Harley Davidson Touring 2004 Service Manual sm02b

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f2010x2x

f1449a2x

Frame

Boss

Air Inlet

Tube

Shock

Absorber

Compression

Fitting

Depress Collar on Fitting and Pull Out Air Inlet Tube.

REAR SHOCK ABSORBERS 2.19

ADJUSTMENT

For the correct air pressure, see Section 2.18 REAR AIR

SUSPENSION.

REMOVAL

NOTE

If replacing both shock absorbers, remove and install one shock at a time. Remove and install the second shock only after the ﬁrst shock is installed, but before the air suspension system is pressurized.

1. Place the motorcycle on a hydraulic center stand with the rear wheel raised off the ground.

2. Remove saddlebags. See Section 2.25 SADDLEBAG,

REMOVAL.

11WARNING1WARNING

Exercise caution when bleeding air from the air valve. Moisture combined with lubricant (either from shock assembly or drip oiler in the air compressor lines) may be ejected onto the rear wheel, tire and/or brake components and adversely affect traction and/or braking efﬁciency, which could result in death or serious injury.

3. Remove protective cap from air valve. Using a no-loss AIR SUSPENSION PUMP AND GAUGE (Part No. HD-

34633), add 3-5 psi (20.7-34.5 kPa) to purge lines of any oil.

4. Depress pin in valve to bleed air from shocks.

5. Depress collar on compression ﬁtting to release air tube. See upper frame of Figure 2-96.

6. Remove the upper shock mounting bolt with lockwasher and ﬂat washer. See lower frame of Figure 2-96.

7. Remove the lower shock mounting bolt with lockwasher and ﬂat washer. Remove the shock absorber assembly from the vehicle.

DISASSEMBLY

Figure 2-96. Remove Air Inlet Tube and

Upper Shock Mounting Bolt (Left Side View)

NOTE

Air shocks are not repairable. Replace the shocks if damaged or worn.

2004 Touring: Chassis 2-79

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CLEANING AND INSPECTION

1. Examine the rubber mounting bushings for cracks or wear. Examine the shock for leaks. The unit should not leak and should compress slightly easier than it extends. Compare the action of the shock with a new one to judge if it is worn. Replace the shock if necessary.

2. Clean and examine the shock mounting hardware. Replace parts that are worn or damaged.

ASSEMBLY

NOTE

If the compression ﬁttings were removed, apply PIPE SEALANT WITH TEFLON to the threads before assembly.

INSTALLATION

1. Install lockwasher and ﬂat washer on the lower shock mounting bolt. Insert bolt through the shock bottom bushing.

2. Apply two or three drops of Loctite Medium Strength Threadlocker 243 (blue) to threads.

3. Start bolt into rear swingarm mount. Tighten bolt to 3540 ft-lbs (47-54 Nm).

4. Install lockwasher and ﬂat washer on the upper shock mounting bolt. Insert bolt through the shock upper bushing

5. Apply two or three drops of Loctite Medium Strength Threadlocker 243 (blue) to threads.

6. Start bolt into frame boss. Tighten bolt to 33-35 ft-lbs (45-48 Nm).

7. Insert air tube into compression ﬁtting until it bottoms. Gently tug on tube to verify that it is locked in place.

NOTE

If replacing both shock absorbers, remove and install the other shock at this time.

8. Pressurize rear air suspension system and check for leaks. For the correct air pressure, see Section 2.18

REAR AIR SUSPENSION.

9. Install saddlebags. See Section 2.25 SADDLEBAG,

INSTALLATION.

2-80 2004 Touring: Chassis

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f2006x2x

Rear

Swingarm

Slot

Rubber

Mount

Pivot

Shaft

Locknut

REAR SWINGARM 2.20

REMOVAL

1. Remove saddlebags. See Section 2.25 SADDLEBAG,

REMOVAL.

2. Remove socket screw with lockwasher to remove passenger footboard from rear swingarm bracket. Repeat step on opposite side of vehicle.

3. Remove both mufﬂers as follows:

Left Side

a. Open worm drive clamps to remove heat shield

from crossover pipe in front of mufﬂer.

b. Using a bungee cord, tie the mufﬂer to the lower

saddlebag support rail.

c. Loosen TORCA clamp between crossover pipe and

muffer.

d. Remove two bolts (with lockwashers) to detach muf-

ﬂer from the lower saddlebag support rail.

e. Remove bungee cord to release mufﬂer from lower

saddlebag support rail.

Right Side

a. Open worm drive clamps to remove heat shield

from rear header pipe in front of mufﬂer.

b. Using a bungee cord, tie the mufﬂer to the lower

saddlebag support rail.

c. Loosen TORCA clamp between rear header pipe

and muffer.

d. Remove two bolts (with lockwashers) to detach muf-

ﬂer from the lower saddlebag support rail.

e. Remove bungee cord to release mufﬂer from lower

saddlebag support rail.

4. Place the motorcycle on a hydraulic center stand. Slide a block of wood beneath the oil pan to support the weight of the transmission once the pivot shaft is removed.

5. Standing on right side of vehicle, remove E-clip from groove at end of axle.

6. Remove cone nut and adjuster cam from axle.

7. Using a soft mallet, gently tap end of axle towards left side to loosen. Catching external spacers on right and left side of hub, pull axle free of wheel and rear swingarm.

8. Pull wheel to release brake disc from caliper. Pry inner and outer brake pads back for additional clearance, if necessary. Use a putty knife with a wide thin blade to avoid scoring or scratching the brake disc.

Figure 2-97. Remove Rear Swingarm Bracket

(Left Side View)

9. Remove caliper from anchor weldment on rear swingarm, and carefully hang over lower saddlebag support rail.

10. Roll wheel forward and slip belt off sprocket. Move wheel out from beneath rear fender.

11. Remove belt guard from bottom of left side swingarm. First remove two rear screws, and then loosen front screw. Push belt guard toward the front of the vehicle until screw engages large end of slot, and then remove.

12. Remove lower shock mounting bolt (with lockwasher and ﬂat washer) to release shock absorber from rear swingarm mount. Repeat step on opposite side of vehicle.

13. Remove two bolts (with lockwashers) to free rear swingarm bracket from left side of vehicle frame. See Figure 2-

97.

14. Moving to right side of vehicle, leave rear swingarm bracket installed, but remove decorative chrome plug.

15. Open two cable clips on T-studs at top of right side swingarm. Free rear brake line hose from cable clips.

NOTE

For best results, insert blade of small screwdriver into gap at side of clip and gently rotate end of screwdriver to pop open.

2004 Touring: Chassis 2-81

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Ram

Socket

Extension

Socket

Figure 2-98. Press Out Drive Side Bearing

16. Holding left side nut within rubber mount, remove right side locknut from end of pivot shaft. Remove cup washer.

17. Using a suitable drift, tap pivot shaft toward left side of vehicle.

18. Moving to left side, pull pivot shaft assembly (pivot shaft, locknut, cup washer, rubber mount and outer spacer) out of transmission mount and left side swingarm. See

Figure 2-102.

19. Standing at rear of vehicle, work rear swingarm free of transmission mount and rear swingarm brackets.

20. Remove outer spacer from right side swingarm tube.

21. Remove rubber mount from behind right side swingarm bracket.

Socket

f1903x2x

Anchor

Weldment

Wood Block

f1967x2x

Spacer

Bearing

DISASSEMBLY/ASSEMBLY

Bearing Removal

1. Move rear swingarm to an hydraulic press.

2. Place swingarm on its side, so that the brake side is on top. The brake side is easily recognized by the anchor weldment for mounting of the brake caliper.

3. Support the swingarm with a block of wood and a large socket as shown in Figure 2-98. Ver ify that assembly is square and the bearing bore is completely vertical.

2-82 2004 Touring: Chassis

Figure 2-99. Press Spacer Into Bearing

4. Slide driver handle (or long socket extension) through the brake side swingarm tube and bearing until it contacts driver (or large socket) placed on inboard side of drive side bearing.

5. Center driver handle (or long socket extension) under ram and press drive side bearing from rear swingarm.

6. Remove tools from rear swingarm. Turn swingarm over and repeat steps 3-5 to press out brake side bearing.

HOME

f1914x2x

Pivot Shaft

Rubber

Mount

Locknut and Cup Washer

Spacer

Right Side

Drive Side

Driver

Figure 2-100. Rear Swingarm Bearing Installer (HD-

45327)

Brake Side

Driver

Brake Side

Driver

Anchor

Weldment

f1909x2x

a. Place swingarm on its side, so that the brake side is

on top. The brake side is easily recognized by the anchor weldment for mounting of the brake caliper.

b. With the spacer inboard, insert bearing into out-

board side of brake side swingarm tube.

c. Insert driver stamped “Brake Side” into swingarm

tube until it contacts installed bearing. Center driver under ram and press on brake side bearing until shoulder on tool makes contact with casting of swingarm. See Figure 2-101.

d. Remove tool and turn rear swingarm over. With the

spacer inboard, insert bearing into outboard side of drive side swingarm tube.

e. Insert driver stamped “Drive Side” into swingarm

tube until it contacts installed bearing. Center driver under ram and press on drive side bearing until it bottoms. Shoulder on tool will with casting of swingarm.

f. Remove tool from swingarm. Remove swingarm

from hydraulic press.

not

mak

e contact

Pivot Shaft Disassembly

1. Partially install locknut on right side of pivot shaft. Install second locknut on right side until it contacts the ﬁrst. Holding ﬁrst locknut to prevent rotation of shaft, remove left side locknut. See Figure 2-102.

2. Remove cup washer, rubber mount and outer spacer.

3. Remove right side locknuts from pivot shaft.

Bearing Installation

1. Obtain

2. Install assembled bearings into rear swingarm. Proceed

Figure 2-101. Press In Brake Side Bearing

new

rear swingarm bearings. Bearings and spacers must be assembled before installation. Proceed as follows:

a. Obtain REAR SWINGARM BEARING INSTALLER

(HD-45327). See Figure 2-100.

b. With the nose topside, center one of the drivers

under ram of hydraulic press.

c. Place bearing over nose of driver. With the collar

topside, place spacer over nose and into bearing.

See Figure 2-99. d. Apply pressure to spacer until it bottoms in bearing. e. Repeat step to assemble second swingarm bearing.

as follows:

Pivot Shaft Assembly

1. With larger OD outboard, slide outer spacer onto left side of pivot shaft until counterbore contacts shoulder on shaft.

2. Install rubber mount with the ﬂat side inboard toward outer spacer.

3. Install cup washer with the concave side facing in toward the rubber mount.

Figure 2-102. Pivot Shaft Assembly

2004 Touring: Chassis 2-83

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4. Apply two drops of Loctite Medium Strength Threadlocker 243 (blue) to threads of left side locknut, and then start on shaft.

5. Partially install locknut on right side of pivot shaft. Install second locknut on right side until it contacts the ﬁrst. Holding second locknut to prevent rotation of shaft, tighten left side locknut to 40-45 ft-lbs (54-61 Nm).

6. Remove right side locknuts from pivot shaft.

INSTALLATION

1. With the slot on the outboard side between the twelve and one o’clock positions, install rubber mount behind rear swingarm bracket on right side of vehicle. Be sure that index tab cast on inboard side of bracket fully engages slot in rubber mount.

2. Place outer spacer into right side swingarm tube.

3. With the belt on the inboard side of the left side swingarm, work the rear swingarm into position between the transmission mount and the rear swingarm brackets. Use a rubber mallet and carefully tap swingarm into position, if necessary.

4. The pivot shaft secures the rear swingarm and transmission to the vehicle frame. See Figure 2-102. Install the pivot shaft as follows:

a. Coat pivot shaft with Loctite ANTI-SEIZE LUBRI-

CANT.

b. From left side of vehicle, slide pivot shaft assembly

(pivot shaft, locknut, cup washer, rubber mount and outer spacer) through left side swingarm and transmission mount. After exiting right side swingarm, guide end of pivot shaft through holes in rubber mount and right side swingarm bracket.

c. With the concave side inboard, slide cup washer

onto end of pivot shaft.

d. Install locknut on pivot shaft. Holding left side nut on

pivot shaft, tighten locknut to 40-45 ft-lbs (54-61 Nm). Now hold right side nut and tighten left side locknut using the same torque value.

e. Carefully raise swingarm up and down slightly to

verify movement (and that assembly is not in a bind).

f. Install decorative chrome plug in right side rear

swingarm bracket.

g. Moving to left side of vehicle, rotate the rubber

mount so that the slot is between the eleven and twelve o’clock positions. Install left side swingarm bracket ﬁtting index tab into rubber mount slot. See

Figure 2-97.

h. Install two bolts (with lockwashers) to secure left

side swingarm bracket to vehicle frame. Tighten bolts to 34-42 ft-lbs (46-57 Nm).

5. Install lockwasher and ﬂat washer on the lower shock mounting bolt. Insert bolt through the shock bottom bushing. Apply two or three drops of Loctite Medium Strength Threadlocker 243 (blue) to threads. Start bolt into rear swingarm mount. Tighten bolt to 35-40 ft-lbs (47-54 Nm). Repeat step on opposite side of vehicle.

6. Install belt guard at bottom of left side swingarm. Push belt guard toward the rear of the vehicle until front screw engages small end of slot. Install two rear screws, and then tighten front screw.

7. Capture rear brake line hose in two cable clips at top of right side swingarm. Snap cable clips closed.

8. Place wheel in rear swingarm. Slide wheel far enough forward to slip belt over sprocket and then slide the wheel back.

CAUTION

Do not bend or fold belt backward or into loops smaller than 5 inches (127 mm) in diameter. Sharp bending can weaken the belt and cause premature failure.

9. Seat caliper on anchor weldment of rear swingarm. Position wheel in swingarm, so that brake disc is centered between brake pads.

10. Coat the axle with Loctite ANTI-SIEZE LUBRICANT.

11. With the larger OD on the outboard side, hold external spacer between rear swingarm and belt sprocket. Slide axle through left side of rear swingarm, external spacer, and belt sprocket into wheel hub.

12. When axle emerges from hub on brake disc side of wheel, push axle through bracket and right side of rear swingarm.

13. Rotate axle so that the ﬂat on the threaded end is topside. With the thumb down and the cam forward, install adjuster cam on end of axle.

14. Apply a thin ﬁlm of ANTI-SIEZE LUBRICANT to the inboard side of the cone nut avoiding contact with threads. Install cone nut on axle, but ﬁnger tighten only.

15. Verify that adjuster cam just contacts weld nub on both sides of rear swingarm. If necessary, push wheel forward slightly to achieve the desired result. Snug the cone nut to 15-20 ft-lbs (20-27 Nm). See Figure 2-103.

16. Check deﬂection at the loosest spot in the belt. Use BELT TENSION GAUGE (HD-35381A), or install narro saddle (HD-35381-3) on existing gauge, and apply 10 lbs. (4.5 kg) of force at the midpoint of the bottom belt strand. See Figure 2-104. Belt deﬂection should be as follows:

shor

external spacer, caliper

Table 2-4. Belt Deﬂection in the Air

Orientation

Motorcycle Upright

With Rear Wheel in the Air

See Section 6.4 SECONDARY DRIVE BELT AND SPROCKETS for belt deﬂection speciﬁcation with motorcycle on jiffy stand.

NOTE

Inches Millimeters

3/16 - 1/4 4.8 - 6.4

2-84 2004 Touring: Chassis

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10 lbs. (4.5 kg)

of Force

f1652x6x

See Tabl e 2-4.

Transmission

Sprocket

Rear Wheel

Sprocket

Belt Tension Gauge Adapter

Part No. HD-35381-3

Belt Tension Gauge Part No. HD-35381A

RIGHT SIDELEFT SIDE

Increase

Belt

Deflection

Reduce

Belt

Deflection

Weld

Nut

Nub

8398

Figure 2-103. Move Rear Wheel Forward Until Adjuster Cams Just Contact Weld Nubs

17. If belt is too tight, move to step 18 to increase belt deﬂection. If belt is too loose, reduce belt deﬂection as described below:

a. Rotate weld nut on left side of axle in a clockwise

direction.

b. Check belt deﬂection. Apply 10 lbs. (4.5 kg) of force

at the midpoint of the bottom belt strand. Belt deﬂection should be within the range speciﬁed in

Ta ble 2-4.

c. If belt is still too loose, repeat steps 17(a) through

17(b). If belt is now too tight, move to step 18.

Cone

Nut

Weld

Nub

E-Clip

Adjuster

8407

Cam

20. Recheck belt deﬂection to verify that it is still within speciﬁcation.

If the belt deﬂection is not within speciﬁcation, loosen cone nut and then snug to 15-20 ft-lbs (20-27 Nm) before returning to step 17.

21. With the ﬂat side out, install

new

E-clip in groove on right

side of axle.

22. Depress rear brake pedal several times to set brake pads to proper operating position within caliper.

18. If belt is too tight, increase belt deﬂection as follows:

19.

If the axle moves during tightening of the cone nut, then the the belt deﬂection procedure must be restarted.

a. Rotate weld nut on left side of axle in a counter-

clockwise direction.

b. Push wheel forward slightly so that adjuster cam

just contacts weld nub on both sides of rear swingarm. See Figure 2-103.

c. Check belt deﬂection. Apply 10 lbs. (4.5 kg) of force

at the midpoint of the bottom belt strand. Belt deﬂection should be within the range speciﬁed in

Ta ble 2-4.

d. If belt is still too tight, repeat steps 18(a) through

18(c). If belt is now too loose, move to step 17.

Holding

weld nut on left side of axle, tighten cone nut on

right side to 95-105 ft-lbs (128.8-142.4 Nm).

NOTE

Figure 2-104. Check and Adjust Belt Deﬂection

2004 Touring: Chassis 2-85

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11WARNING1WARNING

After installation of caliper and BEFORE moving motorcycle, pump rear brake pedal until pistons push pads against the brake disc. If ﬂuid pressure is not pumped up, the rear brake will not be available the ﬁrst time it is used, a situation that could result in death or serious injury.

23. Install both mufﬂers as follows:

NOTE

TORCA mufﬂer clamps have eliminated the need for silicone or graphite tape during assembly. To ensure sealing integrity of mufﬂer clamps and prevent the possibility of leakage, Harley-Davidson recommends that TORCA clamp assemblies be discarded and replaced each time they are removed.

Left Side

a. Slide

b. Using a bungee cord, tie mufﬂer to lower saddlebag

c. Tighten the two bolts (with lockwashers) to fasten

new

TORCA clamp onto free end of crossover

pipe.

support rail. Install mufﬂer on crossover pipe. Place TORCA clamp into position between crossover pipe and mufﬂer.

the mufﬂer to the lower saddlebag support rail.

Passenger Footboard

Bracket

Chrome

Plug

Rear

Swingarm

Bracket

f1787x2x

CAUTION

Verify that the exhaust pipes do not contact the vehicle frame or any mounted components. Contact will cancel the effect of the rubber isolation mounts and transmit vibration to the rider via the vehicle frame.

d. Verify that exhaust pipes are in alignment and do

not contact the vehicle frame or mounted components.

e. Tighten the TORCA clamp to 45-60 ft-lbs (61-81

Nm).

f. Open worm drive clamps and install heat shield on

crossover pipe. Position clamp so that screw is on the outboard side in the most accessible position.

CAUTION

Verify that the heat shields do not contact the vehicle frame or any mounted components. Contact will cancel the effect of the rubber isolation mounts and transmit vibration to the rider via the vehicle frame.

g. Remove bungee cord from mufﬂer.

Right Side

a. Slide

new

TORCA clamp onto free end of rear

header pipe.

Locknut

Pivot Shaft

L(eft) Side

Casting Stamp

f2073x2x

Figure 2-105. Remove Chrome Plugs and Check

Pivot Shaft Locknut Torque (Left Side View)

2-86 2004 Touring: Chassis

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b. Using a bungee cord, tie mufﬂer to lower saddlebag

support rail. Install mufﬂer on rear header pipe. Place TORCA clamp into position between rear header pipe and mufﬂer.

c. Tighten the two bolts (with lockwashers) to fasten

the mufﬂer to the lower saddlebag support rail.

CAUTION

d. Verify that exhaust pipes are in alignment and do

not contact the vehicle frame or mounted components.

e. Tighten the TORCA clamp to 45-60 ft-lbs (61-81

Nm).

f. Open worm drive clamps and install heat shield on

rear header pipe. Position clamp so that screw is on the outboard side in the most accessible position.

CAUTION

25. Install saddlebags. See Section 2.25 SADDLEBAG,

INSTALLATION.

NOTE

Remove the decorative chrome plugs in the rear swingarm brackets and check the torque on the pivot shaft locknuts every 10,000 miles (16,000 km). See Figure 2-105. Holding right side nut on the pivot shaft, tighten left side locknut to 4045 ft-lbs (54-61 Nm). Then hold left side nut and tighten right side locknut using the same torque value.

g. Remove bungee cord from mufﬂer.

24. Install socket screw with lockwasher to fasten passenger footboard to rear swingarm bracket. Tighten screw to 1518 ft-lbs (20-24 Nm). Repeat step on opposite side of vehicle.

2004 Touring: Chassis 2-87

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THROTTLE CABLES (NON-CRUISE) 2.21

ADJUSTMENT

NOTE For throttle and idle cable adjustment or replacement on cruise equipped models, see Section 8.30 CRUISE CON-

TROL (FLHRC, FLTR, FLHTCU).

The throttle control must operate freely without binding. With the tension adjuster screw backed off, the throttle control grip must freely return to the closed (idle) position. The throttle control also must open and close freely when the front wheel is turned to both the right and left fork stops. If the throttle grip does not return to the idle position freely, check the adjuster screw tension. If the adjuster screw is backed off, inspect the cables for short bends.

11WARNING1WARNING

Do not overtighten the tension adjuster screw. An overtightened screw will prevent the engine from automatically returning to idle in an emergency situation. This can lead to loss of vehicle control, which could result in death or serious injury.

1. Slide rubber boot off throttle cable adjuster. See Figure

2-106. Holding cable adjuster with a 3/8 inch wrench,

loosen jam nut turning in a clockwise direction. Back jam nut away from cable adjuster until it stops. Turn adjuster clockwise until it contacts jam nut. Repeat procedure on idle cable adjuster.

2. Point the front wheel straight ahead. Turn the throttle control grip so that the throttle is wide open (fully counterclockwise) and then hold in position. Now turn the throttle cable adjuster counter-clockwise until the throttle cam stop just touches the stop plate. See Figure 2-107. Release the throttle control grip and then tighten the jam nut against the throttle cable adjuster. Cover cable adjuster mechanism with rubber boot.

3. Turn the front wheel full right. Turn the idle cable adjuster counterclockwise until the cable housing just touches the spring in the cable guide (as seen through slot). Work the throttle grip to verify that the throttle cable returns to the idle position when released. If the cable does not return to idle, turn the adjuster clockwise slightly until the correct response is achieved. Tighten jam nut against the idle cable adjuster and cover cable adjuster mechanism with rubber boot.

Throttle Control

Grip

Jam Nut

Tension

Adjuster

Screw

Throttle Cable

Idle Cable

Adjuster

Figure 2-106. Throttle Cable Assembly - Throttle Side (FLHR)

Adjuster

f1376b2x

2-88 2004 Touring: Chassis

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f1225x2x

5/32 Inch

(4.0 mm)

Cardboard

Insert

Throttle

Cable Guide

Idle

Cable Guide

Cable

Housing

Spring

Cable

Barrel End

Stop Plate

Throttle

Cam Stop

Figure 2-107. Throttle Cable Assembly - Carburetor Side

Throttle

Wheel

REMOVAL

THROTTLE SIDE

CAUTION

Do not remove the switch housing assembly without ﬁrst placing the 5/32 inch (4.0 mm) cardboard insert between the brake lever and lever bracket. Removal without the insert may result in damage to the rubber boot and plunger of the Front Stoplight Switch.

NOTE Use the eyelet of an ordinary cable strap if the cardboard insert is not available.

1. Place the cardboard insert between the brake lever and

lever bracket. See Figure 2-108.

2. Using a T25 TORX drive head, remove the upper and

lower switch housing screws.

3. Using a T27 TORX drive head, loosen the upper screw

securing the handlebar clamp to the master cylinder housing. Remove the lower clamp screw with ﬂat washer.

f1381a2x

Figure 2-108. Install Cardboard Insert

2004 Touring: Chassis 2-89

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4. Remove the brass ferrules from the notches on the inboard side of the throttle control grip. Remove the ferrules from the cable end ﬁttings.

5. Remove the friction shoe from the end of the tension adjuster screw.

NOTE

The friction shoe is a loose ﬁt and may fall out or become dislodged if the lower switch housing is turned upside down or shaken.

6. Remove the throttle control grip from the end of the handlebar.

7. Pull the crimped inserts at the end of the throttle and idle cable housings from the lower switch housing.

For best results, use a rocking motion while pulling. Place a drop of light oil on the retaining rings, if necessary. Remove the cables from the switch housing.

CARBURETOR/INDUCTION MODULE SIDE

1. Remove the air cleaner and backplate. See Section 4.5

AIR CLEANER, REMOVAL.

2. Raise fuel tank to access cables in area of frame backbone. For carbureted models, see Section 4.7 FUEL

TANK (CARBURETED), PA RTIAL REMOVAL, FLHT/C,

or FLHR/S. For fuel injected models, see Section 9.4

FUEL TANK (FUEL INJECTED), PARTIAL REMOVAL, FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

Carbureted:

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. See Figure 2-107.

Induction Module:

pull idle cable barrel from upper hole in throttle wheel. Pull throttle cable barrel from lower hole. Using slots, release idle and throttle cables from guides in throttle cable bracket. See Figure 2-111.

4. Free cables from J-clamp riveted to right side of frame backbone.

5. If present, remove screw (with ﬂat washer) to release Jclamp from wellnut in right side of steering head. Remove J-clamp from cables.

Using a needle nose pliers, carefully pull

Using a needle nose pliers, carefully

7961

Lower

Switch

Housing

Throttle

Cable Insert

(Silver)

Idle

Cable Insert

(Gold)

Figure 2-109. Install Throttle/Idle Cables

in Lower Switch Housing

2. Inspect the cables for damage or wear. Replace the cables if frayed, kinked or bent.

3. Obtain tube of Lubit-8 Tufoil Chain and Cable Lube (HD Part No. 94968-85TV- 1/4 ﬂ. oz.). Insert pin of tube between throttle cable and cable housing. Squirt a few drops of lubricant into cable housing moving pin around cable OD. Repeat the procedure squirting a few drops between the idle cable and cable housing.

INSTALLATION

THROTTLE SIDE

1. Apply a light coating of graphite to the handlebar and inside surface of the switch housings.

2. Push the throttle and idle cables into the lower switch housing until they snap in place. See Figure 2-109. Proceed as follows:

Note the different diameter inserts crimped into the end of the throttle and idle cable housings.

Push the larger diameter insert (silver) on the throttle cable housing into the larger hole in front of the tension adjuster screw.

Push the smaller diameter insert (gold) on the idle cable housing into the smaller hole at the rear of the tension adjuster screw.

CLEANING AND INSPECTION

1. Clean all parts in a non-ﬂammable cleaning solvent and blow dry with compressed air.

2-90 2004 Touring: Chassis

NOTE

To aid assembly, place a drop of light oil on the retaining rings of the crimped inserts. Always replace the retaining rings if damaged or distorted.

HOME

Ferrule

Throttle

Grip

8. Position the brake lever/master cylinder assembly

GrooveNotch

inboard of the switch housing assembly engaging the tab on the lower switch housing in the groove at the top of the brake lever bracket.

9. Align the holes in the handlebar clamp with those in the master cylinder housing and start the lower screw (with ﬂat washer). Position for rider comfort. Beginning with the top screw, tighten the screws to 60-80 Nm) torque using a T27 TORX drive head.

10. Using a T25 TORX drive head, tighten the lower and upper switch housing screws to 35-45

NOTE

Always tighten the lower switch housing screw ﬁrst so that any gap between the upper and lower housings is at the front of the switch assembly.

11. Remove the cardboard insert between the brake lever and lever bracket.

in-lbs

(6.8-9.0

(4-5 Nm).

Idle

Cable

Figure 2-110. Install Throttle/Idle Control Cables on

Throttle Control Grip

3. With the concave side facing upward, install the friction shoe so that the pin hole is over the point of the adjuster screw.

NOTE

The friction shoe is a loose ﬁt and may fall out or become dislodged if the lower switch housing is turned upside down or shaken.

4. Slide the throttle control grip over the end of the right handlebar until it bottoms against the closed end. Rotate the grip so that the ferrule notches are at the top. To prevent binding, pull the grip back about 1/8 inch (3.2 mm).

5. Position the lower switch housing beneath the throttle control grip. Install the brass ferrules onto the cables so that the end ﬁttings seat in the ferrule recess. Seat the ferrules in their respective notches on the throttle control grip. Verify that the cables are captured in the grooves molded into the grip. See Figure 2-110.

6. Position the upper switch housing over the handlebar and lower switch housing. Verify that the wire harness conduit runs in the depression at the bottom of the handlebar.

7. Start the upper and lower switch housing screws, but do not tighten.

Throttle

Cable

f1474x2x

12. Turn the Ignition/Light Key Switch to IGNITION and apply brake lever to test operation of brake lamp.

CARBURETOR/INDUCTION MODULE SIDE

1. Route the throttle and idle cables as follows:

FLHT/C:

line to the inner fairing. Pass the cables through the inner fairing grommet and then loop them toward the rear along the right side of the steering head.

FLHR/C:

handlebar to the handlebar clamp shroud. Pass the cables through the opening in the shroud and then loop them toward the rear along the right side of the steering head. Capture cables in J-clamp and then start screw (with ﬂat washer) to fasten J-clamp to wellnut in right side of steering head. Tighten screw to 9-18

2.0 Nm).

2. Route the throttle and idle cables rearward along the right side of the frame backbone. After passing through J-clamp riveted to frame backbone, route cables downward to carburetor/induction module.

Carbureted:

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. See

Figure 2-107.

Route the cables downward following the brake

Route the cables downward following the right

in-lbs

(1.0-

Install sleeve on throttle cable housing into

2004 Touring: Chassis 2-91

HOME

f2162x9x

Throttle Cable

Guide

Figure 2-111. Throttle Cable Assembly -

Induction Module Side

Induction Module:

ing into shorter cable guide at top of throttle cable bracket. Drawing throttle cable downward, ﬁt barrel end into lower hole in throttle wheel. Install sleeve and spring on idle cable housing into longer cable guide at bottom of throttle cable bracket inserting barrel end into upper hole in throttle wheel. See Figure 2-111.

4. Tighten cables as necessary to keep barrel ends from dislodging. Verify that cables are seated in channel of throttle wheel. Verify operation by turning throttle grip and observing cable action. Adjust throttle cables as described under ADJUSTMENT.

Install sleeve on throttle cable hous-

Idle Cable

Guide

LUBRICATION

1. See REMOVAL, THROTTLE SIDE, in this section, steps 1-5.

2. Move upper switch housing to the side in order to access lower housing.

1CAUTION

Lubit-8 Tufoil Chain and Cable Lube contains detergents. Keep out of reach of children. Contact with eyes may result in minor or moderate injury.

3. Obtain tube of Lubit-8 Tufoil Chain and Cable Lube (HD Part No. 94968-85TV- 1/4 ﬂ. oz.). Insert pin of tube between throttle cable and cable housing inside lower switch housing. Squeeze tube to squirt a quantity of lubricant into cable housing moving pin around cable OD. See Figure 2-112.

4. Repeat the procedure squirting a quantity of lubricant between the idle cable and cable housing.

5. See INSTALLATION, THROTTLE SIDE, in this section, steps 3-12.

6. Turn the Ignition/Light Key Switch to IGNITION and apply brake lever to test operation of brake lamp.

Insert

Lubricant

Here

5. Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER PA RTIAL REMOVAL), FLHT/C, or FLHR/S. For fuel

injected models, see Section 9.4 FUEL TANK (FUEL

INJECTED), INSTALLATION (AFTER PARTIAL REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

6. Install the air cleaner assembly. See Section 4.5 AIR

CLEANER, INSTALLATION.

2-92 2004 Touring: Chassis

7958

Figure 2-112. Right Handlebar Lower Switch Housing

HOME

11WARNING1WARNING

f1140axx

Flat

Washer

Retaining

Ring

Anchor

Handlebar

Clamp

Clutch

Lever

Bracket

Anti-Rattle

Spring

and Screw

Screw

Bushing

O-Ring

Rubber Boot

Pivot Pin

Hand Lever

Clutch Cable

f1896x7x

Inner

Ramp

Retaining

Ring

Cable

Fitting

Coupling

Clutch Cable

CLUTCH CABLE 2.22

ADJUSTMENT

See Section 6.3 CLUTCH, ADJUSTMENT.

REMOVAL

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

MAXI-FUSE, REMOVAL.

2. To access the clutch release cover assembly, remove right side exhaust system. See Section 3.7 REMOVING

ENGINE FROM CHASSIS, steps 3-9.

3. Remove the magnetic drain plug at the bottom right side of the oil pan and drain the transmission lubricant into a suitable container. Remove the ﬁller plug/dipstick.

4. Slide rubber boot off clutch cable adjuster. Holding cable adjuster with 1/2 inch wrench, loosen jam nut using 9/16 inch wrench. Back jam nut away from cable adjuster. Move adjuster toward jam nut to introduce free play at hand lever. See Figure 2-113.

5. Remove retaining ring from pivot pin groove at bottom of clutch lever bracket. Remove pivot pin.

6. Remove clutch hand lever from clutch lever bracket. If necessary, use a T27 TORX drive head and remove two screws (with ﬂat washers) to release handelbar clamp from clutch lever bracket.

7. Remove anchor pin and clutch cable eyelet from clutch hand lever. See Figure 2-114.

8. Remove six socket head screws and washers to free

clutch release cover from transmission case. Remove and discard gasket. See Figure 2-115.

f1440x6x

Jam

Nut

Rubber

Boot

Figure 2-114. Clutch Hand Lever Assembly

Figure 2-115. Clutch Release Cover Assembly

Figure 2-113. Clutch Cable Adjuster Mechanism

Cable

Adjuster

Cable

End

Always wear proper eye protection when removing retaining rings. Use the correct retaining ring pliers. Verify that the tips of the pliers are not damaged or excessively worn. Slippage may propel the ring with enough force to cause eye injury.

9. Remove retaining ring securing ball and ramp mechanism to clutch release cover.

2004 Touring: Chassis 2-93

HOME

10. Lift inner ramp out of clutch release cover and turn the assembly over so that ball sockets are facing outboard. Remove hook of ramp from button on coupling. Remove coupling from clutch cable end.

11. Remove balls from outer ramp sockets. Remove outer ramp from clutch release cover.

12. Unscrew the cable ﬁtting from the clutch release cover. Remove clutch cable and ﬁtting.

13. Cut cable strap in hole of crossbrace to free clutch cable from right frame downtube. See Figure 2-116. Continue as follows:

FLHR/C/S:

Remove T40 TORX screw with ﬂat washer (FLHRS) or acorn nut (FLHR/C) to release clutch cable from P-clamp fastened to upper fork bracket. See Figure

2-117.

FLTR:

Release clutch cable from cable clip anchored in

hole on left side of instrument nacelle.

FLHT/C/U:

Remove the outer fairing. See Section 2.29

UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD, REMOVAL. Cut cable strap to

release clutch cable from left fairing bracket. See Figure

2-118.

14. Remove clutch cable from motorcycle.

NOTE If ball and ramp or throwout bearing and clutch pushrod need service, see Section 7.5 CLUTCH RELEASE COVER.

Right Frame

Downtube

Cable Strap

Clutch Cable

f1472b2x

Figure 2-116. Clutch Cable Routing (Right Side View)

Clutch Cable

f2257x2x

INSTALLATION

1. See Figure 2-114. Insert clutch cable eyelet into groove

of clutch hand lever aligning eyelet with hole without bushing. Insert anchor pin through lever and eyelet.

2. Insert lever into groove of clutch lever bracket ﬁtting

sleeve at end of cable housing into bore on inboard side of bracket.

3. Align hole in hand lever with hole in bracket and install

pivot pin. Install retaining ring in pivot pin groove.

4. If removed, use a T27 TORX drive head and install two

screws (with ﬂat washers) to secure handelbar clamp to clutch lever bracket. See Figure 2-114. Starting with the top screw, tighten screws to 60-80

5. Start clutch cable routing as follows:

FLHR/C/S:

Capture clutch cable in P-clamp and fasten to upper fork bracket using T40 TORX screw with ﬂat washer (FLHRS) or acorn nut (FLHR/C). Orient P-clamp as shown in Figure 2-117. On left side of steering head, run cable downward between engine guard and front of left frame downtube.

FLTR:

Capture clutch cable in cable clip and anchor clip in hole on left side of instrument nacelle. Run cable forward and then rearward beneath instrument nacelle following left side of steering head. Run cable downward between engine guard and front of left frame downtube.

in-lbs

(6.8-9.0 Nm).

Clamp

Figure 2-117. Clutch Cable Routing - FLHR/C

(Left Side View)

FLHT/C/U:

Feed clutch cable through grommet on left side of inner fairing. Route cable on inboard side of left fairing bracket between upper and lower wings of radio (or storage box) support bracket. Cable strap clutch cable to left fairing bracket using oblong hole at this location. See Figure 2-118. Run cable downward along left side of steering head, and then between engine guard and front of left frame downtube. Install the outer fairing. See Section 2.29 UPPER FAIRING/WINDSHIELD

(FLHT/C/U), OUTER FAIRING/WINDSHIELD, INSTALLATION.

2-94 2004 Touring: Chassis

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CAUTION

8496

Clutch

Release

Cover

Filler

Plug

OMF50

O-Ring

9421

Cable Strap

12. Install the retaining ring so that the opening is to the right of the outer ramp tang slot in the clutch release cover.

13. Verify that the two locating dowels are in place on the right side of the transmission case. Hang a

new

gasket

on the dowels.

14. Holding the clutch release cover in position, install six socket head screws. Tighten screws to 120-144

in-lbs

(13.6-16.3 Nm).

15. Tighten clutch cable ﬁtting to 36-60

in-lbs

(4-7 Nm).

16.Check the O-ring on the transmission drain plug for tears, cuts or general deterioration. Replace as necessary.

Figure 2-118. Secure Clutch Cable to Fairing Bracket

6. Complete clutch cable routing as follows:

All Models:

Continue downward progression while crossing to right side of motorcycle and then run cable between outboard side of voltage regulator and inboard side of right frame downtube. Threading cable strap through hole in crossbrace, secure clutch cable to downtube as shown in Figure 2-116. Following inboard side of frame downtube, route cable between bottom of cam cover and top of lower frame tube to area of clutch release cover.

7. Inspect cable ﬁtting O-ring and replace if damaged or deformed. Install clutch cable ﬁtting into clutch release cover. See Figure 2-115. Do not tighten cable ﬁtting at this time.

8. Place outer ramp in clutch release cover recess with tang in cover slot.

9. Apply a multi-purpose grease to the balls and outer ramp sockets. Place a ball in each of three outer ramp sockets.

10. Hold coupling with button facing outboard. Place cable end in recess of coupling. With ball sockets facing outboard, place hook of inner ramp on button of couplng. Holding inner ramp and coupling together, turn the assembly over.

11. Place inner ramp (ball socket side down) over balls in outer ramp sockets.

Do not overtighten ﬁller plugs or drain plugs. Overtightening plugs can cause leaks.

17.Install transmission the drain plug. Tighten the plug to 14-21 ft-lbs (19-28 Nm).

Figure 2-119. Transmission Case (Right Side)

11WARNING1WARNING

Always wear proper eye protection when installing retaining rings. Use the correct retaining ring pliers. Verify that the tips of the pliers are not damaged or excessively worn. Slippage may propel the ring with enough force to cause eye injury.

Figure 2-120. Transmission Lubricant Filler Plug/Dipstick

2004 Touring: Chassis 2-95

HOME

18. Remove the ﬁller plug from the clutch release cover, if installed. See Figure 2-119. Check the O-ring for tears, cuts or general deterioration. Replace as necessary. See Figure 2-120.

19. Fill the transmission with 20-24 oz. (590-710 ml) of transmission lubricant or until the lubricant level on the dipstick of the ﬁller plug is at the F(ULL) mark with the motorcycle in a level, upright position and the ﬁller plug resting on the threads. Use only Harley-Davidson TRANSMISSION LUBRICANT, Part No. 99892-84 (quart) or Part No. 99891-84 (gallon).

20. Install the transmission ﬁller plug/dipstick in the clutch release cover. Tighten the plug to 25-75

in-lbs

(2.8-8.5

Nm).

21. Adjust the clutch cable. See Section 6.3 CLUTCH,

ADJUSTMENT.

22. Install right side exhaust system. See Section 3.8

INSTALLING ENGINE IN CHASSIS, steps 46-52.

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

MAXI-FUSE, INSTALLATION.

2-96 2004 Touring: Chassis

HOME

HANDLEBARS 2.23

HANDLEBAR ADJUSTMENT

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

MAXI-FUSE, REMOVAL.

FLHR/C/S:

Section 2.31 WINDSHIELD/HEADLAMP NACELLE

(FLHR/C/S), NACELLE REMOVAL (FLHR/C), steps 1-

11, or NACELLE REMOVAL (FLHRS), steps 1-7.

FLTR:

UPPER FAIRING/WINDSHIELD (FLTR), BEZEL, REMOVAL.

FLHT/C/U:

UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING CAP, REMOVAL.

3. Loosen rear screws on the upper handlebar clamps. On FLTR models, loosen the front screws instead.

4. Position handlebars for rider posture and comfort.

5. To be sure that the handlebars are centered, verify that the knurled area on the outboard side of the left side handlebar clamp is equal to that on the right side.

6. Snug upper handlebar clamp screws.

Remove the handlebar clamp shroud. See

Remove the instrument bezel. See Section 2.30

Remove the fairing cap. See Section 2.29

11WARNING1WARNING

Improperly aligned handlebars can contact the fuel tank when turned to the left or right fork stops. Contact with the fuel tank while riding can cause loss of vehicle control resulting in death or serious injury.

7. Slowly turn handlebars to the full right fork stop and then the full left fork stop to be sure there is no contact with the fuel tank. If contact occurs and handlebars are properly aligned, raise handlebars as necessary until the proper clearance is obtained.

8. Tighten the upper handlebar clamp screws to 12-16 ftlbs (16.3-21.7 Nm).

FLHR/C/S:

Section 2.31 WINDSHIELD/HEADLAMP NACELLE

(FLHR/C/S), NACELLE INSTALLATION (FLHR/C),

steps 3-15, or NACELLE INSTALLATION (FLHRS), steps 5-13.

FLTR:

UPPER FAIRING/WINDSHIELD (FLTR), BEZEL, INSTALLATION.

FLHT/C/U:

UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING CAP, INSTALLATION.

Install the handlebar clamp shroud. See

Install the instrument bezel. See Section 2.30

Install the fairing cap. See Section 2.29

10. If necessary, adjust left and right handlebar switch controls as follows:

a. Using a T27 TORX drive head, loosen the two

screws securing the handlebar clamp to the clutch lever bracket (left) or master cylinder housing (right).

b. Position switch controls for rider posture and com-

fort.

c. Beginning with the top screw, tighten the screws to

60-80

in-lbs

(6.8-9.0 Nm).

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

MAXI-FUSE, INSTALLATION.

HANDLEBAR REMOVAL

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

MAXI-FUSE, REMOVAL.

2. Place blanket or protective cover over front of fuel tank to protect against scratches or other damage.

FLHR/C/S:

Section 2.31 WINDSHIELD/HEADLAMP NACELLE

(FLHR/C/S), NACELLE REMOVAL (FLHR/C), steps 1-

11, or NACELLE REMOVAL (FLHRS), steps 1-7.

FLTR:

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT NACELLE, REMOVAL.

FLHT/C/U:

UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING CAP, REMOVAL. Remove the radio (or storage box).

See Section 8.31 PREMIUM SOUND SYSTEM (FLHTC/

U, FLTR), RADIO (FLHTC/U), REMOVAL, steps 3-7.

4. Remove the left and right handlebar switch controls. See Section 8.21 HANDLEBAR SWITCHES, REMOVAL.

5. Remove upper handlebar clamp screws (with ﬂat washers). Remove upper handlebar clamps and handlebar.

Remove the handlebar clamp shroud. See

Remove the instrument nacelle. See Section 2.30

Remove the fairing cap. See Section 2.29

HANDLEBAR INSTALLATION

1. Place

2. To be sure that the handlebars are centered, verify that

3. Snug upper handlebar clamp screws.

new

handlebars on lower handlebar clamps. Install upper handlebar clamps and loosely install clamp screws (with ﬂat washers).

the knurled area on the outboard side of the left side handlebar clamp is equal to that on the right side.

2004 Touring: Chassis 2-97

HOME

f2056x2x

**10

**11

1. Screw

2. Flat washer

3. Upper clamp

4. Lower clamp

5. Cup washer

6. Spacer

7. Rubber bushing

8. Bolt

Figure 2-121. Handlebar Clamp Assemblies

*LEFT CLAMP ONLY

9. Ground cable

**RIGHT CLAMP ONLY

10. Flat washer

11. Large ﬂat washer

11WARNING1WARNING

5. Tighten upper handlebar clamp screws as follows:

a. Tighten front screws until upper and lower handle-

bar clamps make contact.

b. Tighten rear screws to 12-16 ft-lbs (16.3-21.7 Nm).

c. Tighten front screws to 12-16 ft-lbs (16.3-21.7 Nm).

NOTE

A slight gap will exist between the upper and lower clamps at the rear of the handlebars after tightening.

6. Install the left hand grip. See LEFT HAND GRIP,

INSTALLATION, in this section.

7. Install the left and right handlebar switch controls. See Section 8.21 HANDLEBAR SWITCHES, INSTALLA-

TION.

FLHR/C/S:

Section 2.31 WINDSHIELD/HEADLAMP NACELLE

(FLHR/C/S), NACELLE INSTALLATION (FLHR/C),

steps 3-15, or NACELLE INSTALLATION (FLHRS), steps 5-13.

FLTR:

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT NACELLE, INSTALLATION.

FLHT/C/U:

UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING CAP, INSTALLATION. Install the radio (or storage box).

See Section 8.31 PREMIUM SOUND SYSTEM (FLHTC/

U, FLTR), RADIO (FLHTC/U), INSTALLATION, steps 1-

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

MAXI-FUSE, INSTALLATION.

10. Turn the ignition/light key switch to IGNITION and test each handlebar switch for proper operation.

11. Apply front brake hand lever to test operation of brake lamp.

12. Adjust idle and throttle control cables as follows:

Non-Cruise:

(NON-CRUISE), ADJUSTMENT.

Cruise Equipped:

TROL (FLHRC, FLTR, FLHTCU), CABLE ADJUSTMENT.

Install the handlebar clamp shroud. See

Install the instrument nacelle. See Section 2.30

Install the fairing cap. See Section 2.29

See Section 2.21 THROTTLE CABLES

See Section 8.30 CRUISE CON-

LEFT HAND GRIP

4. Slowly turn handlebars to the full right fork stop and then the full left fork stop to be sure there is no contact with the fuel tank. If contact occurs and handlebars are properly aligned, raise handlebars as necessary until the proper clearance is obtained.

2-98 2004 Touring: Chassis

REMOVAL

1. Remove the left handlebar switch controls. See Section

8.21 HANDLEBAR SWITCHES, REMOVAL.

HOME

f2077x2x

f2076x2x

2. Use a sharp blade to carefully cut rubber and then peel off handlebar.

3. Thoroughly clean handlebar to remove all residual adhesive.

INSTALLATION

11WARNING1WARNING

HARLEY-DAVIDSON ADHESIVE contains METHYL ETHYL KETONE, a chemical known to the State of California to cause cancer or other reproductive harm.

11WARNING1WARNING

Use HARLEY-DAVIDSON ADHESIVE in well ventilated areas only. Vapors are ﬂammable and can be harmful to breath. Avoid contact with eyes, mucous membranes, or prolonged contact with skin. Keep out of reach of children.

1. Obtain a ADHESIVE (Part No. 99839-95). Apply a coat of the adhesive to the inside surface of the grip one inch (25.4 mm) from the open end. Apply a coat to the end of the handlebar.

2. Immediately push grip completely onto end of handlebar using a twisting motion. Do not hesitate when installing grip or adhesive may dry before installation is complete.

If the left hand grip is patterned, align it with the pattern on the right grip with the throttle in the fully closed position.

3. Let 6-8 hours elapse (at 70 cure.

4. Install the left handlebar switch controls. See Section

8.21 HANDLEBAR SWITCHES, INSTALLATION.

new

left hand grip and HARLEY-DAVIDSON

NOTE

F.) to allow adhesive to fully

Right Side

3. Holding lower handlebar clamp to prevent rotation, turn bolt at bottom of upper fork bracket until free.

4. Remove lower handlebar clamp, ﬂat washer and cup washer at top of upper fork bracket. See Figure 2-122.

5. Pull bushing from fork bracket bore and discard. See

Figure 2-123.

6. Moving to bottom of upper fork bracket, remove bolt, large ﬂat washer and cup washer. See Figure 2-124.

7. Pull bushing and spacer from fork bracket bore. Remove spacer from bushing. See Figure 2-125. Discard bushing.

Left Side

8. Holding lower handlebar clamp to prevent rotation, turn bolt at bottom of upper fork bracket until free.

9. Remove lower handlebar clamp, ground wire ring terminal and cup washer at top of upper fork bracket.

RUBBER MOUNTS

NOTE For complete disassembly of the handlebar clamp assemblies and/or to replace the rubber mounts, proceed as follows.

REMOVAL

General

1. Turn fork to left fork stop and loosen right side bolt at

bottom of upper fork bracket. Turn fork to right fork stop and loosen left side bolt at bottom of upper fork bracket.

2. Remove handlebars. See HANDLEBAR REMOVAL in

this section.

Figure 2-122. Remove Flat Washer and

Upper Cup Washer (Right Side)

Figure 2-123. Remove Upper Bushing (Right Side)

2004 Touring: Chassis 2-99

HOME

f2058x2x

Figure 2-124. Remove Bolt, Large Washer

and Lower Cup Washer (Right Side)

f2057x2x

Figure 2-125. Remove Spacer From Lower Bushing

5. Install cup washer over threaded end of bolt ﬁtting concave side over collar of bushing. Install ﬂat washer. See

Figure 2-122.

6. Apply two or three drops of Loctite Medium Strength Threadlocker 243 (blue) to threads of bolt and start lower handlebar clamp. Holding clamp to prevent rotation, turn bolt at bottom of upper fork bracket until snug.

Left Side

7. Insert spacer into new bushing until ﬂush with outboard side of collar. See Figure 2-125.

8. Insert bushing into bore at bottom of upper fork bracket ﬁtting collar of bushing over lip of boss.

9. Install cup washer on bolt. Insert bolt into bushing ﬁtting concave side of cup washer over collar of bushing.

10. Moving to top of upper fork bracket, insert bushing into bore ﬁtting collar of bushing over lip of boss. See Figure

2-123.

11. Install cup washer over threaded end of bolt ﬁtting concave side over collar of bushing. Install ground wire ring terminal.

12. Apply two or three drops of Loctite Medium Strength Threadlocker 243 (blue) to threads of bolt and start lower handlebar clamp. Holding clamp to prevent rotation, turn bolt at bottom of upper fork bracket until snug.

10. Pull bushing from fork bracket bore and discard. See

Figure 2-123.

11. Moving to bottom of upper fork bracket, remove bolt and cup washer.

12. Pull bushing and spacer from fork bracket bore. Remove spacer from bushing. See Figure 2-125. Discard bushing.

INSTALLATION

Right Side

1. Insert spacer into new bushing until ﬂush with outboard side of collar. See Figure 2-125.

2. Insert bushing into bore at bottom of upper fork bracket ﬁtting collar of bushing over lip of boss.

3. Install large ﬂat washer and cup washer on bolt. See Fig-

ure 2-124. Insert bolt into bushing ﬁtting concave side of

cup washer over collar of bushing.

4. Moving to top of upper fork bracket, insert bushing into

bore ﬁtting collar of bushing over lip of boss. See Figure

2-123.

General

13. Install handlebars and upper handlebar clamps. See

HANDLEBAR INSTALLATION in this section, steps 1-5.

14. Turn fork to left fork stop and tighten right side bolt at bottom of upper fork bracket to 30-40 ft-lbs (40.7-54.2 Nm). Turn fork to right fork stop and tighten left side bolt to the same torque value.

15. Complete assembly of motorcycle. See HANDLEBAR

INSTALLATION in this section, steps 7-12.

2-100 2004 Touring: Chassis

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f1416x2x

f2171x2x

Tongue

Slot

Seat

Bottom

Frame

Backbone

SEAT 2.24

FLHR

REMOVAL

1. Remove Phillips screw to detach passenger seat mounting bracket from top of rear fender. See Figure 2-126. Slightly lift up back of passenger seat and carefully slide toward rear of vehicle to detach from front seat mounting bracket nuts.

NOTE

The FLHR seat can be converted to a solo seat by removal of the passenger section. When the solo seat conﬁguration is desired, turn the passenger seat upside down and locate the chrome plug pressed into the seat frame hole. See inset of

Figure 2-126. Remove the plug and press into the seat reten-

tion nut hole using ﬁnger pressure only.

2. Using the 5/8 hex, remove two nuts from studs to free front seat mounting bracket from rear fender.

3. Push front seat rearward to free tongue from slot in frame backbone. See Figure 2-127.

f1091d2x

Nut

Front Seat

Passenger Seat

f1456x2x

Figure 2-126. Seat Assembly - FLHR

Retention Nut Plug

Passenger

Seat

Stud Plate

Screw

Figure 2-127. Seat Mounting

INSTALLATION

1. Position front seat on frame with mounting bracket at rear.

2. Firmly push front of seat downward and rearward until tongue engages slot in frame backbone. See Figure 2-

127. Push seat forward until studs are centered in slots

of mounting bracket.

3. Using the 5/8 hex, install two nuts on studs to secure front seat mounting bracket to rear fender.

4. Install passenger seat ﬁtting slots on passenger seat front mounting bracket between rounded caps and hex of front seat mounting bracket nuts.

2004 Touring: Chassis 2-101

HOME

5. Push passenger seat forward until rear fender seat retention nut is centered in hole of rear mounting bracket. Install Phillips screw.

NOTE

If seat retention nut is damaged or lost, see SEAT RETEN-

TION NUT REPLACEMENT for instructions.

11WARNING1WARNING

Pull up on seat to verify that it is properly secured, front and rear. A loose seat may shift during vehicle operation and startle the rider, possibly causing loss of vehicle control resulting in death or serious injury.

FLHRC

REMOVAL

f1550x2x

Slot

Figure 2-128. Route Passenger Seat Strap Through

Slots in Seat - FLHRC

1. Remove right side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

2. Remove bolt (with ﬂat washer) to remove passenger seat strap and saddlebag front mounting bracket from chrome frame tube cover.

3. Using slots in seat, carefully pull passenger seat strap from seat. See Figure 2-128.

4. Remove Phillips screw to detach seat mounting bracket from top of rear fender.

5. Push seat rearward to free tongue at front of seat from slot in frame backbone. See Figure 2-127.

6. Remove seat from frame.

INSTALLATION

1. Place seat on frame backbone.

2. Firmly push front of seat downward and rearward until tongue engages slot in frame backbone. See Figure 2-

127.

3. Push seat forward until rear fender seat retention nut is centered in hole of mounting bracket. Install Phillips screw.

NOTE

If seat retention nut is damaged or lost, see SEAT RETEN-

TION NUT REPLACEMENT for instructions.

11WARNING1WARNING

4. Using slots in seat, route free end of passenger seat strap to right side of vehicle. See Figure 2-128.

5. Insert bolt with ﬂat washer through passenger seat strap and slotted hole of saddlebag front mounting bracket. Insert bolt into forward hole in chrome frame tube cover. Snug saddlebag front mounting bracket bolt, b tighten.

6. Install right side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

7. Using an open end/box wrench, tighten saddlebag front mounting bracket bolt.

ut do not

FLHRS, FLTR

REMOVAL

CAUTION

Removing seat without ﬁrst removing passenger seat strap will result in damage to rear fender paint.

1. Remove right side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

2. Remove bolt (with ﬂat washer) to remove passenger seat strap and saddlebag front mounting bracket from chrome frame tube cover. Draw free end of passenger seat strap to left side of vehicle.

3. Remove Phillips screw to detach seat mounting bracket from top of rear fender.

4. Push seat rearward to free tongue at front of seat from slot in frame backbone. See Figure 2-127.

5. Remove seat from frame.

2-102 2004 Touring: Chassis

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11WARNING1WARNING

INSTALLATION

1. Place seat on frame backbone.

2. Firmly push front of seat downward and rearward until tongue engages slot in frame backbone. See Figure 2-

127.

3. Push seat forward until rear fender seat retention nut is centered in hole of mounting bracket. Install Phillips screw.

NOTE If seat retention nut is damaged or lost, see SEAT RETEN-

TION NUT REPLACEMENT for instructions.

11WARNING1WARNING

4. Draw free end of passenger seat strap to right side of

vehicle. Insert bolt with ﬂat washer through passenger seat strap and slotted hole of saddlebag front mounting bracket. Insert bolt into forward hole in chrome frame tube cover. Snug saddlebag front mounting bracket bolt, b

ut do not tighten.

5. Install right side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

6. Using an open end/box wrench, tighten saddlebag front

mounting bracket bolt.

FLHTC/U

REMOVAL

1. Open Tour-Pak to move passenger seat backrest out of the way.

NOTE

The Tour-Pak must be positioned to the rear to access the seat mounting bracket screw. If the Tour-Pak is in the forward position, remove Tour-Pak and install in rearward position. See Section 2.26 TOUR-PAK for more information.

2. Remove Phillips screw to detach seat mounting bracket from top of rear fender.

3. To protect ﬁnish of Tour-Pak, cover rear seat mounting bracket with palm of hand.

4. While pushing seat forward, raise rear of seat until bracket clears top of Tour-Pak. Push seat rearward slightly to free tongue at front of seat from slot in frame backbone. See Figure 2-127.

5. Remove seat from frame.

FLHT

REMOVAL

1. Remove Phillips screw to detach seat mounting bracket from top of rear fender.

2. Push seat rearward to free tongue at front of seat from slot in frame backbone. See Figure 2-127.

3. Remove seat from frame.

INSTALLATION

1. Place seat on frame backbone.

2. Firmly push front of seat downward and rearward until tongue engages slot in frame backbone. See Figure 2-

127.

3. Push seat forward until rear fender seat retention nut is centered in hole of mounting bracket. Install Phillips screw.

NOTE

If seat retention nut is damaged or lost, see SEAT RETEN-

TION NUT REPLACEMENT for instructions.

INSTALLATION

1. Place seat on frame backbone.

2. To protect ﬁnish of Tour-Pak, cover rear seat mounting bracket with palm of hand.

3. While raising rear of seat approximately 3 inches (76.2 mm), use other hand to ﬁrmly push front of seat downward and rearward until tongue engages slot in frame backbone. See Figure 2-127.

4. Push seat forward until rear fender seat retention nut is centered in hole of mounting bracket. Install Phillips screw.

NOTE If seat retention nut is damaged or lost, see SEAT RETEN-

TION NUT REPLACEMENT for instructions.

2004 Touring: Chassis 2-103

HOME

SEAT RETENTION NUT REPLACEMENT

1. Slide retention nut over tapered end of cable strap so that larger OD of nut rests on cable strap eyelet. From bottom of rear fender, feed cable strap up through fender hole.

2. See Figure 2-129. With tab on retention nut seated in notch of fender hole, pull up on cable strap to hold nut snug against underside of rear fender. From the side opposite the tab, slide on the retention washer to lock the position of the retention nut. Remove cable strap.

Rear

Fender

Tab

f1897x2x

Retention

Washer

Retention

Nut

Figure 2-129. Seat Retention Nut and Washer

2-104 2004 Touring: Chassis

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f1553x2x

f1554x2x

Check Strap

Anchor Tabs

Anchor Brackets

Hinge

Latch

SADDLEBAG 2.25

OPENING

NOTE

Maximum recommended load for each saddlebag is 15 lbs.

FLHRC

1. Raise the decorative buckle and press tabs on both sides of catch to release from receptacle. Repeat step to release second catch. See upper frame of Figure 2-130.

2. Rotate hinge on outboard side of saddlebag to open lid.

FLHRS

1. Depress button on front inboard side of saddlebag, and while holding button in, raise lid. See lower frame of Fig-

ure 2-130.

f1552x2x

f2228x3x

Catch

Receptacle

FLHRC

Button

FLHRS

Figure 2-130. Open Saddlebag (FLHRC/S)

Figure 2-131. Open Saddlebag (FLHR, FLTR, FLHT/C/U)

2. Rotate hinge on inboard side of saddlebag to open lid.

FLHR, FLTR, FLHT/C/U

1. Use key to unlock lid latch if locked.

2. Pull bottom of latch outward and then lift upward raising outboard corners of saddlebag lid. See upper frame of

Figure 2-131.

3. With top of lid tilted toward motorcycle, carefully lift inboard side of lid upward disengaging front and rear anchor tabs from anchor brackets.

4. Pivot lid on latch hinge to open. A nylon check strap suspends the lid in the open position. See lower frame of

Figure 2-131.

2004 Touring: Chassis 2-105

HOME

Rear

Mounting

Bracket

Quick-Release

Stud

Wire

Form

Flat

Bail

Wire

Figure 2-132. Saddlebag Quick-Release Fasteners

Washer

Spring

Plate

Mounting

CLOSING

FLHRC

Front

Bracket

f1075axx

f1451x2x

Front Mounting

Bracket Bolt

1. Rotate hinge on outboard side of saddlebag to close lid.

2. Insert catch into receptacle until tabs fully engage. Repeat step to secure second catch. See upper frame of

Figure 2-130.

FLHRS

1. Rotate hinge on inboard side of saddlebag to close lid. Lid latches automatically.

FLHR, FLTR, FLHT/C/U

1. Rotate lid to closed position engaging both anchor tabs with bottom of anchor brackets. Press bottom of latch inward until it snaps closed. See lower frame of Figure 2-

131.

2. Use key to lock lid latch.

REMOVAL

1. Open saddlebag. See OPENING in this section.

2. Grasp bail wire inside saddlebag and rotate each stud a

full 1/4 turn in a counter-clockwise direction. Remove bail head studs with ﬂat washers. See Figure 2-132.

f1450x2x

Figure 2-133. Saddlebag Mounting Bracket Bolts

(Right Side View)

NOTE

On some HDI vehicles, the bail wire has been removed from the quick release stud. In these cases, turn the stud by engaging the slotted end with a large screwdriver.

3. Remove saddlebag.

Rear Mounting

Bracket Bolt

INSTALLATION

1. Position saddlebag on vehicle.

2. Place ﬂat washers on bail head studs.

2-106 2004 Touring: Chassis

HOME

8863

8862

Rub Bar

8865

8864

Opening

3. With groove at end of stud held in a horizontal position, insert stud through holes in saddlebag and front mounting bracket. When groove engages wire form of spring plate on inboard side of bracket, turn stud clockwise a full 1/4 turn until it snaps in place. Install rear bail head stud in the same manner.

NOTE

On some HDI vehicles, the bail wire has been removed from the quick release stud. In these cases, turn the stud by engaging the slotted end with a large screwdriver.

NOTE

Molded rubber insert at bottom of saddlebag must ﬁt snugly on lower saddlebag support rail. If saddlebag is not fully seated, use an open end/box wrench to loosen bolts securing mounting brackets to saddlebag support and frame. See

Figure 2-133. Alternately tighten bolts to 60-96 in-lbs (7-11

Nm) after seating saddlebag.

4. Close saddlebag. See CLOSING in this section.

LATCH SPRING REPLACEMENT (FLHR, FLTR, FLHT/C/U)

REMOVAL

1. Lay clean pad or blanket on work bench to protect painted surfaces of saddlebag.

2. Remove saddlebag from motorcycle leaving lid open. See REMOVAL in this section.

3. Lay saddlebag ﬂat on pad with the inboard side facing up and the lid closest to you.

4. Remove two T20 TORX screws to release check strap from lid.

5. Remove two T15 TORX screws to release check strap from saddlebag.

6. Remove two remaining T15 TORX screws to remove latch from saddlebag. Move saddlebag back and out of the way.

CAUTION

This procedure assumes that the latch is NOT removed from the saddlebag lid. If there is doubt as to whether the procedure can be accomplished without scratching painted surfaces of the lid, then remove the ﬁve remaining T15 TORX screws to completely remove latch.

7. Position lid right side up with latch closest to you.

Figure 2-134. Lid Right Side Up With Latch on Near Side

8. Raise latch slightly and rotate hinge on inboard side so

that it is topside with the two plastic rub bars pointed upward. See upper frame of Figure 2-134.

Figure 2-135. Lid Up Side Down With Latch on Far Side

2004 Touring: Chassis 2-107

HOME

9. Rotate rub bar section of hinge to expose hinge pin and spring. Using a ﬂat tip screwdriver, carefully bend crimped end link outward. See lower frame of Figure 2-

134.

NOTE

The end link on opposite side of hinge has a weld spot that prevents pin removal.

10. Reposition lid so that it is upside down with the latch farthest from you. Rotate hinge so that plastic rub bars are positioned beneath latch and spring is topside.

11. Using a needle nose pliers, grasp pin through opening just outboard of the spring and push toward the crimped link side. Work pin in this manner until end can be seen exiting crimped link. See upper frame of Figure 2-135. If necessary, pry crimped link outward a little more to achieve the desired result.

12. Grasping end with needle nose pliers, slowly pull pin from links until spring can be slid off opposite end. Only pull pin as far as necessary to remove spring. See lower frame of Figure 2-135.

INSTALLATION

1. Slide new spring onto end of pin. Orient spring as shown in lower frame of Figure 2-135.

2. Slide pin back through links. Using tapered end of needle nose pliers, push end of pin into crimped link

3. Reposition lid so that it is right side up with latch closest to you. As before, raise latch slightly and rotate hinge on inboard side so that it is topside with plastic rub bars pointing upward. Now rotate rub bar section of hinge to expose hinge pin and spring. See Figure 2-134.

4. Holding lid down with elbow, if necessary, use a pliers to bend crimped link back into its original position, so that pin is captured and will not back out of hinge.

5. Reposition lid so that it is upside down with the latch farthest from you. Move saddlebag forward for reinstallation of lid. Align four holes in saddlebag with those in latch.

6. Install two inboard T15 TORX screws to fasten latch to saddlebag. Alternately tighten screws to 20-25 in-lbs (2.3-2.8 Nm).

7. Align holes in check strap with those in lid and saddlebag. Orient check strap so that logo is topside with the bottom of the bar and shield on the lid side.

8. Install two T15 TORX screws to fasten check strap and latch to saddlebag. Alternately tighten screws to 20-25 in-lbs (2.3-2.8 Nm).

9. Install two T20 TORX screws to fasten check strap to lid. Alternately tighten screws to 18-20 in-lbs (2.0-2.3 Nm).

10. Close saddlebag and install on motorcycle. See

INSTALLATION in this section.

CABLE ASSEMBLY/LATCH/SCRIPT (FLHRS)

CABLE ASSEMBLY

Removal

1. Open saddlebag. See OPENING in this section.

2. Remove two screws on inboard side of saddlebag to release plastic shroud. See upper frame of Figure 2-136.

3. Depress wireform and pull button from hole in saddlebag. See lower frame of Figure 2-136.

4. Remove sleeve from hole in saddlebag.

5. Moving to inboard side of saddlebag lid, remove lock ring from hole at end of latch pin. See upper frame of

Figure 2-137.

6. Pull latch pin from metal shroud, saddlebag bracket and latch. Remove metal shroud.

7. Depress spring and pull on cable ball end to remove from slot in latch. Remove latch.

8. Remove spring from cable. See lower frame of Figure 2-

137.

Plastic

f2229x2x

f2232x2x

Figure 2-136. Remove Button Assembly

Shroud

Wireform

2-108 2004 Touring: Chassis

HOME

Body Hex

Jam Nut

f2235x2x

f2233x2x

5. Install cable end ﬁtting into hole in saddlebag bracket.

6. With the rounded edge of the e-clip on the same side as the rounded edge of the saddlebag bracket, install e-clip into groove in cable end ﬁtting.

7. Pull up on cable ball end and install spring on cable. See lower frame of Figure 2-137.

1. Lock Ring

2. Metal Shroud

3. Latch Slot

4. Saddlebag Bracket

5. Spring

6. E-Clip

Verify that ball end on opposite side of cable is installed in pivot of button assembly. See Figure 2-138.

8. Position latch between saddlebag bracket with the cable slot inline with the cable ball end. Depress spring and capture cable ball end in slot of latch.

9. Install metal shroud over latch and saddlebag bracket. At rear of assembly, insert latch pin through metal shroud, saddlebag bracket and latch until end exits front hole in shroud.

10. Install lock ring into hole at end of latch pin. See upper frame of Figure 2-137.

11. Close and open saddlebag lid several times to verify that latch locks every time. Adjust cable if necessary.

NOTE

f2234x2x

Figure 2-137. Remove Latch Assembly

9. Remove e-clip from groove in cable end ﬁtting.

10. Pull cable end ﬁtting from hole in saddlebag bracket.

11. Release cable from channel running along inboard edge of saddlebag.

Installation

1. From the outboard side, insert sleeve into hole in saddlebag.

2. On the inboard side, depress wireform and slide button into sleeve. Release wireform. Gently tug on assembly to verify that wireform has engaged groove in sleeve to lock button in place. See lower frame of Figure 2-136.

3. Holding plastic shroud with the relief positioned over the cable adjuster, install two screws from inboard side of saddlebag. See upper frame of Figure 2-136.

4. Capture cable in channel running along inboard edge of saddlebag.

Adjustment

1. Open saddlebag. See OPENING in this section.

2. Remove two screws on inboard side of saddlebag to release plastic shroud. See upper frame of Figure 2-136.

3. Back jam nut away from body hex. See Figure 2-138.

4. Turn body hex toward or away from jam nut until closest part of latch is approximately 3/8 inch (9.5 mm) from inboard side of saddlebag lid.

5. Turn jam nut until it makes ﬁrm contact with body hex.

Figure 2-138. Cable Adjustment

2004 Touring: Chassis 2-109

HOME

6. Holding plastic shroud with the relief positioned over the cable adjuster, install two screws from inboard side of saddlebag. See upper frame of Figure 2-136.

7. Close and open saddlebag lid several times to verify that latch locks every time. Readjust if necessary.

LATCH

Removal

1. Open saddlebag. See OPENING in this section.

2. Moving to inboard side of saddlebag lid, remove lock ring from hole at end of latch pin. See upper frame of

Figure 2-137.

3. Pull latch pin from metal shroud, saddlebag bracket and latch. Remove metal shroud.

4. Depress spring and pull on cable ball end to remove from slot in latch. Remove latch.

CAUTION

Always install push nuts on the end studs ﬁrst. If center stud is not done last, end stud can sometimes come out of saddlebag hole during installation of the second push nut. If this occurs, forcing the last stud in can bend stud or script and enlarge saddlebag hole.

2. From inside saddlebag, install new push nuts onto

studs. For best results, install push nuts on the end studs ﬁrst.

3. Close saddlebag. See CLOSING in this section.

SADDLEBAG GUARD/SUPPORT RAIL

Installation

1. Position new latch between saddlebag bracket with the cable slot inline with the cable ball end. Depress spring and capture cable ball end in slot of latch.

2. Install metal shroud over latch and saddlebag bracket. At rear of assembly, insert latch pin through metal shroud, saddlebag bracket and latch until end exits front hole in shroud.

3. Install lock ring into hole at end of latch pin. See upper frame of Figure 2-137.

4. Close saddlebag. See CLOSING in this section.

SCRIPT

Removal

1. Open saddlebag. See OPENING in this section.

CAUTION

Do not remove push nuts unless script replacement is necessary. Push nuts are damaged during removal and studs on script may be bent or broken.

2. From inside saddlebag, pry push nuts from studs. Discard push nuts.

3. Remove script from side of saddlebag.

REMOVAL

1. Remove saddlebag from motorcycle. See REMOVAL in this section.

2. Disassemble saddlebag guard, support and/or rails as necessary. See Figure 2-139.

INSTALLATION

1. Assemble saddlebag guard, support and/or rails as necessary. Replace any damaged parts. See Figure 2-139.

2. Install saddlebag on motorcycle. See INSTALLATION in this section.

Installation

1. Install new script on side of saddlebag inserting studs

through holes.

2-110 2004 Touring: Chassis

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FLHTC/U Multi-Rail

Tor que:

1. Saddlebag mounting bracket screws: 60-96 in-lbs (7-11 Nm)

2. Saddlebag support to fender screws: 15-20 ft-lbs (20-27 Nm)

3. Rail to saddlebag support screws: 15-20 ft-lbs (20-27 Nm)

4. Guard/support rail to frame screws: 15-20 ft-lbs (20-27 Nm)

5. Support rail to guard screw: 70-100 in-lbs (8-11 Nm)

6. Guard mount to rail screws: 72-120 in-lbs (8-14 Nm)

7. Rail clamp screws: 30-50 in-lbs (3-6 Nm)

Saddlebag Guard

FLHT, FLHR/C

Saddlebag Guard

f2247x2x

FLTR, FLHRS

f2248x2x

Saddlebag Support Rail

f2249x2x

Figure 2-139. Saddlebag Guards/Support Rail

2004 Touring: Chassis 2-111

HOME

TOUR-PAK 2.26

FLHTC

Tour-Pak

NOTE

For instructions covering riveted components, such as hinges and catches, refer to the Instruction Sheet included with the RIVET TOOL, HD-39787.

REMOVAL

1. Open Tour-Pak. Remove rubber mat.

2. Rotate knurled lock ring in a counter-clockwise direction to separate pin and socket halves of Radio antenna cable connector. Release cable from two clips at bottom of Tour-Pak.

3. Pull Tour-Pak lights connector [12], 3-place Multilock, from cavity inside Tour-Pak. Depress button and separate pin and socket halves. See Figure 2-140.

4. Pull grommet into Tour-Pak and remove from main harness conduit.

5. Feed main harness conduit and connectors through hole in Tour-Pak. See Figure 2-141.

6. Holding nylon cap locknuts at bottom of Tour-Pak, remove ﬁve bolts (with ﬂat washers) to release Tour-Pak from luggage rack. Luggage rack spacers will become free as nuts are removed. Be sure to have a ﬁrm grasp on the Tour-Pak as the last bolt is removed. See Figure

2-142.

f1466a2x

Cable

Clip

Grommet

Hole

Grommet

Cable

Clip

Figure 2-141. Feed Main Harness Thru Tour-Pak Hole

Mounting Bolt

INSTALLATION

1. Place Tour-Pak on luggage rack and open lid.

2. Align rear center hole in Tour-Pak with same hole in luggage rack. Slide 2 inch bolt (with ﬂat washer) through ring terminal of radio antenna ground, and then through To ur-Pak and luggage rack holes. At bottom of luggage rack, install spacer (concave side up) and nylon cap locknut on bolt. With concavity on spacer inline with the rail, hold nut and tighten bolt until snug.

CAUTION

Always install the mounting bolts from inside the TourPak. If the bolts are installed upside down, then the ends of the bolts can tear the molded liner and scratch objects, such as helmets, stored inside the Tour-Pak.

Radio Antenna

Cable Connector

Tour-Pak

Cavity

Tour-Pak Lights

Connector [12]

Tour-Pak

Radio Antenna

Cable

Figure 2-140. Disconnect Tour-Pak Lights Connector

2-112 2004 Touring: Chassis

Mounting Bolt

3. Install remaining 2 inch bolts (with ﬂat washers and nylon cap locknuts) in two front Tour-Pak and luggage rack holes (one each side) in the manner described under step 2 above.

4. Position two spacers between bottom of luggage rack and tabs of license plate bracket. Slide 2-1/4 inch bolts (with ﬂat washers) through two center holes in Tour-Pak and luggage rack, and then through spacers and tabs of license plate bracket. If necessary, loosen two hex bolts at back of license plate bracket to align holes in tabs with bolts. Install ﬂat washers and nylon cap locknuts on bolts and tighten until snug. See inset of Figure 2-142.

HOME

f1850x2x

6. Standing on left side of vehicle, feed socket connectors and main harness conduit through hole in Tour-pak. Capture conduit in grommet. Install grommet in hole with the larger OD facing inside.

Spacer

Nylon Cap

Locknut

Luggage

Rack Rail

Rear Center Hole

Mounting Bolt

(Cap side Up)

Flat

Washer

Flat

Washer

7. Mate pin and socket halves of Tour-pak lights connector [12], 3-place Multilock, and tuck into cavity inside TourPak. See Figure 2-140.

8. Rotate knurled lock ring in a clockwise direction to mate pin and socket halves of Radio antenna cable con-nector. Capture cable in two clips at bottom of Tour-Pak.

9. Install rubber mat. Close Tour-Pak.

FLHTCU

REMOVAL

1. Open Tour-Pak. Open map pocket and remove acorn nuts (with ﬂat washers). Remove map pocket and molded liner from Tour-Pak.

2. Depress external latch and rotate housing to release bulb socket from left side of Tour-Pak.

3. Rotate knurled lock ring in a counterclockwise direction to separate pin and socket halves of Radio antenna cable connector. Release cable from two clips at bottom of Tour-Pak.

4. Pull Tour-Pak lights connector [12], 3-place Multilock, from cavity inside Tour-Pak. Depress button and separate pin and socket halves. See Figure 2-140.

Spacer

f1851x2x

Nylon Cap

Locknut

Stackup at License Plate Bracket

Figure 2-142. Install Tour-Pak Mounting Bolts

5. In a crosswise pattern, alternately tighten ﬁve bolts to

96-120 in-lbs (10.8-13.5 Nm). Be sure that concavity on each spacer is inline with the rail and has not rotated out of position.

5. Pull grommet into Tour-Pak and remove from main harness conduit.

6. Feed main harness conduit and connectors through hole in Tour-Pak. See Figure 2-141.

7. Release rear headset receptacle from bracket at bottom of left side speaker box.

8. Remove trim ring and gently pull on wire harness to draw 6-place Mini-Deutsch connector out of left side speaker box. Depress external latch and use a rocking motion to separate pin and socket halves.

9. Moving to right side of vehicle, disconnect 1-place CB antenna cable connector. Release cable from two clips at bottom of Tour-Pak. See Figure 2-143.

10. Pull right side grommet into Tour-Pak and remove from CB antenna cable. Feed CB antenna cable through hole in Tour-Pak.

11. Remove trim ring and gently pull on wire harness to draw 6-place Mini-Deutsch connector out of right side speaker box. Depress external latch and use a rocking motion to separate pin and socket halves.

2004 Touring: Chassis 2-113

HOME

Grommet

Cable

Clip

Tour-Pak

Mounting Bolt

Figure 2-143. Disconnect CB Antenna Cable Connector

12. Holding nylon cap locknuts at bottom of Tour-Pak, remove ﬁve bolts (with ﬂat washers) to release Tour-Pak from luggage rack. Luggage rack spacers will become free as nuts are removed. Be sure to have a ﬁrm grasp on the Tour-Pak as the last bolt is removed. See Figure

2-142.

CB Antenna

Cable Connector

f1467b2x

5. In a crosswise pattern, alternately tighten ﬁve bolts to 96-120 in-lbs (10.8-13.5 Nm). Be sure that concavity on each spacer is inline with the rail and has not rotated out of position.

6. On right side of vehicle, mate pin and socket halves of 6place Mini-Deutsch connector. Feed connector back up into right side speaker box pressing trim ring into hole.

7. Pass CB antenna cable through hole in Tour-Pak. Capture cable in grommet. Install grommet in hole with the larger OD facing inside.

8. Mate pin and socket halves of 1-place CB antenna cable connector. Capture cable in two clips at bottom of TourPak. See Figure 2-143.

9. Moving to left side of vehicle, mate pin and socket halves of 6-place Mini-Deutsch connector. Feed connector back up into left side speaker box pressing trim ring into hole.

10. Capture rear headset receptacle in bracket at bottom of left side speaker box.

11. Feed socket connectors and main harness conduit through hole in Tour-pak. Capture conduit in grommet. Install grommet in hole with the larger OD facing inside.

INSTALLATION

1. Place Tour-Pak on luggage rack and open lid.

CAUTION

3. Install remaining 2 inch bolts (with ﬂat washers and nylon cap locknuts) in two front Tour-Pak and luggage rack holes (one each side) in the manner described under step 2 above.

12. Mate pin and socket halves of Tour-pak lights connector [12], 3-place Multilock, and tuck into cavity inside TourPak. See Figure 2-140.

13. Rotate knurled lock ring in a clockwise direction to mate pin and socket halves of Radio antenna cable connector. Capture cable in two clips at bottom of Tour-Pak.

14. Install bulb socket on left side of Tour-pak.

15. Install molded liner in Tour-Pak. Install map pocket and secure using acorn nuts (with ﬂat washers). Close TourPak.

2-114 2004 Touring: Chassis

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f1810x2x

Bulb

Lense

Eyelet

Screwdriver

Stepped

Rib

Mounting

Bracket

Tour-Pak

TOUR-PAK LIGHTS/BACKREST/SPEAKER BOX 2.27

GENERAL

All domestic model Tour-Paks are equipped with side marker lights. Ultra models also have a wrap-around rear light assembly that contains two 2-ﬁlament lamps. One ﬁlament is a supplemental brake light and the other a supplemental tail lamp.

SIDE MARKER LIGHTS FLHTC/U

BULB/LENSE REPLACEMENT

1. Open Tour-Pak.

2. On Ultra models, open map pocket and remove acorn nuts (with ﬂat washers). Remove map pocket and molded liner from Tour-Pak.

3. Remove three T15 TORX screws to release lens at side of Tour-Pak.

4. Using the blade of an X-Acto knife or small screwdriver, gently pry up three eyelets on inboard side of mounting bracket. See Figure 2-144. Remove eyelets and then remove mounting bracket from lense. Discard eyelets if damaged.

5. Remove bulb from socket and discard. Install new bulb in socket.

6. Align holes in mounting bracket with those in lense. Push three eyelets through mounting bracket holes into bosses of lense. Use new eyelets if damaged.

7. Place lense assembly into position at side of Tour-Pak, but exercise caution to avoid pinching or kinking wires. Note that center rib on inboard side of lense has a stepped area for routing of the top wire. See Figure 2-

144.

8. From inside Tour-Pak, install three T15 TORX screws.

9. On Ultra models, install molded liner in Tour-Pak. Install map pocket and secure using acorn nuts (with ﬂat washers).

10. Close Tour-Pak.

3. Close Tour-Pak. Turn Tour-Pak over and remove remain-

4. Place Tour-Pak topside up and open lid. Reach inside

5. Locate 2-place Multilock connector in channel at bottom

6. Depress button on socket side of Multilock connector

7. Remove three T15 TORX screws to release lens at side

8. Compress grommet at side of Tour-Pak and push

INSTALLATION

Figure 2-144. Remove Eyelets to Release

Mounting Bracket From Lense

ing six ﬂange nuts at bottom.

Tour-Pak and remove metal plate pulling threaded studs from holes at bottom.

of Tour-Pak. Remove masking tape if necessary. See

Figure 2-145.

and separate pin and socket halves.

of Tour-Pak.

through hole to outboard side. Feed conduit and socket through hole to release side marker light assembly.

REMOVAL

1. Remove Tour-Pak. See Section 2.26 TOUR-PAK, RE- MOVAL, either FLHTC or FLHTCU. Move Tour-Pak to bench area.

2. Open Tour-Pak. Holding Phillips screw inside Tour-Pak (rear right corner), remove ﬂange nut at bottom to release loading coil bracket. Remove Phillips screw with external tooth lockwasher.

1. Feed socket and conduit of new side marker light

assembly through hole at side of Tour-Pak.

2. Compress grommet on conduit and install in hole.

3. Place lense assembly into position at side of Tour-Pak, but exercise caution to avoid pinching or kinking wires. Note that center rib on inboard side of lense has a stepped area for routing of the top wire. See Figure 2-

144.

2004 Touring: Chassis 2-115

HOME

Tour-Pak Lights

Connector [12]

3-place Multilock

Left Side

Side Marker Light

Connector

2-place Multilock

Masking

Tape

Figure 2-145. Side Marker Light Connectors and Conduit

f1753x2x

Right Side

Side Marker Light

Connector

2-place Multilock

4. From inside Tour-Pak, install three T15 TORX screws.

5. Mate pin and socket halves of 2-place Multilock connector. Be sure that connector and conduit are positioned in channel at bottom of Tour-Pak.

CAUTION

If conduit and connector are not completely captured in channel at bottom of Tour-Pak, installation of metal plate can pinch wires or damage connector.

6. Place masking tape over channel to secure position of connector and conduit. See Figure 2-145.

7. With the square cut positioned at the front left corner, install metal plate at bottom of Tour-Pak so that threaded studs exit holes at bottom.

8. Place loading coil into position aligning hole in bracket with hole in rear right corner of metal plate. Slide Phillips screw (with external tooth lockwasher) through holes. At bottom of Tour-Pak, install ﬂange nut on Phillips screw.

9. Close lid and turn Tour-Pak over. Install six ﬂange nuts on threaded studs of metal plate.

10. Install Tour-Pak on vehicle. See Section 2.26 TOUR-

PA K , INSTALLATION, either FLHTC or FLHTCU.

WRAP-AROUND LIGHT ASSEMBLY FLHTCU

BULB REPLACEMENT

1. Open Tour-Pak.

2. Open map pocket and remove acorn nuts (with ﬂat washers). Remove map pocket and molded liner from To u r-Pak.

3. Depress external latch and rotate bulb socket to release from lens.

4. Remove bulb from socket and discard.

5. Install new bulb in socket.

6. Rotate bulb socket to install in lens.

7. Install molded liner in Tour-Pak. Install map pocket and secure using acorn nuts (with ﬂat washers).

8. Close Tour-Pak.

REMOVAL

1. Open Tour-Pak. Open map pocket and remove acorn nuts (with ﬂat washers). Remove map pocket and molded liner from Tour-Pak.

2-116 2004 Touring: Chassis

HOME

f1257x2x

Tour-Pak

Bulb Housing

Caulking

Figure 2-146. Wrap-Around Light Assembly

2. Depress external latch and rotate housing to release bulb sockets from both sides of Tour-Pak.

3. Disconnect 1-place CB antenna cable connector on right side of Tour-Pak. Release cable from rear clip at bottom of Tour-Pak.

4. Remove Keps nut, ring terminal and ﬂat washer from loading coil stud.

5. Holding Phillips screw, remove ﬂange nut at bottom of To ur-Pak to release loading coil bracket. Remove Phillips screw (with external tooth lockwasher) and loading coil from vehicle.

6. Using a 2.5 mm allen head wrench, remove loading coil stud. Remove CB antenna mast from lamp housing.

Metal Clip

INSTALLATION

1. Install light bar, metal clips and ﬂange nuts to secure light bar to Tour-Pak. Inside Tour-Pak, use RTV silicone sealer (Part No. 99710-88) to seal perimeter of light bar. See Figure 2-146.

2. Install radio antenna mast into lamp housing. Thread connector stud into mast. Turn 1/2 in.-20 UNF nut (installed on connector during removal) in a clockwise direction to tighten.

3. Remove 1/2 in.-20 UNF nut and jam nut. Install large ﬂat washer, ring terminal and internal tooth lockwasher onto connector. Reinstall jam nut and tighten.

4. Rotate knurled lock ring in a clockwise direction to mate pin and socket halves of Radio antenna cable connector. Capture cable in rear clip at bottom of Tour-Pak.

5. On right side of Tour-Pak, install CB antenna mast into lamp housing. Install stud into mast and tighten with 2.5 mm allen head wrench.

6. Place loading coil into position aligning hole in bracket with hole in rear right corner of Tour-Pak. Slide Phillips screw (with external tooth lockwasher) through holes. At bottom of Tour-Pak, install ﬂange nut on Phillips screw.

7. Install ﬂat washer, ring terminal and Keps nut onto loading coil stud. Tighten Keps nut.

8. Mate pin and socket halves of 1-place CB antenna cable connector. Capture antenna cable in rear clip at bottom of Tour-Pak.

9. Install bulb sockets on both sides of Tour-pak.

10. Install molded liner in Tour-Pak. Install map pocket and secure using acorn nuts. Close Tour-Pak.

11. Install SWR meter. Check SWR following procedure in Section 6 of the 2004 ELECTRICAL DIAGNOSTIC MANUAL (Part No. 99497-04). When the antenna is adjusted, remove the SWR meter and tighten the antenna connector at the transceiver.

7. On left side of Tour-Pak, rotate knurled lock ring in a counter-clockwise direction to separate pin and socket halves of Radio antenna cable connector. Release cable from rear clip at bottom of Tour-Pak.

8. Remove jam nut from Radio antenna cable connector at back of Tour-Pak. Remove internal tooth lockwasher, ring terminal and large ﬂat washer from connector.

9. Install jam nut back onto connector. Thread a 1/2 in.-20 UNF nut onto connector until contact is made with jam nut. Turn jam nut to in a counter-clockwise direction to remove connector stud from radio antenna mast. Remove mast from lamp housing.

10. Remove caulking from around light bar. Remove four ﬂange nuts and metal clips to free light bar from TourPak. See Figure 2-146.

PASSENGER BACKREST FLHTCU

REMOVAL

1. Open Tour-Pak. Open map pocket and remove acorn nuts (with ﬂat washers). Remove map pocket and molded liner from Tour-Pak.

2. Remove two locknuts and backplate to detach center backrest from Tour-Pak cover. See Figure 2-147.

3. Remove two locknuts and backplate to detach right side backrest from cover.

4. Remove two locknuts to detach left side backrest from cover.

5. Remove backrest.

2004 Touring: Chassis 2-117

HOME

5142

SPEAKER BOX FLHTCU

Right Side

Fasteners

and Backplate

Center

Fasteners

and Backplate

Left Side

Fasteners

Figure 2-147. Tour-Pak Cover (Underside)

Passenger

Backrest

REMOVAL

1. Remove trim ring and gently pull on wire harness to draw 6-place Mini-Deutsch connector out of speaker box. Depress external latch and use a rocking motion to separate pin and socket halves.

2. Open Tour-Pak. Open map pocket and remove acorn nuts (with ﬂat washers). Remove map pocket and molded liner from Tour-Pak.

3. Remove three bolts with ﬂat washers to free speaker box from Tour-Pak.

INSTALLATION

1. Install three bolts with ﬂat washers to secure speaker box to Tour-Pak. Alternately tighten bolts to 25-35 in-lbs (2.8-4.0 Nm).

2. Install molded liner in Tour-Pak. Install map pocket and secure using acorn nuts (with ﬂat washers). Close TourPak.

3. Mate pin and socket halves of 6-place Mini-Deutsch connector. Feed connector back up into speaker box pressing trim ring into hole.

INSTALLATION

1. Position backrest against Tour-Pak cover.

2. From inside Tour-Pak, install two locknuts with backplate to attach center backrest to cover.

3. Install two locknuts and backplate to attach right side backrest to cover.

4. Install two locknuts to attach left side backrest to cover.

5. Install molded liner in Tour-Pak. Install map pocket and secure using acorn nuts (with ﬂat washers). Close TourPak.

2-118 2004 Touring: Chassis

f1077bxx

Retainer

Locknut

Screw

Clamp

Locknut

Screw

U-Bolt

Ear

Fairing

Lower Cap

Rubber Washer

HOME

LOWER FAIRING/ENGINE GUARD 2.28

LOWER FAIRING

REMOVAL

1. Remove two screws from fairing lower cap. See Figure

2-148.

2. Hold locknut at bottom of fairing lower, and using a T40 TORX drive head, turn inside screw to free assembly from engine guard clamp. Discard rubber washer.

3. Remove two locknuts to free retainer from upper rail of engine guard. From within glove box, remove U-bolt.

4. Remove glove box from fairing lower. Remove fairing lower from vehicle.

5. Repeat steps 1-4 on other side of vehicle.

INSTALLATION

1. Place fairing lower into position on vehicle.

2. Holding screw inside fairing lower, install new rubber washer, clamp and locknut to attach fairing bottom to engine guard. Do not tighten locknut.

3. Place glove box into fairing lower. From within glove box, install U-bolt so that it encircles the upper rail of the engine guard. Loosely install retainer and locknuts.

4. Adjust the fairing lower so that ear at top inboard side is approximately 1/4 inch (6.4 mm) from frame downtube. Verify that fairing lower is square, and then alternately tighten locknuts to 35-40 in-lbs (4.0-4.5 Nm).

5. Hold locknut at bottom of fairing lower, and using a T40 TORX drive head, turn inside screw to fasten assembly to engine guard clamp. Tighten screw to 90-100 in-lbs (10.2-11.3 Nm).

6. Install two screws to secure fairing lower cap to fairing lower. Tighten screws to 10-15 in-lbs (1.1-1.7 Nm).

7. Repeat steps 1-6 on other side of vehicle.

ENGINE GUARD

REMOVAL

1. Remove fairing lowers, if present. See LOWER FAIR-

ING, REMOVAL, in this section. Remove fairing lower

clamps from engine guard.

2. Remove T40 TORX screws (with ﬂanged locknuts) to release ends of engine guard from frame weldments.

Figure 2-148. Fairing Lower (Right Side) - FLHTCU

3. Remove hex socket screw (with ﬂat washer) to release tab at top of engine guard from slot at base of steering head.

INSTALLATION

1. Insert tab at top of engine guard into slot at base of steering head. Start hex socket screw (with ﬂat washer) to hang engine guard.

2. Position ends of engine guard outboard of frame weldments on each side of motorcycle. Install T40 TORX screws positioning ﬂanged locknuts on inboard side of frame weldments.

3. Alternately tighten three screws to 15-20 ft-lbs (20.3-

27.1 Nm).

4. Install fairing lowers, if present, but ﬁrst install fairing lower clamps on each side of engine guard. See

LOWER FAIRING, INSTALLATION, in this section.

2004 Touring: Chassis 2-119

HOME

UPPER FAIRING/WINDSHIELD (FLHT/C/U) 2.29

OUTER FAIRING/WINDSHIELD

REMOVAL

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

MAXI-FUSE, REMOVAL.

2. Remove the outer fairing as follows:

a. Standing at the front of the vehicle, use a T27 TORX

drive head to remove the three outer fairing screws (with ﬂat washers) just below the windshield. See

Figure 2-149.

b. Moving to the inner fairing side, remove the two fair-

ing screws just above the wind deﬂectors on the left and right side.

c. Turn the handlebar to the right and remove the outer

fairing screw reaching in below the left side of the fairing cap. Turn the handlebar to the left and remove the fairing screw below the right side of the fairing cap.

d. Tilting the outer fairing toward the front, squeeze the

two external tabs to remove the wire connector at the back of the headlamp assembly.

e. Lift the fairing (with headlamp assembly) off the

motorcycle.

T27 TORX Screws

30 20 10

MPH

f2029x2x

4 5

Figure 2-149. Outer Fairing TORX Screw Locations

100

110

120

RPM

x100

UNLOCK

CAUTION

Since the outer fairing screws hold the windshield in place, the windshield may fall to the ﬂoor if not removed.

3. Remove the windshield.

INSTALLATION

1. Install the outer fairing as follows:

a. Place the fairing (with headlamp assembly) on the

motorcycle installing the wire connector at the back of the headlamp assembly.

b. Place the windshield in position on the inner fairing

aligning the slots with the threaded inserts.

c. Using a T27 TORX drive head, start the three outer

fairing screws (with ﬂat washers) just below the windshield.

d. Moving to the inner fairing side, start the two fairing

screws just above the wind deﬂectors on both the left and right side.

e. Tu rn the handlebar to the left and start the outer fair-

ing screw reaching in below the right side of the fairing cap. Turn the handlebar to the right and start the fairing screw below the left side of the fairing cap.

f. Alternately tighten the four fairing screws on the

inner fairing side to 20-30 in-lbs (2.3-3.4 Nm).

g. Moving to the front of the vehicle, tighten the outer

fairing screws below the windshield to 25-30 in-lbs (2.8-3.4 Nm).

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

MAXI-FUSE, INSTALLATION.

FAIRING CAP

REMOVAL

1. Partially disassemble domestic ignition switch as follows:

NOTE

For partial disassembly of HDI ignition switch, see Section

8.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK,

FLHT/C/U, FLTR (INTERNATIONAL), REMOVAL, steps 1-4.

2-120 2004 Touring: Chassis

HOME

f1305b2x

Rubber

Grommet

Fairing Cap

Switch Connector [105]

12-Place Multilock

TOP VIEW BOTTOM VIEW

Button

f1240x2x f1476x8x

f1297b2x

Knob

Nut

Tab

Down and Forward

Collar

Spacer

Figure 2-150. Ignition Switch Knob (Domestic)

4. Remove the fairing cap from the motorcycle. See Figure

2-151.

INSTALLATION

1. Verify that the rubber grommets are installed on each side of the fairing cap. Barbs on cap ﬁt into holes in grommets. See Figure 2-151.

2. Connect the Fairing cap switch connector [105], 12place Multilock (black), on the right side of fairing cap.

3. With the forks turned fully to the left, install fairing cap over ignition switch housing.

4. Using a T27 TORX drive head, start two fairing cap screws (with ﬂat washers). Verify that grommets in fairing cap fully capture handlebar along with throttle and clutch cables.

5. Assemble domestic ignition switch as follows:

NOTE

For assembly of HDI ignition switch, see Section 8.18 IGNI-

TION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U, FLTR (INTERNATIONAL), INSTALLATION, steps 5-10.

a. Install switch position plate ﬁtting tabs in slots of fair-

ing cap. Plate snaps in place when properly installed. Exercise care to avoid breaking tabs. Replace plate if tabs are broken.

b. Slide spacer over threaded post of ignition switch

housing until it contacts switch position plate. Slide collar over post with the tab side down (and forward). Install nut, and using a 7/8 inch wrench on ﬂats, tighten to 50-70 in-lbs (5.7-7.9 Nm).

a. See upper frame of Figure 2-150. To r emove the

ignition switch knob, insert the Ignition Switch key and turn to the UNLOCK position. Leaving the key installed, rotate the knob to ACCESS. Depressing the release button at bottom (left side) with a small screwdriver, push key down and turn an additional 60 degrees in a counter-clockwise direction. Lift and remove knob.

b. Using a 7/8 inch wrench on ﬂats, loosen switch nut

and remove from threaded post of ignition switch housing. Remove collar and spacer. See lower frame of Figure 2-150.

c. Gently remove the switch position plate by pulling

tabs from slots in fairing cap.

2. Using a T27 TORX drive head, remove the two screws (with ﬂat washers) that secure fairing cap to left and right sides of inner fairing.

3. With the forks turned fully to the left, disconnect the Fairing cap switch connector [105], 12-place Multilock (black), from behind right side of fairing cap. Depress the button on the socket terminal side of the connector (plug) to pull apart the pin and socket halves.

Figure 2-151. Fairing Cap Assembly (FLHT/C/U)

2004 Touring: Chassis 2-121

HOME

Passing Lamp

Connector [73]

f2238x8x

Figure 2-152. Inner Fairing (Front View)

c. With the red arrow pointing toward the ACCESS

position, install the ignition switch knob. Turn key clockwise to UNLOCK position and then turn knob to OFF.

6. Using a T27 TORX drive head, tighten two fairing cap

screws to 25-30 in-lbs (2.8-3.4 Nm).

Turn Signal Lamp

Connector [31]

Chrome

Skirt

3. Using a T40 TORX drive head, remove four screws to release passing lamp bracket from upper and lower fork brackets. Remove passing lamp assembly from the motorcycle.

4. Remove the fairing cap. See FAI RING CAP, REMOVAL, in this section.

5. Pull chrome skirt from inner fairing. See Figure 2-152.

6. Slide rubber boot off clutch cable adjuster. Holding cable adjuster with 1/2 inch wrench, loosen jam nut using 9/16 inch wrench. Back jam nut away from cable adjuster. Move adjuster toward jam nut to introduce free play at hand lever.

7. Remove retaining ring from pivot pin groove at bottom of clutch lever bracket. Remove pivot pin.

8. Using a T27 TORX drive head, remove two screws (with ﬂat washers) to release handlebar clamp from clutch lever bracket. Remove clutch hand lever from clutch lever bracket.

9. Remove anchor pin and clutch cable eyelet from clutch hand lever. See Figure 2-114.

10. Feed clutch cable and cable eyelet through inner fairing grommet to front of motorcycle.

CAUTION

Do not remove the switch housing assembly without ﬁrst placing a 5/32 inch (4.0 mm) cardboard insert between the brake lever and lever bracket. Removal without the insert may result in damage to the rubber boot and plunger of the front stoplight switch.

NOTE

Use the eyelet of a small cable strap if the cardboard insert is not available.

INNER FAIRING

REMOVAL

CAUTION

To avoid scratches or other damage, place protective material over front fender, fuel tank and fairing lowers, if present.

1. Remove the outer fairing. See OUTER FAIRING/WIND-

SHIELD, REMOVAL, in this section.

2. Locate passing lamp (white 2-place Multilock) and front

turn signal lamp (6-place Multilock) connectors. Depress button on socket terminal side and pull apart pin and socket halves of both connectors. See Figure 2-152.

2-122 2004 Touring: Chassis

7959

5/32 Inch

(4.0 mm)

Cardboard

Insert

Figure 2-153. Install Cardboard Insert

HOME

Speaker

Adapter

Voltmeter

Tac hometer

[108]

Indicator Lamps

[21]

Speedometer

[39]

Fuel Gauge

Speaker

Adapter

Oil Pressure

Gauge

Figure 2-154. Inner Fairing Connections (FLHTC/U)

11. Place the cardboard insert between the brake lever and lever bracket. See Figure 2-153.

12. Using a T25 TORX drive head, remove the upper and lower switch housing screws.

13. Using a T27 TORX drive head, loosen the upper screw securing the handlebar clamp to the master cylinder housing. Remove the lower clamp screw with ﬂat washer.

14. Remove the brass ferrules from the notches on the inboard side of the throttle control grip. For best results, place ﬂat tip screwdriver in slot on outboard side and rotate ferrule in notch. Remove the ferrules from the cable end ﬁttings.

NOTE

On non cruise equipped models, remove the friction shoe from the end of the tension adjuster screw. The friction shoe is a loose ﬁt and may fall out or become dislodged if the lower switch housing is turned upside down or shaken.

Ambient

Temperature

Cigarette

Lighter

Gauge

f2238x8x

15. Remove the throttle control grip from the end of the handlebar.

16. Remove two-sided plastic clip inboard of cable adjuster boots to separate throttle and idle control cable housings. Pull the crimped inserts at the end of the cable housings from the lower handlebar switch housing. For best results, place a drop of light oil on the retaining rings and use a rocking motion while pulling.

17. Feed the throttle and idle control cables through the inner fairing grommet to front of motorcycle.

18. See Figure 2-154. Pull socket terminals from spade contacts on the cigarette lighter. Remove cigarette lighter from socket. Holding socket to prevent rotation, unscrew outer shell. Remove socket from inner fairing.

19. Pull socket terminals from speaker spade contacts. Using a T25 TORX drive head, remove three screws to release the speaker adapter from the inner fairing. Repeat step on opposite side of motorcycle.

2004 Touring: Chassis 2-123

HOME

Bulb

Housing

Hex Nut

Lamp

Connector

VOLT

Stud

Mounting

Tab

Gauge

Figure 2-155. Voltmeter Gauge Assembly

Indicator Lamp Connector [21]

10-Place Multilock

Bracket

f1345x2x

23. Pull the interconnect harness connectors from the voltmeter and fuel gauge.

24. Remove four socket head screws to free inner fairing

from fairing bracket. See Figure 2-157.

25. Spread bottom of inner fairing to free from dowels in lower fork bracket. Spread bottom of fairing bracket to release from same dowels.

26. Raise inner fairing and fairing bracket slightly to prevent reengagement with dowels. On Classic and Ultra models, remove the connectors from the oil pressure and ambient air temperature gauges.

27. Raise inner fairing and fairing bracket together and then separate by pulling fairing bracket toward the front and inner fairing toward the rear.

28. When inner fairing becomes free of the radio, remove from motorcycle and move to bench area.

29. Install fairing bracket (with radio and interconnect harness) back onto motorcycle aligning holes with dowels in lower fork bracket. Loosely install T40 TORX screws.

30. At bench area, remove hex nuts from studs at back of voltmeter and fuel gauges. Remove mounting brackets from gauges and remove gauges from inner fairing. See

Figure 2-155. On Classic and Ultra models, repeat step

to remove oil pressure and ambient air temperature gauges.

Rubber

Boot

Lense

Paddle

f2262x8x

Figure 2-156. Indicator Lamp Assembly

20. Unthread rubber boot from odometer reset switch. Pull switch from hole in inner fairing.

21. Bend back the external latches slightly and remove connectors at back of speedometer and tachometer gauges. See Figure 2-154. Leaving anchors on interconnect harness installed in outboard ears of brackets, remove allen head socket screws to remove brackets from gauges. Push gauges toward rear of motorcycle to remove from inner fairing.

22. Separate pin and socket halves of indicator lamps connector (10-place Multilock). See Figure 2-154. Release four paddles to free indicator bulb housing from lense assembly. See Figure 2-156. Remove lense assembly from inner fairing.

31. Remove clutch and throttle cable grommets from the inner fairing.

Fairing Bracket

Screws

Fairing Bracket

Screws

f2238x8x

Figure 2-157. Remove Fairing Bracket Screws

2-124 2004 Touring: Chassis

HOME

INSTALLATION

1. At bench area, install clutch and throttle cable grommets in inner fairing.

2. Install voltmeter and fuel gauges in inner fairing. Slide mounting brackets over studs. Verify that tabs on top and bottom of brackets engage slots in inner fairing. Loosely install hex nuts on studs. Verify that gauge is properly aligned and tighten nuts to 10-20 in-lbs (1.1-2.3 Nm). See Figure 2-155. On Classic and Ultra models, repeat step to install ambient air temperature and oil pressure gauges.

CAUTION

To avoid scratches or other damage, place protective material over front fender, fuel tank and fairing lowers, if present.

3. Remove T40 TORX screws to free fairing bracket (with radio and interconnect harness) from lower fork bracket. Raise fairing bracket and then tilt forward at about a 45 degree angle.

4. Position inner fairing at rear of fairing bracket. Tilting inner fairing rearward at about a 45 degree angle, align upper and lower fork bracket thru holes with those in fairing bracket. Draw fairing bracket and inner fairing together ﬁtting radio into slot in inner fairing.

5. Align upper thru holes in fairing bracket and inner fairing with threaded holes in upper fork bracket and start T40 TORX screws. Align lower thru holes in fairing bracket and inner fairing with dowels in lower fork bracket and start screws. Alternately tighten four T40 TORX screws until snug.

6. Install four socket head screws to attach inner fairing to

fairing brackets. See Figure 2-157.

7. Install the interconnect harness connectors onto the voltmeter and fuel gauge. On Classic and Ultra models, install the connectors onto the oil pressure and ambient air temperature gauges.

8. Place indicator lamp lense assembly into inner fairing.

Slot at bottom of lense engages tab in inner fairing to prevent improper orientation. Engage all four paddles on lense assembly with slots on indicator bulb housing. Mate pin and socket halves of indicator lamps connector (10-place Multilock). See Figure 2-156.

9. Install speedometer and tachometer gauges in inner fairing. Align holes in brackets with those at back of gauges and start two allen head socket screws. Rotate gauges until tabs at top and bottom of brackets engage slots in inner fairing. Verify that gauge is properly aligned and tighten allen head socket screws to 10-20 in-lbs (1.1-2.3 Nm). Install speedometer and tachometer connectors at back of gauges.

10. Slide odometer reset switch through hole in inner fairing. Install rubber boot to secure.

11. With the widest edge at the top, align holes in speaker adapter with those in inner fairing. Install two long screws to fasten top of speaker adapter. Capturing fairing support brace, install short screw in lower outboard hole (positioning ﬂat washer between adapter and support brace). Using a T25 TORX drive head, tighten the lower screw to 22-28 in-lbs (2.5-3.2 Nm). Tighten the two upper screws to 35-50 in-lbs (4.0-5.7 Nm).

NOTE The screw hole on the lower inboard side of the speaker adapter is not used.

12. Push the socket terminals onto the speaker spade con-

tacts. Different size spade contacts prevent improper assembly.

13. Repeat steps 11-12 on opposite side of motorcycle.

14. From rear of inner fairing, slide socket of cigarette lighter

through bore in fairing. Thread outer shell onto socket until tight. Install cigarette lighter in socket. Connect the orange/white wire terminal to the socket spade contact, the black wire terminal to the outer shell contact.

15. Feed the throttle and idle control cables through the right

side inner fairing grommet.

NOTE On non cruise equipped models, install the friction shoe with the concave side up so that the pin hole is over the point of the adjuster screw. The friction shoe is a loose ﬁt and may fall out or become dislodged if the lower switch housing is turned upside down or shaken.

16. Push the throttle and idle control cables into the lower

handlebar switch housing until they snap in place. Proceed as follows:

a. Note the different diameter inserts crimped into the

end of the throttle and idle control cable housings.

b. Push the larger diameter insert (silver) on the throt-

tle cable housing into the larger hole (front).

c. Push the smaller diameter insert (gold) on the idle

cable housing into the smaller hole (rear).

NOTE To aid assembly, place a drop of light oil on the retaining rings of the crimped inserts. Always replace the retaining rings if damaged or distorted.

17. Slide the throttle control grip over the end of the right

handlebar until it bottoms against the closed end. Rotate the grip so that the ferrule notches are at the top. To prevent binding, pull the grip back about 1/8 inch (3.2 mm).

18. Position the lower switch housing beneath the throttle

control grip. Install the brass ferrule onto the throttle cable so that the end ﬁtting seats in the ferrule recess. Be sure that ferrule is oriented so that when installed in notch of throttle control grip, slotted end is on the outboard side. Install ferrule in notch of throttle control grip. Verify that cable is captured in groove molded into the grip. Repeat step to install idle control cable. See Figure

2-158.

2004 Touring: Chassis 2-125

HOME

Ferrule

GrooveNotch

Throttle

Grip

Idle

Cable

Throttle

Cable

f1474x2x

Figure 2-158. Install Throttle/Idle Control Cables on

Throttle Control Grip

19. Position the upper switch housing over the handlebar and lower switch housing.

20. Verify that the wire harness conduit runs in the depression at the bottom of the handlebar. Also be sure that the upper switch housing harness will not be pinched against the handlebar when the switch housing screws are tightened.

21. Start the upper and lower switch housing screws, but do not tighten.

CAUTION

See Figure 2-153. Do not remove the 5/32 inch (4.0 mm) cardboard insert (or cable strap eyelet) wedged between the brake lever and lever bracket. Removal will result in damage to the rubber boot and plunger of the Front Stoplight Switch during installation of the master cylinder assembly.

22. Position the brake lever/master cylinder assembly inboard of the switch housing assembly engaging the tab on the lower switch housing in the groove at the top of the brake lever bracket.

23. Align the holes in the handlebar clamp with those in the master cylinder housing and start the two screws (with ﬂat washers). Position for rider comfort. Beginning with the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0 Nm) using a T27 TORX drive head.

24. Using a T25 TORX drive head, tighten the lower and upper switch housing screws to 35-45 in-lbs (4-5 Nm).

NOTE Always tighten the lower switch housing screw ﬁrst so that any gap between the upper and lower housings is at the front of the switch.

25. Remove the cardboard insert between the brake lever

and lever bracket.

26. Install two-sided plastic clip inboard of cable adjuster

boots to hold throttle and idle control cable housings together.

27. Moving to other side of motorcycle, feed clutch cable

through left side inner fairing grommet.

28. Insert clutch cable eyelet into groove of clutch hand lever

aligning eyelet with hole without bushing. Insert anchor pin through lever and eyelet.

29. Insert lever into groove of clutch lever bracket ﬁtting

sleeve at end of cable housing into bore on inboard side of bracket.

30. Align hole in hand lever with hole in bracket and install

pivot pin. Install retaining ring in pivot pin groove.

31. Using a T27 TORX drive head, install two screws (with

ﬂat washers) to secure handelbar clamp to clutch lever bracket. Starting with the top screw, tighten screws to 60-80 in-lbs (6.8-9.0 Nm).

32. Adjust the clutch. See Section 6.3 CLUTCH, ADJUST-

MENT.

33. Install the fairing cap. See FAIRING CAP, INSTALLA-

TION, in this section.

34. Remove two T40 TORX screws from lower fork bracket.

Install chrome skirt aligning thru holes with screws just removed. Start T40 TORX screws back into lower fork bracket.

35. Loosen two T40 TORX screws from upper fork bracket.

36. Slide slots of passing lamp bracket onto upper and lower

fork bracket screws. Alternately tighten four T40 TORX screws to 15-20 ft-lbs (20-27 Nm) in a crosswise pattern.

37. Route passing lamp conduit upward in front of chrome

skirt and then rearward using relief in upper outboard corner (in front of fairing bracket). Route conduit of other passing lamp in the same manner. Mate pin and socket halves of passing lamp connector (white 2-place Multilock) and front turn signal lamp connector (6-place Multilock).

38. Install the outer fairing. See OUTER FAIRING/WIND-

SHIELD, INSTALLATION, in this section.

2-126 2004 Touring: Chassis

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f1528x2x

Phillips

Screw

Flat Washer

Plastic

Windshield

Wellnut

Outer

Fairing

UPPER FAIRING/WINDSHIELD (FLTR) 2.30

WINDSHIELD ONLY

REMOVAL

1. Standing at front of motorcycle, locate ﬁve Phillips screws at base of windshield. Alternately loosen and then remove screws (with plastic ﬂat washers).

2. Remove windshield from outer fairing.

3. Carefully remove wellnuts from holes in outer fairing. See Figure 2-159. Exercise caution to avoid pushing wellnuts into fairing during removal. Inspect wellnuts for cuts, tears or signs of deterioration. Replace as necessary.

INSTALLATION

1. Preinstall hardware on windshield as follows:

a. Slide plastic ﬂat washers onto Phillips screws.

b. Slide Phillips screws through holes in decal to orient

hardware in slots of windshield.

NOTE

If installing new windshield, poke holes in decal from inboard side of windshield. Punching holes from outboard side will dislocate or tear decal on windshield.

c. Start wellnuts onto Phillips screws.

Wellnuts

f1525x2x

Figure 2-160. Install Windshield

(Decal Removed for Illustration Purposes)

2. Moving to front of motorcycle, push wellnuts into holes in outer fairing. See Figure 2-160.

3. Starting with center screw, alternately tighten the ﬁve Phillips screws to 6-13 in-lbs (0.7-1.5 Nm).

OUTER FAIRING

REMOVAL

NOTE

Windshield may be left in place during outer fairing removal.

1. Place protective material on top of front fender to protect paint from scratches or other damage.

2. Standing on left side of motorcycle, use a T25 TORX drive head to remove screw at edge of fairing outboard of the left speaker. See Figure 2-161. Remove screw outboard of the right speaker.

3. Loosen

top left and right screws just outboard of the fuel

and volt gauges, respectively.

Figure 2-159. Remove Wellnuts From Outer Fairing

4. Remove screw just below left side glove compartment. Remove screw below right side glove compartment.

5. On inboard side of right fairing support, remove rear acorn nut (with ﬂat washer) from stud of front turn signal lamp bracket. Remove front acorn nut with ﬂat washer.

2004 Touring: Chassis 2-127

HOME

MPH

100

110

120

CERTIFIED

x100

RPM

10 0

HARLEY-D

VIDSON

Long Screw Long Screw

f2169x2x

Figure 2-161. Remove/Install Six Outer Fairing Screws

Pull front turn signal lamp assembly from motorcycle and allow to hang at front of engine guard. Repeat step to remove front turn signal lamp assembly on left side. See Figure 2-162.

6. Remove top left and right screws just outboard of the fuel and volt gauges, respectively (previously loosened).

7. Raise outer fairing slightly and then rest on protective fender pad.

8. Squeeze two external tabs to disconnect headlamp jumper harness connector.

9. To avoid possible wire damage, separate pin and socket halves of front turn signal lamp connectors [31L] and [31R], 3-place Multilocks, and move to bench area. See

Figure 2-163.

INSTALLATION

1. Place protective material on top of front fender to protect paint from scratches or other damage.

2. Mate pin and socket halves of front turn signal lamp connectors [31L] and [31R], 3-place Multilocks. Verify that conduit is captured in ﬂexible clips on inner fairing. Allow front turn signal lamp assemblies to hang at front of engine guard until outer fairing installation is complete.

Acorn Nuts

9424

Figure 2-162. Remove Acorn Nuts to Release

Turn Signal Lamp and Bracket

NOTE The front turn signal lamp assemblies are not interchangeable. Note that the letters R(ight) or L(eft) are stamped on the inboard side of the turn signal lamp bracket to help ensure proper assembly.

2-128 2004 Touring: Chassis

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RPM

x100

110

120

90 100

MPH

CERTIFIED

f2167x2x

Bezel Screws

T25 TORX

Instrument

Nacelle

Bezel

10. Alternately tighten four short fairing screws to 6-12 inlbs (0.7-1.4 Nm). Alternately tighten two long fairing

screws to 10-15 in-lbs (1.1-1.7 Nm). Use the torque pattern shown in Figure 2-161.

11. Slide studs on front turn signal lamp bracket through holes in fairings and fairing support. Loosely install acorn nuts with ﬂat washers. Alternately tighten acorn nuts to 40-50 in-lbs (4.5-5.7 Nm).

12. Repeat step 11 to install front turn signal lamp assembly on opposite side of motorcycle.

9408

Figure 2-163. Front Turn Signal Lamp

3. Rest outer fairing on front fender pad and connect headlamp jumper harness connector.

4. To avoid chaﬁng wires of interconnect harness, verify that trim strips are installed inboard of hooks on radio bracket.

CAUTION

If windshield is attached during outer fairing installation, exercise caution to avoid scratching or damaging inner fairing with windshield screws and wellnuts.

5. Place outer fairing against inner fairing. Two slots in outer fairing must engage hooks on radio bracket. Move harness conduit and wiring as necessary to ensure full engagement between outer and inner fairings.

6. Move to side of outer fairing to verify that alignment tabs are properly engaged. Alignment tabs on inner fairing must be positioned outboard of those on the outer fairing. Repeat step on opposite side of motorcycle.

NOTE

Although the tightening sequence described below begins on the left side of the motorcycle, if the left side of the outer fairing ﬁts the inner fairing better than the right, then start the ﬁrst screw on the right side. In other words, install the ﬁrst screw on the side that does not

have the best ﬁt.

BEZEL

REMOVAL

1. Using a T25 TORX drive head, remove screw on left and right side of instrument bezel. See Figure 2-164.

2. Use thumbs to push tab at rear of bezel from slot in front of ignition switch. Gently raise free side of bezel until tabs at front of instrument nacelle become disengaged from slot at front of bezel (concealed behind decorative adhesive strip).

3. Raising bezel slightly, remove anchor on ambient temperature sensor from hole in bottom inboard ear of speedometer bracket.

7. Using a T25 TORX drive head, install screw at edge of fairing outboard of the left speaker. Install screw outboard of the right speaker. Mounting bosses on inner fairing are painted white for easier alignment of holes.

8. Install the top left and right screws just outboard of the fuel and volt gauges, respectively.

9. Moving to left side of motorcycle, install the ﬁrst of two long screws just below the glove compartment. Install the second long screw below the right side glove compartment.

Figure 2-164. Remove Instrument Bezel Screws

2004 Touring: Chassis 2-129

HOME

f2219x8x

Speedometer

Gauge [39]

Clutch

Cable

Speaker

Switch [105]

Indicator

Lamps [21]

Figure 2-165. Instrument Nacelle (Bezel Removed)

Instrument Nacelle

Switches [105]

Tachometer Gauge [108]

Throttle

Cables

Ambient

Temperature

Sensor [107]

4. See Figure 2-165. Disconnect instruments and indicator lamps from interconnect harness as follows:

● Speedometer connector [39], 12-place Packard.

● Ta chometer connector [108], 12-place Packard.

● Indicator lamps connector [21], 10-place Multilock.

5. Remove bezel from motorcycle.

INSTALLATION

1. See Figure 2-165. Looking into the instrument nacelle, connect instruments and indicator lamps to interconnect harness as follows:

● Speedometer connector [39], 12-place Packard.

● Ta chometer connector [108], 12-place Packard.

● Indicator lamps connector [21], 10-place Multilock.

2. Install anchor on ambient temperature sensor into hole in bottom inboard ear of speedometer bracket.

3. Verify that left and right sides of instrument nacelle are properly mated. Pins on left side of nacelle must fully engage holes on right.

4. Insert tab at rear of bezel into slot of instrument nacelle (just in front of ignition switch). Holding left and right sides of nacelle together, place bezel over instrument nacelle ﬂange. When properly mated, tabs at front of instrument nacelle engage lip in slot at front of bezel (behind decorative adhesive strip).

NOTE

If tabs do not properly engage slot at front of bezel, then a loose ﬁt will result. Remove decorative adhesive strip by gently prying up outer edges, and using a ﬂat bladed screwdriver, carefully raise tabs so that they engage lip in slot. If damaged, install new decorative adhesive strip.

5. Using a T25 TORX drive head, install screw on each

side of bezel. Tighten screws to 25-35 in-lbs (2.8-4.0 Nm). See Figure 2-164.

INSTRUMENT NACELLE

REMOVAL

1. Remove bezel. See BEZEL, REMOVAL, in this section.

2. Partially disassemble domestic ignition switch as follows:

NOTE

For partial disassembly of HDI ignition switch, see Section

8.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U, FLTR (INTERNATIONAL), REMOVAL, steps 1-4.

a. To remove the ignition switch knob, insert the Igni-

tion Switch key and turn to the UNLOCK position. Leaving the key installed, rotate the knob to ACCESS. Depressing the release button at bottom

2-130 2004 Touring: Chassis

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TOP VIEW BOTTOM VIEW

Button

f1240x2x f1476x8x

f1297b2x

Knob

Nut

Tab

Down and Forward

Collar

Spacer

6. Unthread rubber boot from odometer reset switch, and while carefully removing left side instrument nacelle from motorcycle, pull odometer reset switch from hole. See

Figure 2-167.

7. See Figure 2-168. Disconnect instrument nacelle switches from interconnect harness as follows:

● Instrument nacelle switch connector [105], 12-place

Multilock.

8. Pull throttle cable clip from hole on right side of instrument nacelle.

9. Using a T40 TORX drive head, remove two bolts (with ﬂat washers) to release right side of instrument nacelle from upper and lower fork brackets.

INSTALLATION

1. Install right side of instrument nacelle on motorcycle.

2. See Figure 2-168. Connect instrument nacelle switches to interconnect harness as follows:

● Instrument nacelle switch connector [105], 12-place

Multilock.

3. While carefully placing left side of instrument nacelle on motorcycle, slide odometer reset switch through hole and install rubber boot.

4. See Figure 2-168. Connect left side switch to instrument nacelle switch harness as follows:

● Speaker Switch connector [105], 4-place Multilock.

Figure 2-166. Ignition Switch Knob (Domestic)

(left side) with a small screwdriver, push key down and turn an additional 60 degrees in a counterclockwise direction. Lift and remove knob. See upper frame of Figure 2-166.

b. Using a 7/8 inch wrench on ﬂats, loosen switch nut

and remove from threaded post of ignition switch housing. Remove collar and spacer. See lower frame of Figure 2-166.

c. Remove the switch position plate from threaded

post of ignition switch housing.

3. See Figure 2-165. Disconnect left side switch from instrument nacelle switch harness as follows:

● Speaker Switch connector [105], 4-place Multilock.

4. Pull clutch cable clip from hole on left side of instrument nacelle.

5. Using a T40 TORX drive head, remove two bolts (with ﬂat washers) to release left side of instrument nacelle from upper and lower fork brackets.

5. Verify that left and right sides of nacelle are properly mated. Four pins on left side of nacelle must fully engage holes on right.

6. Using a T40 TORX drive head, install two bolts (with ﬂat washers) to fasten left side instrument nacelle to upper and lower fork brackets. Alternately tighten bolts to 1520 ft-lbs (20-27 Nm).

7. Capture clutch cable in cable clip. Insert cable clip into hole in left side of instrument nacelle.

8. Using a T40 TORX drive head, install two bolts (with ﬂat washers) to fasten right side instrument nacelle to upper and lower fork brackets. Tighten bolts to 15-20 ft-lbs (2027 Nm).

9. Capture throttle cables in cable clip. Insert cable clip into hole in right side of instrument nacelle.

10. Assemble domestic ignition switch as follows:

NOTE

For assembly of HDI ignition switch, see Section 8.18 IGNI-

TION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U, FLTR (INTERNATIONAL), INSTALLATION, steps 5-10.

a. Install the switch position plate over threaded post

of ignition switch housing. Tabs on plate ﬁt in holes at top of instrument nacelle.

2004 Touring: Chassis 2-131

HOME

f2214x8x

Throttle

Cable Clip

Speaker

Switch [105D]

4-Place Multilock

LEFT SIDE

CONNECTOR

NUMBER

[105A, 105B] Interconnect to Nacelle Switch Harness

[105]

[105C, 105D] Nacelle Switch Harness to Speaker Switch

DESCRIPTION

[A, C] = Pin [B, D] = Socket

RIGHT SIDE

Clutch

Cable Clip

Instrument Nacelle

Switches [105B]

12-Place Multilock

f2213x8x

Figure 2-167. Instrument Nacelle Halves

b. Slide spacer over threaded post of ignition switch

housing until it contacts switch position plate. Slide collar over post with the tab side down (and forward). Install nut, and using a 7/8 inch wrench on ﬂats, tighten to 50-70 in-lbs (5.7-7.9 Nm). See lower frame of Figure 2-166.

c. With the red arrow pointing toward the ACCESS

position, install the ignition switch knob. Turn key clockwise to UNLOCK position and then turn knob to OFF.

11. Install bezel. See BEZEL, INSTALLATION, in this sec- tion.

Speaker

Switch [105C]

4-Place Multilock

INNER FAIRING

REMOVAL

1. Place protective material on top of front fender to protect paint from scratches or other damage.

2. Remove the outer fairing. See OUTER FAIRING,

REMOVAL, in this section.

3. Carefully cut two cable straps and allow wire bundles and conduit to hang naturally.

4. See Figure 2-168. Disconnect main harness from interconnect harness as follows:

2-132 2004 Touring: Chassis

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Main to Interconnect

Harness [156]

Main to Interconnect

Harness [2]

Main to Interconnect

Harness [1]

Radio Antenna

Cable [51]

Left Handlebar

Switch Controls [24]

Right Handlebar

Switch Controls [22]

Radio

Ground

Right Turn

Signal [31R]

Main to Interconnect

Harness [15]

Ignition

Switch [33]

Figure 2-168. Inner Fairing Connections (FLTR)

● Main to interconnect harness connector [1], 12-

place Deutsch (black); below radio (right side).

● Main to interconnect harness connector [2], 12-

place Deutsch (gray); below radio (right side).

● Main to interconnect harness connector [15], 4-

place Packard (black); below radio (right side).

● Main to interconnect harness connector [156], 6-

place Deutsch (gray); below radio (right side).

5. See Figure 2-168. Disconnect ignition switch from main harness. Disconnect radio antenna cable. Proceed as follows:

● Ignition switch connector [33], 4-place Packard

(black); inside fairing bracket tunnel (right side).

Left Turn

Signal [31L]

Headlamp [38]

● Radio antenna cable connector [51]; back of radio

(left side).

6. See Figure 2-168. Disconnect handlebar switch controls from interconnect harness. Disconnect radio ground. Proceed as follows:

● Left handlebar switch controls connector [24], 12-

place Deutsch (gray); T-stud on left side of radio bracket.

● Right handlebar switch controls connector [22], 12-

place Deutsch (black); T-stud on left side of radio bracket.

● Radio ground; single spade and socket terminal;

below radio (left side).

f2269x8x

2004 Touring: Chassis 2-133

HOME

Interconnect

Harness

Figure 2-169. Wrap Main Harness in Shop Towels

f2237x2x

15. Remove right side instrument nacelle. See INSTRU-

MENT NACELLE, REMOVAL, in this section, steps 8-9.

16. Remove shop towels and masking tape from around the harness bundle. Separate radio ground and main harness, ignition switch and handlebar switch control conduit.

17. Remove screw to release main harness ground ring terminal and brake line P-clamp from front of upper fork bracket.

18. Pull main harness and both radio ground and harness ground ring terminals through opening on right side of fairing bracket allowing conduit and connectors to hang over top of engine guard.

19. Pull ignition switch and handlebar switch control conduit out through opening at top of fairing bracket.

20. Remove locknuts and bolts to release fairing bracket from holes at rear of steering head.

7. Draw the main harness conduit, handlebar switch control conduit, radio ground wire and radio antenna cable as far forward as possible. Rest the connectors of the longer harnesses on the front fender.

8. Remove left side of instrument nacelle. See INSTRU-

MENT NACELLE, REMOVAL, in this section, steps 1-6.

9. See Figure 2-165. Disconnect instrument nacelle switches and ambient temperature sensor from interconnect harness as follows:

● Instrument nacelle switch connector [105], 12-place

Multilock.

● Ambient temperature sensor connector [107], 3-

place Multilock.

10. See Figure 2-165. Draw branches of interconnect harness (terminating in odometer reset switch and speedometer, tachometer, indicator lamps, instrument nacelle switch and ambient temperature sensor connectors) from instrument nacelle through tunnel of fairing bracket to front of inner fairing.

11. Separate any branches of the interconnect harness that may be intermingled with the main harness conduit. Allow the interconnect harness to hang along the left side of the front fender.

12. Capturing all connectors, tightly wrap clean shop towels around the main harness conduit, handlebar switch control conduit, radio ground wire and radio antenna cable, and secure with masking tape. See Figure 2-169.

13. Remove four locknuts to release radio bracket and inner fairing from studs of fairing bracket. See Figure 2-170.

14. Lift inner fairing (with attached radio bracket and interconnect harness) from fairing bracket studs and move to bench area.

NOTE

To remove the fairing bracket, proceed with steps 15-20.

INSTALLATION

NOTE

To install the fairing bracket, begin at step 1. If only the inner fairing was removed, start at step 7.

1. Align holes in fairing bracket with those at rear of steering head. Standing on right side, insert bolts until they exit fairing bracket on left side of motorcycle. Install locknuts and tighten to 20-30 ft-lbs (27.1-40.7 Nm).

2. Route ignition switch and handlebar switch control conduit through opening at top of fairing bracket. See Figure

2-171.

3. Route main harness and both radio ground and harness ground ring terminals through opening on right side of fairing bracket. See Figure 2-171.

4. Install screw to fasten harness ground ring terminal and brake line P-clamp to front of upper fork bracket.

5. Draw wire harnesses and conduit out tunnel of fairing

bracket and pull as far forward as possible. Tightly wrap clean shop towels around all conduit and connectors and secure with masking tape. See Figure 2-169.

6. Install right side instrument nacelle. See INSTRUMENT

NACELLE, INSTALLATION, in this section, steps 8-9.

7. Place protective material on top of front fender to protect paint from scratches or other damage. Rest inner fairing (with attached radio bracket and interconnect harness) on front fender.

8. Place inner fairing over four fairing bracket studs while feeding end of harness bundle through opening beneath radio. See Figure 2-170. Ver ify that sides of inner fairing are positioned outboard of both fairing supports (on engine guards).

9. Install four locknuts to secure radio bracket and inner fairing to fairing bracket studs. Tighten locknuts to 96144 in-lbs (10.9-16.3 Nm).

2-134 2004 Touring: Chassis

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f2231x2x

Ignition

Switch

Radio

Ground

Main

Harness

Left and Right

Handlebar Controls

f2105x2x

Fairing

Bracket

Bolt

Stud

Locknut

Inner

Fairing

Slot

Opening

Figure 2-170. Inner Fairing Assembly

Radio

Bracket

Outer Fairing

Hooks

Locknut

Trim

Strip

10. Draw the harness bundle as far forward as possible, resting the end of the bundle on the front fender. See

Figure 2-169.

11. Find branch of interconnect harness terminating in odometer reset switch and speedometer, tachometer, indicator lamps, instrument nacelle switch and ambient temperature sensor connectors. Feed connectors and conduit from front of inner fairing through tunnel of fairing bracket and then out through opening at top of fairing bracket to instrument nacelle.

12. See Figure 2-165. Connect instrument nacelle switches and ambient temperature sensor to interconnect harness as follows:

● Instrument nacelle switch connector [105], 12-place

Multilock.

● Ambient temperature sensor connector [107], 3-

place Multilock.

13. Returning to front of inner fairing, remove shop towels and masking tape from around the harness bundle. Separate radio ground and main harness, ignition switch and handlebar switch control conduit.

14. See Figure 2-168. Connect handlebar switch controls to interconnect harness. Connect radio ground. Proceed as follows:

● Left handlebar switch controls connector [24], 12-

place Deutsch (gray); T-stud on left side of radio bracket.

● Right handlebar switch controls connector [22], 12-

place Deutsch (black); T-stud on left side of radio bracket.

Figure 2-171. Route Main Harness and Conduit

Thru Fairing Bracket

● Radio ground; single spade and socket terminal;

below radio (left side).

15. See Figure 2-168. Connect main harness to interconnect harness as follows:

2004 Touring: Chassis 2-135

HOME

● Main to interconnect harness connector [1], 12-

place Deutsch (black); below radio (right side).

● Main to interconnect harness connector [2], 12-

place Deutsch (gray); below radio (right side).

● Main to interconnect harness connector [15], 4-

place Packard (black); below radio (right side).

● Main to interconnect harness connector [156], 6-

place Deutsch (gray); below radio (right side).

16. See Figure 2-168. Connect ignition switch to main harness. Connect radio antenna cable. Proceed as follows:

● Ignition switch connector [33], 4-place Packard

(black); inside fairing bracket tunnel (right side).

● Radio antenna cable connector [51]; back of radio

(left side).

17. Loop wire bundles and conduit as necessary to orient connectors as shown in Figure 2-168. Install two new cable straps, one near the end of the left side loop and another near the end of the right side loop. Cut any excess cable strap material.

CAUTION

To avoid chaﬁng wires of interconnect harness and possible damage to slots of outer fairing during installation, verify that trim strips are installed on hooks of radio bracket.

INSTALLATION

1. Place spring inside hinge inserting spring pin into closest hole. With coil and one spring pin positioned inside hinge, second spring pin is outside.

2. Place hinge into position capturing free end of external spring pin between ribs molded into glove box door.

3. Install plastic barrels to hold hinge in door. Slot in barrel prevents interference with spring pin installed between ribs of door. Push barrels in until tight.

NOTE

Install new glove box door bumpers in inner fairing if damaged or missing. Insert tail of rubber bumper into hole, and moving to front of inner fairing, pull anchor through hole.

4. Place glove box door into position against inner fairing. Holding locknuts (with ﬂat washers) at front of inner fairing, use a T25 TORX drive head to tighten hinge screws.

5. To conceal glove door fasteners, snap screw cap cover into place below hinge.

6. Install the outer fairing. See OUTER FAIRING, INSTAL-

LATION, in this section.

18. Install the outer fairing. See OUTER FAIRING, INSTAL-

LATION, in this section.

19. Install left side of instrument nacelle. See INSTRUMENT

NACELLE, INSTALLATION, in this section, steps 5-7

and 9-10.

20. Install bezel. See BEZEL, INSTALLATION, in this sec- tion.

GLOVE BOX DOOR/HINGE

REMOVAL

1. Remove the outer fairing. See OUTER FAIRING,

REMOVAL, in this section.

2. To access glove box door fasteners, pull out screw cap cover below hinge.

3. Holding locknuts at front of inner fairing, use a T25 TORX drive head to loosen

4. Hold glove box door closed as hinge screws are completely removed. If not held closed, door will pop open as spring loaded hinge is released and door may be dropped to the ﬂoor.

5. If hinge replacement is necessary, remove plastic barrels to release hinge from door.

hinge screws.

2-136 2004 Touring: Chassis

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WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S) 2.31

WINDSHIELD REMOVAL

1. See Figure 2-172. Standing at the front of the motorcycle, use a ﬁnger to raise the wireform latch springs on both sides of the windshield.

2. Gently pull on the top of the windshield until the upper notches on the windshield brackets are free of the upper grommets.

3. Carefully raise the windshield until the lower notches are free of the lower grommets.

4. Remove windshield from motorcycle.

WINDSHIELD INSTALLATION

CAUTION

To avoid scratching headlamp nacelle or passing lamp bracket, be sure that all four notches on the windshield brackets are ﬁrmly seated on a rubber grommet.

1. Standing at the front of the motorcycle, carefully insert the windshield brackets between the headlamp nacelle and the passing bracket. Lower the windshield into position until the lower notches on the windshield brackets are seated on the lower grommets.

2. Gently push the top of the windshield toward the rear until the upper notches fully engage the upper grommets. See Figure 2-172.

3. Push down on the wireform latch springs, so that they overhang the rubber grommets. If some adjustment is necessary, loosen the retaining screws and rotate the latch springs into the proper position.

NACELLE REMOVAL (FLHR/C)

1. Remove the windshield. See WINDSHIELD REMOVAL on this page.

2. Remove the Phillips screw at the bottom of the headlamp door (chrome ring). Remove the headlamp door.

3. Remove the eight Phillips screws to free the headlamp housing from the headlamp nacelle.

Windshield

Clutch

Cable

Passing

Lamp Bracket

Wireform

Latch Spring

Figure 2-172. Windshield (FLHR/C)

Upper

Grommet

Headlamp

Nacelle

f2278x2x

2004 Touring: Chassis 2-137

HOME

Fork Lock

Plate

Phillips

Screw

Handlebar

Clamp Shroud

Chrome

Strip

Headlamp

Nacelle

Left Side

Trim Strip

Flange

Nut

Flat

Washer

Keps

Nut

f2195x2x

Figure 2-173. Headlamp Nacelle Assembly

4. Squeeze the two external tabs (if present) to remove the wire connector at the back of the headlamp bulb. Remove the headlamp housing assembly from the motorcycle.

5. Reaching inside the headlamp nacelle, remove the ﬂange nut to release the chrome strip at the top of the nacelle. See Figure 2-173.

6. Carefully pry off the fork lock plate at the rear of the handlebar clamp shroud. Remove two Phillips screws beneath the lock plate.

7. Loosen the Phillips screw from tab at the front of the handlebar clamp shroud (but do not remove).

8. Remove the two acorn nuts from the left side fork bracket studs. Remove acorn nuts from the right side fork bracket studs.

9. Cover the front fender with suitable material to protect the fender paint. Remove the passing lamp bracket from the left and right side fork bracket studs and carefully set on front fender.

10. Remove the grommets (and clutch cable clamp) from the left and right side fork bracket studs.

11. Raise the handlebar clamp shroud, and after separating the halves of the headlamp nacelle slightly, slide the shroud forward running the shaft of the Phillips screw down the gap. See Figure 2-174.

12. Reaching inside the headlamp nacelle, separate the pin and socket halves of the Accessory Switch and Passing Lamp Switch connectors.

13. Carefully separate the halves of the headlamp nacelle and remove from motorcycle.

NACELLE INSTALLATION (FLHR/C)

1. Fit halves of the headlamp nacelle together engaging the holes in the nacelle with the left and right side fork bracket studs.

2. Reaching inside the headlamp nacelle, mate pin and socket halves of the Accessory Switch and Passing Lamp Switch connectors.

3. If disassembled, install screw assembly on the handlebar clamp shroud as shown in Figure 2-174.

4. Part the halves of the headlamp nacelle slightly. With the ﬂat washer on the inboard side of the nacelle, slide the shroud rearward running the shaft of the Phillips screw down the gap. Position the shroud over the ﬂange at the top of the nacelle.

5. Mate the halves of the headlamp nacelle and tighten the Phillips screw to 10-20 in-lbs (1.1-2.3 Nm).

6. Install two Phillips screws to secure the handlebar clamp shroud to the fork lock mechanism. Install the fork lock plate.

Screw

Assembly

Figure 2-174. Handlebar Clamp Shroud and Screw

Assembly

f1458b2x

2-138 2004 Touring: Chassis

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f2194x2x

Screw

Assembly

f2193x2x

11WARNING1WARNING

To avoid possible damage to the brake hose, throttle cables and/or handlebar switch wires, verify that trim strips are installed on inside edges of the headlamp nacelle. Cutting or severe chaﬁng of the brake hose, throttle cables and/or handlebar switch wires could cause loss of function while riding, possibly resulting in death or serious injury.

7. Verify that trim strips are installed on inside edges of headlamp nacelle. Install new trim strips if cracked, broken or missing.

8. Inserting the weld stud on the chrome strip into the hole at the top of the headlamp nacelle, reach inside the nacelle to install ﬂange nut. Tighten ﬂange nut to 15-20 in-lbs (1.7-2.3 Nm).

9. Install the grommets on the left and right side fork studs.

10. Slide the passing lamp bracket onto the left and right side fork bracket studs. Verify that the four grommets are in place on the inboard side of the passing lamp brackets.

11. Install the acorn nuts on the fork bracket studs and tighten to 72-108 in-lbs (8.1-12.2 Nm). Be sure to cap- ture the clutch cable clamp on the upper left stud before installing the acorn nut.

12. Install the wire connector at the back of headlamp bulb.

13. Align holes in headlamp housing with those in headlamp nacelle (headlamp door bracket at bottom). Install the eight Phillips screws.

14. Fit the square-shaped portion of the headlamp door spring into the slot at the top of the headlamp housing and then snap the headlamp door (chrome ring) into place. Install the Phillips screw at the bottom of the headlamp door.

15. Install the windshield. See WINDSHIELD INSTALLA-

TION in this section.

Figure 2-175. Remove Screw From Slot in Wind Deﬂector

Figure 2-176. Handlebar Clamp Shroud/Wind Deﬂector

and Screw Assembly

5. Carefully pry off the fork lock plate at the rear of the handlebar clamp shroud. Remove two Phillips screws beneath the lock plate.

NACELLE REMOVAL (FLHRS)

1. Remove the Phillips screw at the bottom of the headlamp door (chrome ring). Remove the headlamp door.

2. Remove the eight Phillips screws to free the headlamp housing from the headlamp nacelle.

3. Squeeze the two external tabs (if present) to remove the wire connector at the back of the headlamp bulb. Remove the headlamp housing assembly from the motorcycle.

4. Reaching inside the headlamp nacelle, remove the ﬂange nut to release the chrome strip at the top of the nacelle.

6. Loosen Phillips screw at front of wind deﬂector (but do not remove). Reaching inside the headlamp nacelle, release screw head from slot in tab and then draw screw assembly down and out through headlamp nacelle. See

Figure 2-175.

7. Raise handlebar clamp shroud/wind deﬂector and

remove from motorcycle. See Figure 2-176.

NOTE

If damage requires separation of parts, remove three ﬂange bolts to remove handlebar clamp shroud from wind deﬂector.

8. Reaching inside the headlamp nacelle, separate the pin and socket halves of the Accessory Switch connector.

2004 Touring: Chassis 2-139

HOME

9. Using a T-40 TORX drive head, remove the left side fork bracket bolts (with ﬂat washers). Remove the right side fork bracket bolts (with ﬂat washers).

10. Carefully separate the halves of the headlamp nacelle and remove from motorcycle.

NACELLE INSTALLATION (FLHRS)

1. Fit halves of the headlamp nacelle together aligning the holes in the nacelle with those in the upper and lower fork brackets.

2. Start right side fork bracket bolts (with ﬂat washers). Start left side fork bracket bolts (with ﬂat washers). Be sure to capture clutch cable clamp when installing upper fork bracket bolt on left side of motorcycle (open side of clamp faces forward).

3. Using a T-40 TORX drive head, alternately tighten the fork bracket bolts to 15-20 ft-lbs (20-27 Nm) in a crosswise pattern.

4. Reaching inside the headlamp nacelle, mate pin and socket halves of the Accessory Switch connector.

5. Position the handlebar clamp shroud/wind deﬂector on ﬂange at top of headlamp nacelle.

NOTE If separated, install three ﬂange bolts to fasten handlebar clamp shroud to wind deﬂector. Alternately tighten bolts to 12-18 ft-lbs (16.3-24.4 Nm).

6. If disassembled, assemble screw assembly as shown in

Figure 2-176.

7. Holding screw assembly, reach inside headlamp nacelle

and insert head of Phillips screw up through opening to engage slot in tab at front of wind deﬂector. See Figure

2-175. Tighten screw to 10-20 in-lbs (1.1-2.3 Nm).

8. Install two Phillips screws to secure the handlebar clamp

shroud to the fork lock mechanism. Install the fork lock plate.

11. Install the wire connector at the back of headlamp bulb.

12. Align holes in headlamp housing with those in headlamp nacelle (headlamp door bracket at bottom). Install the eight Phillips screws.

13. Fit the square-shaped portion of the headlamp door spring into the slot at the top of the headlamp housing and then snap the headlamp door (chrome ring) into place. Install the Phillips screw at the bottom of the headlamp door.

11WARNING1WARNING

9. Verify that trim strips are installed on inside edges of headlamp nacelle. Install new trim strips if cracked, broken or missing.

10. Inserting the weld stud on the chrome strip into the hole at the top of the headlamp nacelle, reach inside the nacelle to install ﬂange nut. Tighten ﬂange nut to 15-20

in-lbs (1.7-2.3 Nm).

2-140 2004 Touring: Chassis

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f2238x8x

Front Fender Tip Lamp [32]

f2212x8x

Front Fender

Tip Lamp [32]

Used on FLHR Only

FRONT FENDER 2.32

REMOVAL

NOTE

If fender tip lamp is absent, start procedure at step 5.

1. FLHT/C/U: Reaching in below the fairing cap on the left

side of the steering head, locate the front fender tip lamp connector (black 2-place Multilock). See Figure 2-177. Remove the outer fairing only if necessary. See Section

2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD, REMOVAL.

FLHR: Remove the Phillips screw at the bottom of the headlamp door (chrome ring). Remove the headlamp door. Remove the eight Phillips screws to free the headlamp housing from the headlamp nacelle. Squeeze the two external tabs to remove the wire connector at the back of the headlamp bulb. Remove the headlamp housing assembly from the vehicle. Locate the front fender tip lamp connector (black 2-place Multilock). See Figure 2-

178.

2. Depress the button on the socket terminal side of the connector and pull apart the pin and socket halves.

Figure 2-177. Inner Fairing (FLHT/C/U)

3. Draw socket connector down to fender area.

4. Carefully cut cable strap to release front fender tip lamp wires from brake line hose.

5. Place the motorcycle on a hydraulic center stand with the front wheel raised off the ground.

6. Use shop rag or tape to protect fender area adjacent to caliper, as incidental contact can occur during caliper removal.

7. Remove both the upper and lower mounting bolts from lugs of front fork leg to release brake caliper assembly. Lift caliper upward to remove from brake disc. Using thru hole, cable strap caliper to rail of engine guard. Repeat step to release caliper on opposite side of wheel.

Do not operate the front brake hand lever with the front wheel removed or the caliper pistons may be forced out. Reseating pistons requires disassembly of the caliper.

8. Insert screwdriver or steel rod through hole in axle on right side of vehicle. While holding axle stationary, remove the axle nut, lockwasher and ﬂat washer on the left side.

9. Loosen the two axle holder nuts at bottom of right side fork leg.

NOTE

Figure 2-178. Headlamp Nacelle (FLHRC)

10. With soft mallet, tap axle toward right side of vehicle until loose. Pull axle from hub while supporting wheel. Remove wheel.

2004 Touring: Chassis 2-141

HOME

11. Bend tabs on lockplates away from ﬂats of four fender mounting bolts. Remove fender mounting bolts and lockplates. Remove fender from vehicle.

INSTALLATION

NOTE

If fender tip lamp is absent, perform steps 1 and 3-12.

1. Align mounting holes in fender and lockplates with those in fork tubes. Install four fender mounting bolts and tighten to 16-20 ft-lbs (22-27 Nm). Bend tabs on lockplates against ﬂats of fender mounting bolts.

2. Route socket housing of front fender tip lamp connector upward behind chrome skirt (FLHT/C/U) or through bottom of headlamp nacelle (FLHR) to area beneath upper fork bracket. Mate pin and socket halves.

NOTE

To connect front fender tip lamp with the outer fairing installed (FLHT/C/U models), reach in below the fairing cap on the left side of the steering head.

3. Place wheel into position between forks with the valve stem on the right side of the vehicle.

4. Coat the axle with ANTI-SIEZE LUBRICANT.

5. Supporting wheel, insert threaded end of axle through right fork leg. Push axle through fork, shor spacer and wheel hub until it begins to emerge from left side.

6. With the three notches on the bearing side, push axle through long shoulder contacts external spacer on right fork side.

7. Install ﬂat washer, lockwasher and axle nut.

8. Insert screwdriver or steel rod through hole in axle on right side of vehicle. While holding axle stationary, tighten axle nut to 50-55 ft-lbs (68-75 Nm).

9. Insert 7/16 inch drill bit into hole in axle.

10. Pull fork leg so that it just contacts drill bit, and then tighten axle holder nuts to 132-180 in-lbs (14.9-20.3 Nm).

external spacer and left fork leg until axle

t external

11. Remove drill bit from axle hole.

12. Install brake caliper as follows:

a. Use shop rag or tape to protect fender area adja-

cent to caliper, as incidental contact can occur during caliper installation.

b. With the bleeder valve topside, position caliper so

that brake disc is situated between friction pads. Now align upper mounting hole in caliper with upper mounting lug on fork leg.

c. Loosely install long caliper mounting bolt into upper

lug of front fork leg.

d. Install short caliper mounting bolt into lower lug of

front fork leg. Tighten lower mounting bolt to 28-38 ft-lbs (37.9-51.5 Nm).

e. Tighten upper caliper mounting bolt to 28-38 ft-lbs

(37.9-51.5 Nm).

f. Repeat step 12 to install caliper on opposite side of

wheel.

13. Install new cable strap to secure front fender tip lamp

wires to brake line hose. Cut any excess cable strap material.

14. FLHT/C/U: Install the outer fairing, if removed. See Sec-

tion 2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U),

OUTER FAIRING/WINDSHIELD, INSTALLATION.

FLHR: Install wire connector at the back of the headlamp bulb. Align holes in headlamp housing with those in headlamp nacelle. Install eight Phillips screws. Install the headlamp door (chrome ring) and door screw.

2-142 2004 Touring: Chassis

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f2279x2x

T40 TORX

Bolt

f1908x2x

T40 TORX Bolt

REAR FENDER 2.33

REMOVAL

1. Place the motorcycle on a hydraulic center stand with the rear wheel raised off the ground.

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

3. Remove rear wheel. See Section 2.4 REAR WHEEL,

REMOVAL.

4. Disconnect the rear fender lights connector anchored at the front of the rear fender. Depress the button on the socket terminal side and pull apart the pin and socket halves. Release anchor from fender hole. See Figure 2-

179.

5. Gently pull side cover from frame downtube (no tools required). Repeat step on opposite side of vehicle.

6. Remove four screws (two on FLHR/C/S and FLTR) to release license plate bracket from luggage rack.

7. Standing on left side of vehicle, use a T40 TORX drive

head to release front of rear fender from battery box. See Figure 2-180.

8. At rear of vehicle, remove inside bolt (and ﬂange nut) to release rear bumper support rail from saddlebag support bracket and saddlebag support rail. Repeat step on opposite side of vehicle. See Figure 2-181.

Figure 2-180. Rear Fender Front Mounting Bolt

(Left Side View)

9. Reaching under bumper, remove nut (with ﬂat washer) to free bumper bracket from weld stud on fender. Remove bumper from vehicle.

10. Using a T40 TORX drive head, remove fender side mounting bolt located just below side cover grommet. Repeat step on opposite side of vehicle. See Figure 2-

182.

f2013x8x

Lights Connector [7]

Figure 2-179. Rear Fender (Top View)

Rear Fender

11. Using a T40 TORX drive head, remove upper rear bolt from saddlebag support bracket. Repeat step on opposite side of vehicle. See Figure 2-183.

Figure 2-181. Release Bumper From Saddlebag Rail

2004 Touring: Chassis 2-143

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T40

TORX Bolt

RIGHT SIDE

T40

TORX Bolt

LEFT SIDE

f1862x2x

f1991x2x

T40

TORX Bolt

Front

T40

TORX Bolt

Rear

Saddlebag

Support Bracket

Figure 2-183. Saddlebag Support Bracket Bolts

(Left Side View)

INSTALLATION

f1864x2x

Figure 2-182. Rear Fender Side Mounting Bolts

12. Remove upper front bolt from saddlebag support bracket. Repeat step on opposite side of vehicle. Be aware that rear fender will drop when the forward bolts are removed.

13. Exercising caution to avoid scratching fender paint on luggage rack or other bracketry, carefully roll the fender out. See Figure 2-184. If necessary, have one person spread the saddlebag support brackets while the fender is rolled out.

1. Exercising caution to avoid scratching fender paint on luggage rack or other bracketry, carefully roll the fender in. See Figure 2-184. If necessary, have one person spread the saddlebag support brackets while the other rolls the fender in.

2. Engaging hole of fender rear spacer nut, use a T40 TORX drive head to start upper front bolt in saddlebag support bracket. Repeat step on opposite side of vehicle. See Figure 2-183.

3. Start upper rear bolt in saddlebag support bracket. Repeat step on opposite side of vehicle.

4. Standing on left side of vehicle, start bolt securing front of rear fender to battery box. See Figure 2-180.

5. Engaging hole in frame and fender front spacer nut, start fender side mounting bolt located just below side cover grommet. Repeat step on opposite side of vehicle. See

Figure 2-182.

6. Reaching under rear fender, hang bumper bracket on fender weld stud. Install ﬂat washer and start nut on stud.

7. Start inside bolt (with ﬂange nut) to fasten rear bumper support rail to saddlebag support bracket and saddlebag support rail. Repeat step on opposite side of vehicle. See Figure 2-181.

2-144 2004 Touring: Chassis

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9740

FLHRS

FLTR

9741

f2014x2x

Figure 2-184. Carefully Roll Out Rear Fender

8. Alternately tighten all rear fender T40 TORX bolts to 1520 ft-lbs (20-27 Nm). Tighten nut on fender weld stud to secure bumper bracket.

9. Install four screws (two on FLHR/C/S and FLTR) to secure license plate bracket to luggage rack.

10. Mate pin and socket halves of rear fender lights connector and snap anchor in rear fender hole. See Figure 2-

179.

11. Align barbed studs in side cover with grommets in frame downtubes and push ﬁrmly into place (no tools required). Repeat step on opposite side of vehicle.

12. Install rear wheel. See Section 2.4 REAR WHEEL,

INSTALLATION.

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

NOTE

Dental ﬂoss can be used to gently saw the heated cloisonne free of the rear fender.

4. Remove remaining adhesive with 3M GENERAL PURPOSE ADHESIVE REMOVER (Part No. 051135).

Installation

1. Peel backing paper off medallion.

2. Place medallion in position over recess in rear fender.

NOTE

The cloisonne is centered left to right over the dimpled recess in the rear fender with the bottom edge of the cloisonne 1.75 inches (44.45 mm) above the bottom edge of the fender.

3. Press ﬁrmly to afﬁx cloisonne.

REAR FENDER CLOISONNE

Removal

1. Apply 3M GENERAL PURPOSE ADHESIVE REMOVER (Part No. 051135) to edge of adhesive backing visible behind cloisonne. Allow to soak.

CAUTION

Avoid excess heat which will damage the painted surface.

2. Carefully apply heat directly onto cloisonne with ROBINAIR HEAT GUN (HD-25070).

3. Lift the cloisonne from fender.

Figure 2-185. Rear Fender Cloisonne

2004 Touring: Chassis 2-145

HOME

JIFFY STAND 2.34

GENERAL

The vehicle is equipped with a jiffy stand (or side stand) that locks when placed in the full forward position (down) with the full weight of the vehicle resting on it.

11WARNING1WARNING

Without the full weight of the motorcycle resting on the jiffy stand, any vehicle movement can cause the jiffy stand to retract slightly from the full forward position. If the jiffy stand is not in the full forward or lock position when the full vehicle weight is rested on it, the vehicle could fall over, which could result in death or serious injury.

11WARNING1WARNING

Always park the vehicle on a ﬁrm, level surface. The weight of the vehicle can cause it to fall over, which could result in death or serious injury.

11WARNING1WARNING

Be sure jiffy stand is fully retracted before riding. If jiffy stand is not fully retracted during vehicle operation, unexpected contact with the road surface can distract the rider. While the jiffy stand will retract upon contact, the momentary disturbance and/or rider distraction can lead to loss of vehicle control resulting in death or serious injury.

Bracket

Flange

Nut

FRONT REAR

f1142a2x

Figure 2-187. Leg Stop Orientation

REMOVAL

(Full Forward Position)

Leg Stop

Longer Side

Faces Rear

Bracket

Spring

f1852x2x

Figure 2-186. Jiffy Stand Assembly

2-146 2004 Touring: Chassis

Stand

Jiffy

Frame

Hole

Flange

Nut

Leg Stop

Lockwasher

Rubber

Stop

Bolt

11WARNING1WARNING

Securely block vehicle under frame to be sure that vehicle will not fall when jiffy stand is removed. Inadequate safety precautions could result in death or serious injury.

1. Block motorcycle under frame, so that vehicle is securely upright and level. Jiffy stand should be able to move through its full range of travel without the weight of the vehicle resting on it.

2. See Figure 2-186. Move jiffy stand to the retracted position (up). Remove ﬂange nut and leg stop from threaded end of jiffy stand leg.

3. Move jiffy stand to the full forward position (down). Grasping end of spring as close to frame tube as possible, twist and turn end with needle nose pliers to unhook from frame hole. Remove jiffy stand leg from bracket.

HOME

CAUTION

7846

Rubber

Stop

4. Inspect jiffy stand assembly for worn or damaged parts. Replace parts as necessary.

INSTALLATION

1. Lubricate the jiffy stand leg with Loctite Aerosol AntiSeize Lubricant. Restrict the application to the area of the jiffy stand leg that rotates within the bracket.

2. Insert threaded end of jiffy stand up through bottom of bracket. With jiffy stand in the full forward position, partially place spring end into frame hole. Rap spring with a rubber mallet to fully seat in hole.

NOTE

Verify that opposite end of spring enters hole at front of leg weldment. If end enters hole from rear, spring coil will rub on leg when jiffy stand is exercised.

Figure 2-188. Jiffy Stand

3. Holding jiffy stand at the full forward position, install leg stop over threaded end with the stamped “side down.” Install ﬂange nut and tighten to 43-53 ft-lbs (58-72 Nm).

11WARNING1WARNING

If leg stop is installed incorrectly, excess wear may cause the vehicle to fall over when rested on the jiffy stand, which could result in death or serious injury.

4. Verify that the longer side of the leg stop faces the rear of the vehicle. See Figure 2-187.

5. Extend and retract jiffy stand leg several times to verify proper operation. Jiffy stand should swing freely to the fully extended and fully retracted positions.

6. Move jiffy stand to the full forward position. Carefully remove support blocking from beneath motorcycle frame and rest motorcycle on jiffy stand.

Verify that rubber stop is in place on prong of jiffy stand. Without the rubber stop, the stand will make hard contact with the lower frame tube when retracted, possibly resulting in chipping or nicking of the powder coat. Replace rubber stop if torn or deteriorated. See Figure 2-

188.

2004 Touring: Chassis 2-147

HOME

FOOTBOARDS/FOOTRESTS 2.35

RIDER FOOTBOARD

REMOVAL

1. Remove right side footboard and bracket assembly as follows:

a. Remove two allen head socket screws (with lock

washers and ﬂat washers) to release footboard brackets from frame weldment. See Figure 2-189. For best results, approach from left side of motorcycle using a 3/8 inch ball allen with extension.

2. Remove left side footboard and bracket assembly as follows:

a. Raise the motorcycle on a hydraulic center stand so

that the weight of the motorcycle is not resting on the jiffy stand.

b. Remove socket screw (with lockwasher and ﬂat

washer) to release footboard forward bracket from frame weldment. See Figure 2-189. For best results, approach from opposite side of motorcycle using a 3/8 inch ball allen with extension.

c. To free footboard rear bracket from frame weldment

and jiffy stand bracket, remove lower hex bolt (with lockwasher) and upper hex bolt (with lockwasher and locknut).

INSTALLATION

1. Install right side footboard and bracket assembly as follows:

a. Insert two allen head socket screws (with lockwash-

ers and ﬂat washers) through frame weldment into footboard brackets. See Figure 2-189. For best results, approach from left side of motorcycle using a 3/8 inch ball allen with extension.

b. Alternately tighten socket screws to 30-35 ft-lbs (41-

48 Nm).

2. Install left side footboard and bracket assembly as follows:

a. Insert allen head socket screw (with lockwasher and

ﬂat washer) through frame weldment into footboard forward bracket. See Figure 2-189. For best results, approach from opposite side of motorcycle using a 3/8 inch ball allen with extension.

b. At footboard rear bracket, slide upper hex bolt

through frame weldment, jiffy stand bracket and footboard bracket thru hole. Install lockwasher and locknut. Slide lower hex bolt through frame weldment and jiffy stand bracket into threaded hole of footboard bracket.

c. Tighten front bracket socket screw to 30-35 ft-lbs

(41-48 Nm).

d. Alternately tighten rear bracket hex bolts to 15-20 ft-

lbs (20-27 Nm).

Left Side

f2242x2x

2-148 2004 Touring: Chassis

Right Side

Figure 2-189. Rider Footboards (All Models Except FLHRS)

HOME

f2243x2x

DISASSEMBLY

NOTE

If only replacing the rubber pad, refer to step 1 below and then see steps 4-5 under ASSEMBLY.

1. Tilt footboard upward. From bottom of footboard, use a large ﬂat blade screwdriver to push four rubber anchors on pad up through holes in footboard.

2. Remove nuts from pivot bolts at underside of footboard.

3. Remove pivot bolts to release footboard from brackets.

4. Remove footboard brackets. See RIDER FOOT-

BOARD, REMOVAL, in this section.

ASSEMBLY

1. Install footboard brackets. See RIDER FOOTBOARD,

INSTALLATION, in this section.

2. Place footboard into position between brackets and install pivot bolts so that the nuts will be on the inboard side.

NOTE

The bottom of FLHRS footboards are stamped L(eft) or R(ight) to ensure proper installation.

3. Install nuts onto pivot bolts and alternately tighten to 84108 in-lbs (9.5-12.2 Nm).

4. Moisten four rubber anchors on new pad with soapy water.

5. Place pad into position on footboard. From bottom of footboard, use pliers to pull rubber anchors down through holes in footboard.

PASSENGER FOOTBOARD

REMOVAL

1. Remove socket screw with lockwasher to remove footboard bracket from rear swingarm bracket.

INSTALLATION

1. Insert pin on footboard bracket into hole in swingarm bracket.

NOTE

Passenger footboards can be adjusted to one of three positions. To move footboards to a new position, remove plastic plugs from holes in rear swingarm bracket as necessary.

2. Install socket screw with lockwasher. Tighten socket screw to 15-18 ft-lbs (20-24 Nm).

Figure 2-190. Passenger Footboard

(All Models Except FLHRS)

DISASSEMBLY

NOTE

If only replacing the rubber pad, refer to step 1 below and then see steps 4-5 under ASSEMBLY.

1. Tilt footboard upward. From bottom of footboard, use a small ﬂat blade screwdriver to push rubber beads on pad up through holes in footboard. Remove pad.

2. Using a brass drift and rubber mallet, tap two retaining pins toward center of footboard and remove.

3. Remove footboard from bracket.

4. Remove steel ball and spring from hole in footboard bracket.

5. Remove footboard bracket from rear swingarm bracket. See PASSENGER FOOTBOARD, REMOVAL, in this section.

ASSEMBLY

1. Install footboard bracket. See PASSENGER FOOT-

BOARD, INSTALLATION, in this section.

2. Place spring into hole in footboard bracket. Place ball on top of spring.

3. Place footboard into position on bracket and install retaining pins from the outboard side. Using a brass drift and rubber mallet, tap pins until centered in lugs of bracket.

4. Moisten rubber beads on new pad with soapy water. Place pad into position on footboard. From bottom of footboard, use needle nose pliers to pull rubber beads down through holes in footboard.

5. Engage nubs on inboard corners of pad with holes in footboard.

2004 Touring: Chassis 2-149

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PASSENGER FOOTREST (FLHRS)

REMOVAL

1. Remove socket screw with lockwasher to remove footrest bracket from rear swingarm bracket.

INSTALLATION

1. Insert pin on footrest bracket into hole in swingarm bracket.

NOTE

Passenger footrests can be adjusted to one of three positions. To move footrests to a new position, remove plastic plugs from holes in rear swingarm bracket as necessary.

2. Install socket screw with lockwasher. Tighten socket screw to 15-18 ft-lbs (20-24 Nm).

DISASSEMBLY

NOTE

If only replacing the rubber pad, refer to step 1 below and then see steps 5-6 under ASSEMBLY.

1. Remove socket screw from end of footrest. Remove rubber pad.

2. Remove retaining ring from groove at end of pivot pin. Remove pivot pin.

3. Remove footrest and wave spring from footrest bracket.

4. Remove footrest bracket from rear swingarm bracket. See PASSENGER FOOTREST (FLHRS), REMOVAL, in this section.

ASSEMBLY

1. Install footrest bracket. See PASSENGER FOOTREST

(FLHRS), INSTALLATION, in this section.

2. With concave side up and ﬂat edge facing opposite the footrest, align hole in wave spring with topside hole in footrest.

3. Place footrest with wave spring between arms of bracket and install pivot pin. Hole in bracket is countersunk to accommodate head of pivot pin.

NOTE

Verify operation of footrest before installing retaining ring. The ease with which the footrest pivots is based on the curvature of the wave spring. Flattening the wave spring allows the footrest to move more easily, while increasing the curvature makes movement more difﬁcult.

4. Install new retaining ring in groove at end of pivot pin.

5. Place new pad into footrest.

6. Apply a small dab of Loctite Medium Strength Threadlocker 243 (blue) to threads of socket screw. Install socket screw and tighten to 15-20 ft-lbs (20-27 Nm).

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EXHAUST SYSTEM 2.36

REMOVAL

1. Remove saddlebags. See Section 2.25 SADDLEBAG,

REMOVAL.

2. See Figure 2-192. Open worm drive clamps to remove six heat shields from exhaust pipes. Mark the location of the heat shields to ensure proper assembly.

3. Using a bungee cord, tie the mufﬂer on the left side of the vehicle to the lower saddlebag support rail.

4. Remove the exhaust ﬂange nuts to release the front and rear header pipes from the cylinder head studs. For best results, use impact wrench with long 1/2 inch swivel socket.

5. See Figure 2-191. Loosen the four TORCA clamps as follows:

Right side of vehicle

● front header pipe to rear header pipe

● rear header pipe to right side mufﬂer

Left side of vehicle

● rear header pipe to crossover pipe

● crossover pipe to left side muffer

NOTE To facilitate removal, spray PB Blaster or other suitable penetrating oil in and around joints of exhaust pipes. For best results, be sure to allow sufﬁcient time for the penetrating oil to work.

6. Remove four bolts (with lockwashers) to detach left and

right side mufﬂers from the lower saddlebag support rails.

7. Standing on right side of vehicle, remove mufﬂer from Y-

shaped rear header pipe.

8. Remove Keps nut and pull bracket tab and stud from

slots in TORCA clamp and exhaust support bracket.

9. Remove Y-shaped rear header pipe from front header

pipe, crossover pipe (to left side mufﬂer) and rear cylinder head. Remove bracket tab from slot in TORCA clamp.

10. Remove bolt (with ﬂat washer and locknut) from trans-

mission exhaust bracket clamp on front header pipe. Use a channel lock to open clamp and then remove from header pipe and transmission exhaust bracket. Remove front header pipe exhaust ﬂange from front cylinder head.

11. Moving to left side of vehicle, remove crossover pipe

from left side mufﬂer.

12. Remove bungee cord to release left side mufﬂer from

lower saddlebag support rail.

13. Remove and discard gaskets from front and rear

exhaust ports. Discard TORCA clamp bolt assembliesone time usage only.

NOTE

TORCA mufﬂer clamps have eliminated the need for silicone or graphite tape during assembly. To ensure sealing integrity of mufﬂer clamps and prevent the possibility of leakage, Harley-Davidson recommends that mufﬂer clamp assemblies be discarded and replaced each time they are removed.

INSTALLATION

NOTE

Always loosely assemble exhaust system on vehicle before following tightening procedure. Assemble as follows:

1. Install new gaskets in both the front and rear cylinder

head exhaust ports (with the tapered side out).

2. Install transmission exhaust bracket onto transmission side door, if removed.

3. Install front header pipe exhaust ﬂange onto front cylinder head. Start ﬂange nuts on cylinder head studs.

4. Engaging transmission exhaust bracket, capture front header pipe in transmission exhaust bracket clamp. Use a channel lock to close clamp, if necessary. Finger tighten clamp bolt (with ﬂat washer and locknut).

5. Slide a new TORCA clamp onto free end of front header pipe.

6. Install rear header pipe onto rear cylinder head and front header pipe. Start ﬂange nuts on cylinder head studs. Move TORCA clamp into position between front and rear header pipes.

7. Slide new TORCA clamps onto free ends of rear header pipe. TORCA clamp to crossover pipe is special in that it has slot for bracket tab to exhaust support bracket.

8. Slide right side mufﬂer onto rear header pipe. Finger tighten two bolts (with lockwashers) to attach mufﬂer to lower saddlebag support rail. Place TORCA clamp into position between rear header pipe and right side mufﬂer.

9. Moving to left side of vehicle, install crossover pipe onto remaining end of rear header pipe (above starter). Place TORCA clamp into position between rear header pipe and crossover pipe.

10. Fit bracket tab into slot of TORCA clamp engaging stud in slot of exhaust support bracket. Start Keps nut on stud.

11. Slide new TORCA clamp onto free end of crossover pipe.

12. Using a bungee cord, tie left side mufﬂer to lower saddlebag support rail. Install left side mufﬂer on crossover pipe. Place TORCA clamp into position between crossover pipe and left side mufﬂer. Finger tighten bolts to attach mufﬂer to saddlebag support rail.

2004 Touring: Chassis 2-151

HOME

CAUTION

13. Tighten the exhaust system as follows: a. Tighten the top nut of the front cylinder head

exhaust ﬂange to 9-18 in-lbs (1-2 Nm). Tighten the bottom nut to 100-120 in-lbs (11.3-13.6 Nm). Final tighten the top nut to 100-120 in-lbs (11.3-13.6 Nm).

Left

Mufﬂer

b. Tighten the bottom nut of the rear cylinder head

exhaust ﬂange to 9-18 in-lbs (1-2 Nm). Tighten the top nut to 100-120 in-lbs (11.3-13.6 Nm). Final tighten the bottom nut to 100-120 in-lbs (11.3-13.6 Nm).

c. Tighten the transmission exhaust bracket clamp bolt

to 60-96 in-lbs (6.8-10.8 Nm).

d. Tighten the two bolts (with lockwashers) to fasten

the right side mufﬂer to the lower saddlebag support rail.

e. Tighten the two bolts (with lockwashers) to fasten

the left side mufﬂer to the lower saddlebag support rail.

Screw

Lock

Washer

Rubber

Mount

Right

Mufﬂer

Saddlebag Support

Rail Bracket

TORCA

Clamp

Rear

Header Pipe

Keps

Nut

TORCA

Clamp

Bracket

Tab

Support Bracket

TORCA

Clamp

Exhaust

Transmission

Exhaust Bracket

Clamp

Crossover

Pipe

TORCA

Clamp

(Special)

Cylinder Head

Gasket

Circlip

Exhaust

Flange

Nut

f1153b2x

2-152 2004 Touring: Chassis

Front

Header Pipe

Transmission

Exhaust Bracket

Figure 2-191. Exhaust System (without Heat Shields)

HOME

CAUTION

Right Mufﬂer

Left Mufﬂer

Rear

Header Pipe

Crossover

Pipe

Heat

Shields

Heat

Shields

Heat

Shields

Figure 2-192. Heat Shields

f. Verify that all exhaust pipes are in alignment and do

not contact the vehicle frame or mounted components.

g. Tighten the four TORCA clamps to 45-60 ft-lbs (61-

81 Nm) in the following order:

● crossover pipe to left side muffer

● rear header pipe to right side muffer

● front header pipe to rear header pipe

● rear header pipe to crossover pipe

14. Tighten Keps nut securing bracket tab to exhaust support bracket.

Worm Drive

Clamps

Front

Header Pipe

f1154b2x

15. Open worm drive clamps and install six heat shields on exhaust pipes as marked during removal. See Figure 2-

192. Position each clamp so that screw is on the out-

board side in the most accessible position and then tighten to 20-40 in-lbs (2.3-4.5 Nm).

16. Remove bungee cord from left side mufﬂer.

17. Install saddlebags. See Section 2.25 SADDLEBAG,

INSTALLATION.

2004 Touring: Chassis 2-153

HOME

NOTES

2-154 2004 Touring: Chassis

Harley Davidson Touring 2004 Service Manual sm02b

Specifications and Main Features

Frequently Asked Questions

User Manual

REAR SHOCK ABSORBERS 2.19

ADJUSTMENT

REMOVAL

DISASSEMBLY

CLEANING AND INSPECTION

ASSEMBLY

INSTALLATION

REAR SWINGARM 2.20

REMOVAL

DISASSEMBLY/ASSEMBLY

Bearing Removal

Pivot Shaft Disassembly

Bearing Installation

Pivot Shaft Assembly

INSTALLATION

THROTTLE CABLES (NON-CRUISE) 2.21

ADJUSTMENT

REMOVAL

THROTTLE SIDE

CARBURETOR/INDUCTION MODULE SIDE

INSTALLATION

THROTTLE SIDE

CLEANING AND INSPECTION

CARBURETOR/INDUCTION MODULE SIDE

LUBRICATION

CLUTCH CABLE 2.22

ADJUSTMENT

REMOVAL

INSTALLATION

HANDLEBARS 2.23

HANDLEBAR ADJUSTMENT

HANDLEBAR REMOVAL

HANDLEBAR INSTALLATION

LEFT HAND GRIP

REMOVAL

INSTALLATION

RUBBER MOUNTS

REMOVAL

INSTALLATION

SEAT 2.24

FLHR

REMOVAL

INSTALLATION

FLHRC

REMOVAL

INSTALLATION

FLHRS, FLTR

REMOVAL

INSTALLATION

FLHTC/U

REMOVAL

FLHT

REMOVAL

INSTALLATION

INSTALLATION

SEAT RETENTION NUT REPLACEMENT

SADDLEBAG 2.25

OPENING

FLHRC

FLHRS

FLHR, FLTR, FLHT/C/U

CLOSING

FLHRC

FLHRS

FLHR, FLTR, FLHT/C/U

REMOVAL

INSTALLATION

LATCH SPRING REPLACEMENT (FLHR, FLTR, FLHT/C/U)

REMOVAL

INSTALLATION

CABLE ASSEMBLY/LATCH/SCRIPT (FLHRS)

CABLE ASSEMBLY

LATCH

Removal

SADDLEBAG GUARD/SUPPORT RAIL

Installation