frame boss
5. Install and adjust panhard rod. See 2.19 PANHARD ROD,
Figure 2-24. Rear Frame (Left Side) Installation.
6. Apply LOCTITE 262 HIGH STRENGTH THREADLOCKER
DISASSEMBLY AND SEALANT (red) and install upper shock screws.
Tighten screws to 55-60 ft-lbs (74.6-81.4 Nm).
1. Remove muffler brackets from rubber mounts. Remove
rubber mounts from rear frame brackets. 7. Fasten mufflers to rubber mounted brackets using screws
with lockwashers. Tighten screws to 96-144 in-lbs (10.9-
2. Remove nut and flat washer to release eyelet of panhard
16.3 Nm).
rod and two nylon bushings from weld stud.
8. Install body. See 2.11 BODY.
ASSEMBLY
Install rubber mount into rear frame bracket. Install muffler
bracket into rubber mount. Repeat step on other side.

2013 Trike Service Supplement: Chassis 2-29

HOME

sm07236

Figure 2-25. Measure Rear Frame

2-30 2013 Trike Service Supplement: Chassis

HOME

INTERMEDIATE FRAME 2.14

REMOVAL
sm05869
1. Separate optional trunk light connector. Separate converter 1
module connector and rear lighting harness connector
from lights converter module.
2. Remove top caddy and lay aside. Remove battery. See
service manual.
3. Feed harnesses and radio antenna cable into battery box.
4. Cut cable straps to release harnesses from upper frame 2
tubes.
5. Remove body. See 2.11 BODY.
6. Remove rear frame. See 2.13 REAR FRAME.
7. See Figure 2-26. Remove two screws (2) to release battery
tray.
8. Disconnect BAS connector. See 7.10 BANK ANGLE
SENSOR (BAS).
9. Remove air valve from right side of intermediate frame
and cut cable straps to release air tubes. Draw air valve
and tubes out through opening at rear of intermediate
frame.
10. Cut cable straps securing reverse motor cables (if
equipped) from right side intermediate frame. 1. Top caddy fasteners
2. Rear battery tray fasteners
11. See Figure 2-27. Remove screw (1) to release rear of left
side caddy. Figure 2-26. Upper Caddy Fasteners
12. Remove three screws (2, 3) and washers from each side
and remove intermediate frame.
sm06473a

1. Rear caddy screw

2. Upper frame screws
3. Lower frame screw
Figure 2-27. Left Side Frame

DISASSEMBLY
1. Remove two screws to release frame connection bracket
(both sides).
2. Remove two screws to release passenger handrail or strap
(as equipped).
3. Squeeze anchor to release tail lamp/turn signal converter
module from hole in left side of intermediate frame.

2013 Trike Service Supplement: Chassis 2-31

HOME

4. Remove two screws to free BAS and bracket. 2. See Figure 2-28. Tighten screws in the sequence shown
to 40-45 ft-lbs (54.2-61.0 Nm).
5. Remove side cover grommets, if necessary (three each
side). 3. See Figure 2-27. Install screw (1). Tighten to 72-96 in-lbs
(8.1-10.9 Nm).
ASSEMBLY
4. Install new cable straps to secure reverse motor energizer
FASTENER TORQUE VALUE lead and power cable, reverse control module harness,
and HO2 sensor harnesses to intermediate frame right
Frame connection bracket 41-45 ft-lbs 55.6-61.0 Nm upper tube.
screws
5. Route air valve and tubes in through opening at rear of
Handrail screws, passenger 60-96 in-lbs 6.8-10.9 Nm
intermediate frame and secure air valve to frame. Tighten
Bank angle sensor bracket 72-108 in-lbs 8.1-12.2 Nm to 12-15 in-lbs (1.4-1.7 Nm). Install cap.
screws
6. See Figure 2-29. Install three new cable straps to secure
air tubes.
NOTE
Orient frame connection brackets so that the threaded hole is 7. See Figure 2-26. Secure battery tray with screws (2) and
toward the front. tighten to 72-96 in-lbs (8.1-10.9 Nm).

1. Install frame connection brackets to intermediate frame. 8. Route connectors (2, 3) and Tour-Pak lights harness with
Tighten to 41-45 ft-lbs (55.6-61.0 Nm). radio antenna cable back through left side of intermediate
frame.
2. Install passenger handrail or strap (as equipped). Tighten
to 60-96 in-lbs (6.8-10.9 Nm). 9. Mate connectors (1, 2, 3).

3. Push anchor into hole in left side of intermediate frame to 10. Install new cable straps to secure harnesses to upper left
secure tail lamp/turn signal converter module. and right frame tubes.

4. Install side cover grommets. 11. Install battery and top caddy.

5. Install BAS and bracket. Tighten to 72-108 in-lbs (8.1- 12. Install rear frame. See 2.13 REAR FRAME.
12.2 Nm).
13. Install body. See 2.11 BODY.
INSTALLATION
FASTENER TORQUE VALUE
Intermediate frame screws 40-45 ft-lbs 54.2-61.0 Nm
Left electrical caddy screw 72-96 in-lbs 8.1-10.9 Nm
Air valve nut 12-15 in-lbs 1.4-1.7 Nm
Battery tray screws 72-96 in-lbs 8.1-10.9 Nm

1. Fit the intermediate frame to the main frame and start two
lower screws and hardened washers. Install four remaining
upper screws and hardened washers.

2-32 2013 Trike Service Supplement: Chassis

HOME

sm05936

1
6

Figure 2-28. Intermediate Frame Screw Torque Sequence

sm05946

Figure 2-29. Secure Air Tubes Using Three Cable Straps

2013 Trike Service Supplement: Chassis 2-33

HOME

REAR FORK 2.15

REMOVAL 15. See Figure 2-31. Remove two fasteners (6) to free rear
fork bracket (4).
16. Remove chrome plug (5) from right side rear fork bracket.

Disconnect negative (-) battery cable first. If positive (+) NOTES

cable should contact ground with negative (-) cable con- • Use a 6-point socket for removal of the pivot shaft locknuts.
nected, the resulting sparks can cause a battery explosion, • Use an air impact wrench to remove the right-side nut.
which could result in death or serious injury. (00049a) Applying heat to the right-side nut may also improve
1. Disconnect battery, negative (-) cable first. removal. If the left-side nut loosens first, remove left-side
mount and use double 1/2-20 nuts to hold pivot shaft while
2. Remove body. See 2.11 BODY. removing right-side nut.
3. Remove left side muffler and crossover pipe. See the 17. Hold left side locknut (7) and use an air impact wrench to
service manual. Discard exhaust clamp and gasket. remove locknut (13) from right side of pivot shaft. Discard
4. See Figure 2-30. Cut two cable straps (1) to release park locknut.
brake cable from top of rear fork. Release cable from J- 18. Remove cup washer (3) from right side of pivot shaft and
clamp near brake line manifold. discard.
5. Release brake lines from four cable clips (2). 19. Tap pivot shaft (11) toward left side of motorcycle.
6. Remove brake line manifold and J-clamp from rear fork 20. Pull pivot shaft assembly with locknut (7), cup washer (3),
stud. rubber mount (8) and outer spacer (9) out of transmission
and rear fork.
21. Work rear fork free of transmission mount. Carefully lower
When lifting a motorcycle using a jack, be sure jack con- rear fork and remove from beneath left side of motorcycle.
tacts both lower frame tubes where down tubes and lower 22. Remove outer spacer (9) from right side rear fork tube.
frame tubes converge. Never lift by jacking on cross-
members, oil pan or other housings. Failure to comply can 23. If necessary, remove rubber mount (14) from right side.
cause serious damage resulting in the need to perform 24. Clamp the pivot shaft assembly in a vise with soft jaws
major repair work. (00586c) and disassemble:
NOTE a. Remove locknut (7) and discard.
The center of gravity is toward the rear of the motorcycle. Verify
that front wheel is secured in wheel vise and tie down straps b. Remove cup washer (3) and left mount (8).
are in place when lifting rear wheels.
25. If necessary, remove adapter plates from axle housing.
7. Position jack under motorcycle to support rear of main
frame. See 1.2 LIFTING MOTORCYCLE WITH A JACK. sm06443

NOTE
Repeat the following steps for both sides of the rear fork.
6
8. See Figure 2-30. To aid in initial alignment during 5
assembly, use a paint pen to mark the adjustment screw
(3) where it exits the front of adapter plate on both sides
of motorcycle.
9. Back the jamnut off and turn the adjustment screw in as
far as it will go. 4
10. Loosen four pinch block bolts (4).
NOTE 1 2 3
Removal of lower screws in right side rear fork flange will also
release park brake bracket. 1. Cable strap (2)
2. Cable clip
11. Remove four screws (5).
3. Adjustment screw
12. Push adapter plates (6) toward axle housing until flange 4. Bolt, pinch block (4 per side)
contacts pinch block. 5. Screw, adapter plate (4 per side)
6. Adapter plate
13. Place a jack under rear of oil pan to support transmission.
Figure 2-30. Rear Fork
14. Remove both passenger footboards and brackets.

2-34 2013 Trike Service Supplement: Chassis

HOME

sm06450

4
3 5
2

6
7
1 8
9

10
14
3 11

12
9
5
13

1. Adjustment screw and jamnut (2)

2. Adapter plate (2)
3. Cup washer (2)
4. Rear fork bracket
5. Crome plug (2)
6. Fastener (2)
7. Pivot shaft locknut, left side
8. Left mount
9. Outer spacer (2)
10. Screw, adaptor plate (4 each side)
11. Pivot shaft
12. Bearing (2)
13. Pivot shaft locknut, right side
14. Right mount
Figure 2-31. Rear Fork Components

REPAIR Bearing Installation

1. Bearings and spacers must be assembled before installa-
PART NUMBER TOOL NAME tion.
HD-45327 REAR FORK BEARING INSTALLER a. Place new bearing flat on suitable press plate.
HD-49796 BEARING SPACER TOOL b. See Figure 2-32. With the collar topside, start spacer
into bearing.
Bearing Removal c. Press spacer until it bottoms against bearing.
See the service manual for bearing removal instructions.

2013 Trike Service Supplement: Chassis 2-35

HOME

sm02930 SM06485

2
1

2
1. Spacer
2. Bearing
Figure 2-32. Press Spacer into Bearing

1. Bearing installer
2. Fork tube
sm03535

Figure 2-34. Install Left Rear Fork Bearing

6. See Figure 2-35. Remove tool and turn rear fork over with
left side (4) resting on a socket (5) large enough to contact
the outer race of the left bearing.

1 2 NOTE
If BEARING SPACER TOOL (Part No. HD-49796) is unavail-
able, one can be fabricated using a piece of steel at least the
diameter of the flanges on inner bushings. Machine the tool to
the length of 4.507 +0.002/ -0.000 in. (114.35 +0.051/ -0.000
1. Drive side driver mm).
2. Brake side driver 7. Place BEARING SPACER TOOL (Part No. HD-49796) (3)
Figure 2-33. Rear Fork Bearing Installer centered on lower bearing and parallel to cutout between
bearing bosses. Press right-side bearing using tool
stamped "Drive Side" (1). Press bearing until it just con-
2. Coat the bearing bores in the rear fork and OD of bearings tacts end of spacer tool. Shoulder on press tool will not
with a light coat of SPECIAL PURPOSE GREASE. make contact with fork tube. Bearing press depth is correct
3. See Figure 2-34. Support fork squarely on press bed with when spacer tool can be rotated by hand with a slight drag.
the left side on top.
4. Insert bearing into fork assembly with spacer down.
NOTE
Note that the drivers supplied with the REAR FORK BEARING
INSTALLER (Part No. HD-45327) are stamped "BRAKE SIDE"
and "DRIVE SIDE". Use the "DRIVE SIDE" driver for both sides.
5. Using REAR FORK BEARING INSTALLER (Part No. HD-
45327) (1) stamped "Drive Side", center driver under ram
and press bearing until bearing is bottomed in fork tube
(2).

2-36 2013 Trike Service Supplement: Chassis

HOME

9. Apply two drops of LOCTITE 243 MEDIUM STRENGTH

sm06466
THREADLOCKER AND SEALANT (blue) to threads of
fork bracket fasteners (6) and secure fork bracket. Tighten
1 to 55-65 ft-lbs (74.6-88.1 Nm).
NOTE
2 Never reuse locknuts or cup washers when assembling the
rear fork pivot shaft components.
3
10. Install new cup washer (3) on left side with concave side
facing the mount. Be sure cup washer is over shoulder on
shaft and start the locknut (7).
4 11. Slide new cup washer (3) onto right side of pivot shaft with
the concave side facing the mount.
12. Be sure cup washer is over shoulder on shaft and install
new locknut (13) onto right side of pivot shaft. Hold one
5
locknut and tighten the other locknut to 50 ft-lbs + 180
degrees additional rotation (67.8 Nm + 180 degrees
1. Tool labeled "Drive Side" additional rotation).
2. Right side housing
3. Spacer tool 13. Verify that rear fork assembly moves freely.
4. Left side housing 14. Start screws to fasten adapter plates to rear fork flanges.
5. Socket Capture park brake bracket on right side using longer
Figure 2-35. Install Right Rear Fork Bearing screws in lower holes.
15. Tighten screws in a crosswise pattern until snug.
INSTALLATION 16. Adjust lateral alignment. See 2.16 LATERAL ALIGNMENT.

FASTENER TORQUE VALUE 17. Fasten J-clamp and brake line tee to rear fork stud using
a new locknut. Tighten locknut to 59-63 in-lbs (6.7-7.1
Rear fork bracket bolts 55-65 ft-lbs 74.6-88.1 Nm Nm).
Rear fork pivot shaft locknut 50 ft-lbs + 180 67.8 Nm + 180
18. Capture brake lines in cable clips.
degrees addi- degrees addi-
tional rotation tional rotation 19. Secure park brake cable to the fork arms using two new
Brake line, rear, tee locknut 59-63 in-lbs 6.7-7.1 Nm cable straps located between the two brake line anchor
clips on each side. Do not capture the brake line.
1. Clean all residual locking agent from the threads of the 20. Capture cable in J-clamp in center of rear fork.
pivot shaft.
21. Adjust belt deflection. See 1.9 DRIVE BELT, Checking
2. See Figure 2-36. If removed, install rubber mount on inner- Drive Belt Deflection.
right side of frame with the slot on the outboard side
between the twelve and one o'clock positions. Be sure 22. Install left side muffler and crossover pipe using a new
that index tab in mount cavity fully engages slot in rubber clamp and gasket. See the service manual.
mount. 23. Install body. See 2.11 BODY.
3. See Figure 2-31. Place outer spacer (9) into right side rear
fork tube flange facing outward. sm05797

4. Place belt on inboard side of rear fork and work rear fork
into position on transmission mount.
5. Coat pivot shaft with ANTI-SEIZE LUBRICANT. Avoid
getting anti-seize on threads of pivot shaft.
6. Install pivot shaft (11) from left side of motorcycle, through
left side fork and transmission mount. Guide end of pivot
shaft through hole in right rubber mount. Use jack under
oil pan to align components as necessary.
7. With the flange facing outward, slide outer spacer (9) onto
left end of pivot shaft.
8. Install left mount (8) with the flat side facing outer spacer.
Rotate mount so the slot is between the eleven and twelve Figure 2-36. Right-Side Mount
o'clock positions. Install left side fork bracket (4) fitting
index tab into rubber mount slot.

2013 Trike Service Supplement: Chassis 2-37

HOME

LATERAL ALIGNMENT 2.16

PROCEDURE 9. Tighten adapter plate screws to 41-45 ft-lbs (55.6-61.0
Nm) in a crosswise pattern.
FASTENER TORQUE VALUE 10. Install rear wheels. See 2.4 REAR WHEELS.
Axle adapter plate screws 41-45 ft-lbs 55.6-61.0 Nm
NOTE
Always check lug nut torque within 500-1000 mi (805-1610
1. Remove rear wheels. See 2.4 REAR WHEELS. km) after wheel installation.
2. Rotate differential by hand to observe belt tracking along 11. Adjust and connect panhard rod. See 2.19 PANHARD
top of drive belt. ROD.
NOTE
Belt tracking does not need to be equal distance from frame sm06127
and battery box, but should track near the middle.
3. Check lateral alignment as follows:
a. See Figure 2-37. Secure magnetic base laser or hold
a long straight edge against axle flange with laser
beam directed forward.
NOTE
Fore/aft axle alignment must be within 0.062 in. (1.6 mm)
to provide an accurate lateral alignment check. See
1.9 DRIVE BELT.
b. See Figure 2-38. Remove chrome plug from fork
bracket. Measure distance from end of pivot shaft nut
to light beam or straight edge on both sides.
Figure 2-37. Place Laser Against Axle Flange
c. Measurements A and B must be within 0.062 in. (1.6
mm). If adjustment is necessary, proceed to the next
step.
sm06128
4. Remove screw retaining panhard rod to right axle clevis. A B
5. Loosen eight axle-to-adapter plate screws and move axle
housing left or right until alignment is within specification.
6. Verify that belt still tracks near the middle and does not
contact battery box or frame.
7. Install chrome plugs in rear fork brackets.

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
Figure 2-38. Measure Both Sides
8. Remove one adapter plate screw at a time and clean
threads as follows:
a. Remove all residual thread locking compound from
hole in adapter plate. Use compressed air to blow out
any debris.
b. If reusing screw, completely remove all thread locking
compound.
c. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) and install
screw finger-tight.
d. Repeat steps for all remaining adapter plate screws.

2-38 2013 Trike Service Supplement: Chassis

HOME

PARK BRAKE ASSEMBLY 2.17

CABLE REMOVAL when screw is removed. Open cable clamp and remove
from cable.
1. Remove rear wheel on side where cable is to be replaced.
See 2.4 REAR WHEELS. 4. Remove cotter pin (8) and flat washer (9) from long clevis
pin (14). Remove clevis pin. Two flat washers (11) will
2. Loosen adjustment knob to completely relieve cable ten- drop out from each side of tension lever when clevis pin
sion. See 1.11 PARK BRAKE. is removed.
3. See Figure 2-39. Disconnect spring (2). NOTE
4. Compress fingers on cable retainer and remove cable If replacing only one cable, remove only one clevis pin (13) to
from bracket (1). release that cable eye and proceed to 2.17 PARK BRAKE
ASSEMBLY, Assemble Handle.
5. Remove end of cable from actuator arm (3).
5. Remove cotter pins (10) and short clevis pins (13) to
release cable eye from between connecting links (12).
sm06470a
4 6. To remove park brake knob, proceed as follows:
a. Remove set screw (22).
b. Remove top screw (20) and lockwasher (19).
1 c. Remove knob (21) and wave washer (18).

ASSEMBLE HANDLE
FASTENER TORQUE VALUE
2 Axle adapter plate screws 41-45 ft-lbs 55.6-61.0 Nm
Park brake cable clamp nut 15-17 ft-lbs 20.3-23.1 Nm
3 Park brake mounting screws 15-17 ft-lbs 20.3-23.1 Nm
Park brake knob screw 10-15 in-lbs 1.1-1.7 Nm

1. See Figure 2-40. If removed, install mounting bracket (7):

a. Remove all residual thread locking compound from
1. Cable bracket threaded hole in adapter plate. Use compressed air
2. Spring to blow out any debris.
3. Actuator arm
b. If reusing screws (6), completely remove all thread
4. Cable retainer
locking compound.
Figure 2-39. Park Brake
c. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) and install
6. Left cable: screw finger-tight.
a. See Figure 2-40. Remove P-clamp (2) from right side
d. Repeat steps for remaining screw.
pinch block.
e. Tighten screws (6) to 41-45 ft-lbs (55.6-61.0 Nm).
b. Cut two cable strap to release cable at top of rear
fork. 2. Position cable eyes between connecting links (12) and
c. Release cable from J-clamp (5) located near brake install short clevis pins (13) from outboard side. Install
line manifold on rear fork. cotter pins (10).
NOTE
7. Remove and disassemble park brake handle assembly to
Always install long cable at bottom and short cable at top. Also
remove the cable. See 2.17 PARK BRAKE ASSEMBLY,
be sure that notch in each connecting link faces rearward.
Handle Disassembly.
3. Rotate side plates out of the way, and position tension
HANDLE DISASSEMBLY lever between connecting links. Insert flat washers (11)
1. See Figure 2-40. Remove boot (1). between tension lever and connecting link on both sides.
Rotate outboard side plate into position to align hole with
2. Remove two screws (15) with lockwashers. Spacers (17) others and insert long clevis pin (14).
will drop out from between side plates when screws are
removed. 4. Install cable clamps (24) on cables and close clamps.
Rotate clamps, so that flat sides face side plates. Position
3. Remove nut (25) and screw (16) to release cable clamps spacer (23) between clamps and insert screw (16) through
(24). Spacer (23) will drop out from between cable clamps outboard side plate, bottom clamp, spacer and top clamp.

2013 Trike Service Supplement: Chassis 2-39

HOME

5. Rotate inboard side plate down to align two holes with 10. Install boot with strap between park brake cables and snap
long clevis pin (14) and cable clamp screw. Push long on inboard side.
clevis pin and clamp screw (16) through inboard side plate.
NOTE
6. Install flat washer (9) and cotter pin (8). If replacing only one cable, proceed to 2.17 PARK BRAKE
ASSEMBLY, Cable Installation.
7. Start nut (25) on clamp screw (16). Push cables forward
until shoulder on ferrules contact cable clamps and tighten 11. Install park brake knob as follows:
nut to 15-17 ft-lbs (20.3-23.1 Nm). a. Install wave washer (18), knob (21) and lockwasher
8. One at a time, hold spacers (17) between side plates and (19).
insert screws (15) with lockwashers. b. Apply LOCTITE 243 MEDIUM STRENGTH
9. Hold handle assembly in position and secure with two THREADLOCKER AND SEALANT (blue) to screw
screws (15). Tighten screws to 15-17 ft-lbs (20.3-23.1 (20) and install. Tighten screw to 10-15 in-lbs (1.1-
Nm). 1.7 Nm).
c. Install set screw (22) but do not tighten.

2-40 2013 Trike Service Supplement: Chassis

HOME

sm05529b

4 5

26

1
20
21

19 22 25
24
23 6
18
7

17 8
9
16
15
11
10
13
12
14
1. Boot 10. Cotter pin (2) 19. Lockwasher
2. P-clamp 11. Flat washer (2) 20. Screw
3. Right wheel cable 12. Connecting link (2) 21. Knob
4. Left wheel cable 13. Short clevis pin (2) 22. Set screw
5. J-clamp 14. Long clevis pin 23. Spacer, clamp
6. Screw, adapter 15. Mounting screw (2) 24. Cable clamp (2)
7. Mounting bracket 16. Screw, cable clamp 25. Nut
8. Cotter pin 17. Spacer, mounting screw (2) 26. Cable retainer
9. Flat washer 18. Wave washer
Figure 2-40. Park Brake Assembly

2013 Trike Service Supplement: Chassis 2-41

HOME

CABLE INSTALLATION 6. Left cable:

a. See Figure 2-40. Fasten P-clamp (2) to right side
FASTENER TORQUE VALUE pinch block.
P-clamp to pinch block screw 14-17 ft-lbs 19.0-23.1 Nm b. Secure cable to top of rear fork with two new cable
straps around fork arm. Do not capture brake lines.
1. See Figure 2-39. Install new cable retainer (4) if neces- Locate cable straps between brake line clips.
sary.
c. Capture cable in J-clamp (5).
2. Install end of cable into actuator arm (3).
d. Tighten P-clamp screw to 14-17 ft-lbs (19.0-23.1 Nm).
3. Engage cable in bracket (1). Bend fingers on cable retainer
outward slightly to lock position of cable in bracket. 7. Adjust park brake. See 1.11 PARK BRAKE.

4. Install spring (2). 8. Install rear wheels. See 2.4 REAR WHEELS.

5. If removed, repeat steps on other brake caliper. NOTE

Always check lug nut torque within 500-1000 mi (805-1610
km) after wheel installation.

2-42 2013 Trike Service Supplement: Chassis

HOME

SHOCK ABSORBERS 2.18

REMOVAL 1. If removed, install three screws to fasten lower shock
mount to pinch blocks.
PART NUMBER TOOL NAME a. Using an appropriate thread chaser, completely
remove all residual threadlocking compound from
HD-34633 AIR SUSPENSION PUMP AND GAUGE
holes in pinch block. Use compressed air to blow out
any debris.
1. Remove body. See 2.11 BODY.
b. If reusing screws, completely remove all threadlocking
2. Place jack to support rear of motorcycle frame. See compound using a wire brush or wire wheel, and then
1.2 LIFTING MOTORCYCLE WITH A JACK. apply LOCTITE 243 MEDIUM STRENGTH
3. Using the no-loss AIR SUSPENSION PUMP AND GAUGE THREADLOCKER AND SEALANT (blue).
(Part No. HD-34633), add 3-5 psi (20.7-34.5 kPa) to purge c. Install screws with flat washers and tighten 41-45 ft-
lines of any oil. lbs (55.6-61.0 Nm).
4. Release air from shocks and remove air tube from com-
pression fitting. 2. Completely remove threadlocking compound from
threaded shock mounting holes using a thread chaser.
5. Remove upper shock mount screw. Completely remove threadlocking compound from shock
absorber mounting screws using a wire brush or wire
6. Raise jack until lower shock mount screw clears rear frame
wheel.
and remove screw.
3. Apply LOCTITE 262 HIGH STRENGTH THREADLOCKER
NOTE
AND SEALANT (red) to screw and fasten shock absorber
Always keep shock absorber upright in a fully vertical position.
to lower shock mount.
Laying shock absorber down can cause oil to drain out through
the compression fitting. Any loss of oil requires replacement 4. Lower jack until upper shock eye is aligned with rear frame
of the shock absorber. boss.
7. If necessary, remove three screws to release lower shock 5. Apply LOCTITE 262 HIGH STRENGTH THREADLOCKER
mount from pinch blocks. AND SEALANT (red) and start upper shock screw.

INSTALLATION 6. Tighten upper and lower screws to 55-60 ft-lbs (74.6-81.4

Nm).
FASTENER TORQUE VALUE 7. Connect air tube to compression fitting. Gently tug on tube
Pinch block screws 41-45 ft-lbs 55.6-61.0 Nm to verify that it is locked in place.
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 8. Pressurize air suspension system and check for leaks.
9. Install body. See 2.11 BODY.

sm05974
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

NOTE
See Figure 2-41. The left and right side lower shock mounts
are not interchangeable but are not stamped for location. If
both have been removed, be sure that they are installed with
the boss on the outboard side.

Figure 2-41. Orient With Lower Shock Mount Boss

Outboard

2013 Trike Service Supplement: Chassis 2-43

HOME

PANHARD ROD 2.19

REMOVAL 1. See Figure 2-42. Hold panhard rod so that long bend end
(11) is on the left side.
1. Remove body. See 2.11 BODY.
2. Place nylon bushing (3) on each side of left ball-end con-
2. See Figure 2-42. Remove screw (6) and flat washer (5) nector (12) and install on stud (4). Install flat washer (2)
from clevis (7). and new locknut (1). Verify nylon washers are correctly
3. Remove locknut (1) and flat washer (2) to release left ball- aligned and not being pinched. Tighten nut to 55-60 ft-lbs
end connector (12) and two nylon bushings (3) from stud (74.6-81.4 Nm).
(4) on rear frame rail. 3. Secure right ball-end connector (8) in clevis (7) at top of
right side pinch block with screw (6) and flat washer (5).
INSTALLATION Tighten to 55-60 ft-lbs (74.6-81.4 Nm).
FASTENER TORQUE VALUE NOTE
Adjust the panhard rod whenever a new rod, a new rear frame
Panhard rod locknut 55-60 ft-lbs 74.6-81.4 Nm
or a new axle/differential housing are installed, or if the rod is
Panhard rod clevis screw 55-60 ft-lbs 74.6-81.4 Nm suspected of being misadjusted. See 2.19 PANHARD ROD,
Adjustment, if necessary.
NOTE
4. Install body. See 2.11 BODY.
Panhard rod is directional and can cause damage if installed
backwards. Take care to orient the rod correctly.

sm05922

4 5
A

2
1

12 11 10
9 8
1. Locknut 7. Clevis
2. Flat washer 8. Right ball-end connector
3. Nylon bushing 9. Right end jamnut
4. Stud 10. Short bend end
5. Flat washer 11. Long bend end
6. Screw 12. Left ball-end connector
Figure 2-42. Panhard Rod

2-44 2013 Trike Service Supplement: Chassis

HOME

ADJUSTMENT 4. With the left ball-end connector (12) attached, position the
right ball-end connector (8) in clevis (7) at the top of the
FASTENER TORQUE VALUE right side pinch block. Verify that screw (6) passes
smoothly through the clevis and ball-end connector.
Panhard rod clevis screw 55-60 ft-lbs 74.6-81.4 Nm
5. If adjustment is not correct, loosen jamnut (9), remove
Panhard rod adjustment 20-30 ft-lbs 27.1-40.7 Nm
ball-end connector from clevis and adjust length until screw
jamnut
(6) passes through easily.
Panhard rod adjustment 20-30 ft-lbs 27.1-40.7 Nm
jamnut 6. When adjustment is correct, secure ball-end connector
(8) in clevis with screw (6) and flat washer (5). Tighten to
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 55-60 ft-lbs (74.6-81.4 Nm).

NOTE NOTE
The panhard rod could contact the reverse ring gear if not
Adjust the panhard rod whenever a new rod, a new rear frame
positioned properly. Be sure to hold panhard rod up and away
or a new axle/differential housing are installed, or if the rod is
from the differential when tightening the right adjustment
suspected of being misadjusted.
jamnut.
1. Raise the vehicle using a suitable lifting device so the rear
7. Loosen left ball-end connector jamnut. Hold panhard rod
tires are just touching the lift. See 1.2 LIFTING MOTOR-
up as far as it will easily rotate and tighten right jamnut (9)
CYCLE WITH A JACK.
to 20-30 ft-lbs (27.1-40.7 Nm).
NOTE
8. Allow panhard rod to rotate down slightly until right ball-
Adjustment is easiest with the rear tires and wheels installed.
end connector is approximately centered in clevis. Hold
If they have been removed, support the rear axle on each side
panhard rod in this position and tighten left jamnut to 20-
with equally adjusted jack stands.
30 ft-lbs (27.1-40.7 Nm).
2. See Figure 2-42. Disconnect the upper shock absorber
NOTE
screw on both sides. Move the shocks away from the
Completely clean threadlocking compound from threads of rear
upper mount and loosely install the upper screws to aid
shock screws and threaded holes.
making measurement.
9. Apply LOCTITE 262 HIGH STRENGTH THREADLOCKER
3. Adjust the jack until the distance (A) between the center
AND SEALANT (red) to upper shock screws and secure
of the upper shock mounting screw and lower shock eye
shock absorbers. Tighten screws to 55-60 ft-lbs (74.6-81.4
is 11.5 in. (292.0 mm) on both sides.
Nm).

2013 Trike Service Supplement: Chassis 2-45

HOME

STEERING DAMPER ASSEMBLY 2.20

REMOVAL 4. Insert screw (6) through steering damper eyelet, spacer
(7) and side mounting bracket (9). Install acorn nut (8) and
NOTE tighten to 16-20 ft-lbs (21.7-27.1 Nm).
Use a clean shop towel to protect front fender while removing
damper. sm06289

1. See Figure 2-43. Remove locknut (1), nylon washer (2)

and steering damper from frame bracket stud. 4 5

2. Remove acorn nut (8), spacer (7) and screw (6) to release
steering damper eyelet from side mounting bracket (9).
10
3. If necessary, remove two screws with flat washers to
release front turn signal/auxiliary lamps bracket and side 9
mounting bracket from upper and lower fork brackets.

INSTALLATION
FASTENER TORQUE VALUE 6
Steering damper side 15-20 ft-lbs 20.3-27.1 Nm
mounting bracket screws
Steering damper bracket 16-20 ft-lbs 21.7-27.1 Nm
screw
3 7 8
Steering damper locknut 16-20 ft-lbs 21.7-27.1 Nm
Steering damper acorn nut 16-20 ft-lbs 21.7-27.1 Nm

1. See Figure 2-43. If removed, install side mounting bracket 2

(9) and front turn signal/auxiliary lamps bracket. Tighten 1
screws to 15-20 ft-lbs (20.3-27.1 Nm).
1. Locknut
2. If removed, install bracket (4) and tighten screw (10) to 2. Nylon washer
16-20 ft-lbs (21.7-27.1 Nm). 3. Steering damper
4. Frame bracket
NOTE
5. Engine guard (Tri Glide models)
Nylon washer (2) can be installed either above or below the
6. Screw
steering damper.
7. Spacer
3. Install steering damper (3), nylon washer (2) and locknut 8. Acorn nut
(1) onto frame bracket stud. Tighten locknut to 16-20 ft- 9. Side mounting bracket
lbs (21.7-27.1 Nm). 10. Screw
Figure 2-43. Steering Damper Assembly

2-46 2013 Trike Service Supplement: Chassis

HOME

FRONT WHEEL 2.21

REMOVAL 4. Install flat washer (5) and axle nut (7).

1. Engage park brake. 5. Insert screwdriver or steel rod through hole in right side
of axle to hold axle stationary. Tighten axle nut to 70-75
2. Raise front wheel using a suitable lifting device. See ft-lbs (94.9-101.7 Nm).
1.2 LIFTING MOTORCYCLE WITH A JACK.
6. Install cotter pin (6) and bend ends. If necessary, further
3. Inspect wheel bearings. See the service manual. tighten axle nut a maximum of 15 degrees to align axle
4. Remove brake calipers. See service manual. Secure cal- hole and nut slot.
ipers to rail of engine guard using cable straps so that 7. Push right fork slider inboard until it contacts outer spacer
caliper is not suspended by brake hose. (2). Hold in this position and tighten axle holder nuts to
NOTE 132-180 in-lbs (14.9-20.3 Nm).
Do not operate front brake with front wheel removed or caliper 8. Install brake calipers. See service manual.
pistons may be forced out. Brake caliper has no serviceable
parts and would result in the need to replace the caliper
assembly.
5. See Figure 2-44. Remove cotter pin (6). After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
6. Insert round punch or steel rod through hole in right side pressure can adversely affect brake performance, which
of axle to hold axle stationary. Remove axle nut (7) and could result in death or serious injury. (00279a)
flat washer (5).
9. Operate front brake hand lever several times to set brake
7. Loosen two axle holder nuts at bottom of right side fork pads to proper operating position within caliper.
slider.
8. Using a soft mallet, gently tap end of axle towards right sm06469

side of motorcycle. Catching outer spacers (2), pull axle 6

free of fork sliders and wheel hub. 5
9. See service manual for wheel repair procedures.

INSTALLATION
7
FASTENER TORQUE VALUE
4
3
Front axle nut 70-75 ft-lbs 94.9-101.7
Nm 3
2
Front axle holder nuts 132-180 14.9-20.3 Nm
in-lbs 1

1. Place wheel into position with the valve stem on the right
side of the motorcycle.
1. Axle
2. See Figure 2-44. Apply a light coat of ANTI-SEIZE LUB- 2. Outer spacer
RICANT to axle, bearing bores and bore of inner spacer 3. Bearing (2)
(4). 4. Inner spacer
NOTE 5. Flat washer
Be sure that grooves on outer spacers are on the outboard 6. Cotter pin
side. Outer spacers on left and right side of wheel hub are 7. Nut
interchangeable. Figure 2-44. Front Wheel
3. Slide axle through right fork slider, outer spacer, wheel
hub, second outer spacer and left fork slider.

2013 Trike Service Supplement: Chassis 2-47

HOME

FRONT FENDER 2.22

REMOVAL 2. Hold fender in place and insert two screws with clipped
washers through fender cover, fender and fork slider on
1. Disconnect front fender tip lamp harness connector. each side. Verify flat on each washer is properly aligned
2. Remove front wheel. See 2.21 FRONT WHEEL. with recess in fork slide.

NOTE 3. Install lockplate and nuts on both sides.

Hold screws from rotating to prevent damage to the fork slider. NOTE
3. Bend tabs on lockplate away from locknuts. Hold screws Hold screws from rotating to prevent damage to the fork slider.
from rotating. Remove locknuts and lockplates from both 4. Hold screws from rotating and tighten locknuts to 24-28
sides. ft-lbs (32.5-38.0 Nm) in a crosswise pattern. Bend tabs on
4. Remove two screws with clipped washers from each side. each lockplate against flats on locknuts.
Remove fender and fender cover. 5. Connect front fender tip lamp harness connector.
INSTALLATION 6. Install front wheel. See 2.21 FRONT WHEEL.

FASTENER TORQUE VALUE

Fender, front, side trim or skirt 10-15 in-lbs 1.1-1.7 Nm
Fender, front, mount screws 24-28 ft-lbs 32.5-38.0 Nm

1. If removed install the fender skirt and side trim. Tighten

fasteners to 10-15 in-lbs (1.1-1.7 Nm).

2-48 2013 Trike Service Supplement: Chassis

HOME

ENGINE STABILIZER 2.23

STABILIZER LINK NOTE
Be sure to install spacers (7) as shown.
FASTENER TORQUE VALUE 4. Attach bracket to cylinder head with screws, washers and
Engine stabilizer link screws 30-35 ft-lbs 40.7-47.5 Nm spacers. Tighten screws (6) to 30-35 ft-lbs (40.7-47.5 Nm).
Engine stabilizer bracket 30-35 ft-lbs 40.7-47.5 Nm 5. Attach stabilizer link to bracket with screw (3) and washer
screws (2). Place washer between link and attaching point.
Engine stabilizer link screws 30-35 ft-lbs 40.7-47.5 Nm 6. Tighten to 30-35 ft-lbs (40.7-47.5 Nm).

Removal sm06895

1. See Figure 2-45. Remove screws (3) and washers (2) 3 4

from each end of stabilizer link (4).
2
2. Remove link.
3. Check each end of the stabilizer link for excessive wear.
The spherical ball end may rotate freely, but should not
have any lateral movement. Replace the link if lateral 1
movement exists.

Installation
1. See Figure 2-45. Secure stabilizer link with screws (3) and
washers (2) between link and attaching point. 5
2. Tighten to 30-35 ft-lbs (40.7-47.5 Nm). 7
Bracket 6
1. See Figure 2-45. Disconnect stabilizer link from bracket
(1).
1. Stabilizer bracket
2. Remove two screws (6) and washers (5). Remove bracket 2. Washer (2)
(1) and spacers (7) from cylinder head. 3. Screw (2)
4. Stabilizer
3. Apply LOCTITE 272 HIGH STRENGTH/HIGH TEMPER-
5. Washer (2)
ATURE THREADLOCKER AND SEALANT (red/orange)
6. Screw (2)
to threads of screws (6).
7. Spacer (2)
Figure 2-45. Engine Stabilizer

2013 Trike Service Supplement: Chassis 2-49

NOTES

2-50 2013 Trike Service Supplement: Chassis

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
3.1 SPECIFICATIONS: ENGINE......................................................................................................3-1

ENGINE
NOTES
HOME

SPECIFICATIONS: ENGINE 3.1

GENERAL SPECIFICATIONS: TWIN CAM
Table 3-2. Oiling System
103™
ITEM SPECIFICATION
Table 3-1. Engine: Twin Cam 103™ Pump Twin gerotor, dual scavenge, crank
mounted and driven, internal oil pump,
ITEM SPECIFICATION dry sump
Number of cylinders 2 Pressure 30-38 psi (207-262 kPa) at 2000 RPM
Type 4-cycle, 45 degree and normal operating temperature of 230
V-Type, air-cooled °F (110 °C)
Compression ratio 9.6:1 Filtration 5 micron media, filtered between pump
and engine
Bore 3.875 in 98.42 mm
Cooling Thermostat controlled oil cooler
Stroke 4.375 in 111.12 mm
Displacement 103.0 in3 1690 cm3
Lubrication system Pressurized, dry sump
with oil cooler

2013 Trike Service Supplement: Engine 3-1

NOTES

3-2 2013 Trike Service Supplement: Engine

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
4.1 FUEL SYSTEM..........................................................................................................................4-1

FUEL SYSTEM
NOTES
HOME

FUEL SYSTEM 4.1

NO UNIQUE CONTENT
Any information not presented in this supplement can be found
in the service manual.

2013 Trike Service Supplement: Fuel System 4-1

NOTES

4-2 2013 Trike Service Supplement: Fuel System

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
5.1 FASTENER TORQUE VALUES.................................................................................................5-1
5.2 AXLE..........................................................................................................................................5-2
5.3 AXLE HOUSING/DIFFERENTIAL.............................................................................................5-5
5.4 DRIVE BELT REPLACEMENT..................................................................................................5-9

DRIVE
NOTES
HOME

FASTENER TORQUE VALUES 5.1

FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.

FASTENER TORQUE VALUE NOTES

Air valve nut 12-15 in-lbs 1.4-1.7 Nm 5.3 AXLE HOUSING/DIFFERENTIAL, Installation
Axle bearing retainer locknuts 41-45 ft-lbs 55.6-61.0 Nm 5.2 AXLE, Installation/Use new locknuts
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 5.3 AXLE HOUSING/DIFFERENTIAL, Installation
Differential assembly screws 65-70 ft-lbs 88.1-94.9 Nm 5.3 AXLE HOUSING/DIFFEREN-
TIAL, Assembly/Use new screws
Differential bearing cap screws 39-44 ft-lbs 52.9-59.7 Nm 5.3 AXLE HOUSING/DIFFERENTIAL, Installation
Footboard screw, passenger 30-35 ft-lbs 40.7-47.5 Nm 5.4 DRIVE BELT REPLACEMENT, Installation
P-clamp to pinch block screw 14-17 ft-lbs 19.0-23.1 Nm 5.3 AXLE HOUSING/DIFFERENTIAL, Installation
Ring gear screws 22-26 ft-lbs 29.8-35.3 Nm 5.3 AXLE HOUSING/DIFFERENTIAL, Assembly

2013 Trike Service Supplement: Drive 5-1

HOME

AXLE 5.2
REMOVAL
sm06045

PART NUMBER TOOL NAME

HD-49303 AXLE PULLER

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
1. Disconnect battery negative (-) cable from battery.
2. Remove rear wheels. See 2.4 REAR WHEELS. Figure 5-2. Remove Axle Using Slide Hammer

3. Remove rear brake calipers with mounting brackets. See

2.5 REAR BRAKE CALIPERS. DISASSEMBLY
4. See Figure 5-1. Remove four locknuts and T-bolts to 1. See Figure 5-3. If necessary, remove and install axle
release bearing retainer plate from axle housing. flange studs (7) using a suitable press.
5. See Figure 5-2. Pull axle out of axle housing. If necessary, 2. Remove retaining ring (2) and discard.
attach AXLE PULLER (Part No. HD-49303) to axle flange
NOTE
using lug nuts. Attach a slide hammer and remove axle.
See Figure 5-4. A minimum 25 ton I-beam style hydraulic press
6. If necessary, remove four screws to free brake reaction is recommended for bearing removal and installation.
plate.
3. See Figure 5-5. Position axle so that bearing is properly
supported between press plates and remove bearing and
sm06046 axle shaft retainer. Discard retainer and bearing.
4. If necessary, remove bearing retainer plate (5).

sm06078
1

3
2

4 5

Figure 5-1. Remove Bearing Retainer From Axle Housing

6
7

1. Axle
2. Retaining ring
3. Axle shaft retainer
4. Bearing
5. Bearing retainer plate
6. Axle flange
7. Axle flange stud
Figure 5-3. Axle Assembly

5-2 2013 Trike Service Supplement: Drive

HOME

NOTE
sm06176
See Figure 5-6. Hold bearing retainer plate (3) up during the
press procedure to prevent it from being captured between
bearing and axle shoulder.
5. Verify that assembly is square and apply pressure with
ram until bearing makes firm contact with axle shoulder.
6. Remove bearing support tube and slide new axle shaft
retainer onto axle.
7. See Figure 5-7. Press axle shaft retainer in a similar
manner until it makes firm contact with bearing. Remove
assembly from press.
8. Install new retaining ring in groove and verify that it is fully
seated.

sm06178
2

Figure 5-4. I-Beam Style Hydraulic Press

sm06177
3

1. Bearing support tube

2. Press bar
3. Bearing retainer plate
Figure 5-6. Install Axle Bearing

Figure 5-5. Remove Axle Bearing

ASSEMBLY

PART NUMBER TOOL NAME

HD-34634 FORK OIL SEAL INSTALLER

1. Slide bearing retainer plate down axle and allow to lay on

axle flange.
2. Slide new bearing onto axle until it contacts shoulder.
3. See Figure 5-6. Slide suitable bearing support tube (1) or
FORK OIL SEAL INSTALLER (Part No. HD-34634) onto
axle until it contacts bearing inner race.
4. Position axle with support tube (1) supported between
press plates. Place press bar (2) or other suitable driver
between ram and center of axle flange.

2013 Trike Service Supplement: Drive 5-3

HOME

sm06179
INSTALLATION
FASTENER TORQUE VALUE
Axle bearing retainer locknuts 41-45 ft-lbs 55.6-61.0 Nm

NOTE
Install the shorter axle on the left side.
1. Push axle into axle housing and rotate until the splines
engage.
2. See Figure 5-1. Secure bearing retainer plate to axle
housing using four T-bolts and new locknuts. Tighten to
41-45 ft-lbs (55.6-61.0 Nm) in a crosswise pattern.
3. Install brake rotor onto axle. Install caliper onto disc. See
2.5 REAR BRAKE CALIPERS.
4. Install rear wheels. See 2.4 REAR WHEELS.
NOTE
Always check lug nut torque within 500-1000 mi (805-1610
km) after wheel installation.

Figure 5-7. Install Bearing Retainer

5-4 2013 Trike Service Supplement: Drive

HOME

AXLE HOUSING/DIFFERENTIAL 5.3

REMOVAL
sm06048
1. Remove seat.
4

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery 1
cable before proceeding. (00048a)
2. Disconnect battery negative cable.
3. Remove body. See 2.11 BODY.
4. Remove both axles. See 5.2 AXLE. 2
3
5. If reverse motor equipped, remove reverse motor and
bracket. See 7.13 REVERSE MOTOR AND BRACKET.
6. See Figure 5-8. Mark the adjustment screws (3) on both 1. Pinch block bolts (4 each side)
sides of motorcycle with a paint pen where they exit the 2. Jamnut
front of adapter plates. Optionally make a note of dimen- 3. Adjustment screw
sion (4). 4. Measured distance
7. Loosen four pinch block bolts (1) on each side. Loosen Figure 5-8. Adjust Axle
jamnut (2) and back off adjustment screws. Push axle
housing forward to remove all drive belt tension.
NOTE sm06477

See Figure 5-9. Handle bearing caps with care as they are not
sold separately. Damage to bearing caps or differential housing
requires replacement of the axle/differential housing assembly.
1
8. Remove two screws (3) to release each bearing cap (2).
NOTE
Place masking tape at rear of rear fork to protect painted sur-
faces. 2
9. Move differential/sprocket assembly forward and remove
drive belt from sprocket. 3
10. Move axle housing rearward as far as it will move and
remove differential/sprocket assembly from the front. For
best results, pull differential forward until it almost contacts
rear fork, and then rotate sideways to remove. 3
NOTE 1. Differential/sprocket assembly
If servicing differential, proceed to 5.3 AXLE HOUSING/DIF- 2. Bearing cap (2)
FERENTIAL, Disassembly. If replacing drive belt or axle 3. Screw (4)
housing, proceed with the following steps. Figure 5-9. Differential and Sprocket Assembly

NOTE
If removing axle housing for belt replacement, do not detach
shock absorbers. Remove upper shock bolts only.
11. Remove both rear shock absorbers. See 2.18 SHOCK
ABSORBERS.
NOTE
Always keep shock absorbers in an upright position with the
air line connector at the top to prevent the loss of oil. Any loss
of oil requires replacement of the shock absorber.
12. Remove rear frame. See 2.13 REAR FRAME.

2013 Trike Service Supplement: Drive 5-5

HOME

13. Release P-clamp and park brake cable from right side 2. Rotate ring gear (5) to align bosses with cutouts on com-
axle pinch block. pensator bowl (4) and separate sprocket from compensator
bowl.
14. Pull axle housing rearward to release pinch blocks from
adapter plate bosses and remove from vehicle. Differential
DISASSEMBLY NOTE
See Figure 5-12. Due to high torque on screws (11), com-
PART NUMBER TOOL NAME pensator bowl may rotate in vise if not properly clamped.
HD-43644-3 CAMSHAFT BEARING INSTALLER 1. Tighten flange of compensator bowl in soft-jawed vise so
HD-49762 PULLER that a ring gear mounting boss is in contact with top of
vise. Remove ten screws with flat washers. Remove differ-
HD-95635-46 ALL-PURPOSE CLAW PULLER
ential (2) from compensator bowl.

Bearings NOTE
Do not separate halves of differential housing. Internal compon-
NOTE ents are not sold separately.
Both bearings are removed in a similar manner. The sprocket 2. If necessary, remove grease seal (3) on each end of dif-
side bearing must be removed to remove the sprocket. Remove ferential.
the opposite side bearing only if bearing replacement is
necessary. NOTE
Never add grease to the differential. The grease added at the
1. See Figure 5-10. Sparingly apply graphite lubricant to factory will last the life of the motorcycle.
threads of forcing screw of ALL-PURPOSE CLAW
PULLER (Part No. HD-95635-46) (1). Start forcing screw
into puller. sm05876

2. Install suitable driver such as CAMSHAFT BEARING 1

INSTALLER (Part No. HD-43644-3) (3) into differential
bore.
3. Center press plug (2) on driver and engage claws on
inboard side of bearing.
4. Verify that tool is square and remove bearing. Hold puller
body with a wrench to prevent rotation while removing
bearing.

Sprocket 2
1. See Figure 5-12. Remove retaining ring (8) from groove
3
in differential.
2. See Figure 5-11. Obtain three 3/8-24 UNF bolts approxim-
ately 5 in. (127 mm) long with three hardened washers.
3. Sparingly apply graphite lubricant to threads of forcing
screw of PULLER (Part No. HD-49762) and install in puller. 1. All-purpose claw puller
2. Press plug
4. See Figure 5-12. Attach puller to sprocket (7) using bolts 3. Camshaft bearing installer
and hardened washers. Thread bolts into sprocket an
equal number of turns. Figure 5-10. Bearing Removal Tools

5. Install suitable driver such as CAMSHAFT BEARING

INSTALLER (Part No. HD-43644-3) into differential bore.
6. Center press plug supplied with puller on driver and turn
forcing screw until it makes firm contact with press plug.
7. Verify that tool is square and turn forcing screw until
sprocket is free.
NOTE
Sprocket bearing is not sold separately. Replace sprocket
assembly if bearing replacement is necessary.
8. Remove six isolators (6) from compensator bowl (4).

Ring Gear
1. See Figure 5-12. Remove four screws (10).

5-6 2013 Trike Service Supplement: Drive

HOME

sm05913
ASSEMBLY

PART NUMBER TOOL NAME

HD-35316-12 MAIN DRIVE GEAR INSTALLER

FASTENER TORQUE VALUE

Differential assembly screws 65-70 ft-lbs 88.1-94.9 Nm
Ring gear screws 22-26 ft-lbs 29.8-35.3 Nm

Differential
1. See Figure 5-12. If removed, press new grease seals (3)
into bore on each end of differential using a suitable press
tool.
NOTE
Figure 5-11. Puller Tool Due to high torque on screws (11), compensator bowl (4) may
rotate in vise if not properly clamped.
2. Tighten flange of compensator bowl in soft-jawed vise so
sm06480
9 that a ring gear mounting boss is in contact with top of
8 vise.
7 3. Install differential (2) in compensator bowl. Start ten new
6 screws (11) with flat washers. Tighten to 65-70 ft-lbs (88.1-
5 94.9 Nm) in a crosswise pattern.

4 Ring Gear
1. Clamp ring gear in soft-jawed vise and install compensator
3 bowl onto ring gear.
2
1 2. Install four screws (10). Tighten to 22-26 ft-lbs (29.8-35.3
Nm) in a crosswise pattern.

10 Sprocket
NOTE
11
Replace isolators in complete sets only.
1. Bearing, ring gear side
1. See Figure 5-12. Lubricate each isolator (6) with 50/50
2. Differential assembly
mix of isopropyl alcohol and water. Do not use a petroleum
3. Seal (2)
based lubricant.
4. Compensator bowl
5. Ring gear (if equipped) 2. Push each isolator into compensator bowl (4) so that strap
6. Isolators (6) engages slot in rib. Verify that each isolator bottoms in
7. Sprocket compensator bowl and that each segment is flush against
8. Retaining ring side walls of rib. Leave one isolator raised slightly to be
9. Bearing, sprocket side used as a guide when positioning sprocket.
10. Screw (4)
3. Using a 50/50 mix of isopropyl alcohol and water, lubricate
11. Screw (10)
sides of each isolator where contact occurs with sprocket
Figure 5-12. Differential/Sprocket Assembly lugs.
4. Align lugs on sprocket (7) with gaps between isolators and
install sprocket onto compensator bowl.
5. Using a suitable driver such as MAIN DRIVE GEAR
INSTALLER (Part No. HD-35316-12), press on sprocket
bearing inner race until sprocket bottoms on compensator
bowl.
6. Install new retaining ring (8) in groove of differential.

Bearings
1. See Figure 5-12. Using a suitable driver such as MAIN
DRIVE GEAR INSTALLER (Part No. HD-35316-12), press

2013 Trike Service Supplement: Drive 5-7

HOME

inner race of new sprocket side bearing (9) until it bottoms 11. See Figure 5-9. Install bearing caps (2). Tighten screws
against sprocket. (3) to 39-44 ft-lbs (52.9-59.7 Nm) in a crosswise pattern.
2. Repeat previous step to install bearing (1) on opposite 12. Pull axle housing rearward and turn each adjustment screw
side. until paint mark made during disassembly is aligned with
adapter plate.
INSTALLATION
13. Remove protective tape from rear fork.
FASTENER TORQUE VALUE 14. Align axle and adjust belt tension. See 1.9 DRIVE BELT,
P-clamp to pinch block screw 14-17 ft-lbs 19.0-23.1 Nm Setting Deflection.
Air valve nut 12-15 in-lbs 1.4-1.7 Nm 15. Install reverse motor bracket and motor. See
Differential bearing cap screws 39-44 ft-lbs 52.9-59.7 Nm 7.13 REVERSE MOTOR AND BRACKET.

Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 16. Install axles. See 5.2 AXLE.
17. Install body. See 2.11 BODY.
1. If removed, install shock absorber mounts on pinch blocks.
18. Connect battery negative (-) cable. Tighten to 60-70 in-lbs
2. Push axle housing forward until pinch blocks engage (6.8-7.9 Nm).
adapter plate bosses.
3. Install P-clamp on left park brake cable with screw. Tighten
to 14-17 ft-lbs (19.0-23.1 Nm).
After installing seat, pull upward on seat to be sure it is
4. Install air valve: locked in position. While riding, a loose seat can shift
a. Route air valve and tubes forward through opening causing loss of control, which could result in death or
at rear of intermediate frame. serious injury. (00070b)
b. Secure air valve in frame with nut (flat side inboard). 19. Install seat.
Tighten to 12-15 in-lbs (1.4-1.7 Nm).
sm05946
c. Install cap.

5. See Figure 5-13. Install three new cable straps to secure

air tubes to intermediate frame.
6. Install rear frame. See 2.13 REAR FRAME.
7. Install and adjust panhard rod. See 2.19 PANHARD ROD.
8. Install shock absorbers. See 2.18 SHOCK ABSORBERS.
9. Place differential into differential housing.
NOTE
Be careful that differential does not roll out of axle housing
when moving axle housing forward.
10. Verify axle adjuster screws are backed off completely and
move axle housing forward as far as it will go. Install drive
belt on sprocket.
Figure 5-13. Secure Air Tubes
NOTE
Differential housing and bearing caps are stamped L(eft) and
R(ight) to prevent improper assembly. Letter stamp on each
cap must be right side up when installed.

5-8 2013 Trike Service Supplement: Drive

HOME

DRIVE BELT REPLACEMENT 5.4

REMOVAL INSTALLATION
1. Remove primary chaincase assembly. See PRIMARY
FASTENER TORQUE VALUE
CHAINCASE in the service manual.
Footboard screw, passenger 30-35 ft-lbs 40.7-47.5 Nm
2. Remove differential to release drive belt from rear wheel
sprocket. Remove axle housing. See 5.3 AXLE
1. Slip new drive belt between left side adapter plate and
HOUSING/DIFFERENTIAL.
pinch blocks without over bending, twisting or kinking.
3. Remove drive belt from transmission sprocket.
2. Pull drive belt forward past pivot shaft joint and work rear
4. Remove rear fork pivot shaft and move rear fork back fork into position on transmission mount.
away from transmission to allow clearance for belt to pass.
3. Install rear fork and pivot shaft. See 2.15 REAR FORK.
See 2.15 REAR FORK.
4. Install passenger footboard. Tighten to 30-35 ft-lbs (40.7-
5. Remove drive belt.
47.5 Nm).
5. Install drive belt onto transmission sprocket.
6. Install axle housing and differential. See 5.3 AXLE
HOUSING/DIFFERENTIAL.
7. Install primary chaincase assembly. See the service
manual.

2013 Trike Service Supplement: Drive 5-9

NOTES

5-10 2013 Trike Service Supplement: Drive

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
6.1 TRANSMISSION........................................................................................................................6-1

TRANSMISSION
NOTES
HOME

TRANSMISSION 6.1
GENERAL
Table 6-2. Overall Drive Ratios
Transmission servicing on Trike Models is essentially the same
as the 2-wheel Touring Models except removal and installation GEAR RATIO
of the rear fork. Follow the general steps outlined in the service 1st Gear 10.537
manual but refer to 2.15 REAR FORK in this manual to remove
2nd Gear 7.303
and install the rear fork. Pay special attention to the installation
and torque procedure of the pivot shaft. 3rd Gear 5.425
4th Gear 4.393
SPECIFICATIONS
5th Gear 3.742
Table 6-1. Sprocket Teeth 6th Gear 3.157

DRIVE ITEM NUMBER OF

TEETH
Primary Engine 34
Clutch 46
Final Transmission 30
Rear wheel 70

2013 Trike Service Supplement: Transmission 6-1

NOTES

6-2 2013 Trike Service Supplement: Transmission

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
7.1 FASTENER TORQUE VALUES.................................................................................................7-1
7.2 SYSTEM FUSES AND RELAYS................................................................................................7-4
7.3 BATTERY TRAY........................................................................................................................7-5
7.4 AUXILIARY LAMPS...................................................................................................................7-6
7.5 FRONT TURN SIGNAL LAMPS................................................................................................7-9
7.6 TAIL LAMPS/REAR TURN SIGNALS......................................................................................7-12
7.7 TAIL LAMP/REAR TURN SIGNAL CONVERTER MODULE...................................................7-13
7.8 LICENSE PLATE LAMPS/BRACKET......................................................................................7-14
7.9 REAR LIGHTS HARNESS.......................................................................................................7-15
7.10 BANK ANGLE SENSOR (BAS).............................................................................................7-17
7.11 REVERSE CONTROL SYSTEM............................................................................................7-18
7.12 REVERSE JUMPER CABLES/WIRES..................................................................................7-21
7.13 REVERSE MOTOR AND BRACKET.....................................................................................7-24
7.14 REVERSE SWITCHES..........................................................................................................7-27
7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS......................................................................7-29
7.16 REVERSE MOTOR TESTING ..............................................................................................7-38
7.17 REAR LIGHTING DIAGNOSTICS.........................................................................................7-41
7.18 BAS FUNCTION: DTCS B1151, B1152, AND B1153............................................................7-45

ELECTRICAL
NOTES
HOME

FASTENER TORQUE VALUES 7.1

FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.

FASTENER TORQUE VALUE NOTES

Auxiliary lamp locknut 15-18 ft-lbs 20.3-24.4 Nm 7.4 AUXILIARY LAMPS, Installation
Bank angle sensor bracket screws 72-108 in-lbs 8.1-12.2 Nm 7.10 BANK ANGLE SENSOR (BAS), Installation
Bank angle sensor screw 35-45 in-lbs 4.0-5.1 Nm 7.10 BANK ANGLE SENSOR (BAS), Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.4 AUXILIARY LAMPS, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.5 FRONT TURN SIGNAL LAMPS, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.6 TAIL LAMPS/REAR TURN SIGNALS, Installa-
tion
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.7 TAIL LAMP/REAR TURN SIGNAL CON-
VERTER MODULE, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.8 LICENSE PLATE LAMPS/BRACKET, Installa-
tion
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.9 REAR LIGHTS HARNESS, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.11 REVERSE CONTROL SYSTEM, Reverse
Solenoid Replacement
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Vehicle
Starter to Circuit Breaker Power Lead
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Breaker to RCM Solenoid
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER CABLES/WIRES, RCM
Solenoid to Reverse Motor Solenoid Energizer
Lead
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Breaker to Reverse Motor Solenoid Power Lead
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER
CABLES/WIRES, Reverse Motor to Battery Ground
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
tion
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.14 REVERSE SWITCHES, Installation
Battery tray screws 72-96 in-lbs 8.1-10.9 Nm 7.3 BATTERY TRAY, Installation
Fairing cap screws 25-30 in-lbs 2.8-3.4 Nm 7.14 REVERSE SWITCHES, Installation
License plate lamps bracket locknuts 60-72 in-lbs 6.8-8.1 Nm 7.8 LICENSE PLATE LAMPS/BRACKET, Installa-
tion/Use new locknuts
RCM solenoid nuts 50-60 in-lbs 5.7-6.8 Nm 7.11 REVERSE CONTROL SYSTEM, Reverse
Solenoid Replacement
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm 7.11 REVERSE CONTROL SYSTEM, Reverse
Solenoid Replacement
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Breaker to RCM Solenoid
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm 7.12 REVERSE JUMPER CABLES/WIRES, RCM
Solenoid to Reverse Motor Solenoid Energizer
Lead

2013 Trike Service Supplement: Electrical 7-1

HOME

FASTENER TORQUE VALUE NOTES

Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Vehicle
Starter to Circuit Breaker Power Lead
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Breaker to RCM Solenoid
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Breaker to Reverse Motor Solenoid Power Lead
Reverse circuit breaker screw 32-40 in-lbs 3.6-4.5 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Reverse motor bracket screws 39-44 ft-lbs 52.9-59.7 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
tion/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
Reverse motor screws 39-44 ft-lbs 52.9-59.7 Nm 7.12 REVERSE JUMPER
CABLES/WIRES, Reverse Motor to Battery
Ground/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
Reverse motor screws 39-44 ft-lbs 52.9-59.7 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
tion/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
Reverse motor solenoid energizer lead 24-30 in-lbs 2.7-3.4 Nm 7.12 REVERSE JUMPER CABLES/WIRES, RCM
nut Solenoid to Reverse Motor Solenoid Energizer
Lead
Reverse motor solenoid energizer lead 24-30 in-lbs 2.7-3.4 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
nut tion
Reverse motor solenoid power lead nut 60-84 in-lbs 6.8-9.5 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Breaker to Reverse Motor Solenoid Power Lead
Reverse motor solenoid power lead nut 60-84 in-lbs 6.8-9.5 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
tion
Reverse motor solenoid screws 70 in-lbs 7.9 Nm 7.13 REVERSE MOTOR AND
BRACKET, Assembly
Reverse switch housing cover screws 35-45 in-lbs 4-5 Nm 7.14 REVERSE SWITCHES, Installation
Reverse switch housing screws 72-108 in-lbs 8-12 Nm 7.14 REVERSE SWITCHES, Installation
Solenoid to reverse motor jumper nut 45 in-lbs 5.1 Nm 7.13 REVERSE MOTOR AND
BRACKET, Assembly
Starter mounting screws 25-27 ft-lbs 33.9-36.6 Nm 7.12 REVERSE JUMPER
CABLES/WIRES, Reverse Motor to Battery
Ground/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
Starter solenoid post nut 70-90 in-lbs 7.9-10.2 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Vehicle
Starter to Circuit Breaker Power Lead
Tail lamp/turn signal chrome base screw 36-48 in-lbs 4.1-5.4 Nm 7.6 TAIL LAMPS/REAR TURN SIGNALS, Installa-
tion/Use LOCTITE 222 LOW STRENGTH
THREADLOCKER AND SEALANT (purple)
Tail lamp/turn signal lens screws 21-24 in-lbs 2.4-2.7 Nm 7.6 TAIL LAMPS/REAR TURN SIGNALS, Installa-
tion
Tail lamp/turn signal lens screws 21-24 in-lbs 2.4-2.7 Nm 7.9 REAR LIGHTS HARNESS, Installation
Transmission ground post nut 66-114 in-lbs 7.5-12.9 Nm 7.12 REVERSE JUMPER
CABLES/WIRES, Reverse Motor to Battery Ground
Trunk door cover screws 30-54 in-lbs 3.4-6.1 Nm 7.8 LICENSE PLATE LAMPS/BRACKET, Installa-
tion

7-2 2013 Trike Service Supplement: Electrical

HOME

FASTENER TORQUE VALUE NOTES

Trunk door cover screws 30-54 in-lbs 3.4-6.1 Nm 7.9 REAR LIGHTS HARNESS, Installation
Turn signal/auxiliary lamps bracket 15-20 ft-lbs 20.3-27.1 Nm 7.4 AUXILIARY LAMPS, Installation
screws
Turn signal/auxiliary lamps bracket 15-20 ft-lbs 20.3-27.1 Nm 7.5 FRONT TURN SIGNAL LAMPS, Installation
screws
Turn signal lamp, front, mounting screw 96-120 in-lbs 10.8-13.6 Nm 7.4 AUXILIARY LAMPS, Installation
Turn signal lamp, front, mounting screw 96-120 in-lbs 10.8-13.6 Nm 7.5 FRONT TURN SIGNAL LAMPS, Installation

2013 Trike Service Supplement: Electrical 7-3

HOME

SYSTEM FUSES AND RELAYS 7.2

GENERAL or relays. See the service manual for removal and installation
of fuse blocks or the main fuse holder.
Fuse blocks are mounted to the electrical caddy under the left
side cover. See Figure 7-1 for replacement of individual fuses

om01155d

1 2 3 4
5 6 7 8
9
11 12
10
23
13 14 15
16
18 19
17
20

21 22

1. Brake (15 amp) 9. Not used 17. Brake relay

2. Accessory (15 amp) 10. Fuel pump (15 amp) 18. Headlamp (15 amp)
3. P&A (15 amp) 11. System relay 19. Lights (15 amp)
4. Radio power/siren (15 amp) 12. Start relay 20. Spare (15 amp)
5. Radio memory (15 amp) 13. P&A ignition (2 amp max) 21. ABS (not used)
6. Battery (15 amp) 14. Instruments (15 amp) 22. Not used
7. ECM power (15 amp) 15. Ignition (15 amp) 23. Main fuse (40 amp)
8. Power outlet (if equipped) (15 16. Lighting relay
amp)
Figure 7-1. Fuses

7-4 2013 Trike Service Supplement: Electrical

HOME

BATTERY TRAY 7.3

REMOVAL 3. Install RCM solenoid, RCM module and reverse circuit
breaker. See 7.11 REVERSE CONTROL SYSTEM.
1. Remove left and right side covers.
4. Install TSM/HFSM onto battery tray.
2. Remove battery. See service manual.
5. Mate connector to BAS.
3. Disconnect Tour-Pak lighting harness and AM-FM antenna
lead. Remove from Tour-Pak. See service manual. 6. Install ignition coil. See service manual.

4. Disconnect rear lighting harness from converter module. 7. Mate rear lighting and trunk light connectors.

5. Disconnect trunk light connector. 8. Route harnesses through side of battery tray and connect
Tour-Pak connectors. Install cable straps to secure har-
6. Remove two screws securing left side electrical caddy to ness.
frame.
9. Route Tour-Pak harnesses and AM-FM antenna lead into
7. Pull the three harnesses from left side of battery tray. Tour-Pak and mate connectors.
8. Remove ignition coil. See service manual. 10. Install left side electrical caddy. See service manual.
9. Pull TSM/HFSM away from battery tray. 11. Install battery and top caddy.
10. Disconnect BAS and pull harness from right side of battery 12. Install left and right side covers.
tray.
11. Remove reverse circuit breaker, RCM module and RCM
solenoid from battery tray. See 7.11 REVERSE CONTROL
SYSTEM. After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
12. Remove four screws securing battery tray to frame. causing loss of control, which could result in death or
13. Pull battery tray from right side of frame. serious injury. (00070b)
13. Install seat.
INSTALLATION
FASTENER TORQUE VALUE
Battery tray screws 72-96 in-lbs 8.1-10.9 Nm Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
1. Install battery tray from right side of frame. death or serious injury. (00316a)

2. Install four screws securing battery tray to frame. Tighten 14. Turn ignition on and test switches and lights for proper
to 72-96 in-lbs (8.1-10.9 Nm). operation.

2013 Trike Service Supplement: Electrical 7-5

HOME

AUXILIARY LAMPS 7.4

REMOVAL 14. Remove locknut, lockwasher and clamp block from stud.
At top of bracket, remove lamp housing and rubber isol-
1. Remove seat. ator.

sm06039
1
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2. Disconnect battery negative (-) cable.
3. Remove outer fairing. See service manual.
4. Disconnect left or right front turn signal/auxiliary lamp
connector, 4-place Multilock, on T-stud at top of left or 3
right fairing support brace (outboard side).
5. Remove two screws with flat washers to release bracket 2
from upper and lower fork brackets. Move assembly to
bench area.
1. Stand-off mount
6. Remove terminal from socket housing. Refer to Table 7-1. 2. Stand-off
3. Turn signal lamp wires
Table 7-1. Front Turn Signal/Auxiliary Lamps Connectors Figure 7-2. Draw Wires Through Passage
[31L/R]

WIRE COLOR CHAMBER NUMBER INSTALLATION

Gray/Black 4
PART NUMBER TOOL NAME
NOTE FRX181 SNAP-ON FLARE NUT SOCKET
For instructions on removing terminals, see service manual.
7. Cut cable strap on each end of conduit. FASTENER TORQUE VALUE

8. Cut terminal off wire and pull through conduit. Auxiliary lamp locknut 15-18 ft-lbs 20.3-24.4 Nm
Turn signal lamp, front, 96-120 in-lbs 10.8-13.6 Nm
9. See Figure 7-3. Remove screw with lockwasher to release
mounting screw
front turn signal lamp from bracket.
Turn signal/auxiliary lamps 15-20 ft-lbs 20.3-27.1 Nm
10. Draw wire through passage in bracket to area of stand-off bracket screws
mount.
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
11. See Figure 7-2. Draw wire from area of stand-off mount
through passage to locknut. 1. Lay new auxiliary lamp next to old auxiliary lamp and cut
12. Remove reflector/bulb assembly if installed. Proceed as wire to proper length.
follows: 2. Draw wire up through stud into lamp housing.
a. Loosen screw as necessary to pull lamp door from
3. See Figure 7-3. Install rubber isolator on stud and insert
lip of lamp housing.
through hole at top of bracket.
b. Disconnect auxiliary lamp connector, 2-place Packard,
4. At bottom of bracket, install clamp block (rounded side
at back of reflector.
up), lockwasher and locknut on stud. Tighten to 15-18 ft-
c. Remove nesting ring. lbs (20.3-24.4 Nm).

13. Draw wire up through stud into lamp housing. 5. Feed wire from lamp housing down through stud to bottom
of bracket.

7-6 2013 Trike Service Supplement: Electrical

HOME

sm06041

14
15
12

11

3
5
2
1
9
6 13
19
4 10

18

17

7 16

1. Socket housing 11. Lamp door

2. Screw (2) 12. Reflector
3. Flat washer (2) 13. Bulb
4. Bracket 14. Nesting ring
5. Screw 15. Auxiliary lamp housing
6. Lockwasher 16. Locknut
7. Stand-off 17. Lockwasher
8. Turn signal lamp 18. Clamp block
9. Door screw 19. Rubber isolator
10. Nut
Figure 7-3. Front Turn Signal/Auxiliary Lamps Assembly

6. Feed wire through passage in bracket to area of stand-off NOTE

mount. For instructions on crimping and installing terminals, see service
manual.
7. See Figure 7-6. From area of stand-off mount, feed wire
through passage to inboard side of bracket. 12. Install new cable strap on each end of conduit.
8. Install screw with lockwasher and front turn signal lamp 13. Install two screws with flat washers to fasten bracket to
to bracket. Tighten to 96-120 in-lbs (10.8-13.6 Nm). upper and lower fork brackets. Tighten to 15-20 ft-lbs
(20.3-27.1 Nm).
9. Feed wire back through conduit.
NOTE
10. Strip 3/16 in. (4.8 mm) insulation off wire and crimp on
On left side of motorcycle, screws also capture steering damper
new socket terminal.
side mounting bracket.
11. Install terminal into socket housing. Refer to Table 7-1. 14. Connect 4-place Multilock connector and install on T-stud
at top of left or right fairing support brace (outboard side).

2013 Trike Service Supplement: Electrical 7-7

HOME

Verify that conduit is routed inboard using relief in upper

outboard corner of chrome skirt.
15. See Figure 7-4. Install reflector/bulb assembly as follows: Be sure that all lights and switches operate properly before
a. Place nesting ring at back of reflector with the concave operating motorcycle. Low visibility of rider can result in
side up. death or serious injury. (00316a)

b. Connect auxiliary lamp connector, 2-place Packard. 19. Turn ignition/light key switch to IGNITION and test auxiliary
lamps for proper operation.
c. Place nesting ring over edge of lamp housing. Rotate
nesting ring until index tab engages slot at bottom of NOTE
lamp housing. Loosen auxiliary lamp locknut using a SNAP-ON FLARE NUT
SOCKET (Part No. FRX181) and adjust beam if necessary.
d. Holding nesting ring in place, rotate reflector so that See service manual.
index tabs at back engage slots in nesting ring.
e. Install lamp door over lip of lamp housing. Rotate sm03618
lamp door so that screw is centered at bottom, and
then tighten door screw until snug.
1
16. Install outer fairing. See service manual.
17. Connect battery negative (-) cable. Tighten to 60-70 in-lbs
(6.8-7.9 Nm).

1
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift 2
causing loss of control, which could result in death or
serious injury. (00070b)
1. Reflector index tabs
18. Install seat.
2. Nesting ring index tab
Figure 7-4. Reflector/Bulb Assembly

7-8 2013 Trike Service Supplement: Electrical

HOME

FRONT TURN SIGNAL LAMPS 7.5

REMOVAL
sm06184

1
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a) 2
1. Disconnect battery negative cable.
2. Remove outer fairing. See service manual.
3
3. Disconnect front turn signal/auxiliary lamp connector, 4-
place Multilock, on fairing support brace.
4. Remove two screws with flat washers to release bracket.
5. Remove terminals from connector housing. Refer to
Table 7-2.
4
Table 7-2. Front Turn Signal/Auxiliary Lamps Connectors
[31L/R]

WIRE COLOR CHAMBER NUMBER

Blue 1
Violet 2
1. Lamp terminal base
Black 3 2. Spring
3. Rubber isolator
NOTE 4. Hole
For connector service procedures, see service manual. Figure 7-6. Reflector Assembly
6. Cut cable strap on each end of conduit.
10. To remove reflector:
7. Cut terminals off wires. Pull wires through conduit.
a. Remove lens and bulb.
8. See Figure 7-7. Remove screw with lockwasher to release
lamp from bracket. b. See Figure 7-6. Insert a right angle pick or a 7/64 in.
hex key through hole (4) and pull reflector from lamp.
9. See Figure 7-5. Draw wires through passage in bracket
to area of stand-off mount. Remove stand-off from wires. c. Remove isolator (3) from lamp if still installed.

sm06039
1

1. Stand-off mount
2. Stand-off
3. Turn signal lamp wires
Figure 7-5. Draw Wires Through Passage

2013 Trike Service Supplement: Electrical 7-9

HOME

INSTALLATION 6. Feed wires back through conduit.

NOTE
FASTENER TORQUE VALUE For connector service procedures, see service manual.
Turn signal lamp, front, 96-120 in-lbs 10.8-13.6 Nm 7. Strip 3/16 in. (4.8 mm) of insulation off wires. Crimp on
mounting screw new socket terminals.
Turn signal/auxiliary lamps 15-20 ft-lbs 20.3-27.1 Nm
8. Install terminals into connector housing. Refer to Table 7-2.
bracket screws
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 9. Install new cable strap on each end of conduit.
10. Secure lamp bracket with two screws with flat washers.
1. See Figure 7-7. Install reflectort/isolator: Tighten to 15-20 ft-lbs (20.3-27.1 Nm).
a. Seat socket assembly in isolator aligning tab on
NOTE
socket with slot in isolator.
On left side, screws also capture steering damper side
b. Feed wires into lamp through lens opening and then mounting bracket.
out through unthreaded hole. 11. Mate connector and install on T-stud at top of fairing sup-
c. Install reflector assembly aligning tab on socket with port brace (outboard side). Verify that conduit is routed
slot inside lamp. inboard using relief in upper outboard corner of chrome
skirt.
d. Using thumbs of both hands, apply even pressure
around outer edge of reflector assembly until fully 12. Install outer fairing. See service manual.
seated. 13. Connect battery negative cable. Tighten to 60-70 in-lbs
e. Liberally apply dielectric grease to contacts in socket (6.8-7.9 Nm).
and at bottom of bulb. Install bulb.
f. Install lens. Rotate lens to position slot at bottom of
lamp. After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
2. Lay new turn signal lamp next to old turn signal lamp and
causing loss of control, which could result in death or
cut wires to proper length.
serious injury. (00070b)
3. Route wires through stand-off, but avoid through-hole for
14. Install seat.
screw. Stand-off is directional, so verify that through-hole
aligns with threaded hole in lamp.
4. See Figure 7-6. Feed wires through passage to inboard
side of bracket. Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
5. Install screw with lockwasher and fasten lamp to bracket.
death or serious injury. (00316a)
Tighten to 96-120 in-lbs (10.8-13.6 Nm).
15. Verify front turn signal lamp operation.

7-10 2013 Trike Service Supplement: Electrical

HOME

sm06042

3
5
2
1

10
9
8

11

1. Connector housing 7. Stand-off

2. Screw (2) 8. Turn signal lamp
3. Flat washer (2) 9. Lens
4. Bracket 10. Bulb
5. Screw 11. Reflector/isolator
6. Lockwasher
Figure 7-7. Front Turn Signal/Auxiliary Lamps Assembly

2013 Trike Service Supplement: Electrical 7-11

HOME

TAIL LAMPS/REAR TURN SIGNALS 7.6

REMOVAL 7. Install seat.

1. Remove seat.

Be sure that all lights and switches operate properly before

operating motorcycle. Low visibility of rider can result in
To prevent accidental vehicle start-up, which could cause death or serious injury. (00316a)
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a) 8. Test tail lamp/turn signal operation.

2. Disconnect battery negative cable.

sm06105
3. Remove two screws to release tail lamp/turn signal lens.
4 2
4. See Figure 7-8. Disconnect tail lamp/turn signal connector
(1).
5. Disconnect rear lighting harness connector (2). Feed 1
socket housing through opening (3) to inboard side of
fender.
6. Remove screw (4) with flat washer to release chrome base
from fender bracket.
7. See Figure 7-9. Remove pin housing and circuit board
from chrome base. Remove pin housing from circuit board.

INSTALLATION
FASTENER TORQUE VALUE
Tail lamp/turn signal chrome 36-48 in-lbs 4.1-5.4 Nm 3
base screw
Tail lamp/turn signal lens 21-24 in-lbs 2.4-2.7 Nm 1. Tail lamp/turn signal connector
screws 2. Rear lighting harness connector
3. Opening
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 4. Chrome base screw

1. See Figure 7-9. Place pin housing over circuit board. Install Figure 7-8. Remove Lens From Chrome Base
pin housing into chrome base.
2. See Figure 7-8. Apply LOCTITE 222 LOW STRENGTH
sm03626
THREADLOCKER AND SEALANT (purple) to screw (4).
Secure chrome base with flat washer and screw. Tighten
to 36-48 in-lbs (4.1-5.4 Nm).
3. Feed socket housing through opening (3) to outboard side
of fender. Connect rear lighting harness connector (2).
4. Connect tail lamp/turn signal connector (1).
5. Install tail lamp/turn signal lens with two screws. Tighten
to 21-24 in-lbs (2.4-2.7 Nm).
NOTE
Over tightening screws can crack the lens.
H-D
6. Connect battery negative cable. Tighten screw to 60-70 USA

in-lbs (6.8-7.9 Nm). 68830-98

Figure 7-9. Remove Pin Housing From Circuit Board

After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)

7-12 2013 Trike Service Supplement: Electrical

HOME

TAIL LAMP/REAR TURN SIGNAL CONVERTER

MODULE 7.7
REMOVAL 5. Test tail lamps/turn signals operation.

1. Remove seat.
sm06071
1

To prevent accidental vehicle start-up, which could cause 3

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2. Disconnect battery negative cable.
3. See Figure 7-10. Disconnect rear lighting (3) and main
harness (2) connectors from converter module.
2
4. See Figure 7-11. Squeeze anchor to release from hole in
intermediate frame.
1. Cable strap anchor
INSTALLATION 2. Main harness connector
3. Rear lighting harness connector (not visible)
FASTENER TORQUE VALUE Figure 7-10. Tail Lamp/Rear Turn Signal Converter Module
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm

1. Push anchor into hole in left side of intermediate frame. sm06069

2. See Figure 7-10. Mate main (2) and rear lighting (3) har-
ness connectors.
3. Connect battery negative cable. Tighten to 60-70 in-lbs
(6.8-7.9 Nm).

After installing seat, pull upward on seat to be sure it is

locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
4. Install seat.

Be sure that all lights and switches operate properly before Figure 7-11. Release Anchor From Intermediate Frame
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

2013 Trike Service Supplement: Electrical 7-13

HOME

LICENSE PLATE LAMPS/BRACKET 7.8

REMOVAL 4. Install two new locknuts with flat washers to fasten license
plate lamp bracket to trunk door. Tighten locknuts to 60-72
1. Remove seat. in-lbs (6.8-8.1 Nm).
5. Connect license plate lamp connector (1) to rear lighting
harness.
To prevent accidental vehicle start-up, which could cause 6. Install trunk door cover and tighten screws in a crosswise
death or serious injury, disconnect negative (-) battery pattern to 30-54 in-lbs (3.4-6.1 Nm).
cable before proceeding. (00048a)
7. Connect battery negative (-) cable. Tighten screw to 60-70
2. Disconnect battery negative (-) cable. in-lbs (6.8-7.9 Nm).
3. Remove four screws and remove trunk door inner cover.
4. See Figure 7-12. Disconnect license plate lamp connector
(1) from rear lighting harness. After installing seat, pull upward on seat to be sure it is
5. Remove terminals from connector housing. locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
NOTE serious injury. (00070b)
For instructions on removing terminals, see service manual.
8. Install seat.
6. Remove two locknuts and flat washers to release license
plate lamp bracket.
NOTE
License plate lamp bracket also serves as the trunk door Be sure that all lights and switches operate properly before
handle. operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
7. Draw harness to outboard side of trunk door while pushing
grommet (2) through hole. 9. Test license plate lamp operation.

8. Remove two screws to release lens/bulb assembly from

sm06081a
license plate lamp bracket.

INSTALLATION
1
FASTENER TORQUE VALUE 2
License plate lamps bracket 60-72 in-lbs 6.8-8.1 Nm
locknuts
Trunk door cover screws 30-54 in-lbs 3.4-6.1 Nm
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm

1. Secure lens/bulb assembly to license plate lamp bracket

with two screws.
1. License plate lamp connector
2. If replacing lens/bulb assembly, place new unit next to old 2. Grommet
unit and cut wires to proper length. Crimp new socket
terminals onto wires. Figure 7-12. Inside Trunk Door

3. See Figure 7-12. Feed terminals and harness with

grommet to inboard side of trunk door. Seat grommet (2)
in hole. Install terminals into connector housing.

7-14 2013 Trike Service Supplement: Electrical

HOME

REAR LIGHTS HARNESS 7.9

REMOVAL
sm06106
1. Remove seat. 1

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2. Disconnect battery negative cable.
3. Disconnect rear lighting harness from converter module.
Disconnect optional trunk light harness connector.
4. Remove rear wheels. See 2.4 REAR WHEELS.
5. Remove four screws and remove trunk door inner cover.
6. See Figure 7-13. Disconnect license plate lamp connector
(3) and optional trunk light connector (4) if equipped. 2
7. Release harness from anchor clips (1). 1. Rear lighting harness connector
8. Remove trunk liner. 2. Opening

9. Release harness from anchor clips inside trunk. Figure 7-14. Chrome Base

10. Remove grommet in front-left corner of body and feed

harness through hole to underside of body. INSTALLATION
11. Disconnect harness from fenders as follows: FASTENER TORQUE VALUE
a. Remove two screws to release tail lamp/turn signal
Tail lamp/turn signal lens 21-24 in-lbs 2.4-2.7 Nm
lens from chrome base.
screws
b. See Figure 7-14. Disconnect rear lighting harness Trunk door cover screws 30-54 in-lbs 3.4-6.1 Nm
connector (1). Feed harness and connector through
opening to inboard side of fender. Battery cable screw 60-70 in-lbs 6.8-7.9 Nm

c. Release harness from three adhesive clips in fender NOTE

well. Feed harness through holes to underside of
The harness is captured in a total of 23 anchor clips. There
body.
are twelve at underside of body, three in each fender well and
d. Repeat steps on opposite fender. five inside trunk.

12. Release harness from twelve anchor clips at underside of 1. See Figure 7-15. Capture harness in anchor clips at
body. underside of body:
a. With the 8-place Multilock and 2-place Multilock con-
nectors at front of body, route harness rearward and
sm06080a
then to left side of body through two adhesive clips
(1, 2).
b. Route right tail lamp (longer branch) of harness ter-
1 minating in 6-place connector to right side of body
2 and then rearward through seven anchor clips (3-9).
c. Route left tail lamp (shorter branch) of harness termin-
ating in 6-place connector rearward along left side of
body through three anchor clips (10-12).
4
3
1. Anchor clips
2. Grommet
3. License plate lamp connector
4. P&A trunk light connector
Figure 7-13. Inside Trunk Door

2013 Trike Service Supplement: Electrical 7-15

HOME

2. Secure harness to fenders as follows: 8. Connect harness to converter module and mate trunk lamp
a. Feed harness through holes and capture in three harness connector.
anchor clips in fender well. 9. Install rear wheels. See 2.4 REAR WHEELS.
b. See Figure 7-14. Feed connector housing to outboard NOTE
side of fender and connect to tail lamp base. Always check lug nut torque within 500-1000 mi (805-1610
c. Install tail lamp lens with two screws. Tighten to 21-24 km) after wheel installation.
in-lbs (2.4-2.7 Nm). 10. Connect battery negative cable. Tighten screw to 60-70
d. Repeat steps on opposite fender. in-lbs (6.8-7.9 Nm).

3. Feed branch of harness terminating in two 2-place Multi-

lock connectors into trunk through hole in front-left corner
of body. Install grommet into body hole. After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
4. Capture harness in five anchor clips inside trunk. causing loss of control, which could result in death or
5. See Figure 7-13. Mate license plate lamp harness con- serious injury. (00070b)
nector (3) and optional trunk light connector (4) if equipped. 11. Install seat.
Secure harness to trunk door with anchor clips (1).
NOTE
Route harness through gap in front left corner of trunk door
cover. Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
6. Install trunk door cover. Tighten in a crosswise pattern to death or serious injury. (00316a)
30-54 in-lbs (3.4-6.1 Nm).
12. Test tail lamps/turn signals and license plate lamp for
7. Install trunk liner. proper operation.

sm05955

1
2

3 4 5 6
10 7

11 8

12 9
13 16
14 17
15 18

Figure 7-15. Adhesive Clip Location (As Viewed From the Top)

7-16 2013 Trike Service Supplement: Electrical

HOME

BANK ANGLE SENSOR (BAS) 7.10

REMOVAL
1. Remove main fuse.
After installing seat, pull upward on seat to be sure it is
2. Remove seat and top caddy. See the service manual. locked in position. While riding, a loose seat can shift
3. See Figure 7-16. Remove screws (2) and remove sensor causing loss of control, which could result in death or
with bracket. serious injury. (00070b)
4. Install top caddy and seat.
4. Disconnect bank angle sensor connector.
5. Install main fuse.
5. Remove screw (1) and sensor from bracket.

INSTALLATION sm06482

FASTENER TORQUE VALUE 2

Bank angle sensor screw 35-45 in-lbs 4.0-5.1 Nm
Bank angle sensor bracket 72-108 in-lbs 8.1-12.2 Nm
screws 1

NOTE
See Figure 7-16. Use ONLY the correct original equipment
screws to install the BAS bracket. If longer screws are used,
the BAS can send an errant "vehicle has been tipped" signal
to the ECM.
1. Secure sensor to bracket with screw (1). Tighten to 35-45
in-lbs (4.0-5.1 Nm).
2. Mate sensor connector. 1. Sensor screw
2. Bracket screw (2)
3. Install bracket and sensor with screws (2). Tighten to 72-
108 in-lbs (8.1-12.2 Nm). Figure 7-16. Bank Angle Sensor (BAS) (battery removed
for clarity)

2013 Trike Service Supplement: Electrical 7-17

HOME

REVERSE CONTROL SYSTEM 7.11

RCM REPLACEMENT REVERSE SOLENOID REPLACEMENT
Removal FASTENER TORQUE VALUE
1. Remove main fuse. RCM solenoid nuts 50-60 in-lbs 5.7-6.8 Nm
2. Remove right side cover. RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm
NOTE Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
Gently pull back white secondary lock before pressing locking
latch to disconnect Molex connector. Secondary lock not sold Removal
separately. Any damage requires socket housing replacement.
1. Remove right side cover.
3. See Figure 7-17. Disconnect Molex connector (1).
4. Remove cable strap (2) securing RCM (3) to electrical
caddy.
To prevent accidental vehicle start-up, which could cause
5. Remove RCM. death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
sm06916
1 2. Remove seat and disconnect battery negative (-) cable.
3. See Figure 7-18. Disconnect 2-place connector (2).
Remove boot (15).
2
4. Remove nuts (14).
5. Remove RCM jumper (13) and reverse motor solenoid
energizer lead (1) from posts of solenoid.
3
6. Remove two nuts (3) to release RCM solenoid.

Installation
1. See Figure 7-18. Install RCM solenoid with nuts (3).
Tighten to 50-60 in-lbs (5.7-6.8 Nm).
1. RCM connector (10-place Molex) 2. Install reverse motor solenoid energizer lead (1) and nut
2. Cable strap (14) onto post at inboard side of new RCM solenoid.
3. Reverse control module (RCM)
3. Install RCM jumper (13) and nut (14) onto post at outboard
Figure 7-17. Reverse Control Module (RCM) side.
4. Tighten nuts (14) to 26-40 in-lbs (2.9-4.5 Nm).
Installation 5. Route 2-place connector (2) through square shaped
1. Place RCM on right electrical caddy and secure with new opening of boot (15) and install boot. Mate connector (2).
cable strap.
6. Connect battery negative (-) cable. Tighten to 60-70 in-lbs
NOTE (6.8-7.9 Nm).
Be sure that connector housings are fully mated on Molex
connector before carefully pushing white secondary lock into
locking latch. Secondary lock not sold separately. Any damage
requires socket housing replacement. After installing seat, pull upward on seat to be sure it is
2. Mate Molex connector. locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
3. Install right side cover. serious injury. (00070b)
4. Install main fuse. 7. Install seat.

7-18 2013 Trike Service Supplement: Electrical

HOME

sm06780
3
4
1 5
2

6
8
7

16
15
13 12 9
14

11

10

1. Reverse motor solenoid energizer lead 9. Circuit breaker

2. RCM solenoid energizer lead 10. Battery tray
3. Nut, solenoid (2) 11. Bracket
4. Screw 12. RCM solenoid
5. Nut, terminal stud 13. RCM jumper
6. Nut 14. Nut, solenoid stud (2)
7. Power lead 15. Boot
8. Post, starter motor 16. Power lead, reverse motor
Figure 7-18. RCM Solenoid and Circuit Breaker

CIRCUIT BREAKER REPLACEMENT 2. Remove seat and disconnect battery negative cable.
3. See Figure 7-18. Remove nuts (5). Remove RCM jumper
FASTENER TORQUE VALUE (13) and power lead (7) from inboard post (stamped BAT).
Reverse circuit breaker screw 32-40 in-lbs 3.6-4.5 Nm
4. Remove reverse motor power lead (16) from outboard
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm post of circuit breaker (stamped AUX).
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 5. Remove screw (4) and nut (6) to release circuit breaker
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm (9) from bracket (11).

Installation
Removal
1. See Figure 7-18. Install circuit breaker and secure with
1. Remove right side cover. screw (4) and nut (6).
a. Tighten screw to 32-40 in-lbs (3.6-4.5 Nm).
b. Tighten nut to 50-60 in-lbs (5.6-6.8 Nm).
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery 2. Install power lead (7) and RCM jumper (13) onto inboard
cable before proceeding. (00048a) post of circuit breaker (stamped BAT). Install reverse motor

2013 Trike Service Supplement: Electrical 7-19

HOME

power lead (16) onto outboard post (stamped AUX). Install

om01332d
nuts (5). 2
1
3. Tighten nuts (5) to 50-60 in-lbs (5.6-6.8 Nm). Install boots.
4. See Figure 7-19. If tripped, push reset switch (1) into circuit
breaker until an audible click is heard.
5. Connect battery negative cable. Tighten to 60-70 in-lbs
(6.8-7.9 Nm).

After installing seat, pull upward on seat to be sure it is

locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
1. Reset lever (push in direction of arrow to reset)
serious injury. (00070b)
2. Manual trip pushbutton
6. Install seat.
Figure 7-19. Reverse Motor Circuit Breaker
7. Install side cover.

7-20 2013 Trike Service Supplement: Electrical

HOME

REVERSE JUMPER CABLES/WIRES 7.12

GENERAL CIRCUIT BREAKER TO RCM SOLENOID
The reverse system uses the following jumper cables/wires:
FASTENER TORQUE VALUE
• Vehicle starter to circuit breaker (power circuit) Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm
• Circuit breaker to RCM solenoid (energizer circuit) RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm
• RCM solenoid to reverse motor solenoid (energizer circuit) Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
• Circuit breaker to reverse motor (power circuit)
• Reverse motor to battery ground
Removal
1. Remove seat and disconnect battery negative (-) cable.
VEHICLE STARTER TO CIRCUIT BREAKER
POWER LEAD
FASTENER TORQUE VALUE To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
Starter solenoid post nut 70-90 in-lbs 7.9-10.2 Nm
cable before proceeding. (00048a)
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm
2. Remove right side cover.
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
3. See Figure 7-18. Remove boot (15) from RCM solenoid.
Remove nut (14) and ring terminal from outer post of RCM
Removal solenoid.
1. Remove seat and disconnect battery negative (-) cable.
4. Remove boot, nut (6) and ring terminal from inner post of
circuit breaker. Remove jumper (13).

Installation
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery 1. See Figure 7-18. Install ring terminal onto inner post of
cable before proceeding. (00048a) circuit breaker (over power lead (7) terminal) with nut.
Tighten to 50-60 in-lbs (5.6-6.8 Nm).
2. Remove right side cover.
2. Install ring terminal and nut (14) onto post of RCM
3. See Figure 7-18. Disconnect cable (7) from starter solenoid solenoid. Tighten to 26-40 in-lbs (2.9-4.5 Nm).
post (8).
3. Install boots.
4. Remove boot, nut (6) and ring terminal from inboard post
of circuit breaker. Remove cable. 4. Connect battery negative cable. Tighten to 60-70 in-lbs
(6.8-7.9 Nm).
Installation
1. Route jumper cable from circuit breaker forward under
frame crossmember to starter solenoid post.
After installing seat, pull upward on seat to be sure it is
2. Install jumper and battery positive cable ring terminals on locked in position. While riding, a loose seat can shift
starter solenoid post. Secure with nut. Tighten to 70-90 causing loss of control, which could result in death or
in-lbs (7.9-10.2 Nm). Install boot. serious injury. (00070b)
3. Secure ring terminal onto post positioned below RCM 5. Install seat.
jumper (13) at inboard side of circuit breaker with nut,
6. Install right side cover.
Tighten to 50-60 in-lbs (5.6-6.8 Nm). Install boot.
4. Connect battery negative (-) cable. Tighten to 60-70 in-lbs RCM SOLENOID TO REVERSE MOTOR
(6.8-7.9 Nm). SOLENOID ENERGIZER LEAD
FASTENER TORQUE VALUE
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift Reverse motor solenoid ener- 24-30 in-lbs 2.7-3.4 Nm
causing loss of control, which could result in death or gizer lead nut
serious injury. (00070b) Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
5. Install seat.
6. Install right side cover.
Removal
1. Remove seat and disconnect battery negative cable.

2013 Trike Service Supplement: Electrical 7-21

HOME

sm06051b

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2. Remove right rear wheel. See 2.4 REAR WHEELS.
3. Remove right side cover.
4. See Figure 7-18. Remove boot (15) from RCM solenoid.
5. Remove nut (14) and ring terminal from inner post of RCM
solenoid.
6. Remove boot from lower post (silver) on reverse motor
solenoid. Remove nut (metric), lockwasher and ring ter-
minal. Figure 7-20. Secure Harnesses to Frame Tube
7. Cut cable straps to release jumper from upper frame tube
and the reverse motor power lead. Remove jumper (1). CIRCUIT BREAKER TO REVERSE MOTOR
Installation SOLENOID POWER LEAD
1. Install ring terminal and nut onto inner post of RCM FASTENER TORQUE VALUE
solenoid. Tighten to 26-40 in-lbs (2.9-4.5 Nm). Install boot
over RCM solenoid. Reverse motor solenoid power 60-84 in-lbs 6.8-9.5 Nm
lead nut
2. See Figure 7-21. Route jumper above and behind reverse
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm
motor to solenoid.
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
3. Install ring terminal, lockwasher and nut (metric) onto lower
post (2) of reverse motor solenoid. Tighten to 24-30 in-lbs
(2.7-3.4 Nm). Install boot. Removal
4. Install cable straps (5) to secure cables together. 1. Remove seat and disconnect battery negative (-) cable.

5. See Figure 7-20. Install new cable straps to secure power

cable, energizer jumper, RCM harness and main harness
to upper frame tube. To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
6. Install right rear wheel. See 2.4 REAR WHEELS.
cable before proceeding. (00048a)
NOTE
2. Remove right rear wheel. See 2.4 REAR WHEELS.
Always check lug nut torque within 500-1000 mi (805-1610
km) after wheel installation. 3. Remove right side cover.
7. Connect battery negative cable. Tighten to 60-70 in-lbs 4. Remove boot, nut (metric), lockwasher and ring terminal
(6.8-7.9 Nm). from front post (copper) on reverse motor solenoid.
5. See Figure 7-18. Remove boot, nut (5) and ring terminal
from outboard post of circuit breaker (stamped AUX).
After installing seat, pull upward on seat to be sure it is 6. Cut cable straps to release jumper from upper frame tube.
locked in position. While riding, a loose seat can shift Remove jumper (16).
causing loss of control, which could result in death or
serious injury. (00070b) Installation
8. Install seat. 1. See Figure 7-21. Install ring terminal onto front post (1) of
reverse motor solenoid. Install lockwasher and nut (metric).
9. Install right side cover.
2. Tighten nut to 60-84 in-lbs (6.8-9.5 Nm). Install boots.
3. Route lead around rear of reverse motor and up toward
the circuit breaker.
4. Install ring terminal and nut onto outboard post of circuit
breaker (stamped AUX). Tighten nut to 50-60 in-lbs (5.6-
6.8 Nm).
5. Install cable straps (5) to secure cables together.

7-22 2013 Trike Service Supplement: Electrical

HOME

6. See Figure 7-20. Install new cable straps to secure power 6. Remove nut and ground jumper from transmission ground
cable, energizer jumper, RCM harness and main harness post.
to upper frame tube.
7. Draw ground jumper rearward to remove from motorcycle.
7. Install right rear wheel. See 2.4 REAR WHEELS.
Installation
NOTE
Always check lug nut torque within 500-1000 mi (805-1610 1. From area of reverse motor, route new ground jumper
km) after wheel installation. forward over rear fork and above park brake cable and
rear brake line.
8. Connect battery negative (-) cable. Tighten screw to 60-70
in-lbs (6.8-7.9 Nm). 2. Secure ground jumper onto transmission ground post
(outboard of battery negative cable ring terminal) with nut.
Tighten to 66-114 in-lbs (7.5-12.9 Nm).
3. Place starter into installed position. Apply LOCTITE 243
After installing seat, pull upward on seat to be sure it is MEDIUM STRENGTH THREADLOCKER AND SEALANT
locked in position. While riding, a loose seat can shift (blue) and secure with two screws. Tighten to 25-27 ft-lbs
causing loss of control, which could result in death or (33.9-36.6 Nm).
serious injury. (00070b)
4. Remove all residual threadlocking compound from lower
9. Install seat. hole in reverse motor bracket using an appropriate thread
10. Install right side cover. chaser.
5. If reusing reverse motor screw:
REVERSE MOTOR TO BATTERY GROUND
a. Completely remove all threadlocking compound using
FASTENER TORQUE VALUE a wire brush or wire wheel.
Transmission ground post nut 66-114 in-lbs 7.5-12.9 Nm b. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to threads
Starter mounting screws 25-27 ft-lbs 33.9-36.6 Nm
of screw.
Reverse motor screws 39-44 ft-lbs 52.9-59.7 Nm
6. See Figure 7-21. Secure ground jumper (3) and RCM
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm
solenoid ground lead (4) with reverse motor screw. Tighten
to 39-44 ft-lbs (52.9-59.7 Nm).
Removal
7. Install right rear wheel. See 2.4 REAR WHEELS.
1. Remove seat and disconnect battery negative cable.
NOTE
Always check lug nut torque within 500-1000 mi (805-1610
km) after wheel installation.
To prevent accidental vehicle start-up, which could cause 8. Install right side cover.
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a) 9. Connect battery negative cable. Tighten to 60-70 in-lbs
(6.8-7.9 Nm).
2. Remove right side cover.
3. Remove right rear wheel. See 2.4 REAR WHEELS.
4. See Figure 7-21. Remove lower reverse motor screw with After installing seat, pull upward on seat to be sure it is
lockwasher to release ground jumper (3) ring terminal. locked in position. While riding, a loose seat can shift
5. Remove two screws to release starter from primary causing loss of control, which could result in death or
chaincase. Pull starter from bore and move as necessary serious injury. (00070b)
to access ground post at top of transmission case. 10. Install seat.

2013 Trike Service Supplement: Electrical 7-23

HOME

REVERSE MOTOR AND BRACKET 7.13

REMOVAL
sm06061
1. Remove seat.

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2. Disconnect battery negative (-) cable.
3. Remove right rear wheel. See 2.4 REAR WHEELS.
4. See Figure 7-21. Remove nut (1) (metric) and lockwasher
to release reverse motor power cable.
5. Remove nut (2) (metric) and lockwasher to release reverse
motor solenoid energize lead.
6. Remove two screws to release reverse motor from bracket.
7. Remove three screws to release reverse motor bracket.
Pull bracket from two dowel pins in flanges of differential
Figure 7-22. Remove Screws to Release Solenoid
housing.

sm06067a
sm06062a
1

2
5
4 1
2

3
4
3
1. Reverse motor power cable (with red shrink
tube)
2. Reverse motor solenoid energize lead
3. Battery ground jumper 1. Screws and lockwashers
4. RCM solenoid ground 2. Solenoid
5. Cable strap 3. Collar
Figure 7-21. Reverse Motor 4. Spring
Figure 7-23. Solenoid Assembly
DISASSEMBLY
1. Remove reverse motor.
2. Remove nut with lockwasher to release solenoid to reverse
motor jumper.
3. See Figure 7-22. Remove two screws with lockwashers.
4. Remove solenoid, disengaging slot in drive shaft from end
of lever on pinion gear.
5. See Figure 7-23. Remove collar (3) and spring (4).

7-24 2013 Trike Service Supplement: Electrical

HOME

ASSEMBLY 5. Pull pinion gear to the fully engaged position (out) to move
lever toward collar. Move lever sideways as necessary to
FASTENER TORQUE VALUE center between spring coils.

Reverse motor solenoid 70 in-lbs 7.9 Nm 6. See Figure 7-25. Hold solenoid with the lettered side up
screws and capture end of lever in slot of plunger.
Solenoid to reverse motor 45 in-lbs 5.1 Nm 7. Slowly move solenoid toward installed position and secure
jumper nut with screws. Tighten to 70 in-lbs (7.9 Nm).
8. Install reverse motor jumper and secure with nut and
1. See Figure 7-24. With spring oriented as shown, push
lockwasher. Tighten nut to 45 in-lbs (5.1 Nm).
spring into bore until it engages notch at middle of lever.
Verify that ends remain proud of mounting flange. 9. Install reverse motor.
2. Apply a small amount of grease where spring and lever INSTALLATION
mate.
FASTENER TORQUE VALUE
sm06063
Reverse motor bracket screws 39-44 ft-lbs 52.9-59.7 Nm
Reverse motor screws 39-44 ft-lbs 52.9-59.7 Nm
Reverse motor solenoid ener- 24-30 in-lbs 2.7-3.4 Nm
gizer lead nut
Reverse motor solenoid power 60-84 in-lbs 6.8-9.5 Nm
lead nut
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm

1. Remove all residual threadlocking compound from all

threaded holes in differential housing and reverse motor
bracket.
2. If reusing screws, remove all threadlocking compound
using a wire brush or wire wheel.
NOTE
Install new dowel pins if damaged or missing.
Figure 7-24. Engage Spring in Notch
3. Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue) to threads of three screws
and secure reverse motor bracket to differential housing.
sm06064
Tighten screws to 39-44 ft-lbs (52.9-59.7 Nm).
4. See Figure 7-21. Install lockwasher, RCM solenoid ground
(4) and battery ground jumper (3) on lower reverse motor
screw.
5. Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue) to threads of two screws
and fasten reverse motor to bracket. Tighten screws to
39-44 ft-lbs (52.9-59.7 Nm).
6. Install reverse motor solenoid energize lead (2) with nut
(metric) and lockwasher. Tighten to 24-30 in-lbs (2.7-3.4
Nm). Install boot.
7. Install reverse motor power cable (1) with nut (metric) and
lockwasher. Tighten to 60-84 in-lbs (6.8-9.5 Nm). Install
boot.
8. Install right rear wheel. See 2.4 REAR WHEELS.
Figure 7-25. Capture Lever in Slot NOTE
Always check lug nut torque within 500-1000 mi (805-1610
3. Engage ends of spring into chamfered holes in collar and km) after wheel installation.
push collar tight against mounting flange. 9. Connect battery negative (-) cable. Tighten screw to 60-70
in-lbs (6.8-7.9 Nm).
4. Insert two screws with lockwashers through holes in
mounting flange and collar.

2013 Trike Service Supplement: Electrical 7-25

HOME

10. Install seat.

After installing seat, pull upward on seat to be sure it is

locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)

7-26 2013 Trike Service Supplement: Electrical

HOME

REVERSE SWITCHES 7.14

REMOVAL
sm06026
1. Remove seat.
5

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a) 4
2. Disconnect battery negative (-) cable.
3. See Figure 7-26. Remove two screws to release cover (1)
and switch bracket (3) from switch housing.
3
NOTE
Exercise care when removing LED from cover. Switch assembly
must be replaced if tabs (2) on LED are damaged.
4. Gently press tab (2) on each side of LED to disengage
from cover.
2
5. Remove outer fairing. See the service manual.
2
6. Remove reverse switch connector, 4-place Molex, from
T-stud at front of left fairing bracket. Separate connector.
7. Remove two screws to release fairing cap. 1
8. Pull back left side of fairing cap slightly and feed socket
housing through opening.
1. Cover
9. Cut two cable straps to release conduit from handlebar. 2. LED tabs
10. Remove two screws to release switch housing from clutch 3. Switch bracket
lever bracket. 4. Cable strap
5. Switch housing screw (2)
11. If replacing switches or switch housing, proceed as follows:
Figure 7-26. Reverse Switch Disassembly
a. Remove terminals from socket housing.
b. Pull switches to draw conduit and terminals out INSTALLATION
through hole in switch housing.
c. If replacing switches, cut cable strap on each end of FASTENER TORQUE VALUE
conduit and remove from switch wires. Reverse switch housing 72-108 in-lbs 8-12 Nm
screws
Fairing cap screws 25-30 in-lbs 2.8-3.4 Nm
Reverse switch housing cover 35-45 in-lbs 4-5 Nm
screws
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm

1. If installing new switches or switch housing, proceed as

follows:
a. Install conduit on switch wires.
b. Feed terminals and conduit into switch housing and
out through hole. Install new cable strap on each end
of conduit.
c. Fasten switch housing to clutch lever bracket. Tighten
screws to 72-108 in-lbs (8-12 Nm).
d. Install terminals in socket housing. Match numbered
tag on each switch wire with number on wire end of
housing or reference wire color on pin side. Refer to
Table 7-3.

2013 Trike Service Supplement: Electrical 7-27

HOME

8. Connect battery negative (-) cable. Tighten screw to 60-70

Table 7-3. Reverse Switch Connector in-lbs (6.8-7.9 Nm).
SOCKET SIDE TAG PIN SIDE WIRE COLOR
NUMBER
1 Blue After installing seat, pull upward on seat to be sure it is
2 White locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
3 Red
serious injury. (00070b)
4 Orange/White
9. Install seat.
2. Install two new cable straps to secure conduit to
handlebar. sm06104

3. Pull back left side of fairing cap slightly and feed socket
housing through opening. Mate connector and install on
T-stud at front of left fairing bracket.
4. Install fairing cap. Tighten screws to 25-30 in-lbs (2.8-3.4
Nm).
5. Install outer fairing. See the service manual.
NOTE
Exercise care when installing LED in cover. Switch assembly
must be replaced if tabs on LED are damaged.
6. See Figure 7-27. Feed LED through top opening to out-
board side of cover and then gently apply even pressure
to each side until tabs engage.
7. Fasten switch bracket and cover to switch housing. Tighten
screws to 35-45 in-lbs (4-5 Nm).

Figure 7-27. Carefully Install LED in Cover

7-28 2013 Trike Service Supplement: Electrical

HOME

REVERSE MOTOR SYSTEM DIAGNOSTICS 7.15

REVERSE MOTOR SYSTEM Placing the vehicle transmission in gear disables the system
and the RCM turns off the reverse enable lamp by removing
the ground signal on [245] terminal 8.
PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT The reverse motor will not operate if the enable and reverse
switches are pressed simultaneously or if the RCM receives
constant battery voltage on terminal 5 (faulty switch).
The reverse system is an electrical system with an output drive
connected directly to the vehicle drive when in operation.
ed01853
1 2 3
The system uses a:
• Reverse Motor
• Reverse Motor Solenoid
4
• Reverse Control Module (RCM)
• RCM Solenoid
• 150 Amp Circuit Breaker
• Reverse Hand Switch Assembly
The reverse motor and attached reverse motor solenoid,
5
resembles a starter motor. See Figure 7-28. The assembly is
single direction (reverse) only and can not be used to move
the vehicle forward. Voltage to the reverse motor assembly is
provided through a 150 Amp manual reset circuit breaker and 1. Reverse motor
the RCM solenoid, in response to the output of the RCM. 2. Reverse motor solenoid
3. Reverse motor solenoid terminal [248]
Operation 4. Reverse motor high current input terminal [249B]
The RCM processes signals and voltages from several circuits 5. Reverse motor solenoid high current input ter-
to provide an output to the RCM solenoid. The ignition switch minal [249A]
supplies battery voltage through the accessory fuse to [245] Figure 7-28. Reverse Motor and Solenoid Assembly
terminal 4 to power the RCM. The fuel pump fuse provides
battery voltage to [245] terminal 3 when the engine is running.
Placing the vehicle in neutral provides a ground signal to [245]
terminal 2. At this time, the system is ready to be enabled. The ed01856 1
lamp comes on when the system is enabled and does not go
off until you put vehicle in gear or shut off the vehicle.
2
See Figure 7-29. Momentarily pressing the enable switch (2)
on the reverse hand switch assembly, will illuminate the reverse
enable lamp (1). With the system enabled, the lamp will stay
illuminated, until the engine stop switch is turned OFF or the
transmission is in gear or the vehicle is turned off with ignition
switch.
3
Once enabled, pressing the reverse drive switch (3) on the
reverse hand switch assembly sends battery voltage to [245]
terminal 6. The RCM then outputs battery voltage on terminal
9 to energize the RCM solenoid. The reverse motor solenoid
energizes the reverse motor, meshing the motor gear with the
ring gear on the drive axle to move the vehicle in reverse at 1. Reverse enable lamp
about 2 mph. Releasing the reverse drive switch stops the 2. Reverse enable switch
reverse motor and disengages the motor drive gear. 3. Reverse drive switch
Figure 7-29. Reverse Hand Switch Assembly

2013 Trike Service Supplement: Electrical 7-29

HOME

ed01871

1 2

1. Reverse motor high current input terminal [249B]

2. Reverse motor solenoid high current input terminal [249A]
3. Reverse motor solenoid terminal [248]
4. Reverse motor and RCM ground
Figure 7-30. Reverse Motor and Solenoid Assembly

Before proceeding with diagnostic tests, make sure all of the

om01332d
2 following are done:
1
• Check all fuses.
• Battery is fully charged.
• Charging system is working properly.
• Trip the 150 Amp circuit breaker and reset.
• Test functionality of the reverse enable lamp. If the enable
lamp is working improperly proceed to the diagnostic pro-
cedure.
See Figure 7-31. The circuit breaker is manually resettable
with a trip pushbutton and a reset lever.

1. Reset lever (push in direction of arrow to reset) To manually trip the circuit breaker:
2. Manual trip pushbutton 1. Push down on the trip pushbutton and the reset switch
Figure 7-31. Reverse Motor Circuit Breaker will extend out.
2. When the reset switch is extended as shown, the circuit
Diagnostic Tips breaker is open/tripped.

There is no breakout box available for testing the reverse motor 3. To reset, press the reset switch toward the circuit breaker
system. When performing the diagnostic tests, use the HAR- body until an audible click is heard and the switch is fully
NESS CONNECTOR TEST KIT (Part No. HD-41404-C) and seated against the circuit breaker body.
a multimeter.

7-30 2013 Trike Service Supplement: Electrical

HOME

4. If the circuit breaker repeatedly opens under non-strenuous It is very important that the vehicle is starting and running cor-
loading conditions, or if the reverse motor will not operate rectly. If the vehicle is not starting and running properly, it can
after resetting circuit breaker and checking fuses. cause the reverse system to work improperly.
5. Proceed with diagnostics. Connector Information
NOTES For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
• It is a normal function that the pinion on the reverse motor
the harness test kit terminal probes, see A.1 CONNECTORS.
will engage the ring gear when the circuit breaker is
tripped.
• There should be a audible "click" when resetting the circuit
breaker. Press the reset switch until it is fully seated
against the circuit breaker body.
• The reverse enable lamp in the hand control housing may
remain on while the circuit breaker is open.

2013 Trike Service Supplement: Electrical 7-31

HOME

em01375 Reverse Motor

Solenoid [249A]
[248]
Reverse Switch BK
BK (6AWG)
(14AWG)

[249B]
Enable
Reverse
Drive Motor [253]

To Fuel Pump Fuse

[247A] 4 3 1 2
To Accessory Fuse BK
[247B] 4 3 1 2

BK
[251B] GND 7
O/W

W
R
BE

RCM Solenoid [251]

RCM
[251A] BK

TN 2 2 Neutral Input BK GN
O/GY 3 3 Fuel Pump Fuse (14AWG)
O/W 4 4 Accessory Fuse
BE 5 5 Reverse Enable
W 6 6 Reverse Input BK
BK 7 7 Ground
[252B]
R 8 8 LED Ground

GN
BK
R/GN 9 9 RCM Solenoid Power
BK 10 10 RCM Solenoid Ground
[246A] 1 2

BK
[252A] 150A Manual [246B]
TN

1 2
[245B] [245A] Reset Circuit

R/GN
BK
Breaker
To Neutral
Switch

BK

Main Fuse
BK 40A
BK

Red [5B]
Band
A B
R

Battery
BK

R
[128A] [128B]
Right BK BK
GND 2 GN To Start Relay

Starter

Figure 7-32. Simplified Reverse Motor System

7-32 2013 Trike Service Supplement: Electrical

HOME

REVERSE ENABLE INDICATOR 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), test for continuity between [245B] terminals 4
INOPERATIVE and 5.

PART NUMBER TOOL NAME 3. Is continuity present?

HD-41404-C HARNESS CONNECTOR TEST KIT a. Yes. Go to Test 2.
b. No. Go to Test 3.

Table 7-4. Reverse Enable Indicator Inoperative Diagnostic 2. Reverse Enable Switch Test
Faults
1. Disconnect reverse switch [247].
POSSIBLE CAUSES
2. Test for continuity between [247B] terminals 4 and 1.
Open in reverse enable circuit
3. Is continuity present?
Reverse switch assembly malfunction
a. Yes. Replace reverse switch assembly. (1833)
RCM malfunction
b. No. Repair short between (O/W) and (BE) wires.
1. Reverse Enable Circuit Test (5041)
1. Disconnect RCM [245].
3. Reverse Enable Short to Voltage Test
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
1. Disconnect reverse switch [247].
41404-C), jumper [245B] terminal 8 to ground.
2. Turn IGN ON.
3. Turn IGN ON.
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
4. Does the reverse enable indicator illuminate?
41404-C), test for battery voltage on [247B] terminal 1.
a. Yes. Replace RCM. (1831)
4. Is battery voltage present?
b. No. Go to Test 2.
a. Yes. Repair short to voltage on (BE) wire. (5041)
2. Reverse Enable Circuit Continuity Test b. No. Go to Test 4.
1. Turn IGN OFF.
4. Reverse Enable Short to Ground Test
2. Disconnect reverse switch [247].
1. Turn IGN OFF.
3. Test for continuity between [245B] terminal 8 and [247B]
2. Test for continuity to ground on [247B] terminal 3.
terminal 3.
3. Is continuity present?
4. Is continuity present?
a. Yes. Repair short to ground on (R) wire. (5041)
a. Yes. Replace reverse switch assembly. (1833)
b. No. Replace RCM. (1831)
b. No. Repair open on (R) wire. (5041)

REVERSE ENABLE INDICATOR ON AT ALL REVERSE MOTOR SPINS BUT DOES NOT
TIMES DRIVE

PART NUMBER TOOL NAME Table 7-6. Reverse Motor Spins But Does Not Drive
Diagnostic Faults
HD-41404-C HARNESS CONNECTOR TEST KIT
POSSIBLE CAUSES
Ring gear malfunction
Table 7-5. Reverse Enable Indicator On At All Times
Diagnostic Faults Reverse motor malfunction
Reverse motor solenoid malfunction
POSSIBLE CAUSES
Short to power in the reverse enable circuit 1. Ring Gear Test
Short to ground in the reverse enable circuit 1. Inspect the ring gear for damage.
Reverse switch assembly malfunction 2. Is damage present?
RCM malfunction a. Yes. Replace the ring gear. (1824)

1. Reverse Enable Circuit Test b. No. Go to Test 2.

1. Disconnect RCM [245].

2013 Trike Service Supplement: Electrical 7-33

HOME

2. Reverse Motor Solenoid Test 2. Is voltage drop greater than 1 Volt?

1. Perform the reverse motor solenoid test. See a. Yes. Go to Test 5.

7.16 REVERSE MOTOR TESTING, Reverse Motor b. No. Replace the circuit breaker. (1834)
Solenoid.
2. Did reverse motor solenoid pass the test? 5. Vehicle Starter Test
a. Yes. Replace reverse motor. (1825) 1. Perform voltage drop between battery positive and the
high current power from the vehicle starter.
b. No. Replace reverse motor solenoid. (1832)
2. Is voltage drop greater than 1 Volt?
REVERSE MOTOR STALLS OR SPINS TOO a. Yes. Repair/replace the vehicle starter to battery
SLOWLY positive wire. (5041)
b. No. Repair/replace the vehicle starter to circuit
Table 7-7. Reverse Motor Stalls or Spins Too Slowly breaker wire. (5041)
Diagnostic Faults
6. Ground Circuit Test
POSSIBLE CAUSES
1. Perform voltage drop between battery negative and
Manual circuit breaker malfunction reverse motor mounting bolts with reverse motor engaged.
Reverse motor malfunction
2. Is voltage drop greater than 1 Volt?
Reverse motor solenoid malfunction
a. Yes. Clean/repair mounting bolts and mounting sur-
Mechanical malfunction face or ground cable from transmission case to
reverse motor mounting bolt. (5041)
1. Circuit Breaker Test
b. No. Go to Test 7.
1. Inspect the circuit breaker, reset if necessary.
2. Perform voltage drop test from battery positive to reverse 7. Reverse Motor Current Draw On Vehicle
motor solenoid terminal [249B] with reverse motor Test
engaged.
1. Perform reverse motor current draw test on vehicle. See
3. Is voltage drop greater than 1 volt? 7.16 REVERSE MOTOR TESTING.
a. Yes. Go to Test 2. 2. Are test results within range?
b. No. Go to Test 6. a. Yes. Go to Test 8.
b. No. Go to Test 9.
2. Reverse Motor Solenoid Voltage Drop
Test 8. Reverse Motor Test
1. Perform voltage drop test from battery positive to reverse 1. Perform the reverse motor solenoid test. See
motor solenoid terminal [249A] with reverse motor 7.16 REVERSE MOTOR TESTING, Reverse Motor
engaged. Solenoid.
2. Is voltage drop greater than 1 volt? 2. Did reverse motor solenoid pass the test?
a. Yes. Go to Test 3. a. Yes. Replace reverse motor. (1828)
b. No. Replace reverse motor solenoid. (1832) b. No. Replace reverse motor solenoid. (1832)

3. Reverse Motor Solenoid Circuit Test 9. Reverse Motor Free Running Current
1. Perform voltage drop test from battery positive to reverse Draw Test
motor solenoid terminal [252B] with reverse motor
1. Perform reverse motor free running current draw bench
engaged.
test. See 7.16 REVERSE MOTOR TESTING, Testing
2. Is voltage drop greater than 1 volt? Reverse Motor on Bench.
a. Yes. Go to Test 4. 2. Are tests results within range?
b. No. Repair/replace the circuit breaker to reverse motor a. Yes. Repair source of mechanical bind. (1827)
solenoid wire. (5041)
b. No. Replace reverse motor. (1828)
4. Circuit Breaker Voltage Drop Test
1. Perform voltage drop test from battery positive to reverse
motor solenoid terminal [252A] with reverse motor
engaged.

7-34 2013 Trike Service Supplement: Electrical

HOME

REVERSE MOTOR RUNS ON 3. Turn IGN ON.

4. Test for battery voltage on [246B] terminal 1 with the
PART NUMBER TOOL NAME reverse drive button not pushed.
HD-41404-C HARNESS CONNECTOR TEST KIT 5. Is battery voltage present?
a. Yes. Repair short to voltage on (R/GN) wire. (5041)
Table 7-8. Reverse Motor Runs On Diagnostic Faults b. No. Go to Test 5.
POSSIBLE CAUSES
5. RCM Test
RCM malfunction
1. Test for battery voltage on [245B] terminal 6 (W) wire with
Reverse motor malfunction the reverse drive button not pushed.
Reverse motor solenoid malfunction
2. Is battery voltage present?
Short to voltage in ground circuit a. Yes. Go to Test 6.
Reverse switch malfunction
b. No. Replace RCM. (1822)
1. Reverse Solenoid Control Circuit Test
6. RCM Switch Test
1. Trip the circuit breaker.
1. Turn IGN OFF.
2. Disconnect reverse motor solenoid [248].
2. Disconnect [247].
3. Reset the circuit breaker.
3. Turn IGN ON.
4. Turn IGN ON.
4. Test for battery voltage on [245B] terminal 6 (W) wire.
5. Does the reverse motor continue to run on?
5. Is battery voltage present?
a. Yes. Replace the reverse motor solenoid. (1818)
a. Yes. Repair short to voltage on (W) wire. (5041)
b. No. Go to Test 2.
b. No. Repair/replace reverse switch. (1833)
2. RCM Solenoid Circuit Test
REVERSE MOTOR INOPERATIVE
1. Turn IGN OFF.
2. Disconnect [246]. PART NUMBER TOOL NAME

3. Turn IGN ON. HD-41404-C HARNESS CONNECTOR TEST KIT

4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

41404-C), test for battery voltage on [248] with the reverse Table 7-9. Reverse Motor Inoperative Diagnostic Faults
drive button not pushed.
POSSIBLE CAUSES
5. Is battery voltage present?
RCM malfunction
a. Yes. Go to Test 3.
Reverse motor malfunction
b. No. Go to Test 4.
Reverse motor solenoid malfunction
3. Reverse Motor Solenoid Control Circuit Short to voltage in ground circuit
Test Reverse switch malfunction
1. Turn IGN OFF. 1. Enable Switch Function Test
2. Disconnect [251]. 1. Turn IGN ON.
3. Turn IGN ON. 2. Activate enable switch.
4. Test for battery voltage on [248] with the reverse drive 3. Is the reverse enable lamp illuminated?
button not pushed.
a. Yes, lamp illuminates only after enable switch
5. Is battery voltage present? pressed. Go to Test 2.
a. Yes. Repair short to voltage on (BK) wire. (5041) b. Yes, lamp illuminated at all times. Go to
b. No. Replace RCM solenoid. (1818) 7.15 REVERSE MOTOR SYSTEM DIAGNOSTICS,
Reverse Enable Indicator On At All Times.
4. RCM Solenoid Control Circuit Test c. No, neutral lamp functional. Go to Test 17.
1. Turn IGN OFF.
2. Disconnect [245].

2013 Trike Service Supplement: Electrical 7-35

HOME

2. RCM Circuit Test 8. RCM Solenoid Ground Circuit Test

1. With the reverse enabled and the reverse drive button 1. Turn IGN OFF
pressed, using HARNESS CONNECTOR TEST KIT (Part
2. Measure resistance between [246B] terminal 2 and ground.
No. HD-41404-C), test for battery voltage at reverse motor
solenoid [248]. 3. Is resistance less than 1 Ohm?
2. Is battery voltage present? a. Yes. Replace RCM solenoid. (1832)
a. Yes. Go to Test 3. b. No. Go to Test 9.
b. No. Go to Test 6.
9. RCM Ground Circuit Test
3. Reverse Motor High Current Circuit Test 1. Disconnect [245].
1. With the reverse drive button pressed check for battery 2. Check for continuity between [245B] terminal 10 and
voltage at the reverse motor solenoid [249B]. [246B] terminal 2.
2. Is battery voltage present? 3. Is continuity present?
a. Yes. Go to Test 4. a. Yes. Replace RCM. (1831)
b. No. Go to Test 14. b. No. Repair open on (BK) wire. (5041)

4. Ground Circuit Test 10. RCM Solenoid Control Circuit Open Test
1. Test for continuity between the reverse motor mounting 1. Turn IGN OFF.
bolts to ground.
2. Check for continuity between [246B] terminal 1 and [245B]
2. Is continuity present? terminal 9.
a. Yes. Go to Test 5. 3. Is continuity present?
b. No. Clean/repair mounting bolts and mounting sur- a. Yes. Go to Test 11.
face. (5041)
b. No. Repair open in (R/GN) wire. (5041)
5. Reverse Motor Solenoid Test
11. RCM Test
1. Perform the reverse motor solenoid test. See
7.16 REVERSE MOTOR TESTING, Reverse Motor 1. Turn IGN ON.
Solenoid. 2. With the reverse drive button pressed, check for battery
2. Did reverse motor solenoid pass the test? voltage at [245B] terminal 6.
a. Yes. Replace reverse motor. (1828) 3. Is battery voltage present?
b. No. Replace reverse motor solenoid. (1832) a. Yes. Replace RCM. (1831)
b. No. Go to Test 12.
6. Reverse Motor Control Circuit Test
1. With the reverse drive button pressed, check for battery 12. RCM Drive Switch Circuit Test
voltage at RCM solenoid [251B] and [251A]. 1. Turn IGN OFF.
2. Is battery voltage present at both terminals? 2. Check for continuity between [247B] terminal 2 and [245B]
a. Yes. Repair open in (BK) wire between RCM solenoid terminal 6.
[251B] and reverse motor solenoid [248]. (5041)
3. Is continuity present?
b. No, only one terminal. Go to Test 7. a. Yes. Replace reverse switch. (1833)
c. No, neither terminal. Go to Test 13. b. No. Repair open in (W) wire. (5041)

7. RCM Solenoid Control Circuit Test 13. Circuit Breaker Supply Voltage Test
1. Turn IGN OFF. 1. Check for battery voltage at circuit breaker [252A].
2. Disconnect [246]. 2. Is battery voltage present?
3. Turn IGN ON. a. Yes. Repair open in (BK) wire between RCM solenoid
[251A] and circuit breaker [252A]. (5041)
4. With the reverse drive button pressed, check for battery
voltage at [246B] terminal 1 (R/GN) wire. b. No. Repair open in (BK) wire between circuit breaker
[252A] and starter. (1830)
5. Is battery voltage present?
a. Yes. Go to Test 8.
b. No. Go to Test 10.

7-36 2013 Trike Service Supplement: Electrical

HOME

14. Reverse Motor Solenoid Test 3. Is continuity present?

1. With the reverse drive button pressed, check for battery a. Yes. Go to Test 21.
voltage at the reverse motor solenoid [249A]. b. No. Repair open in (BK) wire. (5041)
2. Is battery voltage present?
21. Enable Switch Circuit Test
a. Yes. Replace reverse motor solenoid. (1832)
1. Disconnect RCM [245].
b. No. Go to Test 15.
2. Turn IGN ON.
15. Reverse Motor Circuit Solenoid Test 3. With reverse enable button pressed, check for battery
1. With the reverse drive button pressed, check for battery voltage at RCM [245B] terminal 5.
voltage at the circuit breaker [252B].
4. Is battery voltage present?
2. Is battery voltage present? a. Yes. Go to Test 22.
a. Yes. Repair open in (BK) wire between reverse motor
b. No. Go to Test 24.
solenoid [249A] and circuit breaker [252B]. (5041)
b. No. Go to Test 16. 22. Neutral Circuit Open Test
1. Turn IGN OFF.
16. Circuit Breaker Test
2. Disconnect TSSM [30].
1. With the reverse drive button pressed, check for battery
voltage at the circuit breaker [252A]. 3. Turn IGN ON.
2. Is battery voltage present? 4. With the transmission in gear test for battery voltage at
a. Yes. Replace circuit breaker. (1834) RCM [245B] terminal 2.

b. No. Repair open in (BK) wire between circuit breaker 5. Is voltage present?
[252A] and starter. (5041) a. Yes. Go to Test 23.
b. No. Repair open in (TN) wire. (5041)
17. Neutral Circuit Test
1. Place the transmission in neutral. 23. RCM Ignition Power Test
2. Is the neutral lamp functional? 1. With vehicle running, test for voltage at RCM [245B] ter-
a. Yes. Go to Test 18. minal 3.

b. No. See neutral lamp diagnostics. 2. Is voltage present?

a. Yes. Replace RCM. (1831)
18. Accessory Fuse Test b. No. Repair open in (O/GY) wire. (5041)
1. Inspect the accessory fuse.
2. Is fuse good?
24. RCM Accessory Power Circuit Test
a. Yes. Go to Test 19. 1. Turn IGN OFF.

b. No. Repair short to ground in accessory circuit. (5043) 2. Disconnect reverse switch [247].
3. Test for battery voltage at RCM handlebar switch [247B]
19. Accessory Circuit Open Test terminal 4.
1. Turn IGN OFF. 4. Is battery voltage present?
2. Disconnect RCM [245]. a. Yes. Go to Test 25.
3. Turn IGN ON. b. No. Repair open in (O/W) wire between RCM
handlebar switch [247B] and RCM [245B]. (5043)
4. Check for battery voltage at RCM [245B] terminal 4.
5. Is battery voltage present? 25. RCM Handlebar Switch Test
a. Yes. Go to Test 20. 1. With the enable switch pressed check for continuity
b. No. Repair open in (O/W) wire. (5043) between reverse switch [247A] terminals 4 and 1.
2. Is continuity present?
20. Ground Circuit Open Test a. Yes. Repair open in (BE) wire. (5041)
1. Turn IGN OFF.
b. No. Replace RCM handlebar switch assembly. (1833)
2. Test for continuity between RCM [245B] terminal 7 and
ground.

2013 Trike Service Supplement: Electrical 7-37

HOME

REVERSE MOTOR TESTING 7.16

TESTING REVERSE MOTOR ON ed01876
MOTORCYCLE 3
2
PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT

Reverse Motor Current Draw Test

NOTE
1
Make sure the battery is fully charged.
See Figure 7-33. Check reverse motor current draw with an
induction ammeter before disconnecting battery.
1. Raise rear wheels of vehicle off the ground. See the ser-
vice manual.
4
2. Verify the transmission is in neutral.
3. Disconnect connector [13C] at rear of fuel tank.
4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) with purple probes and a patch cord, place a
jumper between P & A, fuse terminal 1E to fuel pump fuse
4B. 1. Reverse motor
5. Place transmission in neutral. Turn ignition switch ON and 2. Motor control solenoid
run/stop switch to RUN. 3. Induction ammeter
4. Battery
6. Clamp induction ammeter over positive battery cable next
to reverse motor. Figure 7-33. Reverse Motor Current Draw Test

7. Activate reverse motor controls while reading ammeter.

a. Typical reverse motor current draw is approximately
TESTING REVERSE MOTOR ON BENCH
90 Amperes. Free Running Current Draw Test
b. If current draw exceeds 150 Amperes, the problem 1. Place reverse motor in vise, using a clean shop towel to
may be in the reverse motor or reverse motor drive. prevent scratches or other damage.
Remove reverse motor for further tests. See
7.16 REVERSE MOTOR TESTING, Testing Reverse 2. See Figure 7-34. Attach one heavy jumper cable (6 gauge
Motor on Bench. minimum).
a. Connect one end to the starter mounting flange.
NOTE
b. Connect the other end to the negative (-) terminal of
Use a DC current probe if an induction ammeter is not avail- a fully charged battery.
able.
3. Connect a second heavy jumper cable (6 gauge minimum).
a. Connect one end to the positive (+) terminal of the
battery.
b. Connect the other end to the battery terminal 4 on
the reverse motor solenoid. Place an induction
ammeter over cable.

4. Connect a smaller jumper cable (14 gauge minimum).

a. Connect one end to the positive (+) terminal of the
battery.
b. Connect the other end to the solenoid relay terminal.

7-38 2013 Trike Service Supplement: Electrical

HOME

5. Check ammeter reading. 2. Observe reverse motor pinion.

a. Ammeter should show 90 Amps maximum. a. If reverse motor pinion extends strongly, solenoid is
working properly.
b. If reading is higher, replace the reverse motor
assembly. See the service manual. b. If reverse motor pinion does not extend strongly,
replace the solenoid.
c. If starter current draw on the vehicle was over 90
Amps and this test was within specification, there may
be a problem with the mechanical components of the ed01873
reverse drive.
2
ed01877
3
2

5
1

6 1. Reverse motor
2. Motor control solenoid
3. Battery
1. Reverse motor Figure 7-35. Pull-In Test
2. Motor control solenoid
3. Induction ammeter
4. Battery
SOLENOID HOLD-IN TEST
5. Solenoid terminal 1. See Figure 7-36. With test leads still connected in the
6. Mounting flange bolt manner specified in 7.16 REVERSE MOTOR TESTING,
Figure 7-34. Free Running Current Draw Test Solenoid Pull-In Test, disconnect solenoid motor ter-
minal/battery negative test lead at negative battery post
only; reconnect loose end of this test lead to positive bat-
REVERSE MOTOR SOLENOID tery post.
Do not disassemble solenoid. Before testing, disconnect field 2. Observe reverse motor pinion.
wire from motor terminal as shown in Figure 7-35. a. If reverse motor pinion remains extended, solenoid
To prevent damage to the solenoid, perform each test for only is working properly.
three to five seconds. b. If reverse motor pinion retracts, replace the solenoid.
Perform the solenoid pull-in, hold-in, and return tests together
in one continuous operation. Conduct all three tests one after
the other in the sequence given without interruption.

SOLENOID PULL-IN TEST

1. See Figure 7-35. Use a 12 Volt battery and connect three
separate test leads as follows:
a. Solenoid housing to negative battery post.
b. Solenoid motor terminal to negative battery post.
c. Solenoid relay terminal to positive battery post.

2013 Trike Service Supplement: Electrical 7-39

HOME

2. Observe reverse motor pinion.

ed01874
a. If reverse motor pinion retracts, solenoid is working
2 properly.
b. If reverse motor pinion does not retract, replace the
solenoid.

ed01875

1 2

1
3

1. Reverse motor
2. Motor control solenoid 3
3. Battery
Figure 7-36. Hold-In Test

SOLENOID RETURN TEST

1. Reverse motor
1. See Figure 7-37. With test leads still connected in the 2. Motor control solenoid
manner specified at the end of 7.16 REVERSE MOTOR 3. Battery
TESTING, Solenoid Hold-In Test, disconnect solenoid
relay terminal/positive battery post test lead at either end. Figure 7-37. Return Test

7-40 2013 Trike Service Supplement: Electrical

HOME

REAR LIGHTING DIAGNOSTICS 7.17

REAR LIGHTING
ed01864
1 2
General
The rear lighting system uses two identical tail lamp assemblies
and an independent license plate lamp assembly. Inline with
the main harness lighting connector [7A] are a tail lamp jumper
(used in conjunction with the reverse motor system if equipped)
and a converter module. See Figure 7-40.

Rear Running Lamps

See Figure 7-38. The tail lamp assemblies use one dual-fila-
ment bulb each.
• One filament for running lights and the other for brake and
turn indication.
• The running lights are powered through the lighting fuse.
1. Tail lamp connector [93]
• The license plate lamp is a single filament bulb and oper- 2. Harness connector [94]
ates with the running lights. The license plate lamp is
powered through the accessory fuse. Figure 7-39. Tail Lamp Assembly

• Tail lamps and the license plate lamp illuminate when the
ignition switch is ON. DIAGNOSTICS
Brake Lamps and Rear Turn Directionals PART NUMBER TOOL NAME
Brake and rear turn indicators use the same lamps in the tail HD-35500 DIGITAL VOM
lamp assemblies, but different filaments. Pressing the brake
pedal or actuating the front brake lever causes the brake lamps When performing the diagnostic tests, use a DIGITAL VOM
to illuminate. Applying brakes during a turn will illuminate the (Part No. HD-35500), or equivalent, for making the voltage and
opposite lamp from the indicating directional, if a directional resistance measurements, and where possible, amperage.
has been selected. When indicating a right or left turn, the
appropriate directional lamp flashes regardless of brakes being Use the flowcharts that follow to supplement the Touring EDM
applied. when troubleshooting lighting and turn signal problems.

Diagnostic Tips
ed01858
• When DTCs B1121, B1122, or B1141 are present, refer
to the Touring EDM, section 3.15 TSM/HFSM: TURN
1 3 SIGNAL ERRORS AND DTCS. Refer to section 3.15 when
2 front and rear directionals appear to be faulty.
• Rear directionals work in tandem with the front directionals.
If the rear or front directional is not working when it should
be, check the integrity of the bulb in the affected directional
before proceeding with the flowcharts.
• If the brake lamps and license plate lamp are inoperative
at the same time, check the accessory fuse. Other
accessories will also be inoperative at that time.
• Lighting ground is through the lighting harness to the
vehicle frame. Make sure the ground connections are good
1. Left tail lamp before replacing parts and assemblies.
2. License plate lamp
3. Right tail lamp Connector Information
Figure 7-38. Rear Lighting For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see A.1 CONNECTORS.

2013 Trike Service Supplement: Electrical 7-41

HOME

em00769 From Main

Harness [7A] Circuit Board
[7D] 7 6 5 3 2 1 1
2

O/W
R/Y

BN
BK
V
BE 3 3 1 1 BE BE Right Rear
BN 4 4 3 3 R/Y R/Y Running/Turn

BE
BE
Tail And Turn Signal 5 BK Lamp
Converter Module BK 6 6 4 4 BK
BE
BE [94RB] [94RA] [93RA] [93RB]
R/Y
BK
V
O/W
BN

V/BN 1 1 BN
BE 2 2 BE
BK 3 3 BK
V 4 4 V [233A] [233B]
BE 5 5 BE
BK 6 6 BK License
O/W 7 7 BE BE 1 1 BE BE
BK 8 8 BK BK 3 3 BK BK
Plate Lamp

[7C] [7B]

Circuit Board
1
2
BE 3 3 1 1 BE BE
Left Rear
V 4 4 3 3 R/Y R/Y
Running/Turn
5 BK
BK 6 6 4 4 BK
Lamp

[94LB] [94LA] [93LA] [93LB]

Figure 7-40. Rear Lighting System

BRAKE LAMPS INOPERATIVE 3. Do brake lamps illuminate with either control?

a. Yes, Brake lamps illuminate only with front brake
PART NUMBER TOOL NAME control. Go to Test 2.
HD-41404-C HARNESS CONNECTOR TEST KIT b. Yes, Brake lamps illuminate only with rear brake
control. Go to Test 4.

Table 7-10. Brake Lamps Inoperative Diagnostic Faults c. No, One tail lamp fails to illuminate. Go to Test 6.
d. No, Both tail lamps fail to illuminate. Go to Test
POSSIBLE CAUSES
11.
Rear brake switch malfunction
Front brake lamp malfunction 2. Rear Stop Lamp Switch Voltage Test
Open in accessory circuit 1. Turn IGN OFF.
Open in brake relay circuit 2. Disconnect rear stop lamp switch [121].

1. Stop Lamp Operational Test 3. Turn IGN ON.

1. Turn IGN ON. 4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for battery voltage on
2. Activate the front and rear brake controls. [121A] terminal 2.
5. Is battery voltage present?
a. Yes. Go to Test 3.
b. No. Repair open on (O/W) wire. (5041)

3. Rear Stop Lamp Switch Test

1. Turn IGN OFF.

7-42 2013 Trike Service Supplement: Electrical

HOME

2. Check for continuity between [121A] terminals 1 and 2 9. Converter Module Test
with the rear brake applied.
1. Turn IGN OFF.
3. Is continuity present?
2. Disconnect tail and turn signal converter module [7B].
a. Yes. Repair open in (R/BE) wire.
3. Turn IGN ON.
b. No. Replace rear stop lamp switch. (5141)
4. While activating the front or rear brake controls, check for
4. Front Stop Lamp switch Voltage Test battery voltage at tail and turn signal converter module
[7C] terminal 1 and ground or terminal 4 and ground.
1. With IGN OFF, disconnect right hand control [22].
5. Is battery voltage present at both terminals?
2. Turn IGN ON.
a. Yes. Go to Test 10.
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for battery voltage on right b. No. Replace converter module. (6809)
hand control [22B] terminal 1.
10. Circuit Board Test
4. Is battery voltage present?
1. Turn IGN OFF.
a. Yes. Go to Test 5.
2. Connect tail and turn signal converter module [7B].
b. No. Repair open on (O/W) wire. (5041)
3. Disconnect [94B].
5. Front Stop Lamp Switch Test 4. Turn IGN ON.
1. Turn IGN OFF.
5. While activating the front or rear brake controls, check for
2. Check continuity between right hand control [22A] ter- battery voltage between [94B] terminal 4 and ground.
minals 1 and 2 with the front brake applied.
6. Is battery voltage present?
3. Is continuity present? a. Yes. Replace circuit board on inoperative side. (5215)
a. Yes. Repair open on (R/BE) wire. (5041)
b. No. Repair open between [94B] terminal 4 and tail
b. No. Replace front stop lamp switch. (5176) and turn signal converter module [7B]. (5041)

6. Bulb Test 11. Brake Fuse Test

1. Inspect the inoperative bulb. 1. Inspect the brake fuse.
2. Is bulb good? 2. Is fuse good?
a. Yes. Go to Test 7. a. Yes. Go to Test 12.
b. No. Replace bulb. (5197) b. No. Repair short to ground and replace brake fuse.
(5041)
7. Inoperative Lamp Voltage Test
1. Disconnect circuit board [93] on inoperative side.
12. Stop Lamp Circuit Voltage Test
1. Disconnect tail and turn signal converter module [7A].
2. Turn IGN ON.
2. While activating the front or rear brake controls, using
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
HARNESS CONNECTOR TEST KIT (Part No. HD-41404-
41404-C) and a multimeter, test for battery voltage
C) and a multimeter, test for battery voltage between tail
between circuit board [93] terminal 3 and ground while
and turn signal converter module [7A] terminal 6 and
activating the front or rear brake controls.
ground.
4. Is battery voltage present?
3. Is battery voltage present?
a. Yes. Go to Test 8.
a. Yes. Go to Test 13.
b. No. Go to Test 9.
b. No. Go to Test 14.
8. Inoperative Lamp Ground Circuit Test 13. Stop Lamp Circuit Ground Test
1. Turn IGN OFF.
1. Turn IGN OFF.
2. Measure the resistance between [93A] terminal 4 and
2. Measure the resistance between [7A] terminal 5 and
ground.
ground.
3. Is resistance less than 0.5 Ohms?
a. Yes. Repair or replace the bulb socket assembly.
(5215)
b. No. Repair open or poor connection between [93A]
terminal 4 and ground. (5041)

2013 Trike Service Supplement: Electrical 7-43

HOME

3. Is the resistance less than 0.5 Ohms? 2. Is battery voltage present?

a. Yes. Replace the tail and turn signal converter a. Yes. Go to Test 16.
module. (6809)
b. No. Repair open in (R/BE) wire. (5041)
b. No. Repair open between tail and turn signal con-
verter module [7A] terminal 5 and ground. (5041) 16. Brake Relay Coil Ground Circuit Test
1. Turn IGN OFF.
14. Brake Relay Switch Supply Circuit Test
2. Test for continuity between [64-2B] socket terminal 3B
1. Turn IGN OFF.
and ground.
2. Remove the brake relay.
3. Is continuity present?
3. Turn IGN ON. a. Yes. Go to Test 17.
4. Test for battery voltage at [64-2B] socket terminal 3A. b. No. Repair open between [64-2B] socket terminal 3B
5. Is battery voltage present? and ground. (5041)
a. Yes. Go to Test 15.
17. Brake Relay Test
b. No. Repair open on (O/V) wire. (5041) 1. Test for continuity between [64-2B] socket terminal 2B
and tail and turn signal converter module [7A] terminal 6.
15. Brake Relay Coil Supply Circuit Test
2. Is continuity present?
1. With stop lamp switch applied, test for battery voltage at
[64-2B] socket terminal 2A. a. Yes. Replace brake relay. (1407)
b. No. Repair open in (R/Y) wire. (5041)

7-44 2013 Trike Service Supplement: Electrical

HOME

BAS FUNCTION: DTCS B1151, B1152, AND

B1153 7.18
GENERAL turned OFF. If the ignition is turned ON with the vehicle in
neutral the siren may sound even if the security system
BAS Operation is disabled. Therefore, the ignition switch should be turned
ON with the vehicle in gear and then shifted to neutral.
Under normal driving conditions the TSM/TSSM/HFSM uses
Once in neutral the vehicle can be started normally.
the BAS along with speed input provided from the ECM to know
when to automatically cancel the turn signals after a turn. The DIAGNOSTICS
TSM/TSSM/HFSM will disable turn signal lamps and starter
activation and will send a message to the ECM to shut down
PART NUMBER TOOL NAME
the ignition and the fuel pump if the vehicle is tipped over. The
odometer will display "tIP" when a tip-over condition is present. HD-48650 DIGITAL TECHNICIAN II

BAS Restart Diagnostic Tips

To restart the vehicle after shutdown has occurred:
• Use DIGITAL TECHNICIAN II (Part No. HD-48650) to
1. Return the vehicle to an upright position. verify Trike learn.
2. Cycle the IGN OFF-ON before restarting the vehicle. • Verify no other circuits are tied to terminal 11 of the
TSM/HFSM.
Bank Angle Sensor (BAS)
• A tip-over event, short to ground, short to battery, and out-
These DTCs set when a TSM/HFSM is configured for Trike of-range fault cannot be detected when the security func-
use and a fault is detected with the BAS. tion is in the alarm mode (lights flashing, siren sounding).
NOTES If "tiP" is displayed on the odometer after the vehicle has been
• On Trike models, it is a normal condition for the engine to returned to the upright position, then perform the procedure to
start and stall during a start attempt with the security reset the "tiP" condition. See the electrical diagnostic manual.
system armed. This is because the external bank angle If the vehicle still displays "tiP" and starts then stalls, remove
sensor (BAS) is attached to the security system wiring. If the BAS. Ensure proper length fasteners are mounting the BAS
a start attempt occurs with the security system armed, it bracket to the frame. If fasteners are too long and a tip event
will also trigger a full alarm state, the turn signal will flash is encountered, the procedure to reset the BAS by cycling the
alternately and if equipped with the security siren, the siren ignition may not work.
sounds.
Connector Information
• Vehicles equipped with a siren and an external BAS will
react differently when disarming than other vehicles. These For additional information about the connectors in the following
vehicles should be placed in gear when the ignition is diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see A.1 CONNECTORS.

Table 7-11. Trike Bank Angle Sensor (BAS) DTCs

DTC DESCRIPTION START WITH DIAGNOSTIC PROCEDURE

B1151 Bank Angle Sensor Short to Ground DTC B1151
B1152 Bank Angle Sensor Short to Battery DTCs B1152 and B1153
B1153 Bank Angle Sensor Open DTCs B1152 and B1153

2013 Trike Service Supplement: Electrical 7-45

HOME

em01351
Security
Siren [142A] [142B]
(Optional)
Power 1 1 BN/GY

Start Relay
Signal 2 2 LGN/BN
5 87
4 87A
Ground 3 3 BK/GN 3 30
TN/GN 2H 2 85
1 86

[64B] [64A]

Ignition
Switch
2 3 [33A]
2 3 [33B]
R/BK
R

Ignition
Fuse
15A
R/BK 1E 1F GY

LGN/BN
LGN/BN

TN/GN
BN/GY

BK/GN
TN/GN
GY

GY
BK R A B R R 2A 2B BN/GY
[30B] 1 2 9 11 12 [134B] C B A
40A 15A
Main Fuse Battery [30A] 1 2 9 11 12 [134A] C B A
Fuse

Ground

Signal
Power
Battery

TSSM Or HFSM
BAS

Figure 7-41. Siren Circuit

DTC B1151 6. Is continuity present?

a. Yes. Go to Test 2.
PART NUMBER TOOL NAME b. No. Go to Test 4.
HD-42682 BREAKOUT BOX
2. BAS Test
1. Disconnect BAS [134B].
Table 7-12. DTC B1151 Diagnostic Faults
2. Test for continuity at breakout box between terminals 11
POSSIBLE CAUSES
and 12.
BAS malfunction
3. Is continuity present?
Alarm siren malfunction
a. Yes. Go to Test 3.
Open in battery fuse circuit
b. No. Replace BAS. (6968)
Short to ground in battery fuse circuit
3. Siren Test
1. Signal Circuit Test
1. Disconnect alarm siren [142B].
1. Turn IGN OFF.
2. Test for continuity at breakout box between terminals 11
2. Set the engine stop switch to RUN.
and 12.
3. Disarm security system.
3. Is continuity present?
4. Connect BREAKOUT BOX (Part No. HD-42682) between a. Yes. Repair short to ground in (LGN/BN) wire. (5041)
wire harness [30B] and TSM/TSSM/HFSM [30A]. See the
electrical diagnostic manual. b. No. Replace alarm siren. (6970)

5. Using a multimeter, test for continuity at breakout box 4. Wiggle Test

between terminals 11 and 12.
1. Perform Wiggle Test. See the electrical diagnostic manual.

7-46 2013 Trike Service Supplement: Electrical

HOME

2. Is an intermittent open present? 4. Ground Circuit Open Test

a. Yes. Repair short to ground in (LGN/BN) wire. (5041) 1. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
b. No. Replace BAS. (6968) 41404-C) and a multimeter, test for continuity between
breakout box terminal 9 and BAS [134B] terminal B.
DTC B1152, B1153 2. Is continuity present?
a. Yes. Go to Test 5.
PART NUMBER TOOL NAME
b. No. Repair open in (TN/GN) wire. (5041)
HD-41404-C HARNESS CONNECTOR TEST KIT
HD-42682 BREAKOUT BOX 5. Ground Circuit Wiggle Test
1. Perform Wiggle Test between BAS [134B] and
Table 7-13. DTC B1152, B1153 Diagnostic Faults TSM/TSSM/HFSM [30B]. See the electrical diagnostic
manual.
POSSIBLE CAUSES
2. Is an intermittent open present?
Open in signal circuit
a. Yes. Repair open in (TN/GN) wire. (5041)
Open in ground circuit
b. No. Go to Test 10.
Open in ignition circuit
BAS malfunction 6. Ignition Circuit Open Test
1. Turn IGN OFF.
1. Signal Circuit Voltage Test
1. Connect BREAKOUT BOX (Part No. HD-42682) between 2. Disconnect BAS [134].
wire harness [30B] and TSM/TSSM/HFSM [30A]. See the 3. Turn IGN ON.
electrical diagnostic manual.
4. Test for battery voltage from BAS [134B] terminal C to
2. Turn IGN ON. ground.
3. Place transmission in neutral. 5. Is battery voltage present?
4. Measure voltage at breakout box between terminals 11 a. Yes. Go to Test 7.
and 12.
b. No. Repair open in (GY) wire. (5041)
5. Is voltage between 0.5-1.0V?
a. Yes. Go to Test 2. 7. BAS Signal Voltage Test
1. Test for battery voltage from BAS [134B] terminal A to
b. No. Go to Test 6.
ground.
2. BAS Connection Test 2. Is battery voltage present?
1. Turn IGN OFF. a. Yes. Go to Test 8.

2. Disconnect TSM/TSSM/HFSM [30A] from breakout box. b. No. Go to Test 12.

3. Inspect BAS [130] for damaged terminals, terminals 8. BAS Ground Circuit Test
backed out or corrosion.
1. Turn IGN OFF.
4. Terminal problems present?
2. Disconnect TSM/TSSM/HFSM [30A] from breakout box.
a. Yes. Repair connection, clear DTCs and verify repairs.
(5041) 3. Check for continuity between BAS [134B] terminal B and
ground.
b. No. Go to Test 3.
4. Is continuity present?
3. Signal Circuit Open Test a. Yes. Repair short to ground in (TN/GN) wire. (5041)
1. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
b. No. Go to Test 9.
41404-C) and a multimeter, test for continuity between
breakout box terminal 11 and BAS [134B] terminal B.
9. TSM/TSSM/HFSM Ground Circuit Test
2. Is continuity present? 1. Check for continuity between breakout box terminal 9 and
a. Yes. Go to Test 4. BAS [134B] terminal B.
b. No. Repair open in (LGN/BN) wire. (5041) 2. Is continuity present?
a. Yes. Replace BAS. (6968)
b. No. Repair open in (TN/GN) wire. (5041)

2013 Trike Service Supplement: Electrical 7-47

HOME

10. BAS Ignition Circuit Test 2. Is an intermittent open present?

1. Check for continuity between breakout box terminal 2 and a. Yes. Repair open in (GY) wire. (5041)
BAS [134B] terminal C. b. No. Replace BAS. (6967)
2. Is continuity present?
12. TSM/TSSM/HFSM Test
a. Yes. Go to Test 11.
1. Turn IGN OFF.
b. No. Repair open in (GY) wire. (5041)
2. Disconnect TSM/TSSM/HFSM [30A] from breakout box.
11. Ignition Circuit Wiggle Test 3. Check for continuity between breakout box terminal 11
1. Perform Wiggle Test between BAS [134B] and and BAS [134B] terminal A.
TSM/TSSM/HFSM [30B]. See the electrical diagnostic
4. Is continuity present?
manual.
a. Yes. Replace TSM/TSSM/HFSM. (6963)
b. No. Repair open in (LGN/BN) wire. (5041)

7-48 2013 Trike Service Supplement: Electrical

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
A.1 CONNECTORS.........................................................................................................................A-1
A.2 WIRING DIAGRAMS.................................................................................................................A-5

APPENDIX A WIRING
NOTES
HOME

CONNECTORS A.1
CONNECTORS
NOTE
Connectors associated with the optional reverse motor system
may not be present on motorcycle being serviced.

Table A-1. Connector Locations

NO. DESCRIPTION TYPE TERMINAL LOCATION

PROBE
COLOR
[1] Main to interconnect harness 16-place Molex MX 150 Sealed Gray Inner fairing - right radio support
(BK) bracket
[2] Main to interconnect harness 12-place Molex MX 150 Sealed Gray Inner fairing - left radio support
(GY) bracket
[4] Accessory 4-place Deutsch DT Sealed Black Under seat
(BK)
[5] Main fuse 2-place Delphi 800 Metripack Red Under left side cover
Sealed (BK)
[6] Audio to interconnect harness 6-place Deutsch DT Sealed Black Inner fairing - left side of radio
(BK)
[7] Rear fender lights harness 8-place Tyco 070 Multilock Gray Intermediate frame (under seat)
Unsealed (BK)
[12] Tour-Pak lights 3-place Tyco 070 Multilock Gray Inside Tour-Pak
Unsealed (BK)
[13] Fuel tank harness 4-place Tyco 070 Multilock Gray Behind fuel tank (under seat)
Unsealed (BK)
[15] Main to interconnect harness 4-place Delphi 630 Sealed (BK) Gray Inner fairing - right fairing bracket
[21] Indicator lamps 10-place Tyco 070 Multilock Gray Inner fairing - above radio
Unsealed (BK)
[22] Interconnect to right handlebar 12-place Molex MX 150 Sealed Gray Inner fairing - right fairing support
switches (BK) bracket
[24] Interconnect to left handlebar 16-place Molex MX 150 Sealed Gray Inner fairing - left fairing support
switches (GY) brace
[27] Radio 23-place Tyco Superseal Breakout Box Inner fairing - back of radio (right
Sealed (BK) side)
[29] HDI position lamp Flag terminals Gray Back of headlamp
[30] TSM, TSSM or HFSM 12-place Deutsch DT Sealed Breakout Box Under right side cover
(GY)
[31L] Left front turn signal/auxiliary 4-place Tyco 070 Multilock Gray Inner fairing - left fairing support
lamp Unsealed (BK) brace (outboard side)
[31R] Right front turn signal/auxiliary 4-place Tyco 070 Multilock Gray Inner fairing - right fairing support
lamp Unsealed (BK) brace (outboard side)
[32] Front fender tip lamp jumper 2-place Tyco 070 Multilock Gray Inner fairing - below upper for bracket
harness (DOM) Unsealed (BK) (left side)
[33] Ignition Switch Faston 250 Spade terminals Red Bottom of ignition switch
(BK)
[34] Right front speaker Tyco Insulated Spade terminals Gray Inner fairing (back of speaker)
(BK)
[35] Left front speaker Tyco Insulated Spade terminals Gray Inner fairing (back of speaker)
(BK)
[38] Headlamp Tyco Unsealed Spade (BK) Gray Inner fairing (back of headlamp)

2013 Trike Service Supplement: Appendix A Wiring A-1

HOME

Table A-1. Connector Locations

NO. DESCRIPTION TYPE TERMINAL LOCATION

PROBE
COLOR
[39] Speedometer 12-place Delphi Micro 64 Breakout Box Inner fairing (back of speedometer)
Sealed (GY)
[41] Rear right speaker/passenger 6-place Molex MX 150 Sealed Black Inside rear right speaker box
controls (BK)
[42] Rear left speaker/passenger 6-place Molex MX 150 Sealed Black Inside rear left speaker box
controls (BK)
[47] Stator 3-place Dekko (BK) Green Bottom of voltage regulator (left side)
[50] CB antenna cable - Inner fairing - back of CB module
[51] Radio antenna cable - Inner fairing - back of radio (left side)
[53] Console pod 12-place Deutsch DTM Sealed Black Rear of battery box (under seat)
(BK)
[64] Fuse block/relays Delphi PED 280 Sealed Gray Under left side cover
[65] VSS 3-place Delphi GT 150 Sealed Gray Top of transmission case (under
(BK) starter)
[76] Passenger headset 7-place DIN (BK) Below rear left speaker box
[77] Voltage regulator 2-place Dekko (BK) Green Bottom of voltage regulator (right
side)
[78] ECM 73-place Delphi Micro 64 Breakout Box Under seat
Sealed (BK)
[79] CKP sensor 2-place Deutsch DTM Sealed Brown Rear of lower front frame cross-
(BK) member
[80] TMAP sensor 4-place Bosch Compact 1.1M Gray Top of induction module
Sealed (BK)
[83] Ignition coil 4-place Delphi GT 150 Sealed Gray Bottom front of battery tray
(BK)
[84] Front fuel injector 2-place Molex BPT Sealed (BK) Purple Below fuel tank (left side)
[85] Rear fuel injector 2-place Molex BPT Sealed (BK) Purple Below fuel tank (left side)
[90] ET sensor 2-place Delphi GT 150 Sealed Gray Back of front cylinder (left side)
(BK)
[91] DLC 4-place Deutsch DT Sealed Black Under left side cover
(GY)
[93L] Tail lamp 4-place Tyco 070 Multilock Gray Circuit board under tail lamp
Unsealed (BK) assembly (Left side)
[93R] Tail lamp 4-place Tyco 070 Multilock Gray Circuit board under tail lamp
Unsealed (BK) assembly (Right side)
[94L] Rear fender lights harness in 6-place Tyco 070 Multilock Gray Circuit board under tail lamp
circuit Unsealed (BK) assembly board (Left side)
[94R] Rear fender lights harness in 6-place Tyco 070 Multilock Gray Circuit board under tail lamp
circuit Unsealed (BK) assembly board (Right side)
[95] Purge solenoid 2-place Delphi 150 Metripack Purple Under seat
Sealed (BK)
[105] Fairing cap switches 12-place Tyco 070 Multilock Gray Inner fairing - above upper fork
Unsealed (BK) bracket (right side)
[107] Ambient Air Temperature (AAT) 3-place Tyco 070 Multilock Gray Steering head, left side
sensor Unsealed (BK)
[108] Tachometer 12-place Delphi Micro 64 Breakout Box Inner fairing (back of tachometer)
sealed (GY) Red

A-2 2013 Trike Service Supplement: Appendix A Wiring

HOME

Table A-1. Connector Locations

NO. DESCRIPTION TYPE TERMINAL LOCATION

PROBE
COLOR
[111] Voltmeter 3-way Faston 250 Spade Red Inner fairing (back of voltmeter)
Unsealed (BK)
[112] Oil pressure gauge lamp 2-way Tyco Positive Lock Red Inner fairing (back of oil pressure
Spade Unsealed (BK) gauge)
[113] Oil pressure gauge 3-way Faston 250 Spade Red Inner fairing (back of oil pressure
Unsealed (BK) gauge)
[114] Air temperature gauge lamp 2-way Tyco Positive Lock Red Inner fairing (back of air temperature
Spade Unsealed (BK) gauge)
[115] Air temperature gauge 3-way Faston 250 Spade Red Inner fairing (back of air temperature
Unsealed (BK) gauge)
[116] Fuel gauge lamp 2-way Tyco Positive Lock Red Inner fairing (back of fuel gauge)
Spade Unsealed (BK)
[117] Fuel gauge 3-way Faston 250 Spade Red Inner fairing (back of fuel gauge)
Unsealed (BK)
[120] Oil pressure switch Push On Right Angle Molded Black Front right crankcase
terminal (BK)
[121] Rear stop lamp switch Tyco Insulated Spade terminals Red Mid-chassis, lower right side between
(BK) frame and exhaust pipe)
[122] Horn Flag terminals (BK) Red Between cylinders (left side)
[128] Starter solenoid Dlephi 56 Spade terminal (W) Red Top of starter
[131] Neutral switch Push On Right Angle Molded Top of transmission (right side)
terminals (BK)
[132] Cigar lighter Tyco Insulated Spade terminals Red Inner fairing
[134] BAS 3-place Delphi GT 150 Sealed Gray Under seat behind battery
[137] HO2 sensor rear exhaust 4-place Molex MX 150 Sealed Gray Under right side cover
header (BK)
[138] HO2 sensor front exhaust 4-place Molex MX 150 Sealed Gray Under right side cover
header (GY)
[141] Fuel pump and fuel level 4-place Delphi GT 280 Sealed Gray Under console on top of fuel tank
sender (BK) canopy
[143] Front fender tip lamp (DOM) 2-place Tyco 070 Multilock Gray Under front fender tip lamp bracket
Unsealed (BK)
[160] B+ 1-place Delphi 480 Metripack Red Under seat
Unsealed (GY)
[203F] ACR (front) 2-place Tyco Superseal 1.5 Red Bracket attached to the throttle body
Sealed
[203R] ACR (rear) 2-place Tyco Superseal 1.5 Red Bracket attached to the throttle body
Sealed
[204] TGS harness 6-place Molex MX 150 Sealed Gray Inner fairing - right fairing support
(BK) bracket
[208] HFSM antenna jumper harness 4-place Deutsch DT Sealed Black Under right side cover
(GY)
[209] HFSM antenna 2-place Molex MX 64 Unsealed Gray Under seat
(BK)
[211] TCA 6-place Molex MX 150 Sealed Gray Right side of engine (induction
(BK) module)
[224] TGS 7-place Tyco Mini Multilock Handlebar throttle (inside right side
(BK) handlebar)

2013 Trike Service Supplement: Appendix A Wiring A-3

HOME

Table A-1. Connector Locations

NO. DESCRIPTION TYPE TERMINAL LOCATION

PROBE
COLOR
[233] License plate lamp 3-place Tyco 070 Multilock Gray Under trunk door cover, left side
Unsealed (WE)
[245] RCM 10-place Molex MX 150 Sealed Gray Under right side cover
[246] RCM solenoid 2-place Tyco 070 Multilock Gray Under right side cover
Unsealed (BK)
[247] Reverse switch assembly 4-place Molex MX 150 Sealed Gray Behind fairing, left side
(GY)
[248] Reverse motor solenoid Ring terminal Bottom of reverse motor solenoid
[249] Reverse motor solenoid/high Ring terminal Front of reverse motor solenoid
current
[251] RCM solenoid Ring terminal Under right side cover
[252] 150A circuit breaker Ring terminal Under right side cover
[253] Reverse motor ground Ring terminal Motor mounting flange
[263] P&A Trunk Light (power feed) 2-place Tyco 070 Multilock Gray Under seat, left side
Unsealed (BK)
[279] Trunk Light 2-place Tyco 070 Multilock Gray Under trunk door cover, left side
Unsealed (BK)
[GND1] Harness grounds Ring terminals Under seat
[GND1A]
[GND2]
[GND7] Harness grounds Ring terminals Transmission case

A-4 2013 Trike Service Supplement: Appendix A Wiring

HOME

WIRING DIAGRAMS A.2

WIRING DIAGRAM INFORMATION ed03175
5
Wire Color Codes
Wire traces on wiring diagrams are labeled with alpha codes. 3 4
Refer to Table A-2. 6
For Solid Color Wires: See Figure A-1. The alpha code
identifies wire color. 7
1 2

GN/Y
For Striped Wires: The code is written with a slash (/) between

W
the solid color code and the stripe code. For example, a trace
8
labeled GN/Y is a green wire with a yellow stripe. [21A] 1 2

Wiring Diagram Symbols [21B] 1 2

9
See Figure A-1. On wiring diagrams and in service/repair

GN/Y
instructions, connectors are identified by a number in brackets
[ ]. The letter inside the brackets identifies whether the housing 1 2 10
is a socket or pin housing.
A=Pin: The letter A and the pin symbol after a connector 11
number identifies the pin side of the terminal connectors.
13
B=Socket: The letter B the socket symbol after a connector
number identifies the socket side of the terminal connectors. 12
Other symbols found on the wiring diagrams include the fol-
1. Connector number
lowing:
2. Terminal code (A=pin, B=socket)
Diode: The diode allows current flow in one direction only in 3. Solid wire color
a circuit. 4. Striped wire color
5. Socket symbol
Wire break: The wire breaks are used to show option variances
6. Pin symbol
or page breaks.
7. Diode
No Connection: Two wires crossing over each other in a wiring 8. Wire break
diagram that are shown with no splice indicating they are not 9. No connection
connected together. 10. Circuit to/from
Circuit to/from: This symbol is used to identify there is a more 11. Splice
complete circuit diagram on another page. The symbol is also 12. Ground
identifying the direction of current flow. 13. Twisted pair

Splice: Splices are where two or more wires are connected Figure A-1. Connector/Wiring Diagram Symbols
together along a wiring diagram. The location of the splice
indicated in the wiring diagram is not the true location of the
splice in the actual harness but to identify that the wires are
spliced to that circuit.
Ground: Grounds can be classified as either clean or dirty
grounds. Clean grounds are identified by a (BK/GN) wire and
are normally used for sensors or modules. These grounds
usually do not have electric motors, coils or anything that may
cause electrical interference on the ground circuit. The dirty
grounds are identified by a (BK) wire and are used for compon-
ents that are not as sensitive to electrical interference.
Twisted pair: This symbol indicates the two wires are twisted
together in the harness. This minimizes the circuit's electromag-
netic interference from external sources. If repairs are neces-
sary to these wires they should remain as twisted wires.

2013 Trike Service Supplement: Appendix A Wiring A-5

HOME

ed03264 Table A-2. Wire Color Codes

ALPHA CODE WIRE COLOR

1 A C E G J BE Blue
2
15 3
15 4
15 5
15
1 BK Black
6
15 7
15 8
15
BN Brown
64-1 2
GN Green
3
9 10
11
15 GY Gray
4 B D F H LGN Light Green

19 O Orange
A C E
12
15 13
15 PK Pink
14
R Red
15 16
15 17
15
64-2 TN Tan
18
15
3
V Violet
W White
4 B D F H
Y Yellow

1. Fuse block [64-1]

2. Brake
3. Accessory
4. P&A
5. Radio power/siren
6. Radio memory
7. Battery
8. ECM power
9. System relay
10. Start relay
11. Fuel pump
12. Instruments
13. Ignition
14. Lighting relay
15. Brake relay
16. Headlamp
17. Lights
18. Spare
19. Fuse block [64-2]
Figure A-2. Fuse Block and Socket Terminals

A-6 2013 Trike Service Supplement: Appendix A Wiring

HOME

WIRING DIAGRAMS

Wiring Diagram List

DIAGRAM LOCATION
Main Harness (1 of 2): 2013 Trike Models Figure A-3
Main Harness (2 of 2): 2013 Trike Models Figure A-4
Fairing Harness: 2013 Trike Models Figure A-5
Reverse, Rear Lighting: 2013 Trike Models Figure A-6

2013 Trike Service Supplement: Appendix A Wiring A-7

et00481 [208A] [208B] Optional BK
[209B] [209A] BAS Security Red
Siren Band
Receive 1 1 Y/BK A B C [134B]
Xmit Antenna A 2 2 BK/O BK/O 1 Xmit Antenna A Start Main Power Main Fuse Voltage B+ Ignition
A B C D [141A] Solenoid

LGN/BN
Xmit Antenna B

TN/GN
GY
Xmit Antenna B 3 3 BK BK 2 Fuel At Starter 40A Regulator Connector Switch
Pump [141B]

Ground
A B C D
[142A] [128B]

Signal
Power
Battery 1 1 BN/GY A B [5B] N P [77B] [160B] 1 2 3 [33B]
Ignition 2 2 GY

O/GY
Y/W

BK/GN
BK
TSM,

R
GN
Fuel Pump Battery

BK
BK
LGN/V

R/GY
Serial Data 3 3

R/BK
R
R

R
TSSM Neutral Switch 4 4 A B C BK
[BATT]
TN Assembly In Tank
Or HFSM

R
Left Turn Lead 5 5 V [142B]
Right Turn Lead 6 6 BN A B C
Right Turn switch Input 7 7 W/BN R

LGN/BN
BN/GY

BK/GN
Left Turn switch Input 8 8 W/V

BK/GN
Start Relay Control 9 9 TN/GN

O/GY
Fuel Tank

Y/W
Clutch Lockout Switch 10 10 BK/R

BK
Alarm Signal 11 11 LGN/BN Harness Brake 15A 64-1B
Ground 12 12 BK/GN
1 2 3 4 [13B] O/V 1B 1A

[13A] Accessory 15A

[30A] [30B] 1 2 3 4 O/W 1D 1C R/GY
P&A 15A

O/GY
Y/W
BK/GN
BK
O/GY O/R 1F 1E
GN/O Radio Power/
Siren 15A
BK/GN O/BE 1H 1G R/GY
BE/BK
See W/BE GN 4G 5 87
Main R/GN
Harness R/GY 3H 3 30 Start
(2 Of 2) LGN/V
TN/GN 3G 2 85 Relay
GY BK/R 4H 1 86
Y/GN
BE/GY Radio Memory 15A
W/BK R/O 2B 2A R
O/W Battery 15A
TN BN/GY 2D 2C R
Left GND 1 ECM Power 15A
16 BE/BK Stud BK BE/GY 2F 2E R
15 R/GN (Dirty)
14 W/BE
13 LGN/V BK
11 W/V Fuel Pump 15A
10 W/BN O/GY 4B 4A
See 9 O/BE
Fairing 8 BN
7 V Y/GN 4C 5 87
Harness 6 W/BK
5 O/W BE/GY 3D 3 30
System
4 O/R
GN/O
Relay
3 GY 3C 2 85
1 O W/BK 4D 1 86

Right GND 2
[1B] Stud BK/GN
P&A 2A (MAX)
(Clean) BK/GN
1B 1A
12 BK/GN
BK/R
Instrs 15A
11
10 TN O 1D 1C R/BK
9 GN/Y
8 BN/GN
7 O Ignition 15A
See Y/BK
6 GY 1F 1E
Fairing Y/W
5
Harness BN/GY
4
87 5 2G
3 BE
2 BK/R Lighting 30 3 1J R
1 R/BE Relay
85 2 2J BK
86 1 1G
[2B]
Headlamp 15A
BE 2D 2C
D BK
C BK/GN Lights 15A
See B BE BE 2F 2E
Fairing A R/O
Harness P&A Dome Light 15A
R/O 3D 3C R
[15B]
R/BE
O/W
TN
BK

Horn
Y/BK

B A 1 2 O/V 3A 5 87
BK

Oil 2
Pressure B BN/GN R/Y 2B 3 30 Brake
Relay

O/W
A GN/Y
O/R
R/Y

R/Y

R/Y
Sender

BN
BE
BK

BK

BK

BE
R/BE 2A 2 85
O

V
(BK) BK 3B 1 86
[139B] 1 [4A] 1 2 3 4 [12B] 3 2 1 1 2 3 5 6 7 [7A]
Neutral Rear
Switch Stop Light Accessory Tour-Pak See
[122] [131] Switch Connector Reverse, 1 [263B] 64-2B
[121] Rear Lighting P&A Trunk Light

Figure A-3. Main Harness (1 of 2): 2013 Trike Models

 Figure A-3. Figure A-3.
Main Harness (1 of 2): 2013 Trike Models Main Harness (1 of 2): 2013 Trike Models
et00486 Twist Grip
Sensor Ignition
Coil
Reverse
Switch
CKP
Sensor Rear Front Throttle Control
Injector Injector TMAP Actuator
[224A] 1 2 3 4 5 6
Sensor
[224B] 1 2 3 4 5 6
Enable
Engine Temp

Ion Sense

Coil Front
Coil Rear
Sensor Drive

GY

BN
BK
BE
R
V

Power
[79A] 1 2 DLC [204A] 1 2 3 4 5 6
[85A] A B [84A] A B
[79B] 1 2 [91A] [204B] 1 2 3 4 5 6 [83A] A B C D [211A] 6 5 4 3 2 1 [247A] 4 3 1 2
2 3 4 [85B] A B [84B] A B [80A] 1 2 3 4
(GY) [83B] A B C D [211B] 6 5 4 3 2 1 [247B] 4 3 1 2

Y/GN
Y/GN
BK/W

W/Y
GN/GY
[80B] 1 2 3 4

BN/O
R/W
BK
R

BE/GN
BK/GY
BK/GN

GY

V/Y
LGN/V
[90A] A B

BK/W

O/W
BN/O
BN/R
BK/O

W
BN/V

R
BE
Y/GN

R/W
BE/O

V/W

BK/PK
Y/BE

BK/GY
LGN/Y
GY/BE
[90B] A B
[78A] [78B]

BK/W
PK/Y
ECM TN
O/GY
O/W
18 18 BK
ACR 19 19 V/GY
Purge Solenoid 20 20 GY/Y

Cruise/Set/Coast 22 22 BE/BK
GN/O
Rear Fuel Injector 23 23 GN/GY
TMAP Sensor Input 24 24 V/W BK/GN
Brake Switch 25 25 R/BE R/BE

System Relay Enable 27 27 GN/O

Front Fuel Injector 28 28 W/Y BE/BK
Twist Grip Hi 29 29 BK/O
Twist Grip Lo 30 30 BK/PK
HO2 Heater Ground 31 31 GN/W

Ion Sense 33 33 GY/BE

Cruise Resume/Accelerate 34 34 W/BE W/BE
Cruise Enable 35 35 R/GN R/GN

See Main Harness (1 Of 2)

TPS 2 36 36 BN/R
TPS 1 37 37 BN/V

TGS 2 39 39 V/Y
Vehicle Speed Input 40 40 W/GN LGN/V

CKP Sensor (-) 43 43 +BK

GY
Rear HO2S 46 46 PK/GN
O2 Return 48 48 BK/BN
IAT 49 49 LGN/Y
5V Sensor Power 1 50 50 BN/O
ET 51 51 PK/Y
Twisted 12 V Power 52 52 Y/GN Y/GN
Pair
Rear Ignition Coil 53 53 Y/BE
Front Ignition Coil 54 54 BE/O

57 57 BK

TGS 1 59 59 BE/GN

5V Sensor Ground 1 61 61 BK/W

5V Sensor Ground 2 62 62 BK/GY
CKP Sensor (+) 63 63 R
Vehicle Speed Ground 64 64 BK/Y
GND
Front HO2S 66 66 PK/O

5V Sensor Power 2 68 68 R/W

Serial Data 69 69 LGN/V

12V Battery 71 71 BE/GY BE/GY

12V Engine Stop Switch 72 72 W/BK W/BK

R/GN
O/GY
O/W
Ground 73 73 BK/GN

BE
TN

BK

BK
W

R
2 3 4 5 6 7 8 9 10 [245B]
2 3 4 5 6 7 8 9 10 [245A]

Accessory Fuse
Fuel Pump Fuse

Ground
LED Ground

RCM Solenoid Ground

Neutral Input

Reverse Input
Reverse Enable

RCM Solenoid Power

PK/GN
BK/BN
BK/BN

GN/W
GN/W

R/GN
W/GN

Y/GN
Y/GN

V/GY
V/GY
Y/GN

Y/GN
Y/GN

BN/O
GY/Y

PK/O

BK/Y

BK
RCM
B A [95B] 1 2 3 4 [138B] 1 2 3 4 [137B] A B C [65B] 1 2 [203FB] 1 2 [203RB] 1 2 [246B]
Purge Front Rear VSS Front Rear RCM
Solenoid HO2S HO2S ACR ACR Solenoid

Figure A-4. Main Harness (2 of 2): 2013 Trike Models

 Figure A-4. Figure A-4.
Main Harness (2 of 2): 2013 Trike Models Main Harness (2 of 2): 2013 Trike Models
et00408
Ground
To Fork Dash Panel
Clamp Indicator Lamps Switches Oil Air
[GND3] [21A] [105A] Fuel Voltmeter Pressure Temperature
1 2 3 4 5 6 7 12 11 10 9 8 7 6 5 4 3 2 1
(BK) (BK) [116A] [110A] [112A] [114A]

BK

O/W
R/GN
V/O

O/R
BN/O

O/BE

GY/BK
GN/Y
W

O
BK
O

BK
BK
BK
BN

Y
TN
V
[116B] [110B] [112B] [114B]
1 W 1 2 1 2 1 2 1 2
Headlamp Hi Beam + S + S + S + S
2 Y 1 3 [117A] 1 3 [111A] 1 3 [113A] 1 3 [115A]
2 2 2 2
Lo Beam [117B] [111B] [113B] [115B]
3 BK

BN/GN
O
BK

BK
Y/W

O
BK

BK
O

BK

BK
BE/V
BK

BK
O
GND
[38B]
HDI Only

[29B] BK

O/W
(BK)
[107B] [107A]
[22B]
BE/V 1 1
Air
1 O/W 2 2
TEMP Signal Temperature
Ground
2 R/BE BK 3 3 Sensor
3 GY
4 W/BK [1A]
5 W/BN
Right Hand 6 BK/R
Controls 7 BN/W BE/BK 16
8 GY/W R/GN 15
9 PK/W W/BE 14
10 V/BK LGN/V 13
11 W/BE
12 BE/BK W/V 11
W/BN 10 See Main
O/BE 9 Harness
[24B] BN 8 (1 Of 2)
V 7
W/BK 6
14 O/BK O/W 5
13 V/BK O/R 4
12 BK/GN GY 3
11 GY/GN
10 GN/BE O 1
Left Hand 9 PK/W
Controls 8 BN/BK [2A]
7 BK/R
6 Y/BK
5 W/V BK/GN 12
4 W BK/R 11
3 BE TN 10
2 Y GN/Y 9
1 O/W BN/GN 8 See Main
O 7
Y/BK 6 Harness
[27B] Y/W 5 (1 Of 2)
BN/GY 4
BE 3
1 LGN/BK BK/R 2
2 BE/Y R/BE 1
3 PK/W
4 GY/W
5 V/BK
6 BN/W
7 O/BK
BK D See Main
BK/GN C
8 BN/BK
BE B
Harness
9 LGN/V (1 Of 2)
10 R/O A
R/O
Radio 11 BK/GN

BN/GY

BK/GN
LGN/V
12

BK/GN
BN/GY
LGN/V
O/BE [15A]

O/W

Y/W
13 BN/O

BK

BK

O/W
O

O
15 V/GY
16 W/O [39B] 1 2 5 6 7 8 9 11 [108B] 1 2 5 6 7
17 LGN/W (BK) (GY)
18 GY/R 1 2 5 6 7 8 9 11 1 2 5 6 7 O/R
19 BK/GN

Reset Switch
Ignition

Trip Odometer-
Accessory
Serial Data

Battery

Ground

Fuel Level
Tri p Switch

Accessory
Serial Data

Battery

Ground
Ignition
20 R/O
21 V/O BK
22 GY/GN
23 GN/BE
[132B] [132A]
Cigar
BK/GN

GY/BK
[34B]
GY/BK

Lighter
V/GY
BE/Y

BK
BK
R/O

O/R
BE
BN

BK

BE
BK

BK
BK
BE

Right Front [32A]

V
LGN/BK
Speaker GY/R
[6B] 6 3 2 1 2 1 [32B] 4 3 2 1 [31RA] 4 3 2 1 [31LA] RPM x 100 2 1 [189B]
Audio Front Fender RH Front LH Front Trip Odometer Heated
Harness Tip Lamp Turn Signal Turn Signal Reset Switch Grips
[35B]
[154A]
Left Front LGN/W
Speaker W/O

Speedometer Tachometer

Figure A-5. Fairing Harness: 2013 Trike Models

 Figure A-5. Figure A-5.
Fairing Harness: 2013 Trike Models Fairing Harness: 2013 Trike Models
et00487 Reverse Motor
Reverse Switch Solenoid [249A]
[248]
BK
BK (6AWG)
Enable (14AWG)

Drive
[249B]

BK
Reverse
RCM Motor [253]
Solenoid
[251]
[247A] 4 3 1 2
[247B] To Fuel To Accessory BK
4 3 1 2
Pump Fuse Fuse GND 7
[251B]
O/W

W
R
BE

RCM
[251A] BK

TN 2 2 Neutral Input BK GN
O/GY 3 3 Fuel Pump Fuse (14AWG)
O/W 4 4 Accessory Fuse
BE 5 5 Reverse Enable
W 6 6 Reverse Input BK
BK 7 7 Ground
[252B]
R 8 8 LED Ground

GN
BK
R/GN 9 9 RCM Solenoid Power
BK 10 10 RCM Solenoid Ground
[246A] 1 2

BK
[252A] 150A Manual [246B] 1 2
To Neutral [245B] [245A] Reset Circuit
Switch [263A]

R/GN
BK
Breaker [279A]

1 R/O R/O 1
BK 2

BK
40 A
BK Main Fuse

BK Red
Band BK Right Rear
[5B] R/Y Running/Turn
A B
BE Lamp

R/Y
BK

BE
R
Battery [94RB] [94RA] 4 3 1 [93RB]
4 3 2 1 [93RA]
[128A] 1
[128B] 2
Right BK BE 3 3
GND 2 GN To Start Relay BN 4 4
5 1 2 1 2
BK 6 6 1 2 3
Starter
Circuit Board
V/BN 1 1 BN
1 BE 2 2 BE
BN License
See 2 BK 3 3 BK
O/W BE
Main 3 V V 4 4 V [233A] [233B] BK
Plate Lamp
5 BE 5 5 BE
Harness BK
6 R/Y BK 6 6 BK
(1 Of 2) 7 BE O/W 7 7 BE BE 1 1 BE
BK 8 8 BK BK 3 3 BK
BE
[7D]
[7C] [7B]

V/BN
O/W

O/W
R/Y

BN
BE
BE

BK

BE
BK

BE
BK

BK
BK Left Rear

V
R/Y Running/Turn
BE Lamp

R/Y
BK

BE
[94LB] [94LA] 4 3 1 [93LB]
4 3 2 1 [93LA]
1
2
Tail And Turn Signal 3 3
BE
Converter Module 4 4
V
5 1 2 1 2
BK 6 6 1 2 3

Circuit Board

Figure A-6. Reverse, Rear Lighting: 2013 Trike Models

 Figure A-6. Figure A-6.
Reverse, Rear Lighting: 2013 Trike Models Reverse, Rear Lighting: 2013 Trike Models
 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
FRX181 SNAP-ON FLARE NUT SOCKET 7.4 AUXILIARY LAMPS, Installation
HD-25070 ROBINAIR HEAT GUN 2.11 BODY, Trunk Door Seal
HD-34633 AIR SUSPENSION PUMP AND GAUGE 2.18 SHOCK ABSORBERS, Removal
HD-34633A AIR SUSPENSION PUMP AND GAUGE 1.12 REAR SUSPENSION ADJUSTMENTS, General
HD-34634 FORK OIL SEAL INSTALLER 5.2 AXLE, Assembly
HD-34736-B VALVE SPRING COMPRESSOR 2.9 TRUNK DOOR LOCKSET, Lockset
HD-35316-12 MAIN DRIVE GEAR INSTALLER 5.3 AXLE HOUSING/DIFFERENTIAL, Assembly
HD-35381A BELT TENSION GAUGE 1.9 DRIVE BELT, Checking Drive Belt Deflection
HD-35500 DIGITAL VOM 7.17 REAR LIGHTING DIAGNOSTICS, Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 7.15 REVERSE MOTOR SYSTEM DIA-
GNOSTICS, Reverse Motor System
HD-41404-C HARNESS CONNECTOR TEST KIT 7.17 REAR LIGHTING DIAGNOSTICS, Brake Lamps
Inoperative
HD-41404-C HARNESS CONNECTOR TEST KIT 7.18 BAS FUNCTION: DTCS B1151, B1152, AND
B1153, DTC B1152, B1153
HD-42682 BREAKOUT BOX 7.18 BAS FUNCTION: DTCS B1151, B1152, AND
B1153, DTC B1151
HD-43644-3 CAMSHAFT BEARING INSTALLER 5.3 AXLE HOUSING/DIFFERENTIAL, Disassembly
HD-43644-3 CAMSHAFT BEARING INSTALLER 5.3 AXLE HOUSING/DIFFERENTIAL, Disassembly
HD-45327 REAR FORK BEARING INSTALLER 2.15 REAR FORK, Repair
HD-48650 DIGITAL TECHNICIAN II 7.18 BAS FUNCTION: DTCS B1151, B1152, AND
B1153, Diagnostics

TOOLS
HD-49303 AXLE PULLER 5.2 AXLE, Removal
HD-49762 PULLER 5.3 AXLE HOUSING/DIFFERENTIAL, Disassembly
HD-49796 BEARING SPACER TOOL 2.15 REAR FORK, Repair
HD-59000B FORK OIL LEVEL GAUGE 1.15 FORK OIL, Procedure
HD-95635-46 ALL-PURPOSE CLAW PULLER 5.3 AXLE HOUSING/DIFFERENTIAL, Disassembly
SNAP-ON BB200A BASIC VACUUM BRAKE BLEEDER 2.7 BLEEDING BRAKES, Procedure

I
NOTES

II TOOLS
 2013 Harley-Davidson Trike Model Service Manual
Supplement
FASTENER TORQUE VALUE NOTES
Air cleaner cover bracket screws 108-132 in-lbs 12.2-14.9 Nm 1.4 MAINTENANCE SCHEDULE, General
Air cleaner cover screw 36-60 in-lbs 4.1-6.8 Nm 1.4 MAINTENANCE SCHEDULE, General
Air valve nut 12-15 in-lbs 1.4-1.7 Nm 2.14 INTERMEDIATE FRAME, Installation
Air valve nut 12-15 in-lbs 1.4-1.7 Nm 5.3 AXLE HOUSING/DIFFERENTIAL, Installation
Auxiliary lamp locknut 15-18 ft-lbs 20.3-24.4 Nm 7.4 AUXILIARY LAMPS, Installation
Axle adapter plate screws 41-45 ft-lbs 55.6-61.0 Nm 2.16 LATERAL ALIGNMENT, Procedure/Use
LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue)
Axle adapter plate screws 41-45 ft-lbs 55.6-61.0 Nm 2.17 PARK BRAKE ASSEMBLY, Assemble
Handle/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
Axle adjustment screw jamnut 15-25 ft-lbs 20.3-34.0 Nm 1.9 DRIVE BELT, Setting Deflection
Axle bearing retainer locknuts 41-45 ft-lbs 55.6-61.0 Nm 5.2 AXLE, Installation/Use new locknuts
Bank angle sensor bracket screws 72-108 in-lbs 8.1-12.2 Nm 2.14 INTERMEDIATE FRAME, Assembly
Bank angle sensor bracket screws 72-108 in-lbs 8.1-12.2 Nm 7.10 BANK ANGLE SENSOR (BAS), Installation
Bank angle sensor screw 35-45 in-lbs 4.0-5.1 Nm 7.10 BANK ANGLE SENSOR (BAS), Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 1.4 MAINTENANCE SCHEDULE, General
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 1.9 DRIVE BELT, Setting Deflection

TORQUE VALUES
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 1.10 REAR WHEEL COMPENSATOR, Checking
Isolator Wear
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 2.4 REAR WHEELS, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 2.11 BODY, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 5.3 AXLE HOUSING/DIFFERENTIAL, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.4 AUXILIARY LAMPS, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.5 FRONT TURN SIGNAL LAMPS, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.6 TAIL LAMPS/REAR TURN SIGNALS, Installa-
tion
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.7 TAIL LAMP/REAR TURN SIGNAL CON-
VERTER MODULE, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.8 LICENSE PLATE LAMPS/BRACKET, Installa-
tion
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.9 REAR LIGHTS HARNESS, Installation
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.11 REVERSE CONTROL SYSTEM, Reverse
Solenoid Replacement
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Vehicle
Starter to Circuit Breaker Power Lead
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Breaker to RCM Solenoid
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER CABLES/WIRES, RCM
Solenoid to Reverse Motor Solenoid Energizer
Lead
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Breaker to Reverse Motor Solenoid Power Lead
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.12 REVERSE JUMPER
CABLES/WIRES, Reverse Motor to Battery Ground
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
tion

III
 2013 Harley-Davidson Trike Model Service Manual
Supplement
FASTENER TORQUE VALUE NOTES
Battery cable screw 60-70 in-lbs 6.8-7.9 Nm 7.14 REVERSE SWITCHES, Installation
Battery tray screws 72-96 in-lbs 8.1-10.9 Nm 2.14 INTERMEDIATE FRAME, Installation
Battery tray screws 72-96 in-lbs 8.1-10.9 Nm 7.3 BATTERY TRAY, Installation
Body attachment screws (inside trunk) 14-17 ft-lbs 19.0-23.1 Nm 2.11 BODY, Installation/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue) on screws
Body attachment screws (outside trunk) 24-26 ft-lbs 32.5-35.3 Nm 2.11 BODY, Installation/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Brake caliper, front, pad pin 75-102 in-lbs 8.5-11.5 Nm 1.4 MAINTENANCE SCHEDULE, General
Brake caliper, rear, banjo bolt 17-19 ft-lbs 23.1-25.8 Nm 2.5 REAR BRAKE CALIPERS, Installation
Brake caliper, rear, banjo bolt 17-19 ft-lbs 23.1-25.8 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Rear Brake Line
Brake caliper, rear, cable bracket screws 132-156 in-lbs 14.9-17.6 Nm 2.5 REAR BRAKE CALIPERS, Repair
Brake caliper, rear, mounting/pad pins 32-36 ft-lbs 43.4-48.8 Nm 1.4 MAINTENANCE SCHEDULE, General
Brake caliper, rear, mounting/pad pins 32-36 ft-lbs 43.4-48.8 Nm 1.7 REAR BRAKE PADS AND DISCS, Replace-
ment
Brake caliper, rear, mounting bracket 41-45 ft-lbs 55.6-61.0 Nm 2.5 REAR BRAKE CALIPERS, Installation/Use
screws LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue)
Brake caliper, rear, mounting bracket 41-45 ft-lbs 55.6-61.0 Nm 2.5 REAR BRAKE CALIPERS, Repair/Use LOC-
screws TITE 243 MEDIUM STRENGTH THREADLOCKER
AND SEALANT (blue)
Brake caliper, rear, reaction bracket 41-45 ft-lbs 55.6-61.0 Nm 2.5 REAR BRAKE CALIPERS, Repair/Use LOC-
screws TITE 243 MEDIUM STRENGTH THREADLOCKER
AND SEALANT (blue)
Brake caliper bleeder valve 80-100 in-lbs 9.0-11.3 Nm 2.7 BLEEDING BRAKES, Procedure
Brake lamp switch, rear, bracket fastener 80-100 in-lbs 9.0-11.3 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Installation
Brake line, rear, tee locknut 59-63 in-lbs 6.7-7.1 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Rear Brake Line/Use new locknut

Brake line, rear, tee locknut 59-63 in-lbs 6.7-7.1 Nm 2.15 REAR FORK, Installation/Use new locknut
Brake master cylinder, front, reservoir 10-12 in-lbs 1.1-1.4 Nm 1.4 MAINTENANCE SCHEDULE, General
cover screws
Brake master cylinder, front, reservoir 10-12 in-lbs 1.1-1.4 Nm 2.7 BLEEDING BRAKES, Procedure
cover screws
Brake master cylinder, rear, banjo bolt 17-22 ft-lbs 23.0-29.8 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Installation
Brake master cylinder, rear, banjo bolt 17-22 ft-lbs 23.0-29.8 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Rear Brake Line
Brake master cylinder, rear, mounting 30-40 ft-lbs 40.7-54.2 Nm 2.6 REAR BRAKE MASTER CYL-
bracket nut INDER/PEDAL, Installation/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Brake master cylinder, rear, mounting 126-150 in-lbs 14.2-16.9 Nm 2.6 REAR BRAKE MASTER CYL-
bracket screws INDER/PEDAL, Installation

IV TORQUE VALUES
 2013 Harley-Davidson Trike Model Service Manual
Supplement
FASTENER TORQUE VALUE NOTES
Brake master cylinder, rear, reservoir 6-8 in-lbs 0.7-0.9 Nm 1.4 MAINTENANCE SCHEDULE, General
cover screws
Brake master cylinder, rear, reservoir 6-8 in-lbs 0.7-0.9 Nm 1.7 REAR BRAKE PADS AND DISCS, Replace-
cover screws ment
Brake master cylinder, rear, reservoir 6-8 in-lbs 0.7-0.9 Nm 2.7 BLEEDING BRAKES, Procedure
cover screws
Brake pedal shaft locknut 15-20 ft-lbs 20.3-27.1 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Installation
Clutch adjuster screw locknut 72-120 in-lbs 8.1-13.6 Nm 1.4 MAINTENANCE SCHEDULE, General
Clutch inspection cover screws 84-108 in-lbs 9.5-12.2 Nm 1.4 MAINTENANCE SCHEDULE, General
Differential assembly screws 65-70 ft-lbs 88.1-94.9 Nm 5.3 AXLE HOUSING/DIFFEREN-
TIAL, Assembly/Use new screws
Differential bearing cap screws 39-44 ft-lbs 52.9-59.7 Nm 5.3 AXLE HOUSING/DIFFERENTIAL, Installation
Engine mount, front, end cap fasteners 42-48 ft-lbs 48.8-54.2 Nm 2.6 REAR BRAKE MASTER CYL-
INDER/PEDAL, Rear Brake Line
Engine oil drain plug 14-21 ft-lbs 19.0-28.5 Nm 1.4 MAINTENANCE SCHEDULE, General
Engine stabilizer bracket screws 30-35 ft-lbs 40.7-47.5 Nm 2.23 ENGINE STABILIZER, Stabilizer Link/Apply
LOCTITE 272 HIGH STRENGTH/HIGH TEMPER-
ATURE THREADLOCKER AND SEALANT
(red/orange) to threads
Engine stabilizer link screws 30-35 ft-lbs 40.7-47.5 Nm 2.23 ENGINE STABILIZER, Stabilizer Link
Engine stabilizer link screws 30-35 ft-lbs 40.7-47.5 Nm 2.23 ENGINE STABILIZER, Stabilizer Link
Fairing cap screws 25-30 in-lbs 2.8-3.4 Nm 7.14 REVERSE SWITCHES, Installation
Fender, front, mount screws 24-28 ft-lbs 32.5-38.0 Nm 2.22 FRONT FENDER, Installation
Fender, front, side trim or skirt 10-15 in-lbs 1.1-1.7 Nm 2.22 FRONT FENDER, Installation
Fender, rear, screws 108-132 in-lbs 12.2-14.9 Nm 2.12 REAR FENDERS, Installation/Apply LOCTITE
243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue) to threads
Footboard screw, passenger 30-35 ft-lbs 40.7-47.5 Nm 5.4 DRIVE BELT REPLACEMENT, Installation
Frame connection bracket screws 41-45 ft-lbs 55.6-61.0 Nm 2.14 INTERMEDIATE FRAME, Assembly
Front axle holder nuts 132-180 in-lbs 14.9-20.3 Nm 2.21 FRONT WHEEL, Installation
Front axle nut 70-75 ft-lbs 94.9-101.7 Nm 2.21 FRONT WHEEL, Installation
Ground strap to forward stud (inside 14-17 ft-lbs 19.0-23.1 Nm 2.11 BODY, Installation
trunk)
Ground strap to upper stud 96-120 in-lbs 10.8-13.5 Nm 2.11 BODY, Assembly
Handlebar switch housing screw 35-45 in-lbs 4.0-5.1 Nm 1.4 MAINTENANCE SCHEDULE, General
Handrail screws, passenger 60-96 in-lbs 6.8-10.9 Nm 2.14 INTERMEDIATE FRAME, Assembly
Intermediate frame screws 40-45 ft-lbs 54.2-61.0 Nm 2.14 INTERMEDIATE FRAME, Installation
Left electrical caddy screw 72-96 in-lbs 8.1-10.9 Nm 2.14 INTERMEDIATE FRAME, Installation
License plate bracket screws 18-30 in-lbs 2.0-3.4 Nm 2.8 TRUNK DOOR, Assembly/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
License plate lamps bracket locknuts 60-72 in-lbs 6.8-8.1 Nm 7.8 LICENSE PLATE LAMPS/BRACKET, Installa-
tion/Use new locknuts
Lower fork bracket pinch bolts 70-75 ft-lbs 94.9-101.7 Nm 1.13 STEERING HEAD BEARINGS, Checking

TORQUE VALUES V
 2013 Harley-Davidson Trike Model Service Manual
Supplement
FASTENER TORQUE VALUE NOTES
Lower fork bracket pinch bolts 70-75 ft-lbs 94.9-101.7 Nm 1.15 FORK OIL, Procedure
Lug nuts 90-100 ft-lbs 122.0-135.6 Nm 1.9 DRIVE BELT, Setting Deflection/Always check
lug nut torque within 500-1000 mi (805-1610 km)
after wheel installation.
Lug nuts 90-100 ft-lbs 122.0-135.6 Nm 2.4 REAR WHEELS, Installation/Always check lug
nut torque within 500-1000 mi (805-1610 km) after
wheel installation.
Muffler bracket screws 96-144 in-lbs 10.9-16.3 Nm 2.13 REAR FRAME, Installation
Panhard rod adjustment jamnut 20-30 ft-lbs 27.1-40.7 Nm 2.19 PANHARD ROD, Adjustment
Panhard rod adjustment jamnut 20-30 ft-lbs 27.1-40.7 Nm 2.19 PANHARD ROD, Adjustment
Panhard rod clevis screw 55-60 ft-lbs 74.6-81.4 Nm 2.19 PANHARD ROD, Installation
Panhard rod clevis screw 55-60 ft-lbs 74.6-81.4 Nm 2.19 PANHARD ROD, Adjustment
Panhard rod locknut 55-60 ft-lbs 74.6-81.4 Nm 2.19 PANHARD ROD, Installation
Park brake actuator shaft locknut 32-36 ft-lbs 43.4-48.8 Nm 1.11 PARK BRAKE, Adjustment/Use new locknut
Park brake cable clamp nut 15-17 ft-lbs 20.3-23.1 Nm 2.17 PARK BRAKE ASSEMBLY, Assemble Handle
Park brake knob screw 10-15 in-lbs 1.1-1.7 Nm 2.17 PARK BRAKE ASSEMBLY, Assemble
Handle/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
Park brake mounting screws 15-17 ft-lbs 20.3-23.1 Nm 2.17 PARK BRAKE ASSEMBLY, Assemble Handle
P-clamp to pinch block screw 14-17 ft-lbs 19.0-23.1 Nm 2.17 PARK BRAKE ASSEMBLY, Cable Installation
P-clamp to pinch block screw 14-17 ft-lbs 19.0-23.1 Nm 5.3 AXLE HOUSING/DIFFERENTIAL, Installation
Pinch block screws 41-45 ft-lbs 55.6-61.0 Nm 1.9 DRIVE BELT, Setting Deflection/Use LOCTITE
243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Pinch block screws 41-45 ft-lbs 55.6-61.0 Nm 2.18 SHOCK ABSORBERS, Installation/Use
LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue)
Primary chaincase drain plug 14-21 ft-lbs 19.0-28.5 Nm 1.4 MAINTENANCE SCHEDULE, General
RCM solenoid nuts 50-60 in-lbs 5.7-6.8 Nm 7.11 REVERSE CONTROL SYSTEM, Reverse
Solenoid Replacement
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm 7.11 REVERSE CONTROL SYSTEM, Reverse
Solenoid Replacement
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Breaker to RCM Solenoid
RCM solenoid post nuts 26-40 in-lbs 2.9-4.5 Nm 7.12 REVERSE JUMPER CABLES/WIRES, RCM
Solenoid to Reverse Motor Solenoid Energizer
Lead
Rear fork bracket bolts 55-65 ft-lbs 74.6-88.1 Nm 2.15 REAR FORK, Installation/Apply two drops of
LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue) to threads
Rear fork pivot shaft locknut 50 ft-lbs + 180 67.8 Nm + 180 2.15 REAR FORK, Installation/Always use new
degrees addi- degrees addi- locknuts and cup washers
tional rotation tional rotation
Rear frame screws 41-45 ft-lbs 55.6-61.0 Nm 2.13 REAR FRAME, Installation/ Use LOCTITE
262 HIGH STRENGTH THREADLOCKER AND
SEALANT (red)

VI TORQUE VALUES
 2013 Harley-Davidson Trike Model Service Manual
Supplement
FASTENER TORQUE VALUE NOTES
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Vehicle
Starter to Circuit Breaker Power Lead
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Breaker to RCM Solenoid
Reverse circuit breaker nuts 50-60 in-lbs 5.6-6.8 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Breaker to Reverse Motor Solenoid Power Lead
Reverse circuit breaker screw 32-40 in-lbs 3.6-4.5 Nm 7.11 REVERSE CONTROL SYSTEM, Circuit
Breaker Replacement
Reverse motor bracket screws 39-44 ft-lbs 52.9-59.7 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
tion/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
Reverse motor screws 39-44 ft-lbs 52.9-59.7 Nm 7.12 REVERSE JUMPER
CABLES/WIRES, Reverse Motor to Battery
Ground/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
Reverse motor screws 39-44 ft-lbs 52.9-59.7 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
tion/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
Reverse motor solenoid energizer lead 24-30 in-lbs 2.7-3.4 Nm 7.12 REVERSE JUMPER CABLES/WIRES, RCM
nut Solenoid to Reverse Motor Solenoid Energizer
Lead
Reverse motor solenoid energizer lead 24-30 in-lbs 2.7-3.4 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
nut tion
Reverse motor solenoid power lead nut 60-84 in-lbs 6.8-9.5 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Circuit
Breaker to Reverse Motor Solenoid Power Lead
Reverse motor solenoid power lead nut 60-84 in-lbs 6.8-9.5 Nm 7.13 REVERSE MOTOR AND BRACKET, Installa-
tion
Reverse motor solenoid screws 70 in-lbs 7.9 Nm 7.13 REVERSE MOTOR AND
BRACKET, Assembly
Reverse switch housing cover screws 35-45 in-lbs 4-5 Nm 7.14 REVERSE SWITCHES, Installation
Reverse switch housing screws 72-108 in-lbs 8-12 Nm 7.14 REVERSE SWITCHES, Installation
Ring gear screws 22-26 ft-lbs 29.8-35.3 Nm 5.3 AXLE HOUSING/DIFFERENTIAL, Assembly
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 2.13 REAR FRAME, Installation/Use LOCTITE 262
HIGH STRENGTH THREADLOCKER AND
SEALANT (red)
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 2.18 SHOCK ABSORBERS, Installation/Use
LOCTITE 262 HIGH STRENGTH THREAD-
LOCKER AND SEALANT (red)
Shock absorber screws 55-60 ft-lbs 74.6-81.4 Nm 2.19 PANHARD ROD, Adjustment/Use LOCTITE
262 HIGH STRENGTH THREADLOCKER AND
SEALANT (red)
Solenoid to reverse motor jumper nut 45 in-lbs 5.1 Nm 7.13 REVERSE MOTOR AND
BRACKET, Assembly
Spark plug 12-18 ft-lbs 16.3-24.4 Nm 1.4 MAINTENANCE SCHEDULE, General

TORQUE VALUES VII

 2013 Harley-Davidson Trike Model Service Manual
Supplement
FASTENER TORQUE VALUE NOTES
Starter mounting screws 25-27 ft-lbs 33.9-36.6 Nm 7.12 REVERSE JUMPER
CABLES/WIRES, Reverse Motor to Battery
Ground/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
Starter solenoid post nut 70-90 in-lbs 7.9-10.2 Nm 7.12 REVERSE JUMPER CABLES/WIRES, Vehicle
Starter to Circuit Breaker Power Lead
Steering damper acorn nut 16-20 ft-lbs 21.7-27.1 Nm 2.20 STEERING DAMPER ASSEMBLY, Installation
Steering damper bracket screw 16-20 ft-lbs 21.7-27.1 Nm 2.20 STEERING DAMPER ASSEMBLY, Installation
Steering damper locknut 16-20 ft-lbs 21.7-27.1 Nm 2.20 STEERING DAMPER ASSEMBLY, Installation
Steering damper side mounting bracket 15-20 ft-lbs 20.3-27.1 Nm 2.20 STEERING DAMPER ASSEMBLY, Installation
screws
Tail lamp/turn signal chrome base screw 36-48 in-lbs 4.1-5.4 Nm 2.12 REAR FENDERS, Assembly/Use LOCTITE
222 LOW STRENGTH THREADLOCKER AND
SEALANT (purple)
Tail lamp/turn signal chrome base screw 36-48 in-lbs 4.1-5.4 Nm 7.6 TAIL LAMPS/REAR TURN SIGNALS, Installa-
tion/Use LOCTITE 222 LOW STRENGTH
THREADLOCKER AND SEALANT (purple)
Tail lamp/turn signal lens screws 21-24 in-lbs 2.4-2.7 Nm 2.12 REAR FENDERS, Installation
Tail lamp/turn signal lens screws 21-24 in-lbs 2.4-2.7 Nm 7.6 TAIL LAMPS/REAR TURN SIGNALS, Installa-
tion
Tail lamp/turn signal lens screws 21-24 in-lbs 2.4-2.7 Nm 7.9 REAR LIGHTS HARNESS, Installation
Top caddy screws 72-96 in-lbs 8.1-10.9 Nm 1.4 MAINTENANCE SCHEDULE, General
Tour-Pak rack screws 60-84 in-lbs 6.8-9.5 Nm 2.10 TOUR-PAK, Installation/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Tour-Pak screws 60-84 in-lbs 6.8-9.5 Nm 2.10 TOUR-PAK, Installation/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Transmission dipstick 25-75 in-lbs 2.8-8.5 Nm 1.4 MAINTENANCE SCHEDULE, General
Transmission dipstick 25-75 in-lbs 2.8-8.5 Nm 1.5 LUBRICANTS, Checking Transmission Lub-
ricant Level
Transmission drain plug 14-21 ft-lbs 19.0-28.5 Nm 1.4 MAINTENANCE SCHEDULE, General
Transmission ground post nut 66-114 in-lbs 7.5-12.9 Nm 7.12 REVERSE JUMPER
CABLES/WIRES, Reverse Motor to Battery Ground
Trunk door cover screws 30-54 in-lbs 3.4-6.1 Nm 2.8 TRUNK DOOR, Installation
Trunk door cover screws 30-54 in-lbs 3.4-6.1 Nm 7.8 LICENSE PLATE LAMPS/BRACKET, Installa-
tion
Trunk door cover screws 30-54 in-lbs 3.4-6.1 Nm 7.9 REAR LIGHTS HARNESS, Installation
Trunk door hinge locknuts 60-84 in-lbs 6.8-9.5 Nm 2.8 TRUNK DOOR, Installation/Use new locknuts
Trunk door hinge screws 48-72 in-lbs 5.4-8.1 Nm 2.8 TRUNK DOOR, Assembly/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
Trunk door lanyard screws 48-72 in-lbs 5.4-8.1 Nm 2.8 TRUNK DOOR, Installation
Trunk door latch housing screws 48-60 in-lbs 5.4-6.8 Nm 2.9 TRUNK DOOR LOCKSET, Latch Assembly
Trunk door latch mechanism screws 8-10 in-lbs 0.9-1.1 Nm 2.9 TRUNK DOOR LOCKSET, Latch Assembly
Trunk door latch pin bracket screws 48-72 in-lbs 5.4-8.1 Nm 2.8 TRUNK DOOR, Installation

VIII TORQUE VALUES

 2013 Harley-Davidson Trike Model Service Manual
Supplement
FASTENER TORQUE VALUE NOTES
Trunk door latch pin jamnut 48-72 in-lbs 5.4-8.1 Nm 2.8 TRUNK DOOR, Assembly
Trunk door latch pin jamnut 48-72 in-lbs 5.4-8.1 Nm 2.9 TRUNK DOOR LOCKSET, Latch Pin
Trunk door lock housing nuts 9-11 in-lbs 1.0-1.2 Nm 2.9 TRUNK DOOR LOCKSET, Latch Assembly
Trunk latch housing cover screw 25-28 in-lbs 2.8-3.2 Nm 2.9 TRUNK DOOR LOCKSET, Lockset
Turn signal/auxiliary lamps bracket 15-20 ft-lbs 20.3-27.1 Nm 7.4 AUXILIARY LAMPS, Installation
screws
Turn signal/auxiliary lamps bracket 15-20 ft-lbs 20.3-27.1 Nm 7.5 FRONT TURN SIGNAL LAMPS, Installation
screws
Turn signal lamp, front, mounting screw 96-120 in-lbs 10.8-13.6 Nm 7.4 AUXILIARY LAMPS, Installation
Turn signal lamp, front, mounting screw 96-120 in-lbs 10.8-13.6 Nm 7.5 FRONT TURN SIGNAL LAMPS, Installation
Wheel center cap clamp screw 72-96 in-lbs 8.1-10.9 Nm 2.4 REAR WHEELS, Installation/Use LOCTITE
243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)

TORQUE VALUES IX
NOTES

X TORQUE VALUES
 Critical Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
A
Air Suspension D
Recommended Pressure (Table). . . . . . . . . . . . . . . 1-20 Diagnostics
Alignment BAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 DTC B1151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Auxiliary lamps DTC B1152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 DTC B1153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Rear Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Axle Reverse Motor System. . . . . . . . . . . . . . . . . . . . . . . 7-29
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Differential
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Axle Housing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Drive Belt
Lateral Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 Checking and Adjusting Deflection. . . . . . . . . . . . . . 1-15
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
B
Bank Angle Sensor E
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45 Engine
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 General Specifications: Twin Cam 103. . . . . . . . . . . 3-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Engine Oil Level
Battery Tray Cold Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Hot Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Engine Stabilizer
Bleeding Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Body Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
F
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Fender, Front

INDEX
Threaded Insert Replacement. . . . . . . . . . . . . . . . . 2-24 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Trunk Door Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Brake Caliper, Rear Fender, Rear
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Brake Line, Rear Foreword
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Important General Information. . . . . . . . . . . . . . . . . . . i-I
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Fork Oil
Brake Lines Checking and Filling. . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Front Wheel
Brake Master Cylinder, Rear Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 2-12 Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 I
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Intermediate Frame
Brake Pads and Discs Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Brakes Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Bleeding. . . . . . . . . . . . . . . . . . . . . See Bleeding Brakes Isolator
Fluid Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Bulb Chart (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 L
Bulb Replacement
License Plate Lamp/Bracket
Specifications (Table). . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
C Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Circuit Breaker to RCM Solenoid Jumper Lifting Vehicle
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Jacking Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Light Bulbs
Circuit Breaker to Reverse Motor Solenoid Jumper See Bulb Replacement (Table). . . . . . . . . . . . . . . . . . 1-3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 LOCTITE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

XI
 M S
Maintenance Schedule Service Bulletins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-I
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Service Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-I
Shock Absorbers
P Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Panhard Rod Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 Specifications
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Park Brake SPX Kent-Moore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Starter Free Running Current Draw Test. . . . . . . . . . . . . 7-38
Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Steering Damper
Cable Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Handle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Handle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . 2-39 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
R Steering Head Bearings
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
RCM Solenoid to Reverse Motor Solenoid Jumper Suspension, Air
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Recommended Pressure (Table). . . . . . . . . . . . . . . 1-20
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Rear Air Suspension T
Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 Tail Lamp/Rear Turn Signal Converter Module
Rear Fork Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Disassembly/Assembly. . . . . . . . . . . . . . . . . . . . . . 2-35 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 Tail Lamp/Rear Turn Signals
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Rear Frame Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 Tour-Pak
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 Trademarks
Rear Lights Harness Harley-Davidson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Referenced Products. . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Transmission
Rear Tire Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Troubleshooting
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Brake Line Inspection (Table). . . . . . . . . . . . . . . . . . 1-11
Rear Wheel Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Reverse Control System Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
RCM Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
RCM Solenoid Replacement. . . . . . . . . . . . . . . . . . 7-18 Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Reverse Circuit Breaker Replacement. . . . . . . . . . . 7-19 Reverse Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Switch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Switch Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Trunk Door
Reverse Jumper Cables/Wires. . . . . . . . . . . . . . . . . . . . 7-21 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Reverse Motor to Battery Ground Jumper. . . . . . . . 7-23 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Reverse Motor/Bracket Hinge Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Hinge Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Reverse Motor Solenoid Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Trunk Door Latch Assembly
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Disassembly/Assembly. . . . . . . . . . . . . . . . . . . . . . 2-20
Solenoid Hold-In Test. . . . . . . . . . . . . . . . . . . . . . . . 7-39 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Solenoid Pull-In Test. . . . . . . . . . . . . . . . . . . . . . . . . 7-39 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Solenoid Return Test. . . . . . . . . . . . . . . . . . . . . . . . 7-40 Trunk Door Latch Pin
Reverse Motor System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Reverse Motor Current Draw Test. . . . . . . . . . . . . . 7-38 Trunk Door Lock Assembly
Assembly/Installation. . . . . . . . . . . . . . . . . . . . . . . . 2-19
Removal/Disassembly. . . . . . . . . . . . . . . . . . . . . . . 2-19

XII INDEX
Trunk Door Seal
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Turn Signal Lamps, Front
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
V
Vehicle Starter to Circuit Breaker Jumper
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
VIN
Vehicle Identification Number. . . . . . . . . . . . . . . . . . . 2-5
W
Wiring Diagram Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . A-5

INDEX XIII
NOTES

XIV INDEX