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4
MAINTENANCE SCHEDULE 1.1
Table 1-1. Scheduled Maintenance Table
1
1
2
2
3
3
4
4
5
1
5
0
5
0
5
0
5
0
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
mi
mi
mi
mi
mi
mi
mi
mi
mi
mi
km
mi
7
8
2
0
0
0
0
0
0
0
km
Service
Data
Check condition and
clean connections.
Oil level
Separate HOT and
COLD checks per
procedure.
Oil capacity
4 qt. (3.8 L) per
chart in procedure.
Service
Operation
Battery
Engine Oil
km
R
1
2
3
4
4
5
6
1
8
6
4
2
0
8
6
4
6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
km
km
km
km
km
km
km
km
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Engine
Oil Filter
Primary Chain
Te nsion
Primary Chain
Lubricant
Clutch
Adjustment
R
– Replace or changeI – Inspect (adjust, clean or replace as required)
X
– Perform
R
RRRRRRRRRR
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R
RRRRRRRRRR
XL
XL XL XL XL XL XL XL XL XL XL
T
– Tighten to proper torque
Hand tighten
1/2-3/4 turn after
gasket contact.
Deflection
Cold: 5/8-7/8 in.
(15.9-22.2 mm)
Hot: 3/8-5/8 in. (9.5-
15.9 mm)
Lubricant capacity
32 oz (946 mL) Part
No.’s
99887-84 (qt)
99886-84 (gal)
Free play at adjuster
screw
1/2-1 turn
Free play at hand
lever
1/16-1/8 in.
(1.6-3.2 mm)
L
– Lubricate (with specified lubricant)
D
– Disassemble (lube and inspect as required)
2004 FLT Police: Maintenance 1-1
HOME
Service
Operation
Tr ansmission
Lubricant
1
1
2
2
3
3
4
4
5
1
5
0
5
0
5
0
5
0
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
mi
mi
mi
mi
mi
mi
mi
mi
mi
mi
mi
1
2
3
4
4
5
6
7
8
1
8
6
4
2
0
8
6
4
2
0
6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
km
km
km
km
km
km
km
km
km
km
km
R RRRRRRRRRR
Service
Data
Lubricant level
Dipstick at FULL
with motorcycle
level and filler plug
resting on threads.
Lubricant capacity
20-24 oz (590-710
mL) Part No.’s
99892-84 (qt),
99891-84 (gal)
Tr ansmission drain
plug torque
14-21 ft-lbs
(19-28 Nm).
Filler plug torque
25-75
in-lbs
(2.8-8.5 Nm)
Tire Condition
and Pressure
Wheel Spokes
Steering
Head Bearings
Brake Pad
Linings and Discs
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See page 2-3 in
this document
Spoke nipple
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torque
40-50
in-lbs
(4.5-5.6 Nm)
Lubricate through
neck fitting with
Special
Purpose Grease
,
Part No. 9985797 (cartridge)
L
L L IL L D
For swing-by inspection or disassembly instructions, see
page 2-71 of the
2004 Touring
Models Service
Manual
Minimum brake pad
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thickness
0.04 in.
(1.02 mm)
R
– Replace or changeI – Inspect (adjust, clean or replace as required)
X
– Perform
T
– Tighten to proper torque
1-2 2004 FLT Police: Maintenance
L
– Lubricate (with specified lubricant)
D
– Disassemble (lube and inspect as required)
HOME
Service
Operation
mi
km
1
1
2
2
3
3
4
4
5
1
5
0
5
0
5
0
5
0
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
mi
mi
mi
mi
mi
mi
mi
mi
mi
mi
1
2
3
4
4
5
6
7
8
1
8
6
4
2
0
8
6
4
2
0
6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
km
km
km
km
km
km
km
km
km
km
Service
Data
Brake Fluid
Reservoir Level
and Condition
Drive Belt
Rear Shock
Absorbers
Air Cleaner
Fuel Valve, Lines
and Fittings
Fuel Tank Filter
Enrichener Control
Throttle Cables
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IL
IL IL IL IL IL IL IL IL IL IL
D.O.T. 5 Brake fluid
Part No.’ s 9990277 (12 oz),
99901-77 (gal)
On ground without
rider
1/4-5/16 in.
(6.4-7.9 mm) on
bottom strand
with 10 lb. (4.5
kg) upward force
See page 2-79 of
the 2004 Touring
Models Service
Manual
Air cleaner cover
screw torque
36-60
(4-7 Nm)
Check for leaks.
Hex fitting torque
I
15-20 ft-lbs
(20-27 Nm)
See page 4-5 of
the 2004 Touring
Models Service
Manual
Lubricant
Part No. 9496885TV- 1/4 fl. oz.
Handlebar clamp
screw torque
60-80
(6.8-9.0 Nm)
Switch housing
screw torque
35-45
(4-5 Nm)
in-lbs
in-lbs
in-lbs
R
– Replace or changeI – Inspect (adjust, clean or replace as required)
X
– Perform
T
– Tighten to proper torque
L
– Lubricate (with specified lubricant)
D
– Disassemble (inspect and repack as required)
2004 FLT Police: Maintenance 1-3
HOME
Service
Operation
1
0
0
0
mi
1
6
0
0
km
mi
km
1
1
2
2
3
3
4
4
5
5
0
5
0
5
0
5
0
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
mi
mi
mi
mi
mi
mi
mi
mi
mi
1
2
3
4
4
5
6
7
8
8
6
4
2
0
8
6
4
2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
km
km
km
km
km
km
km
km
km
Service
Data
Electrical
Components
Spark Plugs
Engine Idle Speed
Critical Fastener
Torque
Stabilizer Links
and Engine
Mounts
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IRIRIRIRIR
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T
T T T T T
T
T T T T
Check for proper
operation.
Plug type
HD-6R12
Plug gap
0.038-0.043 in.
(0.97-1.09 mm)
Plug torque
12-18 ft-lbs
(16-24 Nm)
Idle speed
950-1050 rpm
Verify tightness.
See CRITICAL
FASTENERS on
page 1-30 of the
2004 Touring
Models Service
Manual
Verify tightness.
See ENGINE
MOUNTS on page
1-30 of the 2004
Touring Models
Service Manual
Front Fork Oil
Windshield
Grommets (FLHP)
Road Test
R
– Replace or changeI – Inspect (adjust, clean or replace as required)
X
– Perform
X
T
– Tighten to proper torque
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1-4 2004 FLT Police: Maintenance
Fork oil (Type E)
D
Part No. 9988480 (16 oz)
-
-
L
– Lubricate (with specified lubricant)
D
– Disassemble (lube and inspect as required)
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