Harley Davidson Touring 2004 Service Manual sm06a
H
OME
SPECIFICATIONS 6.1
OVERALL GEAR RATIOS
Overall gear ratios indicate the number of engine revolutions
required to drive the rear wheel one revolution.
Gear
All Models
1 10.11
2 6.96
3 4.95
4 3.86
5 3.15
CHAINS AND BELTS
Primary Chain Adjustments
Free Play
COLD Engine
Inches Millimeters
5/8-7/8 inch 15.9-22.2 mm
SPROCKETS
Number of Teeth
Sprocket
Engine 25
Clutch 36
Tr ansmission 32
Rear wheel 70
All Models
CLUTCH
Clutch
Ty pe Wet-multiple disc
Clutch lever free play
Clutch screw adjustment
Description
1/16-1/8 in.
1.6-3.2 mm
loosen 1/2-1 turn after
lightly seating
HOT Engine
3/8-5/8 inch 9.5-15.9 mm
Primary Chaincase Lubricant
Ounces Milliliters
Amount
32 946
Quart Gallon
Part Number
99887-84 99886-84
Rear Belt Adjustment
Deflection
On Jiffy Stand Without
Rider or Luggage
10 psi (69 kPa)
in Rear Shocks
Motorcycle Upright
With Rear Wheel
in the Air
Inches Millimeters
1/4 - 5/16
at 10 lbs force
3/16 - 1/4
at 10 lbs force
6.4 - 7.9
at 4.5 kg force
4.8 - 6.4
at 4.5 kg force
TORQUE VALUES
Item
Primary chain tensioner
shoe nut
Te nsioner shoe adjuster
plate screws
Primary chain inspection
cover screws
Clutch adjuster screw
locknut
Clutch inspection cover
screws
Clutch diaphragm spring
retainer to clutch hub bolts
Rear axle cone nut 95-105 ft-lbs 129-142 Nm
Rear swingarm pivot
shaft locknut
Rear swingarm bracket
bolts
ft/in-lbs Nm
21-29 ft-lbs 29-39 Nm
12-14 ft-lbs 16-19 Nm
84-108
in-lbs
72-120
in-lbs
84-108
in-lbs
90-110
in-lbs
40-45 ft-lbs 54-61 Nm
34-42 ft-lbs
10-12 Nm
8-14 Nm
10-12 Nm
10-12 Nm
46-57 Nm
Continued ...
2004 Touring: Drive 6-1
H
OME
TORQUE VALUES (CONT.’D)
Item
Shock bottom
mounting bolt
Exhaust pipe TORCA
clamps
Heat shield worm drive
clamp screws
Tr ansmission mainshaft
sprocket nut
Mainshaft sprocket nut
lockplate socket head
screws
Rear wheel sprocket bolts 55-65 ft-lbs 75-88 Nm
Primary chaincase to
crankcase and transmission
Front and rear starter
mounting screws
Starter jackshaft bolt 60-80
Engine compensating
sprocket nut
Clutch hub mainshaft nut 70-80 ft-lbs 95-108 Nm
Primary chaincase cover
allen head socket screws
Primary chaincase drain
plug
Passenger footboard
socket screws
Shifter lever
socket screws
1/4”
5/16”
ft/in-lbs Nm
35-40 ft-lbs 47-54 Nm
45-60 ft-lbs 61-81 Nm
20-40
in-lbs
60 ft-lbs, then
35° to 45°
90-110
in-lbs
18-21 ft-lbs 24-28 Nm
13-20 ft-lbs 18-27 Nm
in-lbs
150-165 ft-lbs 203-224 Nm
84-108
in-lbs
36-60
in-lbs
15-18 ft-lbs 20-24 Nm
90-110
in-lbs
18-22 ft-lbs 24-30 Nm
2.3-4.5 Nm
81 Nm, then
35° to 45°
10-12 Nm
6.8-9.0 Nm
9-12 Nm
4.1-6.8 Nm
10.2-12.4 Nm
6-2 2004 Touring: Drive
H
CAUTION
f1840x6x
Primary
Chain
Retaining
Ring
Adjuster Shoe
Narrow End Forward
Top Center Nut
OME
PRIMARY CHAIN AND SPROCKETS 6.2
PRIMARY CHAIN ADJUSTMENT
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect the
primary chain tension. Proceed as follows:
1. See Figure 6-1. Using a T27 TORX drive head, remove
four screws to free the primary chain inspection cover
from the primary chaincase cover.
2. Check the primary chain tension. Push on the upper
strand to verify that it has free up and down movement
midway between the engine compensating sprocket
(front) and the clutch sprocket (rear).
3. Measure the free play to be sure that it falls within the
ranges specified for a hot or cold engine:
Table 6-1. Primary Chain Adjustment
(Free Play)
COLD ENGINE
HOT ENGINE
Inches Millimeters
5/8-7/8 inch 15.9-22.2 mm
3/8-5/8 inch 9.5-15.9 mm
4. If the chain is too tight or too loose, then adjust as follows:
a. Locate the chain tensioner assembly and loosen the
top center nut a maximum of two turns. See Figure
6-2.
b. Raise or lower the chain tensioner assembly as
necessary to obtain the specified free play.
f1210x6x
1
4
Inspection
Primary
Chain
Cover
1
32
Clutch
43
Inspection
Cover
5
2
Figure 6-1. Primary Chaincase Cover
Figure 6-2. Chain Tensioner Assembly
NOTE
As chains stretch and wear, they run tighter at one spot than
another. Always adjust the free play at the tightest spot in the
chain. Replace the primary chain if it is worn to the point
where it cannot be properly adjusted.
Always keep the primary chain properly adjusted. Allowing the chain to run too tight or too loose will result in
excessive chain and sprocket wear.
c. Tighten the top center nut of the chain tensioner
assembly to 21-29 ft-lbs (29-39 Nm).
5. Align holes in
new
gasket with holes in the primary
chaincase cover. Using a T27 TORX drive head, install
four screws to secure primary chain inspection cover to
primary chaincase cover. Alternately tighten screws to
84-108
in-lbs
(10-12 Nm) in a crosswise pattern. See
Figure 6-1.
ADJUSTER SHOE REPLACEMENT
If the nylon adjuster shoe is worn or damaged, replace as follows:
1. Remove the primary chaincase cover. See Section 6.5
PRIMARY CHAINCASE, REMOVAL, steps 1-8.
2004 Touring: Drive 6-3
H
OME
f1096dxd
1
2
1. Sprocket Nut
2. Sprocket Cover
3. Sliding Cam
4. Compensating Sprocket
5. Shaft Extension
EXPLODED VIEW
2
1
3
6. Alternator Rotor SpacerLow Output Rotor Only
0.020 inch (0.508 mm)
4
4
3
5
5
7. Alternator Rotor
8. Sprocket Shaft Spacer
9. Engine Sprocket Shaft
NOTE
Alternator stator, oil seal and left
crankcase not shown.
6
CROSS SECTIONAL VIEW
7
Figure 6-3. Engine Compensating Sprocket Components
2. Loosen top center nut from captured bolt of chain tensioner assembly. See Figure 6-2.
6-4 2004 Touring: Drive
9
8
6
3. Lower the chain tensioner assembly until the adjuster
shoe just contacts the inner primary housing.
H
7947
B
Measure at Clutch Sprocket
A
7949
Dial Vernier
Caliper
Straightedge
Measure at Compensating Sprocket
OME
1WARNING1WARNING
Always wear proper eye protection when removing retaining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
worn. Slippage may propel the ring with enough force to
cause eye injury.
4. Remove retaining ring from nub and pull adjuster shoe
from chain tensioner. Discard adjuster shoe and retaining ring.
5. Slide
new
adjuster shoe onto chain tensioner. Be sure
that the narrow end of the shoe is at the front, the wider
end at the rear.
1WARNING1WARNING
Always wear proper eye protection when installing retaining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
worn. Slippage may propel the ring with enough force to
cause eye injury.
6. To lock position of adjuster shoe, install
ring onto nub of chain tensioner. Verify that retaining ring
is fully seated in the groove.
7. Raise or lower the chain tensioner assembly as necessary to obtain the specified free play. See PRIMARY
CHAIN ADJUSTMENT, steps 2-4.
8. Tighten the top center nut of the chain tensioner assembly to 21-29 ft-lbs (29-39 Nm).
9. Install the primary chaincase cover. See Section 6.5
PRIMARY CHAINCASE, INSTALLATION, steps 20-31.
new
retaining
DISASSEMBLY
See Section 6.5 PRIMARY CHAINCASE, REMOVAL, steps
1-16.
CLEANING AND INSPECTION
1. Periodically inspect the primary chain for cracked, broken or badly worn links. Replace as necessary.
2. Inspect compensating sprocket components for damage
or wear. Replace parts as necessary.
3. Inspect clutch sprocket for damage or wear. If broken or
damaged teeth are found, the clutch shell and sprocket
assembly must be replaced.
Figure 6-4. Check Sprocket Alignment
Sprocket Alignment (Figure 6-3, 6-4)
The engine compensating sprocket is aligned with the clutch
sprocket by a spacer installed between the alternator rotor
and shaft extension (low output rotor only). Reinstall the
same thickness spacer removed or determine the correct
spacer size as follows:
1. With the primary chaincase cover removed, verify that
the primary chain tension is properly adjusted. See PRI-
MARY CHAIN ADJUSTMENT in this section.
2. At both the engine compensating sprocket and clutch
sprocket sides, push the primary chain inward as far as it
will go.
2004 Touring: Drive 6-5
H
OME
3. Place a straightedge vertically across the flanges (cover
gasket surface) near the engine compensating sprocket.
4. Using a dial vernier caliper, measure the distance from
the straightedge to the chain link sideplate. Measure as
close to the engine compensating sprocket as possible
and record the measurement. See A of Figure 6-4.
5. Repeat the measurement on the clutch sprocket side.
See B of Figure 6-4.
For proper primary chain alignment, the difference
between the two measurements must not exceed 0.030
inch (0.76 mm). If the measurement is not within specification, install the appropriate variable thickness spacer
on the engine sprocket shaft between the alternator rotor
and shaft extension. See the adjacent table for the various spacer thicknesses.
Table 6-2. Alternator Rotor Spacers
Inches
0.010 0.25 35850-84
0.020 0.51 35851-84
0.030 0.76 35852-84
0.060 1.52 24032-70
0.090 2.29 24033-70
0.120 3.05 24034-70
0.150 3.81 24035-70
0.180 4.57 24036-70
0.210 5.33 24037-70
Millimeters Part Number
ASSEMBLY
See Section 6.5 PRIMARY CHAINCASE, INSTALLATION,
steps 8-31.
6-6 2004 Touring: Drive
H
f1440x6x
Rubber
Boot
Jam
Nut
Cable
Adjuster
Cable
End
f1421x6x
Clutch
Cable
Clutch Lever
Bracket
Ferrule
Adjust for 1/16-1/8 inch
(1.6-3.2 mm) gap
between ferrule
and bracket
OME
CLUTCH 6.3
ADJUSTMENT
CAUTION
Perform the clutch adjustment with the motorcycle at
room temperature. The clearance at the adjuster screw
will increase as the power train temperature increases. If
adjuster screw is adjusted while the powertrain is hot,
clearance at push rod bearing could be insufficient with
power train cold and clutch slippage could occur.
Adjust the clutch at the 1000 mile (1600 km) service interval,
and at every 5000 mile (8000 km) service interval thereafter.
NOTE
Also perform adjustment procedure whenever any clutch
components are replaced. Then repeat adjustment after first
500 miles (800 km) of use.
1. Stand motorcycle upright and level.
Figure 6-6. Clutch Cable Adjuster Mechanism
Adjuster
Screw
Locknut
Retaining
Ring
Figure 6-5. Clutch Adjustment
Release
Plate
f1509b6x
Figure 6-7. Adjust Clutch Free Play
2. Using a T27 TORX drive head, remove five screws (with
captive washers) to free clutch inspection cover from primary chaincase cover.
3. See Figure 6-6. Slide rubber boot off cable adjuster.
Holding cable adjuster with 1/2 inch wrench, loosen jam
nut using a 9/16 inch wrench. Back jam nut away from
cable adjuster. Move adjuster toward jam nut to introduce a large amount of free play at hand lever.
4. See Figure 6-5. Loosen locknut on clutch adjuster screw.
To take up all free play in push rods, turn screw inward
(clockwise) until lightly seated.
5. Back out adjuster screw 1/2 to 1 turn. While holding
adjuster screw with an allen wrench, tighten locknut to
72-120
in-lbs
(8-14 Nm).
6. Squeeze clutch lever to maximum limit three times to set
ball and ramp release mechanism.
2004 Touring: Drive 6-7
H
OME
7. Turn cable adjuster away from jam nut until slack is eliminated at hand lever. Pull clutch cable ferrule away from
clutch lever bracket to check free play. Turn cable
adjuster as necessary to obtain 1/16 to 1/8 inch (1.6-3.2
mm) free play between end of cable ferrule and clutch
lever bracket, as shown in Figure 6-7.
8. Hold adjuster with 1/2 inch wrench. Using 9/16 inch
wrench, tighten jam nut against cable adjuster. Cover
cable adjuster mechanism with rubber boot.
9. Remove quad ring from groove in primary chaincase
cover. Wipe all lubricant from the quad ring and inspect
for cuts, tears or signs of deterioration. Replace as necessary.
10. Swab all lubricant from the quad ring groove. Install
quad ring in primary chaincase cover with the nubs contacting the ring groove walls.
NOTE
If lubricant is not thoroughly removed from both the quad ring
and groove, compression of the ring during installation of the
clutch inspection cover can cause lubricant to be squeezed
to the outboard side of the ring groove, resulting in some
temporary weepage around the inspection cover.
11. Using a T27 TORX drive head, install five screws (with
captive washers) to secure clutch inspection cover to the
primary chaincase cover. Alternately tighten screws to
84-108
in-lbs
(10-12 Nm) in the pattern shown in Figure
6-1.
REMOVAL/INSTALLATION
To remove the clutch without disassembly, see Section 6.5
PRIMARY CHAINCASE, REMOVAL, steps 1-16.
For installation instructions, see Section 6.5 PRIMARY
CHAINCASE, INSTALLATION, steps 8-31.
NOTE
If only the clutch pack is to be disassembled, see PA RT IAL
DISASSEMBLY below, a procedure that can be performed on
the motorcycle without removing the clutch shell or hub.
For complete disassembly of the clutch, which includes
clutch pack disassembly and bearing replacement, see
COMPLETE DISASSEMBLY.
PARTIAL DISASSEMBLY
CLUTCH PACK ONLY
1. Remove the primary chaincase cover. See Section 6.5
PRIMARY CHAINCASE, REMOVAL, steps 1-8.
2. Remove six bolts to release diaphragm spring retainer
from clutch hub. See Figure 6-9.
3. Remove diaphragm spring retainer, diaphragm spring
and pressure plate from clutch hub.
f1523x6x
Clutch
Shell
Damper
Spring Seat
Figure 6-8. Clutch Pack Stack-Up (Cut-Away View)
4. Remove friction plates, steel plates, damper spring and
damper spring seat from clutch hub.
5. See CLEANING AND INSPECTION in this section.
Damper
Spring
Clutch
Hub
Steel Plate
Narrow
Friction Plate
ASSEMBLY
CLUTCH PACK ONLY
1. Submerge and soak all friction and steel plates in PRIMARY CHAINCASE LUBRICANT for at least five minutes.
2. Install the narrow friction plate on the clutch hub engaging tabs on plate with slots in clutch shell.
3. Install damper spring seat on clutch hub so that it seats
inboard of narrow friction plate.
4. Install damper spring on clutch hub with the concave
side up (facing opposite damper spring seat). See Fig-
ure 6-8.
5. Install a steel plate and then a friction plate on the clutch
hub. Install seven remaining sets in the same manner,
alternating between steel plates and friction plates.
6. Install pressure plate on clutch hub aligning holes in
plate with threaded bosses on hub.
7. Seat diaphragm spring in recess of pressure plate with
the concave side down.
8. Align holes in diaphragm spring retainer with threaded
bosses on clutch hub. Tabs on spring retainer contact
flats on inboard side of bosses.
9. Install six bolts to secure diaphragm spring retainer to
clutch hub. Alternately tighten bolts to 90-110
(10.2-12.4 Nm).
10. Install the primary chaincase cover. See Section 6.5
PRIMARY CHAINCASE, INSTALLATION, steps 20-31.
in-lbs
6-8 2004 Touring: Drive
H
OME
5
6
f1514x6x
4
2
3
7
8
1
9
10
11
12
1. Retaining Ring
2. Clutch Shell
3. Bearing
4. Retaining Ring
5. Clutch Hub
6. Mainshaft Nut
7. Friction Plate (9)
8. Steel Plate (8)
9. Narrow Friction Plate
14
13
24
10. Damper Spring
11. Damper Spring Seat
12. Pressure Plate
13. Diaphragm Spring
14. Diaphragm Spring Retainer
15. Bolt (6)
16. Release Plate
16
15
23
22
17. Retaining Ring
18. Locknut
19. Adjuster Screw
20. Push Rod
21. Oil Slinger
17
18
19
20
21
22. Thrust Washer (2)
23. Throw Out Bearing
24. Retaining Ring
Figure 6-9. Clutch Assembly
2004 Touring: Drive 6-9
H
OME
CLEANING AND INSPECTION
1. Wash all parts in cleaning solvent, except for friction
plates and bearing, if removed. Blow dry with compressed air.
Remove retaining ring from clutch hub.
2. Check
friction plates
●
Wipe all lubricant from the friction plates. Measure
as follows:
the thickness of each plate with a dial caliper or
micrometer. If the thickness of any plate is less than
0.143 inch (3.62 mm), discard the friction plates and
replace with an entirely new set.
Look for worn or damaged fiber surface material
●
(both sides).
NOTE
Replace all nine friction plates with an entirely new set if any
individual plate shows evidence of wear or damage.
3. Check
steel plates
Discard any plate that is grooved or bluish in color.
●
as follows:
Blue plates are likely warped or distorted.
●
Check each plate for distortion. Lay the plate on a
precision flat surface. Insert a feeler gauge between
the plate and the flat surface in several places.
Replace any steel plate that is warped more than
0.006 inch (0.15 mm).
4. See Figure 6-9. Holding the clutch hub, rotate the clutch
shell to check bearing for smoothness. Replace the
bearing if it runs rough or binds.
f1519x6x
Press clutch hub from bearing.
5. Check the primary chain sprocket and the starter ring
gear on the clutch shell. Replace the clutch shell if either
sprocket or ring gear are badly worn or damaged.
6. Check the slots that mate with the clutch plates on both
the clutch shell and hub. Replace shell or hub if slots are
worn or damaged.
7. Check the diaphragm spring and diaphragm spring
retainer for cracks or bent tabs. Obtain a new diaphragm
spring or diaphragm spring retainer if either condition
exists.
COMPLETE DISASSEMBLY
CLUTCH PACK AND BEARING
1. Remove clutch assembly from the motorcycle. See Section 6.5 PRIMARY CHAINCASE, REMOVAL, steps 1-16.
2. Remove six bolts to release diaphragm spring retainer
from clutch hub. See Figure 6-9.
3. Remove diaphragm spring retainer, diaphragm spring
and pressure plate from clutch hub.
f1522x6x
Figure 6-10. Remove Clutch Hub from Clutch Shell
4. Remove friction plates, steel plates, damper spring and
damper spring seat from clutch hub.
CAUTION
To avoid possible bearing damage, do not disassemble
the clutch shell and hub assembly unless the bearing,
hub or shell require replacement. Replace the bearing if
disassembled.
6-10 2004 Touring: Drive
Loading...