Harley Davidson Touring 2004 Service Manual sm04a

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SPECIFICATIONS 4.1

CVH CARBURETOR JET SIZES

Model

Main Fuel

Jet No.

49 state 190 45 HDI 195 45 California 185 45

Slow Fuel

Jet No.

FUEL TANK CAPACITY

Capacity

To tal 5.0 Gallons 18.9 liters Reserve 0.9 Gallons 3.4 liters

English Metric

TORQUE VALUES

Item ft/in-lbs Nm

Enrichener cable mounting bracket hex nut

Cylinder head breather bolts

Air cleaner cover bracket screws

Air cleaner cover screw 36-60 Fuel valve hex jam nut 15-20 ft-lbs 20-27 Nm Fuel tank adapter 22-26 ft-lbs 30-35 Nm Fuel tank rear mounting

bolt Fuel tank front mounting

bolts Battery hold-down clamp

bolt Console mounting bolt

acorn nut

20-35

in-lbs

120-144

in-lbs

20-40

in-lbs

15-20 ft-lbs 20-27 Nm

50-90

in-lbs

2.3-4.0 Nm

13.6-16.3 Nm

2.3-4.5 Nm

4.1-6.8 Nm

5.7-10.2 Nm

2004 Touring: Fuel 4-1

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FUEL SYSTEM TROUBLESHOOTING (CARBURETED) 4.2

CARBURETOR TROUBLESHOOTING

OVERFLOW

Check for:

1. Restricted fuel tank vent system.

2. Loose ﬂoat bowl screws.

3. Damaged ﬂoat bowl O-ring.

4. Improper fuel level in ﬂoat bowl.

5. Damaged or leaking ﬂoat assembly.

6. Particle contamination in fuel inlet ﬁtting cavity.

7. Worn or dirty inlet valve or seat.

Check for:

1. Idle speed improperly adjusted.

2. Inlet system air leak (faster idling).

3. Loose low speed jet.

4. Contaminated or plugged low speed system.

5. Enrichener valve not seated or leaking.

6. Leaking accelerator pump.

POOR FUEL ECONOMY

Check for:

1. High speed riding style.

2. Excessive use of enrichener system.

3. Fuel level too high.

4. Restricted fuel tank vent system.

5. Dirty air cleaner element.

6. Excessive accelerator pump output.

7. Plugged or restricted bowl vent.

8. Vacuum piston assembly malfunction.

9. Loose jets.

10. Worn or damaged needle or needle jet.

11. Plugged air jets or passages.

12. Enrichener valve not seated or leaking.

13. Idle speed improperly adjusted.

Remedy:

1. Correct restricted hose. Replace vapor valve.

2. Tighten screws.

3. Replace O-ring.

4. Adjust ﬂoat tab for correct fuel level.

5. Replace ﬂoat assembly.

6. Clean and clear cavity and fuel supply tract.

7. Clean or replace valve and clean seat.

POOR IDLING

Remedy:

1. Adjust operating idle speed.

2. Correct as required.

3. Tighten jet.

4. Clean contaminants and clear passages.

5. Adjust, clean or replace.

6. Repair.

Remedy:

1. Modify riding habits.

2. Limit system use.

3. Adjust ﬂoat level.

4. Correct restricted hose. Replace vapor valve.

5. Clean or replace as required.

6. Check and clean accelerator pump bypass oriﬁce.

7. Clean and clear passages.

8. See Vacuum Piston Troubleshooting.

9. Tighten jets.

10. Replace needle or needle jet.

11. Clean and clear passages.

12. Adjust, clean or replace.

13. Adjust operating idle speed.

Check for:

1. Throttle cables misadjusted.

2. Inlet system air leak.

3. Restricted fuel tank vent system.

4. Restricted fuel supply passages.

5. Plugged bowl vent or overﬂow.

6. Enrichener valve not seated or leaking.

7. Worn or damaged needle or needle jet.

8. Vacuum piston malfunction.

9. Plugged jets or passages.

10. Fuel level (ﬂoat chamber) too low.

11. Accelerator pump leaking or no output.

4-2 2004 Touring: Fuel

POOR ACCELERATION

Remedy:

1. Adjust throttle cables.

2. Correct as required.

3. Correct restricted hose. Replace vapor valve.

4. Correct and clear restriction.

5. Clean and clear passages.

6. Adjust, clean or replace.

7. Replace assembly.

8. See Vacuum Piston Troubleshooting.

9. Clean and clear as required.

10. Adjust ﬂoat level.

11. Repair as necessary.

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HARD STARTING

Check for:

1. Enrichener system plugged, not properly functioning or improperly operated.

2. Inlet system air leak.

3. Restricted fuel supply.

4. Fuel overﬂow.

5. Plugged slow jet or passages.

POOR PERFORMANCE ON ROAD

Check for:

1. Inlet system air leak.

2. Restricted fuel tank vent system.

3. Dirty or damaged air cleaner element.

4. Accelerator pump inoperative.

5. Plugged bowl vent or overﬂow.

6. Vacuum piston assembly malfunction.

7. Loose or plugged fuel and air jets or passages.

8. Worn or damaged needle or needle jet.

9. Restricted fuel supply tract.

10. Enrichener valve not seated or leaking.

11. Idle speed improperly adjusted.

POOR HIGH SPEED PERFORMANCE

Remedy:

1. Clean, adjust, or replace; or read Owner’s Manual.

2. Correct as required.

3. Check fuel supply and/or passages. Verify that vacuum operated fuel valve is functional.

4. See Overﬂow Troubleshooting.

5. Clean and clear jet or passages.

Remedy:

1. Correct as required.

2. Correct restricted hose. Replace vapor valve.

3. Clean or replace.

4. Repair as required.

5. Clean and clear passages.

6. See Vacuum Piston Troubleshooting.

7. Clean, clear and correct as required.

8. Replace assembly.

9. Correct and clear restriction.

10. Adjust, clean or replace.

11. Adjust operating idle speed.

Check for:

1. Inlet system air leak.

2. Restricted fuel tank vent system.

3. Dirty or damaged air cleaner element.

4. Accelerator pump inoperative.

5. Plugged bowl, vent or overﬂow.

6. Vacuum piston assembly malfunction.

7. Restricted fuel supply tract.

8. Loose or plugged main jets or passages.

9. Improper fuel level.

10. Worn or damaged needle or needle jet.

11. Enrichener valve not seated or leaking.

Remedy:

1. Clean or replace.

2. Correct restricted hose. Replace vapor valve.

3. Clean or replace.

4. Repair as required.

5. Clean and clear passages.

6. See Vacuum Piston Troubleshooting.

7. Correct and clean restriction.

8. Tighten, clean, clear as required.

9. Adjust ﬂoat level.

10. Replace assembly.

11. Adjust, clean or replace.

2004 Touring: Fuel 4-3

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VACUUM PISTON ASSEMBLY TROUBLESHOOTING

PISTON DOES NOT RAISE PROPERLY

Check for:

1. Diaphragm cap loose, damaged or leaking.

2. Diaphragm pinched at lip groove.

3. Piston atmosphere vent blocked.

4. Piston vacuum passage plugged.

5. Torn diaphragm.

6. Piston binding.

7. Spring binding.

8. Enrichener valve open, not seated or leaking.

PISTON DOES NOT CLOSE PROPERLY

Check for:

1. Piston diaphragm ring dirty or damaged.

2. Piston binding.

3. Spring damaged.

Remedy:

1. Tighten or replace cap.

2. Reposition diaphragm lip.

3. Clear vent.

4. Clean and clear passage.

5. Replace piston diaphragm assembly.

6. Clean piston slides and body or replace piston.

7. Correct or replace spring.

8. Adjust, clean or replace.

Remedy:

1. Clean or replace piston.

2. Clean piston slides and body or replace piston.

3. Replace spring.

4-4 2004 Touring: Fuel

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CAUTION

f1381b2x

Idle Control

Cable

Throttle Control

Cable

Vacuum Piston

Chamber

Idle Speed

Set Screw

Accelerator

Pump Nozzle

Air

Jets

Vacuum Fitting

(At Back)

Float Chamber

ENRICHENER (CARBURETED) 4.3

GENERAL

The carburetor is a constant velocity, gravity fed type with a ﬂoat operated inlet valve, a variable venturi, a throttle stop screw for idle speed adjustment and a fuel enrichment system for starting. See Figure 4-1.

The fuel enrichment circuit will cause engine idle speed to increase to approximately 2000 rpm with enrichener knob pulled out fully and engine running at normal operating temperature. With enrichener knob pulled out partially and engine running at normal operating temperature, engine idle speed will also increase above normal idle speed. The increase in idle speed is intended to alert the rider that engine is warmed up, and that enrichener knob should be pushed in all the way. Continued use of enrichener after engine is warmed up may cause fouled spark plugs.

Idle and transfer ports provide a balanced fuel mixture during the transition period from stop to mid-range. A vacuum piston controls venturi opening.

The carburetor is speciﬁcally designed to control exhaust emissions. All jets are ﬁxed. The idle mixture has been preset at the factory.

The idle mixture screw is recessed in the carburetor casting. The opening is sealed with a plug because it is intended that the idle mixture be non-adjustable.

NOTE

Adjusting mixture setting by procedures other than speciﬁed in this section may be in violation of Federal or State regulations.

This system partially compensates for changes in the mixture that are normally caused by changes in altitude. Because atmospheric pressure decreases as altitude increases, the pressure difference in the upper and lower chambers is reduced, which provides less fuel to the engine.

The carburetor is equipped with an accelerator pump. The accelerator pump system uses sudden throttle openings (rapid accelerations) to quickly inject fuel into carburetor venturi to provide extra fuel for smooth acceleration.

OPERATION

Enrichener

The enrichener knob, located under the left side of the fuel tank, controls opening and closing of the enrichener circuit in the carburetor. The enrichener knob can be adjusted to any position, from full-in to full-out.

Figure 4-1. CVH Carburetor

Never accelerate the engine above 2500 RPM immediately after a cold start. Allow the engine to run slowly for 15-30 seconds. This will allow the engine to warm up and let oil reach all surfaces needing lubrication. Extended idling with enrichener in the full out position for a period longer than 30 seconds is not recommended.

NOTE

H-D CV carburetors have an enrichener circuit that will

●

cause the engine to idle at approximately 2000 rpm with the engine at normal operating temperature and the enrichener knob pulled fully out.

2004 Touring: Fuel 4-5

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The increase in idle speed is intended to alert the rider

●

that the engine is warmed up to normal operating temperature and the enrichener knob should be pushed all the way in.

●

Continuing to use the enrichener when the engine is at full operating temperature WILL CAUSE FOULED SPARK PLUGS.

CAUTION

Pay close attention to the vehicle's warm-up time. Either excessive or insufﬁcient use of the enrichener may cause poor performance, erratic idle, poor fuel economy and spark plug fouling.

NOTE

The following starting and operating instructions for all carbureted motorcycles should be viewed as recommendations only. They may be modiﬁed for individual vehicles.

Cool Engine

Outside Temperature Cooler than 60˚ F

Tu rn the fuel valve to the ON position. BE SURE THAT THE THROTTLE IS CLOSED. Pull the enrichener knob to the “full out” position. Turn the Ignition/Light Key Switch knob to the IGNITION position. Turn the Engine Stop Switch to the RUN position. Press the Engine Start Switch to operate the electric starter.

1. After initial 15-30 second warm-up, ride for 3 minutes or 2 miles (3.2 km) with enrichener knob in full out position. See Figure 4-2.

2. Push the enrichener knob in to the 1/2 way position. Ride an additional 2 minutes or 2 miles (3.2 km).

3. Push the enrichener knob fully in.

NOTE

If outside temperature is cooler than 20˚ F it may be necessary to pump the throttle control grip 2 or 3 times.

Outside Temperature Warmer than 60˚ F

1. After the initial 15-30 second warm-up, ride for 1 minute or 1/2 mile (0.8 km) with enrichener knob in full out position. See Figure 4-2.

2. Push the enrichener knob in to the 1/2 way position. Ride an additional 1 minute or 1/2 mile (0.8 km).

3. Push the enrichener knob fully in.

Full-In

(Normal Running Position)

1/2-Way

Position

Full-Out

(Cold Engine Starts)

f1808x4x

Figure 4-2. Set the Enrichener Knob

Warm Climate Or Hot Engine

Tu rn the fuel valve to the ON position. Turn the Ignition/Light Key Switch knob to the IGNITION position. Turn the Engine Stop Switch to the RUN position. Open throttle 1/8 - 1/4 turn. Press the Engine Start Switch to operate the electric starter. DO NOT USE ENRICHENER.

NOTE

If the engine does not start after a few turns or if one cylinder ﬁres weakly but engine does not start, it is usually because of an over-rich (ﬂooded) condition. This is especially true of a hot engine. If the engine is ﬂooded, push enrichener knob in all the way, turn ignition on and operate starter with throttle wide open. DO NOT "pump" the throttle while turning over the engine.

ADJUSTMENTS

Slow Idle

NOTE

Make certain the enrichener knob is pushed all the way in before adjusting engine idle. The CV carburetor enrichenercircuit will cause the engine idle speed to increase to between 1500 and 2000 rpm with the enrichener knob pulled out fully and the engine at normal operating temperature. (With the enrichener knob pulled out partially and normal engine operating temperature, the engine idle speed will increase above normal idle speed (950-1050 rpm) to approximately 2000 rpm maximum with the enrichener knob pulled out fully). The increase in idle speed is intended to alert the rider that the engine is warmed-up and the enrichener knob should be pushed all the way in. Continued use of the enrichener, after engine is at normal operating temperature, may cause fouled spark plugs.

With the engine at normal operating temperature and the enrichener all the way in (enrichener valve closed) adjust the throttle stop screw so the engine idles at 1000 rpm.

4-6 2004 Touring: Fuel

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CAUTION

f1438x4x

Enrichener

Knob

Mounting

Bracket

Knurled

Nut

Enrichener

Cable

Hex Nut

Flat

Lockwasher

NOTE

Use a test tachometer, connected to negative ignition coil terminal to measure engine rpm on models without tachometers.

Enrichener Control

At the 1000 mile (1600 km) service interval, and at every 5000 mile (8000 km) service interval thereafter, inspect the enrichener control as follows:

The fuel enrichener knob should open, remain open and then close without binding. The knurled plastic nut next to the enrichener knob controls the ease at which the cable slides within the conduit.

If adjustment is needed:

1. See Figure 4-3. Loosen hex nut at backside of mounting bracket.

2. Move cable assembly free of slot in mounting bracket.

3. Hold cable assembly at ﬂat with adjustable wrench. Hand turn knurled nut counterclockwise to reduce sliding resistance until knob slides inward unaided.

4. Turn knurled nut clockwise to increase sliding resistance until knob remains fully out without holding and then closes with relative ease.

Figure 4-3. Enrichener Control

5. Slide enrichener cable into slot of mounting bracket. Flat on threads must face rear of motorcycle for script on enrichener knob to be right side up. With external tooth lockwasher and hex nut positioned on the inboard side of the mounting bracket, tighten hex nut to 20-35 (2.3-4.0 Nm).

in-lbs

Do not lubricate the cable or inside of conduit. The cable must have sliding resistance to work properly.

2004 Touring: Fuel 4-7

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1. Top

2. Screw and washer (3)

3. Spring

4. Vacuum piston

5. Spring seat

6. Jet needle

7. Vacuum hose

8. Needle jet

9. Needle jet holder

10. Main jet

11. Slow jet

12. 4-sided Fuel valve with clip

13. Pin

14. Float

15. O-ring

16. O-ring

17. Screw and washer (4)

18. Cable guide

19. Starter cap

20. Cable sealing cap

21. Enrichener valve

22. Spring

23. Bracket, throttle cable

24. Screw (throttle cable bracket)

25. Screw (throttle cable bracket)

26. Screw (idle speed adjust)

27. Spring

28. Collar

29. Seal ring

30. Manifold

31. Flange

32. Seal, intake manifold (2)

33. Lever

34. Float bowl

35. E-clip

36. Accelerator pump nozzle

NOTE

With the exception of the jet sizes, all FL models are equipped with the same basic carburetor.

37. Spring

38. Pump housing

39. Spring

40. Diaphragm

41. O-Ring (2)

42. Washer

43. Screw (3)

44. Boot

45. Rod

46. Collar

47. Screw (4)

48. Rod

49. Cotter pin (2)

50. Washer

51. Washer

52. Washer

53. Washer

54. Collar

f2277x4x

4-8 2004 Touring: Fuel

Figure 4-4. Carburetor

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8982

Float Bowl

Vent

CARBURETOR 4.4

REMOVAL

1WARNING1WARNING

Gasoline is extremely ﬂammable and highly explosive. When servicing the fuel system, do not smoke or allow open ﬂame or sparks in the vicinity. Inadequate safety precautions could result in death or serious injury.

1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

2. Remove air cleaner assembly. See Section 4.5 AIR

CLEANER, REMOVAL.

3. Locate the fuel enrichener knob under the left side of the fuel tank, and loosen hex nut at backside of mounting bracket. Slide cable assembly free of slot in mounting bracket.

4. Rotate handle on fuel valve to the horizontal position to shut the gasoline supply to the carburetor OFF.

Figure 4-5. Drain Carburetor Float Bowl

1WARNING1WARNING

Some gasoline will drain from the fuel inlet hose when disconnected from the carburetor. Thoroughly wipe up any spilled fuel immediately. Dispose of rags in a suitable manner. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

5. Using a side cutters, cut clamp and remove fuel inlet hose from ﬁtting at side of carburetor.

NOTE

On California models, pull purge tube from ﬁtting on same side of carburetor.

6. Gently work carburetor free of seal ring on intake manifold.

1WARNING1WARNING

As the carburetor is removed, be sure to keep assembly upright as the ﬂoat bowl contains gasoline. Tilting the carburetor or turning it upside down will cause the gasoline to drain onto surrounding area. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

7. If cruise control equipped, remove E-clip from groove at end of cruise cable housing. Remove cruise cable housing from cable guide in throttle cable bracket. Push plastic end ﬁtting on cruise cable to outboard side to release from wheel pin.

8. Using a needle nose pliers, carefully pull idle cable barrel from upper inboard hole in throttle wheel. Pull throttle cable barrel from remaining hole. Release idle and throttle cables from guides in throttle cable bracket.

9. Pull vacuum hose elbow from ﬁtting on inboard side of carburetor.

10. Carefully remove carburetor while drawing enrichener cable to right side of motorcycle.

11. Keeping carburetor upright, move assembly to bench

area. Tilting carburetor, carefully pour gasoline in ﬂoat bowl into a suitable container. Gasoline will exit ﬂoat bowl vent shown in Figure 4-5.

INSTALLATION

1. Place carburetor into approximate position on right side of motorcycle while feeding enrichener cable over to left side.

2. Push vacuum hose elbow onto ﬁtting on inboard side of carburetor.

3. Install sleeve on throttle cable housing into shorter cable guide in throttle cable bracket. Drawing throttle cable downward, ﬁt barrel end into lower outboard hole in throttle wheel. Install sleeve and spring on idle cable housing into longer cable guide inserting barrel end into upper inboard hole in throttle wheel.

2004 Touring: Fuel 4-9

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8981

10. Install air cleaner assembly. See Section 4.5 AIR

CLEANER, INSTALLATION.

11. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

12. Rotate handle of fuel valve clockwise to the vertical position and carefully inspect for leaks. Return the valve to the OFF position when ﬁnished.

13. Adust the engine idle speed. See Section 4.3

ENRICHENER (CARBURETED), ADJUSTMENTS.

DISASSEMBLY

Vacuum Piston Chamber

Figure 4-6. Remove Enrichener Cable

4. Verify that cables are fully seated in channel of throttle wheel, and using cable adjusters at handlebar, tighten cables as necessary to keep barrel ends from dislodging. Verify operation by turning throttle grip and observing cable action.

5. If cruise control equipped, slide plastic end ﬁtting over cap of wheel pin. Push on end ﬁtting until it snaps in place. Slip cruise cable housing into cable guide in throttle cable bracket. Install cruise cable housing.

The ﬁt between the carburetor and seal ring is tight. Prior to assembly, lubricate mating surfaces with liquid dishwashing soap or tire mounting lube. Always install dried out, cracked or otherwise damaged.

6. Lubricate inside diameter of seal ring. Also apply a light ﬁlm of lubricant to carburetor housing where casting comes into contact with seal ring. Gently work carburetor into seal ring.

7. Slide

new

clamp onto free end of fuel inlet hose. Install hose onto brass ﬁtting at side of carburetor. Making sure clamp is positioned inboard of lip on ﬁtting, crimp clamp using HOSE CLAMP PLIERS (HD-97087-65B).

new

E-clip into groove at end of

NOTE

new

seal ring if

1. Placing a 14mm open end wrench on hex, loosen ﬁtting at enrichener bore of carburetor housing. See Fig-

ure 4-6. Rotate enrichener cable in a counterclockwise

direction to unthread ﬁtting and remove valve assembly.

2. Remove gold Phillips screw (with lockwasher) at side of carburetor to release throttle cable bracket. Remove gold Phillips screw (with top collar) to free throttle cable bracket from carburetor top. Set bracket aside.

3. Remove three remaining top screws to release carburetor top from body.

4. Remove vacuum piston spring. Carefully raise dia-

phragm to remove vacuum piston assembly. Remove spring seat and jet needle from vacuum piston bore. See

Figure 4-7.

plastic

Float Chamber

1. Turn carburetor upside down and remove four Phillips screws at bottom to remove ﬂoat bowl from carburetor body.

7754

Vacuum

Piston

NOTE

On California models, push purge tube onto ﬁtting on same side of carburetor.

8. Moving to left side of motorcycle, slide threaded portion of enrichener cable into slot of mounting bracket. Flat on threads must face rear of motorcycle for script on enrichener knob to be right side up. With the external tooth lockwasher and hex nut positioned on the inboard side of the mounting bracket, tighten hex nut to 20-35

lbs

(2.3-4.0 Nm).

9. Adjust throttle cables. See Section 2.21 THROTTLE

CABLES (NON-CRUISE), ADJUSTMENT.

4-10 2004 Touring: Fuel

in-

Spring

Jet

Needle

Figure 4-7. Vacuum Piston Chamber Components

Spring

Seat

Page 11

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7751

Wireform

Clip

Float

Float Pin

Fuel Valve

7750

Needle Jet

Main Jet

Needle Jet Holder

7755

Slow Jet

f1868x4x

Rod

Spring

O-Rings

Diaphragm

Rubber

Boot

NOTE

Since accelerator pump rod is now loose, remove from hole in lever at side of carburetor body.

CAUTION

Tapping the ﬂoat pin out from the squared pedestal side will result in damage that requires carburetor replacement

2. Using a small center punch and hammer, carefully tap ﬂoat pin from holes in pedestals. The rounded pedestal has an interference ﬁt to ensure that the ﬂoat pin is securely held, so always tap out the pin in the direction of the cast-in arrow (that is, from the interference side). See Figure 4-8.

3. Remove ﬂoat and fuel valve. Carefully slide clip on fuel valve from tab on ﬂoat. Remove wireform clip from groove in fuel valve. See A of Figure 4-9.

4. Using slot at top, turn main jet with ﬂat tip screwdriver to unthread from needle jet holder. If necessary, hold hex on needle jet holder with a 5/16 inch wrench to prevent rotation. See Figure 4-11.

5. Using a 5/16 inch wrench, turn hex on needle jet holder to unthread from main jet bore.

6. Turn carburetor right side up to drop out needle jet, which is loose in main jet bore. See B of Figure 4-9.

7. Insert thin bladed ﬂat tip screwdriver into slow jet bore. See Figure 4-11. Using slot at top of slow jet, unthread to remove. See C of Figure 4-9.

8. Disassemble accelerator pump from ﬂoat bowl. See Fig-

ure 4-10. Proceed as follows:

Figure 4-9. Float Chamber Components

Figure 4-8. Remove Float Pin in Direction of Arrow

Rounded

Pedestal

Float Pin

Arrow

a0183x4x

Figure 4-10. Accelerator Pump Components

a. Remove rubber boot from post at top of accelerator

pump upper housing.

b. Tu rn ﬂoat bowl upside down. Alternately loosen and

then remove three Phillips screws (with lockwashers) to release accelerator pump lower housing.

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c. Remove spring and diaphragm from accelerator

pump upper housing. Remove two O-rings from lower housing.

CLEANING AND INSPECTION

Carburetor Housing

1. Clean all internal air/fuel passages in carburetor housing with carburetor cleaner. Blow out passages using low pressure compressed air. Proceed as follows:

1WARNING1WARNING

Main Circuit

a. Plugging main jet hole in carburetor throat, spray

carburetor cleaner into air inlet hole of main circuit. See A of Figure 4-12. While spraying, verify that solution exits main jet bore at bottom of carburetor housing. See B of Figure 4-12.

b. Using a tapered, rubber-tipped nozzle on the air

hose (to prevent both loss of air pressure and to avoid scratching or nicking the bore), apply low pressure compressed air into air inlet hole to blow carburetor cleaner out of hole in carburetor throat. Placing gloved ﬁnger over hole in carburetor throat, blow carburetor cleaner out of main jet bore at bottom of carburetor housing.

Compressed air can pierce the skin and cause injury. Never use your hand to check for leaks or to determine air ﬂow rates. Wear safety glasses to shield your eyes from ﬂying dirt and debris. Failure to comply could result in death or serious injury.

Slow Speed Circuit

a. Spray carburetor cleaner into air inlet hole of slow

speed circuit. See A of Figure 4-12. While spraying, verify that solution exits slow jet bore at bottom of carburetor housing. See B of Figure 4-12. Placing gloved ﬁnger over slow jet bore, verify that solution exits four pin holes just inboard of the throttle plate, as well as the single pin hole outboard of the throttle plate.

b. Using a tapered, rubber-tipped nozzle on the air

hose (to prevent both loss of air pressure and to avoid scratching or nicking the bore), apply low pressure compressed air into air inlet hole to blow carburetor cleaner out of slow jet bore. Placing gloved ﬁnger over slow jet bore, blow carburetor cleaner out of pin holes inboard and outboard of throttle plate.

8979

Slow Jet

Main Jet

Fuel Valve

Bore

Figure 4-11. Carburetor Housing

Float Bowl Vent

a. Spray carburetor cleaner into air inlet hole of ﬂoat

bowl vent. See A of Figure 4-12. While spraying, verify that solution exits two holes in ﬂoat bowl chamber at bottom of carburetor housing. See B of Figure 4-

12.

b. Using a tapered, rubber-tipped nozzle on the air

hose (to prevent both loss of air pressure and to avoid scratching or nicking the bore), apply low pressure compressed air into air inlet hole of ﬂoat bowl vent to blow carburetor cleaner out of holes in ﬂoat bowl chamber.

Vacuum Piston Chamber Components

1. Thorougly clean all loose parts (except diaphragm) with carburetor cleaner. See Figure 4-7. Blow dry using low pressure compressed air.

1WARNING1WARNING

2. Inspect parts as follows: a. Hold vacuum piston up to strong light source. Exam-

ine diaphragm for pin holes, cuts, tears or pinching. Replace if any damage is found.

b. Examine passage at bottom of vacuum piston bore.

Verify that passage is clean and open.

c. Examine vacuum piston spring for stretching, kink-

ing, distortion or other damage. Inspect spring seat for cracks. Replace parts if necessary.

d. Examine slides at sides of vacuum piston to verify

that surfaces are clean and smooth. Clean or buff out any rough surfaces.

e. Examine tip of jet needle for grooves or scratches.

Needle should be completely straight, while surface condition at taper should be smooth and even. Replace needle if necessary.

4-12 2004 Touring: Fuel

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Slow Speed

Circuit

Air Inlet

Main Jet

Bore

Float Bowl

Vent

Air Inlet

Main Circuit

Air Inlet

Vent

Holes

Slow Jet

Bore

8980

8978

b. Inspect ﬂoat pin for damage or distortion. Replace

ﬂoat pin if corroded, nicked or bent.

c. Clean ﬂoat and inspect for cracks or other damage.

Submerge ﬂoat in a glass of water. Replace ﬂoat if not water tight.

d. Depress pin on fuel valve to verify that it returns to

the full-out position. Thoroughly clean valve with carburetor cleaner if pin is dirty or sticks. Inspect rubber cone on valve for dirt, cracks, hardening or wear. Inspect wireform clip for distortion. Replace fuel valve assembly if any of these conditions are found.

e. Inspect fuel valve seat in carburetor housing for dirt,

damage or corrosion. Replace carburetor if seat damage or corrosion is present.

f. Verify cleanliness of main jet, needle jet holder and

needle jet. Verify that oriﬁces in needle jet holder are clean and open. Replace parts if damaged.

g. Verify cleanliness of slow jet. Be sure that all oriﬁces

are clean and open. Replace jet if damaged.

Accelerator Pump

h. Inspect the accelerator pump diaphragm for holes,

cuts, tears or cracks. Replace diaphragm if deformed or damaged.

i. Examine spring for stretching, kinking or distortion.

Replace if any damage is found.

j. Inspect the accelerator pump rod for straightness.

Replace the rod if bent.

k. Inspect rubber boot and two O-rings for cuts, tears

or signs of deterioration. Replace if necessary.

Figure 4-12. Clean Air/Fuel Passages

Float Chamber Components

1. Thorougly clean all loose parts with carburetor cleaner. See Figure 4-9. Blow dry using low pressure compressed air.

1WARNING1WARNING

2. Inspect parts as follows:

a. Inspect O-ring in groove of ﬂoat bowl for cuts, tears

or signs of deterioration. Replace O-ring if distorted or if sealing surface is damaged.

ASSEMBLY

Vacuum Piston Chamber

1. Install vacuum piston into carburetor body. Slides on piston are offset, so piston will ﬁt into slide track groove only one way. If vacuum piston does not ﬁt, rotate assembly 180

2. Insert jet needle into vacuum piston bore, so that it enters center hole at bottom. In the installed position, head of needle contacts boss at bottom of vacuum piston bore, while length of shaft resides in main jet bore.

3. With the legged side down, slide spring seat over top of needle in vacuum piston bore. Slide spring over spring seat.

4. Verify that lip on edge of diaphragm is seated in groove of carburetor ﬂange.

NOTE Diaphragm expands when in contact with fuel. If diaphragm is difﬁcult to seat in groove because of this condition, allow diaphragm to dry before attempting to install.

2004 Touring: Fuel 4-13

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5. Fit free end of spring over boss on inboard side of carburetor top, and keeping spring straight, align holes in top with those in ﬂange.

6. Holding top to ﬂange, check for proper diaphragm seal by pushing up on vacuum piston (from intake side) and releasing. If diaphragm is sealed correctly, very slight resistance should be felt when pushing up, and piston should be slow to extend. If piston movement is restricted, spring is cocked. Lift up on top and then lower carefully keeping spring coils straight.

7. Install three black top screws in holes furthest from throttle wheel. Alternately tighten screws until snug.

8. Slide gold top collar into remaining hole in carburetor top. With end of idle screw resting against idle cam stop, align holes in throttle cable bracket with those in carburetor body and top cover. To prevent bending bracket or cam stop, ﬁrst install gold Phillips screw (with lockwasher) at side of carburetor. At carburetor top, install remaining Phillips screw.

Start Float Position

Correct Float Position

a0186x4x

Float

Intake Manifold Side Down

9. Carefully insert enrichener valve into carburetor bore. Start threaded end of plastic ﬁtting into bore, and then rotate cable in a clockwise direction to install. Exercising caution to avoid damaging the plastic construction, tighten ﬁtting using a 14mm open end wrench. See Fig-

ure 4-6.

Float Chamber

1. Place needle jet into main jet bore. See Figure 4-11. Be sure end with chamfered edge and larger ID goes in ﬁrst.

2. Insert needle jet holder into main jet bore, and using a 5/ 16 inch wrench, turn hex until snug.

3. Thread main jet into needle jet holder. Using slot at top of main jet, tighten with ﬂat tip screwdriver until snug.

4. Insert slow jet into slow jet bore. See Figure 4-11. Insert thin bladed ﬂat tip screwdriver into bore, and using slot at top of slow jet, tighten until snug.

5. Install wireform clip into groove on pin side of fuel valve, if removed. Using wireform clip, carefully hang fuel valve onto tab of ﬂoat, so that tip of rubber cone hangs ﬂush with top of ﬂoat (the top being the side opposite the pivot arm).

6. Place ﬂoat into cavity of carburetor inserting fuel valve into bore between pedestals. See Figure 4-11.

CAUTION

Tapping the ﬂoat pin in from the rounded pedestal side will result in damage that requires carburetor replacement.

Float

0.413- 0.453 in.

(10.49-11.51 mm)

15˚ to 20˚

Pin Return Spring Collapsed

Incorrect Float Position

Float

Greater Than 20˚

Figure 4-13. Float Check and Adjustment

7. Insert ﬂoat pin through squared pedestal and pivot arm of ﬂoat into rounded pedestal. Since the rounded pedestal has an interference ﬁt to ensure that the ﬂoat pin is securely held, always install pin from the loose side (in the direction opposite the cast-in arrow). Using a small center punch and hammer, carefully tap ﬂoat pin until ends are ﬂush with outboard sides of pedestals.

8. Perform ﬂoat level check as follows:

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a. Place carburetor on a clean ﬂat surface with the

intake manifold side down. See A of Figure 4-13.

b. Tilt the carburetor 15

direction until ﬂoat comes to rest. See B of Figure 4-

13.

The measurements will be incorrect if the carburetor is tilted less than 15 ° or more than 20 °.

c. Using a dial vernier caliper or dial caliper depth

gauge, measure the distance from the face of the carburetor ﬂange to the outboard edge of the ﬂoat. Be careful not to push on ﬂoat while measuring.

d. If the measurement is between 0.413 inch and

0.453 inch (10.49 -11.51 mm), then the ﬂoat level is within speciﬁcation. Proceed to step 9.

e. If the ﬂoat level is not within speciﬁcation, remove

the ﬂoat, and referencing the table below, carefully bend the tab slightly to adjust the ﬂoat level. For example, to increase the ﬂoat measurement, bend the tab toward the carburetor body. This will have the affect of decreasing the amount of gas in the ﬂoat bowl after assembly.

to 20° in a counter-clockwise

NOTE

Table 4-1. Float Level Tab

Float

Measurement

To Increase

To D e crease

Bend Tab

oward

Carburetor Body

way From

Carburetor Body

Amount of Gas

in Float Bowl

Decreased

Increased

f. Install ﬂoat and check ﬂoat level again. Repeat pro-

cedure as necessary until ﬂoat level is within speciﬁcation.

9. Install new O-ring into groove of ﬂoat bowl, if removed. Be sure to thoroughly clean groove before O-ring installation.

10. Assemble accelerator pump as follows:

a. With the ﬂat side toward the casting, install two O-

rings into counterbores of accelerator pump lower housing.

b. Install diaphragm into accelerator pump upper

housing. Verify that lip on edge of diaphragm is fully seated in groove.

c. Place spring onto spring seat at center of installed

diaphragm.

d. Keeping spring straight, mate upper and lower

housings of accelerator pump. Install three Phillips screws (with lockwashers).

e. Install rubber boot onto post at top of accelerator

pump upper housing.

f. Hook accelerator pump rod into hole on inboard

side of lever at side of carburetor body.

11. Install ﬂoat bowl at bottom of carburetor body engaging free end of accelerator pump rod in hole of rubber boot.

12. Install four Phillips screws to secure ﬂoat bowl at bottom of carburetor body. Tighten screws until snug.

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AIR CLEANER 4.5

GENERAL

At the 1000 mile (1600 km) service interval, and at every 5000 mile (8000 km) service interval thereafter, inspect the air cleaner ﬁlter element, and clean or replace as necessary.

REMOVAL

1. Remove large allen head socket screw in center of air cleaner cover. Remove air cleaner cover with rubber seal. See Figure 4-14.

2. Remove three T27 TORX screws to release cover bracket from ﬁlter element.

3. Remove ﬁlter element pulling two breather tubes from holes on inboard side.

4. Remove gasket from sleeve on inboard side of ﬁlter element. Discard gasket.

5. Remove breather tubes from ﬁttings on two cylinder head breather bolts.

6. Remove two cylinder head breather bolts from backplate using a 7/16 inch deepwell socket.

7. Remove backplate from cylinder heads. On carbureted California models, pull clean air inlet tube (to charcoal canister) from hole on inboard side of backplate.

8. Remove two O-rings from grooves around breather bolt holes on inboard side of backplate. Discard O-rings.

9. Remove gasket from inboard side of backplate. Discard gasket.

CLEANING AND INSPECTION

1. Thoroughly clean air cleaner cover and backplate.

2. Replace the ﬁlter element if damaged or if ﬁlter media cannot be adequately cleaned.

1WARNING1WARNING

Do not use gasoline or solvents to clean the ﬁlter element. Volatile or ﬂammable cleaning agents may cause an intake system ﬁre, which could result in death or serious injury.

3. Wash the ﬁlter element and breather tubes in warm, soapy water. To remove soot and carbon, soak element for 30 minutes in warm water with mild detergent.

Gasket

O-Ring

Cylinder Head

Breather Bolt

Backplate

Breather

Tube

Cover

Bracket

Gasket

Filter

Element

Figure 4-14. Air Cleaner Assembly

T27 Torx

Screw

f1650x4x

Air Cleaner

Cover

Cover Screw

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1WARNING1WARNING

4. Dry the ﬁlter element using low pressure compressed air (32 psi/221 kPa maximum). Rotate the element while moving air nozzle up and down the element interior. Do not rap the element on a hard surface.

5. Hold the ﬁlter element up to a strong light source. The element can be considered sufﬁciently clean if light is uniformly visible through the media.

6. Inspect the breather tubes for cuts, tears, holes or signs of deterioration. Replace as necessary. Direct compressed air through breather tubes to verify that they are not plugged.

INSTALLATION

NOTE

Air cleaner mounting without installation of the breather tubes allows crankcase vapors to be vented into the atmosphere in violation of legal emissions standards.

8. Place ﬁlter element onto backplate with the ﬂat side down, so that hole on inboard side of element ﬁts over molded boss in backplate.

9. Align holes in cover bracket with those in ﬁlter element and start three screws. Stamp on cover bracket points to downside. Using a T27 TORX drive head, alternately tighten screws to 20-40

10. Verify that rubber seal is properly seated around perimeter of air cleaner cover. Replace seal if cut, torn or shows signs of deterioration.

11. Fit air cleaner cover into backplate. Apply a small dab of Loctite Medium Strength Threadlocker 243 (blue) to threads of large allen head socket screw. Install screw in center of air cleaner cover and tighten to 36-60 (4.1-6.8 Nm).

in-lbs

(2.3-4.5 Nm).

in-lbs

1. Install

2. Aligning ﬂat edge of gasket with molded tab, install

3. On California models, push clean air inlet tube (to char-

4. Align holes in backplate with those in cylinder heads and

5. Slide

6. Insert breather tubes about 1/4 inch (6.4 mm) into holes

7. Install breather tubes onto ﬁttings of two cylinder head

new

O-rings in grooves around breather bolt

holes on inboard side of backplate.

new

gasket on inboard side of backplate. On California models, install gasket by aligning small holes with plastic pins.

coal canister) into hole on inboard side of backplate.

install cylinder head breather bolts. Using a 7/16 inch deepwell socket, alternately tighten bolts to 120144

in-lbs

(13.6-16.3 Nm).

new

gasket over sleeve on inboard side of ﬁlter element. Be sure holes in gasket are aligned with those in ﬁlter.

on inboard side of ﬁlter element.

breather bolts.

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VACUUM OPERATED FUEL VALVE (CARBURETED) 4.6

GENERAL

A fuel valve is located under the fuel tank on the left side of the motorcycle. The gasoline supply to the carburetor is dependent upon the position of the valve handle as well as the internal workings of the vacuum-operated valve.

To access the main fuel supply, turn the valve handle to the fully vertical position, so that the indicator points up to ON. To access the reserve supply, turn the handle up to the fully vertical position, so that the indicator points down to RES(ERVE). Move the handle to the horizontal position to shut the gasoline supply to the carburetor OFF. Always turn the valve to the OFF position to refuel, or whenever the engine is not running.

Gasoline will not ﬂow through the fuel valve until the following conditions are met:

1. The valve handle must be turned to the ON or RES(ERVE) position.

2. A vacuum of approximately 0.5-1.0 inches of Mercury (Hg) must be applied to the vacuum ﬁtting at the back of the fuel valve.

In service, the vacuum ﬁtting is connected to the intake manifold. The partial vacuum applied at the ﬁtting creates a difference in pressure between the front side of the diaphragm (which is vented to the atmosphere via the bottom ﬁtting on the fuel valve) and the rear. This pressure differential causes the diaphragm to move against an internal spring, thereby opening an oriﬁce that enables the ﬂow of gasoline to the carburetor. When the vacuum at the vacuum ﬁtting is removed, the internal spring pressure closes the oriﬁce, which effectively halts the supply of fuel to the carburetor.

down

f1960x4x

Carburetor

Fuel Inlet

Hose

Convoluted

Tubing

Hose

Clamp

Fuel

Outlet

Fitting

Filter

Strainer

Jam

Nut

Gasket

Valve

Handle

Vacuum

Fitting

Atmospheric

Pressure

Port

TROUBLESHOOTING

If the fuel valve is not functioning properly, refer to the troubleshooting chart on the next page.

REMOVAL

DRAINING FUEL TANK

1WARNING1WARNING

4-18 2004 Touring: Fuel

Figure 4-15. Vacuum Operated Fuel Valve

1. Turn the handle of the fuel valve to OFF.

1WARNING1WARNING

A small amount of gasoline may drain from the carburetor fuel inlet hose when disconnected from the fuel valve ﬁtting. Thoroughly wipe up any spilled fuel immediately and dispose of rags in a suitable manner. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

2. Using a side cutters, cut clamp and remove hose from fuel outlet ﬁtting at the front of the fuel valve. See Figure

4-15. Drain free end of hose into a suitable container.

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1WARNING1WARNING

3. Remove elbow of intake manifold vacuum tube from ﬁtting on inboard side of the fuel valve.

4. Attach a length of fuel hose to the fuel outlet ﬁtting. The hose must be long enough to reach a suitable gasoline container.

5. Turn the handle of the fuel valve to RES(ERVE).

6. Using the correct hose adapter, connect the Mity-Vac® Hand Pump (HD-23738A) to the vacuum ﬁtting.

CAUTION

To avoid damage to the diaphragm of the fuel valve, do not apply a vacuum greater than 25 inches of Mercury (Hg) to the vacuum ﬁtting.

7. Gently apply a vacuum of 1-10 inches of Mercury (Hg) to the vacuum ﬁtting to get a good ﬂow of gasoline through the valve.

8. When the fuel tank is completely drained, remove the Mity-Vac® Hand Pump from the vacuum ﬁtting.

9. Holding fuel tank adapter, turn the hex jam nut in a clockwise direction to remove the fuel valve assembly.

10. Remove the fuel ﬁlter strainer from the valve head.

11. Remove the hex jam nut from the fuel valve.

12. Remove the gasket from the valve head. Discard the gasket.

CLEANING AND INSPECTION

1. Clean or replace the fuel ﬁlter strainer.

2. Flush the tank. See Section 4.7 FUEL TANK (CARBU-

RETED), CLEANING AND INSPECTION.

INSTALLATION

1. Install a

2. Install the fuel ﬁlter strainer ﬁtting the internal tube into the larger hole in the valve head.

3. Apply Loctite Pipe Sealant with Teﬂon 565 to threads of fuel valve and fuel tank adapter.

4. With the hex side down, turn the jam nut two full turns in a counterclockwise direction to thread onto fuel tank adapter.

5. Insert fuel ﬁlter strainer into fuel tank. Holding the hex jam nut to prevent rotation, turn the fuel valve two full turns in a clockwise direction to thread onto hex jam nut.

Do not thread fuel valve onto hex jam nut more than two turns or nut may “bottom” on valve, a condition which may result in a gasoline leak. Any gasoline leak is a potential ﬁre hazard that could result in death or serious injury.

new

gasket on the valve head.

Table 4-2. Troubleshooting Vacuum Operated Fuel Valve

Problem Cause Solution

1. Vacuum valve not opening. 1.1 Hose not connected to vacuum ﬁtting.

1.2 Leaking diaphragm. 1.2.1 Replace fuel valve assembly.

1.3 Hose connected to atmospheric pressure port.

1.4 Vacuum hose assembly pinched or cracked.

2. Vacuum valve does not close. 2.1 Damaged sealing surface on valve side of diaphragm.

2.2 Plugged vacuum ﬁtting.

2.3 Broken or missing internal spring.

3. Valve leaks gasoline at atmospheric pressure port.

3.1 Leaking diaphragm. 3.1.1 Replace fuel valve assembly.

3.2 Loose diaphragm housing screws.

1.1.1 Connect hose to vacuum ﬁtting.

1.3.1 Connect hose to vacuum ﬁtting.

1.4.1 Replace vacuum hose assembly.

2.2.1 Replace fuel valve assembly.

2.2.2 Clean as necessary.

2.3.1 Replace fuel valve assembly.

3.2.1 Tighten screws.

2004 Touring: Fuel 4-19

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6. Holding the fuel valve to prevent rotation, turn the hex jam nut in a counterclockwise direction until snug. Tighten the hex jam nut to 15-20 ft-lbs (20.3-27.1 Nm).

CAUTION

Do not allow dirt or ﬂuids to get into the vacuum tube that connects the fuel valve to the intake manifold. Contaminants can block the vacuum signal which could cause the fuel valve to malfunction.

7. Connect elbow of intake manifold vacuum tube to ﬁtting on inboard side of the fuel valve.

8. Slide new clamp onto free end of carburetor fuel inlet hose. Install hose onto fuel outlet ﬁtting at front of fuel valve. Crimp clamp using HOSE CLAMP PLIERS (HD97087-65B).

9. Turn the handle of the fuel valve to OFF and ﬁll the fuel tank. Carefully inspect for leaks at ﬁtting.

10. Turn the valve handle to ON and start engine. No priming or special procedures are required to start fuel ﬂow. Carefully inspect for leaks at ﬁtting.

11. Stop engine and return the valve to the OFF position.

f2052x4x

Fuel Tank

Side

O-Ring

Figure 4-16. Fuel Tank Adapter

FUEL TANK ADAPTER

If leakage or damage is observed at the fuel tank adapter, replace O-ring and/or adapter as follows:

1. Remove fuel valve assembly. See REMOVAL in this sec- tion.

2. Slide a 7/8 inch socket over hex on adapter, and looking down at top of fuel tank, rotate in a clockwise direction to remove. See Figure 4-16.

3. Remove O-ring from adapter. Discard O-ring.

4. Apply a very thin ﬁlm of clean H-D 20W50 engine oil to new O-ring. Install O-ring into groove of adapter.

5. Hand thread adapter into fuel tank bore. Looking down at top of fuel tank, rotate adapter in a countercloc direction until snug.

6. Slide a 7/8 inch socket over hex and tighten to 22-26 ftlbs (30-35 Nm).

7. Install fuel valve assembly. See INSTALLATION in this section.

kwise

4-20 2004 Touring: Fuel

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1WARNING1WARNING

f1924x8x

Fuel Tank

Fuel Vapor

Vent Tube

(To Vapor Valve)

Fuel Tank Harness

Connector [13]

Not Present on FLHR/C/S

FUEL TANK (CARBURETED) 4.7

COMPLETE REMOVAL

NOTE

For fuel injected models, see Section 9.4 FUEL TANK (FUEL

INJECTED) for removal and installation instructions.

FLHT/C

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

1WARNING1WARNING

To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury.

2. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal.

1WARNING1WARNING

Figure 4-17. Fuel Level Sender Connector (FLHT/C)

3. Drain the fuel tank. See Section 4.6 VACUUM OPER-

ATED FUEL VALVE (CARBURETED), DRAINING FUEL TANK, steps 1-8.

4. Carefully cut anchored cable strap securing main harness bundles, fuel level sender conduit, and fuel vapor vent tube to left side of frame backbone.

5. Disconnect fuel tank harness connector [13], 3-place Multilock, in front of battery. See Figure 4-17.

6. Open fuel door on console. Remove two Allen head screws inboard of rubber bumpers. These screws secure console to clip nuts on the canopy bracket.

7. Remove Allen head screw to detach ﬂange at rear of console from clip nut on fuel tank weldment.

8. Lay a clean shop cloth on forward part of rear fender. Remove ﬁller cap from neck of fuel tank. Remove console and lay upside down on shop cloth. Reinstall ﬁller cap.

9. Gently pry fuel vapor vent tube from ﬁtting on ﬁller neck of fuel tank. Exercise caution to avoid pulling ﬁtting from ﬁller neck.

10. Remove two fuel tank front mounting bolts (with ﬂat washers) from left and right side of frame. Remove bolt (with ﬂat washer) to free rear of fuel tank from frame backbone.

A small amount of gasoline may drain from the crossover hose when disconnected from the fuel tank. Thoroughly wipe up any spilled fuel immediately and dispose of rags in a suitable manner. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

11. Using a side cutters, cut clamp from one end of crossover hose beneath fuel tank. Drain free end of hose into a suitable container.

12. Remove fuel tank from motorcycle.

FLHR/S

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury.

2. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal.

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1WARNING1WARNING

3. Drain the fuel tank. See Section 4.6 VACUUM OPER-

ATED FUEL VALVE (CARBURETED), DRAINING FUEL TANK, steps 1-8.

4. Remove two fuel tank front mounting bolts (with ﬂat washers) from left and right side of frame. Remove bolt (with ﬂat washer) to free rear of fuel tank from frame backbone. On FLHRS models, removal of rear bolt also releases instrument console bracket.

5. Carefully cut anchored cable strap securing main harness bundle, instrument console conduit, and fuel vapor vent tube to left side of frame backbone.

6. Remove acorn nut from instrument console. If present, also remove Phillips screw and large ﬂat washer (absent on FLHRS models).

7. Raise instrument console and bend back ﬂexible clamp on canopy to release main harness conduit. Depress button on socket side and remove fuel level sender connector [141], 3-place Mini-Deutsch.

CAUTION

When removing instrument console, exercise caution to avoid damaging speedometer unit. Wrap console in a clean, dry shop towel to prevent damage.

8. Secure instrument console to top of rear fender using bungee cords.

9. Remove console mounting bolt from slot at top of canopy.

10. Gently pry fuel vapor vent tube from ﬁtting.

11. At bottom left side of fuel tank, gently pull on convoluted tubing to draw fuel gauge connector [117], 4-place Multilock, out of tunnel. Depress button on socket terminal side and pull apart pin and socket halves.

1WARNING1WARNING

A small amount of gasoline may drain from the crossover hose when disconnected from the fuel tank. Thoroughly wipe up any spilled fuel immediately and dis-pose of rags in a suitable manner. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

12. Using a side cutters, cut clamp from one end of crossover hose beneath fuel tank. Drain free end of hose into a suitable container.

13. Remove fuel tank from motorcycle.

CLEANING AND INSPECTION

1. Inspect the fuel tank for leaks and other damage. Replace damaged tanks that cannot be successfully repaired.

2. If sludge, rust or varnish deposits are evident, clean fuel tank as follows:

1WARNING1WARNING

Even with the fuel tank completely drained, a small amount of gasoline may leak from the bore when the fuel valve is loosened or removed. Thoroughly wipe up any spilled fuel immediately and dispose of rags in a suitable manner. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

a. Remove the fuel valve assembly and plug fuel tank

opening. See Section 4.6 VACUUM OPERATED

FUEL VALVE (CARBURETED), REMOVAL.

b. Remove canopy as follows:

FLHT/C, FLTR: See Section 8.29 FUEL LEVEL

SENDER (CARBURETED), FLHT/C CANOPY, REMOVAL, steps 11-13.

FLHR: See Section 8.29 FUEL LEVEL SENDER

(CARBURETED), FLHR/S CANOPY, REMOVAL,

steps 10-12.

1WARNING1WARNING

An open ﬂame or spark may cause a fuel tank explosion if all traces of fuel are not purged from the tank. Use extreme caution when servicing fuel tanks. Inadequate safety precautions could result in death or serious injury.

c. Fill the tank with commercial cleaning solvent or a

soap and water solution. Shake the tank to agitate the cleaning agent.

1WARNING1WARNING

To assist in loosening deposits, use only non-ferrous metal balls (such as lead pellets) with fuel tank cleaning solutions. The use of ferrous materials may cause a spark, which can then ignite fuel vapors inside the tank. The resulting ﬂames or explosion could result in death or serious injury.

d. If necessary, non-ferrous metallic balls or pellets

may be added to the tank to help loosen deposits.

e. Thoroughly ﬂush the fuel tank after cleaning. Allow

tank to air dry.

f. Install fuel valve assembly. See Section 4.6 VAC-

UUM OPERATED FUEL VALVE (CARBURETED), INSTALLATION.

4-22 2004 Touring: Fuel

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f1739b9x

Console

Fuel

Tank

Anchored

Cable Strap

Fuel

Overﬂow

Hose

Main

Harness

Bundle

Main

Harness

Bundle

Fuel Vapor

Vent Tube

(To Vapor Valve)

Fuel Level

Sender Conduit

Hose Cutter

Part No. HD-41185

3. Slide new clamp onto free end of carburetor fuel inlet

hose. Install hose onto fuel outlet ﬁtting at side of fuel valve. Crimp clamp.

4. Install the intake manifold vacuum hose onto the vacuum ﬁtting at the back of the fuel valve.

Hose Clamp Pliers

Part No. HD-97087-65B

Figure 4-18. Hose Cutter/Hose Clamp Pliers

g. Install canopy as follows:

FLHT/C, FLTR: See Section 8.29 FUEL LEVEL

SENDER (CARBURETED), FLHT/C CANOPY, INSTALLATION, steps 1-3.

FLHR: See Section 8.29 FUEL LEVEL SENDER

(CARBURETED), FLHR/S CANOPY, INSTALLATION, steps 1-3.

3. Inspect crossover hose for cuts, cracks, nicks or other damage. Be sure aging has not caused the hose to become hard and brittle. If replacing from bulk storage, use SAE R9 or equivalent fuel hose only. Remove old hose and cut new hose to same length using HOSE CUTTER (HD-41185). See Figure 4-18.

5. Star

6. Install bolt (with ﬂat washer) to secure rear of fuel tank to

7. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

8. Connect fuel vapor vent tube to ﬁtting on ﬁller neck of

9. Remove ﬁller cap. Position console on canopy. Route

10. Install Allen head screw to fasten rear ﬂange of console

11. Open fuel door on console. Install two Allen head screws

t fuel tank front mounting bolts (with ﬂat washers)

into left and right side of frame.

frame backbone. Tighten bolt to 15-20 ft-lbs (20-27 Nm).

27 Nm).

fuel tank.

cables from beneath console as shown in Figure 4-19. Be sure that hoses and wires are not pinched by the console during installation. Reinstall ﬁller cap.

to clip nut on fuel tank weldment. Tighten screw to 25-30 in-lbs (2.8-3.4 Nm).

to secure front of console to clip nuts on canopy bracket. Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).

INSTALLATION (AFTER COMPLETE REMOVAL)

FLHT/C

CAUTION

Exercise caution to avoid pinching wire harness between fuel tank and vehicle frame. Wire damage may result in electrical problems.

1. Work fuel tank into position aligning front ﬂange holes with those in frame.

2. Slide new clamp onto free end of crossover hose. Run-

ning hose beneath frame backbone, install hose onto ﬁtting at bottom front of fuel tank. Crimp clamp using HOSE CLAMP PLIERS (HD-97087-65B). See Figure 4-

18.

Figure 4-19. Console Cable/Hose Routing -FLHT/C, FLTR

(Top View)

2004 Touring: Fuel 4-23

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12. Connect fuel tank harness connector [13], 3-place Multilock, in front of battery. See Figure 4-17.

13. Snap anchor of new cable strap into hole on left side of frame backbone. Tighten cable strap capturing main harness bundles, fuel level sender conduit, and fuel vapor vent tube. Cut any excess cable strap material.

NOTE

Route fuel overﬂow hose inboard of wire bundles on right side of frame, but do not capture in cable straps. See Figure 4-19.

14. Insert bolt through battery negative cable (black) into threaded hole of battery negative (-) terminal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).

15. Install seat. See Section 2.24 SEAT, INSTALLATION.

16. Turn the handle of the fuel valve to OFF and ﬁll the fuel tank. Carefully inspect for leaks. Turn the valve handle to ON and start engine. Repeat inspection.

17. Stop engine and return the valve to the OFF position.

FLHR/S

CAUTION

Exercise caution to avoid pinching the wiring harness between the fuel tank and vehicle frame. Wire damage may result in electrical problems.

1. Work fuel tank into position aligning front ﬂange holes with those in frame.

2. Slide new clamp onto free end of crossover hose. Running hose beneath frame backbone, install hose onto ﬁtting at bottom front of fuel tank. Crimp clamp using HOSE CLAMP PLIERS (HD-97087-65B).

3. Slide new clamp onto free end of carburetor fuel inlet hose. Install hose onto fuel outlet ﬁtting at side of fuel valve. Crimp clamp.

4. Install the intake manifold vacuum hose onto the vacuum ﬁtting at the back of the fuel valve.

5. Connect fuel vapor vent tube to ﬁtting at top of canopy.

6. Slide head of console mounting bolt into slot at top of canopy.

7. Moving instrument console toward installed position, install fuel level sender connector [141], 3-place MiniDeutsch, at top of canopy. Bend ﬂexible clamp to capture main harness conduit.

8. Align hole in instrument console with console mounting bolt and place into position on fuel tank.

9. Star

10. Install bolt (with ﬂat washer) to secure rear of fuel tank to

t fuel tank front mounting bolts (with ﬂat washers)

into left and right side of frame.

frame backbone. On FLHRS models, capture instrument console bracket during installation. Tighten bolt to 15-20 ft-lbs (20-27 Nm).

Convoluted

Tubing

8870

Figure 4-20. Fuel Gauge (FLHR/S)

11. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (2027 Nm).

12. Install acorn nut at top of instrument console and tighten to 50-90 in-lbs (5.7-10.2 Nm). If present, also install Phillips screw and large ﬂat washer (absent on FLHRS models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).

13. Connect fuel gauge to main harness. Route pin housing and convoluted tubing forward and then inboard between front of crossover hose ﬁtting and bottom of fuel tank. Mate pin and socket halves of fuel gauge connector [117], 4-place Multilock. Feed connector into tunnel of fuel tank. See Figure 4-20.

14. Snap anchor of new cable strap into hole on left side of frame backbone. Tighten cable strap capturing main harness bundle, instrument console conduit, and fuel vapor vent tube. Cut any excess cable strap material.

NOTE Route fuel overﬂow hose inboard of wire bundles on right side of frame, but do not capture in cable straps. See Figure 4-19.

15. Insert bolt through battery negative cable (black) into

threaded hole of battery negative (-) terminal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).

16. Install seat. See Section 2.24 SEAT, INSTALLATION.

17. Turn the handle of the fuel valve to OFF and ﬁll the fuel

tank. Carefully inspect for leaks. Turn the valve handle to ON and start engine. Repeat inspection.

18. Stop engine and return the valve to the OFF position.

PARTIAL REMOVAL

NOTE For fuel injected models, see Section 9.4 FUEL TANK (FUEL

INJECTED) for removal and installation instructions.

FLHT/C

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

4-24 2004 Touring: Fuel

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CAUTION

1WARNING1WARNING

To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury.

2. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal.

3. Carefully cut anchored cable strap securing main harness bundles, fuel level sender conduit, and fuel vapor vent tube to left side of frame backbone.

4. Disconnect fuel tank harness connector [13], 3-place Multilock, in front of battery. See Figure 4-17.

5. Open fuel door on console. Remove two Allen head screws inboard of rubber bumpers. These screws secure console to clip nuts on the canopy bracket.

6. Remove Allen head screw to detach ﬂange at rear of console from clip nut on fuel tank weldment.

7. Lay a clean shop cloth on forward part of rear fender. Remove ﬁller cap from neck of fuel tank. Remove console and lay upside down on shop cloth. Reinstall ﬁller cap.

8. Gently pry fuel vapor vent tube from ﬁtting on ﬁller neck of fuel tank. Exercise caution to avoid pulling ﬁtting from ﬁller neck.

9. Remove two fuel tank front mounting bolts (with ﬂat washers) from left and right side of frame. Remove bolt (with ﬂat washer) to free rear of fuel tank from frame backbone.

10. Raise the fuel tank approximately 2 inches. Move the fuel tank crossover hose to the rear of the ignition coil, so that the tank can be raised an additional 2-3 inches. Move fuel tank straight back and rest on frame backbone.

11. Obtain three 1 x 2 inch wooden blocks. Raise the front of the fuel tank off the frame backbone by placing one block in the recess centered at the bottom of the tank. At the rear of the tank, place two blocks in the recess, one block on top of the other.

3. Remove two fuel tank front mounting bolts (with ﬂat washers) from left and right side of frame. Remove bolt (with ﬂat washer) to free rear of fuel tank from frame backbone. On FLHRS models, removal of rear bolt also releases instrument console bracket.

4. Carefully cut anchored cable strap securing main harness bundle, instrument console conduit, and fuel vapor vent tube to left side of frame backbone.

5. Remove acorn nut from instrument console. If present, also remove Phillips screw and large ﬂat washer (absent on FLHRS models).

6. Raise instrument console and bend back ﬂexible clamp on canopy to release main harness conduit. Depress button on socket side and remove fuel level sender connector [141], 3-place Mini-Deutsch.

When removing instrument console, exercise caution to avoid damaging speedometer unit. Wrap console in a clean, dry shop towel to prevent damage.

7. Secure instrument console to top of rear fender using bungee cords.

8. Remove console mounting bolt from slot at top of canopy.

9. Gently pry fuel vapor vent tube from ﬁtting.

10. At bottom left side of fuel tank, gently pull on convoluted tubing to draw fuel gauge connector [117], 4-place Multilock, out of tunnel. Depress button on socket terminal side and pull apart pin and socket halves.

11. Raise the fuel tank approximately 2 inches. Move the fuel tank crossover hose to the rear of the ignition coil, so that the tank can be raised an additional 2-3 inches. Move fuel tank straight back and rest on frame backbone.

12. Obtain three 1 x 2 inch wooden blocks. Raise the front of the fuel tank off the frame backbone by placing one block in the recess centered at the bottom of the tank. At the rear of the tank, place two blocks in the recess, one block on top of the other.

FLHR/S

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

1WARNING1WARNING

To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury.

2. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal.

INSTALLATION (AFTER PARTIAL REMOVAL)

FLHT/C

1. Remove wooden blocks and move fuel tank toward its installed position. Half way down, move fuel tank crossover hose in front of ignition coil. Work fuel tank into position aligning front ﬂange holes with those in frame.

2004 Touring: Fuel 4-25

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CAUTION

Exercise caution to avoid pinching the wiring harness between the fuel tank and vehicle frame. Wire damage may result in electrical problems.

2. Star

3. Install bolt (with ﬂat washer) to secure rear of fuel tank to

4. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

5. Connect fuel vapor vent tube to ﬁtting on ﬁller neck of

6. Remove ﬁller cap. Position console on canopy. Route

7. Install Allen head screw to fasten rear ﬂange of console

8. Open fuel door on console. Install two Allen head screws

9. Connect fuel tank harness connector [13], 3-place Mul-

10. Snap anchor of new cable strap into hole on left side of

t fuel tank front mounting bolts (with ﬂat washers)

into left and right side of frame.

frame backbone. Tighten bolt to 15-20 ft-lbs (20-27 Nm).

27 Nm).

fuel tank.

cables from beneath console as shown in Figure 4-19. Be sure that hoses and wires are not pinched by the console during installation. Reinstall ﬁller cap.

to clip nut on fuel tank weldment. Tighten screw to 25-30 in-lbs (2.8-3.4 Nm).

to secure front of console to clip nuts on canopy bracket. Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).

tilock, in front of battery. See Figure 4-17.

frame backbone. Tighten cable strap capturing main harness bundles, fuel level sender conduit, and fuel vapor vent tube. Cut any excess cable strap material.

2. Connect fuel vapor vent tube to ﬁtting at top of canopy.

3. Slide head of console mounting bolt into slot at top of canopy.

4. Moving instrument console toward installed position, install fuel level sender connector [141], 3-place MiniDeutsch, at top of canopy. Bend ﬂexible clamp to capture main harness conduit.

5. Align hole in instrument console with console mounting bolt and place into position on fuel tank.

6. Star

7. Install bolt (with ﬂat washer) to secure rear of fuel tank to

8. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

9. Install acorn nut at top of instrument console and tighten

10. Connect fuel gauge to main harness. Route pin housing

11. Snap anchor of new cable strap into hole on left side of

t fuel tank front mounting bolts (with ﬂat washers)

into left and right side of frame.

frame backbone. On FLHRS models, capture instrument console bracket during installation. Tighten bolt to 15-20 ft-lbs (20-27 Nm).

27 Nm).

to 50-90 in-lbs (5.7-10.2 Nm). If present, also install Phillips screw and large ﬂat washer (absent on FLHRS models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).

and convoluted tubing forward and then inboard between front of crossover hose ﬁtting and bottom of fuel tank. Mate pin and socket halves of fuel gauge connector [117], 4-place Multilock. Feed connector into tunnel of fuel tank. See Figure 4-20.

frame backbone. Tighten cable strap capturing main harness bundle, instrument console conduit, and fuel vapor vent tube. Cut any excess cable strap material.

NOTE

Route fuel overﬂow hose inboard of wire bundles on right side of frame, but do not capture in cable straps. See Figure 4-19.

11. Insert bolt through battery negative cable (black) into threaded hole of battery negative (-) terminal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).

12. Install seat. See Section 2.24 SEAT, INSTALLATION.

FLHR/S

CAUTION

Exercise caution to avoid pinching the wiring harness between the fuel tank and vehicle frame. Wire damage may result in electrical problems.

NOTE

Route fuel overﬂow hose inboard of wire bundles on right side of frame, but do not capture in cable straps. See Figure 4-19.

12. Insert bolt through battery negative cable (black) into threaded hole of battery negative (-) terminal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).

13. Install seat. See Section 2.24 SEAT, INSTALLATION.

4-26 2004 Touring: Fuel

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EVAPORATIVE EMISSIONS CONTROL SYSTEM 4.8

CALIFORNIA MODELS ONLY

GENERAL

Harley-Davidson motorcycles sold in the state of California are equipped with an evaporative (EVAP) emissions control system. In conformance with California Air Resource Board (CARB) regulations, the EVAP system prevents both fuel and crankcase vapors from escaping into the atmosphere. See

Figure 4-21.

The EVAP system functions as follows:

● The fuel vapor vent tube connected to a ﬁtting on

the ﬁller neck (top of canopy on FLHR/C/S models) allows fuel vapors in the fuel tank to be vented through the vapor valve to the charcoal canister. If the motorcycle is tipped, the vapor valve also prevents the loss of gasoline through the vent tube.

Carburetor Fuel

Clean Air Inlet Tube

● When the engine is running, negative pressure

(vacuum) draws the fuel vapors stored in the charcoal canister through the purge tube to the carburetor (or induction module) where they are burned as part of the normal combustion process.

● On carbureted models, fuel vapors emanating from

the carburetor throat are drawn to the charcoal canister through the clean air inlet tube connected to the inboard side of the air cleaner backplate. Crankcase vapors passing from the breather tubes into the air ﬁlter element follow the fuel vapors to the charcoal canister. These vapors, after passing through the charcoal canister, also travel through the purge tube to the carburetor where they are burned.

● When the engine is not running, the gravity-oper-

ated bafﬂe plate at the air cleaner air inlet port closes to prevent fuel and crankcase vapors from escaping into the atmosphere.

Filler Neck Fitting

Vacuum

Tube

(Top of Canopy on FLHR/C/S)

Tank

Air Cleaner

Backplate

Fuel

Valve

Purge

Tube

Fuel Vapor

Vent Tube

Charcoal

Canister

Figure 4-21. California Evaporative Emissions Control System (Carbureted Models)

Vapor

Valve

Fuel Vapor

Vent Tube

2004 Touring: Fuel 4-27

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1WARNING1WARNING

Verify that the evaporative emissions tubes/hoses do not contact hot exhaust or engine parts. Tubes/hoses contain ﬂammable vapors that can be ignited if damaged, possibly causing ﬁre or explosion which could result in death or serious injury.

TROUBLESHOOTING

The EVAP system has been designed to operate with a minimum of maintenance. Check that all tubes/hoses are correctly routed and properly connected. Also, verify that the tubes/hoses are not pinched or kinked.

Vapor Valve

Vent

Tube

135˚

Elbow

Arm

Hole

VAPOR VALVE

NOTE

On 49 State models, the charcoal canister is absent and the bottom tube of the vapor valve is vented to the atmosphere.

REMOVAL

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

2. Remove left side saddlebag. See Section 2.25 SADDLE-

BAG, REMOVAL.

3. Gently pull side cover from frame downtubes (no tools required).

4. Locate vapor valve attached to frame cross member in front of battery box (left side). See Figure 4-22.

5. Cut cable strap to release vapor valve from mounting bracket.

6. Remove 135˚ elbow from neck at top of vapor valve.

7. On California models, raise vapor valve slightly and pull hose ﬁtting on vent tube from bottom ﬁtting on vapor valve.

NOTE

On 49 State models, just pull out vapor valve with bottom vent tube attached. Remove hose ﬁtting on vent tube from bottom ﬁtting of vapor valve.

INSTALLATION

1. Hold vapor valve in its approximate position on left side of mounting bracket (with long nec On California models, install hose ﬁtting on vent tube to bottom ﬁtting of vapor valve.

NOTE

On 49 State models, attach hose ﬁtting on vent tube to bottom ﬁtting on vapor valve. Insert vapor valve through opening above fuse block bracket (upper weldment between downtubes), and hold in its approximate position on left side of mounting bracket.

ked end at the top).

Cable Strap

Small

Figure 4-22. Vapor Valve Mounting Bracket

2. From right side of bracket, insert end of small cable strap (P/N 10065) through hole in arm and then around body of vapor valve. Mate ends of cable strap and pull tight engaging strap in slot of arm. Cut any excess cable strap material. See Figure 4-22.

3. Install free end of 135˚ valve.

4. Verify that vapor valve is completely vertical. Momentarily push on top of vapor valve to verify that it returns to the completely vertical position.

Slot

elbow onto neck at top of vapor

f2184x4x

1WARNING1WARNING

Verify that the vent tubes do not contact hot exhaust or engine parts. Tubes contain ﬂammable vapors that can be ignited if damaged, possibly causing ﬁre or explosion, which could result in death or serious injury.

5. Recheck bottom vent tube routing to be sure that hose ﬁttings are not pinched or kinked, and that there is no contact with the drive belt. For California models, see

Figure 4-24.

On 49 State models, verify that vent tube at bottom of vapor valve is routed through opening above fuse block bracket (upper weldment between downtubes) to outboard side. Orient vent tube so that it runs downward along the back of the forward frame downtube, where the free end is then tucked into opening at front of lower weldment (containing side cover grommet).

6. Align barbed studs in side cover with grommets in frame downtubes and push ﬁrmly into place (no tools required).

4-28 2004 Touring: Fuel

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1WARNING1WARNING

CARB.

TANK

f1063b9x

Left Side View

Top View

PURGE TUBE Fuel Vapor Vent Tube

To Carburetor or Induction Module

Fuel Vapor Vent Tube

From Filler Neck of Fuel Tank Via Vapor Valve

Clean Air Inlet Tube

From Air Cleaner Backplate on Carbureted Models Only

Retaining Pin

7. Install left side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

8. Install seat. See Section 2.24 SEAT, INSTALLATION.

CHARCOAL CANISTER

REMOVAL

1. Remove rear fender. See Section 2.33 REAR FENDER,

REMOVAL.

Always disconnect the negative battery cable ﬁrst. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion, which could result in death or serious injury.

2. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal.

3. Unthread bolt and remove battery positive cable (red) from battery positive (+) terminal.

4. Using a T40 TORX drive head, loosen bolt to move lip of hold-down clamp off edge of battery. Remove battery from battery box.

5. Reaching into battery box, pry plastic retaining pin out of hole on left side. See inset of Figure 4-23.

6. Reaching in between battery box and right side frame member, pull clean air inlet tube (to air cleaner backplate on carbureted models) from ﬁtting on right side of charcoal canister. On fuel injected models, pull 90 connector from ﬁtting.

7. Moving to rear left side of motorcycle, center a ﬂashlight on drive belt and direct the beam forward. Note the two tube connections on the left side of the canister. See

Figure 4-23. Reaching in between battery box and frame

member, pull tubes from canister.

8. With the handle of a rubber mallet, rap canister toward left side of motorcycle until tongue at top of canister is free of grooves in bottom of battery box. From right side of motorcycle, pull canister out of opening between battery box and frame member.

1WARNING1WARNING

˚ elbow

Figure 4-23. Charcoal Canister

3. Moving to rear right side of motorcycle, attach clean air inlet tube (to air cleaner backplate on carbureted models) to ﬁtting on right side of canister. On fuel injected models, install 90 pointing down.

The clean air inlet tube is absent on fuel injected models.

4. Place battery in battery box, terminal side forward.

˚ elbow connector with the free end

NOTE

INSTALLATION

1. With tongued side up, slide canister into cavity using opening between battery box and right side frame member. Start tongue into grooves on left side of battery box. Push the canister toward the right side of the motorcycle until fully engaged. Snap plastic retaining pin into hole at bottom of battery box (left side) to lock position of canister. See inset of Figure 4-23.

2. Attach tubes to ﬁttings on left side of canister. Install the purge tube to the carburetor (or induction module) onto the top ﬁtting stamped “CARB.” Install the fuel vapor vent tube from the fuel tank (via the vapor valve) to the bottom ﬁtting stamped “TANK.”

Always connect the positive battery cable ﬁrst. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion, which could result in death or serious injury.

5. Insert bolt through battery positive cable (red) into threaded hole of battery positive (+) terminal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).

6. Insert bolt through battery negative cable (black) into threaded hole of battery negative (-) terminal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).

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Clean Air Inlet Tube

From Air Cleaner Backplate on Carbureted Models Only

Purge Tube

To Carburetor

or Induction Module

Fuel Vapor Vent Tube

From Vapor Valve

Fuel Vapor Vent Tube

From Fuel Tank

f1884x4x

Figure 4-24. Charcoal Canister Tube/Hose Routing (Left Side View)

7. Rotate hold-down clamp so that the lip (with rubber pad) rests on the edge of the battery. Using a T40 TORX drive head, tighten the clamp bolt to 15-20 ft-lbs (20-27 Nm).

8. Install rear fender. See Section 2.33 REAR FENDER,

INSTALLATION.

Charcoal Canister Hose Routing

1WARNING1WARNING

Purge Tube:

From top ﬁtting on left side of charcoal canister (stamped “CARB”), purge tube is routed forward where it runs under frame crossmember, and then angles upward between crossmember and inner primary housing. Captured in clip anchored in hole at front of crossmember (rear and inboard of cruise hole), purge tube goes over crossover pipe, runs along left side of rear cylinder rocker cover and into tunnel of fuel tank. It then crosses to right side of motorcycle just to the rear of the top engine mounting bracket, where it connects to a ﬁtting on the carburetor (or induction module). See Figure 4-24.

Fuel Vapor Vent Tube:

From bottom ﬁtting on left side of charcoal canister (stamped “TANK”), vent tube is routed forward and then upward in front of battery box to bottom ﬁtting on vapor valve mounted to rear of upper frame crossmember.

Another section connected to top ﬁtting of vapor valve follows the inboard side of the main harness bundle, where it is captured in anchored cable strap on left side of frame backbone before passing under console pod/instrument console to ﬁtting on ﬁller neck of fuel tank (top of canopy on FLHR/C/S models).

Clean Air Inlet Tube:

From 90˚ elbow connector on right side of charcoal canister, clean air inlet tube runs forward under frame crossmember and then upward (inboard of starter connections) following angle of crossmember, where it is routed over crossover pipe and rear cylinder rocker cover into tunnel of fuel tank on right side of frame backbone. Tube turns right just to the rear of the top engine mounting bracket, where it connects to ﬁtting on inboard side of air cleaner backplate.

NOTE

The clean air inlet tube is absent on fuel injected models, so the ﬁtting on the right side of the canister terminates in a 90 elbow connector (the free end pointing down).

4-30 2004 Touring: Fuel

Harley Davidson Touring 2004 Service Manual sm04a

Specifications and Main Features

Frequently Asked Questions

User Manual

SPECIFICATIONS 4.1

CVH CARBURETOR JET SIZES

FUEL TANK CAPACITY

TORQUE VALUES

FUEL SYSTEM TROUBLESHOOTING (CARBURETED) 4.2

ENRICHENER (CARBURETED) 4.3

GENERAL

OPERATION

Enrichener

Cool Engine

Warm Climate Or Hot Engine

ADJUSTMENTS

Slow Idle

Enrichener Control

CARBURETOR 4.4

REMOVAL

INSTALLATION

DISASSEMBLY

CLEANING AND INSPECTION

Carburetor Housing

ASSEMBLY

AIR CLEANER 4.5

GENERAL

REMOVAL

CLEANING AND INSPECTION

INSTALLATION

VACUUM OPERATED FUEL VALVE (CARBURETED) 4.6

GENERAL

TROUBLESHOOTING

REMOVAL

CLEANING AND INSPECTION

INSTALLATION

FUEL TANK ADAPTER

FUEL TANK (CARBURETED) 4.7

COMPLETE REMOVAL

FLHT/C

FLHR/S

CLEANING AND INSPECTION

INSTALLATION (AFTER COMPLETE REMOVAL)

FLHT/C

FLHR/S

PARTIAL REMOVAL

FLHT/C

FLHR/S

INSTALLATION (AFTER PARTIAL REMOVAL)

FLHT/C

FLHR/S

EVAPORATIVE EMISSIONS CONTROL SYSTEM 4.8

CALIFORNIA MODELS ONLY

TROUBLESHOOTING

Vapor Valve

REMOVAL

INSTALLATION

CHARCOAL CANISTER

REMOVAL

INSTALLATION

Charcoal Canister Hose Routing

Purge Tube:

Fuel Vapor Vent Tube:

Clean Air Inlet Tube: