Harley Davidson Touring 2004 Service Manual spa02a

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SPECIFICATIONS 2.1

FUEL TANK
MODEL
FLHTP FLHP
WHEEL BASE
MODEL
in. mm in. mm in. mm in. mm in. mm in. mm
FLHTP 63.5 1612.9 93.70 2379.9 39.0 990.6 5.1 129.5 61.0 1549.4 27.3 693.4 FLHP 63.5 1612.9 93.70 2379.9 34.5 876.3 5.1 129.5 55.1 1399.5 27.3 693.4
MODEL
FLHTP 758.0 343.8 1200 544.3 500 226.8 770 349.3 FLHP 723.0 327.9 1200 544.3 500 226.8 770 349.3
Gross vehicle weight rating (GVWR) (maximum allowable loaded vehicle weight) and corresponding gross axle weight rating (GAWR) are printed on a label fixed to the bottom of the right front frame downtube.
TOTAL
gal. liter gal. liter qt. liter oz. liter oz. liter
5.0 18.92 - - 4.0 3.79 24 0.71 32 0.95
OVERALL
LENGTH
DRY WEIGHT GVWR GAWR FRONT GAWR REAR
lb. kg lb. kg lb. kg lb. kg
NOTE
FUEL TANK
RESERVE
OVERALL
WIDTH
OIL TANK W/FILTER
ROAD
CLEARANCE
See Section 2.3 TIRES for important information regarding tire data and tire inflation.
TRANSMISSION
(APPROX.)
OVERALL
HEIGHT
NOTE
PRIMARY
CHAINCASE
SADDLE
HEIGHT (Laden)
2004 FLT Police: Chassis 2-1
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VEHICLE IDENTIFICATION NUMBER 2.2

GENERAL

A 17-digit serial number, or Vehicle Identification Number (VIN), is stamped on the right side of the frame backbone at the rear of the steering head (and under the main harness conduit). A label bearing the VIN code is also affixed to the left side of the steering head. An abbreviated VIN is stamped
Market Designation
1 = Domestic 5 = International (HDI)
Manufacturer and Make
Harley-Davidson
Motorcycle Type
1 - Heavyweight
Vin Check Digit
Varies; can be 0 thru 9, or X.
between the front and rear cylinders on the left side of the crankcase.
NOTE
Always give the complete VIN when ordering parts or making an inquiry about your motorcycle.
Model Designation
FH - FLHPI FM - FLHTPI FT - FLHPEI
Model Year
4 - 2004
Engine Type
V - Carbureted W - Fuel Injected
Introduction Date/Special Models
1 = Regular introduction date 2 = Mid-year introduction date 3 = California model 4 = Anniversary model
Assembly Plant
Y - York, PA K - Kansas City, MO
Serial Number
1HD 1 FM W 13 4 Y 110000
Sample VIN as it appears on the steering head - 1HD1FMW134Y110000 Sample abbreviated VIN as it appears on the engine - FMW4110000
Figure 2-1. Vehicle Identification Number (VIN)
2-2 2004 FLT Police: Chassis
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11WARNING1WARNING

TIRES 2.3

GENERAL

The rear tire on FL police motorcycles is fit for solo riding only. If converted to a two-up bike, that is, configured for pas­senger use (with luggage), then the rear tire needs to be changed to one with a higher weight rating. Since it has long been Harley-Davidson policy not to mix different types of tires on the same vehicle, we strongly recommend that both front and rear tires be replaced. In order to alert the customer to this safety issue, the following warning appears on a label fit­ted to the rear fender approximately 1/4 inch (6.4 mm) behind the domestic seat mounting hole.
11WARNING1WARNING
This vehicle has tires with weight ratings for one person operation. If this vehicle is modified to carry two people, the tires must be changed. See your local Harley-David­son dealer for the proper replacement tires. Failure to fol­low this warning could cause tire failure which could result in death or serious injury. (00096a)
Table 2-1. Tire Data
MODEL
TIRE
LOCATION
SIZE
NOTE Use the tires recommended for civilian/pleasure vehicles of the same year and model family.
The Dunlop front and rear tires on Harley-Davidson motorcycles are not interchangeable. DO NOT put a front tire at the rear of the vehicle or a rear tire at the front. Improper placement of tires can adversely affect motor­cycle stability and handling, which may lead to loss of vehicle control resulting in death or serious injury. (00026a)
Tire size, manufacturer’s description and inflation pressure are listed below.
MANUFACTURER’S
DESIGNATION
TIRE
PRESSURE
(Cold)
FLHTP/FLHP
Front MT90B1672H
Rear MT90B1671H
Dunlop
D402F PT
Dunlop
D402 PT
36 psi
(248 kPa)
36 psi
(248 kPa)
2004 FLT Police: Chassis 2-3
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SEAT 2.4

OPERATION

CAUTION
Maximum seat air pressure is 100 psi (689 kPa). Normal air pressure is between 30-45 psi (207-310 kPa). Minimum air pressure is determined by rider weight. Do not oper­ate with pressure so low that system bottoms out on bumpy roads. (00167a)
NOTE
To set minimum air pressure, have rider sit on seat and bounce to simulate riding conditions. Visually check for any contact between air spring and frame components. Add air as necessary.
1. Standing on left side of vehicle, press down on rear of seat and pull quick release pin from hole in support post. See Figure 2-2. Raise seat toward fuel tank console.
2. To lock seat in place, move seat down until support post engages hole in rear seat bracket.
5872
Support
Post
Figure 2-2. Seat Latch
3. While pressing down on rear of seat, insert quick release pin into hole of support post.
The seat does not adjust forward or backward.
Quick Release
Pin
Rear Seat
Bracket
NOTE
1. Air spring hose
2. Air spring
3. Screw (2) @ 36-60 in-lbs (4.1-6.8 Nm)
4. Trim panel
5. Seat faring
6. Screw
7. Rivnut (4)
8. Screw
9. Bushing
10. Seat support bracket
11. Nut @ 48-84 in-lbs (5.4-9.5 Nm)
12. Seat
13. Seat mount bracket (2)
14. Washer
15. Screw @ 60-120 in-lbs (6.8-13.6 Nm)
16. Screw (4) @ 15-20 ft-lbs (20.3-27.1 Nm)
17. Rubber bumper
18. Flange locknut (2) @ 96-144 in-lbs (10.9-16.3 Nm)
19. Quick release pin
20. Flange nut (2) @ 60-120 in-lbs (6.8-13.6 Nm)
21. Washer (2)
22. Rear seat bracket
23. Set screw (2)
24. Nut (2) @ 50-70 in-lbs (5.7-7.9 Nm)
25. Quick release fitting
6
5
10
11
9
8
13
16
15
14
19
7
12
17
18
20
4
3
2
23
1
25
21
22
24
p0047c2x
2-4 2004 FLT Police: Chassis
Figure 2-3. Air Seat Support
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Air
Reservoir
Air Valve
f1842x2x
Air Pressure
Gauge

AIR SEAT RESERVOIR

Removal

1. Remove luggage rack. See Section 2.6 LUGGAGE
RACK, REMOVAL, steps 1-5.
2. Alternately loosen screws on each side of motorcycle to release ends of luggage rack from frame tube weld­ments. Continue loosening screws until luggage rack can be raised high enough to remove air reservoir.
3. Remove two Phillips screws (with lockwashers) from lug­gage rack to release top of air reservoir bracket.
4. Remove two Phillips screws from license plate bracket to free rear of air reservoir bracket. Be sure to hold reser­voir as the last screw is removed or damage to fender paint may occur when assembly is released.
5. Raise luggage rack and remove air reservoir from motor­cycle.
6. Remove tee fittings from reservoir, if necessary.

Installation

1. Install tee fittings to air reservoir, if removed.
2. Position air reservoir beneath luggage rack exercising caution to avoid scratching fender paint.
Figure 2-4. Air Seat Reservoir Air Valve
3. Slide Phillips screws through two holes in license plate bracket and two holes in luggage rack engaging weld nuts in air reservoir bracket. Alternately tighten screws until snug.
4. Alternately tighten screws on each side of motorcycle to secure ends of luggage rack to frame tube weldments.
5. Install luggage rack. See Section 2.6 LUGGAGE RACK,
INSTALLATION, steps 1-4 and 6-13.
1. Air seat reservoir and bracket
2. Lockwasher (2)
3. Screw (2)
4. Air pressure gauge
5. Air tube
6. Compression fitting
7. Air valve
8. Protective cap
9. Tee fitting (2)
10. Screw (2)
6
8
3
5
7
2
4
9
1
Figure 2-5. Air Seat Reservoir
10
p0048b2x
2004 FLT Police: Chassis 2-5
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FOOTBOARDS 2.5

GENERAL

FLHTP and FLHP models are equipped with adjustable foot­boards.

ADJUSTMENT

Right Side

1. Loosen two allen head socket screws (with lockwashers and flat washers) to release right side footboard brackets from frame weldment. For best results, approach from left side of vehicle using a 3/8 inch ball allen with exten­sion.
2. Move the footboard to one of two positions. Alternately tighten allen head socket screws to 30-35 ft-lbs (40.7-
47.5 Nm).
11WARNING1WARNING
Rear brake will not operate properly if brake pedal can­not be fully depressed. After adjusting right footboard, check for minimum clearance of 2.25 inches (57 mm) between bottom of brake pedal and top of footboard. Failure to allow for proper clearance can lead to loss of braking performance, which could result in death or seri­ous injury.
4. 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 (with lockwasher) through frame weldment and jiffy stand bracket into threaded hole of footboard bracket. Alternately tighten two hex bolts to 15-20 ft-lbs (20.3-27.1 Nm).
NOTE
Perform a visual check to verify that both footboards are at the same height.

Left Side

1. Loosen the allen head socket screw (with lockwasher and flat washer) to release the footboard forward bracket from frame weldment. For best results, approach from opposite side of vehicle using a 3/8 inch ball allen.
2. 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).
3. Move the footboard to one of two positions. Alternately tighten allen head socket screw to 30-35 ft-lbs (40.7-47.5 Nm).
2-6 2004 FLT Police: Chassis
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6046

LUGGAGE RACK 2.6

REMOVAL

1. Remove both saddlebags.
2. On the right side of the motorcycle, locate the air seat reservoir air valve under the luggage rack, and on the left side, the rear shock air valve just below the chrome frame cover. See Figure 2-6.
11WARNING1WARNING
Exercise caution when bleeding air from the air valves. 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.
f1842x2x
f2018x2x
Air Seat
Reservoir
Air Valve
Rear Shock
Air Valve
Figure 2-7. Remove Luggage Rack
3. Remove protective cap from each air valve and depress pin to bleed air from both reservoir and shocks. To purge rear air suspension lines of any oil, add 3-5 psi (20.7-
34.5 kPa) before releasing air. Depress collar on each compression fitting and pull out air tube.
4. Remove bolt (with flat washer) to remove saddlebag front mounting bracket from chrome frame cover. Remove Phillips screw and then remove frame cover. Repeat step on opposite side of motorcycle.
5. Remove two bolts to free license plate bracket from bot­tom support tube.
6. Remove screws (with spacers) on each side of motorcy­cle to release ends of luggage rack from frame tube weldments.
7. Remove pole lamp. See Section 8.5 POLE LAMP.
8. Slide luggage rack toward rear of motorcycle to clear front bushings, and then rotate rack upward to clear frame tubes. See Figure 2-7.

INSTALLATION

Figure 2-6. Air Valves
1. Place luggage rack into position inboard of frame tubes.
2004 FLT Police: Chassis 2-7
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2. Install screws (with spacers) on each side of motorcycle to secure ends of luggage rack to frame tube weldments.
3. Install two bolts to fasten license plate bracket to bottom support tube.
4. Position chrome frame cover on frame tube and install Phillips screw. Install bolt (with flat washer) to install sad­dlebag front mounting bracket, but do not tighten. Repeat step on opposite side of motorcycle.
5. Install pole lamp. See Section 8.5 POLE LAMP.
6. Depress collar on compression fitting of air seat reser­voir, and insert air tube until it bottoms. Gently tug on tube to verify that it is locked in place.
CAUTION
Maximum seat air pressure is 100 psi (689 kPa). Normal air pressure is between 30-45 psi (207-310 kPa). Minimum air pressure is determined by rider weight. Do not oper­ate with pressure so low that system bottoms out on bumpy roads. (00167a)
7. Fill air reservoir to desired pressure. Install protective cap on air valve. See upper frame of Figure 2-6.
Table 2-2. Rear Air Suspension Pressures
Shock Loading
Solo rider up to 150 lbs. (68 kg) 0 0
Solo rider 150-200 lbs. (68-91 kg) 0-10 0-69
Solo rider 200-250 lbs. (91-113 kg) 5-15 35-103
Maximum GVWR (see Section 2.1
SPECIFICATIONS)
Recommended
Pressures
PSI
0-35
20-35 138-241
kPa
0-241
11WARNING1WARNING
Use this table as a starting point in determining suit­able rear air suspension pressures. Do not exceed maximum GVWR when loading vehicle and do not pressurize system in excess of 35 psi (241 kPa). Excessive load weight and/or air suspension pres­sure can adversely affect handling and lead to loss of vehicle control, which could result in death or seri­ous injury.
NOTE
To set minimum air pressure, have rider sit on seat and bounce to simulate riding conditions. Visually check for any contact between air spring and frame components. Add air as necessary.
8. Observe air pressure gauge. If leakage occurs, then remove tube and inspect end for burrs or damage. If either condition is found, snip off end of tube and insert back into fitting.
9. Depress collar on compression fitting of each shock and insert air tube until it bottoms. Gently tug on tube to verify that it is locked in place.
10. Fill shocks to desired pressure. See Ta ble 2-2.
CAUTION
All air components fill rapidly. Use a small hand or foot operated air pump to avoid possible damage to shocks or air suspension components.
NOTE
An AIR SUSPENSION PUMP AND GAUGE (Part No. HD-
34633) is available at your Harley-Davidson dealer.
11. Observe air pressure gauge while filling. If leakage occurs, remove tubes and inspect ends for burrs or dam­age. If either condition is found, snip off end of tube and insert back into fitting.
12. When air pressure remains constant, install protective cap on air valve.
13. Install saddlebags. Using an open end/box wrench, tighten saddlebag front mounting bracket bolts.
2-8 2004 FLT Police: Chassis
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1. Headlamp Nacelle
2. Nut
3. Flat Washer
4. Flange Nut
5. Chrome Strip
6. Phillips Screw (2)
7. Tachometer Bracket
8. Acorn Nut (2)
9. Fork Lock Plate
10. Handlebar Clamp Shroud
11. Stud Plate
f1458d2x
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8
9
6
10
11
5
4
3
2
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INSTRUMENT MOUNTING BRACKET: FLHP 2.7

GENERAL

The Instrument Mounting Bracket relocates the tachometer to allow for the addition of a radio and speaker.
NOTE
The two rear holes in the handlebar clamp shroud allow the rider to adjust the handlebars without having to remove the shroud. To keep out moisture and debris, be sure to install plastic plugs back into holes after handlebar adjustment.

INSTALLATION

1. Remove windshield. See Section 2.31 WINDSHIELD/ HEADLAMP NACELLE (FLHR/C/S), REMOVAL, in the 2004 Touring Models Service Manual (Part No. 99483-
04).
2. Remove 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.
4. Squeeze the two external tabs (if present) to remove the wire connector at the back of the headlamp bulb. Remove headlamp housing assembly from the vehicle.
5. Reaching inside the headlamp nacelle, remove flange nut to release the chrome strip at the top of the nacelle. See Figure 2-8.
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 two acorn nuts from the left side fork studs. Remove acorn nuts from the right side fork studs.
9. Cover front fender with suitable material to protect fender paint. Remove the passing lamp bracket from the left and right side fork studs and carefully set on front fender.
10. Remove grommets (and clutch cable clamp) from the left and right side fork studs.
11. Reaching inside the headlamp nacelle, disconnect tachometer connector [108], 3-place Deutsch.
12. Remove the handlebar clamp shroud from the vehicle, while gently pulling the tachometer conduit and connec­tor out of the headlamp nacelle. See Figure 2-9.
Figure 2-8. Headlamp Nacelle Assembly
13. Remove two acorn nuts and flat washers to release tachometer bracket from the handlebar clamp shroud.
14. A peel and stick foam tape on the stud plate holds it in place on the inboard side of the handlebar clamp shroud, Place the instrument mounting bracket over the studs and secure using hardware provided by manufacturer. See upper frame of Figure 2-11.
2004 FLT Police: Chassis 2-9
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f1458e2x
Figure 2-9. Handlebar Clamp Shroud
1
2
5531
Install instrument mounting bracket on stud plate.
p0044x5x
5532
3
6
5
4
1. Acorn Nut
2. Instrument Mounting Bracket
3. Handlebar Clamp Shroud
Figure 2-10. Instrument Mounting Bracket Assembly
15. Secure slotted tab of instrument mounting bracket to front of handlebar clamp shroud using nut and bolt pro­vided by manufacturer. See middle frame of Figure 2-11.
16. Place tachometer bracket over studs on instrument mounting bracket and install two acorn nuts with flat washers. See lower frame of Figure 2-11.
17. Part the halves of the headlamp nacelle slightly. With the flat washer on the handlebar clamp shroud facing the inside surface of the nacelle, slide the Phillips screw down the gap until the shroud is in position at top of nacelle. See Figure 2-9.
4. Stud Plate
5. Screw
6. Nut
Install instrument mounting bracket front bolt.
5530
Install tachometer bracket.
Figure 2-11. Install Instrument Mounting Bracket
18. Raising handlebar clamp shroud slightly, feed tachome­ter connector and conduit into the headlamp nacelle. Install shroud over mating flange while routing tachome­ter conduit through opening for left side handlebar. Reaching inside headlamp nacelle, mate pin and socket halves of tachometer connector.
2-10 2004 FLT Police: Chassis
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19. With the halves of the nacelle mated, tighten the Phillips screw in the tab of the handlebar clamp shroud to 10-20
in-lbs
(1.1-2.3 Nm). If necessary, temporarily install a small cable strap into holes at the bottom of the nacelle (headlamp housing flange) to hold the halves together.
20. Install two Phillips screws to fasten handlebar clamp shroud to the fork lock mechanism. Install fork lock plate.
21. Inserting weld stud on chrome strip into 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).
22. Install grommets on the left and right side fork studs.
23. Slide passing lamp bracket onto the left and right side fork studs. Verify that four grommets are positioned on the inboard side of the passing lamp brackets.
24. Install acorn nuts on the fork studs and tighten to 72-108
in-lbs
(8.1-12.2 Nm). Be sure to capture the clutch cable clamp on the upper left stud before installing the acorn nut.
25. Install wire connector at the back of headlamp bulb.
26. Align holes in headlamp housing with those in headlamp nacelle (headlamp door bracket at bottom). Install the eight Phillips screws.
27. 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 Phillips screw at the bottom of the head­lamp door.
28. Install windshield. See Section 2.31 WINDSHIELD/ HEADLAMP NACELLE (FLHR/C/S), INSTALLATION, in the 2004 Touring Models Service Manual (Part No. 99483-04).
2004 FLT Police: Chassis 2-11
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NOTES
2-12 2004 FLT Police: Chassis
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