Harley Davidson Touring 2004 Service Manual sm08a

Spare

ECM Power

f2223x9x

EFI System

Relay

System Fuse Block (Under Left Side Cover)

EFI Fuse Block (Under Right Side Cover)

FLHR/C/S

FLTR, FLHT/C/U

1. Headlamp

2. Ignition

3. Lighting

4. Instruments

5. Brakes/Cruise

6. Radio Memory

7. Radio Power

8. Accessory

9. Battery

10. Brake Light Relay

11. P&A

12. Starter Relay

f2210x8x

f2204x8x

Fuel Pump

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SPECIFICATIONS 8.1

IGNITION TIMING

ALL FL Models

RANGE TDC - 50˚ BTDC START

ALTERNATOR SYSTEM

TDC

Output Voltage @ 3600 rpm 14.3-14.7 38 Amp: FLHR, FLHRI, FLHRCI, FLHRS, FLHRSI, FLHT, FLHTC 45 Amp: FLHTI, FLHTCI, FLHTCUI, FLTRI

BATTERY

Voltage 12V Amperes – 28 AH @ 20 Hour Rate

FUSES

System Fuses

Maxi-Fuse 40 Orange

Headlamp 15 Blue

Ignition 15 Blue

Lighting 15 Blue

Instruments 15 Blue

Brakes/Cruise 15 Blue

Radio Memory 15 Blue

Radio Power 10 Red

Accessory 15 Blue

Battery 15 Blue

P & A 15 Blue

EFI Fuses

Fuel Pump 15 Blue

ECM Power 15 Blue

Circuit

Rating

(Amperes)

Color

Figure 8-1. Fuse Locations

2004 Touring: Electrical 8-1

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SPARK PLUG

Part No.

32317-86A 6R12 12 mm

Be sure spark plugs are gapped to speciﬁcation before installation.

No. Size Gap

0.038-0.043 in.

0.97-1.09 mm

NOTE

TORQUE VALUES

Item

Ignition module socket head screws

MAP sensor TORX screw 25-35 Ignition coil bracket

socket screws Spark plug 12-18 ft-lbs 16-24 Nm Stator to crankcase TORX

screws Battery cable bolt 60-96 Voltage regulator locknuts 70-100 Battery hold-down clamp

TORX bolt Headlamp door screw 9-18 Passing lamp bracket fork

bracket TORX bolts Passing lamp bracket fork

bracket stud acorn nuts Ta il lamp lense screws 20-24 Ta il lamp circuit board/

plastic bracket Rear fender tip lamp nuts 20-25 Front fender tip lamp nuts 20-25 Front fender trim strip tee

bolt nuts Ignition switch to upper

fork bracket Fairing cap TORX screws 25-30 Ignition switch button

head screws

Ignition switch nut

DOM 50-70 HDI 125-150

ft/in-lbs Nm

50-60

in-lbs

84-144

in-lbs

55-75

in-lbs

15-20 ft-lbs 20-27 Nm

in-lbs

15-20 ft-lbs 20-27 Nm

72-108

in-lbs

40-48

in-lbs

in-lbs in-lbs

10-15

in-lbs

36-60

in-lbs

18-23

in-lbs

5.7-6.8 Nm

2.8-4.0 Nm

9.5-16.3 Nm

6.2-8.5 Nm

6.8-10.9 Nm

7.9-11.3 Nm

1.0-2.0 Nm

8.1-12.2 Nm

2.3-2.7 Nm

4.5-5.4 Nm

2.3-2.8 Nm

2.3 - 2.8 Nm

1.1-1.7 Nm

4.1-6.8 Nm

2.8-3.4 Nm

2.0-2.6 Nm

5.7-7.9 Nm

14.1-16.9 Nm

Continued ...

Item

Fork lock to upper fork bracket (FLHR/C/S)

Ignition switch screws (FLHR/C/S)

Instrument bezel TORX screws

Handlebar clamp to master cylinder housing screws

Lower and upper handlebar switch housing TORX screws

Handlebar clamp to clutch lever bracket TORX screws

Neutral switch 120-180 Horn stud ﬂange nut

(10mm) Horn bracket acorn nut to

rubber mount stud 2 inch diameter gauge

nuts Tachometer bracket

socket screws Speedometer speed

sensor screw Speedometer bracket

socket screws Console mounting bolt

acorn nut (FLHR/C/S) Console pod Phillips

screws Fuel tank canopy TORX

screws Cruise module locknuts 60-96 Radio to support bracket

socket screws Upper fairing speaker

lower TORX screw Upper fairing speaker

upper TORX screws Throttle cable J-clamp

screw to wellnut (FLHR/C/S)

Ground post ﬂange nuts 50-90

ft/in-lbs Nm

36-60

20-30

25-35

60-80

35-45

60-80

80-100

10-20

84-108

10-20

50-90

6-11

18-24

35-45

22-28

35-50

9-18

in-lbs

4.1-6.8 Nm

2.3-3.4 Nm

2.8-4.0 Nm

6.8-9.0 Nm

4-5 Nm

6.8-9.0 Nm

13.6-20.3 Nm

9.0-11.3 Nm

1.1-2.3 Nm

9-12 Nm

1.1-2.3 Nm

5.7-10.2 Nm

0.7-1.2 Nm

2.0-2.7 Nm

6.8-10.9 Nm

4.0-5.1 Nm

2.5-3.2 Nm

4.0-5.7 Nm

1.0-2.0 Nm

5.7-10.2 Nm

8-2 2004 Touring: Electrical

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BULB CHART 8.2

Lamp Description,

All Lamps 12V

HEADLAMP

FLHT/C/U, FLHR/C/S 1 4.58/5 55/60 68329-03 FLTR

POSITION LAMP (HDI)

PASSING LAMPS

(DOM) 2 2.50 30 68674-69B (HDI)

TAIL AND STOP LAMP

Tail Lamp 0.59 6 68167-88 Stop Lamp 2.10 24 68167-88 Tail Lamp (HDI) 0.59 6 68167-88 Stop Lamp(HDI) 2.10 24 68167-88 License Plate (HDI)

TURN SIGNAL LAMP

Front/Running 2 2.25/.59 27/7 68168-89 Front (HDI) 2 1.75 21 68163-84 Rear 2 2.25 27 68572-64B Rear (HDI)

TOUR-PAK

Side Marker Lamps * 4 0.3 3.7 53439-79 Tail/Brake Lamps (Ultra)

FENDER TIP LAMPS *

Number of

Bulbs

24.58/5 55/60 68329-03

10.323.9 53438-92

22.923568847-98A 1

10.375.2 53436-97

21.75 21 68163-84

20.59768168-89A

2 0.3 3.7 53439-79

Current Draw

(Amperage)

Wattage

Harley-Davidson

Part No.

INSTRUMENT PANEL LAMPS FLHT/C/U, FLTR

High Beam 1 0.15 2.1 68024-94 Oil Pressure 1 0.15 2.1 68024-94 Neutral 1 0.15 2.1 68024-94 Turn Signal

GAUGE LAMPS FLHT/C/U, FLTR

Speedometer ** Tachometer ** Voltmeter 1 0.24 3.4 67445-00 Oil Pressure Gauge 1 0.24 3.4 67445-00 Air Temperature Gauge 1 0.24 3.4 67445-00 Fuel Gauge 1 0.24 3.4 67445-00 Engine **

INSTRUMENT PANEL/ GAUGE LAMPS

FLHR/C/S High Beam ** Oil Pressure ** Neutral ** Turn Signal ** Fuel Gauge ** Speedometer ** Odometer ** Engine **

* Not Applicable to HDI ** LED Illuminated. LEDs are not repairable. Assembly must be replaced if LED fails.

20.152.1 68024-94

2004 Touring: Electrical 8-3

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NOTES

8-4 2004 Touring: Electrical

Maxi-Fuse

f2207x8x

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SYSTEM FUSES 8.3

MAXI-FUSE

REMOVAL

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

DLEBAG, REMOVAL.

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

3. Depress latches on maxi-fuse holder and then slide cover rearward to disengage tongue from groove in fuse block cover. See Figure 8-2.

4. Pull maxi-fuse from maxi-fuse holder. See Figure 8-3.

Figure 8-3. Remove Maxi-Fuse

INSTALLATION

1. Insert maxi-fuse into maxi-fuse holder. See Figure 8-3.

2. Slide cover forward to engage tongue in groove of fuse block cover and then insert maxi-fuse holder into cover until latches engage. See Figure 8-2.

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

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

BAG, INSTALLATION.

Fuse

Block

f2206x8x

Figure 8-2. Remove Left Side Cover

Maxi-Fuse

Cover

MAXI-FUSE HOLDER

REMOVAL

1. Remove maxi-fuse. See MAXI-FUSE, REMOVAL, in this section.

2. Remove socket terminals from maxi-fuse holder. See Section B.3 PACKARD ELECTRICAL CONNECTORS,

800 METRI-PACK SERIES.

INSTALLATION

3. Install socket terminals into maxi-fuse holder. See Section B.3 PACKARD ELECTRICAL CONNECTORS,

800 METRI-PACK SERIES.

4. Install maxi-fuse. See MAXI-FUSE, INSTALLATION, in this section.

SYSTEM FUSES/RELAYS

REMOVAL

1. Remove maxi-fuse. See MAXI-FUSE, REMOVAL, in this section.

2. Pull fuse block from tabs on mounting bracket. Tabs on bracket ﬁt into slots on each side of fuse block cover.

2004 Touring: Electrical 8-5

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Spare Fuse

Holder

f2203x8x

Fuse Block

Cover

INSTALLATION

1. Install system fuse/relay in fuse block. See lower frame of Figure 8-4.

NOTE

For FLHR/C/S conﬁguration, see upper frame of Figure 8-1 in Section 8.1 SPECIFICATIONS.

2. Slide cover over fuse block until slots fully engage tabs on block. See upper frame of Figure 8-4.

3. Slide fuse block into position on mounting bracket. Tabs on bracket ﬁt into slots on each side of fuse block cover.

4. Install maxi-fuse. See MAXI-FUSE, INSTALLATION, in this section.

f2209x8x

FUSE BLOCK

REMOVAL

1. Remove system fuses and relay(s). See SYSTEM

FUSES/RELAYS, REMOVAL, in this section.

5. Remove socket terminals from fuse block. See Section

B.3 PACKARD ELECTRICAL CONNECTORS, 280

METRI-PACK SERIES.

1. Headlamp

2. Ignition

3. Lighting

4. Instruments

5. Brakes/Cruise

6. Radio Memory

Figure 8-4. Fuse Block (FLTR, FLHTC/U)

NOTE

The fuse block cover also serves as the spare fuse holder. One spare 10 amp and 15 amp fuse are provided.

3. Remove the fuse block cover. Raise lipped side slightly to disengage slots from tabs on fuse block. See upper frame of Figure 8-4.

4. Remove system fuse/relay from fuse block. Replace fuse if the element is burned or broken. Automotive type ATO fuses are used. See lower frame of Figure 8-4.

NOTE

For FLHR/C/S conﬁguration, see upper frame of Figure 8-1 in Section 8.1 SPECIFICATIONS.

7. Radio Power

8. Accessory

9. Battery

10. Brake Light Relay

11. P&A

INSTALLATION

1. Install socket terminals into fuse block. See Section B.3

PA CKARD ELECTRICAL CONNECTORS, 280 METRIPA CK SERIES.

2. Install system fuses and relay(s). See SYSTEM FUSES/

RELAYS, INSTALLATION, in this section.

EFI FUSES

See Section 9.2 ELECTRICAL BRACKET ASSEMBLY, EFI

FUSES.

8-6 2004 Touring: Electrical

f2191x8x

Ignition Control Module

Connector [10]

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IGNITION CONTROL MODULE (CARBURETED) 8.4

REMOVAL

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

DLEBAG, REMOVAL.

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

3. Depress external latches and use a rocking motion to to remove electrical connector. See Figure 8-5.

4. Remove two socket screws to detach ignition control module from electrical bracket.

INSTALLATION

1. Align holes in ignition control module with those in electrical bracket. Install two socket screws and tighten to 50-60

in-lbs

(5.7-6.8 Nm).

2. Align tabs on socket housing with grooves on pin housing and push connector halves together until latches click.

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

Figure 8-5. Electrical Bracket (Under Right Side Cover)

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

BAG, INSTALLATION.

2004 Touring: Electrical 8-7

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SENSORS (CARBURETED) 8.5

MANIFOLD ABSOLUTE PRESSURE SENSOR

MAP Sensor

Removal

1. Partially remove fuel tank. See Section 4.7 FUEL TANK

(CARBURETED), PA RTIAL REMOVAL, FLHT/C, or FLHR/S.

2. Pull external latch outward and use rocking motion to remove electrical connector.

3. Remove T20 TORX screw to release retaining clip from intake manifold. See Figure 8-6.

T20 TORX

Screw

4. Carefully pull pressure port (enveloped in rubber seal) from hole in intake manifold.

5. If reusing sensor, inspect condition of rubber seal. Replace the seal if it is cut, torn or shows signs of deterioration.

Installation

1. Install rubber seal on pressure port, if removed.

2. With port side down, slide end of retaining clip in slot at side of sensor. Aligning hole in retaining clip with threaded hole in intake manifold, carefully press pressure port into bore,

Retaining

Clip

Figure 8-6. Intake Manifold

3. Install T20 TORX screw and tighten to 25-35

4.0 Nm). See Figure 8-6.

4. Align latch on socket housing with locking tab on pin housing and push connector halves together until latch clicks.

5. Install fuel tank. See Section 4.7 FUEL TANK (CARBU-

RETED), INSTALLATION (AFTER PARTIAL REMOVAL), FLHT/C, or FLHR/S.

in-lbs

(2.8-

CRANKSHAFT POSITION SENSOR

See Section 9.3 SENSORS, CRANKSHAFT POSITION

SENSOR.

8-8 2004 Touring: Electrical

8316

f1925x8x

Front

Rear

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IGNITION COIL 8.6

REMOVAL

1. Partially remove fuel tank. For carbureted models, see Section 4.7 FUEL TANK (CARBURETED), PA RT IAL

REMOVAL, FLHT/C or FLHR/S. For fuel injected mod-

els, see Section 9.4 FUEL TANK (FUEL INJECTED),

PA RTIAL REMOVAL, FLHT/C/U/I, FLTRI or FLHR/C/S/I.

2. Unplug spark plug cables from ignition coil towers.

3. Pull external latch outward and use rocking motion to remove electrical connector from left side of ignition coil.

4. Pull sides of ignition coil bracket outward to remove from bosses of front fuel tank mount. See Figure 8-7.

5. Remove two socket screws to free ignition coil from bracket.

INSTALLATION

1. Align holes in Properly positioned, connector pin housing should be positioned at cut in bracket. Install two socket screws and tighten to 84-144

8-8.

2. With the coil towers facing rear of vehicle, hold ignition coil and bracket at bottom of frame backbone. Pull sides of bracket outward and install on bosses of front fuel tank mount. See Figure 8-7.

3. Install electrical connector on left side of ignition coil. Align latch on socket housing with locking tab on pin housing and push connector halves together until latch clicks.

4. Install spark plug cable to front cylinder onto left side coil tower. Verify that spark plug cable is captured in doublesided cable clip at bottom left side of frame backbone. Install

new

See Figure 8-10.

5. Install spark plug cable to rear cylinder onto right side coil tower. Verify that spark plug cable is captured in two single-sided cable clips at bottom left side of frame backbone. Install missing. See Figure 8-10.

new

ignition coil with holes in bracket.

in-lbs

(9.5-16.3 Nm). See Figure

cable clip on T-stud if damaged or missing.

new

cable clips on T-studs if damaged or

6. 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.

Figure 8-7. Remove Ignition Coil Bracket From Vehicle

Figure 8-8. Install Bracket to Ignition Coil

2004 Touring: Electrical 8-9

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SPARK PLUGS/SPARK PLUG CABLES 8.7

SPARK PLUGS

Inspect spark plugs at 5000 miles (8,000 km) and replace at 10,000 miles (16,000 km).

The number 6R12 plug is supplied as original equipment and is the only plug that should be used. The resistor plug reduces radio interference created by the ignition system and will not adversely affect performance or fuel economy.

REMOVAL

1. Remove spark plug cables. See SPARK PLUG CABLES on the next page.

2. Remove spark plug using a 5/8 inch spark plug socket.

INSPECTION

See Figure 8-9. Examine plugs as soon as they have been removed. The deposits on the plug base are an indication of the plug efﬁciency and are a guide to the general condition of rings, valves, carburetor and ignition system.

a. A wet black and shiny deposit on plug base, elec-

trodes and ceramic insulator tip indicate an oil fouled plug. The condition may be caused by worn rings and pistons, loose valves or seals, weak battery or faulty ignition.

b. A dry ﬂuffy or sooty black deposit indicates a too

rich carburetor air-fuel mixture or long periods of engine idling. Excessive use of the enrichener may also cause this condition.

c. An overheated plug can be identiﬁed by a light

brown, glassy deposit. This condition may be accompanied by cracks in the insulator or by erosion of the electrodes. This condition is caused by too lean an air-fuel mixture, a hot running engine, valves not seating or improper ignition timing. The glassy deposit on the spark plug is a conductor when hot and may cause high speed misﬁring. A plug with eroded electrodes, heavy deposits or a cracked insulator should be replaced.

d. A plug with white, yellow or light tan to rusty brown

powdery deposit indicates balanced combustion. The deposits may be cleaned off at regular intervals if desired.

CLEANING

Figure 8-9. Types of Plug Base Deposits

2. Use a thin ﬁle to ﬂatten spark plug electrodes. A spark plug with sharp edges on its electrodes requires 25%40% less ﬁring voltage than one with rounded edges.

3. Adjust spark plug gap. See ADJUSTMENT below.

ADJUSTMENT

Use only a wire-type gauge. Bend the outside electrode so only a slight drag on the gauge is felt when passing it between electrodes. Never make adjustments by bending the center electrode. Set gap on all plugs at 0.038-0.043 in. (0.97-1.09 mm).

INSTALLATION

1. Before installing spark plugs, check condition of threads in cylinder head and on plug. If necessary soften deposits with penetrating oil and clean out with a thread chaser.

2. Apply a very light coating of ANTISEIZE LUBRICANT to spark plug threads. Install spark plug. Tighten spark plug to 12-18 ft-lbs (16-24 Nm).

1. Degrease ﬁring end of spark plug using ELECTRICAL CONTACT CLEANER. Dry spark plug with compressed air.

8-10 2004 Touring: Electrical

If a torque wrench is not available, ﬁnger-tighten spark plug and then using a spark plug wrench, tighten plug an additional 1/4-turn.

OME

3. Connect spark plug cables to spark plugs. Make sure boots/caps are secured properly.

4. Check engine idle speed, and adjust if necessary.

SPARK PLUG CABLES

Resistor-type high-tension cables have a carbon-impregnated fabric core (instead of solid wire) for radio noise suppression and improved reliability of electronic components. Use the exact replacement cable for best results.

REMOVAL

1WARNING1WARNING

Never disconnect a spark plug cable with the engine running. Doing so will result in an electric shock from the ignition system that could result in death or serious injury.

CAUTION

When disconnecting a spark plug cable from the spark plug terminal, always grasp and pull on the rubber boot at the end of the cable assembly (as close to the spark plug terminal as possible). Pulling on the cable portion will damage the carbon core.

1. Disconnect spark plug cables from ignition coil and spark plug terminals.

INSPECTION

1. Check cables for cracks or loose terminals.

2. Check spark plug cable resistance with an ohmmeter. Resistance must be as follows:

Table 8-1. Spark Plug Cable Resistance

Position

Front /Rear 20 Inches (508 mm) 5,000 - 11,666

3. Replace cables that are worn or damaged, or that do not meet resistance speciﬁcations.

4. Check cable boots/caps for cracks or tears. Also check for loose ﬁt on ignition coil and spark plugs. Replace boots/caps if defects are noted.

Cable Length Resistance (Ohms)

INSTALLATION

1. Connect spark plug cables to spark plugs.

2. Install spark plug cable to front cylinder onto left side coil tower. Verify that spark plug cable is captured in doublesided cable clip at bottom left side of frame backbone. Install

new

cable clip on T-stud if damaged or missing.

See Figure 8-10.

3. Install spark plug cable to rear cylinder onto right side coil tower. Verify that spark plug cable is captured in two single-sided cable clips at bottom left side of frame backbone. Install missing. See Figure 8-10.

new

cable clips on T-studs if damaged or

Figure 8-10. Spark Plug Cable Clips (Left Side View)

8497

2004 Touring: Electrical 8-11

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ALTERNATOR/STATOR 8.8

REMOVAL

Rotor

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

1WARNING1WARNING

f2120x8x

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

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

3. Remove the primary chaincase cover. Remove the clutch, primary chain, compensating sprocket and shaft extension as a single assembly. See Section 6.5 PRI-

MARY CHAINCASE, REMOVAL, steps 3-15.

4. Remove the alternator rotor spacer, if present.

1CAUTION

The high-output rotor is used on fuel injected vehicles, FLHR/C/S/I excepted. Since the high-output rotor contains magnets that are considerably more powerful than those used on low-output rotors, the ROTOR REMOVER/ INSTALLER and SHAFT PROTECTOR SLEEVE (HD-

41771) must be used to prevent parts damage and possi-

ble hand injury during removal and installation.

5. Remove the rotor as follows:

High Output Rotor - 45 Amp

a. Verify that threads of engine sprocket shaft are

clean, especially of old Loctite material. Thread the Shaft Protector Sleeve onto the shaft. See Figure 8-

11.

b. Tu rn thumbscrews of Rotor Remover/Installer into

threaded holes in rotor face.

c. Rotate handle of forcing screw in a clockwise direc-

tion to remove rotor from shaft.

Engine

Sprocket Shaft

1. Clean Sprocket Shaft Threads.

Shaft Protector

Sleeve

2. Install Shaft Protector Sleeve.

Thumbscrew

Forcing Screw

Low Output Rotor - 38 Amp

CAUTION

Do not strike or drop rotor. Damage to magnet adhesive may result in rotor failure.

a. Fabricate wire hooks or use the ends of two allen

wrenches to carefully pull rotor at holes in rotor face.

b. Pull rotor from stator. Magnets in rotor cause some

resistance during removal.

8-12 2004 Touring: Electrical

Thumbscrew

Handle

3. Install Rotor Remover/Installer. Rotate Handle in a Clockwise Direction.

Figure 8-11. Remove Rotor from Engine Sprocket Shaft

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Stator

Connector [46]

12. Using a T27 TORX drive head, remove four screws to free stator from crankcase. Discard screws.

13. Using point of awl, carefully lift capped rib on grommet away from crankcase and then insert into bore between grommet and casting. See Figure 8-14. Tilt awl slightly squirting isopropyl alcohol or glass cleaner into opening. Repeat this step at one or two other locations around grommet.

14. While pushing on capped rib from outside of crankcase, draw grommet through bore by pulling on cable stop with needle nose pliers. Rock grommet back and forth to facilitate removal, if necessary. Exercise caution to avoid damaging ribs on grommet if stator is to be reused.

15. Draw stator cables and socket terminals through crankcase bore. For best results, feed one cable and socket terminal through at a time.

f2256x8x

Figure 8-12. Voltage Regulator (Left Side View)

6. Locate stator connector [46], 2-place Packard, ﬁxed to bracket at bottom of voltage regulator. Cut small cable strap and slide connector toward left side of motorcycle to release groove from tongue on bracket. Raise the external latch and separate pin and socket halves. See

Figure 8-12.

7. Remove locknut from left side leg of voltage regulator. Loosen right side locknut. Raise voltage regulator as necessary to free left side leg from stud on lower frame crossmember.

8. Remove P-clip from stud. Remove P-clip from cable conduit.

9. Draw cable conduit and connector to rear of front engine stabilizer link and then up to area in front of primary chaincase.

10. Depress tangs inside socket housing and back out sockets through wire end of connector. Proceed as follows:

a. Looking into the socket housing, take note of the

cavity on each side of the terminal. See upper frame of Figure 8-13.

b. Gently insert pick (Snap-On TT600-3) into the cavity

about 1/4 inch (6.4 mm) or until it stops, and pivot the side of the pick toward the terminal body. Repeat step on other cavity. See lower frame of Fig-

ure 8-13.

c. Gently tug on cable to pull terminal from chamber. If

terminal is still locked, one or both tangs are not fully depressed. Repeat steps 10(b) and 10(c) as necessary.

d. Repeat procedure to release second terminal.

CLEANING AND INSPECTION

1. Check inside of rotor and remove any metal fragments captured by magnets.

2. Clean the rotor using a petroleum solvent. Clean the stator and grommet by wiping it with a clean cloth.

f1912x8x

Cavity

Terminal A

f1911x8x

Pick

11. Remove conduit from cables. For best results, pull one cable and socket terminal through conduit at a time.

Figure 8-13. Remove Socket Terminals

2004 Touring: Electrical 8-13

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Capped

Rib

Awl

Figure 8-14. Remove Grommet From Crankcase

Opening

Stator

f1634x8x

INSTALLATION

1. From inside crankcase, feed socket terminals and stator cables through hole in crankcase. For best results, feed one cable and socket terminal through at a time.

2. Thorougly lubricate grommet with isopropyl alcohol or glass cleaner. Ribs of grommet must be clean and free of dirt and oily residue.

3. Carefully grasp cable stop behind grommet with a needle nose pliers. Push grommet into crankcase bore while carefully pulling on outside cable. Installation is complete when cable stop contacts casting and capped rib of grommet exits crankcase bore.

4. If necessary, carefully run awl around edge of capped rib so that it rests ﬂat against seating surface on crankcase.

NOTE

The Shaft Protector Sleeve not only protects the threads from the splines of the rotor, but acts as a guide to ensure that the rotor is properly centered.

b. Center ball on forcing screw in recess at end of

engine sprocket shaft. Rotate the handle of the tool in a counterclockwise direction to ease rotor into position over stator.

c. Loosen thumbscrews and remove Rotor Remover/

Installer. Remove Shaft Protector Sleeve.

d. Install the shaft extension on the engine sprocket

shaft. (No alternator rotor spacer is provided.)

Low Output Rotor - 38 Amp

a. Slide rotor over stator with the concave side

inboard.

1CAUTION

When installing rotor, keep ﬁngers away from edge that mates with crankcase. Since rotor is magnetized, as it nears the crankcase it may be pulled in with considerable force, resulting in pinched ﬁngers or other hand injury.

b. See inset of Figure 8-16. Install the 0.020 inch

(0.508 mm) thick alternator rotor spacer and the shaft extension on the engine sprocket shaft.

7. Install conduit onto cables. For best results, feed one socket terminal and cable through conduit at a time.

8. Install sockets into stator/voltage regulator connector as follows:

a. Using a ﬁngernail or a thin ﬂat blade, like that on an

X-Acto knife, carefully bend the tangs outward away from each terminal body. See Figure 8-15.

b. Feed each socket into wire end of stator/voltage

regulator connector until it “clicks” in place.

CAUTION

Do not reuse T27 TORX screws. The threads of the screws contain a locking compound in pellet form. When the screw is started, the pellet breaks releasing the compound.

5. Using a T27 TORX drive head, install four fasten stator to crankcase. Alternately tighten screws to 55-75

in-lbs

(6.2-8.5 Nm).

6. Install the rotor as follows:

new

screws to

High Output Rotor - 45 Amp

a. Install the Shaft Protector Sleeve and Rotor

Remover/Installer, if removed. See Figure 8-11.

8-14 2004 Touring: Electrical

X-Acto Knife

Tang

f1913x8x

Figure 8-15. Bend Tangs Outward

OME

Rotor

Alternator Rotor Spacer

0.020 Inch (0.508 mm) Thick

f2221x8x

Cable Strap

Stator Connector

f2119x8x

38 AMP

Connector [46]

Stator

Socket

Housing

Flange

Locknut

P-Clamp

Housing

Secondary

Lock

Cable Straps and Anchors

Lower Frame Tube

Voltage

Regulator

P-Clamp

Anchored

Cable Strap

Brake Pedal

Weldment

Cable Stop

Grommet

Rotor

T27 TORX

Screw

Alternator Rotor Spacer

Figure 8-16. Stator/Voltage Regulator Assemblies - 45 AMP

c. Verify that sockets will not back out of chambers. A

slight tug on each cable will conﬁrm that it is locked.

9. Feed connector and cable conduit under front engine stabilizer link and then forward along outboard side of voltage regulator leg. See Figure 8-12.

Voltage Regulator

Connector [77]

Stator

38 Amp:

FLHR, FLHRI, FLHRCI, FLHRS, FLHRSI, FLHT, FLHTC

45 Amp:

FLHTI, FLHTCI, FLHTCUI, FLTRI

Ring Terminal

10. Install P-clip on cable conduit approximately ﬁve inches (127 mm) from socket housing. Slide P-clip over left side stud on lower frame crossmember. Properly oriented, Pclip is positioned at front of stud with the open side up and angled so that it is inline with the lower rail of the engine guard.

2004 Touring: Electrical 8-15

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