Harley Davidson Sport Glide FLSB Main Service (V1.0)

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Main Service Report

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.

(1.1) (Every 5k) Check front & rear tyre pressure & tread condition. Check for cracks and/or deformity.<br>(Front: 2.5 bar (36psi), Rear: 2.9 bar (42psi) cold - minimum tread 1mm)

(2.1) (Every 5k) Check operation of all electrical equipment & switches.
(2.2) (Every 5k) Check the battery terminal torque and clean the connections. Check battery holding charge.

(3.1) (Every 5k) Inspect front & rear brake fluid sight glass.<br>Replace fluid every 2 years. (Brake fluid sight glass should appear dark if level correct - use DOT4 brake fluid).
(3.2) (Every 5k) Test brake fluid that moisture content is <3%. Replace front & rear brake fluid every 2 years.
(3.3) (Every 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) (Every 5k) Check and adjust clutch as required (mechanical). Free-play at lever: 1.6 - 3.2mm
(3.5) (Every 5k) Check, adjust & lubricate brake and clutch controls. Use Harley lube.
(3.6) (Every 5k) Check, adjust & lubricate the throttle controls. Use Harley lube.

(4.1) (Every 5k) Check tightness of front & rear brake reservoir cover screws.
(4.2) (Every 10k) Check tightness of upper & lower fork bracket pinch bolts.
(4.3) (Every10k) Check tightness of upper & lower switch housing screws.
(4.4) (Every 10k)Check tightness of clutch lever handlebar clamp screws.
(4.5) (Every 10k) Check tightness of master cylinder handlebar clamp screws.
(4.6) (Every 10k) Check tightness of front & rear axle nuts.
(4.7) (Every 10k) Check tightness of front & rear brake master cylinder banjo bolts.
(4.8) (Every 10k) Check tightness of front & rear brake caliper banjo bolts.
(4.9) (Every 10k) Check tightness of front & rear ABS module (HCU) banjo bolts.
(4.10) (Every 10k) Check tightness of handlebar clamp screws.

(5.1) (Every 5k) Inspect oil lines & brake system for leaks, contact or abrasion.
(5.2) (Every 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) (Every 10k) Replace primary chaincase lubricant, replace drain plug, O-Ring and cover seal. Use Formula+ Transmission & Primary Chain Lube (0.95L).<br>(Torque settings - Drain plug: 19.0 - 28.5Nm, Clutch inspection cover screws: 9.5 - 12.2Nm).
(5.4) (Every 20k) Replace transmission lubricant. <br>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) (Every 5k) Inspect & lubricate jiffy stand. Clean and apply anti-seize lube
(5.6) (Every 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.
(5.7) (Every 5k) Clean & inspect oil cooler

(6.1) (Every 5k) Inspect air cleaner & service/oil as required.
(6.2) (Every 5k) Inspect fuel lines & fittings for leaks, contact or abrasion.
(6.3) (Every 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. Check rear drive belt sprocket mounting bolts for tightness.
(6.4) (Every 5k) Inspect exhaust system for cracks, loose/missing fasteners etc.
(6.5) (Every 30k/2Yrs) Replace spark plugs. Gap: 0.97 - 1.09mm, Torque: 16.3 - 24.2Nm
(6.6) (Every 5k) Check gear change linkage arm for play. Adjust and tighten if required.
(6.7) (Every 50k) Disassemble, inspect & rebuild forks & replace fork oil.
(6.8) (Every 100k) Replace fuel filter element.
(6.9) (Every 5k) Check windshield fixings & operation.
(6.10) (After every service) Road test - verify component & system functions.
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