Service Tips

"Advance preparation for the Cycle tour, especially the tour of some distance, is far preferable to disappointment and difficulty on the road later. 'Forewarned is forearmed' is a legendary saying that may be applied with particular force to the Cross Country Tour."
H.C. (Hap) Scherer, Transcontinentalist reporting in the April 1920 edition of The Enthusiast® magazine

What was true more than 80 years ago is true today. Roads and motorcycles are a lot different from those in the 1920s. But the need for proper maintenance and preparation is just as important as ever, especially before a long trip. The quality of the time we spend on the road often depends on what we do in the garage.
A quick, pre-ride routine will keep your Harley® ready and your mind at peace:

1.	Before riding your motorcycle at any time, do a general inspection of the entire bike to be sure it's in safe riding condition.

2.	You can start by checking the oil and filter and inspect other fluid levels. Harley-Davidson® motorcycles are made to make oil changes easy. If you do it yourself, don't slack off on the maintenance schedule. And make sure the old oil is properly disposed. It should be sealed in an approved container and taken to a legitimate oil disposal facility.

3.	Next you'll want to check the controls to be sure they operate properly. On your list of controls to inspect should be the front and rear brakes, throttle, clutch and shifter. You should also examine the steering for smoothness by turning the handlebars through the full operating range.

4.	Check tire pressure often, daily when you are touring, and always using a good gauge. Consult your owners' manual for correct pressure and load rating. Air pressure can change with the air temperature. While you're at it, inspect the tires. Replace them if there's less than 50 percent of the tread left, or if there's any cracks, cuts or signs of distress. Tires should be changed by your dealer. They are expertly trained to replace tires and to inspect your wheels.

5.	Check for any fuel, oil or hydraulic fluid leaks. Give the cases and lines a once over to make sure there are no leaks.

6.	For high-mileage bikes, inspect the drive belt, sprockets and brakes.

7.	Check your headlights, directionals, tail light and brake light every time you ride. Not only do they help you see where you're going, but they are your best way of being seen by others. If a light is out, it is easy to change yourself. Consult your owners' manual and/or service manual for correct type and removal and replacement procedure. If replacing a headlight, be certain the beam is focused properly.

8.	Before you start riding, sit on your bike and take a look in the mirrors to be sure they're adjusted properly. Even if you don't think you've moved the mirrors, do a quick check just to be sure.

9.	You can double the life of your battery by checking and correcting its water level regularly. It's as easy as looking at it with a flashlight for most models. In warm weather climates, check the water level on a regular basis. Otherwise, every 2,500 miles is a good guideline. For those who can't ride as often as they'd like, install a battery charger with a convenient disconnect. If you travel often, for instance, the charger will help you avoid a dead-battery homecoming.

10.	The Harley-Davidson Extended Service Plan™ prevents a breakdown from ruining a trip. If you ever get stranded on the road, you'll be reimbursed for out-of-pocket expenses* you pay while covered repairs are being made to your bike, including car rental costs and pick-up charges. Plus, if you're ever stuck overnight, your Harley-Davidson Extended Service Plan will even pick up the tab for your hotel and meals.*See contract for complete details.

11.	Doing basic maintenance yourself can save you time and money in the long run, but don't venture into the land of do-it-yourself if it's not your natural habitat. The risks just aren't worth it.

AT 1,000 MILES / 1,600 KILOMETERS

ITEM SERVICED	PROCEDURE	NOTES
Engine oil and filter	Replace
Oil lines and brake system	Inspect for leaks	1
Air cleaner	Inspect, service as required
Tires	Check pressure, inspect tread
Wheel spokes	Check tightness	1
Primary chaincase lubricant	Replace
Transmission lubricant	Replace
Clutch	Check adjustment	1
Rear belt and sprockets	Inspect, adjust belt	1
Throttle, brake and clutch controls	Check, adjust and lubricate	1
Jiffy stand	Inspect and lubricate	1
Fuel lines and fittings	Inspect for leaks	1
Brake fluid	Check levels and condition	3
Brake pads and discs	Inspect for wear
Spark plugs	Inspect
Electrical equipment and switches	Check operation
Steering head bearings	Lubricate	2
Air suspension	Check pressure, operation and leakage	1
Cruise control	Inspect disengage switch and components	1
Fuel door, Tour-Pak, saddlebags	Lubricate hinges and latches
Critical fasteners	Check tightness	1
Road test	Verify component and system functions

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 miles (80,000 kilometers)

3. Change D.O.T. 4 and flush brake system every two years

AT 5,000 MILES / 8,000 KILOMETERS

ITEM SERVICED	PROCEDURE	NOTES
Engine oil and filter	Replace
Oil lines and brake system	Inspect for leaks	1
Air cleaner	Inspect, service as required
Tires	Check pressure, inspect tread
Wheel spokes	Check tightness	1
Clutch	Check adjustment	1
Rear belt and sprockets	Inspect, adjust belt	1
Throttle, brake and clutch controls	Check, adjust and lubricate	1
Jiffy stand	Inspect and lubricate	1
Fuel lines and fittings	Inspect for leaks	1
Brake fluid	Check levels and condition	2
Brake pads and discs	Inspect for wear
Spark plugs	Inspect
Electrical equipment and switches	Check operation
Air suspension	Check pressure, operation and leakage	1
Cruise control	Inspect disengage switch and components	1
Fuel door, Tour-Pak, saddlebags	Lubricate hinges and latches
Road test	Verify component and system functions

NOTES

1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified

2. Change D.O.T. 4 and flush brake system every two years

AT 10,000 MILES / 16,000 KILOMETERS

ITEM SERVICED	PROCEDURE	NOTES
Engine oil and filter	Replace
Oil lines and brake system	Inspect for leaks	1
Air cleaner	Inspect, service as required
Tires	Check pressure, inspect tread
Primary chaincase lubricant	Replace
Clutch	Check adjustment	1
Rear belt and sprockets	Inspect, adjust belt	1
Throttle, brake and clutch controls	Check, adjust and lubricate	1
Jiffy stand	Inspect and lubricate	1
Fuel lines and fittings	Inspect for leaks	1
Brake fluid	Check levels and condition	3
Brake pads and discs	Inspect for wear
Spark plugs	Inspect
Electrical equipment and switches	Check operation
Steering head bearings	Lubricate	2
Air suspension	Check pressure, operation and leakage	1
Windshield bushings (if applicable)	Inspect	1
Cruise control	Inspect disengage switch and components	1
Fuel door, Tour-Pak, saddlebags	Lubricate hinges and latches
Critical fasteners	Check tightness	1
Engine mounts and stablizers	Inspect	1
Road test	Verify component and system functions

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 miles (80,000 kilometers)

3. Change D.O.T. 4 and flush brake system every two years

AT 15,000 MILES / 24,000 KILOMETERS

ITEM SERVICED	PROCEDURE	NOTES
Engine oil and filter	Replace
Oil lines and brake system	Inspect for leaks	1
Air cleaner	Inspect, service as required
Tires	Check pressure, inspect tread
Clutch	Check adjustment	1
Rear belt and sprockets	Inspect, adjust belt	1
Throttle, brake and clutch controls	Check, adjust and lubricate	1
Jiffy stand	Inspect and lubricate	1
Fuel lines and fittings	Inspect for leaks	1
Brake fluid	Check levels and condition	2
Brake pads and discs	Inspect for wear
Spark plugs	Inspect
Electrical equipment and switches	Check operation
Air suspension	Check pressure, operation and leakage	1
Cruise control	Inspect disengage switch and components	1
Fuel door, Tour-Pak, saddlebags	Lubricate hinges and latches
Road test	Verify component and system functions

NOTES

1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified

2. Change D.O.T. 4 and flush brake system every two years

AT 20,000 MILES / 32,000 KILOMETERS

ITEM SERVICED	PROCEDURE	NOTES
Engine oil and filter	Replace
Oil lines and brake system	Inspect for leaks	1
Air cleaner	Inspect, service as required
Tires	Check pressure, inspect tread
Wheel spokes	Check tightness	1
Primary chaincase lubricant	Replace
Transmission lubricant	Replace
Clutch	Check adjustment	1
Rear belt and sprockets	Inspect, adjust belt	1
Throttle, brake and clutch controls	Check, adjust and lubricate	1
Jiffy stand	Inspect and lubricate	1
Fuel lines and fittings	Inspect for leaks	1
Brake fluid	Check levels and condition	3
Brake pads and discs	Inspect for wear
Spark plugs	Replace
Electrical equipment and switches	Check operation
Steering head bearings	Lubricate	2
Air suspension	Check pressure, operation and leakage	1
Windshield bushings (if applicable)	Inspect	1
Cruise control	Inspect disengage switch and components	1
Fuel door, Tour-Pak, saddlebags	Lubricate hinges and latches
Critical fasteners	Check tightness	1
Engine mounts and stablizers	Inspect	1
Road test	Verify component and system functions

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 miles (80,000 kilometers)

3. Change D.O.T. 4 and flush brake system every two years

AT 25,000 MILES / 40,000 KILOMETERS

ITEM SERVICED	PROCEDURE	NOTES
Engine oil and filter	Replace
Oil lines and brake system	Inspect for leaks	1
Air cleaner	Inspect, service as required
Tires	Check pressure, inspect tread
Clutch	Check adjustment	1
Rear belt and sprockets	Inspect, adjust belt	1
Throttle, brake and clutch controls	Check, adjust and lubricate	1
Jiffy stand	Inspect and lubricate	1
Fuel lines and fittings	Inspect for leaks	1
Fuel tank filter	Replace	1
Brake fluid	Check levels and condition	2
Brake pads and discs	Inspect for wear
Spark plugs	Inspect
Electrical equipment and switches	Check operation
Steering head bearings	Adjust	1
Air suspension	Check pressure, operation and leakage	1
Cruise control	Inspect disengage switch and components	1
Fuel door, Tour-Pak, saddlebags	Lubricate hinges and latches
Road test	Verify component and system functions

NOTES

1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified

2. Change D.O.T. 4 and flush brake system every two years

Often over-looked and more often under-estimated is the importance of winterizing your bike for storage over the winter. Taking the proper steps prior to storing your bike can dramatically increase the longevity of its key components.

Prior to storing the bike you should have a few things on hand.

Fresh Oil and Filter
Fuel Stabilizer
Motorcycle Cover
Battery Tender

One of the most important steps you can take is to change the oil and filter prior to storage. Oil has a nasty habit of absorbing combustibles and other nasty junk. You don't want to leave this in the engine over the winter. So, take the bike out for a ride and get it good and warmed up. On the way home, stop by the gas station and top off the tank.

While the bike is still good and hot, change out the oil and filter. Given the price of lubricants vs. the price of your drivetrain, it may also be a good time to change out the transmission and primary chain case fluids.

Next, add a good fuel stabilizer to your topped off tank. Gasoline is made of compounds that over time can evaporate and leave behind a sludge that can gunk up the fuel system.

Run the bike for 5 minutes or so to get the fresh oil and stabilized fuel throughout the engine. If your bike has a petcock, turn it off. It is not necessary to run the carburetor out of fuel if you are using a stabilizer.

Wash and Wax the bike. Not just a quickie, but the full treatment. All of the dirt and grim on the bike and eat away at its finishes over the winter months. A good wash and wax will go a long way to protect the shiny stuff over the cold months. Areas to be particularly aware of are around the wheels and brake components. Brake dust can become corrosive and can quickly eat away at the finish of your wheels and other parts in the area.

Check the air in the tires, and suspension if it applies, and adjust appropriately.

Pick your storage spot well. You want to store the bike in a well ventilated and cover it with a BREATHABLE storage cover. Don't use a cover designed to keep the rain out, because it will keep the moisture in which will diminish the finishes on your bike. Pick a nice out of the way place away from extreme temperature changes, chemicals or electrical appliances. Keeping the bike away from chemicals can seem fairly obvious, but did you know that many appliances such as heaters and electric motors can create ozone which is hard on rubber and other surfaces. Also, don't store the bike on a dirt or gravel surface. As moisture rises from the dirt or gravel, it can become trapped on the underside of your bike.

If possible get both tires off the ground. This is not crucial, but if you can't do this, at least roll the bike back or forth a few times over the winter to prevent flat spots.

Finally, connect the battery to a SMART battery tender that will keep the battery charged, but not overcharged. Tuck the bike into its cover and dream of warmer days.

One more thing, it is NOT a good idea to go out and start the bike once in a while during the winter. If you start the bike and it does not get completely warmed up, condensation can develop inside the motor. As a rule, don't start the bike in the winter unless you intend on riding it until it reaches full operating temperature.

Beartooth Harley-Davidson/Buell's Parts Professionals can direct you to the proper supplies and answer any other questions you may have about winterization.