HOME 1.1 GENERAL SERVICING A NEW MOTORCYCLE Safety Safety is always the most important consideration when per- forming any job. Be sure you have a complete understanding of the task to be performed. Use common sense. Use the proper tools. Protect yourself and bystanders with approved eye protection. Don't just do the job - do the job safely. Perform the service and maintenance operations as indicated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or serious injury. (00010a) Removing Parts Always consider the weight of a part when lifting.
Use a hoist whenever necessary. Do not lift heavy parts by hand. A hoist and adjustable lifting beam or sling are needed to remove some parts.The lengths of chains or cables from the hoist to the part should be equal and parallel and should be positioned directly over the center of the part. Be sure that no obstructions will interfere with the lifting operation. Never leave a part suspended in mid-air. Service operations to be performed before customer delivery are specified in the applicable model year predelivery and set- up instructions. The performance of new motorcycle initial service is required to keep warranty in force and to verify proper emissions sys- tems operation.
See 1.2 MAINTENANCE SCHEDULE . SAFE OPERATING MAINTENANCE NOTES • Do not attempt to retighten engine head bolts. Retightening can cause engine damage. Be sure to check capacity rating and condition of hoists, slings, chains and cables before use. Exceeding capacity ratings or using lifting devices that are in poor condition can lead to an accident, which could result in death or serious injury. (00466c) • During the initial break-in period, use only Harley-Davidson 20W50 engine oil. Failure to use the recommended oil will result in improper break-in of the engine cylinders and piston rings. Always use blocking or proper stands to support the part that has been hoisted.
If a part cannot be removed, verify that all bolts and attaching hardware have been removed. Check to see if any parts are in the way of the part being removed. A careful check of certain equipment is necessary after periods of storage, and frequently between regular service intervals, to determine if additional maintenance is required. Check: When removing hoses, wiring or tubes, always tag each part to verify proper installation. 1. Tires for abrasions, cuts and correct pressure. 2. Secondary drive belt for proper tension and condition. Cleaning 3. Brakes, steering and throttle for responsiveness.
If you intend to reuse parts, follow good shop practice and thoroughly clean the parts before assembly. Keep all dirt out of parts; the unit will perform better and last longer. Seals, filters and covers are used in this vehicle to keep out environmental dirt and dust. These items must be kept in good condition to guarantee satisfactory operation. 4. Brake fluid level and condition. Hydraulic lines and fittings for leaks. Also, check brake pads and rotors for wear. 5. Cables for fraying, crimping and free operation. 6. Engine oil and transmission fluid levels. When you are instructed in a step to clean fastener threads or threaded holes, proceed as follows:
Clean all LOCTITE material from fastener threads and threaded holes. Use a wire brush to clean fastener threads. Use a thread chaser or other suitable tool to clean threaded holes. Use PJ-1 cleaner or equivalent to remove all traces of oil and contaminants from threads. Blow out all threaded holes with low pressure compressed air. 7. Headlamp, auxiliary lamp, tail lamp, brake lamp, horn and turn signal operation. SHOP PRACTICES Repair Notes Clean and inspect all parts as they are removed. Be sure all holes and passages are clean and open. After cleaning, cover all parts with clean lint-free cloth, paper or other material. Be sure the part is clean when it is installed.
General maintenance practices are given in this section. NOTES • Repair = Disassembly/Assembly. • Replacement = Substitute a new part for existing com- ponent. Always clean around lines or covers before they are removed. Plug, tape or cap holes and openings to keep out dirt, dust and debris. All special tools and torque values are noted at the point of use. Always verify cleanliness of blind holes before assembly. Tightening a screw with dirt, water or oil in the hole can cause castings to crack or break. All required parts or materials can be found in the appropriate PARTS CATALOG. 2009 VRSC Service: Maintenance 1-1