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Harley Davidson 2004 Touring Models. Service Manual - page 34

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f1903x2x

Ram

Socket

Extension

Anchor

Weldment

Socket

Socket

Wood

Block

Figure 2-98. Press Out Drive Side Bearing

16. Holding left side nut within rubber mount, remove right

side locknut from end of pivot shaft. Remove cup

f1967x2x

washer.

Spacer

17. Using a suitable drift, tap pivot shaft toward left side of

vehicle.

18. Moving to left side, pull pivot shaft assembly (pivot shaft,

locknut, cup washer, rubber mount and outer spacer) out

of transmission mount and left side swingarm. See

Bearing

Figure 2-102.

19. Standing at rear of vehicle, work rear swingarm free of

transmission mount and rear swingarm brackets.

20. Remove outer spacer from right side swingarm tube.

21. Remove rubber mount from behind right side swingarm

bracket.

DISASSEMBLY/ASSEMBLY

Figure 2-99. Press Spacer Into Bearing

Bearing Removal

1. Move rear swingarm to an hydraulic press.

4. Slide driver handle (or long socket extension) through

the brake side swingarm tube and bearing until it con-

2. Place swingarm on its side, so that the brake side is on

tacts driver (or large socket) placed on inboard side of

top. The brake side is easily recognized by the anchor

drive side bearing.

weldment for mounting of the brake caliper.

5. Center driver handle (or long socket extension) under

3. Support the swingarm with a block of wood and a large

ram and press drive side bearing from rear swingarm.

socket as shown in Figure 2-98. Verify that assembly is

6. Remove tools from rear swingarm. Turn swingarm over

square and the bearing bore is completely vertical.

and repeat steps 3-5 to press out brake side bearing.

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2004 Touring: Chassis

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a. Place swingarm on its side, so that the brake side is

on top. The brake side is easily recognized by the

anchor weldment for mounting of the brake caliper.

Drive Side

Brake Side

Driver

Driver

b. With the spacer inboard, insert bearing into out-

board side of brake side swingarm tube.

c. Insert driver stamped “Brake Side” into swingarm

tube until it contacts installed bearing. Center driver

under ram and press on brake side bearing until

shoulder on tool makes contact with casting of swin-

garm. See Figure 2-101.

d. Remove tool and turn rear swingarm over. With the

spacer inboard, insert bearing into outboard side of

drive side swingarm tube.

Figure 2-100. Rear Swingarm Bearing Installer (HD-

e. Insert driver stamped “Drive Side” into swingarm

45327)

tube until it contacts installed bearing. Center driver

under ram and press on drive side bearing until it

bottoms. Shoulder on tool will not make contact

Brake Side

f1909x2x

with casting of swingarm.

Driver

f.

Remove tool from swingarm. Remove swingarm

from hydraulic press.

Pivot Shaft Disassembly

Anchor

1. Partially install locknut on right side of pivot shaft. Install

Weldment

second locknut on right side until it contacts the first.

Holding first locknut to prevent rotation of shaft, remove

left side locknut. See Figure 2-102.

2. Remove cup washer, rubber mount and outer spacer.

3. Remove right side locknuts from pivot shaft.

Pivot Shaft Assembly

1.

With larger OD outboard, slide outer spacer onto left

side of pivot shaft until counterbore contacts shoulder on

shaft.

Figure 2-101. Press In Brake Side Bearing

2.

Install rubber mount with the flat side inboard toward

outer spacer.

3.

Install cup washer with the concave side facing in toward

Bearing Installation

the rubber mount.

1. Obtain new rear swingarm bearings. Bearings and spac-

ers must be assembled before installation. Proceed as

follows:

Right Side

Locknut and

a. Obtain REAR SWINGARM BEARING INSTALLER

Cup Washer

(HD-45327). See Figure 2-100.

b. With the nose topside, center one of the drivers

under ram of hydraulic press.

c. Place bearing over nose of driver. With the collar

topside, place spacer over nose and into bearing.

Pivot

See Figure 2-99.

Spacer

Shaft

d. Apply pressure to spacer until it bottoms in bearing.

Rubber

e. Repeat step to assemble second swingarm bearing.

Mount

f1914x2x

2. Install assembled bearings into rear swingarm. Proceed

as follows:

Figure 2-102. Pivot Shaft Assembly

2004 Touring: Chassis

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LEFT SIDE

RIGHT SIDE

Increase

Reduce

Belt

Belt

Deflection

Deflection

Cone

Nut

Weld

Nub

Weld

Weld

Nut

E-Clip

Nub

Adjuster

Cam

8398

8407

Figure 2-103. Move Rear Wheel Forward Until Adjuster Cams Just Contact Weld Nubs

17.

If belt is too tight, move to step

18 to increase belt

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

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

ification.

described below:

If the belt deflection is not within specification, loosen

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

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

before returning to step 17.

direction.

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

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

side of axle.

at the midpoint of the bottom belt strand. Belt

22. Depress rear brake pedal several times to set brake

deflection should be within the range specified in

pads to proper operating position within caliper.

Table 2-4.

c. If belt is still too loose, repeat steps 17(a) through

17(b). If belt is now too tight, move to step 18.

Transmission

Rear Wheel

Sprocket

Sprocket

18.

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

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

clockwise direction.

b. Push wheel forward slightly so that adjuster cam

just contacts weld nub on both sides of rear swing-

arm. See Figure 2-103.

10 lbs. (4.5 kg)

of Force

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

f1652x6x

See Table 2-4.

at the midpoint of the bottom belt strand. Belt

deflection should be within the range specified in

Table 2-4.

Belt Tension Gauge

Part No. HD-35381A

d. If belt is still too tight, repeat steps 18(a) through

18(c). If belt is now too loose, move to step 17.

19.

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

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

Belt Tension Gauge Adapter

NOTE

Part No. HD-35381-3

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

the belt deflection procedure must be restarted.

Figure 2-104. Check and Adjust Belt Deflection

2004 Touring: Chassis

2-85

HOME

1WARNING

Passenger

After installation of caliper and BEFORE moving motor-

Footboard

cycle, pump rear brake pedal until pistons push pads

Bracket

against the brake disc. If fluid pressure is not pumped

up, the rear brake will not be available the first time it is

used, a situation that could result in death or serious

injury.

23. Install both mufflers as follows:

NOTE

TORCA muffler clamps have eliminated the need for silicone

or graphite tape during assembly. To ensure sealing integrity

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

ley-Davidson recommends that TORCA clamp assemblies be

discarded and replaced each time they are removed.

Chrome

Plug

Left Side

Rear

a. Slide new TORCA clamp onto free end of crossover

Swingarm

pipe.

Bracket

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

support rail. Install muffler on crossover pipe. Place

f1787x2x

TORCA clamp into position between crossover pipe

and muffler.

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

the muffler to the lower saddlebag support rail.

CAUTION

Verify that the exhaust pipes do not contact the vehicle

frame or any mounted components. Contact will cancel

the effect of the rubber isolation mounts and transmit

vibration to the rider via the vehicle frame.

Locknut

d. Verify that exhaust pipes are in alignment and do

not contact the vehicle frame or mounted compo-

nents.

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

Nm).

f.

Open worm drive clamps and install heat shield on

crossover pipe. Position clamp so that screw is on

the outboard side in the most accessible position.

Pivot

Shaft

CAUTION

Verify that the heat shields do not contact the vehicle

frame or any mounted components. Contact will cancel

L(eft) Side

the effect of the rubber isolation mounts and transmit

Casting Stamp

vibration to the rider via the vehicle frame.

g. Remove bungee cord from muffler.

f2073x2x

Right Side

a. Slide new TORCA clamp onto free end of rear

Figure 2-105. Remove Chrome Plugs and Check

header pipe.

Pivot Shaft Locknut Torque (Left Side View)

2-86

2004 Touring: Chassis

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THROTTLE CABLES (NON-CRUISE)

2.21

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

ADJUSTMENT

2-106. Holding cable adjuster with a 3/8 inch wrench,

loosen jam nut turning in a clockwise direction. Back jam

NOTE

nut away from cable adjuster until it stops. Turn adjuster

For throttle and idle cable adjustment or replacement on

clockwise until it contacts jam nut. Repeat procedure on

cruise equipped models, see Section 8.30 CRUISE CON-

idle cable adjuster.

TROL (FLHRC, FLTR, FLHTCU).

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

The throttle control must operate freely without binding. With

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

the tension adjuster screw backed off, the throttle control grip

terclockwise) and then hold in position. Now turn the

must freely return to the closed (idle) position. The throttle

throttle cable adjuster counter-clockwise until the throttle

control also must open and close freely when the front wheel

cam stop just touches the stop plate. See Figure 2-107.

is turned to both the right and left fork stops. If the throttle

Release the throttle control grip and then tighten the jam

grip does not return to the idle position freely, check the

nut against the throttle cable adjuster. Cover cable

adjuster screw tension. If the adjuster screw is backed off,

adjuster mechanism with rubber boot.

inspect the cables for short bends.

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

counterclockwise until the cable housing just touches

the spring in the cable guide (as seen through slot).

1WARNING

Work the throttle grip to verify that the throttle cable

Do not overtighten the tension adjuster screw. An over-

returns to the idle position when released. If the cable

tightened screw will prevent the engine from automati-

does not return to idle, turn the adjuster clockwise

cally returning to idle in an emergency situation. This

slightly until the correct response is achieved. Tighten

can lead to loss of vehicle control, which could result in

jam nut against the idle cable adjuster and cover cable

death or serious injury.

adjuster mechanism with rubber boot.

Throttle Control

Grip

Jam Nut

Tension

Adjuster

Screw

Throttle Cable

Idle Cable

Adjuster

Adjuster

f1376b2x

Figure 2-106. Throttle Cable Assembly - Throttle Side (FLHR)

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2004 Touring: Chassis

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Throttle

Cable Guide

Idle

Cable Guide

Cable

Housing

Spring

Cable

Barrel End

Throttle

Stop Plate

Throttle

Wheel

Cam Stop

f1381a2x

Figure 2-107. Throttle Cable Assembly - Carburetor Side

REMOVAL

f1225x2x

THROTTLE SIDE

CAUTION

Do not remove the switch housing assembly without first

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

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.

NOTE

Use the eyelet of an ordinary cable strap if the cardboard

insert is not available.

5/32 Inch

(4.0 mm)

1. Place the cardboard insert between the brake lever and

Cardboard

lever bracket. See Figure 2-108.

Insert

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

lower switch housing screws.

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

securing the handlebar clamp to the master cylinder

housing. Remove the lower clamp screw with flat

washer.

Figure 2-108. Install Cardboard Insert

2004 Touring: Chassis

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4.

Remove the brass ferrules from the notches on the

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

7961

rules from the cable end fittings.

Lower

5.

Remove the friction shoe from the end of the tension

Switch

adjuster screw.

Housing

NOTE

The friction shoe is a loose fit and may fall out or become dis-

lodged if the lower switch housing is turned upside down or

shaken.

Throttle

Cable Insert

(Silver)

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

dlebar.

Idle

Cable Insert

7.

Pull the crimped inserts at the end of the throttle and idle

(Gold)

cable housings from the lower switch housing.

For best results, use a rocking motion while pulling.

Figure 2-109. Install Throttle/Idle Cables

Place a drop of light oil on the retaining rings, if neces-

in Lower Switch Housing

sary. Remove the cables from the switch housing.

2.

Inspect the cables for damage or wear. Replace the

cables if frayed, kinked or bent.

CARBURETOR/INDUCTION MODULE SIDE

3.

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

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

1.

Remove the air cleaner and backplate. See Section 4.5

between throttle cable and cable housing. Squirt a few

AIR CLEANER, REMOVAL.

drops of lubricant into cable housing moving pin around

2.

Raise fuel tank to access cables in area of frame back-

cable OD. Repeat the procedure squirting a few drops

bone. For carbureted models, see Section 4.7 FUEL

between the idle cable and cable housing.

TANK (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 FLHR/C/S/I.

INSTALLATION

3.

Carbureted: Using a needle nose pliers, carefully pull

idle cable barrel from upper inboard hole in throttle

wheel. Pull throttle cable barrel from remaining hole.

THROTTLE SIDE

Release idle and throttle cables from guides in throttle

cable bracket. See Figure 2-107.

1.

Apply a light coating of graphite to the handlebar and

inside surface of the switch housings.

Induction Module: Using a needle nose pliers, carefully

pull idle cable barrel from upper hole in throttle wheel.

2.

Push the throttle and idle cables into the lower switch

Pull throttle cable barrel from lower hole. Using slots,

housing until they snap in place. See Figure 2-109. Pro-

release idle and throttle cables from guides in throttle

ceed as follows:

cable bracket. See Figure 2-111.

Note the different diameter inserts crimped into the end

4.

Free cables from J-clamp riveted to right side of frame

of the throttle and idle cable housings.

backbone.

Push the larger diameter insert (silver) on the throttle

5.

If present, remove screw (with flat washer) to release J-

cable housing into the larger hole in front of the tension

clamp from wellnut in right side of steering head.

adjuster screw.

Remove J-clamp from cables.

Push the smaller diameter insert (gold) on the idle cable

housing into the smaller hole at the rear of the tension

adjuster screw.

CLEANING AND INSPECTION

NOTE

To aid assembly, place a drop of light oil on the retaining

1. Clean all parts in a non-flammable cleaning solvent and

rings of the crimped inserts. Always replace the retaining

blow dry with compressed air.

rings if damaged or distorted.

2-90

2004 Touring: Chassis

HOME

8.

Position the brake lever/master cylinder assembly

Ferrule

Notch

Groove

inboard of the switch housing assembly engaging the

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

of the brake lever bracket.

9.

Align the holes in the handlebar clamp with those in the

master cylinder housing and start the lower screw (with

flat washer). Position for rider comfort. Beginning with

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

Nm) torque using a T27 TORX drive head.

10. Using a T25 TORX drive head, tighten the lower and

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

NOTE

Always tighten the lower switch housing screw first so that

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

of the switch assembly.

Throttle

Grip

11. Remove the cardboard insert between the brake lever

and lever bracket.

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

Idle

Throttle

f1474x2x

apply brake lever to test operation of brake lamp.

Cable

Cable

Figure 2-110. Install Throttle/Idle Control Cables on

Throttle Control Grip

CARBURETOR/INDUCTION MODULE SIDE

1.

Route the throttle and idle cables as follows:

3. With the concave side facing upward, install the friction

shoe so that the pin hole is over the point of the adjuster

FLHT/C: Route the cables downward following the brake

screw.

line to the inner fairing. Pass the cables through the

inner fairing grommet and then loop them toward the

NOTE

rear along the right side of the steering head.

The friction shoe is a loose fit and may fall out or become dis-

FLHR/C: Route the cables downward following the right

lodged if the lower switch housing is turned upside down or

handlebar to the handlebar clamp shroud. Pass the

shaken.

cables through the opening in the shroud and then loop

them toward the rear along the right side of the steering

4. Slide the throttle control grip over the end of the right

handlebar until it bottoms against the closed end. Rotate

head. Capture cables in J-clamp and then start screw

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

(with flat washer) to fasten J-clamp to wellnut in right

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

side of steering head. Tighten screw to 9-18 in-lbs (1.0-

2.0 Nm).

5. Position the lower switch housing beneath the throttle

control grip. Install the brass ferrules onto the cables so

2.

Route the throttle and idle cables rearward along the

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

right side of the frame backbone. After passing through

ferrules in their respective notches on the throttle control

J-clamp riveted to frame backbone, route cables down-

grip. Verify that the cables are captured in the grooves

ward to carburetor/induction module.

molded into the grip. See Figure 2-110.

3.

Carbureted: Install sleeve on throttle cable housing into

6. Position the upper switch housing over the handlebar

shorter cable guide in throttle cable bracket. Drawing

and lower switch housing. Verify that the wire harness

throttle cable downward, fit barrel end into lower out-

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

board hole in throttle wheel. Install sleeve and spring on

dlebar.

idle cable housing into longer cable guide inserting bar-

7. Start the upper and lower switch housing screws, but do

rel end into upper inboard hole in throttle wheel. See

not tighten.

Figure 2-107.

2004 Touring: Chassis

2-91

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LUBRICATION

f2162x9x

Idle Cable

Guide

1. See REMOVAL, THROTTLE SIDE, in this section, steps

1-5.

Throttle Cable

Guide

2.

Move upper switch housing to the side in order to access

lower housing.

1CAUTION

Lubit-8 Tufoil Chain and Cable Lube contains detergents.

Keep out of reach of children. Contact with eyes may

result in minor or moderate injury.

3.

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

switch housing. Squeeze tube to squirt a quantity of

lubricant into cable housing moving pin around cable

OD. See Figure 2-112.

4.

Repeat the procedure squirting a quantity of lubricant

between the idle cable and cable housing.

Figure 2-111. Throttle Cable Assembly -

Induction Module Side

5.

See INSTALLATION, THROTTLE SIDE, in this section,

steps 3-12.

6.

Turn the Ignition/Light Key Switch to IGNITION and

Induction Module: Install sleeve on throttle cable hous-

apply brake lever to test operation of brake lamp.

ing into shorter cable guide at top of throttle cable

bracket. Drawing throttle cable downward, fit barrel end

into lower hole in throttle wheel. Install sleeve and spring

on idle cable housing into longer cable guide at bottom

of throttle cable bracket inserting barrel end into upper

hole in throttle wheel. See Figure 2-111.

Insert

4.

Tighten cables as necessary to keep barrel ends from

Lubricant

Here

dislodging. Verify that cables are seated in channel of

throttle wheel. Verify operation by turning throttle grip

and observing cable action. Adjust throttle cables as

described under ADJUSTMENT.

5.

Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER

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

injected models, see Section 9.4 FUEL TANK (FUEL

7958

INJECTED), INSTALLATION

(AFTER PARTIAL

REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

Figure 2-112. Right Handlebar Lower Switch Housing

6.

Install the air cleaner assembly. See Section 4.5 AIR

CLEANER, INSTALLATION.

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2004 Touring: Chassis

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CLUTCH CABLE

2.22

ADJUSTMENT

f1140axx

Flat

Screw

Washer

See Section 6.3 CLUTCH, ADJUSTMENT.

Pivot Pin

Clutch Cable

Clutch

Lever

Handlebar

REMOVAL

Bracket

Clamp

Bushing

1.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

Hand Lever

MAXI-FUSE, REMOVAL.

Retaining

Ring

2.

To access the clutch release cover assembly, remove

right side exhaust system. See Section 3.7 REMOVING

Anchor

Pin

ENGINE FROM CHASSIS, steps 3-9.

Rubber Boot

Anti-Rattle

3.

Remove the magnetic drain plug at the bottom right side

Spring

of the oil pan and drain the transmission lubricant into a

and Screw

O-Ring

suitable container. Remove the filler plug/dipstick.

4.

Slide rubber boot off clutch cable adjuster. Holding cable

Figure 2-114. Clutch Hand Lever Assembly

adjuster with 1/2 inch wrench, loosen jam nut using 9/16

inch wrench. Back jam nut away from cable adjuster.

Move adjuster toward jam nut to introduce free play at

Inner

hand lever. See Figure 2-113.

Retaining

Ramp

Ring

5.

Remove retaining ring from pivot pin groove at bottom of

clutch lever bracket. Remove pivot pin.

Cable

Fitting

6.

Remove clutch hand lever from clutch lever bracket. If

necessary, use a T27 TORX drive head and remove two

screws (with flat washers) to release handelbar clamp

from clutch lever bracket.

7.

Remove anchor pin and clutch cable eyelet from clutch

hand lever. See Figure 2-114.

8.

Remove six socket head screws and washers to free

clutch release cover from transmission case. Remove

and discard gasket. See Figure 2-115.

Clutch Cable

Coupling

f1896x7x

Figure 2-115. Clutch Release Cover Assembly

f1440x6x

Jam

Nut

Rubber

Boot

1WARNING

Always wear proper eye protection when removing re-

Cable

End

taining rings. Use the correct retaining ring pliers. Verify

that the tips of the pliers are not damaged or excessively

worn. Slippage may propel the ring with enough force to

Cable

Adjuster

cause eye injury.

9.

Remove retaining ring securing ball and ramp mech-

Figure 2-113. Clutch Cable Adjuster Mechanism

anism to clutch release cover.

2004 Touring: Chassis

2-93

HOME

10. Lift inner ramp out of clutch release cover and turn the

assembly over so that ball sockets are facing outboard.

Right Frame

f1472b2x

Remove hook of ramp from button on coupling. Remove

Downtube

coupling from clutch cable end.

11. Remove balls from outer ramp sockets. Remove outer

ramp from clutch release cover.

12. Unscrew the cable fitting from the clutch release cover.

Remove clutch cable and fitting.

13. Cut cable strap in hole of crossbrace to free clutch cable

from right frame downtube. See Figure 2-116. Continue

as follows:

FLHR/C/S: Remove T40 TORX screw with flat washer

(FLHRS) or acorn nut (FLHR/C) to release clutch cable

from P-clamp fastened to upper fork bracket. See Figure

2-117.

FLTR: Release clutch cable from cable clip anchored in

hole on left side of instrument nacelle.

FLHT/C/U: Remove the outer fairing. See Section 2.29

UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER

FAIRING/WINDSHIELD, REMOVAL. Cut cable strap to

Clutch Cable

Cable Strap

release clutch cable from left fairing bracket. See Figure

2-118.

Figure 2-116. Clutch Cable Routing (Right Side View)

14. Remove clutch cable from motorcycle.

NOTE

Clutch Cable

f2257x2x

If ball and ramp or throwout bearing and clutch pushrod need

service, see Section 7.5 CLUTCH RELEASE COVER.

INSTALLATION

1. See Figure 2-114. Insert clutch cable eyelet into groove

of clutch hand lever aligning eyelet with hole without

bushing. Insert anchor pin through lever and eyelet.

2. Insert lever into groove of clutch lever bracket fitting

sleeve at end of cable housing into bore on inboard side

of bracket.

3. Align hole in hand lever with hole in bracket and install

Clamp

pivot pin. Install retaining ring in pivot pin groove.

4. If removed, use a T27 TORX drive head and install two

screws (with flat washers) to secure handelbar clamp to

clutch lever bracket. See Figure 2-114. Starting with the

Figure 2-117. Clutch Cable Routing - FLHR/C

top screw, tighten screws to 60-80 in-lbs (6.8-9.0 Nm).

(Left Side View)

5. Start clutch cable routing as follows:

FLHR/C/S: Capture clutch cable in P-clamp and fasten

FLHT/C/U: Feed clutch cable through grommet on left

to upper fork bracket using T40 TORX screw with flat

side of inner fairing. Route cable on inboard side of left

washer (FLHRS) or acorn nut (FLHR/C). Orient P-clamp

fairing bracket between upper and lower wings of radio

as shown in Figure 2-117. On left side of steering head,

(or storage box) support bracket. Cable strap clutch

run cable downward between engine guard and front of

cable to left fairing bracket using oblong hole at this loca-

left frame downtube.

tion. See Figure 2-118. Run cable downward along left

FLTR: Capture clutch cable in cable clip and anchor clip

side of steering head, and then between engine guard

in hole on left side of instrument nacelle. Run cable for-

and front of left frame downtube. Install the outer fairing.

ward and then rearward beneath instrument nacelle fol-

See Section

2.29 UPPER FAIRING/WINDSHIELD

lowing left side of steering head. Run cable downward

(FLHT/C/U), OUTER FAIRING/WINDSHIELD, INSTAL-

between engine guard and front of left frame downtube.

LATION.

2-94

2004 Touring: Chassis

HOME

12. Install the retaining ring so that the opening is to the right

9421

of the outer ramp tang slot in the clutch release cover.

13. Verify that the two locating dowels are in place on the

right side of the transmission case. Hang a new gasket

on the dowels.

14. Holding the clutch release cover in position, install six

socket head screws. Tighten screws to 120-144 in-lbs

(13.6-16.3 Nm).

15. Tighten clutch cable fitting to 36-60 in-lbs (4-7 Nm).

16. Check the O-ring on the transmission drain plug for

tears, cuts or general deterioration. Replace as nec-

Cable

essary.

Strap

CAUTION

Do not overtighten filler plugs or drain plugs. Overtight-

Figure 2-118. Secure Clutch Cable to Fairing Bracket

ening plugs can cause leaks.

17. Install transmission the drain plug. Tighten the plug to

6.

Complete clutch cable routing as follows:

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

All Models: Continue downward progression while

crossing to right side of motorcycle and then run cable

between outboard side of voltage regulator and inboard

side of right frame downtube. Threading cable strap

8496

Clutch

through hole in crossbrace, secure clutch cable to down-

Release

tube as shown in Figure 2-116. Following inboard side of

Cover

frame downtube, route cable between bottom of cam

cover and top of lower frame tube to area of clutch

release cover.

7.

Inspect cable fitting O-ring and replace if damaged or

deformed. Install clutch cable fitting into clutch release

cover. See Figure 2-115. Do not tighten cable fitting at

this time.

Filler

8.

Place outer ramp in clutch release cover recess with

Plug

tang in cover slot.

9.

Apply a multi-purpose grease to the balls and outer

ramp sockets. Place a ball in each of three outer ramp

sockets.

Figure 2-119. Transmission Case (Right Side)

10.

Hold coupling with button facing outboard. Place cable

end in recess of coupling. With ball sockets facing out-

OMF50

board, place hook of inner ramp on button of couplng.

Holding inner ramp and coupling together, turn the

assembly over.

11.

Place inner ramp (ball socket side down) over balls in

outer ramp sockets.

1WARNING

Always wear proper eye protection when installing re-

O-Ring

taining rings. Use the correct retaining ring pliers. Verify

that the tips of the pliers are not damaged or excessively

worn. Slippage may propel the ring with enough force to

cause eye injury.

Figure 2-120. Transmission Lubricant Filler Plug/Dipstick

2004 Touring: Chassis

2-95

HOME

5. Tighten upper handlebar clamp screws as follows:

f2056x2x

1

a. Tighten front screws until upper and lower handle-

bar clamps make contact.

2

b. Tighten rear screws to 12-16 ft-lbs (16.3-21.7 Nm).

c. Tighten front screws to 12-16 ft-lbs (16.3-21.7 Nm).

3

NOTE

A slight gap will exist between the upper and lower clamps at

the rear of the handlebars after tightening.

6.

Install the left hand grip. See LEFT HAND GRIP,

INSTALLATION, in this section.

*9

4

7.

Install the left and right handlebar switch controls. See

Section

8.21 HANDLEBAR SWITCHES, INSTALLA-

TION.

8.

FLHR/C/S: Install the handlebar clamp shroud. See

5

Section

2.31 WINDSHIELD/HEADLAMP NACELLE

**10

(FLHR/C/S), NACELLE INSTALLATION

(FLHR/C),

6

steps

3-15, or NACELLE INSTALLATION (FLHRS),

steps 5-13.

7

FLTR: Install the instrument nacelle. See Section 2.30

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT

NACELLE, INSTALLATION.

5

**11

FLHT/C/U: Install the fairing cap. See Section

2.29

UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING

CAP, INSTALLATION. Install the radio (or storage box).

8

See Section 8.31 PREMIUM SOUND SYSTEM (FLHTC/

U, FLTR), RADIO (FLHTC/U), INSTALLATION, steps 1-

6.

1.

Screw

2.

Flat washer

*LEFT CLAMP ONLY

9.

Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

3.

Upper clamp

MAXI-FUSE, INSTALLATION.

9. Ground cable

4.

Lower clamp

10.

Turn the ignition/light key switch to IGNITION and test

5.

Cup washer

**RIGHT CLAMP ONLY

each handlebar switch for proper operation.

6.

Spacer

7.

Rubber bushing

10. Flat washer

11.

Apply front brake hand lever to test operation of brake

8.

Bolt

11. Large flat washer

lamp.

12.

Adjust idle and throttle control cables as follows:

Figure 2-121. Handlebar Clamp Assemblies

Non-Cruise: See Section 2.21 THROTTLE CABLES

(NON-CRUISE), ADJUSTMENT.

Cruise Equipped: See Section 8.30 CRUISE CON-

1WARNING

TROL (FLHRC, FLTR, FLHTCU), CABLE ADJUST-

MENT.

Improperly aligned handlebars can contact the fuel tank

when turned to the left or right fork stops. Contact with

the fuel tank while riding can cause loss of vehicle con-

trol resulting in death or serious injury.

LEFT HAND GRIP

4. Slowly turn handlebars to the full right fork stop and then

the full left fork stop to be sure there is no contact with

REMOVAL

the fuel tank. If contact occurs and handlebars are prop-

erly aligned, raise handlebars as necessary until the

1. Remove the left handlebar switch controls. See Section

proper clearance is obtained.

8.21 HANDLEBAR SWITCHES, REMOVAL.

2-98

2004 Touring: Chassis

HOME

2. Use a sharp blade to carefully cut rubber and then peel

Right Side

off handlebar.

3.

Holding lower handlebar clamp to prevent rotation, turn

3. Thoroughly clean handlebar to remove all residual adhe-

bolt at bottom of upper fork bracket until free.

sive.

4. Remove lower handlebar clamp, flat washer and cup

washer at top of upper fork bracket. See Figure 2-122.

INSTALLATION

5.

Pull bushing from fork bracket bore and discard. See

Figure 2-123.

1WARNING

6.

Moving to bottom of upper fork bracket, remove bolt,

HARLEY-DAVIDSON ADHESIVE contains METHYL

large flat washer and cup washer. See Figure 2-124.

ETHYL KETONE, a chemical known to the State of Cali-

7.

Pull bushing and spacer from fork bracket bore. Remove

fornia to cause cancer or other reproductive harm.

spacer from bushing. See Figure 2-125. Discard bush-

ing.

1WARNING

Use HARLEY-DAVIDSON ADHESIVE in well ventilated

Left Side

areas only. Vapors are flammable and can be harmful to

breath. Avoid contact with eyes, mucous membranes, or

8.

Holding lower handlebar clamp to prevent rotation, turn

prolonged contact with skin. Keep out of reach of chil-

bolt at bottom of upper fork bracket until free.

dren.

9.

Remove lower handlebar clamp, ground wire ring termi-

1. Obtain a new left hand grip and HARLEY-DAVIDSON

nal and cup washer at top of upper fork bracket.

ADHESIVE (Part No. 99839-95). Apply a coat of the

adhesive to the inside surface of the grip one inch (25.4

mm) from the open end. Apply a coat to the end of the

handlebar.

f2077x2x

2.

Immediately push grip completely onto end of handlebar

using a twisting motion. Do not hesitate when installing

grip or adhesive may dry before installation is complete.

NOTE

If the left hand grip is patterned, align it with the pattern on

the right grip with the throttle in the fully closed position.

3.

Let 6-8 hours elapse (at 70° F.) to allow adhesive to fully

cure.

4. Install the left handlebar switch controls. See Section

8.21 HANDLEBAR SWITCHES, INSTALLATION.

Figure 2-122. Remove Flat Washer and

Upper Cup Washer (Right Side)

RUBBER MOUNTS

f2076x2x

NOTE

For complete disassembly of the handlebar clamp assem-

blies and/or to replace the rubber mounts, proceed as fol-

lows.

REMOVAL

General

1.

Turn fork to left fork stop and loosen right side bolt at

bottom of upper fork bracket. Turn fork to right fork stop

and loosen left side bolt at bottom of upper fork bracket.

2.

Remove handlebars. See HANDLEBAR REMOVAL in

Figure 2-123. Remove Upper Bushing (Right Side)

this section.

2004 Touring: Chassis

2-99

HOME

5. Install cup washer over threaded end of bolt fitting con-

f2058x2x

cave side over collar of bushing. Install flat washer. See

Figure 2-122.

6. Apply two or three drops of Loctite Medium Strength

Threadlocker 243 (blue) to threads of bolt and start lower

handlebar clamp. Holding clamp to prevent rotation, turn

bolt at bottom of upper fork bracket until snug.

Left Side

7.

Insert spacer into new bushing until flush with outboard

side of collar. See Figure 2-125.

Figure 2-124. Remove Bolt, Large Washer

and Lower Cup Washer (Right Side)

8.

Insert bushing into bore at bottom of upper fork bracket

fitting collar of bushing over lip of boss.

f2057x2x

9.

Install cup washer on bolt. Insert bolt into bushing fitting

concave side of cup washer over collar of bushing.

10. Moving to top of upper fork bracket, insert bushing into

bore fitting collar of bushing over lip of boss. See Figure

2-123.

11. Install cup washer over threaded end of bolt fitting con-

cave side over collar of bushing. Install ground wire ring

terminal.

12. Apply two or three drops of Loctite Medium Strength

Threadlocker 243 (blue) to threads of bolt and start lower

Figure 2-125. Remove Spacer From Lower Bushing

handlebar clamp. Holding clamp to prevent rotation, turn

bolt at bottom of upper fork bracket until snug.

General

10. Pull bushing from fork bracket bore and discard. See

Figure 2-123.

13. Install handlebars and upper handlebar clamps. See

11. Moving to bottom of upper fork bracket, remove bolt and

HANDLEBAR INSTALLATION in this section, steps 1-5.

cup washer.

14. Turn fork to left fork stop and tighten right side bolt at

12. Pull bushing and spacer from fork bracket bore. Remove

bottom of upper fork bracket to 30-40 ft-lbs (40.7-54.2

spacer from bushing. See Figure 2-125. Discard bush-

Nm). Turn fork to right fork stop and tighten left side bolt

ing.

to the same torque value.

15. Complete assembly of motorcycle. See HANDLEBAR

INSTALLATION in this section, steps 7-12.

INSTALLATION

Right Side

1.

Insert spacer into new bushing until flush with outboard

side of collar. See Figure 2-125.

2.

Insert bushing into bore at bottom of upper fork bracket

fitting collar of bushing over lip of boss.

3.

Install large flat washer and cup washer on bolt. See Fig-

ure 2-124. Insert bolt into bushing fitting concave side of

cup washer over collar of bushing.

4.

Moving to top of upper fork bracket, insert bushing into

bore fitting collar of bushing over lip of boss. See Figure

2-123.

2-100

2004 Touring: Chassis

HOME

SEAT

2.24

FLHR

Seat

Bottom

Tongue

REMOVAL

1. Remove Phillips screw to detach passenger seat mount-

ing bracket from top of rear fender. See Figure 2-126.

Slightly lift up back of passenger seat and carefully slide

toward rear of vehicle to detach from front seat mounting

bracket nuts.

NOTE

The FLHR seat can be converted to a solo seat by removal of

the passenger section. When the solo seat configuration is

desired, turn the passenger seat upside down and locate the

chrome plug pressed into the seat frame hole. See inset of

Figure 2-126. Remove the plug and press into the seat reten-

tion nut hole using finger pressure only.

2.

Using the 5/8 hex, remove two nuts from studs to free

f1416x2x

front seat mounting bracket from rear fender.

f2171x2x

3.

Push front seat rearward to free tongue

from slot in

frame backbone. See Figure 2-127.

Slot

f1091d2x

Screw

Passenger

Seat

Nut

Frame

Backbone

Front Seat

Figure 2-127. Seat Mounting

INSTALLATION

1.

Position front seat on frame with mounting bracket at

Stud Plate

rear.

2.

Firmly push front of seat downward and rearward until

tongue engages slot in frame backbone. See Figure 2-

127. Push seat forward until studs are centered in slots

of mounting bracket.

3.

Using the 5/8 hex, install two nuts on studs to secure

Passenger Seat

front seat mounting bracket to rear fender.

f1456x2x

Retention Nut Plug

4.

Install passenger seat fitting slots on passenger seat

front mounting bracket between rounded caps and hex

Figure 2-126. Seat Assembly - FLHR

of front seat mounting bracket nuts.

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