Harley Davidson 2004 Touring Models. Service Manual

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Service

Operation

Data

Lubricant

Part No. 94968-

85TV- 1/4 fl. oz.

Handlebar clamp

screw torque

Throttle Cables

60-80 in-lbs

(6.8-9.0 Nm)

Switch housing

screw torque

35-45 in-lbs

(4-5 Nm)

Plug type

HD-6R12

Plug gap

0.038-0.043 in.

Spark Plugs

(0.97-1.09 mm)

Plug torque

12-18 ft-lbs

(16-24 Nm)

Electrical

Check for proper

Components

operation.

Idle speed

Engine Idle Speed

950-1050 rpm

Critical Fastener

Verify tightness.

Torque

See Table 1-6.

Stabilizer Links

See ENGINE

and Engine

MOUNTS in

Mounts

Section 1.5.

Fork oil (Type E)

Front Fork Oil

Part No. 99884-

80 (16 oz)

Road Test

R - Replace or change

I - Inspect (adjust, clean or replace as required)

L - Lubricate (with specified lubricant)

X - Perform

T - Tighten to proper torque

D - Disassemble (lube and inspect as required)

1-14

2004 Touring: Maintenance

HOME

SCHEDULED MAINTENANCE PROCEDURES

1.5

BATTERY

f1641x3x

At the 1000 mile (1600 km) service interval, and at every

5000 mile (8000 km) service interval thereafter, inspect the

battery as follows:

1. Battery top must be clean and dry. Dirt on the top of the

battery may cause the battery to self-discharge at a

faster than normal rate.

2. Inspect battery screws, clamps, and cables for break-

age, loose connections and corrosion. Clean clamps.

Coat terminals with grease.

3. Inspect battery for discoloration, raised top, or warped

case which may indicate battery has been overheated or

overcharged.

4. Inspect the battery case for cracks or leaks.

NOTE

For charging information, see Section 8.10 BATTERY, BAT-

TERY CHARGING.

Figure 1-1. Remove Engine Oil Filter

ENGINE OIL/ENGINE OIL FILTER

Clean the oil filter mount flange of any old gasket mate-

At the 1000 mile (1600 km) service interval, and at every

rial.

5000 mile (8000 km) service interval thereafter, change the

engine oil and engine oil filter as follows:

Lubricate gasket with clean engine oil and install new oil

filter on filter mount. Hand tighten oil filter 1/2-3/4 turn

NOTE

after gasket first contacts filter mounting surface. Do

If the motorcycle is ridden hard, under dusty conditions, or in

NOT use OIL FILTER WRENCH for oil filter installation.

cold weather, the oil and filter should be changed more often.

NOTE

1. Ride vehicle until engine is at normal operating tempera-

ture.

Use of the Premium 10 micron synthetic media oil filter is

highly recommended, Part No. 63798-99 (Chrome) or 63731-

2. Locate oil filler plug/dipstick on right side of vehicle at top

99 (Black).

of transmission case. To remove the oil filler plug, pull

steadily while moving plug back and forth.

8. Install engine oil drain plug and tighten to 14-21 ft-lbs

3. Locate oil drain plug at front left side of the oil pan.

(19-28 Nm).

Remove the oil drain plug and allow oil to drain com-

9. With vehicle resting on jiffy stand, add 3-1/2 quarts (3.3

pletely.

liters) engine oil as specified in Table 1-1. Use the proper

4. Inspect the oil drain plug O-ring for cuts, tears or signs of

grade of oil for the lowest temperature expected before

deterioration. Replace as necessary.

the next oil change.

5. Remove the oil filter as follows:

Table 1-1. Recommended Engine Oils

a. Obtain the OIL FILTER WRENCH (HD-42311). The

tool allows easy removal of the oil filter without risk

Harley-

Lowest

Cold Weather

of damage to the crankshaft position sensor or

Harley-Davidson

Viscosity

Davidson

Ambient

Starts Below

cable.

Type

Rating

Temperature

50˚F (10˚C)

b. Place the jaws of the wrench over the oil filter with

SAE

Below 40˚F

the tool oriented vertically. See Figure 1-1.

HD Multi-grade

HD 360

Excellent

10W40

(4˚C)

c. Using a 3/8 inch drive with a 4 inch extension, turn

SAE

Above 40˚F

HD Multi-grade

HD 360

Good

wrench in a counterclockwise direction. Do not use

20W50

(4˚C)

with air tools.

SAE

Above 60˚F

HD Regular Heavy

HD 360

Poor

(16˚C)

NOTE

SAE

Above 80˚F

HD Extra Heavy

HD 360

Poor

Use OIL FILTER WRENCH (HD-44067) if HD-42311 is not

(27˚C)

available.

2004 Touring: Maintenance

1-15

HOME

COLD CHECK

HOT CHECK

f1254b3x

Figure 1-2. Engine Oil Dipstick

CAUTION

1WARNING

Oil level cannot be accurately measured on a cold

To protect against shock and accidental start-up of vehi-

engine. For preride inspection, with motorcycle leaning

cle, disconnect the negative battery cable before pro-

on jiffy stand on level ground, oil should register on dip-

ceeding. Inadequate safety precautions could result in

stick between arrows when engine is cold. Do NOT add

death or serious injury.

oil to bring the level to the FULL mark on a COLD engine.

Unthread bolt and remove battery negative cable (black)

10.

Perform engine oil level COLD CHECK as follows:

from battery negative (-) terminal.

a. With the vehicle resting on the jiffy stand on level

See Figure 1-3. Using a T27 TORX drive head, remove

ground, wipe off the dipstick and insert it back into

four screws to free the primary chain inspection cover

the oil pan with the plug pushed completely into the

from the primary chaincase cover.

fill spout.

Check the primary chain tension. Push on the upper

b. Remove the dipstick and note the level of the oil. Oil

strand to verify that it has free up and down movement

level should register between the two arrows on the

midway between the engine compensating sprocket

dipstick. See Figure 1-2. If oil level is at or below the

(front) and the clutch sprocket (rear).

lower arrow, add only enough oil to bring the level

between the two arrows on the dipstick.

Table 1-2. Primary Chain Adjustment

11.

Perform engine oil level HOT CHECK as follows:

a. Ride vehicle until engine is at normal operating tem-

(Free Play)

Inches

Millimeters

perature.

COLD ENGINE

5/8-7/8 inch

15.9-22.2 mm

b. With the vehicle resting on the jiffy stand on level

ground, allow engine to idle for 1-2 minutes. Turn

HOT ENGINE

3/8-5/8 inch

9.5-15.9 mm

engine off.

c. Wipe off the dipstick and insert it back into the oil

pan with the plug pushed completely into the fill

f1210x6x

spout.

d. Remove the dipstick and note the level of the oil.

Add only enough oil to bring the level to the FULL

mark on the dipstick. See Figure 1-2. Do not overfill.

12.

Start engine and carefully check for leaks around hoses,

Clutch

drain plug and oil filter.

Inspection

Primary

Cover

Chain

Inspection

Cover

PRIMARY CHAIN

At the 1000 mile (1600 km) service interval, and at every

5000 mile (8000 km) service interval thereafter, inspect the

primary chain tension and adjust if necessary.

Drain Plug

Proceed as follows:

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

Figure 1-3. Primary Chaincase Cover

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2004 Touring: Maintenance

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PRIMARY CHAIN LUBRICANT

f1841x6x

Top

At the 1000 mile (1600 km) service interval, and at every

Center

5000 mile (8000 km) service interval thereafter, replace the

Nut

primary chain lubricant as follows:

Using a T27 TORX drive head, remove five screws (with

Chain Inspection

captive washers) to free clutch inspection cover from pri-

Cover Opening

mary chaincase cover.

Remove magnetic drain plug at bottom of primary chain-

case cover. Drain lubricant into suitable container. See

Figure 1-3.

Clean drain plug. If plug has accumulated a lot of debris,

inspect the condition of chaincase components.

Inspect drain plug O-ring for cuts, tears or signs of dete-

rioration. Replace as necessary.

Install drain plug back into primary chaincase cover.

Figure 1-4. Primary Chaincase Cover

Tighten plug to 36-60 in-lbs (4.1-6.8 Nm).

Pour 32 ounces (946 ml) of Harley-Davidson PRIMARY

5. Measure the free play to be sure that it falls within the

CHAINCASE LUBRICANT through the clutch inspection

range specified for a hot or cold engine. See Table 1-2.

cover opening, Part No. 99887-84 (quart) or Part No.

99886-84 (gallon). See Figure 1-5.

6. If the chain is too tight or too loose, then adjust as fol-

lows:

CAUTION

a. Locate the chain tensioner assembly and loosen the

top center nut a maximum of two turns. See Figure

Do not overfill the primary chaincase with lubricant.

1-4.

Overfilling may cause rough clutch engagement, incom-

plete disengagement, clutch drag and/or difficulty in

b. Raise or lower the chain tensioner assembly as

finding neutral at engine idle.

necessary to obtain the specified free play.

7. Remove quad ring from groove in primary chaincase

NOTE

cover. Wipe all lubricant from the quad ring and inspect

As chains stretch and wear, they run tighter at one spot than

for cuts, tears or signs of deterioration. Replace as nec-

essary.

another. Always adjust the free play at the tightest spot in the

chain. Replace the primary chain if it is worn to the point

where it cannot be properly adjusted.

Primary

Chaincase Cover

CAUTION

Always keep the primary chain properly adjusted. Allow-

ing the chain to run too tight or too loose will result in

excessive chain and sprocket wear.

c. Tighten the top center nut of the chain tensioner

assembly to 21-29 ft-lbs (29-39 Nm).

7. Align holes in new gasket with holes in the primary

chaincase cover. Using a T27 TORX drive head, install

four screws to secure primary chain inspection cover to

primary chaincase cover. Alternately tighten screws to

84-108 in-lbs (10-12 Nm) in a crosswise pattern. See

Figure 1-3.

8. Insert bolt through battery negative cable (black) into

Lubricant

threaded hole of battery negative (-) terminal. Tighten

bolt to 60-96 in-lbs (6.8-10.9 Nm).

f1508b6x

9. Install seat. See Section 2.24 SEAT, INSTALLATION.

Figure 1-5. Fill Primary Chaincase With Lubricant

2004 Touring: Maintenance

1-17

HOME

CLUTCH ADJUSTMENT

f1440x6x

Jam

Nut

At the 1000 mile (1600 km) service interval, and at every

5000 mile (8000 km) service interval thereafter, adjust the

Rubber

clutch as follows:

Boot

Cable

CAUTION

End

Perform the clutch adjustment with the motorcycle at

Cable

room temperature. The clearance at the adjuster screw

Adjuster

will increase as the powertrain temperature increases. If

adjuster screw is adjusted while the powertrain is hot,

clearance at push rod bearing could be insufficient with

Figure 1-6. Clutch Cable Adjuster Mechanism

powertrain cold and clutch slippage could occur.

NOTE

Adjust for 1/16-1/8 inch

(1.6-3.2 mm) gap

Perform adjustment procedure whenever clutch components

between ferrule

are replaced during normal servicing. Repeat adjustment

Clutch

and bracket

after 500 miles (800 km) of use.

Cable

Stand vehicle upright and level.

Using a T27 TORX drive head, remove five screws (with

captive washers) to free clutch inspection cover from pri-

mary chaincase cover.

See Figure 1-6. Slide rubber boot off cable adjuster.

Holding cable adjuster with 1/2 inch wrench, loosen jam

nut using a 9/16 inch wrench. Back jam nut away from

Ferrule

cable adjuster. Move adjuster toward jam nut to intro-

Clutch Lever

duce a large amount of free play at hand lever.

f1421x6x

Bracket

See Figure 1-8. Loosen locknut on clutch adjuster screw.

To take up all free play in push rods, turn screw inward

Figure 1-7. Adjust Clutch Free Play

(clockwise) until lightly seated.

Swab all lubricant from the quad ring groove. Install

quad ring in primary chaincase cover with the nubs con-

f1509b6x

Clutch

tacting the ring groove walls.

Adjuster

NOTE

Screw

If lubricant is not thoroughly removed from both the quad ring

and groove, compression of the ring during installation of the

clutch inspection cover can cause lubricant to be squeezed

to the outboard side of the ring groove, resulting in some

temporary weepage around the inspection cover.

Using a T27 TORX drive head, install five screws (with

captive washers) to secure clutch inspection cover to the

primary chaincase cover. Alternately tighten screws to

84-108 in-lbs (10-12 Nm) in the pattern shown in Figure

1-3.

1WARNING

When adding lubricant, do not allow dirt, debris or other

contaminants to enter the primary chaincase. Exercise

caution so that lubricant does not contact rear wheel,

Locknut

tire and brake components. Such contact can adversely

affect traction and may lead to loss of vehicle control,

which could result in death or serious injury.

Figure 1-8. Clutch Assembly

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2004 Touring: Maintenance

HOME

Back out adjuster screw 1/2 to 1 turn. While holding

adjuster screw with an allen wrench, tighten locknut to

8496

Clutch

72-120 in-lbs (8-14 Nm).

Release

Cover

Squeeze clutch lever to maximum limit three times to set

ball and ramp release mechanism.

Turn cable adjuster away from jam nut until slack is elim-

inated at hand lever. Pull clutch cable ferrule away from

clutch lever bracket to check free play. Turn cable

adjuster as necessary to obtain 1/16 to 1/8 inch (1.6 -

3.2 mm) free play between end of cable ferrule and

clutch lever bracket, as shown in Figure 1-7.

Filler

Hold adjuster with 1/2 inch wrench. Using 9/16 inch

Plug

wrench, tighten jam nut against cable adjuster. Cover

cable adjuster mechanism with rubber boot.

Remove quad ring from groove in primary chaincase

cover. Wipe all lubricant from the quad ring and inspect

Figure 1-9. Transmission Case (Right Side)

for cuts, tears or signs of deterioration. Replace as nec-

essary.

OMF50

10.

Swab all lubricant from the quad ring groove. Install

quad ring in primary chaincase cover with the nubs con-

tacting the ring groove walls.

11.

Using a T27 TORX drive head, install five screws (with

captive washers) to secure clutch inspection cover to the

primary chaincase cover. Alternately tighten screws to

84-108 in-lbs (10-12 Nm) in the pattern shown in Figure

1-3.

O-Ring

TRANSMISSION LUBRICANT

Figure 1-10. Transmission Lubricant Filler Plug/Dipstick

At the 1000 mile (1600 km) service interval, and at every

5000 mile (8000 km) service interval thereafter, replace the

transmission lubricant as follows:

Fill the transmission with

20-24 oz. (590-710 ml) of

transmission lubricant or until the lubricant level on the

1. Remove the filler plug from the clutch release cover on

dipstick of the filler plug is at the F(ULL) mark with the

the right side of the transmission case. See Figure 1-9.

motorcycle in a level, upright position and the filler plug

Check the O-ring for tears, cuts or general deterioration.

resting on the threads.

Replace as necessary. See Figure 1-10.

Use only Harley-Davidson SEMI-SYNTHETIC TRANS-

2. Locate transmission drain plug on the right side of the oil

MISSION LUBRICANT: Part No.’s 99892-84 (quart),

pan. Remove the magnetic plug and drain the transmis-

98853-96 (case of quarts), 99891-84 (gallon), or 98852-

sion lubricant into a suitable container.

96 (case of gallons).

3. Remove any foreign material from the drain plug. Check

Install the transmission filler plug/dipstick in the clutch

the O-ring on the drain plug for tears, cuts or general

release cover. Tighten the plug to 25-75 in-lbs (2.8-8.5

deterioration. Replace as necessary.

Nm).

4. Install the transmission lubricant drain plug and tighten

to 14-21 ft-lbs (19-28 Nm).

TIRES

1WARNING

At the 1000 mile (1600 km) service interval, and at every

When adding lubricant, do not allow dirt, debris or other

5000 mile (8000 km) service interval thereafter, inspect both

contaminants to enter the transmission case. Exercise

the tire condition and pressure.

caution so that lubricant does not contact rear wheel,

Inspect for wear as follows:

tire and brake components. Such contact can adversely

affect traction and may lead to loss of vehicle control,

a. Locate the arrows on the tire sidewalls. The arrows

which could result in death or serious injury.

point to location of the tread wear indicator bars.

See upper frame of Figure 1-11.

2004 Touring: Maintenance

1-19

HOME

WHEEL SPOKES

o0250xox

At the 1000 mile (1600 km) service interval, the 5000 mile

(8000 km) service interval, and then every

15,000 mile

Sidewall

(24,000 km) service interval thereafter, inspect spoke tight-

Arrow

ness, if applicable. Proceed as follows:

Raise wheel off the ground.

CAUTION

If nipples require more than one full turn to tighten

spoke, remove tire to check that spoke protrusion has

not damaged tube.

Lightly tap each spoke with a spoke wrench. Loose

spokes will sound dull and must be tightened. Tighten

Indicator Bar on

spokes to 40-50 in-lbs (4.5-5.6 Nm). If more than a few

Tread Surface

spokes are loose, true the entire wheel following the pro-

cedure under Section 2.7 TRUING LACED WHEEL.

o0249xox

STEERING HEAD BEARINGS

Figure 1-11. Tread Wear Indicator Bars

At the 1000 mile (1600 km) service interval, and at every

10,000 mile (16,000 km) service interval thereafter, grease

the steering head bearings using Special Purpose Grease,

b. Immediately replace tires if any tread wear indicator

Part No. 99857-97. Turn handlebar full right to access the

bar is on the tire tread surface, indicating that 1/32

grease fitting at the left side of the steering head. Connect

inch (0.8 mm) or less of tire tread pattern remains.

grease gun to fitting and inject grease until it exudes from top

See lower frame of Figure 1-11.

and bottom of steering head. See Figure 1-12.

NOTE

At every 25,000 mile (40,000 km) service interval, check the

Harley-Davidson recommends that the tires be replaced

swing-by following the procedure under Section

2.17

BEFORE the tread wear indicator bars are on the tire tread

STEERING HEAD BEARINGS and adjust as necessary.

surface.

At every 50,000 mile (80,000 km) service interval, disassem-

Inspect for damage. Replace tires if:

ble the steering head and inspect the bearings for brinelling,

● Cords or fabric become visible through cracked

scoring, or other damage. Replace and/or repack the bear-

ings as required. See Section 2 for more information.

sidewalls, snags or deep cuts.

● Bump, bulge or split line is observed.

● Puncture, deep cut or other damage is present that

is not repairable.

f2108x2x

3. Check tire pressure.

Steering

Head

Table 1-3. Tire Pressure (Cold)

FRONT

REAR

DUNLOP TIRES ONLY

PSI

BARS

PSI

BARS

Solo Rider

2.5

Rider & One Passenger

2.5

2.8

Grease

Fitting

1WARNING

Do not inflate tires beyond the maximum inflation pres-

sure specified on tire sidewall. Overinflation can lead to

Figure 1-12. Steering Head Bearing Grease Fitting

tire failure while vehicle is in operation, which could

result in death or serious injury.

1-20

2004 Touring: Maintenance

HOME

BRAKE FLUID

DRIVE BELT

At the 1000 mile (1600 km) service interval, and at every

5000 mile (8000 km) service interval thereafter, inspect the

5000 mile (8000 km) service interval thereafter, inspect drive

brake fluid condition and level. Proceed as follows:

belt for damage and proper deflection. Proceed as follows:

Remove left side saddlebag. See Section 2.25 SAD-

CAUTION

DLEBAG, REMOVAL.

To prevent dirt from entering the master cylinder reser-

Check deflection at the loosest spot in the belt with the

voir, thoroughly clean the cover before removal.

transmission in neutral and the motorcycle cold. Use

BELT TENSION GAUGE (HD-35381A), or install narrow

1. Remove two Phillips screws from cover of master cylin-

saddle (HD-35381-3) on existing gauge, and apply 10

der reservoir. Remove cover (with gasket).

lbs. (4.5 kg) of force at the midpoint of the bottom belt

2. Stand the vehicle upright so that the master cylinder res-

strand. See Figure 1-13. Belt deflection should be as fol-

ervoir is in a level position. Fluid level should be 1/ 8 inch

lows:

(3.2 mm) from the top. Add fluid as necessary.

Table 1-4. Belt Deflection

NOTE

Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID,

Orientation

Inches

Millimeters

Part No. 99902-77 (12 oz.) or Part No. 99901-77 (gallon).

On Jiffy Stand

Without Rider or Luggage

1/4 - 5/16

6.4

- 7.9

3. Install cover (with gasket) on the master cylinder reser-

10 psi (69 kPa) in Rear Shocks

voir. Install two Phillips screws and tighten to 6-8 in-lbs

(0.7-0.9 Nm).

Motorcycle Upright

3/16 - 1/4

4.8

- 6.4

With Rear Wheel in the Air

1WARNING

If belt deflection is within specification, install left side

Whenever the brake system is serviced, it should be

saddlebag. If adjustment is necessary, move to step 3.

tested on dry, clean pavement at slow speeds before put-

ting the motorcycle into regular service. Improperly ser-

Remove right side saddlebag. See Section 2.25 SAD-

viced brakes can lead to an accident that could result in

DLEBAG, REMOVAL.

death or serious injury.

Remove right side muffler as follows:

BRAKE PADS AND DISCS

Transmission

Rear Wheel

Sprocket

At the 1000 mile (1600 km) service interval, and at every

5000 mile (8000 km) service interval thereafter, inspect the

brake pads and discs as follows:

Brake Pads

If brake pad friction material is worn to 0.04 inch (1.02 mm) or

less, replace the entire set of pads.

10 lbs. (4.5 kg)

of Force

f1652x6x

See Table 1-4.

1WARNING

For correct and safe brake operation, brake pads must

Belt Tension Gauge

be replaced in sets at the same time. Mismatched brake

Part No. HD-35381A

pads could lead to an accident resulting in death or seri-

ous injury.

Brake Discs

The minimum brake disc thickness is stamped on the side of

the disc.

Belt Tension Gauge Adapter

Part No. HD-35381-3

When checking the brake pads and discs, inspect the brake

lines and hoses for damage or leaks.

Figure 1-13. Check and Adjust Belt Deflection

2004 Touring: Maintenance

1-21

HOME

LEFT SIDE

RIGHT SIDE

Increase

Reduce

Belt

Deflection

Cone

Nut

Weld

Nub

Weld

Nut

E-Clip

Nub

Adjuster

Cam

8398

8407

Figure 1-14. Move Rear Wheel Forward Until Adjuster Cams Just Contact Weld Nubs

a. Open worm drive clamps to remove heat shield

c. Push wheel forward slightly so that adjuster cam

from rear header pipe in front of muffler.

just contacts weld nub on both sides of rear swing-

arm. See Figure 1-14.

b. Using a bungee cord, tie the muffler to the lower

saddlebag support rail.

d. Check belt deflection. Apply 10 lbs. (4.5 kg) of force

at the midpoint of the bottom belt strand. Belt

c. Loosen TORCA clamp between rear header pipe

deflection should be within the range specified in

and muffer.

Table 1-4.

d. Remove two bolts (with lockwashers) to detach muf-

e. If belt is still too tight, repeat steps 7(b) through 7(d).

fler from the lower saddlebag support rail.

If belt is now too loose, move to step 6.

e. Remove bungee cord to release muffler from lower

saddlebag support rail.

8. Holding weld nut on left side of axle, tighten cone nut on

right side to 95-105 ft-lbs (128.8-142.4 Nm).

Standing on right side of vehicle, remove E-clip from

NOTE

groove at end of axle. Loosen cone nut, and then snug

If the axle moves during tightening of the cone nut, then the

to 15-20 ft-lbs (20-27 Nm). See Figure 1-14.

the belt deflection procedure must be restarted.

If belt is too tight, move to step 7 to increase belt deflec-

tion. If belt is too loose, reduce belt deflection as

9. Recheck belt deflection to verify that it is still within spec-

ification.

described below:

a. Rotate weld nut on left side of axle in a clockwise

If the belt deflection is not within specification, loosen

cone nut and then snug to 15-20 ft-lbs (20-27 Nm)

direction.

before returning to step 6.

b. Check belt deflection. Apply 10 lbs. (4.5 kg) of force

10. With the flat side out, install new E-clip in groove on right

at the midpoint of the bottom belt strand. Belt

side of axle.

deflection should be within the range specified in

Table 1-4.

11. Install right side muffler as follows:

c. If belt is still too loose, repeat steps 6(a) through

NOTE

6(b). If belt is now too tight, move to step 7.

TORCA muffler clamps have eliminated the need for silicone

or graphite tape during assembly. To ensure sealing integrity

If belt is too tight, increase belt deflection as follows:

of muffler clamps and prevent the possibility of leakage, Har-

a. Using a hydraulic center stand, raise motorcycle so

ley-Davidson recommends that TORCA clamp assemblies be

that the rear wheel is off the ground.

discarded and replaced each time they are removed.

b. Rotate weld nut on left side of axle in a counter-

a. Slide new TORCA clamp onto free end of rear

clockwise direction.

header pipe.

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2004 Touring: Maintenance

HOME

b. Using a bungee cord, tie muffler to lower saddlebag

REAR SHOCK ABSORBERS

support rail. Install muffler on rear header pipe.

Place TORCA clamp into position between rear

At the 1000 mile (1600 km) service interval, and at every

header pipe and muffler.

5000 mile (8000 km) service interval thereafter, inspect the

c. Tighten the two bolts (with lockwashers) to fasten

rear shock absorbers for signs of leakage or damage, and

the muffler to the lower saddlebag support rail.

replace if necessary. For adjustment of rear air suspension

pressures, see Section 2.18 REAR AIR SUSPENSION.

CAUTION

Verify that the exhaust pipes do not contact the vehicle

AIR CLEANER

frame or any mounted components. Contact will cancel

the effect of the rubber isolation mounts and transmit

At the 1000 mile (1600 km) service interval, and at every

vibration to the rider via the vehicle frame.

5000 mile (8000 km) service interval thereafter, inspect the

air cleaner filter element, and clean or replace as necessary.

d. Verify that exhaust pipes are in alignment and do

not contact the vehicle frame or mounted compo-

Remove large allen head socket screw in center of air

nents.

cleaner cover. Remove air cleaner cover with rubber

seal. See Figure 1-15.

e. Tighten the TORCA clamp to 45-60 ft-lbs (61-81

Remove three T27 TORX screws to release cover

Nm).

bracket from filter element.

Open worm drive clamps and install heat shield on

rear header pipe. Position clamp so that screw is on

CAUTION

the outboard side in the most accessible position.

Never run the engine with the filter element removed.

The filter prevents dirt and dust from entering the

CAUTION

engine.

Verify that the heat shields do not contact the vehicle

Remove filter element pulling two breather tubes from

frame or any mounted components. Contact will cancel

holes on inboard side.

the effect of the rubber isolation mounts and transmit

Remove gasket from sleeve on inboard side of filter ele-

vibration to the rider via the vehicle frame.

ment. Discard gasket.

g. Remove bungee cord from muffler.

Remove breather tubes from fittings on two cylinder

head breather bolts.

12. Install saddlebags. See Section

2.25 SADDLEBAG,

Remove two cylinder head breather bolts from backplate

INSTALLATION.

using a 7/16 inch deepwell socket.

f1650x4x

Cylinder Head

Breather

Breather Bolt

O-Ring

Tube

Cover

Bracket

T27 Torx

Air Cleaner

Screw

Cover

Gasket

Filter

Backplate

Element

Cover Screw

Figure 1-15. Air Cleaner Assembly

2004 Touring: Maintenance

1-23

HOME

Remove backplate from cylinder heads. On carbureted

21. Insert breather tubes about 1/4 inch (6.4 mm) into holes

California models, pull clean air inlet tube (to charcoal

on inboard side of filter element.

canister) from hole on inboard side of backplate.

22. Install breather tubes onto fittings of two cylinder head

Remove two O-rings from grooves around breather bolt

breather bolts.

holes on inboard side of backplate. Discard O-rings.

NOTE

Remove gasket from inboard side of backplate. Discard

Air cleaner mounting without installation of the breather

gasket.

tubes allows crankcase vapors to be vented into the atmo-

sphere in violation of legal emissions standards.

10. Thoroughly clean air cleaner cover and backplate.

11. Replace the filter element if damaged or if filter media

23. Place filter element onto backplate with the flat side

cannot be adequately cleaned.

down, so that hole on inboard side of element fits over

molded boss in backplate.

12. Wash the filter element and breather tubes in warm,

24. Align holes in cover bracket with those in filter element

soapy water. To remove soot and carbon, soak element

for 30 minutes in warm water with mild detergent.

and start three T27 TORX screws. Stamp on cover

bracket points to downside. Alternately tighten screws to

20-40 in-lbs (2.3-4.5 Nm) in a crosswise pattern.

1WARNING

25. Verify that rubber seal is properly seated around perime-

Do not use gasoline or solvents to clean the filter ele-

ter of air cleaner cover. Replace seal if cut, torn or shows

ment. Volatile or flammable cleaning agents may cause

signs of deterioration.

an intake system fire, which could result in death or seri-

26. Fit air cleaner cover into backplate. Apply a small dab of

ous injury.

Loctite Medium Strength Threadlocker

243 (blue) to

threads of large allen head socket screw. Install screw in

center of air cleaner cover. Tighten screw to 36-60 in-lbs

1WARNING

(4.1-6.8 Nm).

Compressed air can pierce the skin and cause injury.

Never use your hand to check for leaks or to determine

air flow rates. Wear safety glasses to shield your eyes

FUEL SYSTEM LINES

from flying dirt and debris. Failure to comply could result

in death or serious injury.

AND FITTINGS

13.

Dry the filter element using low pressure compressed air

At the 1000 mile (1600 km) service interval, and at every

(32 psi/221 kPa maximum). Rotate the element while

5000 mile (8000 km) service interval thereafter, inspect the

moving air nozzle up and down the element interior. Do

fuel system lines and fittings for leaks or damage.

not rap the element on a hard surface.

14.

Hold the filter element up to a strong light source. The

element can be considered sufficiently clean if light is

FUEL TANK FILTER (CARBURETED)

uniformly visible through the media.

15.

Inspect the breather tubes for cuts, tears, holes or signs

At every 25,000 mile (40,000 km) service interval, remove

of deterioration. Replace as necessary. Direct com-

and inspect the fuel tank filter as follows:

pressed air through the breather tubes to verify that they

are not plugged.

WARNING

16.

Install new O-rings in grooves around breather bolt

holes on inboard side of backplate.

Gasoline is extremely flammable and highly explosive.

When servicing the fuel system, do not smoke or allow

17.

Aligning flat edge of gasket with molded tab, install new

open flame or sparks in the vicinity. Inadequate safety

gasket on inboard side of backplate. On California mod-

precautions could result in death or serious injury.

els, install gasket by aligning small holes with plastic

pins.

Turn the handle of the fuel valve to OFF.

18.

On California models, push clean air inlet tube (to char-

coal canister) into hole on inboard side of backplate.

1WARNING

19.

Align holes in backplate with those in cylinder heads and

A small amount of gasoline may drain from the carbure-

install cylinder head breather bolts. Using a 7/16 inch

tor fuel inlet hose when disconnected from the fuel valve

deepwell socket, alternately tighten bolts to 10-12 ft-lbs

fitting. Thoroughly wipe up any spilled fuel immediately

(13.6-16.3 Nm).

and dispose of rags in a suitable manner. Gasoline is

20.

Slide new gasket over sleeve on inboard side of filter

extremely flammable and highly explosive. Inadequate

element. Be sure holes in gasket are aligned with those

safety precautions could result in death or serious

in filter.

injury.

1-24

2004 Touring: Maintenance

HOME

When the fuel tank is completely drained, remove the

f1960x4x

Mity-Vac® Hand Pump from the vacuum fitting.

Filter

Holding fuel tank adapter, turn the hex jam nut in a

Strainer

clockwise direction to remove the fuel valve assembly.

10.

Remove the fuel filter strainer from the valve head.

Clean or replace.

11.

Remove the hex jam nut from the fuel valve.

12.

Remove the gasket from the valve head. Discard the

gasket.

Carburetor

13.

Install a new gasket on the valve head.

Fuel Inlet

Hose

14.

Install the fuel filter strainer fitting the internal tube into

Jam

the larger hole in the valve head.

Nut

15.

Apply Loctite Pipe Sealant with Teflon 565 to threads of

Vacuum

fuel valve and fuel tank adapter.

Fitting

Gasket

16.

With the hex side down, turn the jam nut two full turns in

a counterclockwise direction to thread onto fuel tank

adapter.

17.

Insert fuel filter strainer into fuel tank. Holding the hex

jam nut to prevent rotation, turn the fuel valve two full

Hose

turns in a clockwise direction to thread onto hex jam nut.

Clamp

Convoluted

Tubing

1WARNING

Fuel

Outlet

Do not thread fuel valve onto hex jam nut more than two

Fitting

turns or nut may “bottom” on valve, a condition which

Atmospheric

Valve

Pressure

may result in a gasoline leak. Any gasoline leak is a

Handle

Port

potential fire hazard that could result in death or serious

injury.

Figure 1-16. Vacuum Operated Fuel Valve

18. Holding the fuel valve to prevent rotation, turn the hex

jam nut in a counterclockwise direction until snug.

Tighten the hex jam nut to 15-20 ft-lbs (20.3-27.1 Nm).

Using a side cutters, cut clamp and remove hose from

fuel outlet fitting at the front of the fuel valve. See Figure

1-16. Drain free end of hose into a suitable container.

CAUTION

Remove elbow of intake manifold vacuum tube from fit-

Do not allow dirt or fluids to get into the vacuum tube

ting on inboard side of the fuel valve.

that connects the fuel valve to the intake manifold. Con-

Attach a length of fuel hose to the fuel outlet fitting. The

taminants can block the vacuum signal which could

hose must be long enough to reach a suitable gasoline

cause the fuel valve to malfunction.

container.

19. Connect elbow of intake manifold vacuum tube to fitting

Turn the handle of the fuel valve to RES(ERVE).

on inboard side of the fuel valve.

Using the correct hose adapter, connect the Mity-Vac®

20. Slide new clamp onto free end of carburetor fuel inlet

Hand Pump (HD-23738A) to the vacuum fitting.

hose. Install hose onto fuel outlet fitting at front of fuel

valve. Crimp clamp using HOSE CLAMP PLIERS (HD-

97087-65B).

CAUTION

21. Turn the handle of the fuel valve to OFF and fill the fuel

To avoid damage to the diaphragm of the fuel valve, do

tank. Carefully inspect for leaks at fitting.

not apply a vacuum greater than 25 inches of Mercury

(Hg) to the vacuum fitting.

22. Turn the valve handle to ON and start engine. No prim-

ing or special procedures are required to start fuel flow.

7. Gently apply a vacuum of 1-10 inches of Mercury (Hg) to

Carefully inspect for leaks at fitting.

the vacuum fitting to get a good flow of gasoline through

the valve.

23. Stop engine and return the valve to the OFF position.

2004 Touring: Maintenance

1-25

HOME

f1438x4x

Mounting

f1225x2x

Lockwasher

Bracket

Enrichener

Knob

Hex

Nut

Knurled

Enrichener

Nut

Flat

Cable

5/32 Inch

(4.0 mm)

Figure 1-17. Enrichener Control

Cardboard

Insert

ENRICHENER CONTROL

At the 1000 mile (1600 km) service interval, and at every

Figure 1-18. Install Cardboard Insert

5000 mile (8000 km) service interval thereafter, inspect the

enrichener control as follows:

Notch

Ferrule

The fuel enrichener knob should open, remain open and then

close without binding. The knurled plastic nut next to the

enrichener knob controls the ease at which the cable slides

within the conduit.

Groove

If adjustment is needed, proceed as follows:

1. See Figure 1-17. Loosen hex nut at backside of mount-

ing bracket.

2. Move cable assembly free of slot in mounting bracket.

3. Hold cable assembly at flat with adjustable wrench.

Hand turn knurled nut counterclockwise to reduce sliding

Idle

resistance until knob slides inward unaided.

Cable

Throttle

4. Turn knurled nut clockwise to increase sliding resistance

Grip

Cable

until knob remains fully out without holding and then

f1474x2x

closes with relative ease.

Figure 1-19. Remove Throttle/Idle Cables

5. Slide enrichener cable into slot of mounting bracket.

With external tooth lockwasher and hex nut positioned

on the inboard side of the mounting bracket, tighten hex

Lubrication

nut to 20-35 in-lbs (2.3-4.0 Nm).

CAUTION

Do not remove the switch housing assembly without first

Do not lubricate the cable or inside of conduit. The cable

placing the 5/32 inch (4.0 mm) cardboard insert between

must have sliding resistance to work properly.

the brake lever and lever bracket. Removal without the

insert may result in damage to the rubber boot and

plunger of the Front Stoplight Switch.

THROTTLE CABLES

NOTE

Use the eyelet of an ordinary cable strap if the cardboard

insert is not available.

At the 1000 mile (1600 km) service interval, and at every

5000 mile (8000 km) service interval thereafter, inspect and

Place the cardboard insert between the brake lever and

lubricate the throttle and clutch cables as follows:

lever bracket. See Figure 1-18.

1-26

2004 Touring: Maintenance

HOME

Apply a light coating of graphite to the handlebar.

10.

Slide the throttle control grip over the end of the right

handlebar until it bottoms against the closed end. Rotate

the grip so that the ferrule notches are at the top. To pre-

Insert

vent binding, pull the grip back about 1/8 inch (3.2 mm).

Lubricant

11.

Position the lower switch housing beneath the throttle

Here

control grip. Install the brass ferrules onto the cables so

that the end fittings seat in the ferrule recess. Seat the

ferrules in their respective notches on the throttle control

grip. Verify that the cables are captured in the grooves

molded into the grip. See Figure 1-19.

12.

Position the upper switch housing over the handlebar

and lower switch housing. Verify that the wire harness

7958

conduit runs in the depression at the bottom of the han-

dlebar.

Figure 1-20. Lubricate Throttle/Idle Cables

13.

Start the upper and lower switch housing screws, but do

not tighten.

2. Using a T25 TORX drive head, remove the upper and

14.

Position the brake lever/master cylinder assembly

lower switch housing screws.

inboard of the switch housing assembly engaging the

tab on the lower switch housing in the groove at the top

3. Using a T27 TORX drive head, loosen the upper screw

of the brake lever bracket.

securing the handlebar clamp to the master cylinder

housing. Remove the lower clamp screw with flat

15.

Align the holes in the handlebar clamp with those in the

washer.

master cylinder housing and start the lower screw (with

4. Remove the brass ferrules from the notches on the

flat washer). Position for rider comfort. Beginning with

inboard side of the throttle control grip. Remove the fer-

the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0

rules from the cable end fittings. See Figure 1-19.

Nm) torque using a T27 TORX drive head.

16.

Using a T25 TORX drive head, tighten the lower and

NOTE

upper switch housing screws to 35-45 in-lbs (4-5 Nm).

On non cruise equipped models, remove the friction shoe

from the end of the tension adjuster screw. The friction shoe

NOTE

is a loose fit and may fall out or become dislodged if the lower

Always tighten the lower switch housing screw first so that

switch housing is turned upside down or shaken.

any gap between the upper and lower housings is at the front

5. Remove the throttle control grip from the end of the han-

of the switch assembly.

dlebar.

6. Move upper switch housing to the side in order to access

lower housing.

f1376b2x

Throttle Control

Grip

1CAUTION

Lubit-8 Tufoil Chain and Cable Lube contains detergents.

Avoid contact with eyes. Keep out of reach of children.

7. Obtain tube of Lubit-8 Tufoil Chain and Cable Lube (HD

Part No. 94968-85TV- 1/4 fl. oz.). Insert pin of tube

between throttle cable and cable housing inside lower

Jam Nut

switch housing. Squeeze tube to squirt a quantity of

lubricant into cable housing moving pin around cable

OD. See Figure 1-20.

8. Repeat the procedure squirting a quantity of lubricant

Tension

between the idle cable and cable housing.

Adjuster

Screw

NOTE

Idle Cable

Throttle Cable

On non cruise equipped models, install the friction shoe with

Adjuster

the concave side up so that the pin hole is over the point of

the adjuster screw. The friction shoe is a loose fit and may fall

out or become dislodged if the lower switch housing is turned

Figure 1-21. Throttle Cable Assembly - Throttle Side

upside down or shaken.

(FLHR/S)

2004 Touring: Maintenance

1-27

HOME

Idle

Throttle

Cable Guide

Cable

Housing

Spring

Cable

Barrel End

Throttle

Stop Plate

Throttle

Wheel

Cam Stop

f1381a2x

Figure 1-22. Throttle Cable Assembly - Carburetor Side

17. Remove the cardboard insert between the brake lever

Turn the front wheel full right. Turn the idle cable adjuster

and lever bracket.

counterclockwise until the cable housing just touches

the spring in the longer cable guide. Work the throttle

18. Turn the Ignition/Light Key Switch to IGNITION and

grip to verify that the throttle cable returns to the idle

apply brake lever to test operation of brake lamp.

position when released. If the cable does not return to

idle, turn the adjuster clockwise slightly until the correct

Adjustment

response is achieved. Tighten jam nut against the idle

cable adjuster and cover cable adjuster mechanism with

NOTE

rubber boot.

For throttle and idle cable adjustment on cruise equipped

models, see Section

8.30 CRUISE CONTROL (FLHRC,

Verify that the throttle control operates freely without

FLTR, FLHTCU).

binding. With the tension adjuster screw backed off, the

throttle control grip must freely return to the closed (idle)

1. Slide rubber boot off throttle cable adjuster. See Figure

position. The throttle control also must open and close

1-21. Holding cable adjuster with a 3/8 inch wrench,

freely when the front wheel is turned to both the right

loosen jam nut turning in a clockwise direction. Back jam

and left fork stops.

nut away from cable adjuster until it stops. Turn adjuster

If the throttle grip does not return to the idle position

clockwise until it contacts jam nut. Repeat procedure on

freely, check the adjuster screw tension. If the adjuster

idle cable adjuster.

screw is backed off, inspect the cables for short bends.

2. Point the front wheel straight ahead. Turn the throttle

control grip so that the throttle is wide open (fully coun-

terclockwise) and then hold in position. Now turn the

throttle cable adjuster counterclockwise until the throttle

SPARK PLUGS

cam stop just touches the stop plate on the carburetor.

See Figure 1-22. Tighten jam nut against the throttle

Inspect the spark plugs at every 5000 mile (8,000 km) ser-

cable adjuster and then release the throttle control grip.

vice interval. Replace the spark plugs at every 10,000 mile

Cover cable adjuster mechanism with rubber boot.

(16,000 km) service interval. Proceed as follows:

1-28

2004 Touring: Maintenance

HOME

The HD-6R12 plug has a resistor element to reduce radio

interference originating in the motorcycle ignition system.

Throttle

Only resistor type plugs should be used with the electronic

Stop Screw

ignition system.

Table 1-5. Spark Plug Data

SIZE

12 mm

GAP

0.038-0.043 in. (0.97-1.09 mm)

TYPE

HD-6R12 (No Substitute)

Remove plugs and examine immediately. The deposits

on the plug base are an indication of the plug efficiency

and are a guide to the general condition of rings, valves,

carburetor and ignition system.

a. A wet black and shiny deposit on plug base, elec-

trodes and ceramic insulator tip indicate an oil

fouled plug. The condition may be caused by worn

rings and pistons, loose valves, weak battery or

faulty ignition.

f1381d2x

b. A dry fluffy or sooty black deposit indicates a too

rich carburetor air/fuel mixture or long periods of

Figure 1-23. Idle Speed Adjustment

engine idling.

c. An overheated plug can be identified by a light

brown, glassy deposit. This condition may be

ENGINE IDLE SPEED

accompanied by cracks in the insulator or by ero-

sion of the electrodes. This condition is caused by

At the 1000 mile (1600 km) service interval, and at every

too lean an air/fuel mixture, a hot running engine,

5000 mile (8000 km) service interval thereafter, inspect the

valves not seating or improper ignition timing. The

engine idle speed as follows:

glassy deposit on the spark plug is a conductor

when hot and may cause high speed misfiring. A

NOTES

plug with eroded electrodes, heavy deposits or a

●

The C.V. carburetor has an enrichener circuit that will

cracked insulator should be replaced.

cause the engine to idle at approximately 1500 rpm with

d. A plug with a white, yellow or light tan to rusty brown

the engine at normal operating temperature and the

powdery deposit indicates balanced combustion.

enrichener knob pulled fully out.

The deposits may be cleaned off at regular intervals

if desired.

●

The increase in idle speed is intended to alert the rider

that the engine is warmed up to normal operating tem-

Set the spark plug gap using a wire-type gauge. Bend

perature and the enrichener knob should be pushed all

the outside of the electrode so only a slight drag on the

the way in.

gauge is felt when passing it between electrodes. Never

make adjustments by bending the center electrode. Set

●

Continuing to use the enrichener when the engine is at

gap on all plugs at 0.038-0.043 in. (0.97-1.09 mm)

full operating temperature WILL CAUSE FOULED

Before installing spark plugs, check condition of threads

PLUGS.

in cylinder head and on plug. If necessary soften depos-

●

TECHNICIAN - Be sure the engine is warmed up to nor-

its with penetrating oil and clean out with a thread

mal operating temperature and the enrichener knob is

chaser.

pushed all the way in BEFORE adjusting engine idle

Install spark plug finger tight and then torque to 12-18 ft-

speed. Be aware that because there are variations in

lbs (16-24 Nm).

individual components, it is possible for a properly

warmed up engine to idle at

2000 rpm with the

enrichener knob pulled PARTIALLY OUT.

ELECTRICAL COMPONENTS

See Figure 1-23. With the engine at normal operating

temperature and the enrichener all the way in

At the 1000 mile (1600 km) service interval, and at every

(enrichener valve closed) adjust the throttle stop screw

5000 mile (8000 km) service interval thereafter, inspect the

so the engine idles at 950-1050 rpm.

operation of all electrical components and switches.

2004 Touring: Maintenance

1-29

HOME

NOTE

ENGINE MOUNTS

To measure engine rpm on models without tachometers, use

At every 10,000 mile (16,000 km) service interval, inspect the

a test tachometer connected to the negative ignition coil ter-

condition and tightness of the stabilizer links and engine

minal.

mounts. Proceed as follows:

NOTE

Raise fuel tank to access top engine stabilizer bolts and jam

nuts. For carbureted models, see Section 4.7 FUEL TANK

CRITICAL FASTENERS

(CARBURETED), PARTIAL REMOVAL, FLHT/C, or FLHR/S.

For fuel injected models, see Section 9.4 FUEL TANK (FUEL

INJECTED), PARTIAL REMOVAL, FLHT/C/U/I, FLTRI, or

At the 1000 mile (1600 km) service interval, and at every

FLHR/C/S/I.

10,000 mile (16,000 km) service interval thereafter, inspect

the tightness of all critical fasteners. Replace fastener if dam-

aged or missing.

Top

● On left side of vehicle, tighten top engine mounting

Table 1-6. Critical Fastener Torque

bracket bolts to front and rear cylinder heads to 35-40 ft-

lbs (48-54 Nm). See A of Figure 1-24.

Fastener

ft/in-lbs

● Top stabilizer link - tighten eyelet bolt to top engine

Axle

mounting bracket to 18-22 ft-lbs (24-30 Nm). See B of

Figure 1-24.

Front axle nut

50-55 ft-lbs

68-75 Nm

● Moving to right side of vehicle, tighten eyelet bolt to

Rear axle cone nut

95-105 ft-lbs

129-142 Nm

frame weldment to 18-22 ft-lbs (24-30 Nm). See C of Fig-

Brakes

ure 1-24.

Banjo Bolts

17-22 ft-lbs

23-30 Nm

● Verify tightness of jam nuts on top stabilizer link.

Front Brake Disc Mounting

16-24 ft-lbs

22-33 Nm

Screws

Bottom

Front Brake Caliper Mounting

28-38 ft-lbs

38-52 Nm

Bolts

● Front stabilizer link - on left side of vehicle, tighten eyelet

Brake Caliper Pad Pins

180-200 in-lbs

20-23 Nm

bolt to frame weldment to 18-22 ft-lbs (24-30 Nm). See D

of Figure 1-24.

Rear Brake Disc Mounting

30-45 ft-lbs

41-61 Nm

Screws

● Moving to right side of vehicle, tighten eyelet bolt to

Rear Master Cylinder Mounting

block on front engine mounting bracket to 18-22 ft-lbs

30-40 ft-lbs

41-54 Nm

Nut

(24-30 Nm). See E of Figure 1-24.

Reservoir Cover Screws

6-8 in-lbs

0.7-0.9 Nm

● Verify tightness of jam nuts on front stabilizer link.

Front Forks

● Tighten center front engine mounting bracket to rubber

mount bolt to 15-20 ft-lbs (20-27 Nm). See F of Figure 1-

Axle Holder Nuts

132-180 in-lbs

14.9-20.3 Nm

24.

Hand Controls

● Tighten the two front engine mount to frame crossmem-

ber bolts to 15-20 ft-lbs (20-27 Nm). See G of Figure 1-

Clutch Lever/Handlebar Clamp

60-80 in-lbs

6.8-9.0 Nm

24.

Master Cylinder/Handlebar

60-80 in-lbs

6.8-9.0 Nm

● Tighten two engine to front engine mounting bracket

Clamp Screws

bolts to 33-38 ft-lbs (45-52 Nm). See H of Figure 1-24.

Upper/Lower Switch Housing

35-45 in-lbs

4-5 Nm

Screws

● Tighten four engine to transmission bolts to 30-35 ft-lbs

(41-48 Nm).

Handlebars

NOTE

Lower Clamp (Riser) Bolts

30-40 ft-lbs

40.7-54.2 Nm

Install fuel tank. For carbureted models, see Section 4.7

Pivot Shaft

FUEL TANK (CARBURETED), INSTALLATION (AFTER

PARTIAL REMOVAL), FLHT/C, or FLHR/S. For fuel injected

Locknuts

40-45 ft-lbs

54-61 Nm

models, see Section 9.4 FUEL TANK (FUEL INJECTED),

Swingarm Bracket Bolts

34-42 ft-lbs

46-57 Nm

INSTALLATION (AFTER PARTIAL REMOVAL), FLHT/C/U/I,

FLTRI, or FLHR/C/S/I.

1-30

2004 Touring: Maintenance

HOME

SPECIFICATIONS

2.1

DIMENSIONS (IN.)

DIMENSIONS (MM)

FLHT/C/U

FLHR/C/S

FLTR

FLHT/C/U

FLHR/C/S

FLTR

Wheel Base

63.5

Wheel Base

1613

Overall Length

93.7/97.5/98.3

93.7

Overall Length

2380/2476/2497

2380

Overall Width

39.0

34.45/34.45/39.40

35.75

Overall Width

990

875/875/1001

908

Road Clearance

5.12

5.12/5.12/4.70

5.12

Road Clearance

130

130/130/119

130

Overall Height

61.0

55.06/55.06/46.40

55.0

Overall Height

1549

1399/1399/1179

1397

Saddle Height*

27.3

27.3/26.9/26.1

26.9

Saddle Height*

693

693/683/663

683

* With 180 Lb. Rider

* With 81.6 kg Rider

WEIGHT (LBS.)

WEIGHT (KG)

FLHT/C/U

FLHR/C/S

FLTR

FLHT/C/U

FLHR/C/S

FLTR

DRY WEIGHT**

758/776/788

723/710/721

731

DRY WEIGHT**

344/352/358

328/322/327

332

GVWR

1259

GVWR

571

GAWR - Front

500

GAWR - Front

227

GAWR - Rear

827

GAWR - Rear

375

** As shipped from the factory

NOTE

Gross Vehicle Weight Rating (GVWR) (maximum allowable

loaded vehicle weight) and corresponding Gross Axle Weight

Ratings (GAWR) are given on a label located on the inside of

the right front frame downtube.

CAPACITIES (U.S.)

CAPACITIES (METRIC)

FLHT/C/U

FLHR/C/S

FLTR

FLHT/C/U

FLHR/C/S

FLTR

Fuel Tank (gallons)

Fuel Tank (liters)

Total***

18.9

Reserve

0.9

Reserve

3.4

Oil Tank (quarts)

Oil Tank (liters)

with filter

3.78

Transmission

(Ounces, approximate)

20-24

(Milliliters)

591-710

Primary Chaincase

(Ounces, approximate)

(Milliliters)

946

Left

Right

Left

Right

Left

Right

Left

Right

Left

Right

Left

Right

Front Fork (Ounces)

Front Fork (Milliliters)

10.0

11.1

10.0

11.1

295

328

295

328

*** Includes Reserve on Carbureted Models

2004 Touring: Chassis

2-1

Harley Davidson 2004 Touring Models. Service Manual - page 29