Harley Davidson Touring 2004 Service Manual sm02b

HOME

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

HOME

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

HOME

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

HOME

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

t

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

w

2-84 2004 Touring: Chassis

HOME

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

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

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

rear header 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.

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

HOME

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

HOME

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

HOME

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.

3.

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

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.

3.

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

Pin

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

HOME

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.

2.

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).

9.

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.

3.

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

1

2

3

*9

**10

4

5

6

7

5

**11

8

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

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.

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.

8.

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-

6.

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

HOME

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