Harley Davidson 2004 Touring Models. Service Manual

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BREATHER ASSEMBLY

3.5

REMOVAL

INSTALLATION

See TOP END OVERHAUL in the Touring Models Service

Manual.

NOTE

f1531x4x

If breather style is different from that illustrated, see

BREATHER ASSEMBLY under TOP END under SUBAS-

SEMBLY SERVICE AND REPAIR, in the Touring Models Ser-

vice Manual.

DISASSEMBLY

1. See Figure 3-1. Remove two fasteners from breather

assembly.

2. Remove breather cover and gasket. Discard cover gas-

ket.

3. Remove the breather baffle and gasket. Discard gasket.

4. Pull filter element from bore on inboard side of breather

baffle. Discard filter element.

5. Pull stem of umbrella valve from hole at top of breather

baffle. Discard umbrella valve.

CLEANING AND INSPECTION

1WARNING

Compressed air can pierce the skin and flying debris

from compressed air could cause serious eye injury.

Wear safety glasses when working with compressed air.

Never use your hand to check for air leaks or to deter-

Fastener

mine air flow rates. (00061a)

Breather cover

Cover gasket

Clean all parts in a non-volatile cleaning solution or sol-

Umbrella valve

vent.

Breather baffle

Thoroughly dry all parts with low pressure compressed

Filter element

air.

Breather baffle gasket

Rocker arm support plate

ASSEMBLY

Figure 3-1. Breather Components

1. See Figure

3-1. Insert stem of new umbrella valve

through center hole at top of breather baffle. Use dena-

tured alcohol or glass cleaner to lubricate stem. Care-

fully pull rubber bead on stem through hole in baffle.

Verify that rubber bead is pulled completely through hole

and resides on bottom side of baffle.

2. Press new filter element into bore at bottom of baffle

Hole in filter element accommodates umbrella valve

stem.

3. Place breather baffle gasket on a clean flat surface.

Aligning holes, place breather baffle, cover gasket and

breather cover on top. Slide two screws through stackup

to keep assembly together until time of installation.

3-6

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ROCKER HOUSING

3.6

VALVE SPRING TO ROCKER HOUS-

f1576x3x

ING CLEARANCE

1. After torquing cylinder head bolts, continue top end over-

haul by installing the rocker housings. See ASSEMBLY

under TOP END OVERHAUL in the Touring Models Ser-

vice Manual.

2. Install a new rocker housing gasket on the cylinder head

flange.

CAUTION

Even though all bolt holes (rocker housing, rocker arm

support plate and breather assembly) may appear to be

in alignment, the rocker housing gasket may be installed

upside down. An upside down gasket will result in an

open breather channel causing an oil leak when the vehi-

cle is started, possibly resulting in engine and/or prop-

erty damage.

WRONG

3. See Figure 3-2. Verify that the rocker housing gasket is

installed correctly by noting that the breather channel is

f157x3x

concealed.

4. With the indent facing forward, place the rocker housing

into position aligning the holes in the housing with those

in the gasket.

RIGHT

1. Breather channel exposed (wrong)

2. Breather channel concealed (right)

Figure 3-2. Rocker Housing Gasket

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3-7

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5. Apply a small dab of LOCTITE THREADLOCKER 243

(blue) (HD-99642-97) to threads of six rocker housing

f1578x3x

bolts.

6. See Figure 3-3. Start the rocker housing bolts, two long

bolts on the left side of the engine, four intermediate

bolts in the interior.

NOTE

Rocker housing and rocker cover bolts have both an internal

and external hex, which allows the bolts to be installed with

either a short 3/16 inch allen wrench (tight spaces), or a 7/16

inch socket or open end/box wrench (open spaces). If the

engine is left in the chassis for service, the short 3/16 inch

allen wrench is indispensable when installing the rocker

housing and rocker cover bolts on the left side of the engine

f1578x3x

(particularly the rear) where there is close proximity to the

frame.

7. From the cam cover side, press rocker cover diagonally

toward the intake valve.

1. Long bolt 1-3/4 in.

8. See Figure 3-5. Snug bolts in torque sequence to hold

2. Intermediate bolt 1-1/4 in.

housing in position. Do not torque.

3. Intermediate bolt 1-1/4 in.

4. O-ring

9. See Figure 3-4. Using a feeler gauge, check for clear-

5. Intermediate bolt 1-1/4 in.

ance around both valve spring assemblies and the

6. Intermediate bolt 1-1/4 in.

rocker housing.

7. Long bolt 1-3/4 in.

10. If spring assembly contacts rocker housing at any point

Figure 3-3. Rocker Housing Bolt Lengths

around springs, loosen rocker cover bolts and press on

9977

side of cover opposite contact point to produced notice-

able clearance between housing and valve assembly.

8877

Figure 3-4. Valve Spring to Rocker Housing Clearance

3-8

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11. Tighten rocker housing bolts to 120-168 in-lbs (13.6-

f1578x3x

18.9 Nm) in the pattern shown in Figure 3-5.

NOTE

If the engine was left in the chassis for service, final tighten

the rear left rocker housing bolt (rear cylinder) using a torque

wrench with a 1/4 inch drive. Since this tool may not be avail-

able in foot-pounds, tighten the bolt to 120-168 in-lbs.

12. Re-check clearance at both valve spring assemblies and

repeat until there is sufficient clearance between spring

assemblies and rocker housing with the bolts torqued.

CAUTION

O-rings that are missing, distorted, pinched or otherwise

damaged will result in either oil leakage or low oil pres-

sure. Use of the wrong o-ring will have the same results.

Since many o-rings are similar in size and appearance,

always use new o-rings keeping them packaged until use

to avoid confusion.

13. Install new o-ring in groove around breather baffle hole

in rocker housing. Apply a thin film of clean SYN3 engine

Figure 3-5. Rocker Housing Torque Sequence

oil to o-ring before installation.

14. Continue the top end overhaul by installing the hydraulic

lifters in the crankcase bores. See ASSEMBLY under

TOP END OVERHAUL in the Touring Models Service

Manual.

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PISTONS

3.8

GENERAL

f2113x4x

Major components of the FLHTCSE engine differ from other

touring models in specification and appearance. However,

service procedures for the following components are the

same as those found in the Touring Models Service Manual.

See PISTON on SUBASSEMBLY SERVICE AND REPAIR in

the Touring Models Service Manual.

For service wear limits, refer to Table 3-20. and Table 3-19.

NOTE

The piston is measured on the bare aluminum to avoid mea-

suring errors. An oval-shaped spot is present on each side of

the piston for proper placement of the micrometer. See upper

frame of Figure 3-8. Since the oval openings are too small for

a standard flat anvil micrometer, which would result in mea-

suring errors, use a 4-5 inch micrometer with spherical ball

f2109x3x

anvil adapters. See lower frame of Figure 3-8.

9974

Oval opening

4-5 inch micrometer

Spherical ball anvil adapters

Figure 3-8. FLHTCSE Piston Measurement

Figure 3-7. FLHTCSE Piston Orientation Arrow

(arrow points to front of engine)

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BORING AND HONING CYLINDERS

3.9

5. Thoroughly wash the cylinder bore with liquid dish soap

CYLINDER BORE FINISHED SIZE

and warm water to remove all abrasive particles and

residual girt. Continue cleaning until a clean cloth shows

1. For cylinder removal, cleaning, inspection, boring and

no evidence or dirt or debris.

honing and installation, see CYLINDER in the Touring

Models Service Manual.

6. Immediately apply a thin film of clean engine oil to a

Refer to Table 3-24. Bore the cylinder to 0.003 in. (0.08

clean white paper towel and thoroughly wipe the inside

of the cylinder. This prevents the cylinder bore from rust-

mm) under the desired finished size. See BORING and

HONING CYLINDER in the Touring Models Service

ing.

Manual. Refer to Table 3-24.

NOTE

After wiping the cylinder with a clean, oiled paper towel, the

CAUTION

towel will be dark with contamination. Repeat this process

using a new lightly oiled paper towel each time until the towel

An improper crosshatch pattern or too fine a hone will

remains white. The cylinder is now clean.

result in insufficient oil retention and possible piston

seizure and/or high oil consumption.

7. With the cylinder at room temperature, check the piston

Hone the cylinder to its finished size using a 280 grit

clearance in the cylinder in which the piston will run. See

rigid hone followed by a 240 grit flexible ball hone. Hon-

INSPECTION under PISTON in Touring Models Service

ing must be done with the torque plates attached. All

Manual.

honing must be done from the bottom (crankcase end of

8. For cylinder installation, see CYLINDER in Touring Mod-

the cylinder. Work for a 60˚ crosshatch pattern.

els Service Manual.

Stop frequently to examine the cylinder bore and/or take

measurements. Remember, a precise 60˚ cross hatch

pattern in the piston travel area is important.

Table 3-24. Oversize Pistons/Cylinder Bores

PISTON

CYLINDER BORE FINISHED SIZE

TYPE

SIZE

MINIMUM

MAXIMUM

Standard

STD

3.8750 in. (98.4250 mm)

3.8755 in. (98.438 mm)

0.005 in. (0.13 mm)

3.8800 in. (98.552 mm)

3.8805 in. (98.565 mm)

Oversize

0.010 (0.25 mm)

3.8850 in. (98.679 mm)

3.8855 in. (98.692 mm)

3-12

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FLYWHEEL/CONNECTING ROD ASSEMBLY

3.11

GENERAL

SPROCKET SHAFT BEARING

INNER RACE REPLACEMENT

For removal, inspection, and installation, see FLYWHEEL/

CONNECTING ROD ASSEMBLY under SUBASSEMBLY

SERVICE AND REPAIR in the Touring Models Service Man-

PART NO.

SPECIALTY TOOL

ual.

For service wear limits, refer to Table 3-21. and Table 3-22.

HD-44358

Flywheel support fixture

NOTE

HD-95637-46A

Wedge attachment

If the flywheel or connecting rods need to be replaced, then

they must be replaced together as one assembly.

Mainshaft bearing inner race

HD-34902B

puller/installer

9978

HD-25070

Robinair heat gun

1. If reusing flywheel, remove bearing inner race and thrust

washer as follows:

a. Obtain FLYWHEEL SUPPORT FIXTURE

(HD-

44358). See Figure 3-11. Install brass jaws or shop

towels around teeth of vise to prevent damage to

tool. Clamp tool in vise with the round hole topside.

b. Insert crankshaft end through hole resting flywheel

assembly on fixture. Slide knurled locating pin down

slot in tool to engage crank pin hole. Hand tighten

locating pin.

c. Slide hold-down clamp down slot to engage inboard

side of right flywheel half, and then hand tighten

knurled nut at bottom to secure. Repeat step to

secure hold-down clamp on opposite side of fly-

wheel.

NOTE

For proper clamping force, hold-down clamp must not be

tilted. Rotate hex on outboard stud until clamp is level.

d. Position WEDGE ATTACHMENT (HD-95637-46A)

on inboard side of thrust washer and turn hex nuts

an equal number of turns to draw halves of wedge

together.

CAUTION

Install wedge attachment only so far as necessary to

Figure 3-10. FLHTCSE

ensure positive contact with thrust washer. Installing

Flywheel/Connecting Rod Assembly

tool with more contact than absolutely necessary will

result in damage to flywheel.

e. Obtain two 3/8-16 inch bolts 6-1/2 inches long (with

flat washers). Install flat washers on bolts. Obtain

bridge, forcing screw and hardened plug from

MAINSHAFT BEARING INNER RACE PULLER/

INSTALLER (HD-34902B).

Slide one bolt into channel on each side of bridge

so that flat washer is between bridge and bolt head.

Thread bolts into wedge attachment an equal num-

ber of turns.

g. Sparingly apply graphite lubricant to threads of forc-

ing screw to prolong service life and ensure smooth

operation. Start forcing screw into center hole of

bridge.

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CAUTION

f1869x3d

Failure to use hardened plug may result in damage to

forcing screw and/or sprocket shaft.

h. Place cupped side of hardened plug against end of

sprocket shaft. Thread forcing screw into bridge until

the steel ball at the end of the screw makes firm

contact with hardened plug.

Using the ROBINAIR HEAT GUN (HD-25070), uni-

formly heat the bearing inner race for about 30 sec-

onds using a circular motion.

NOTE

Hold-down clamp

To facilitate removal without heat, apply a light penetrating oil

Locating pin

to shaft and leading edge of bearing inner race.

Figure 3-11. Flywheel Support Fixture (Part No. HD-

44358)

1WARNING

Never use both heat and penetrating oil. Use only one or

f2154x3x

the other. Excessive heat can cause the penetrating oil

to ignite resulting in flames or fire. Inadequate safety

precautions can result in death or serious injury.

Turn forcing screw until thrust washer and bearing

inner race move approximately 1/8 inch (3.2 mm).

k. Turn hex nuts an equal number of turns to separate

halves of WEDGE ATTACHMENT.

After bottoming thrust washer on shaft, reposition

WEDGE ATTACHMENT

(HD-95637-46A) on

inboard side of bearing inner race. Turn hex nuts an

equal number of turns to draw halves of wedge

together.

CAUTION

Install wedge attachment only so far as necessary to

ensure positive contact with bearing inner race. Install-

ing tool with more contact than absolutely necessary

will result in damage to flywheel.

m. Verify that the tool assembly is square, so that the

bearing inner race is not cocked during removal.

See Figure 3-12.

n. Using the ROBINAIR HEAT GUN (HD-25070), uni-

formly heat the bearing inner race for about 30 sec-

onds using a circular motion.

NOTE

Forcing screw

To facilitate removal without heat, apply a light penetrating oil

3/8-16 Inch bolt with flat washer

to shaft and leading edge of bearing inner race.

Bridge

o. Turn forcing screw until bearing inner race is pulled

Hardened plug

free of sprocket shaft.

Wedge attachment

p. Remove thrust washer from sprocket shaft.

Bearing inner race

Sprocket shaft

q. Discard thrust washer and bearing inner race.

Figure 3-12. Remove Inner Race From Sprocket Shaft

2. Place new thrust washer over sprocket shaft with the ink

stamp facing outside

(and the chamfer on the ID

inboard).

2004 FLHTCSE: Engine

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3. Place new bearing inner race on bench top. Using the

ROBINAIR HEAT GUN (HD-25070), uniformly heat

h9772-55b

bearing inner race for about 60 seconds using a circular

motion.

Wearing suitable gloves to protect hands from burns,

place heated bearing inner race over sprocket shaft.

NOTE

To facilitate installation without heat, apply a light penetrating

oil to shaft and leading edge of bearing inner race.

Figure 3-13. Sprocket Shaft Timken Bearing

Cone Installer (Part No. HD-97225-55B)

1WARNING

Never use both heat and penetrating oil. Use only one or

f2152x3x

the other. Excessive heat can cause the penetrating oil

to ignite resulting in flames or fire. Inadequate safety

precautions can result in death or serious injury.

See Figure

3-13. Obtain the SPROCKET SHAFT

TIMKEN BEARING CONE INSTALLER (HD-97225-

55B). Assemble tool as described below.

a. See Figure 3-14. Thread pilot shaft onto sprocket

shaft until contact is made with shoulder.

b. Sparingly apply graphite lubricant to threads of pilot

shaft to prolong service life and ensure smooth

operation.

c. Slide sleeve over pilot until it contacts bearing inner

race.

d. Slide Nice bearing and large flat washer over pilot

until contact is made with sleeve.

e. Thread handle onto pilot shaft. See upper frame of

f2153x3x

Figure 3-14.

Rotate handle of tool in a clockwise direction until bear-

ing inner race bottoms against thrust washer. See lower

frame of Figure 3-14.

Remove handle, flat washer, Nice bearing, sleeve and

pilot from sprocket shaft.

Pilot shaft

Handle

Flat washer

Nice bearing

Sleeve

Inner race

Thrust washer

Figure 3-14. Press Inner Race Onto Sprocket Shaft

3-16

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OIL VENT LINE

3.12

REPLACEMENT

9968

PART NO.

SPECIALTY TOOL

HD-41137

Hose clamp pliers

IMPORTANT NOTE

Dispose of oil in accordance with local regulations.

1. See Figure 3-15. Back the chrome nut off of the crank-

case oil fitting.

2. Using side cutters, cut the clamps on the short length of

Oil spout fitting

hose at the oil spout end of the vent line.

Hose

Oil vent line parallel to transmission cover

3. Remove the oil vent line.

S-bend

Crankcase fitting nut

4. If necessary, remove both fittings and clean sealant from

threads in crankcase and oil fill.

Figure 3-15. Oil Vent Line (clamps removed)

NOTE

The spout fitting is a nipple styled fitting.

If removed, identify the crankcase end fitting and using

pipe sealant or TEFLON^® tape, prepare the tapered

threaded end of fitting. Thread fitting into crankcase and

tighten to 130-150 in-lbs (14.7-16.9 Nm).

If removed, identify oil spout fitting and using pipe seal-

ant or TEFLON^® tape, prepare the tapered threaded end

of fitting. Thread fitting into oil spout and tighten to 130-

150 in-lbs (14.7-16.9 Nm).

Slide crankcase fitting nut and rubber ferrule on crank-

case end of vent line.

Push new hose with new clamps on the oil spout end of

chrome vent line.

Orient s-bend in vent line toward crankcase and slide

chrome vent line into case fitting.

10.

Push hose onto oil spout fitting.

11.

Position line parallel with transmission cover and with

clearance to other components.

12.

Push rubber ferrule into crankcase fitting. Thread

chrome nut over ferrule and hand tighten.

13.

Tighten chrome nut to 60-80 in-lbs (6.8-9.0 Nm).

14.

Using HOSE CLAMP PLIERS (HD-41137), crimp the

clamps on the hose.

15.

Operate motorcycle and inspect for leaks.

2004 FLHTCSE: Engine

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OIL COOLER OPERATION

3.13

GENERAL

8871

For engine oil flow through the engine, See ENGINE OIL

FLOW under GENERAL INFORMATION in Touring Models

Service Manual.

See Figure 3-16. The FLHTCSEis equipped with a factory

installed oil cooler controlled by a thermostat in the oil filter

mount.

Engine oil flows from the crankcase through the oil filter

mount to the oil cooler through a supply hose. The oil circu-

lates through the finned tubes of the cooler to dissipate heat

and returns to the oil filter mount through a return hose.

Under pressure from the crankcase, engine oil enters the

lower port in the oil filter mount. A passage way directs oil to

flow to the oil filter. The oil circulates through the oil filter ele-

ment and out the oil filter threaded fitting.

From the oil filter, the filtered oil flows in two directions:

1. From the oil filter adapter Into the thermostat chamber.

2. Through a side passage and out the supply oil fitting to

the oil cooler.

Oil filter mount

Transfer passage cover

See Figure 3-18.The thermostat chamber is located in line

Thermostat plug

with the return port to the engine crankcase. The thermostat

Oil return fitting

assembly consists of a temperature sensitive plunger com-

Oil supply fitting

pressed between a spring-loaded piston, spring and an open

Supply hose

cage spreader.

Return hose

While the engine oil temperature is below 180˚ F (82˚ C), the

Oil cooler

thermostat is in its closed position. See Closed Thermostat

under 3.13 OIL COOLER OPERATION.

Figure 3-16. Oil Cooler and Bracket

(chrome cover removed for photo clarity)

The filtered oil is circulated through the transfer passage

where it returns to the crankcase. At the same time, oil is

supplied under pressure to the oil cooler even though the oil

cooler return port is blocked.

While the engine operates at average temperatures, approxi-

mately 195˚ F (91˚ C), the thermostat partially opens allowing

cooler oil from the cooler to mix with warmer oil from the oil

transfer passage as the oil returns to the crankcase. See Par-

tially Open Thermostat under 3.13 OIL COOLER OPERA-

TION.

When the engine oil exceeds 210˚ F (99˚ C), the thermostat

is in its fully open position. See Fully Open Thermostat under

under 3.13 OIL COOLER OPERATION.

In this position, all the oil flows through the oil cooler and

back through the oil filter mount before returning to the crank-

case.

NOTE

Regardless of whether the thermostat is closed, partially

open or fully open, oil is always pressurized in the transfer

passage, the oil cooler supply hose, the oil cooler and the oil

return hose.

The oil cooler should always be checked for dirt and debris to

maintain cooler efficiency at every service interval.

3-18

2004 FLHTCSE: Engine

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9980

8872

Transfer passage cover

Thermostat plug

8875

Return hose fitting

Supply hose fitting

Figure 3-17. Oil Filter Mount on Engine

9982

1. Open cage spreader

2. Thermostat plunger

3. Piston

4. Spring

5. O-ring

6. Thermostat plug

Figure 3-18. Thermostat Assembly

9931

Oil filter adapter

Passage to oil filter element

Return to crankcase

Supply from crankcase

Return hose fitting

Supply hose fitting

Open passage from oil filter

Open passage to oil cooler supply

Figure 3-20. Oil Filter Mount

1. Return port to crankcase (thermostat removed)

2. Supply port from crankcase

Figure 3-19. Oil Filter Mount Ports to Crankcase

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Closed Thermostat

8876

See Figure 3-21. While the engine oil is cool, the thermostat

is in its closed position. The spring holds the piston over the

return passage from the oil cooler. Even though oil pressure

is supplied to the oil cooler, oil is blocked from returning from

the oil cooler.

See Figure 3-22. When closed, the piston opens a port in the

transfer passage along the side of the thermostat chamber.

The filtered oil is circulated around the piston through the

transfer passage and into a port in the thermostat chamber

where it flows through the open cage spreader and returns to

the crankcase.

Partially Open Thermostat

As the engine oil exceeds 180˚ F (82˚ C), the thermostat

plunger begins to expand and compresses the spring push-

ing against the piston. The piston partially opens the return

passage from the oil cooler and partially closes the port from

the chamber to the transfer passage.

While the engine operates at an average temperature, 195˚ F

(91˚ C), the thermostat remains partially open allowing cooler

oil from the cooler to mix with warmer oil from the oil filter.

1. Return passage from oil cooler

2. Open passage from oil filter

Fully Open Thermostat

Figure 3-21. Thermostat Chamber

See Figure 3-23. The thermostat fully opens when the engine

oil temperature exceeds 210˚ F (99˚ C). The piston fully

8874

closes the port to the transfer passage and opens the return

passage from the oil cooler.

In this position, all the oil flows from the oil filter through the

oil cooler and back through the return passage before return-

ing to the crankcase. The oil from the oil cooler return will

back up under pressure in the transfer passage even though

the port from the oil filter is closed.

1. Port open from oil filter

2. Oil under pressure

3. Port open to crankcase return

Figure 3-22. Closed Thermostat

8873

Port open to oil cooler return

Oil under pressure

Port closed from oil filter

Figure 3-23. Fully Open Thermostat

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OIL COOLER

3.14

REMOVAL

INSTALLATION

1. Cover the front fender to protect finish.

PART NO.

SPECIALTY TOOL

IMPORTANT NOTE

Dispose of oil in accordance with local regulations.

HD-41137

Hose clamp pliers

2. Place a container under the motorcycle to catch excess

oil.

1. If replacing the hoses, install new hoses with clamps at

3. Remove the fasteners holding the oil cooler and cover to

the oil filter mount. Using HOSE CLAMP PLIERS (HD-

mounting bracket.

41137), clamp the supply and return hoses at the oil fil-

ter mount.

4. Pull the cooler and cover forward and, using side cutters,

cut the clamps on the supply and return hoses.

2. Apply LOCTITE Thread Sealant to threads of oil pres-

sure switch and install oil pressure switch. Tighten to 96-

5. Remove the oil cooler with cover.

144 in-lbs. (10.84-16.26 Nm).

NOTE

3. Connect oil pressure switch wire lead.

The oil cooler guard is held in place with adhesive tape.

4. Attach hoses to oil cooler. Using HOSE CLAMP PLIERS

6. If replacing the oil hoses, remove oil pressure switch to

(HD-41137), clamp the supply and return hoses at the

gain access to clamps. Cut clamps at oil filter mount.

oil cooler.

Remove oil hoses.

5. Install oil cooler and cover to mounting bracket. Tighten

7. The oil cooler should be checked for dirt and debris.

fasteners to 80-110 in-lbs (9.1-12.4 Nm).

6. Operate motorcycle and inspect for leaks.

8871

Return hose clamp

Supply hose clamp

Oil cooler and guard

Bracket

Figure 3-24. Oil Cooler and Mount

(chrome cover removed for photo clarity)

2004 FLHTCSE: Engine

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OIL FILTER MOUNT

3.15

REMOVAL

9980

PART NO.

SPECIALTY TOOL

HD-42311 or HD-44067

Oil filter wrench

1. Place a container under motorcycle to catch excess oil.

2. Bend a cardboard funnel and fit to motorcycle to route

fluid away from regulator and oil cooler to container.

3. Using OIL FILTER WRENCH (HD-42311 or HD-44067),

remove oil filter. Discard oil filter

IMPORTANT NOTE

Dispose of oil in accordance with local regulations.

4. If necessary, remove the threaded oil filter adapter and

oil pressure switch.

5. Using side cutters, cut the clamps and remove oil cooler

hoses.

6. If necessary, loosen but do not remove thermostat plug.

Figure 3-25. Oil Filter Mount (engine removed from frame)

7. Bend tabs of the lockplate away from bolt heads.

8. Remove oil filter mount lockplate fasteners and flat

washers. Discard lockplate.

9931

Remove middle bolt with flat washer and remove oil filter

mount.

DISASSEMBLY

1. If necessary, remove the thermostat. See 3.16 THER-

MOSTAT.

2. See Figure 3-26. Remove the o-rings in the oil filter

mount.

3. Remove the transfer passage cover.

4. Remove the transfer passage cover gasket.

5. Remove the two oil cooler line fittings.

6. Clean the oil passages in a cleaning solution or solvent.

7. Remove thread locking adhesive from the threads of the

oil filter adapter.

Figure 3-26. Oil Filter Mount O-rings

(thermostat removed)

8. Inspect the oil passages and the oil filter mount.

3-22

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ASSEMBLY

CAUTION

1. See Figure 3-27. Install a new gasket on the transfer

To avoid cross threading tapped holes, exercise care

passage cover.

when starting hex head bolts in crankcase.

2. Install the transfer passage cover. Tighten to 90-120 in-

7. Align holes in filter mount flange with holes in crankcase

lbs (10.2-13.5 Nm).

and tighten bolts until snug.

3. Using pipe sealant or TEFLON tape, prepare the

8. Install flat washer on remaining fastener, apply LOCTITE

tapered threaded end of oil supply and return fittings and

to threads and install in middle hole of mount flange.

install fittings.

9. Starting at the top, alternately tighten the fasteners to

4. If removed, replace the thermostat components:

130-150 in-lbs (14.7-16.9) Nm.

a. Replace the spreader.

10. Bend the ends of the lockplate to capture the top and

b. Replace the thermostat plunger and piston.

bottom fasteners.

c. Replace the spring.

11. If disassembled, tighten the Thermostat plug to 15-20 ft-

d. Install a new o-ring and loosely install thermostat

lbs (20.4-27.1 Nm).

plug.

12. Apply LOCTITE THREADLOCKER 243 (blue) to tapered

threads of oil filter adapter. Install oil filter adapter and

tighten to 12-16 ft-lbs (16.3-21.7 Nm).

INSTALLATION

13. Install a new oil filter. See SCHEDULED MAINTE-

NANCE in Touring Models Service Manual.

PART NO.

SPECIALTY TOOL

NOTE

If removed, install oil pressure switch using LOCTITE Thread

HD-41137

Hose clamp pliers

Sealant and tighten to 96-144 in-lbs (10.84-16.26 Nm).

1. Install the oil cooler oil hoses to the filter mount with new

9983

clamps.

2. Using HOSE CLAMP PLIERS (HD-41137), crimp the

clamps.

3. Place flat washers in recessed bolt holes at top and bot-

tom of filter mount flange.

4. Align holes in lockplate with holes in flat washers.

5. Slide two fasteners through lockplate, flat washers and

filter mount flange. Apply LOCTITE

243 (blue)

(HD-

99642-97) to threads of installed bolts.

6. See Figure 3-26. Install new o-rings into grooves in oil

filter mount.

Figure 3-27. Transfer Passage Cover and Gasket

2004 FLHTCSE: Engine

3-23

HOME

THERMOSTAT

3.16

TEST PROCEDURE

REMOVAL

Using an infrared thermometer, measure the tempera-

1. Allow the motorcycle to cool.

ture at the oil pan and at the oil cooler while operating

2. Place a catch pan under motorcycle.

motorcycle.

3. Bend a cardboard funnel and fit to motorcycle to route

Compare temperatures.

fluid away from regulator and oil cooler to container.

a. If the temperature of the oil cooler follows the tem-

IMPORTANT NOTE

perature of the oil pan at temperatures below 180˚ F

Dispose of oil in accordance with local regulations.

(82˚ C), then the thermostat may be stuck open.

Allow the engine to cool, remove the thermostat.

4. See Figure 3-28. With a ball Allen wrench, loosen and

and proceed.

remove the thermostat plug.

b. If the temperature of the oil cooler is less than that

5. Remove the spring.

of the oil pan below 180˚ F (82˚ C) but, above 180˚

6. Remove the thermostat plunger and piston with a pair of

F (82˚ C), follows the temperature of the oil pan, the

needle nosed pliers.

thermostat is operating correctly.

7. Remove the open cage spreader with a pick.

c. If the oil pan exceeds 210˚ F (99˚ C) and the oil

cooler is cooler, then the thermostat may be stuck

closed. Allow the engine to cool, remove the ther-

INSTALLATION

mostat and proceed.

1. See Figure 3-28. Insert the open cage spreader part

Verify that thermostat plunger is fully retracted.

way into thermostat chamber.

Place thermostat plunger in a container of water with a

2. Install the thermostat plunger and piston together.

thermometer.

3. Locate the plunger in the spreader and push in to bottom

Refer to Table 3-25. Heat water to START TO OPEN

of chamber.

temperature. Verify that the plunger extends.

4. Install the spring.

Heat water pass START TO OPEN temperature to FULL

OPEN temperature and verify that plunger is fully

5. Fit a new o-ring and install thermostat plug. Tighten to

extended.

15-20 ft-lbs (20.4-27.1 Nm).

If plunger does not extend per specifications, replace

thermostat assembly.

9982

Table 3-25. Thermostat Operating Range

ITEM

FAHRENHEIT

CELSIUS

START TO OPEN

180˚

82˚

(closed)

AVERAGE

195˚

91˚

(partially open)

1. Open cage spreader

FULL OPEN

2. Thermostat plunger

210˚

99˚

(fully open)

3. Piston

4. Spring

5. O-ring

6. Thermostat plug

Figure 3-28. Thermostat Components

3-24

2004 FLHTCSE: Engine

HOME

SPECIFICATIONS

6.1

Table 6-1. Gear Ratios

Table 6-4. Drive Belt Deflection

GEAR

RATIO

DEFLECTION

IN.

10.11

On Jiffy Stand

Without Rider or

6.958

1/4-5/16

6.4-7.9

Luggage with 10-

at 10 lbs force

at 4.5 kg force

4.953

psi (69 kPa) in

Rear Shocks

3.862

3.15

Motorcycle

3/16-1/4

4.8-6.4

Upright With rear

at 10 lbs force

at 4.5 kg force

Wheel in Air

Table 6-2. Primary Chain Free Play

Table 6-5. Sprockets

FREE PLAY

IN.

SPROCKET

NUMBER OF TEETH

COLD Engine

5/8-7/8

15.9-22.2

Engine

HOT Engine

3/8-5/8

9.5-15.9

Clutch

Transmission

Rear wheel

Table 6-3. Primary Chaincase Lubricant

Amount

946

Part No.

Quart Bottle

99824-03/00QT

2004 FLHTCSE: Drive

6-1

Harley Davidson 2004 Touring Models. Service Manual - page 63