Top 10 2000 Harley Davidson FLSTC Heritage Softail Classic Questions & Answers

first take off the brake caliper takes a 10 mm socket..Next jack front of bike up just enough to take pressure off front tire...take off the axle nut lbit more to take pressure off axleock washer and flat washer...Next remove two axle support nuts from the right side of bike 1/2 in socket. now jack bike up a hair more to releave pressure off axle push, hammer with a rubber hammer or what ever it takes to drive it through. jack bike up so it clears fender. Sometimes the tire won't clear the fender bolts if so just release air from tire and it will clear. good luck. Its not hare at all.

Down and dirty way - take it to the dealer and have them install a new tire....

The hard way: place bike on bike jack and remove rear wheel by removing the axle nut and drifting the axle out of the wheel. Derail the belt/chain and drop the wheel out of the brake caliper. Remove valve stem to deflate the tire. Get a set of tire spoons and a 12 pack of COLD brew cause working with tire spoons is no FUN! Pry the bead loose with one spoon and the work your way around the wheel prying the tire beed to the outside of the wheel. Repeat this process for the back side of the tire (in the same direction as the first side so the tire will come off the wheel. Reverse and repeat to install new tire.

By now you will be loading your wheel into the truck and heading to the HD shop. It just really isn't worth the hastle to save the $25 or so to have this job done.

Align wheel with new tire on it with the brake caliper so that you have one shoe on each side of the rotor (you may have to actually remove the caliper if your pads are thick. Install your belt drive/chain drive and then lift the wheel to insert the axle through the swing arm, the chain tensioner and wheel. Reverse
on the other side. Place axle nut on axle and torque to about 80lbs.

Good to go.

Set the alarm by holding the key fob button until you see running lights flash twice. Turn off the alarm by pushing the key fob button twice and the lights will flash once.

Locate & route Black lead to ground / 2004-later softail: On the frame strap under the seat directly in front of the battery.

Locate & route the pink lead to Signal / For 2004 & later FXST/C/I The #3 cavity in the connector {39b} on the back of the speedometer. The socket terminal on the signal (pk) lead fits the #3 cavity.

Locate & route the Orange and white lead to power / Ummm.. it's saying for 2004 and later to adapt to the fuse block For earlier [ For 1996 to 2003 softail: locate the power lead (o/w) in the tail lamp pin connector {7a} under the seat behind the right rear corner of he battery.] "here you are looking to run it to a fused line, not directly to power/battery" I hope this helped.

To get the starter off a FatBoy (Softail series) is a bit more difficult than most bikes because of interference from the oil tank. You may elect to remove the tank but I have done it without removing the tank only later wish that I had taken it off. You'll have to make up your mind on that.

First, disconnect and remove the battery. Then remove the outer primary cover. With that cover off, you can remove the small bolt that holds the "starter jackshaft" on and remove the jack shaft. You may have to take the nut off the clutch assembly and slide it forward just a bit to get the jackshaft out. If you have to do this, remove the snap ring that holds the clutch pushrod adjuster in and remove the small plate. The nut is inside the hole and has LEFT-HANDED threads. Retorque 60-80 foot pounds. Loosen the nut and slide the clutch assemble forward just enough to get the jackshaft out of the hole. If the jackshaft coupler come out with the jackshaft mark which end goes in what direction. There is a snap ring on the inside and the coupling must be in the correct direction upon reassembly.

From the other side, remove the battery cable from the starter. Remove the two large bolts that hold the starter to the inner primary case. The negative cable may be connected to the rear most bolt on some year models. The starter should now come out.

If you decide to remove the oil tank, drain the oil and remove all hoses. There are two hex head bolts at the top of the tank and two rubber mounts that must be taken off. Then the tank will lift up just enough to get the starter out. Good Luck.

A 1992 Heritage doesn't have fuses, they have circuit breakers from the factory. A circuit breaker is looks like a small metal container that is about about a half inch tall and wide and about an inch long. It works like a fuse in that execessive current will trip the circuit breaker just like the ones in your house but as soon as the bi-metal strip inside of it cools, it will reset itself until the next time the current level is exceeded. The current level is determined by the currrent handling capability of the wire in the circuit it is controlling.

Now, the Heritage was notorious of blowing the filaments in the rear tail light bulb. Have you tried a new bulb in it. If that's not what it is, you'll need a test light or a DVOM (digital volt ohm meter) and a schematic to trace out the problem.

The horn is probably not on the same circuit as the tail light. Use the test light or DVOM to check for voltage at the plug on the horn. It's probably got a bad ground or just the horn itself is bad.

Good Luck
steve

To remove the starter on you Softail, first disconnect the negative side of the battery.

Then drain the primary and remove any footboards, shifters, ect. so that you can get the outer primary cover off. Once the cover is off, remove the small bolt that holds the starter jackshaft on and remove the jackshaft. The jackshaft coupling may come out with the jackshaft. Mark which way the coupling goes back in as there is a snap ring on the inside that is not in the center.

Now, go to the right side of the bike and remove the exhaust system, and remove the bolts that hold the oil in. Do not take the tank out but you need to be able to lift the tank just a bit. Remove the battery cable from the starter using a 12mm wrench. There are two large bolts that hold the starter into the inner primary, remove these two bolts and unplug the small wire at the top of the solenoid and the starter will come out.

Good Luck
Steve

Steven, I am assuming that your Road King is fuel injected. If so here's where you can find a clear and straight forward wiring diagram. Obviously this diagram stops at the ECM (Electronic Control Mondule) and if that got damaged due to a short, improper ground or power surge then the ECM may need to be replaced to get your bike fully functional again, however that's probably the worst case. Here's the link:http://www.nightrider.com/biketech/motorcycle_efi_basics.htm

Pre-Twin Cam motors have a check ball (#11 in illustration below):

http://4.bp.blogspot.com/-_S3nmiD7Aiw/TZ5U_VVapEI/AAAAAAAADDM/6m98aYAzxjI/s1600/DSC04354a.jpg

S&S oil pumps operate on the same principal as stock Harley.
This ball and it's cast-in seat can wear over time, and/or get some crud in there, allowing oil to leak past it when the engine is off (gravity fed).

Remove screw cap and remove check ball (a small magnet works great).
Check to see if there is a wear "ring" around it.
Clean it off, and the seat it seals against.
Sometimes, it wears to the point that it needs replaced.

When oil leaks past it over an extended time (like a couple of months), the oil collects in the sump of the engine crankcase.
When you first start the engine, being a "dry" sump engine (the scavenger side of the oil pump is almost TWICE the capacity as the feed side), the oil pump right away tries to send as much of the extra oil back to the oil tank, but some is going to come out the breather(s), and maybe even burn in the combustion chamber.

If this is the case, here's a quick check:

Before starting, check and note oil level in tank.
After starting and running for a bit (5-10 minutes), shut off the motor and recheck the oil level in the oil tank.
If it has risen noticablly, the above is your problem.

The jackshaft must be installed back onto the starter shaft prior to installing the jackshaft with the shallow side of the coupling going/facing towards the jackshaft and also facingthe jackshaft splines. Remember to reinstall the coupling retaining ring if it was removed. ALSO, be sure to install the coupling on the starter output shaft with the counter bore facing the jackshaft. THEN put the spring inside the coupling and install the pinion gear on the shaft put the lockplate and the thrust washer on the bolt and put the bolt in place in the jackshaft. If you removed the retaining ring put it back on shaft and then slide the jackshaft assembly back into position in the inner primary. In order to hold the lockplate and thrust washer in place be certain that the lockplate tab is properly in the keyway. THEN, having aligned the lockplate tab and thrust washer properly in the slot with the jackshaft keyway screw the jackshaft bolt into the starter shaft and while holding the pinion gear in position tighten the bolt to 84-108 in-lbs (9.5-12.2 Nm) and bend the locking tab against bolt head.