Tech Tips Online TT263 – August 31, 2006 New Saddlebag Repair Kits and FLHRS Latch Adjustment
New Saddlebag Repair Kits and FLHRS Latch Adjustment
From time to time a leather saddlebag will lose a rivet, buckle, or stud, and will require repair.
The intention of this Tech Tip is to make you aware of two new repair kits available for leather
saddlebags, as well as to remind you of a repair technique for the Road King Custom
saddlebag.
The FLHRS saddlebag is opened by a button on the back edge of the bag. When this button
is pushed, it engages a cable that releases the lid. Occasionally, this button may not work
properly and the saddlebag will become hard to open. If this happens, the release
mechanism can be adjusted. Consult your Touring Service Manual, Section 2 (Chassis),
under the heading: “Cable Assembly/Latch/Script (FLHRS)” for instructions and illustrations
on this adjustment.
Harley-Davidson has developed a new repair kit (PN 52154-07) for FLSTN P&A saddlebags
(PN 53015-05). Depending on use, the lids on these saddlebags might over time develop a
‘gap’ between the sealing surfaces on the inboard side of the bag and the lids. The new
repair kit contains a shorter wire form hasp and fasteners, which will pull the latch assembly
closer to the rear of the bag thereby creating a better lid seal. Please see P & A Service
Bulletin # P-63 for more details. (NOTE: the saddlebag will require a little more effort to
open and close the lid with this new fastener.)
A rivet repair kit—PN 88272-06--has become available for saddlebags. The kit includes long
and short rivets (in black and silver colors), and washers. These rivets should be used to
replace missing/damaged rivets that hold straps or buckles to saddlebags.
For a complete listing of repair kits for leather and vinyl seats, saddlebags, and accessories,
refer to Tech Tip 216. Additionally, please remember that I-sheets contain listings of service
parts for most accessory seat and saddlebag kits.
TT262 – August 28, 2006 Painted Parts
Painted Parts
On painted parts a surface condition called “worming” has been reported by the Dealer
network. Worming is a surface condition (on top of clear coat) that appears to the Dealer
Technician as water marks that will not wipe off.
Recommendation TT261 – August 17, 2006 - Advanced Audio System Radio Returns
Advanced Audio System Radio Returns
When you receive a “REFURB” radio for a warranty situation please submit the warranty
claim immediately after the repair is made. You could receive an Approved Warranty Claim
within 48 hours (if the claim is filed correctly). When that is received please print off of copy of
the approved claims and include it in the box when returning the radio. It is very important
that we receive the warranty radios so we can keep a supply in stock for these situations.
TT260 - August 16, 2006 - Radio Diagnostic Trouble codes B2007 and B2010
Radio Diagnostic Trouble codes B2007 and B2010
An issue has been found with radios on early ’07 touring models. Trouble codes B2007 and
B2010 are set and will not clear, but the radio functions properly. These radios can be
identified by checking the calibration I.D. in diagnostic mode.
To view the calibration I.D., use this procedure:
Turn ignition ON and verify the radio is ON, and in FM mode
Radios that have a calibration I.D. that ends with the letters “AN” have this issue. Calibration
I.D.’s that end with “AP” are the current production and do not have this issue.
If you encounter a radio with these trouble codes and a calibration I.D. that ends with “AN”,
ignore the codes.
TT259 - August 15, 2006 - 2007 Maintenance Specifications
Printable maintenance charts for 07's similar to what is in the service manuals.
TT258 – August 9, 2006 Primary Drive / Starter Noise Complaints
Primary Drive / Starter Noise Complaints
Several dealers and customers have commented about a “clunking” noise coming from the
primary housing during start up. Most dealers suspect a loose compensator because the
noise seems to come from the front of the housing. Customers tend to associate it with a
starter issue like improper starter drive engagement into the clutch’s ring gear. In fact the
condition they are noticing is what is referred to as “Starter Knock”. This is a normal sound
and condition for all 2007 Twin Cam models.
Changes in the primary drive system increased the diameter and inertial effects of the
rotating components (clutch and sprocket assembly, ring gear, and engine sprocket). Also,
the engine control system is calibrated to start the engine as quickly as possible (short crank
to run times) and to run up to the predetermined engine idle speed as quickly as possible to
provide very positive starting.
Because the engine fires and then runs up to speed very quickly, there is a large torque input
and instantaneous speed differential between the engine and spring loaded compensator
mounted between the engine and the driveline. The compensator is there to dampen the high
torque spikes inherent in a large displacement V-Twin.
Because of the increased inertia in the rotating components in the driveline, their rotational
speed cannot increase as fast as the engine, so the springs in the compensator momentarily
bottom and results in the sound that you hear.
The same sound exists in the 2006 Dyna models, but to a lesser extent. The increase in
displacement to 1584cc increased the torque spike and speed differential in the 2007’s and
causes the sound to be more noticeable.
There is no damage associated with the compensator bottoming.
Identifying characteristics of this condition: TT257 – August 7, 2006 V-rod Starter Solenoid Wire Orientation
V-rod Starter Solenoid Wire Orientation
Please note that some V-rod models (2002 to present) have had the Starter solenoid Black
and Green wires mismatched at connector 128B. TT256 – August 3, 2006 V-Rod Fuel Modules
TT255 – August 2, 2006 Buell Ulysses P&A Side Cases (90057-05Y)
TT254 – August 1, 2006 Evolution Style Base Gaskets
TT253 – July 28, 2006 04-06 XL Rocker Box Gaskets
TT252 – July 25, 2006 07 XL Sportster Engine Temperature Sensor Wire Routing
TT251 - July 14, 2006 - 2007 Harley-Davidson Smart Security System Dealer Quick Start Guide
TT250 - July 14, 2006 - 2007 Model Year Information
TT249 - July 14, 2006 - 7mm Valve Guide Pilot
TT248 – July 7, 2006 - 2006 Dyna Black Mesh Conduit
TT247 – June 30, 2006 - Destroyer C-25 calibration for International markets.
TT246 – June 28, 2006 - Advanced Audio System Software Update .
TT245 – June 19, 2006 - 19” Wheel Tubes.
TT244 - June 2, 2006 - Heated Seats.
TT243 – May 23, 2006 - Advanced Audio System - AAS.
TT242 – May 12, 2006 - Electrical Diagnostic Tips.
TT241 - May 05, 2006 - Remanufactured Engine Installation.
TT240 - April 28, 2006 - Dyna Ignition Switch/Fork Lock.
TT239 - April 21, 2006 - 2006 Dyna Primary Chaincase Cover Drain Plug.
TT238 - April 13, 2006 - 2006 Dyna Fuse Block Labels.
TT237 - April 4, 2006 - Trouble Codes 35 and 44
TT236 - March 24, 2006 - Calibration Information.
TT235 - March 7, 2006 - 103 Stage 1 Street Legal Calibrations.
TT234 - February 22, 2006 - 1340 V² Flywheel Pinion Race Refurbishing.
TT233 - February 13, 2006 - 2006 Dyna Service Manual.
TT232 - February 6, 2006 - 2006 FLHTCUSE “CVO” Tour-Pak Lock.
TT231 - February 1, 2006 - Fuel Tank Top Plate Installation Procedures.
TT230 - January 30, 2006 - Buell Translucent Air Box Cover Hardware.
TT229 - January 23, 2006 - 2006 FLHTCUSE “CVO” Heated Seat.
TT228 - January 17, 2006 - 2006 Advanced Audio System Information.
TT227 - January 9, 2006 - 2006 Dyna neutral switch part number.
TT224 - December 12, 2005 - TSSM Enhancements.
TT223 - December 6, 2005 - Service Bulletin M-1180 Correction.
TT221 - November 28, 2005 - 2006 HDI Dyna Model O2 Sensor Plugs.
TT220 - November 14, 2005- Service Bulletin M-1180 Correction.
TT219 - November 07, 2005 - Diagnostic Trouble Code Information.
TT218 - October 31, 2005 - 2006 Dyna Model Wire Harness.
TT217 - October 24, 2005 - Instructions for setting V-Rod Model clocks.
TT216 - October 17, 2005 - Leather/Vinyl Products Repair Information.
TT215 - October 10, 2005 - EFI Heat Management Strategy.
TT214 - October 3, 2005 - XL Stator plug connector.
TT213 - September 26, 2005 - VRSCSE2 & VRSCR Model Ignition Switch Covers.
TT212 - September 21, 2005 - 2006 Dyna Model Primary Drive Locking Tool.
TT211 - September 16, 2005 - Sportster and Buell XB Model Flywheel Sprocket Shaft Nut Torque Update.
TT210 - September 13, 2005 - 2006 Fairing Equipped Touring Model Ignition Switches.
TT209 - August 22, 2005 - Advanced Audio System Information.
TT208 - August 15, 2005 - Stage Downloads.
August 10, 2005 - Diagnosing Oil Consumption.
August 3, 2005 - 2006 Fuse Block Covers.
August 3, 2005 - 2006 Model Year Information.
July 25, 2005 - 2006 Calibrations.
July 19, 2005 - Cruise Control Set/Resume Switch.
July 13, 2005 - PDI Recommendation.
July 5, 2005 - ECM Running Change.
June 27, 2005 - Screamin’ Eagle 6-Speed Transmission Speed Sensor Plugs.
June 21, 2005 - Front Brake Light Switch Installation Procedure.
June 13, 2005 - Fuse Part Number Quick Reference Guide.
June 6, 2005 - Sportster Models Labor Code 4332.
May 31, 2005 - Screamin Eagle Pro EFI Race Tuner.
May 25, 2005 - Screamin' Eagle Stage I& II Kits.
May 16, 2005 - CVO Tour-Pak Interior Light Kits.
May 9, 2005 - 2005 XL Model Wire Harness Elbow.
May 2, 2005 - Bulletins M-1089A & PAB844.
April 25, 2005 - XL Model Rear Fenders.
April 18, 2005 - 2005 FLT Police Model Parts Catalogue corrections.
April 11, 2005 - Recall 0118 Clarification.
April 4, 2005 - Softail Flywheel Balancer Sprocket.
March 28, 2005 - Owner’s Manual Corrections: 2005 VRSCSE Clock Adjustment.
March 22, 2005 - Twin Cam Piston Identification Markings.
March 16, 2005 - Service Bulletin M-1162.
March 7, 2005 - Warranty News and Updates.
February 28, 2005 - VRSCR Front Fork Oil Level Correction.
February 21, 2005 - 2004/2005 V-Rod Leak Detection Process.
February 15, 2005 - ECM Connector.
February 7, 2005 - 2006 VRSCR Front Tire.
January 31, 2005 - Springer Softail Labor Code Update.
January 24, 2005 - H-D Pre-Delivery and Setup Manual.
January 17, 2005 - Screamin’ Eagle Pro EFI Race Tuner.
January 10, 2005 - Twin Cam Valve Spring and Camshaft Information.
January 4, 2005 - Horn Issues.
December 20, 2004 - PNA Warranty Procedure.
December 13, 2004 - Job/Time Codes
December 6, 2004 - XL883 Ignition module calibration changes
November 24, 2004 - Fuel Valve Verification Procedure
November 1, 2004 - Twin Cam Flywheels
October 25, 2004 - Automatic VIN Detection
October 11, 2004 - EFI Race Tuner Calibrations
October 4, 2004 - Paint Repair Techniques
September 27, 2004 - Stage Calibrations
September 20, 2004 - Halogen Headlamps
September 13, 2004 - Older Tech Tips Archived
September 6, 2004 - Trouble Code Diagnostics
August 05, 2004 - 2005 Performance Configurations. Replacement ECM’s
August 30, 2004 - 2005 Touring Models Maintenance Schedule
August 05, 2004 - 2005 Performance Configurations
August 2, 2004 - BUELL XB models oil line clamp
July 22, 2004 - 2005 Quick Facts
July 14, 2004 - Fluctuating Fuel Gauge Readings on V-Rod
June 28, 2004 - Oil Leaks?
June 21, 2004 - Low Fuel Lamp On EFI Models
June 15, 2004 - Screamin' Eagle Parts Information
June 7, 2004 - 2004 Twin Cam Combustion Codes
May 31, 2004 - Labor Code Information
May 10, 2004 - 2004 XL Rear Caliper
April 26, 2004 - Crank Position Sensors
April 19, 2004 - Milliampere Draw Information
April 05, 2004 - Left Rear Speaker Box
March 29, 2004 - 2004 V-Rod Enhancements
March 22, 2004 - VRSCA/B Maxi-Fuse
March 08, 2004 - Fuel Tank Material Change
March 01, 2004 - EFI Tuner Download Issue
February 9, 2004 - Accessory Instruments On 2004 Models
February 2, 2004 - 1998-2002 Radio Upgrade. 2004 ECM Calibrations
January 26, 2004 - Repair Kits for Adjustable Rider Backrest Seats
January 19, 2004 - Crank Position Sensor Change
January 12, 2004 - Softail Transmission Mounting Brackets
January 05, 2004 - FLHTCSEI Rear Speakers
December 14, 2003 - Ultra Sidecar Sound System
December 8, 2003 - Saddlebag Location On 2004 Models
December 01, 2003 - Passing Lamp Changes - North American Vehicles Only
November 24, 2003 - PISTON FITMENT
November 10, 2003 - Recent Changes, various (induction module screws).
November 10, 2003 - Accessory Power - 2004 Models
November 3, 2003 - V-Rod Cooling System Issues
October 29, 2003 - Engine Noise and Vibration Complaints
October 20, 2003 - TSM/TSSM Information
October 13, 2003 - ECM and ICM Issues
October 06, 2003 - P&A Compass Tips
October 02, 2003 - Domestic Stock EFI Calibrations
October 01, 2003 - EFI Performance Calibration Information
September 29, 2003 - Buell Speed Sensor
September 22, 2003 - Painted Parts Orders
September 08, 2003 - P&A Compass Tips
August 11, 2003 - New Radio Changes Affect 1998 - 2003 Models
August 04, 2003 - Adjustable Rider Backrest Kits For Touring Models
July 28, 2003 - Twin Cam Breather Assemblies
July 14, 2003 - Accessory Fitment Questions
July 07, 2003 - Muffler Recommendations
May 05, 2003 - Saddlebags & Sidecover Damage on Touring Models
April 07, 2003 - Setting Idle Speed With Digital Technician
March 31, 2003 - Warranty Information
March 24, 2003 - EFI Race Tuner Kit Changes
March 17, 2003 - Injected Twin Cam High Temperature Idle
February 24, 2003 - HTTC Forged Stroker Piston Ring Identification
February 17, 2003 - 2003 Radio
February 03, 2003 - Digital Technician Phase 8 DVD Update
January 27, 2003 - Warranty Information
January 20, 2003 - 2000 and 2001 Softail Deuce Swingarm/Frame Contact
January 13, 2003 - Vehicle Cranks but Won't Start
January 06, 2003 - 100th Anniversary Sterling Silver, Black and Gunmetal Painted Parts Clarification
December 30, 2002 - Code 35 on Magnetti-Marelli EFI Systems
December 23, 2002 - V-Rod Check Engine Light with No Codes Present
December 19, 2002 - New Radio Sound Warranty Repair Rates
December 16, 2002 - New Shift Lever
December 09, 2002 - Radio Antenna Issues
December 02, 2002 - S3, M2 Battery Cable Routing
November 25, 2002 - Kent-Moore Special Tools Catalog Change
November 18, 2002 - V Rod Fuel Range Function
November 11, 2002 - Cruise Control Troubleshooting
November 04, 2002 - Speedometer Diagnostics
October 28, 2002 - Buell Vehicle Speed Sensor Change
October 21, 2002 - XL Speedometer
October 14, 2002 - New Password Learn Procedures
October 07, 2002 - Idle Speed On Delphi EFI
September 30, 2002 - Race Kit Muffler Installation
September 23, 2002 - XB9R Clutch Adjustment
September 16, 2002 - Digital Technician "Bug"
September 09, 2002 - Front Injector Harness On Touring Models
September 02, 2002 - Missing Parts/Shortages On New Vehicles
August 26, 2002 - TSM/TSSM Diagnostic Cable
August 19, 2002 - New Battery Labels
August 12, 2002 - 2003 FLHRSEI2 Paint
August 05, 2002 - 2003 FXSTDSE Metal Leaf Graphics
July 29, 2002 - SADDLEBAG LATCH SPRING, (Part No. 90707-00) REPLACEMENT
July 22, 2002 - No Start Condition P1010 P1009
July 15, 2002 - Police Emergency Equipment
July 08, 2002 - Missing Part/Shortage On York Vehicles
July 04, 2002 - 1998-2002 Radio Sound Ultra Upgrades
July 01, 2002 - Performance Cartridge Downloads
June 24, 2002 - New Softail ECM Calibration
June 17, 2002 - Speedometer Signal and Code P0505 ( idle )
June 10, 2002 - ECM Calibration Information
May 06, 2002 - Unused Stage Downloads
April 29, 2002 - O-Ring Information
April 22, 2002 - TSSM Information
April 15, 2002 - Battery Charging Information
April 08, 2002 - Milliamp Draw Test
April 01, 2002 - Touring Model Lighting Circuit Change
March 03, 2002 - Trouble Codes After Stage Reflash
February 25, 2002 - Metal Leaf Graphics (2.58 MB)
February 04, 2002 - New Radio Sound Warranty Repair Rates
January 04, 2002 - 2002 Model Year Brake Observations
December 10, 2001 VRSCA - SPECIAL EDITION Revision to Rear Brake Pedal Adjustment
November 12, 2001 Touring Brake Caliper and Rotor Cover
October 23, 2001 Cruise Connector Protective Boot
October 22, 2001 Cruise Connector Protective Boot
October 17, 2001 Scream’in Eagle EFI Performance Options
October 12, 2001FLHRSEI - SEAT
October 03, 2001 EFI Performance Options
September 20, 2001 VRSCA Cleaning Care Products
August 14, 2001 Twin Cam 88™ Oil Pump Alignment
TT55 August 2002, various collection of earlier TT's
TT54 June 2001, various: TC-88 Oil Pump Alignment. TC-88 Camshaft Replacement
Primary Chain Tension Anchor Plate Screw and more
TT53 January 2001, various including Police Vehicle Start-up Concerns. Security System Activation
Disarming the Security System on Touring Models
TT52 June 2000, various including TC-88 Cam Support Plate Repair.
Electronic Speedometers Scratches
TT51 December 1999, various incuding TC CamSupport Plate. 00 Brake Bleed screws.
Engine Oil change tips
TT50 June 1999, various including TC Oil pressure Sender tip. EFI Idle.
Accessory Headlamp and Passing Lamp Bezels Gaskit kit
TT49 December 1998, various including 99 Speedo Malfunction. Voltage Regulators
Brake Fluid
TT48 August 1998, various including Tip for Short Circuits. Code56 and more
TT47 March 1998, various including EFI Idle, EFI Performance Products,
FL Fender Alignment and much more.
TT46 October 1997, various including Front Brake Switch/Cruise Control, EFI Idle, ‘98 Model Diagnostic Codes
TT45 April 1996, various including RK fuel Guage check, 1996 FLHT Fairing and more
TT44 January 1996, various including international FLHT ignition switches, spoke wheel change, turn signal modules
TT43 September 1995, various including Ignition Timing - 96 Models, speedo replacements and more
TT42 April 1995, Softail jiffy stand spring removal, install, EVO Cam Bearing Failures and more
TT41 December 1994, sprocket nut torquing, fluid ref guide and more
TT40 October 1994, Road King seat modifications, FX Disc retrofit and more
TT39 July 1994, gasket changes. FL fender mounting, cleaning products, 'Field' tips and more
TT38 February 1994, XL Starter/Oil hose routing, 'Field' tips and more
TT37 December 1993, Sportster oil tank retro fit correction and much more
TT36 October 1993, carb float level adjustment. Need old parts? A list of Suppliers and more
TT35, August 1993, 1994 models technical updates.
TT34 July 1993, Sportster retro oiltank fit, Dyna front wheel offset and more
TT33 January 1993,
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