Harley Davidson Touring 2004 Service Manual spb02a
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SPECIFICATIONS 2.1
Table 2-1. Dimensions
ITEM IN. MM
Wheel Base 63.5 1613
Overall Length
Overall Width 38.5 977.9
Road Clearance 4.21
Overall Height 51.75 1314.45
Saddle Height* 26.7
With 180 Lb. Rider
*
91.9
2334
106.9
678
Table 2-2. Weight
ITEM LBS. KG
DRY WEIGHT** 776/788 352.3/357.8
GVWR 1259 572
GAWR – Front 500 227
GAWR – Rear 827 375
As shipped from the factory
**
Table 2-3. Capacities
ITEM U.S. METRIC
Fuel Tank (gallons)
To t al
Reserve
Oil Tank (quarts)
with filter 4 Quarts 3.78 Liters
Tr ansmission
(Ounces, approximate)
Primary Chaincase
(Ounces, approximate) 32 Ounces 946 Mililiters
Front Fork (Ounces)
5
0.9 Gal.
20-24
Ounces
Left Right Left Right
10.6 10.6
18.9
3.4 Liters
591-710 Mil-
liliters
314ml314
ml
NOTE
Gross Vehicle Weight Rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding Gross Axle Weight
Ratings (GAWR) are given on a label located on the inside of
the right front frame downtube.
2004 FLHTCSE: Chassis 2-1
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TORQUE VALUES 2.2
ITEM TORQUE NOTES
Actuator bleeder valve 80-100
Actuator bleeder valve 80-100
Banjo bolt 17-22 ft-lbs 23-31 Nm page 2-24
Banjo bolt 17-23 ft-lbs 23-31 Nm page 2-25
Brake caliper pad pins 180-200
Brake fluid reservoir cover 6-8
Brake pedal to brake arm 25-29 ft-lbs 34-39 Nm page 2-9
Clutch fluid line flare nut 80-115
Clutch fluid line flare nut 80-115
Clutch fluid reservoir cover 6-8
Clutch master cylinder banjo bolt 17-22 ft-lbs 23-31 Nm page 2-21
Clutch reservoir cover screws 6-8
Clutch reservoir cover screws 6-8
Fender mounting bolt 15-20 ft-lbs 20.4-27.1 Nm page 2-28
Filler strip 15-20 ft-lbs 20.4-27.1 Nm page 2-30
Footboard hinge bolts 84-108
Footboard hinge bolts 84-108
Front axle cover set screw 60-84
Handlebar clamp screws 71-80
Handlebar top clamp 12-16 ft-lbs 16.3-20.3 Nm page 2-16
Left footboard brackets 15-20 ft-lbs 20.4-27.1 Nm page 2-7
Pad pins 180-200
Passenger backrest docking points 15-20 ft-lbs 20.4-27.1 Nm page 2-28
Passenger backrest mounting bracket 15-20 ft-lbs 20.4-27.1 Nm page 2-30
Passenger mounting bracket fasteners 15-20 ft-lbs 20.4-27.1 Nm page 2-28
Rear axle cone nut 95-105 ft-lbs 128.9-142.4 Nm page 2-4
Right footboard brackets 30-35 ft-lbs 41.7-47.4 Nm page 2-7
Right footboard brackets 30-35 ft-lbs 41.7-47.4 Nm page 2-7
Saddlebag support to support bracket 15-20 ft-lbs 20.4-27.1 Nm page 2-30
Secondary actuator bleeder valve 80-100
Shift lever clamp bolts 90-110
Shift lever peg 144-168
Tr iple clamp cover backside fasteners 70-110
Tr iple clamp lower Allen head fastener 120-180
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
9-11 Nm page 2-24
9-11 Nm page 2-25
21-22 Nm page 2-6
0.7-0.9 Nm page 2-6
9-13 Nm page 2-24
9-13 Nm page 2-25
0.7-0.9 Nm page 2-21
0.7-0.9 Nm page 2-24
0.7-0.9 Nm page 2-25
9.5-12.2 Nm page 2-7
9.5-12.2 Nm page 2-7
6.8-9.5 Nm page 2-10
8-9 Nm page 2-21
21-22 Nm page 2-6
9-11 Nm page 2-21
10.2-12.4 Nm page 2-9
16.3-18.9 Nm page 2-9
7.9-12.4 Nm page 2-11
13.5-20.3 Nm page 2-11
2-2 2004 FLHTCSE: Chassis
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10528
VEHICLE IDENTIFICATION NUMBER (V.I.N.) 2.3
GENERAL
See Figure 2-1. An abbreviated V.I.N. is stamped on the left
side crankcase at the base between the cylinders.
NOTE
Always give the full 17 digit Vehicle Identification Number
when ordering parts or making any inquiry about your motorcycle.
See Figure 2-2. The full 17 digit serial, or Vehicle Identification Number (V.I.N.) is stamped on the right side of the steering head and on a label located on the left side of the
steering head.
Figure 2-1. Abbreviated V.I.N. Location
Market Designation
Model Designation
Engine Type
Varies - 1 thru 8
1 - Manufactured for U.S.A.
5 - Manufactured for International Countries
E - 1690 (EFI)
Model Year - 2004
Y - Manufactured in York, PA
K - Manufactured in Kansas City, MO
Sequential Number
1 HD1 PJ E 1*4 Y 950000
*
Var ies - can be 0 thru 9 or X
Sample V.I.N. as it appears on the steering head - 1HD1PJE1*4Y950000
Sample abbreviated V.I.N. as it appears on the left crankcase - PJE4950000
Figure 2-2. Vehicle Identification Number
PJ - FLHTCSE
2004 FLHTCSE: Chassis 2-3
HOME
REAR WHEEL 2.4
REMOVAL
1. Block motorcycle under frame so rear wheel is off the
ground.
2. Remove saddlebags. See SADDLEBAG in Touring Models Service Manual.
3. Remove mufflers. See REAR WHEEL in Touring Models
Service Manual.
4. Remove e-clip from groove on right end of rear axle.
5. Remove cone nut and adjuster cam from axle.
6. Using a soft mallet, gently tap end of axle towards left
side to loosen.
7. Pull the axle out to saddlebag support.
8. To clear the saddlebag support, rotate the axle to lowest
cam position and push the bottom of the tire to the right
to angle the assembly in the fender with the left end of
axle tilted down.
9. Pull the axle the rest of the way out.
10. Pull wheel to release brake disc from caliper. Pry inner
and outer brake pads back for additional clearance. If
necessary, use a putty knife with a wide thin blade to
avoid scratching the brake disc.
NOTE
Do not operate the rear brake pedal with the rear wheel
removed or the caliper pistons may be forced out. Reseating
pistons requires disassembly of the caliper.
11. Move wheel forward to slip belt off sprocket and remove
wheel from rear fork.
4. Tilt the bottom of the tire to the right.
5. Orient the axle to the lowest cam position and angle the
axle to match angle of rear wheel.
6. With the larger OD on the outboard side, hold external
spacer between the rear fork and belt sprocket. Slide the
axle through left side of rear swingarm, external spacer,
and sprocket into the wheel hub.
7. When the axle emerges from the hub, straighten the
wheel and push axle through short external spacer, caliper bracket and rear fork.
8. Rotate flat on threaded end of axle to the top. With the
thumb down and the cam forward, install adjuster cam
on end of axle.
9. Apply a thin film of LOCTITE ANTI-SEIZE to inboard
side of cone nut. Install cone nut on axle, but finger
tighten only.
10. Verify that adjuster cam just contacts weld nub on both
sides of rear fork. If necessary push wheel forward
slightly to achieve the desired result. Snug the cone nut
to 15-20 ft-lbs (20-27 Nm).
11. Lower motorcycle to ground.
12. Rotate weld nut on left side of axle in a clockwise direction.
13. Check belt deflection. See DRIVE BELT under SCHEDULED MAINTENANCE PROCEDURES.
14. When belt deflection is within specifications, hold weld
nut and final tighten cone nut to 95-105 ft-lbs (128.9-
142.4 Nm).
15. With the flat side out, install
16. Install mufflers. See REAR WHEEL in the Touring Models Service Manual.
new
e-clip in axle groove.
1WARNING1WARNING
NOTE
Removal of the rear wheel can be also facilitated by removing the lower shock bolts and dropping the rear fork below
the saddlebag support brackets. This provides access to the
rear axle.
INSTALLATION
1. Place rear wheel in rear swingarm. Slide wheel forward
and slip belt over sprocket.
CAUTION
Do not bend or fold belt backward or into loops smaller
than 5 inches in diameter. Sharp bending can weaken
the belt and cause premature failure.
2. Seat caliper on anchor weldment of rear swingarm. Position wheel in rear fork, so that brake disc is centered
between brake pads.
3. Coat the axle with LOCTITE ANTI-SEIZE.
2-4 2004 FLHTCSE: Chassis
After installation of caliper and BEFORE moving motorcycle, pump rear brake pedal until pistons push pads
against the brake disc. If fluid pressure is not pumped
up, the rear brake will not be available the first time it is
used, a situation that could result in death or serious
injury.
17. Press rear brake pedal several times to set brake pads.
18. Install saddelbags. See SADDLEBAG in the Touring
Models Service Manual.
HOME
1. Bridge bolt
2. Pad pin
3. Spring washer and rivet
1
3
2
8696
Inner brake pad
Outer brake pad
o0035x0x
1. Two tabs
2. Single tab
3. Curved portion faces rear
1
2
3
REAR BRAKE PADS 2.5
GENERAL
Follow service instructions for INSPECTION, BRAKE DISC
THICKNESS/WARPAGE, BRAKE PADS, and BRAKE LINE/
HOSE INSPECTION. See REAR BRAKE CALIPER in Touring Models Service Manual.
Procedures for rear brake pad replacement are similar. However, the brake pads must be rotated along the arc of the
brake disc to clear the disc rivets and spring washers during
brake pad removal and installation.
REPLACEMENT
1. Raise the rear wheel off the ground.
2. Remove right side saddlebag. See SADDLEBAGS,
REMOVAL in Touring Models Service Manual.
3. See Figure 2-3. Loosen both pad pins, but do not
remove.
4. Remove two Phillips screws to release cover from rear
master cylinder reservoir.
Figure 2-3. Rear Brake Disc and Caliper
CAUTION
As the pistons are pushed back into the caliper, fluid
level may rise more than 1/8 inch (3.2 mm) and overflow
the reservoir. Watch the fluid level as the pistons are
retracted and remove fluid from the reservoir if necessary.
5. Pry the inner pad back pushing the pistons into their
bores. Use a putty knife with a wide thin blade to avoid
scoring or scratching the brake disc.
CAUTION
Do not completely pull pad pins from caliper during the
next step. Completely removing pad pins at this time will
make assembly difficult.
6. Once the pistons have been retracted, pull the pad pins
part way out to free the inside pad.
7. Slide the inside pad along the arc of the brake disc to
remove pads from calipers. Note the orientation of the
pad.
1WARNING1WARNING
Figure 2-4. Rear Brake Pad Orientation
Always replace brake pads in pairs. Never replace just
one brake pad. Mismatched brake pads can lead to brake
system damage and loss of braking performance, which
could result in death or serious injury.
2004 FLHTCSE: Chassis 2-5
HOME
8. See Figure 2-4. Orient
brake disc. Curved portion must face rear of motorcycle.
9. Hold brake pad against brake disc and rotate the rear
wheel to rotate the pad forward into caliper.
10. Install pad pins, but do not fully tighten.
11. Pump rear brake pedal to move inside pistons out until
they contact inner brake pad.
12. Pry the outside pad back pushing the pistons into their
bores. Use a putty knife with a wide thin blade to avoid
scoring or scratching the brake disc.
13. Verify that inner pad is captured between brake disc and
pistons.
14. Completely remove pad pins to free outer brake pad.
Note the orientation of the outer brake pad.
15. Orient
16. Hold brake pad against brake disc and rotate the rear
new
outer brake pad against the brake disc.
Curved portion of pad must face rear of motorcycle.
wheel to rotate the pad forward into caliper. If the inside
pad moved during the previous step, reinstall.
new
inner brake pad against the
20. Verify that brake fluid level is 1/8 inch (3.2 mm) below top
of reservoir with master cylinder in a level position. Add
D.O.T. 5 SILICONE BRAKE FLUID, if necessary. Install
master cylinder reservoir cover. Install two Phillips
screws to fasten cover to reservoir and tighten to 6-8
lbs
(0.7-0.9 Nm).
21. Install right side saddlebag. See SADDLEBAGS,
INSTALLATION in Touring Models Service Manual.
22. Test operation of brake lamp with the rear brake applied
and the ignition/light key switch turned to IGNITION.
in-
1WARNING1WARNING
After completing repairs or bleeding the system, always
test motorcycle brakes at low speed. If brakes are not
operating properly or braking efficiency is poor, testing
at high speeds may result in death or serious injury.
23. Test ride motorcycle. If the brakes fell spongy, bleed the
brake lines. See BLEEDING HYDRAULIC BRAKE
LINES in Touring Models Service Manual.
17. Inspect pad pins and clean or replace as required.
18. Install two pad pins and tighten to 180-200
22.6 Nm).
in-lbs
(20.3-
1WARNING1WARNING
After installation of new pads and BEFORE moving
motorcycle, pump rear brake pedal until pistons push
pads against the brake disc. If fluid pressure is not
pumped up, the rear brake will not be available the first
time it is used, a situation that could result in death or
serious injury.
19. Pump rear brake pedal to move pistons out until they
contact both brake pads. Verify piston location against
pads.
2-6 2004 FLHTCSE: Chassis
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10518
FOOTBOARDS AND CONTROLS 2.6
RIDER FOOTBOARDS
NOTE
Unless the inserts or bottom assemblies are being replaced,
they do not have to be removed from footboard brackets.
Removal
1. See Figure 2-5. With footboards in up position, use a
screwdriver to work cover rubber collars out through
footboards. Remove insert assemblies.
2. See Figure 2-6. Remove right footboard pivot bolts, nuts
and remove footboard bottom assembly.
3. Remove screws, washer, lock washer and right rear footboard bracket.
4. Remove screws, lock washers, nuts and right front footboard bracket.
5. Remove left footboard pivot bolts, nuts and remove footboard bottom assembly.
6. Remove screws, washers, lock washers and both front
and rear left footboard brackets.
Figure 2-5. Footboard Cover Rubber Collars
PASSENGER FOOTBOARDS
Removal
1. See Figure 2-6. Remove socket screw and lockwasher
to remove footboard bracket from swingarm bracket
Installation
1. See Figure 2-6. Install right front footboard bracket. Posi-
tion for rider posture. Install lock washers, washers, nuts
and screws. Tighten screws to 30-35 ft-lbs (41.7-47.4
Nm).
2. Install right rear footboard bracket. Position for rider posture. Install lock washer, washer and screw. Tighten
screws to 30-35 ft-lbs (41.7-47.4 Nm).
NOTE
The right and left footboard frame mounts allow a small variance in height and angle.
3. Install right footboard bottom assembly. Install and
tighten pivot bolts and nut to 84-108
Nm).
4. Install left footboard brackets. Position for rider posture.
Install washers, lock washers, and screws. Tighten
screws to 30-35 ft-lbs (41.7-47.4 Nm).
5. Install left footboard bottom assembly. Install and tighten
pivot bolts and nut to 84-108
6. Moisten footboard cover rubber collars with soapy water.
7. With left footboard bottom assembly in up position, hold
new
footboard cover in position.
8. From underside of footboard use a pliers to pull each
rubber collar through footboard hole.
9. Repeat for other side.
in-lbs
in-lbs
(9.5-13.5
(9.5-13.5 Nm).
Installation
1. Insert pin on footboard bracket into hole in swingarm
bracket.
NOTE
Passenger footboards can be adjusted to one of three positions. To move footboards to a new position, remove plastic
plugs from holes in rear swingarm bracket as necessary.
2. Install socket screw with lockwasher. Tighten socket
screw to 15-18 ft-lbs (20-24 Nm).
CAUTION
Avoid contacting chrome surfaces with abrasive materials (stones, sand, etc.) as damage will result.
2004 FLHTCSE: Chassis 2-7
HOME
Disassembly
NOTE
If only replacing the rubber pad, refer to step 1 below and
then see steps 4-5 under ASSEMBLY.
1. Tilt footboard bottom assembly upward. From bottom
side, use a small blade screwdriver to push rubber
beads on pad up through holes in footboard bottom
assembly. Remove insert assembly.
2. Using a brass drift and rubber mallet, tap two retaining
pins toward center of footboard and remove.
3. Remove footboard bottom assembly from footboard
bracket.
4. Remove ball and spring from hole in footboard bracket.
5. Remove footboard bracket from rear swingarm bracket.
See PASSENGER FOOTBOARD, REMOVAL in this section.
z0020d
6
5
1
2
4
3
7
Assembly
1. Install footboard bracket. See PASSENGER FOOTBOARD INSTALLATION, in this section.
2. Place spring into hole in footboard bracket. Place ball on
top of spring.
3. Place footboard bottom assembly into position on
bracket and install retaining pins from the outboard side.
Using a brass drift and rubber mallet, tap pins until centered in lugs of bracket.
4. Moisten rubber beads on new insert assembly with
soapy water. Place insert assembly into position on footboard bottom assembly. Press firmly on footboard insert
in areas of rubber beads.
9
22
11
21
24
23
13
14
15
10
12
2
8
18
17
1. Insert Assembly, passenger footboard, right-side
(Left-side not shown)
2. Pivot pin
3. Spring
4. Ball
5. Socket screw
6. Lockwasher
7. Bracket, footboard, passenger
8. Bottom assembly, footboard, passenger
9. Insert assembly, rider, left-side
10. Bottom assembly, with hinge, left-side
11. Nut
12. Pivot bolt
Figure 2-6. Footboard and Passenger Footrest Components
15
19
20
14
15
14
16
13. Bracket, support, footboard, left-side
14. Washer
15. Lockwasher
16. Bracket, support, footboard, right-side
17. Bottom assembly, right-side
18. Insert assembly, right-side
19. Bracket, support footboard, right rear
20. Screw
21. Screw
22. Bracket, support footboard, left rear
23. Lockwasher
24. Locknut
2-8 2004 FLHTCSE: Chassis
HOME
SHIFT LEVER
Replacement
1. Remove and replace shift lever pegs. Tighten fasteners
to 144-168
2. If necessary, loosen clamp bolts and pull shift levers off
splined shaft.
3. Position shift levers on splined shaft for rider posture and
tighten clamp bolts to 90-110 in-lbs (10.2-12.4 Nm).
in-lbs (16.3-18.9 Nm).
REAR BRAKE PEDAL PAD
Replacement
1. Remove screws (4) and remove brake pedal from brake
arm. Disassemble.
f2287x0x
1
3
4
1. Metal brake pedal cover
2. Rubber tread
3. Metal backing plate
4. Screws
Figure 2-7. Rear Brake Pedal
2. See Figure 2-7. Assemble metal brake pedal cover to
rubber tread.
3. Slide metal backing plate into metal brake pedal cover/
rubber tread assembly.
4. Install pedal to brake arm with screws. Tighten screws to
22-29 in-lbs (2.5-3.3 Nm).
2
2004 FLHTCSE: Chassis 2-9
HOME
FRONT AXLE COVERS 2.7
REPLACEMENT
1. See Figure 2-8. Loosen but do not remove set screw
under cover. Remove cover.
2. Remove set screws from cover.
3. Liberally apply LOCTITE THREADLOCKER 262 (red)
(HD-94759-77) to threads of set screw.
4. Orient cover over axle end so that set screw is on the
bottom and will tighten down against a flat on the axle
nut.
5. Install and tighten set screw to 60-84 in-lbs (6.8-9.5
Nm).
6. Repeat for opposite side.
10522
Figure 2-8. Front Axle Cover Set Screw
2-10 2004 FLHTCSE: Chassis
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