Harley Davidson Touring 2004 Service Manual sm04a
HOME
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
in-lbs
15-20 ft-lbs 20-27 Nm
15-20 ft-lbs 20-27 Nm
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
HOME
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.
HOME
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
HOME
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
HOME
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
HOME
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
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 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
HOME
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
HOME
r
a
y
l
e
v
H
d
i
D
a
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
18
19
22
20
21
14. Float
15. O-ring
2
3
5
1
28
6
31
4
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
30
47
31
7
29
32
8
9
16
10
17
36
NOTE
With the exception of the jet sizes, all
FL models are equipped with the
same basic carburetor.
12
34
41
39
43
49
11
13
14
52
53
46
33
40
38
42
45
44
49
35
26
27
51
15
24
23
25
54
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
48
50
37
f2277x4x
4-8 2004 Touring: Fuel
Figure 4-4. Carburetor
HOME
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
Loading...