Harley Davidson Softail Breakout Service

Title Page

General Information

Audit items marked ‘N/A’ are as a result of the mileage interval frequency not being due on this service .
Please note: This service document should be used in conjunction with a HD service schedule and manual.
Abbreviations: Service intervals
1Y/5k - Every 1 year or 5,000 miles
2Y/5k - Every 2 years or 5,000 miles

(1.1) 1Y/5k - Check front & rear tyre pressure & tread condition. Check for cracks and/or deformity. (Front: 36psi, Rear: 42psi cold - minimum tread 1mm)

(2.1) 1Y/5k - Check operation of all electrical equipment & switches.
(2.2) 1Y/5k - Check the battery terminal torque and clean the connections. Check battery holding charge. (Torque setting 6.8 - 8.1Nm)

(3.1) 1Y/5k - Inspect front & rear brake fluid sight glass. Replace fluid every 2 years. (Brake fluid sight glass should appear dark if level correct - use DOT4 brake fluid).
(3.2) 2Y/5k - Replace front & rear brake fluid every 2 years.
(3.3) 1Y/5k - Inspect front and rear brake pads & discs for wear. (Brake pads should be 1.02mm minimum, Discs - see stamp on side of disc for minimum).
(3.4) 2Y/5k - Check and adjust clutch as required (mechanical). Adjuster screw: 8.1 - 13.6Nm, Inspection Cover Screws: 9.5 - 12.2Nm, Free-play at lever: 1.6 - 3.2mm
(3.5) 2Y/5k - Check, adjust & lubricate brake and clutch controls. Use Harley lube.

(4.1) 1Y/10k - Check front & rear brake reservoir cover screw torque. Brake reservoir screw torque: (Front 1.0 - 1.2Nm, Rear 0.7 - 0.9Nm)
(4.2) 1Y/10k - Check upper & lower fork bracket pinch bolt torque (40.7 - 47.5Nm)
(4.3) 1Y/10k - Check upper & lower switch housing screw torque (4.0 - 5.1Nm)
(4.4) 1Y/10k - Check clutch lever handlebar clamp screw torque (6.8 - 9.0Nm)
(4.5) 1Y/10k - Check master cylinder handlebar clamp screw torque (6.8 - 9.0Nm)
(4.6) 1Y/10k - Check front & rear axle nut torque (Front: 95.0 - 101.8Nm, Rear: 129 - 142Nm).
(4.7) 1Y/10k - Check front & rear brake master cylinder banjo bolt torque (Both: 23.1 - 29.9).
(4.8) 1Y/10k - Check front & rear brake caliper banjo bolt torque (Both: 23.1 - 29.9).
(4.9) 1Y/10k - Check front & rear ABS module (HCU) banjo bolt torque (Both: 13.6 - 16.3Nm).
(4.10) 1Y/10k - Check handlebar clamp screw torque (16.3 - 20.3Nm)

(5.1) 1Y/5k - Inspect oil lines & brake system for leaks, contact or abrasion.
(5.2) 2Y/5k - Replace engine oil & filter (SYN3 Synthetic or SAE 20W50 oil - drain plug torque 19.0 - 28.5Nm). Oil capacity 2.8L with filter
(5.3) 2Y/10k - Replace primary chaincase lubricant, replace drain plug, O-Ring and cover seal. Use Formula+ Transmission & Primary Chain Lube (0.95L). (Torque settings - Drain plug: 19.0 - 28.5Nm, Clutch inspection cover screws: 9.5 - 12.2Nm).
(5.4) 2Y/20k - Replace transmission lubricant. Use Formula+ Transmission & Primary Chain Lube (0.83L). (Torque settings - Drain plug: 19.0 - 28.5Nm, Filler plug/dipstick: 2.8 - 8.5Nm).
(5.5) 2Y/5k - Inspect & lubricate jiffy stand. Clean and apply anti-seize lube
(5.6) 10k - Lubricate the steering head - Fill grease fitting on steering neck until grease starts to come out of top & bottom of steering head. Use Special Purpose Grease.

(6.1) 2Y/5k - Inspect air cleaner & service as required.
(6.2) 1Y/5k - Inspect fuel lines & fittings for leaks, contact or abrasion.
(6.3) 1Y/5k - Inspect drive belt & sprockets for wear & adjust belt (6.5 - 8.0 mm deflection at 4.5kg of lift). Upward force applied at mid-point of bottom belt strand.
(6.4) 1Y/5k - Inspect exhaust system for cracks, loose/missing fasteners etc.
(6.5) 2Y/30k - Replace spark plugs. Gap: 0.97 - 1.09mm, Torque: 16.3 - 24.2Nm