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Harley Davidson 2004 Touring Models. Service Manual - page 35

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5.

Push passenger seat forward until rear fender seat

retention nut is centered in hole of rear mounting

f1550x2x

bracket. Install Phillips screw.

Slot

NOTE

If seat retention nut is damaged or lost, see SEAT RETEN-

TION NUT REPLACEMENT for instructions.

1WARNING

Pull up on seat to verify that it is properly secured, front

and rear. A loose seat may shift during vehicle operation

and startle the rider, possibly causing loss of vehicle

control resulting in death or serious injury.

FLHRC

Figure 2-128. Route Passenger Seat Strap Through

Slots in Seat - FLHRC

REMOVAL

1.

Remove right side saddlebag. See Section 2.25 SAD-

4. Using slots in seat, route free end of passenger seat

DLEBAG, REMOVAL.

strap to right side of vehicle. See Figure 2-128.

2.

Remove bolt (with flat washer) to remove passenger

5. Insert bolt with flat washer through passenger seat strap

seat strap and saddlebag front mounting bracket from

and slotted hole of saddlebag front mounting bracket.

chrome frame tube cover.

Insert bolt into forward hole in chrome frame tube cover.

3.

Using slots in seat, carefully pull passenger seat strap

Snug saddlebag front mounting bracket bolt, but do not

from seat. See Figure 2-128.

tighten.

6.

Install right side saddlebag. See Section 2.25 SADDLE-

4.

Remove Phillips screw to detach seat mounting bracket

BAG, INSTALLATION.

from top of rear fender.

7.

Using an open end/box wrench, tighten saddlebag front

5.

Push seat rearward to free tongue at front of seat from

mounting bracket bolt.

slot in frame backbone. See Figure 2-127.

6.

Remove seat from frame.

FLHRS, FLTR

INSTALLATION

1.

Place seat on frame backbone.

REMOVAL

2.

Firmly push front of seat downward and rearward until

tongue engages slot in frame backbone. See Figure 2-

CAUTION

127.

Removing seat without first removing passenger seat

3.

Push seat forward until rear fender seat retention nut is

strap will result in damage to rear fender paint.

centered in hole of mounting bracket. Install Phillips

screw.

1.

Remove right side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

NOTE

2.

Remove bolt (with flat washer) to remove passenger

If seat retention nut is damaged or lost, see SEAT RETEN-

seat strap and saddlebag front mounting bracket from

TION NUT REPLACEMENT for instructions.

chrome frame tube cover. Draw free end of passenger

seat strap to left side of vehicle.

3.

Remove Phillips screw to detach seat mounting bracket

1WARNING

from top of rear fender.

Pull up on seat to verify that it is properly secured, front

4.

Push seat rearward to free tongue at front of seat from

and rear. A loose seat may shift during vehicle operation

slot in frame backbone. See Figure 2-127.

and startle the rider, possibly causing loss of vehicle

5.

Remove seat from frame.

control resulting in death or serious injury.

2-102

2004 Touring: Chassis

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SEAT RETENTION NUT REPLACEMENT

Rear

Retention

1.

Slide retention nut over tapered end of cable strap so

Washer

Fender

that larger OD of nut rests on cable strap eyelet. From

bottom of rear fender, feed cable strap up through fender

hole.

2.

See Figure 2-129. With tab on retention nut seated in

notch of fender hole, pull up on cable strap to hold nut

snug against underside of rear fender. From the side

Tab

opposite the tab, slide on the retention washer to lock

Retention

the position of the retention nut. Remove cable strap.

Nut

f1897x2x

Figure 2-129. Seat Retention Nut and Washer

2-104

2004 Touring: Chassis

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SADDLEBAG

2.25

OPENING

NOTE

Maximum recommended load for each saddlebag is 15 lbs.

FLHRC

1. Raise the decorative buckle and press tabs on both

Hinge

sides of catch to release from receptacle. Repeat step to

Latch

release second catch. See upper frame of Figure 2-130.

2. Rotate hinge on outboard side of saddlebag to open lid.

FLHRS

1. Depress button on front inboard side of saddlebag, and

f1554x2x

while holding button in, raise lid. See lower frame of Fig-

ure 2-130.

Check Strap

Anchor Brackets

f1552x2x

Catch

Receptacle

Anchor Tabs

f1553x2x

FLHRC

Figure 2-131. Open Saddlebag (FLHR, FLTR, FLHT/C/U)

Button

2.

Rotate hinge on inboard side of saddlebag to open lid.

FLHR, FLTR, FLHT/C/U

1.

Use key to unlock lid latch if locked.

2.

Pull bottom of latch outward and then lift upward raising

outboard corners of saddlebag lid. See upper frame of

Figure 2-131.

3.

With top of lid tilted toward motorcycle, carefully lift

inboard side of lid upward disengaging front and rear

anchor tabs from anchor brackets.

4.

Pivot lid on latch hinge to open. A nylon check strap sus-

FLHRS

f2228x3x

pends the lid in the open position. See lower frame of

Figure 2-131.

Figure 2-130. Open Saddlebag (FLHRC/S)

2004 Touring: Chassis

2-105

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f1451x2x

Front Mounting

Front

Bracket Bolt

Rear

Mounting

Mounting

Bracket

Bracket

Quick-Release

Stud

Wire

Form

Spring

Flat

Plate

Washer

Bail

Wire

f1075axx

Figure 2-132. Saddlebag Quick-Release Fasteners

CLOSING

FLHRC

1. Rotate hinge on outboard side of saddlebag to close lid.

2.

Insert catch into receptacle until tabs fully engage.

Repeat step to secure second catch. See upper frame of

Figure 2-130.

FLHRS

Rear Mounting

f1450x2x

Bracket Bolt

1.

Rotate hinge on inboard side of saddlebag to close lid.

Lid latches automatically.

Figure 2-133. Saddlebag Mounting Bracket Bolts

(Right Side View)

FLHR, FLTR, FLHT/C/U

1.

Rotate lid to closed position engaging both anchor tabs

NOTE

with bottom of anchor brackets. Press bottom of latch

On some HDI vehicles, the bail wire has been removed from

inward until it snaps closed. See lower frame of Figure 2-

the quick release stud. In these cases, turn the stud by

131.

engaging the slotted end with a large screwdriver.

2.

Use key to lock lid latch.

3. Remove saddlebag.

REMOVAL

INSTALLATION

1.

Open saddlebag. See OPENING in this section.

2.

Grasp bail wire inside saddlebag and rotate each stud a

1.

Position saddlebag on vehicle.

full

1/4 turn in a counter-clockwise direction. Remove

2.

Place flat washers on bail head studs.

bail head studs with flat washers. See Figure 2-132.

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2004 Touring: Chassis

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3. With groove at end of stud held in a horizontal position,

insert stud through holes in saddlebag and front mount-

Rub Bar

ing bracket. When groove engages wire form of spring

plate on inboard side of bracket, turn stud clockwise a

full 1/4 turn until it snaps in place. Install rear bail head

stud in the same manner.

NOTE

On some HDI vehicles, the bail wire has been removed from

the quick release stud. In these cases, turn the stud by

engaging the slotted end with a large screwdriver.

NOTE

8862

Molded rubber insert at bottom of saddlebag must fit snugly

on lower saddlebag support rail. If saddlebag is not fully

seated, use an open end/box wrench to loosen bolts secur-

ing mounting brackets to saddlebag support and frame. See

Figure 2-133. Alternately tighten bolts to 60-96 in-lbs (7-11

Nm) after seating saddlebag.

4. Close saddlebag. See CLOSING in this section.

LATCH SPRING REPLACEMENT

(FLHR, FLTR, FLHT/C/U)

8863

REMOVAL

Figure 2-134. Lid Right Side Up With Latch on Near Side

1. Lay clean pad or blanket on work bench to protect

painted surfaces of saddlebag.

Opening

2. Remove saddlebag from motorcycle leaving lid open.

See REMOVAL in this section.

3. Lay saddlebag flat on pad with the inboard side facing

up and the lid closest to you.

4. Remove two T20 TORX screws to release check strap

from lid.

5. Remove two T15 TORX screws to release check strap

from saddlebag.

8864

6. Remove two remaining T15 TORX screws to remove

latch from saddlebag. Move saddlebag back and out of

the way.

CAUTION

This procedure assumes that the latch is NOT removed

from the saddlebag lid. If there is doubt as to whether the

procedure can be accomplished without scratching

painted surfaces of the lid, then remove the five remain-

ing T15 TORX screws to completely remove latch.

7. Position lid right side up with latch closest to you.

8865

8.

Raise latch slightly and rotate hinge on inboard side so

Figure 2-135. Lid Up Side Down With Latch on Far Side

that it is topside with the two plastic rub bars pointed

upward. See upper frame of Figure 2-134.

2004 Touring: Chassis

2-107

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9.

Rotate rub bar section of hinge to expose hinge pin and

CABLE ASSEMBLY/LATCH/SCRIPT

spring. Using a flat tip screwdriver, carefully bend

crimped end link outward. See lower frame of Figure 2-

(FLHRS)

134.

NOTE

CABLE ASSEMBLY

The end link on opposite side of hinge has a weld spot that

prevents pin removal.

Removal

10. Reposition lid so that it is upside down with the latch

1.

Open saddlebag. See OPENING in this section.

farthest from you. Rotate hinge so that plastic rub bars

are positioned beneath latch and spring is topside.

2.

Remove two screws on inboard side of saddlebag to

11. Using a needle nose pliers, grasp pin through opening

release plastic shroud. See upper frame of Figure 2-136.

just outboard of the spring and push toward the crimped

3.

Depress wireform and pull button from hole in saddle-

link side. Work pin in this manner until end can be seen

bag. See lower frame of Figure 2-136.

exiting crimped link. See upper frame of Figure 2-135. If

necessary, pry crimped link outward a little more to

4.

Remove sleeve from hole in saddlebag.

achieve the desired result.

5.

Moving to inboard side of saddlebag lid, remove lock

12. Grasping end with needle nose pliers, slowly pull pin

ring from hole at end of latch pin. See upper frame of

from links until spring can be slid off opposite end. Only

Figure 2-137.

pull pin as far as necessary to remove spring. See lower

frame of Figure 2-135.

6.

Pull latch pin from metal shroud, saddlebag bracket and

latch. Remove metal shroud.

INSTALLATION

7.

Depress spring and pull on cable ball end to remove

from slot in latch. Remove latch.

1.

Slide new spring onto end of pin. Orient spring as shown

in lower frame of Figure 2-135.

8.

Remove spring from cable. See lower frame of Figure 2-

137.

2.

Slide pin back through links. Using tapered end of

needle nose pliers, push end of pin into crimped link

3.

Reposition lid so that it is right side up with latch closest

to you. As before, raise latch slightly and rotate hinge on

inboard side so that it is topside with plastic rub bars

pointing upward. Now rotate rub bar section of hinge to

expose hinge pin and spring. See Figure 2-134.

4.

Holding lid down with elbow, if necessary, use a pliers to

bend crimped link back into its original position, so that

pin is captured and will not back out of hinge.

5.

Reposition lid so that it is upside down with the latch

farthest from you. Move saddlebag forward for

Plastic

Shroud

reinstallation of lid. Align four holes in saddlebag with

f2229x2x

those in latch.

6.

Install two inboard T15 TORX screws to fasten latch to

saddlebag. Alternately tighten screws to 20-25 in-lbs

(2.3-2.8 Nm).

7.

Align holes in check strap with those in lid and

saddlebag. Orient check strap so that logo is topside

with the bottom of the bar and shield on the lid side.

8.

Install two T15 TORX screws to fasten check strap and

latch to saddlebag. Alternately tighten screws to 20-25

in-lbs (2.3-2.8 Nm).

9.

Install two T20 TORX screws to fasten check strap to lid.

Wireform

Alternately tighten screws to 18-20 in-lbs (2.0-2.3 Nm).

f2232x2x

10.

Close saddlebag and install on motorcycle. See

Figure 2-136. Remove Button Assembly

INSTALLATION in this section.

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2004 Touring: Chassis

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5.

Install cable end fitting into hole in saddlebag bracket.

f2233x2x

6.

With the rounded edge of the e-clip on the same side as

the rounded edge of the saddlebag bracket, install e-clip

into groove in cable end fitting.

7.

Pull up on cable ball end and install spring on cable. See

lower frame of Figure 2-137.

2

NOTE

1.

Lock Ring

2.

Metal Shroud

Verify that ball end on opposite side of cable is installed in

3.

Latch Slot

pivot of button assembly. See Figure 2-138.

1

4.

Saddlebag

3

Bracket

8.

Position latch between saddlebag bracket with the cable

5.

Spring

slot inline with the cable ball end. Depress spring and

6.

E-Clip

capture cable ball end in slot of latch.

9.

Install metal shroud over latch and saddlebag bracket. At

rear of assembly, insert latch pin through metal shroud,

saddlebag bracket and latch until end exits front hole in

shroud.

4

10. Install lock ring into hole at end of latch pin. See upper

frame of Figure 2-137.

11. Close and open saddlebag lid several times to verify that

latch locks every time. Adjust cable if necessary.

Adjustment

5

1.

Open saddlebag. See OPENING in this section.

6

f2234x2x

2.

Remove two screws on inboard side of saddlebag to

release plastic shroud. See upper frame of Figure 2-136.

Figure 2-137. Remove Latch Assembly

3.

Back jam nut away from body hex. See Figure 2-138.

4.

Turn body hex toward or away from jam nut until closest

9. Remove e-clip from groove in cable end fitting.

part of latch is approximately 3/8 inch (9.5 mm) from

inboard side of saddlebag lid.

10. Pull cable end fitting from hole in saddlebag bracket.

5.

Turn jam nut until it makes firm contact with body hex.

11. Release cable from channel running along inboard edge

of saddlebag.

Installation

Body Hex

1. From the outboard side, insert sleeve into hole in saddle-

bag.

2. On the inboard side, depress wireform and slide button

into sleeve. Release wireform. Gently tug on assembly

to verify that wireform has engaged groove in sleeve to

lock button in place. See lower frame of Figure 2-136.

3. Holding plastic shroud with the relief positioned over the

cable adjuster, install two screws from inboard side of

Jam Nut

saddlebag. See upper frame of Figure 2-136.

f2235x2x

4. Capture cable in channel running along inboard edge of

saddlebag.

Figure 2-138. Cable Adjustment

2004 Touring: Chassis

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2

1

3

1

7

4

FLHTC/U

Multi-Rail

Saddlebag Guard

3

f2247x2x

Torque:

6

1. Saddlebag mounting bracket screws: 60-96 in-lbs (7-11 Nm)

2. Saddlebag support to fender screws: 15-20 ft-lbs (20-27 Nm)

3. Rail to saddlebag support screws: 15-20 ft-lbs (20-27 Nm)

4

4. Guard/support rail to frame screws: 15-20 ft-lbs (20-27 Nm)

5

4

5. Support rail to guard screw: 70-100 in-lbs (8-11 Nm)

6. Guard mount to rail screws: 72-120 in-lbs (8-14 Nm)

7. Rail clamp screws: 30-50 in-lbs (3-6 Nm)

3

Saddlebag Guard

FLHT, FLHR/C

f2248x2x

4

5

3

FLTR, FLHRS

Saddlebag Support Rail

f2249x2x

4

Figure 2-139. Saddlebag Guards/Support Rail

2004 Touring: Chassis

2-111

HOME

TOUR-PAK

2.26

FLHTC

Tour-Pak

Hole

Radio Antenna

NOTE

Cable Connector

For instructions covering riveted components, such as hinges

and catches, refer to the Instruction Sheet included with the

RIVET TOOL, HD-39787.

REMOVAL

1.

Open Tour-Pak. Remove rubber mat.

2.

Rotate knurled lock ring in a counter-clockwise direction

to separate pin and socket halves of Radio antenna

cable connector. Release cable from two clips at bottom

of Tour-Pak.

3.

Pull Tour-Pak lights connector [12], 3-place Multilock,

Grommet

from cavity inside Tour-Pak. Depress button and sepa-

rate pin and socket halves. See Figure 2-140.

Cable

Tour-Pak

Clip

Mounting Bolt

4.

Pull grommet into Tour-Pak and remove from main har-

ness conduit.

Figure 2-141. Feed Main Harness Thru Tour-Pak Hole

5.

Feed main harness conduit and connectors through hole

in Tour-Pak. See Figure 2-141.

INSTALLATION

6.

Holding nylon cap locknuts at bottom of Tour-Pak,

remove five bolts (with flat washers) to release Tour-Pak

1.

Place Tour-Pak on luggage rack and open lid.

from luggage rack. Luggage rack spacers will become

free as nuts are removed. Be sure to have a firm grasp

2.

Align rear center hole in Tour-Pak with same hole in lug-

on the Tour-Pak as the last bolt is removed. See Figure

gage rack. Slide 2 inch bolt (with flat washer) through

2-142.

ring terminal of radio antenna ground, and then through

Tour-Pak and luggage rack holes. At bottom of luggage

rack, install spacer (concave side up) and nylon cap

locknut on bolt. With concavity on spacer inline with the

rail, hold nut and tighten bolt until snug.

f1466a2x

Cable

Clip

CAUTION

Grommet

Always install the mounting bolts from inside the Tour-

Pak. If the bolts are installed upside down, then the ends

of the bolts can tear the molded liner and scratch

objects, such as helmets, stored inside the Tour-Pak.

3.

Install remaining

2 inch bolts (with flat washers and

nylon cap locknuts) in two front Tour-Pak and luggage

Cavity

rack holes (one each side) in the manner described

under step 2 above.

Tour-Pak Lights

4.

Position two spacers between bottom of luggage rack

Connector [12]

and tabs of license plate bracket. Slide 2-1/4 inch bolts

(with flat washers) through two center holes in Tour-Pak

Tour-Pak

and luggage rack, and then through spacers and tabs of

Radio Antenna

Mounting Bolt

license plate bracket. If necessary, loosen two hex bolts

Cable

at back of license plate bracket to align holes in tabs with

bolts. Install flat washers and nylon cap locknuts on bolts

Figure 2-140.

Disconnect Tour-Pak Lights Connector

and tighten until snug. See inset of Figure 2-142.

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2004 Touring: Chassis

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6.

Standing on left side of vehicle, feed socket connectors

and main harness conduit through hole in Tour-pak.

f1850x2x

Capture conduit in grommet. Install grommet in hole with

the larger OD facing inside.

7.

Mate pin and socket halves of Tour-pak lights connector

Rear Center Hole

Mounting Bolt

[12], 3-place Multilock, and tuck into cavity inside Tour-

(Cap side Up)

Pak. See Figure 2-140.

8.

Rotate knurled lock ring in a clockwise direction to mate

pin and socket halves of Radio antenna cable con-nec-

Flat

tor. Capture cable in two clips at bottom of Tour-Pak.

Washer

9.

Install rubber mat. Close Tour-Pak.

FLHTCU

REMOVAL

Spacer

1.

Open Tour-Pak. Open map pocket and remove acorn

nuts

(with flat washers). Remove map pocket and

molded liner from Tour-Pak.

2.

Depress external latch and rotate housing to release

Nylon Cap

bulb socket from left side of Tour-Pak.

Locknut

3.

Rotate knurled lock ring in a counterclockwise direction

to separate pin and socket halves of Radio antenna

cable connector. Release cable from two clips at bottom

Flat

of Tour-Pak.

Washer

4.

Pull Tour-Pak lights connector [12], 3-place Multilock,

Luggage

from cavity inside Tour-Pak. Depress button and sepa-

Rack Rail

rate pin and socket halves. See Figure 2-140.

5.

Pull grommet into Tour-Pak and remove from main har-

Spacer

ness conduit.

Nylon Cap

Locknut

6.

Feed main harness conduit and connectors through hole

in Tour-Pak. See Figure 2-141.

7.

Release rear headset receptacle from bracket at bottom

of left side speaker box.

8.

Remove trim ring and gently pull on wire harness to

draw 6-place Mini-Deutsch connector out of left side

speaker box. Depress external latch and use a rocking

motion to separate pin and socket halves.

f1851x2x

Stackup at License Plate Bracket

9.

Moving to right side of vehicle, disconnect 1-place CB

antenna cable connector. Release cable from two clips

Figure 2-142. Install Tour-Pak Mounting Bolts

at bottom of Tour-Pak. See Figure 2-143.

10.

Pull right side grommet into Tour-Pak and remove from

CB antenna cable. Feed CB antenna cable through hole

in Tour-Pak.

5.

In a crosswise pattern, alternately tighten five bolts to

11.

Remove trim ring and gently pull on wire harness to

96-120 in-lbs (10.8-13.5 Nm). Be sure that concavity on

draw 6-place Mini-Deutsch connector out of right side

each spacer is inline with the rail and has not rotated out

speaker box. Depress external latch and use a rocking

of position.

motion to separate pin and socket halves.

2004 Touring: Chassis

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4.

Position two spacers between bottom of luggage rack

and tabs of license plate bracket. Slide 2-1/4 inch bolts

f1467b2x

Grommet

(with flat washers) through two center holes in Tour-Pak

and luggage rack, and then through spacers and tabs of

license plate bracket. If necessary, loosen two hex bolts

Cable

at back of license plate bracket to align holes in tabs with

Clip

bolts. Install flat washers and nylon cap locknuts on bolts

and tighten until snug. See inset of Figure 2-142.

5.

In a crosswise pattern, alternately tighten five bolts to

96-120 in-lbs (10.8-13.5 Nm). Be sure that concavity on

each spacer is inline with the rail and has not rotated out

of position.

6.

On right side of vehicle, mate pin and socket halves of 6-

place Mini-Deutsch connector. Feed connector back up

into right side speaker box pressing trim ring into hole.

7.

Pass CB antenna cable through hole in Tour-Pak. Cap-

Tour-Pak

ture cable in grommet. Install grommet in hole with the

Mounting Bolt

CB Antenna

larger OD facing inside.

Cable Connector

8.

Mate pin and socket halves of 1-place CB antenna cable

connector. Capture cable in two clips at bottom of Tour-

Figure 2-143. Disconnect CB Antenna Cable Connector

Pak. See Figure 2-143.

9.

Moving to left side of vehicle, mate pin and socket halves

of 6-place Mini-Deutsch connector. Feed connector back

12. Holding nylon cap locknuts at bottom of Tour-Pak,

up into left side speaker box pressing trim ring into hole.

remove five bolts (with flat washers) to release Tour-Pak

from luggage rack. Luggage rack spacers will become

10.

Capture rear headset receptacle in bracket at bottom of

free as nuts are removed. Be sure to have a firm grasp

left side speaker box.

on the Tour-Pak as the last bolt is removed. See Figure

11.

Feed socket connectors and main harness conduit

2-142.

through hole in Tour-pak. Capture conduit in grommet.

Install grommet in hole with the larger OD facing inside.

12.

Mate pin and socket halves of Tour-pak lights connector

INSTALLATION

[12], 3-place Multilock, and tuck into cavity inside Tour-

Pak. See Figure 2-140.

1.

Place Tour-Pak on luggage rack and open lid.

13.

Rotate knurled lock ring in a clockwise direction to mate

2.

Align rear center hole in Tour-Pak with same hole in lug-

pin and socket halves of Radio antenna cable connector.

gage rack. Slide 2 inch bolt (with flat washer) through

Capture cable in two clips at bottom of Tour-Pak.

ring terminal of radio antenna ground, and then through

Tour-Pak and luggage rack holes. At bottom of luggage

14.

Install bulb socket on left side of Tour-pak.

rack, install spacer (concave side up) and nylon cap

15.

Install molded liner in Tour-Pak. Install map pocket and

locknut on bolt. With concavity on spacer inline with the

secure using acorn nuts (with flat washers). Close Tour-

rail, hold nut and tighten bolt until snug.

Pak.

CAUTION

Always install the mounting bolts from inside the Tour-

Pak. If the bolts are installed upside down, then the ends

of the bolts can tear the molded liner and scratch

objects, such as helmets, stored inside the Tour-Pak.

3.

Install remaining

2 inch bolts (with flat washers and

nylon cap locknuts) in two front Tour-Pak and luggage

rack holes (one each side) in the manner described

under step 2 above.

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TOUR-PAK LIGHTS/BACKREST/SPEAKER BOX

2.27

GENERAL

Mounting

Tour-Pak

All domestic model Tour-Paks are equipped with side marker

Bracket

lights. Ultra models also have a wrap-around rear light

assembly that contains two 2-filament lamps. One filament is

a supplemental brake light and the other a supplemental tail

lamp.

SIDE MARKER LIGHTS

FLHTC/U

Bulb

BULB/LENSE REPLACEMENT

Lense

Eyelet

Stepped

1.

Open Tour-Pak.

Rib

Screwdriver

2.

On Ultra models, open map pocket and remove acorn

nuts

(with flat washers). Remove map pocket and

f1810x2x

molded liner from Tour-Pak.

3.

Remove three T15 TORX screws to release lens at side

Figure 2-144. Remove Eyelets to Release

of Tour-Pak.

Mounting Bracket From Lense

4.

Using the blade of an X-Acto knife or small screwdriver,

gently pry up three eyelets on inboard side of mounting

bracket. See Figure 2-144. Remove eyelets and then

3.

Close Tour-Pak. Turn Tour-Pak over and remove remain-

remove mounting bracket from lense. Discard eyelets if

ing six flange nuts at bottom.

damaged.

4.

Place Tour-Pak topside up and open lid. Reach inside

5.

Remove bulb from socket and discard. Install new bulb

Tour-Pak and remove metal plate pulling threaded studs

in socket.

from holes at bottom.

6.

Align holes in mounting bracket with those in lense.

5.

Locate 2-place Multilock connector in channel at bottom

Push three eyelets through mounting bracket holes into

of Tour-Pak. Remove masking tape if necessary. See

bosses of lense. Use new eyelets if damaged.

Figure 2-145.

7.

Place lense assembly into position at side of Tour-Pak,

but exercise caution to avoid pinching or kinking wires.

6.

Depress button on socket side of Multilock connector

Note that center rib on inboard side of lense has a

and separate pin and socket halves.

stepped area for routing of the top wire. See Figure 2-

7.

Remove three T15 TORX screws to release lens at side

144.

of Tour-Pak.

8.

From inside Tour-Pak, install three T15 TORX screws.

8.

Compress grommet at side of Tour-Pak and push

9.

On Ultra models, install molded liner in Tour-Pak. Install

through hole to outboard side. Feed conduit and socket

map pocket and secure using acorn nuts (with flat wash-

through hole to release side marker light assembly.

ers).

10.

Close Tour-Pak.

INSTALLATION

REMOVAL

1.

Feed socket and conduit of new side marker light

assembly through hole at side of Tour-Pak.

1. Remove Tour-Pak. See Section 2.26 TOUR-PAK, RE-

2.

Compress grommet on conduit and install in hole.

MOVAL, either FLHTC or FLHTCU. Move Tour-Pak to

bench area.

3.

Place lense assembly into position at side of Tour-Pak,

2. Open Tour-Pak. Holding Phillips screw inside Tour-Pak

but exercise caution to avoid pinching or kinking wires.

(rear right corner), remove flange nut at bottom to

Note that center rib on inboard side of lense has a

release loading coil bracket. Remove Phillips screw with

stepped area for routing of the top wire. See Figure 2-

external tooth lockwasher.

144.

2004 Touring: Chassis

2-115

HOME

Tour-Pak Lights

f1753x2x

Connector [12]

3-place Multilock

Left Side

Right Side

Side Marker Light

Masking

Side Marker Light

Connector

Tape

Connector

2-place Multilock

2-place Multilock

Figure 2-145. Side Marker Light Connectors and Conduit

4.

From inside Tour-Pak, install three T15 TORX screws.

WRAP-AROUND LIGHT ASSEMBLY

5.

Mate pin and socket halves of 2-place Multilock connec-

FLHTCU

tor. Be sure that connector and conduit are positioned in

channel at bottom of Tour-Pak.

BULB REPLACEMENT

CAUTION

1.

Open Tour-Pak.

2.

Open map pocket and remove acorn nuts (with flat

If conduit and connector are not completely captured in

washers). Remove map pocket and molded liner from

channel at bottom of Tour-Pak, installation of metal plate

Tour-Pak.

can pinch wires or damage connector.

3.

Depress external latch and rotate bulb socket to release

6.

Place masking tape over channel to secure position of

from lens.

connector and conduit. See Figure 2-145.

4.

Remove bulb from socket and discard.

7.

With the square cut positioned at the front left corner,

5.

Install new bulb in socket.

install metal plate at bottom of Tour-Pak so that threaded

6.

Rotate bulb socket to install in lens.

studs exit holes at bottom.

7.

Install molded liner in Tour-Pak. Install map pocket and

8.

Place loading coil into position aligning hole in bracket

secure using acorn nuts (with flat washers).

with hole in rear right corner of metal plate. Slide Phillips

8.

Close Tour-Pak.

screw (with external tooth lockwasher) through holes. At

bottom of Tour-Pak, install flange nut on Phillips screw.

9.

Close lid and turn Tour-Pak over. Install six flange nuts

REMOVAL

on threaded studs of metal plate.

1.

Open Tour-Pak. Open map pocket and remove acorn

10. Install Tour-Pak on vehicle. See Section 2.26 TOUR-

nuts

(with flat washers). Remove map pocket and

PAK, INSTALLATION, either FLHTC or FLHTCU.

molded liner from Tour-Pak.

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2004 Touring: Chassis

HOME

INSTALLATION

f1257x2x

Tour-Pak

1.

Install light bar, metal clips and flange nuts to secure

light bar to Tour-Pak. Inside Tour-Pak, use RTV silicone

sealer (Part No. 99710-88) to seal perimeter of light bar.

See Figure 2-146.

2.

Install radio antenna mast into lamp housing. Thread

connector stud into mast. Turn

1/2 in.-20 UNF nut

(installed on connector during removal) in a clockwise

direction to tighten.

3.

Remove 1/2 in.-20 UNF nut and jam nut. Install large flat

washer, ring terminal and internal tooth lockwasher onto

connector. Reinstall jam nut and tighten.

4.

Rotate knurled lock ring in a clockwise direction to mate

pin and socket halves of Radio antenna cable connector.

Metal Clip

Capture cable in rear clip at bottom of Tour-Pak.

Bulb Housing

5.

On right side of Tour-Pak, install CB antenna mast into

Caulking

lamp housing. Install stud into mast and tighten with 2.5

mm allen head wrench.

6.

Place loading coil into position aligning hole in bracket

Figure 2-146. Wrap-Around Light Assembly

with hole in rear right corner of Tour-Pak. Slide Phillips

screw (with external tooth lockwasher) through holes. At

bottom of Tour-Pak, install flange nut on Phillips screw.

2.

Depress external latch and rotate housing to release

bulb sockets from both sides of Tour-Pak.

7.

Install flat washer, ring terminal and Keps nut onto load-

ing coil stud. Tighten Keps nut.

3.

Disconnect 1-place CB antenna cable connector on right

8.

Mate pin and socket halves of 1-place CB antenna cable

side of Tour-Pak. Release cable from rear clip at bottom

connector. Capture antenna cable in rear clip at bottom

of Tour-Pak.

of Tour-Pak.

4.

Remove Keps nut, ring terminal and flat washer from

9.

Install bulb sockets on both sides of Tour-pak.

loading coil stud.

10.

Install molded liner in Tour-Pak. Install map pocket and

secure using acorn nuts. Close Tour-Pak.

5.

Holding Phillips screw, remove flange nut at bottom of

Tour-Pak to release loading coil bracket. Remove Phil-

11.

Install SWR meter. Check SWR following procedure in

lips screw (with external tooth lockwasher) and loading

Section

6 of the

2004 ELECTRICAL DIAGNOSTIC

coil from vehicle.

MANUAL (Part No. 99497-04). When the antenna is

adjusted, remove the SWR meter and tighten the

6.

Using a 2.5 mm allen head wrench, remove loading coil

antenna connector at the transceiver.

stud. Remove CB antenna mast from lamp housing.

7.

On left side of Tour-Pak, rotate knurled lock ring in a

PASSENGER BACKREST

counter-clockwise direction to separate pin and socket

FLHTCU

halves of Radio antenna cable connector. Release cable

from rear clip at bottom of Tour-Pak.

REMOVAL

8.

Remove jam nut from Radio antenna cable connector at

back of Tour-Pak. Remove internal tooth lockwasher,

1.

Open Tour-Pak. Open map pocket and remove acorn

ring terminal and large flat washer from connector.

nuts

(with flat washers). Remove map pocket and

molded liner from Tour-Pak.

9.

Install jam nut back onto connector. Thread a 1/2 in.-20

UNF nut onto connector until contact is made with jam

2.

Remove two locknuts and backplate to detach center

nut. Turn jam nut to in a counter-clockwise direction to

backrest from Tour-Pak cover. See Figure 2-147.

remove connector stud from radio antenna mast.

3.

Remove two locknuts and backplate to detach right side

Remove mast from lamp housing.

backrest from cover.

4.

Remove two locknuts to detach left side backrest from

10.

Remove caulking from around light bar. Remove four

cover.

flange nuts and metal clips to free light bar from Tour-

Pak. See Figure 2-146.

5.

Remove backrest.

2004 Touring: Chassis

2-117

HOME

SPEAKER BOX

5142

FLHTCU

Right Side

REMOVAL

Fasteners

Passenger

and Backplate

Backrest

1.

Remove trim ring and gently pull on wire harness to

draw 6-place Mini-Deutsch connector out of speaker

box. Depress external latch and use a rocking motion to

separate pin and socket halves.

2.

Open Tour-Pak. Open map pocket and remove acorn

Center

nuts

(with flat washers). Remove map pocket and

Fasteners

molded liner from Tour-Pak.

and Backplate

3.

Remove three bolts with flat washers to free speaker box

from Tour-Pak.

INSTALLATION

1.

Install three bolts with flat washers to secure speaker

box to Tour-Pak. Alternately tighten bolts to 25-35 in-lbs

(2.8-4.0 Nm).

Left Side

Fasteners

2.

Install molded liner in Tour-Pak. Install map pocket and

secure using acorn nuts (with flat washers). Close Tour-

Pak.

3.

Mate pin and socket halves of 6-place Mini-Deutsch con-

nector. Feed connector back up into speaker box press-

ing trim ring into hole.

Figure 2-147. Tour-Pak Cover (Underside)

INSTALLATION

1.

Position backrest against Tour-Pak cover.

2.

From inside Tour-Pak, install two locknuts with backplate

to attach center backrest to cover.

3.

Install two locknuts and backplate to attach right side

backrest to cover.

4.

Install two locknuts to attach left side backrest to cover.

5.

Install molded liner in Tour-Pak. Install map pocket and

secure using acorn nuts (with flat washers). Close Tour-

Pak.

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2004 Touring: Chassis

HOME

LOWER FAIRING/ENGINE GUARD

2.28

LOWER FAIRING

U-Bolt

Ear

REMOVAL

1. Remove two screws from fairing lower cap. See Figure

2-148.

Retainer

2. Hold locknut at bottom of fairing lower, and using a T40

TORX drive head, turn inside screw to free assembly

Locknut

from engine guard clamp. Discard rubber washer.

3. Remove two locknuts to free retainer from upper rail of

engine guard. From within glove box, remove U-bolt.

4. Remove glove box from fairing lower. Remove fairing

lower from vehicle.

5. Repeat steps 1-4 on other side of vehicle.

Screw

INSTALLATION

Fairing

Lower Cap

1. Place fairing lower into position on vehicle.

Screw

2. Holding screw inside fairing lower, install new rubber

Rubber

washer, clamp and locknut to attach fairing bottom to

Washer

engine guard. Do not tighten locknut.

Clamp

3.

Place glove box into fairing lower. From within glove box,

Locknut

install U-bolt so that it encircles the upper rail of the

f1077bxx

engine guard. Loosely install retainer and locknuts.

4. Adjust the fairing lower so that ear at top inboard side is

Figure 2-148. Fairing Lower (Right Side) - FLHTCU

approximately 1/4 inch (6.4 mm) from frame downtube.

Verify that fairing lower is square, and then alternately

tighten locknuts to 35-40 in-lbs (4.0-4.5 Nm).

3.

Remove hex socket screw (with flat washer) to release

5. Hold locknut at bottom of fairing lower, and using a T40

tab at top of engine guard from slot at base of steering

TORX drive head, turn inside screw to fasten assembly

head.

to engine guard clamp. Tighten screw to 90-100 in-lbs

(10.2-11.3 Nm).

6. Install two screws to secure fairing lower cap to fairing

INSTALLATION

lower. Tighten screws to 10-15 in-lbs (1.1-1.7 Nm).

7. Repeat steps 1-6 on other side of vehicle.

1.

Insert tab at top of engine guard into slot at base of

steering head. Start hex socket screw (with flat washer)

to hang engine guard.

ENGINE GUARD

2.

Position ends of engine guard outboard of frame weld-

ments on each side of motorcycle. Install T40 TORX

screws positioning flanged locknuts on inboard side of

frame weldments.

REMOVAL

3.

Alternately tighten three screws to 15-20 ft-lbs (20.3-

1. Remove fairing lowers, if present. See LOWER FAIR-

27.1 Nm).

ING, REMOVAL, in this section. Remove fairing lower

clamps from engine guard.

4.

Install fairing lowers, if present, but first install fairing

lower clamps on each side of engine guard. See

2. Remove T40 TORX screws (with flanged locknuts) to

release ends of engine guard from frame weldments.

LOWER FAIRING, INSTALLATION, in this section.

2004 Touring: Chassis

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HOME

UPPER FAIRING/WINDSHIELD (FLHT/C/U)

2.29

OUTER FAIRING/WINDSHIELD

T27 TORX Screws

2

REMOVAL

1

3

1.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

2.

Remove the outer fairing as follows:

a. Standing at the front of the vehicle, use a T27 TORX

drive head to remove the three outer fairing screws

(with flat washers) just below the windshield. See

40

50

60

70

80

30

40

50

30

90

20

60

20

100

10

70

Figure 2-149.

10

0

MPH

120

110

0

RPMx100

80

b. Moving to the inner fairing side, remove the two fair-

ing screws just above the wind deflectors on the left

and right side.

c. Turn the handlebar to the right and remove the outer

fairing screw reaching in below the left side of the

fairing cap. Turn the handlebar to the left and

remove the fairing screw below the right side of the

fairing cap.

d. Tilting the outer fairing toward the front, squeeze the

6

7

4

5

two external tabs to remove the wire connector at

f2029x2x

the back of the headlamp assembly.

e. Lift the fairing

(with headlamp assembly) off the

Figure 2-149. Outer Fairing TORX Screw Locations

motorcycle.

e. Turn the handlebar to the left and start the outer fair-

CAUTION

ing screw reaching in below the right side of the fair-

Since the outer fairing screws hold the windshield in

ing cap. Turn the handlebar to the right and start the

place, the windshield may fall to the floor if not removed.

fairing screw below the left side of the fairing cap.

f.

Alternately tighten the four fairing screws on the

3.

Remove the windshield.

inner fairing side to 20-30 in-lbs (2.3-3.4 Nm).

g. Moving to the front of the vehicle, tighten the outer

fairing screws below the windshield to 25-30 in-lbs

INSTALLATION

(2.8-3.4 Nm).

2.

Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

1.

Install the outer fairing as follows:

MAXI-FUSE, INSTALLATION.

a. Place the fairing (with headlamp assembly) on the

motorcycle installing the wire connector at the back

of the headlamp assembly.

FAIRING CAP

b. Place the windshield in position on the inner fairing

aligning the slots with the threaded inserts.

REMOVAL

c. Using a T27 TORX drive head, start the three outer

fairing screws

(with flat washers) just below the

1.

Partially disassemble domestic ignition switch as follows:

windshield.

NOTE

d. Moving to the inner fairing side, start the two fairing

For partial disassembly of HDI ignition switch, see Section

screws just above the wind deflectors on both the

8.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK,

left and right side.

FLHT/C/U, FLTR (INTERNATIONAL), REMOVAL, steps 1-4.

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2004 Touring: Chassis

HOME

4.

Remove the fairing cap from the motorcycle. See Figure

TOP VIEW

BOTTOM VIEW

2-151.

INSTALLATION

1.

Verify that the rubber grommets are installed on each

side of the fairing cap. Barbs on cap fit into holes in

grommets. See Figure 2-151.

2.

Connect the Fairing cap switch connector [105], 12-

Button

place Multilock (black), on the right side of fairing cap.

Button

3.

With the forks turned fully to the left, install fairing cap

f1240x2x

f1476x8x

over ignition switch housing.

f1297b2x

4.

Using a T27 TORX drive head, start two fairing cap

screws (with flat washers). Verify that grommets in fair-

ing cap fully capture handlebar along with throttle and

clutch cables.

5.

Assemble domestic ignition switch as follows:

Knob

NOTE

For assembly of HDI ignition switch, see Section 8.18 IGNI-

Nut

TION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U,

FLTR (INTERNATIONAL), INSTALLATION, steps 5-10.

a.

Install switch position plate fitting tabs in slots of fair-

Tab

Collar

ing cap. Plate snaps in place when properly

Down and Forward

installed. Exercise care to avoid breaking tabs.

Replace plate if tabs are broken.

b.

Slide spacer over threaded post of ignition switch

Spacer

housing until it contacts switch position plate. Slide

collar over post with the tab side down (and for-

Figure 2-150. Ignition Switch Knob (Domestic)

ward). Install nut, and using a 7/8 inch wrench on

flats, tighten to 50-70 in-lbs (5.7-7.9 Nm).

a. See upper frame of Figure 2-150. To remove the

ignition switch knob, insert the Ignition Switch key

and turn to the UNLOCK position. Leaving the key

Rubber

f1305b2x

installed, rotate the knob to ACCESS. Depressing

Grommet

the release button at bottom (left side) with a small

screwdriver, push key down and turn an additional

60 degrees in a counter-clockwise direction. Lift and

remove knob.

b. Using a 7/8 inch wrench on flats, loosen switch nut

and remove from threaded post of ignition switch

housing. Remove collar and spacer. See lower

frame of Figure 2-150.

c. Gently remove the switch position plate by pulling

tabs from slots in fairing cap.

2.

Using a T27 TORX drive head, remove the two screws

(with flat washers) that secure fairing cap to left and right

sides of inner fairing.

3.

With the forks turned fully to the left, disconnect the Fair-

Fairing Cap

Switch Connector [105]

ing cap switch connector

[105],

12-place Multilock

12-Place Multilock

(black), from behind right side of fairing cap. Depress the

button on the socket terminal side of the connector

(plug) to pull apart the pin and socket halves.

Figure 2-151. Fairing Cap Assembly (FLHT/C/U)

2004 Touring: Chassis

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