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Harley Davidson 2004 Touring Models. Service Manual - page 37

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11. Bend tabs on lockplates away from flats of four fender

11.

Remove drill bit from axle hole.

mounting bolts. Remove fender mounting bolts and lock-

12.

Install brake caliper as follows:

plates. Remove fender from vehicle.

a. Use shop rag or tape to protect fender area adja-

cent to caliper, as incidental contact can occur dur-

ing caliper installation.

INSTALLATION

b. With the bleeder valve topside, position caliper so

that brake disc is situated between friction pads.

Now align upper mounting hole in caliper with upper

NOTE

mounting lug on fork leg.

If fender tip lamp is absent, perform steps 1 and 3-12.

c. Loosely install long caliper mounting bolt into upper

lug of front fork leg.

1. Align mounting holes in fender and lockplates with those

in fork tubes. Install four fender mounting bolts and

d. Install short caliper mounting bolt into lower lug of

tighten to 16-20 ft-lbs (22-27 Nm). Bend tabs on lock-

front fork leg. Tighten lower mounting bolt to 28-38

plates against flats of fender mounting bolts.

ft-lbs (37.9-51.5 Nm).

2. Route socket housing of front fender tip lamp connector

e. Tighten upper caliper mounting bolt to 28-38 ft-lbs

upward behind chrome skirt (FLHT/C/U) or through bot-

(37.9-51.5 Nm).

tom of headlamp nacelle (FLHR) to area beneath upper

Repeat step 12 to install caliper on opposite side of

fork bracket. Mate pin and socket halves.

wheel.

NOTE

13.

Install new cable strap to secure front fender tip lamp

To connect front fender tip lamp with the outer fairing

wires to brake line hose. Cut any excess cable strap

installed (FLHT/C/U models), reach in below the fairing cap

material.

on the left side of the steering head.

14.

FLHT/C/U: Install the outer fairing, if removed. See Sec-

3. Place wheel into position between forks with the valve

tion 2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U),

stem on the right side of the vehicle.

OUTER FAIRING/WINDSHIELD, INSTALLATION.

4. Coat the axle with ANTI-SIEZE LUBRICANT.

FLHR: Install wire connector at the back of the head-

lamp bulb. Align holes in headlamp housing with those in

5. Supporting wheel, insert threaded end of axle through

headlamp nacelle. Install eight Phillips screws. Install

right fork leg. Push axle through fork, short external

the headlamp door (chrome ring) and door screw.

spacer and wheel hub until it begins to emerge from left

side.

6. With the three notches on the bearing side, push axle

through long external spacer and left fork leg until axle

shoulder contacts external spacer on right fork side.

Install flat washer, lockwasher and axle nut.

Insert screwdriver or steel rod through hole in axle on

right side of vehicle. While holding axle stationary,

tighten axle nut to 50-55 ft-lbs (68-75 Nm).

Insert 7/16 inch drill bit into hole in axle.

10. Pull fork leg so that it just contacts drill bit, and then

tighten axle holder nuts to 132-180 in-lbs (14.9-20.3

Nm).

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REAR FENDER

2.33

REMOVAL

f2279x2x

T40 TORX

Bolt

Place the motorcycle on a hydraulic center stand with

the rear wheel raised off the ground.

Remove seat. See Section 2.24 SEAT, REMOVAL.

Remove rear wheel. See Section 2.4 REAR WHEEL,

REMOVAL.

Disconnect the rear fender lights connector anchored at

the front of the rear fender. Depress the button on the

socket terminal side and pull apart the pin and socket

halves. Release anchor from fender hole. See Figure 2-

179.

Gently pull side cover from frame downtube (no tools

required). Repeat step on opposite side of vehicle.

Remove four screws (two on FLHR/C/S and FLTR) to

release license plate bracket from luggage rack.

Figure 2-180. Rear Fender Front Mounting Bolt

(Left Side View)

Standing on left side of vehicle, use a T40 TORX drive

head to release front of rear fender from battery box.

See Figure 2-180.

Reaching under bumper, remove nut (with flat washer) to

free bumper bracket from weld stud on fender. Remove

At rear of vehicle, remove inside bolt (and flange nut) to

bumper from vehicle.

release rear bumper support rail from saddlebag support

bracket and saddlebag support rail. Repeat step on

10.

Using a T40 TORX drive head, remove fender side

opposite side of vehicle. See Figure 2-181.

mounting bolt located just below side cover grommet.

Repeat step on opposite side of vehicle. See Figure 2-

182.

11.

Using a T40 TORX drive head, remove upper rear bolt

f2013x8x

from saddlebag support bracket. Repeat step on oppo-

Rear Fender

site side of vehicle. See Figure 2-183.

Lights Connector [7]

T40 TORX Bolt

f1908x2x

Figure 2-179. Rear Fender (Top View)

Figure 2-181. Release Bumper From Saddlebag Rail

2004 Touring: Chassis

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T40

LEFT SIDE

T40

TORX Bolt

Saddlebag

TORX Bolt

Front

Rear

Support Bracket

f1862x2x

f1864x2x

f1991x2x

Figure 2-183. Saddlebag Support Bracket Bolts

RIGHT SIDE

(Left Side View)

T40

TORX Bolt

INSTALLATION

Exercising caution to avoid scratching fender paint on

luggage rack or other bracketry, carefully roll the fender

in. See Figure 2-184. If necessary, have one person

spread the saddlebag support brackets while the other

rolls the fender in.

Engaging hole of fender rear spacer nut, use a T40

TORX drive head to start upper front bolt in saddlebag

support bracket. Repeat step on opposite side of vehi-

cle. See Figure 2-183.

Start upper rear bolt in saddlebag support bracket.

Repeat step on opposite side of vehicle.

Standing on left side of vehicle, start bolt securing front

Figure 2-182. Rear Fender Side Mounting Bolts

of rear fender to battery box. See Figure 2-180.

Engaging hole in frame and fender front spacer nut, start

fender side mounting bolt located just below side cover

12.

Remove upper front bolt from saddlebag support

grommet. Repeat step on opposite side of vehicle. See

bracket. Repeat step on opposite side of vehicle. Be

Figure 2-182.

aware that rear fender will drop when the forward bolts

are removed.

Reaching under rear fender, hang bumper bracket on

fender weld stud. Install flat washer and start nut on

13.

Exercising caution to avoid scratching fender paint on

luggage rack or other bracketry, carefully roll the fender

stud.

out. See Figure 2-184. If necessary, have one person

Start inside bolt (with flange nut) to fasten rear bumper

spread the saddlebag support brackets while the fender

support rail to saddlebag support bracket and saddle-

is rolled out.

bag support rail. Repeat step on opposite side of vehi-

cle. See Figure 2-181.

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NOTE

Dental floss can be used to gently saw the heated cloisonne

free of the rear fender.

Remove remaining adhesive with 3M GENERAL PUR-

POSE ADHESIVE REMOVER (Part No. 051135).

Installation

Peel backing paper off medallion.

Place medallion in position over recess in rear fender.

NOTE

f2014x2x

The cloisonne is centered left to right over the dimpled

recess in the rear fender with the bottom edge of the cloi-

sonne 1.75 inches (44.45 mm) above the bottom edge of the

Figure 2-184. Carefully Roll Out Rear Fender

fender.

Press firmly to affix cloisonne.

Alternately tighten all rear fender T40 TORX bolts to 15-

20 ft-lbs (20-27 Nm). Tighten nut on fender weld stud to

secure bumper bracket.

9740

FLHRS

Install four screws

(two on FLHR/C/S and FLTR) to

secure license plate bracket to luggage rack.

10.

Mate pin and socket halves of rear fender lights connec-

tor and snap anchor in rear fender hole. See Figure 2-

179.

11.

Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

required). Repeat step on opposite side of vehicle.

12.

Install rear wheel. See Section

2.4 REAR WHEEL,

INSTALLATION.

13.

Install seat. See Section 2.24 SEAT, INSTALLATION.

9741

FLTR

REAR FENDER CLOISONNE

Removal

1. Apply 3M GENERAL PURPOSE ADHESIVE REMOVER

(Part No. 051135) to edge of adhesive backing visible

behind cloisonne. Allow to soak.

CAUTION

Avoid excess heat which will damage the painted sur-

face.

Figure 2-185. Rear Fender Cloisonne

2. Carefully apply heat directly onto cloisonne with ROBIN-

AIR HEAT GUN (HD-25070).

3. Lift the cloisonne from fender.

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JIFFY STAND

2.34

GENERAL

The vehicle is equipped with a jiffy stand (or side stand) that

locks when placed in the full forward position (down) with the

full weight of the vehicle resting on it.

1WARNING

Leg Stop

Without the full weight of the motorcycle resting on the

Longer Side

jiffy stand, any vehicle movement can cause the jiffy

Faces Rear

stand to retract slightly from the full forward position. If

Bracket

the jiffy stand is not in the full forward or lock position

when the full vehicle weight is rested on it, the vehicle

could fall over, which could result in death or serious

Flange

Nut

injury.

1WARNING

Always park the vehicle on a firm, level surface. The

weight of the vehicle can cause it to fall over, which

FRONT

REAR

could result in death or serious injury.

1WARNING

Be sure jiffy stand is fully retracted before riding. If jiffy

stand is not fully retracted during vehicle operation,

unexpected contact with the road surface can distract

the rider. While the jiffy stand will retract upon contact,

f1142a2x

the momentary disturbance and/or rider distraction can

lead to loss of vehicle control resulting in death or seri-

ous injury.

Figure 2-187. Leg Stop Orientation

(Full Forward Position)

REMOVAL

Frame

1WARNING

Hole

Securely block vehicle under frame to be sure that vehi-

Flange

Nut

cle will not fall when jiffy stand is removed. Inadequate

safety precautions could result in death or serious

Leg Stop

injury.

Lockwasher

Block motorcycle under frame, so that vehicle is securely

upright and level. Jiffy stand should be able to move

Bolt

through its full range of travel without the weight of the

vehicle resting on it.

Bracket

Rubber

See Figure 2-186. Move jiffy stand to the retracted posi-

Stop

tion (up). Remove flange nut and leg stop from threaded

end of jiffy stand leg.

Spring

Move jiffy stand to the full forward position

(down).

Jiffy

Stand

Grasping end of spring as close to frame tube as possi-

f1852x2x

ble, twist and turn end with needle nose pliers to unhook

Figure 2-186. Jiffy Stand Assembly

from frame hole. Remove jiffy stand leg from bracket.

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4. Inspect jiffy stand assembly for worn or damaged parts.

Replace parts as necessary.

7846

INSTALLATION

1. Lubricate the jiffy stand leg with Loctite Aerosol Anti-

Seize Lubricant. Restrict the application to the area of

the jiffy stand leg that rotates within the bracket.

2. Insert threaded end of jiffy stand up through bottom of

bracket. With jiffy stand in the full forward position, par-

tially place spring end into frame hole. Rap spring with a

Rubber

rubber mallet to fully seat in hole.

Stop

NOTE

Verify that opposite end of spring enters hole at front of leg

weldment. If end enters hole from rear, spring coil will rub on

Figure 2-188. Jiffy Stand

leg when jiffy stand is exercised.

3. Holding jiffy stand at the full forward position, install leg

Extend and retract jiffy stand leg several times to verify

stop over threaded end with the stamped “side down.”

proper operation. Jiffy stand should swing freely to the

Install flange nut and tighten to 43-53 ft-lbs (58-72 Nm).

fully extended and fully retracted positions.

Move jiffy stand to the full forward position. Carefully

1WARNING

remove support blocking from beneath motorcycle frame

and rest motorcycle on jiffy stand.

If leg stop is installed incorrectly, excess wear may

cause the vehicle to fall over when rested on the jiffy

stand, which could result in death or serious injury.

CAUTION

Verify that the longer side of the leg stop faces the rear

Verify that rubber stop is in place on prong of jiffy stand.

of the vehicle. See Figure 2-187.

Without the rubber stop, the stand will make hard con-

tact with the lower frame tube when retracted, possibly

resulting in chipping or nicking of the powder coat.

Replace rubber stop if torn or deteriorated. See Figure 2-

188.

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FOOTBOARDS/FOOTRESTS

2.35

RIDER FOOTBOARD

INSTALLATION

Install right side footboard and bracket assembly as fol-

lows:

REMOVAL

a. Insert two allen head socket screws (with lockwash-

Remove right side footboard and bracket assembly as

ers and flat washers) through frame weldment into

follows:

footboard brackets. See Figure

2-189. For best

results, approach from left side of motorcycle using

a. Remove two allen head socket screws (with lock

a 3/8 inch ball allen with extension.

washers and flat washers) to release footboard

b. Alternately tighten socket screws to 30-35 ft-lbs (41-

brackets from frame weldment. See Figure 2-189.

48 Nm).

For best results, approach from left side of motorcy-

cle using a 3/8 inch ball allen with extension.

Install left side footboard and bracket assembly as fol-

Remove left side footboard and bracket assembly as fol-

lows:

a. Insert allen head socket screw (with lockwasher and

flat washer) through frame weldment into footboard

a. Raise the motorcycle on a hydraulic center stand so

forward bracket. See Figure 2-189. For best results,

that the weight of the motorcycle is not resting on

approach from opposite side of motorcycle using a

the jiffy stand.

3/8 inch ball allen with extension.

b. Remove socket screw (with lockwasher and flat

b. At footboard rear bracket, slide upper hex bolt

washer) to release footboard forward bracket from

through frame weldment, jiffy stand bracket and

frame weldment. See Figure 2-189. For best results,

footboard bracket thru hole. Install lockwasher and

approach from opposite side of motorcycle using a

locknut. Slide lower hex bolt through frame weld-

3/8 inch ball allen with extension.

ment and jiffy stand bracket into threaded hole of

footboard bracket.

c. To free footboard rear bracket from frame weldment

and jiffy stand bracket, remove lower hex bolt (with

c. Tighten front bracket socket screw to 30-35 ft-lbs

lockwasher) and upper hex bolt (with lockwasher

(41-48 Nm).

and locknut).

d. Alternately tighten rear bracket hex bolts to 15-20 ft-

lbs (20-27 Nm).

Left Side

Right Side

f2242x2x

Figure 2-189. Rider Footboards (All Models Except FLHRS)

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DISASSEMBLY

NOTE

If only replacing the rubber pad, refer to step 1 below and

then see steps 4-5 under ASSEMBLY.

1. Tilt footboard upward. From bottom of footboard, use a

large flat blade screwdriver to push four rubber anchors

on pad up through holes in footboard.

2. Remove nuts from pivot bolts at underside of footboard.

3. Remove pivot bolts to release footboard from brackets.

4. Remove footboard brackets. See RIDER FOOT-

BOARD, REMOVAL, in this section.

ASSEMBLY

f2243x2x

1. Install footboard brackets. See RIDER FOOTBOARD,

INSTALLATION, in this section.

Figure 2-190. Passenger Footboard

(All Models Except FLHRS)

2. Place footboard into position between brackets and

install pivot bolts so that the nuts will be on the inboard

side.

DISASSEMBLY

NOTE

The bottom of FLHRS footboards are stamped L(eft) or

If only replacing the rubber pad, refer to step 1 below and

R(ight) to ensure proper installation.

then see steps 4-5 under ASSEMBLY.

3. Install nuts onto pivot bolts and alternately tighten to 84-

Tilt footboard upward. From bottom of footboard, use a

108 in-lbs (9.5-12.2 Nm).

small flat blade screwdriver to push rubber beads on pad

up through holes in footboard. Remove pad.

4. Moisten four rubber anchors on new pad with soapy

water.

Using a brass drift and rubber mallet, tap two retaining

pins toward center of footboard and remove.

5. Place pad into position on footboard. From bottom of

Remove footboard from bracket.

footboard, use pliers to pull rubber anchors down

through holes in footboard.

Remove steel ball and spring from hole in footboard

bracket.

Remove footboard bracket from rear swingarm bracket.

See PASSENGER FOOTBOARD, REMOVAL, in this

PASSENGER FOOTBOARD

section.

REMOVAL

ASSEMBLY

1. Remove socket screw with lockwasher to remove foot-

Install footboard bracket. See PASSENGER FOOT-

board bracket from rear swingarm bracket.

BOARD, INSTALLATION, in this section.

Place spring into hole in footboard bracket. Place ball on

top of spring.

INSTALLATION

Place footboard into position on bracket and install

1. Insert pin on footboard bracket into hole in swingarm

retaining pins from the outboard side. Using a brass drift

bracket.

and rubber mallet, tap pins until centered in lugs of

bracket.

NOTE

Moisten rubber beads on new pad with soapy water.

Passenger footboards can be adjusted to one of three posi-

Place pad into position on footboard. From bottom of

tions. To move footboards to a new position, remove plastic

footboard, use needle nose pliers to pull rubber beads

plugs from holes in rear swingarm bracket as necessary.

down through holes in footboard.

2. Install socket screw with lockwasher. Tighten socket

Engage nubs on inboard corners of pad with holes in

screw to 15-18 ft-lbs (20-24 Nm).

footboard.

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PASSENGER FOOTREST (FLHRS)

ASSEMBLY

Install footrest bracket. See PASSENGER FOOTREST

(FLHRS), INSTALLATION, in this section.

REMOVAL

Remove socket screw with lockwasher to remove foot-

With concave side up and flat edge facing opposite the

rest bracket from rear swingarm bracket.

footrest, align hole in wave spring with topside hole in

footrest.

Place footrest with wave spring between arms of bracket

INSTALLATION

and install pivot pin. Hole in bracket is countersunk to

accommodate head of pivot pin.

Insert pin on footrest bracket into hole in swingarm

bracket.

NOTE

Verify operation of footrest before installing retaining ring.

Passenger footrests can be adjusted to one of three posi-

The ease with which the footrest pivots is based on the cur-

tions. To move footrests to a new position, remove plastic

vature of the wave spring. Flattening the wave spring allows

plugs from holes in rear swingarm bracket as necessary.

the footrest to move more easily, while increasing the curva-

ture makes movement more difficult.

Install socket screw with lockwasher. Tighten socket

screw to 15-18 ft-lbs (20-24 Nm).

Install new retaining ring in groove at end of pivot pin.

Place new pad into footrest.

DISASSEMBLY

Apply a small dab of Loctite Medium Strength Thread-

NOTE

locker

243 (blue) to threads of socket screw. Install

socket screw and tighten to 15-20 ft-lbs (20-27 Nm).

If only replacing the rubber pad, refer to step 1 below and

then see steps 5-6 under ASSEMBLY.

Remove socket screw from end of footrest. Remove rub-

ber pad.

2. Remove retaining ring from groove at end of pivot pin.

Remove pivot pin.

3. Remove footrest and wave spring from footrest bracket.

4. Remove footrest bracket from rear swingarm bracket.

See PASSENGER FOOTREST (FLHRS), REMOVAL, in

this section.

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EXHAUST SYSTEM

2.36

NOTE

REMOVAL

TORCA muffler clamps have eliminated the need for silicone

or graphite tape during assembly. To ensure sealing integrity

1. Remove saddlebags. See Section 2.25 SADDLEBAG,

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

REMOVAL.

ley-Davidson recommends that muffler clamp assemblies be

2. See Figure 2-192. Open worm drive clamps to remove

discarded and replaced each time they are removed.

six heat shields from exhaust pipes. Mark the location of

the heat shields to ensure proper assembly.

3. Using a bungee cord, tie the muffler on the left side of

INSTALLATION

the vehicle to the lower saddlebag support rail.

4. Remove the exhaust flange nuts to release the front and

NOTE

rear header pipes from the cylinder head studs. For best

Always loosely assemble exhaust system on vehicle before

results, use impact wrench with long 1/2 inch swivel

following tightening procedure. Assemble as follows:

socket.

Install new gaskets in both the front and rear cylinder

5. See Figure 2-191. Loosen the four TORCA clamps as

head exhaust ports (with the tapered side out).

follows:

Right side of vehicle

Install transmission exhaust bracket onto transmission

side door, if removed.

● front header pipe to rear header pipe

● rear header pipe to right side muffler

Install front header pipe exhaust flange onto front cylin-

der head. Start flange nuts on cylinder head studs.

Left side of vehicle

Engaging transmission exhaust bracket, capture front

● rear header pipe to crossover pipe

header pipe in transmission exhaust bracket clamp. Use

● crossover pipe to left side muffer

a channel lock to close clamp, if necessary. Finger

NOTE

tighten clamp bolt (with flat washer and locknut).

To facilitate removal, spray PB Blaster or other suitable pene-

Slide a new TORCA clamp onto free end of front header

trating oil in and around joints of exhaust pipes. For best

pipe.

results, be sure to allow sufficient time for the penetrating oil

Install rear header pipe onto rear cylinder head and front

to work.

header pipe. Start flange nuts on cylinder head studs.

Remove four bolts (with lockwashers) to detach left and

Move TORCA clamp into position between front and rear

right side mufflers from the lower saddlebag support

header pipes.

rails.

Slide new TORCA clamps onto free ends of rear header

Standing on right side of vehicle, remove muffler from Y-

pipe. TORCA clamp to crossover pipe is special in that it

shaped rear header pipe.

has slot for bracket tab to exhaust support bracket.

Remove Keps nut and pull bracket tab and stud from

Slide right side muffler onto rear header pipe. Finger

slots in TORCA clamp and exhaust support bracket.

tighten two bolts (with lockwashers) to attach muffler to

Remove Y-shaped rear header pipe from front header

lower saddlebag support rail. Place TORCA clamp into

pipe, crossover pipe (to left side muffler) and rear cylin-

position between rear header pipe and right side muffler.

der head. Remove bracket tab from slot in TORCA

Moving to left side of vehicle, install crossover pipe onto

clamp.

remaining end of rear header pipe (above starter). Place

10.

Remove bolt (with flat washer and locknut) from trans-

TORCA clamp into position between rear header pipe

mission exhaust bracket clamp on front header pipe.

and crossover pipe.

Use a channel lock to open clamp and then remove from

10.

Fit bracket tab into slot of TORCA clamp engaging stud

header pipe and transmission exhaust bracket. Remove

in slot of exhaust support bracket. Start Keps nut on

front header pipe exhaust flange from front cylinder

stud.

head.

11.

Slide new TORCA clamp onto free end of crossover

11.

Moving to left side of vehicle, remove crossover pipe

pipe.

from left side muffler.

12.

Using a bungee cord, tie left side muffler to lower sad-

12.

Remove bungee cord to release left side muffler from

dlebag support rail. Install left side muffler on crossover

lower saddlebag support rail.

pipe. Place TORCA clamp into position between cross-

13.

Remove and discard gaskets from front and rear

over pipe and left side muffler. Finger tighten bolts to

exhaust ports. Discard TORCA clamp bolt assemblies-

attach muffler to saddlebag support rail.

one time usage only.

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b. Tighten the bottom nut of the rear cylinder head

CAUTION

exhaust flange to 9-18 in-lbs (1-2 Nm). Tighten the

top nut to

100-120 in-lbs (11.3-13.6 Nm). Final

Verify that the exhaust pipes do not contact the vehicle

tighten the bottom nut to 100-120 in-lbs (11.3-13.6

frame or any mounted components. Contact will cancel

Nm).

the effect of the rubber isolation mounts and transmit

c. Tighten the transmission exhaust bracket clamp bolt

vibration to the rider via the vehicle frame.

to 60-96 in-lbs (6.8-10.8 Nm).

13. Tighten the exhaust system as follows:

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

the right side muffler to the lower saddlebag support

a. Tighten the top nut of the front cylinder head

rail.

exhaust flange to 9-18 in-lbs (1-2 Nm). Tighten the

bottom nut to 100-120 in-lbs (11.3-13.6 Nm). Final

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

tighten the top nut to

100-120 in-lbs (11.3-13.6

the left side muffler to the lower saddlebag support

Nm).

rail.

Left

Muffler

Crossover

Rubber

TORCA

Pipe

Mount

Clamp

Screw

Saddlebag Support

Rail Bracket

Bracket

Lock

Tab

Washer

Keps

Nut

TORCA

Exhaust

Clamp

Support Bracket

(Special)

Right

Muffler

Cylinder Head

TORCA

Gasket

Clamp

Circlip

Transmission

Exhaust Bracket

Exhaust

Clamp

Flange

Nut

Rear

Header Pipe

TORCA

Clamp

Front

Header Pipe

Transmission

f1153b2x

Exhaust Bracket

Figure 2-191. Exhaust System (without Heat Shields)

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Heat

Shields

Left Muffler

Crossover

Pipe

Right Muffler

Heat

Shields

Rear

Header Pipe

Worm Drive

Clamps

Front

Header Pipe

Heat

Shields

f1154b2x

Figure 2-192. Heat Shields

Verify that all exhaust pipes are in alignment and do

15. Open worm drive clamps and install six heat shields on

not contact the vehicle frame or mounted compo-

exhaust pipes as marked during removal. See Figure 2-

nents.

192. Position each clamp so that screw is on the out-

board side in the most accessible position and then

g. Tighten the four TORCA clamps to 45-60 ft-lbs (61-

tighten to 20-40 in-lbs (2.3-4.5 Nm).

81 Nm) in the following order:

● crossover pipe to left side muffer

CAUTION

● rear header pipe to right side muffer

Verify that the heat shields do not contact the vehicle

● front header pipe to rear header pipe

frame or any mounted components. Contact will cancel

● rear header pipe to crossover pipe

the effect of the rubber isolation mounts and transmit

vibration to the rider via the vehicle frame.

14. Tighten Keps nut securing bracket tab to exhaust sup-

port bracket.

16. Remove bungee cord from left side muffler.

17. Install saddlebags. See Section

2.25 SADDLEBAG,

INSTALLATION.

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NOTES

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SPECIFICATIONS

3.1

MANUFACTURING TOLERANCES

General

Hydraulic Lifter

IN.

Number of cylinders

Fit in crankcase (loose)

0.0008-0.0020

0.02-0.05

Type

4-cycle, 45˚V², air-cooled

85 ft-lbs (115.2 Nm) @ 3000

Torque

rpm, chrome dual exhaust

Cylinder Head

IN.

Bore

3.75 in. (95.25 mm)

Valve guide in head (tight)

0.0020-0.0033

0.051-0.084

Stroke

4.00 in. (101.6 mm)

Valve seat in head (tight)

0.003-0.0045

0.076-0.114

Piston displacement (approx.)

88 cu. in. (1450 cc)

Head gasket surface

0-0.006

0-0.0152

Compression ratio

9.0:1

(flatness)

Combustion chamber

5.187 cu. in. (85 cc) bathtub

Twin cams, chain driven with

Cam system

Valve

IN.

spring loaded tensioners

Fit in guide: exhaust

0.0015-0.0033

0.038-0.084

Max. sustained engine speed

5500 rpm

Fit in guide: intake

0.0008-0.0026

0.020-0.066

Idle speed

1000 rpm +/- 50

Seat width

0.040-0.062

1.02-1.58

Weight

165 lbs (74.8 kg)

Stem protrusion from

1.990-2.024

50.55-51.41

cylinder head boss

Ignition System

Sequential, non waste spark,

Type

MAP-N control

Valve Spring

Outer

Inner

Ignition timing:

72-92 lbs

38-49 lbs

20^o-30^o

1050 rpm (Hot Idle)

@ 1.751-1.848 in.

@ 1.577-1.683 in.

Closed

Spark plug size

12 mm

33-42 kg

17-22 kg

Spark plug type

Harley-Davidson 6R12

@ 44.45-46.9 mm

@ 40.1-42.8 mm

Spark plug gap

0.038-0.043 in. (0.97-1.09 mm)

183-207 lbs

98-112 lbs

@ 1.282-1.378 in.

@ 1.107-1.213 in.

Spark plug torque

12-18 ft-lbs (16-24 Nm)

Open

83-94 kg

44-51 kg

@ 32.6-35.0 mm

@ 28.1-30.8 mm

Oiling System

2.105-2.177 in.

1.926-1.996 in.

Free length

Twin gerotor, dual scavenge, crank mounted

53.47-55.3 mm

48.9-50.7 mm

Pump

and driven, internal oil pump, dry sump

30-38 psi (207-262 kN/m²) at

Pressure

2000 rpm and normal operating temperature

Piston

IN.

of 230^oF (110^oC)

Fit in cylinder:

10 micron media,

Early Style Piston

0.0006-0.0017

0.015-0.043

Filtration

filtered between pump and engine

Late Style Piston

0.0014-0.0025

0.036-0.064

Ring end gap:

Rocker Arm

IN.

Top compression ring

0.010-0.020

0.25-0.51

Shaft fit in bushing

2nd compression ring

0.014-0.024

0.36-0.61

0.0005-0.0020

0.013-0.051

(loose)

Oil control ring

0.010-0.050

0.25-1.27

End clearance

0.003-0.013

0.08-0.33

Ring side clearance:

Bushing fit in rocker arm

0.002-0.004

0.051-0.102

Top compression ring

0.0012-0.0037

0.030-0.094

(tight)

2nd compression ring

0.0012-0.0037

0.030-0.094

Rocker Arm Shaft

IN.

Oil control ring

0.0031-0.0091

0.079-0.23

Shaft fit in rocker arm

0.0007-0.0022

0.018-0.056

Piston pin fit (loose)

0.0002-0.0005

0.005- 0.013

support plate (loose)

2004 Touring: Engine

3-1

HOME

MANUFACTURING TOLERANCES (CONT.)

TORQUE VALUES

Connecting Rod

IN.

Item

ft/in-lbs

Piston pin fit (loose)

0.0007-0.0012

0.018-0.030

Breather assembly bolts

90-120 in-lbs

10-14 Nm

Side play between

0.005-0.015

0.13-0.38

flywheels

Cam cover screws

125-155 in-lbs

14-18 Nm

Connecting rod to

Cam cover plate screws

20-30 in-lbs

2.3-3.4 Nm

0.0004-0.0017

0.0102-0.0432

crankpin (loose)

Cam support plate screws

90-120 in-lbs

10-14 Nm

Bearing retainer plate

20-30 in-lbs

2-3 Nm

screws

Flywheel

IN.

15 ft-lbs,

20.3 Nm,

Crank sprocket flange bolt

loosen one full

Runout

0.000-0.010

0.000-0.254

turn, 24 ft-lbs

turn, 32.5 Nm

(flywheels at rim)

15 ft-lbs,

20.3 Nm,

Runout

0.000-0.002

0.000-0.051

Primary cam sprocket

loosen one full

loosen one

(shaft at flywheel)

flange bolt

turn, 34 ft-lbs

full turn, 46.1

End play

0.003-0.010

0.076-0.254

Crank position sensor

90-120 in-lbs

10.2-13.6 Nm

screw

Crankshaft/Sprocket

Piston jet screws

25-35 in-lbs

2.8-4.0 Nm

IN.

Shaft Bearings

Transmission housing to

15 ft-lbs,

20 Nm,

crankcase bolts

30-35 ft-lbs

41-48 Nm

Bearing fit (loose)

0.0002-0.0015

0.005-0.038

Crankcase to front engine

Crankshaft runout

0.0-0.003

0.0-0.076

33-38 ft-lbs

45-52 Nm

mounting bracket bolts

Bearing fit in

0.0038-0.0054

0.097-0.137

10 ft-lbs,

14 Nm,

crankcase (tight)

Crankcase bolts

15-19 ft-lbs

20-26 Nm

Bearing inner race on

120-144 in-lbs,

13.6-16.3 Nm,

0.0004-0.0014

0.010-0.036

crankshaft (tight)

Cylinder head bolts

15-17 ft-lbs

20.3-23.1 Nm

+ 90^o turn

Cylinder studs

10-20 ft-lbs

14-27 Nm

Engine oil drain plug

14-21 ft-lbs

19-28 Nm

Lifter cover screws

90-120 in-lbs

10-14 Nm

Oil pan screws

84-108 in-lbs

9-12 Nm

Oil filter

1/2-3/4 turn after gasket contact

Oil filter mount

12-16 ft-lbs

16-22 Nm

Crankcase oil fittings/plugs

120-168 in-lbs

13.6-18.9 Nm

Oil hose cover screws

84-108 in-lbs

10-12 Nm

Oil pressure switch/sender

96-120 in-lbs

11-14 Nm

Rocker arm support

18-22 ft-lbs

24-30 Nm

plate bolts

Rocker cover bolts

15-18 ft-lbs

20-24 Nm

Rocker housing bolts

120-168 in-lbs

13.6-18.9 Nm

Spark plugs

12-18 ft-lbs

16-24 Nm

Stator screws

55-75 in-lbs

6.2-8.5 Nm

Upper engine mounting

bracket:

To cylinder heads

35-40 ft-lbs

48-54 Nm

To top stabilizer link

18-22 ft-lbs

24-30 Nm

Engine temperature

120-180 in-lbs

13.6-20.3 Nm

sensor

Intake flange adapter

96-144 in-lbs

10.9-16.3 Nm

screws

Exhaust flange adapter

100-120 in-lbs

11.3-13.6 Nm

nuts

3-2

2004 Touring: Engine

HOME

SERVICE WEAR LIMITS

3.2

GENERAL

REPLACE IF

Wear limits can be used as a guide when deciding whether to

Cylinder Bore

IN.

reuse engine parts. Replace used parts whenever the follow-

ing wear limits are exceeded.

Standard

More than 3.752

More than 95.301

0.005 in. oversize

More than 3.757

More than 95.428

REPLACE IF

Rocker Arm/

0.010 in. oversize

More than 3.762

More than 95.555

Rocker Arm Shaft

IN.

Shaft fit in bushing (loose)

More than 0.0035

More than 0.089

REPLACE IF

End clearance

More than 0.025

More than 0.635

Piston

IN.

Shaft fit in rocker arm

More than 0.0035

More than 0.089

support plate (loose)

Fit in cylinder (loose)

More than 0.003

More than 0.076

Piston pin fit (loose)

More than 0.0008

More than 0.020

Ring end gap

REPLACE IF

Top compression

More than 0.030

More than 0.76

Hydraulic Lifter

IN.

2nd compression

More than 0.034

More than 0.86

Fit in crankcase

More than 0.003

More than 0.08

Oil control ring rails

More than 0.050

More than 1.27

Roller fit

More than 0.0015

More than 0.038

Ring side clearance

Roller end clearance

More than 0.015

More than 0.38

Top compression

More than 0.0045

More than 0.11

2nd compression

More than 0.0045

More than 0.11

Oil control ring rails

More than 0.010

More than 0.25

REPLACE IF

Cam Support Plate

IN.

REPLACE IF

Connecting Rod

More than 0.090

More than 2.29

Cam chain

IN.

tensioner shoe wear

1/2 thickness of shoe

Piston pin fit (loose)

More than 0.002

More than 0.051

Crankshaft bushing fit

Less than 0.0008

Less than 0.0203

in cam support plate

Side play between

More than 0.020

More than 0.508

flywheels

Crankshaft bushing

More than 0.8545

More than 21.704

maximum ID

Fit on crankpin (loose)

More than 0.002

More than 0.051

REPLACE IF

Flywheel

Cylinder Head

IN.

Runout (flywheels at rim)

More than 0.015

More than 0.381

Valve guide in head (tight)

Less than 0.002

Less than 0.051

Runout (shaft at flywheel)

More than 0.003

More than 0.076

Valve seat in head (tight)

Less than 0.002

Less than 0.051

End play

More than 0.010

More than 0.254

Head warpage

More than 0.006

More than 0.152

REPLACE IF

Crankshaft/Sprocket

REPLACE IF

Shaft Bearings

Cylinder

IN.

Bearing to shaft

More than 0.0015

More than 0.038

Taper

More than 0.002

More than 0.051

clearance

Out of round

More than 0.002

More than 0.051

Shaft runout

More than 0.003

More than 0.076

Warpage of gasket or

Bearing fit in

More than 0.006

More than 0.152

Less than 0.0038

Less than 0.097

O-ring surfaces: top

crankcase (tight)

Warpage of gasket or

Bearing inner race

More than 0.004

More than 0.102

Less than 0.0004

Less than 0.010

O-ring surfaces: base

on shaft (tight)

2004 Touring: Engine

3-3

HOME

SERVICE WEAR LIMITS (CONT.)

REPLACE IF

Breather Assembly

IN.

Breather cover warpage

More than 0.005

More than 0.13

Breather baffle warpage

More than 0.005

More than 0.13

REPLACE IF

Valve Stem to

Guide Clearance

IN.

Intake

More than 0.0035

More than 0.089

Exhaust

More than 0.0040

More than 0.102

3-4

2004 Touring: Engine

HOME

GENERAL INFORMATION

3.3

FUEL

LUBRICATION

Use a good quality leaded or unleaded gasoline (91 pump

octane or higher). Octane rating is usually posted on the

CHECKING ENGINE OIL LEVEL

pump.

CAUTION

Oil level cannot be accurately measured on a cold

Using gasolines with alcohol additives (such as metha-

engine. For preride inspection, with motorcycle leaning

nol) can cause rubber components within the fuel sys-

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

tem to fail or result in engine damage.

stick between arrows when engine is cold. Do NOT add

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

GASOLINE/ALCOHOL BLENDS

1. Perform engine oil level COLD CHECK as follows:

Harley-Davidson motorcycles were designed to give the best

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

performance using unleaded gasoline. Some fuel suppliers

ground, wipe off the dipstick and insert it back into

sell gasoline/alcohol blends as a fuel. The type and amount

the oil pan with the plug pushed completely into the

of alcohol added to the fuel is important.

fill spout.

● DO NOT USE GASOLINES CONTAINING METHANOL.

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

Using gasoline/methanol blends will result in starting

level should register between the two arrows on the

and driveablility deterioration and damage to critical fuel

dipstick. See Figure 3-1. If oil level is at or below the

system components.

lower arrow, add only enough oil to bring the level

● ETHANOL is a mixture of 10% ethanol (Grain alcohol)

between the two arrows on the dipstick.

and 90% unleaded gasoline. Gasoline/ethanol blends

2. Perform engine oil level HOT CHECK as follows:

can be used in your motorcycle if the ethanol content

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

does not exceed 10%.

perature.

● REFORMULATED OR OXYGENATED GASOLINES

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

(RFG):

“Reformulated gasoline” is a term used to

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

describe gasoline blends that are specifically designed

engine off.

to burn cleaner than other types of gasoline. Your motor-

cycle will run normally using this type of gas.

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

pan with the plug pushed completely into the fill

You may find that some gasoline blends adversely affect the

spout.

starting, driveability or fuel efficiency of your bike. If you

experience one or more of these problems, we recommend

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

you try a different brand of gasoline or gasoline with a higher

Add only enough oil to bring the level to the FULL

octane rating.

mark on the dipstick. See Figure 3-1. Do not overfill.

COLD CHECK

HOT CHECK

f1254b3x

Figure 3-1. Engine Oil Dipstick

2004 Touring: Engine

3-5

HOME

Remove the oil filter as follows:

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

tool allows easy removal of the oil filter without risk

of damage to the crankshaft position sensor or

cable.

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

the tool oriented vertically. See Figure 3-3.

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

wrench in a counterclockwise direction. Do not use

with air tools.

Figure 3-2. Oil Filter Wrench (Part No. HD-42311)

NOTE

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

f1641x3x

available.

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

rial.

Lubricate gasket with clean engine oil and install new oil

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

after gasket first contacts filter mounting surface. Do

NOT use OIL FILTER WRENCH for oil filter installation.

NOTE

Use of the Premium 10 micron synthetic media oil filter is

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

99 (Black).

Install engine oil drain plug with O-ring. Tighten plug to

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

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

liters) engine oil as specified in Table 3-1. Use the proper

grade of oil for the lowest temperature expected before

the next oil change.

Figure 3-3. Remove Engine Oil Filter

Table 3-1. Recommended Engine Oils

Harley-

Lowest

Cold Weather

CHANGING ENGINE OIL AND FILTER

Harley-Davidson

Viscosity

Davidson

Ambient

Starts Below

Type

Rating

Temperature

50˚F (10˚C)

NOTE

SAE

Below 40˚F

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

HD Multi-grade

HD 360

Excellent

10W40

(4˚C)

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

SAE

Above 40˚F

engine oil and engine oil filter. If motorcycle is ridden hard,

HD Multi-grade

HD 360

Good

20W50

(4˚C)

under dusty conditions or in cold weather, change engine oil

SAE

Above 60˚F

HD Regular Heavy

HD 360

Poor

and filter more often.

(16˚C)

SAE

Above 80˚F

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

HD Extra Heavy

HD 360

Poor

(27˚C)

ture.

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

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

CAUTION

steadily while moving plug back and forth.

Oil level cannot be accurately measured on a cold

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

engine. For preride inspection, with motorcycle leaning

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

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

pletely.

stick between arrows when engine is cold. Do NOT add

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

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

deterioration. Replace as necessary.

10. Perform engine oil level COLD CHECK as follows:

3-6

2004 Touring: Engine

HOME

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

ground, wipe off the dipstick and insert it back into

CAUTION

the oil pan with the plug pushed completely into the

Check the engine oil level if the oil pressure indicator

fill spout.

lamp remains illuminated. If the oil level is normal, stop

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

the engine immediately. Do not ride the vehicle until the

level should register between the two arrows on the

probem is located and corrected.

dipstick. See Figure 3-1. If oil level is at or below the

lower arrow, add only enough oil to bring the level

If the indicator lamp is not extinguished, it may be the result

between the two arrows on the dipstick.

of a low oil level or diluted oil supply. In freezing weather, the

oil feed and return lines can clog with ice or sludge. A defect

11.

Perform engine oil level HOT CHECK as follows:

in the lamp wiring, faulty oil pressure switch/sender, dam-

aged oil pump, plugged oil filter element, incorrect oil viscos-

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

ity, broken or weak spring in the oil pressure relief valve and/

perature.

or damaged or incorrectly installed O-rings in the engine may

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

also cause the indicator lamp to remain on.

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

To troubleshoot the problem, always check the engine oil

engine off.

level first. If the oil level is OK, determine if oil returns to the

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

pan from the oil return hose. If oil does not return, shut off the

pan with the plug pushed completely into the fill

engine until the problem is located and corrected.

spout.

To check the engine oil pressure, proceed as follows:

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

Add only enough oil to bring the level to the FULL

Verify engine oil level. See CHECKING ENGINE OIL

mark on the dipstick. See Figure 3-1. Do not overfill.

LEVEL in this section.

12.

Start engine and carefully check for oil leaks around

Locate the oil pressure switch/sender at the front right

drain plug and oil filter.

side of the crankcase.

On FLHR/C/S models, pull elbow from post of oil pres-

sure switch. On FLHT/C/U and FLTR models, pull exter-

WINTER LUBRICATION

nal latch outward and use rocking motion to remove

Packard connector from oil pressure sender.

Combustion in an engine produces water vapor. During start-

On FLHR/C/S models, use a 15/16 inch Open End Crow

ing and warm-up in cold weather, especially in freezing tem-

peratures, the vapor condenses to water before the

Foot (Snap-On FC30B) to remove oil pressure switch

crankcase is hot enough to exhaust it through the breather

from crankcase. On FLHT/C/U and FLTR models, use 1-

system. If the engine is run long enough for the crankcase to

1/16 inch Open End Crow Foot (Snap-On FC34A) to

become thoroughly heated, the water returns to vapor and is

remove oil pressure sender.

then exhausted.

Start OIL PRESSURE GAUGE ADAPTER (HD-96921-

110) into crankcase bore. Using a 5/8 inch open end

An engine used for only short trips, and seldom allowed to

wrench, turn adapter until snug. See Figure 3-4.

thoroughly warm up, accumulates increasing amounts of

water in the oil pan. Water mixed with oil forms a sludge that

Moving to left side of vehicle, route banjo fitting and hose

causes accelerated engine wear. In freezing temperatures,

of OIL PRESSURE GAUGE

(HD-96921-52B) over

the water becomes slush or ice, which may clog oil lines and

shifter lever and oil filter to right side of engine. See Fig-

result in engine failure.

ure 3-5.

Always change the engine oil more often in winter. If the

Slide washer on banjo bolt and insert through banjo fit-

engine is used for short runs, change the oil even more fre-

ting on gauge. Install second washer on bolt and thread

quently. The farther below freezing the temperature drops the

into adapter until snug.

more often the oil should be changed.

Run vehicle or simulate road running until engine is at

normal operating temperature, approximately

230^oF.

(110^oC.). Gauge reading will not be accurate if engine is

OIL PRESSURE INDICATOR LAMP

not completely warmed.

Verify that oil pressure is 30-38 psi (207-262 kN/m²)at

The red OIL PRESSURE indicator lamp illuminates to indi-

2000 rpm.

cate improper circulation of the engine oil. The lamp illumi-

nates when the ignition is first turned on (before the engine is

10.

Remove banjo bolt (and washers) from adapter. Remove

started), but should be extinguished once the engine is run-

gauge from vehicle and then remove adapter from

ning.

crankcase.

2004 Touring: Engine

3-7

Content .. 35 36 37 38 ..