Harley Davidson Touring 2004 Service Manual sm02a

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SPECIFICATIONS 2.1

DIMENSIONS (IN.)

FLHT/C/U

Wheel Base 63.5 63.5 63.5 Overall Length Overall Width 39.0 Road Clearance 5.12 Overall Height 61.0 Saddle Height* 27.3

With 180 Lb. Rider

93.7/97.5/98.3

FLHR/C/S FLTR

93.7 93.7

34.45/34.45/39.40

5.12/5.12/4.70

55.06/55.06/46.40

27.3/26.9/26.1

35.75

WEIGHT (LBS.)

FLHT/C/U FLHR/C/S FLTR

DRY WEIGHT** 758/776/788 723/710/721 731 GVWR 1259 1259 1259 GAWR – Front 500 500 500 GAWR – Rear 827 827 827

As shipped from the factory

5.12

55.0

26.9

DIMENSIONS (MM)

FLHT/C/U

Wheel Base 1613 1613 1613 Overall Length Overall Width 990 Road Clearance 130 Overall Height 1549 Saddle Height* 693

With 81.6 kg Rider

2380/2476/2497

FLHR/C/S FLTR

2380 2380

875/875/1001

130/130/119

1399/1399/1179

693/683/663

1397

WEIGHT (KG)

FLHT/C/U

DRY WEIGHT** 344/352/358 328/322/327 332 GVWR 571 571 571 GAWR – Front 227 227 227 GAWR – Rear 375 375 375

As shipped from the factory

FLHR/C/S FLTR

908 130

683

NOTE

Gross Vehicle Weight Rating (GVWR) (maximum allowable loaded vehicle weight) and corresponding Gross Axle Weight Ratings (GAWR) are given on a label located on the inside of the right front frame downtube.

CAPACITIES (U.S.)

FLHT/C/U

Fuel Tank (gallons) To tal***

Reserve Oil Tank (quarts)

with ﬁlter 4 4 4 Tr ansmission

(Ounces, approximate) 20-24 20-24 20-24 Primary Chaincase

(Ounces, approximate) 32 32 32

Front Fork (Ounces)

***

Includes Reserve on Carbureted Models

0.9

Left Right Left Right Left Right

10.0 11.1 11.1 11.1 10.0 11.1

FLHR/C/S FLTR

0.9

CAPACITIES (METRIC)

FLHT/C/U

Fuel Tank (liters) To tal***

Reserve Oil Tank (liters)

with ﬁlter 3.78 3.78 3.78 Tr an smission

(Milliliters) 591-710 591-710 591-710 Primary Chaincase

(Milliliters) 946 946 946

Front Fork (Milliliters)

Includes Reserve on Carbureted Models

***

18.9

3.4

Left Right Left Right Left Right

295 328 328 328 295 328

FLHR/C/S FLTR

18.9

3.4

18.9

3.4

2004 Touring: Chassis 2-1

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TIRE DATA

11WARNING1WARNING

Tires, rims and air valves must be correctly matched to wheel rims. See your Harley-Davidson dealer for service. Mismatching tires, tubes, rims and air valves may result in damage to the tire bead during mounting or may allow the tire to slip on the rim, possibly causing tire failure, which could result in death or serious injury.

11WARNING1WARNING

Using tires in ways other than those speciﬁed below may adversely affect motorcycle stability. Instability may lead to loss of vehicle control, which could result in death or serious injury.

Use tubeless tires on all Harley-Davidson cast and

●

disc wheels.

●

Tubeless tires ﬁtted with the correct size inner tubes also may be used on all Harley-davidson laced wheels, but protective rubber rim strips must be installed to prevent damage to the inner tubes.

●

Do not use inner tubes in radial tires. Do not use radial tires on laced wheels.

Always use the correct size tires and tubes. Tire

●

sizes are molded on the tire sidewall. Tube sizes are printed on the tube.

11WARNING1WARNING

Maximum inﬂation pressure must not exceed speciﬁcation on tire sidewall. Exceeding inﬂation speciﬁcations can adversely affect handling or result in tire failure, which could result in death or serious injury.

Tire Pressure (Cold)

Dunlop Tires

Only

Front Rear

PSI BARS PSI BARS Solo Rider 36 2.5 36 2.5 Rider & One Passenger 36 2.5 40 2.8

REAR WHEEL SPROCKET

All Models 70 teeth

TORQUE VALUES

Item

Front brake disc TORX screws

Front axle nut

Front axle holder nuts

Front brake caliper mounting bolts

Rear brake disc TORX screws

Rear wheel sprocket bolts 55-65 ft-lbs

Rear axle cone nut 95-105 ft-lbs 129-142 Nm Wheel spokes

Front engine mount to frame bolts

Front engine mounting bracket to rubber mount bolt

Voltage regulator locknuts

Handlebar clamp to master cylinder housing TORX screws

Brake caliper bleeder valve

Rear brake pedal shaft locknut

Brake pedal/master cylinder assembly to mounting bracket hex nut

Banjo bolt to master cylinder

Banjo bolt to brake caliper

Fairing lower U-bolt retainer locknuts

Fairing lower to engine guard clamp TORX screw

Fairing lower cap screws

Front brake master cylinder reservoir cover screws

Rear brake master cylinder reservoir cover screws

Brake caliper pad pins

Brake caliper bridge bolts

ft/in-lbs Nm

16-24 ft-lbs 22-33 Nm

50-55 ft-lbs

132-180

in-lbs

28-38 ft-lbs

30-45 ft-lbs

40-50

in-lbs

15-20 ft-lbs 20-27 Nm

70-100

in-lbs

60-80

in-lbs

80-100

in-lbs

15-20 ft-lbs

30-40 ft-lbs 41-54 Nm

17-22 ft-lbs 23-30 Nm

35-40

in-lbs

90-100

in-lbs

10-15

in-lbs

6-8

in-lbs

6-8

in-lbs

180-200

in-lbs

28-38 ft-lbs 38-52 Nm

68-75 Nm

14.9-20.3 Nm

37.9-51.5 Nm

41-61 Nm

75-88 Nm

4.5-5.6 Nm

7.9-11.3 Nm

6.8-9.0 Nm

9.0-11.3 Nm

20-27 Nm

4.0-4.5 Nm

10.2-11.3 Nm

1.1-1.7 Nm

0.7-0.9 Nm

20-23 Nm

Continued ...

2-2 2004 Touring: Chassis

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TORQUE VALUES (CONT.’D)

Item

Fork oil drain plugs

Fork pinch bolts

Fork stem nut

Fork tube plug

Fork cap bolt

Damper rod/cartridge 6mm screw

Damper rod locknut (cartridge type fork)

Shock bottom mounting bolt

Shock top mounting bolt

Rear swingarm bracket bolts

Rear swingarm pivot shaft locknut

Handlebar switch housing TORX screws

Handlebar clamp to clutch lever bracket screws

Clutch release cover socket head screws

Clutch cable ﬁtting 36-60

Tr ansmission lubricant drain plug

Tr ansmission ﬁller plug/ dipstick

Battery cable bolt

Tour-Pak mounting bolts

Inner fairing screws

Outer fairing screws (below windshield)

Fairing cap TORX screws

Speedometer/tachometer bracket socket screws

2 inch diameter gauge nuts

Passing lamp bracket fork bracket TORX bolts

Windshield wellnut screws (FLTR)

Front turn signal lamp bracket stud acorn nuts (FLTR)

ft/in-lbs Nm

72-96

30-35 ft-lbs

60-80 ft-lbs

22-58 ft-lbs

50-60 ft-lbs

132-216

13-20 ft-lbs

35-40 ft-lbs

33-35 ft-lbs

34-42 ft-lbs

40-45 ft-lbs

35-45

60-80

120-144

14-21 ft-lbs

25-75

60-96

96-120

20-30

25-30

10-20

15-20 ft-lbs 20-27 Nm

6-13

40-50

in-lbs

8-11 Nm

41-48 Nm

81-109 Nm

30-79 Nm

68-81 Nm

14.9-24.4 Nm

18-27 Nm

47-54 Nm

45-48 Nm

46-57 Nm

54-61 Nm

4-5 Nm

6.8-9.0 Nm

13.6-16.3 Nm

4-7 Nm

19-28 Nm

2.8-8.5 Nm

6.8-10.9 Nm

10.8-13.5 Nm

2.3-3.4 Nm

2.8-3.4 Nm

1.1-2.3 Nm

0.7-1.5 Nm

4.5-5.7 Nm

Continued ...

Item

Short fairing screws (FLTR)

Long fairing screws (FLTR)

Instrument bezel TORX screws (FLTR)

Instrument nacelle to fork bracket TORX bolts (FLTR)

Fairing bracket/steering head thru bolt (FLTR)

Radio bracket/inner fairing to fairing bracket stud locknuts (FLTR)

Headlamp nacelle handlebar clamp shroud Phillips screw

Headlamp nacelle trim strip ﬂange nut

Passing lamp bracket fork bracket stud acorn nuts

Front fender mounting bolts

Rear fender TORX bolts

Jiffy stand leg stop ﬂange nut

Intake ﬂange adapter screws

Exhaust ﬂange adapter nuts

Exhaust pipe TORCA clamps

Heat shield worm drive clamps

Tr ansmission exhaust bracket clamp bolt

Passenger footboard/ footrest socket screws

Rider footboard pivot bolt nut

Air valve mount hex nut 40-50 Handlebar upper clamp

screws Handlebar lower clamp

bolts (risers)

Ignition switch nut

Speaker box to Tour-Pak bolts

Throttle cable J-clamp screw to wellnut (FLHR/C)

DOM 50-70 HDI 125-150

ft/in-lbs Nm

6-12

10-15

25-35

15-20 ft-lbs 20-27 Nm

20-30 ft-lbs 27.1-40.7 Nm

96-144

10-20

15-20

72-108

16-20 ft-lbs 22-27 Nm

15-20 ft-lbs 20-27 Nm

43-53 ft-lbs 58-72 Nm

96-144

100-120

45-60 ft-lbs 61-81 Nm

20-40

60-96

15-18 ft-lbs 20-24 Nm

84-108

12-16 ft-lbs 16.3-21.7 Nm

30-40 ft-lbs 40.7-54.2 Nm

25-35

9-18

in-lbs

0.7-1.4 Nm

1.1-1.7 Nm

2.8-4.0 Nm

10.9-16.3 Nm

1.1-2.3 Nm

1.7-2.3 Nm

8.1-12.2 Nm

10.9-16.3 Nm

11.3-13.6 Nm

2.3-4.5 Nm

6.8-10.8 Nm

9.5-12.2 Nm

4.5-5.6 Nm

5.7-7.9 Nm

14.1-16.9 Nm

2.8-4.0 Nm

1.0-2.0 Nm

2004 Touring: Chassis 2-3

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NOTES

2-4 2004 Touring: Chassis

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VEHICLE IDENTIFICATION NUMBER (VIN) 2.2

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 between the front and rear cylinders on the left side of the crankcase.

Model Designation

DD – FLHT DJ – FLHTC FB – FLHRI FC – FLHTCUI FD – FLHR FF – FLHTCI FG – FLHTCUI W/SC FH – FLHPI

Market Designation

1 = Domestic 5 = International (HDI)

FK – FLHTCI Shrine FL – FLHTCUI Shrine FM – FLHTPI FR – FLHRCI FS – FLTRI FT – FLHPEI FV – FLHTI FW – FLHRI Shrine FX – FLHRS FY – FLHRSI

NOTE

Always give the complete VIN when ordering parts or making an inquiry about your motorcycle.

Introduction Date and Special Models

1 = Regular introduction date 2 = Mid-year introduction date 3 = California model 4 = Anniversary model

Engine Type

V = Carbureted W = Fuel Injected

VIN Check Digit

Var ies; can be 0 through 9, or X.

1HD 1DJ V 13 4 Y 500001

Motorcycle Type

1 = Heavyweight (901 cc and larger engine displacement)

Manufacturer and Make

Harley-Davidson

Sample VIN as it appears on the steering head –1HD1DJV134Y500001 Sample abbreviated VIN as it appears on the engine crankcase– DJV4500001

Figure 2-1. Vehicle Identiﬁcation Number (VIN)

Model Year

4 = 2004

Serial Number

Assembly Plant

Y = York, PA K = Kansas City, MO

2004 Touring: Chassis 2-5

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FRONT WHEEL 2.3

GENERAL

Maximum tire mileage and good handling qualities are directly related to care given wheels and tires. Wheels and tires should be regularly inspected for wear. If handling problems occur, see Section 1.1 TROUBLESHOOTING, HAN-

DLING, for possible causes.

Always keep tires inﬂated to the recommended pressure and balance the wheel whenever a tire or tube is replaced.

PRELIMINARY INSPECTION

1. Measure brake disc thickness for excessive wear. Minimum acceptable thickness is stamped on side of disc. Also replace discs if warped or badly scored. Obtain

new

T40 TORX screws if brake discs were removed.

2. Whenever the wheel is removed for tire replacement or any other purpose, inspect the wheel bearings as follows:

a. Insert ﬁnger into wheel bearing and rotate the inner

race in both directions. Repeat step on opposite side of wheel.

b. Replace the wheel bearings if there is rough rota-

tion, abnormal noise or anything unusual. Always replace wheel bearings as a set. Never replace just one wheel bearing.

2. Remove both the upper and lower mounting bolts from lugs of front fork leg to release brake caliper assembly.

3. Lift caliper upward to remove from brake disc. Allow the caliper to hang loose.

4. Repeat steps 1 thru 3 to release caliper on opposite side of wheel.

NOTE

Do not operate the front brake hand lever with the front wheel removed or the caliper pistons may be forced out. Reseating pistons requires disassembly of the caliper.

5. Insert screwdriver or steel rod through hole in axle on right side of vehicle. While holding axle stationary, remove the axle nut, lockwasher and ﬂat washer on the left side.

6. Loosen the two axle holder nuts at bottom of right side fork leg.

7. With soft mallet, tap axle toward right side of vehicle until loose. Catching external spacers on left and right side, pull axle from hub while supporting wheel.

8. Move wheel to bench area and inspect bearings. See

PRELIMINARY INSPECTION on this page.

REMOVAL

1. Use shop rag or tape to protect fender area adjacent to caliper, as incidental contact can occur during caliper removal.

9428

Figure 2-2. Inspect Wheel Bearings

DISASSEMBLY

1. If wheel bearing replacement is necessary, proceed as follows:

a. Obtain the WHEEL BEARING REMOVER/IN-

STALLER (HD-44060). Pick out the wheel bearing remover tools for the front wheel. See Figure 2-3.

b. To prolong service life and ensure smooth opera-

tion, sparingly apply graphite lubricant to threads of forcing screw.

c. Install hex nut, ﬂat washer and Nice bearing on forc-

ing screw. Insert end of forcing screw through hole in bridge.

d. Install steel ball inside

end of forcing screw.

e. Insert collet into bearing ID. Feel for inside edge of

bearing using lip at end of collet and then back off slightly.

f. Holding forcing screw to prevent rotation, turn hex

on collet until lip makes ﬁrm contact with inside edge of bearing. See upper frame of Figure 2-4.

lar

collet. Install collet at

ger

2-6 2004 Touring: Chassis

HOME

f1775x2x

Wheel

Bearing

f1774x2x

Nice

Bearing

Hex Nut

Forcing

Screw

Flat

Washer

Bridge

Collet Hex

with Ball Bearing

Hold Forcing Screw and Turn Hex on Collet to Expand.

Hold Forcing Screw and Turn Hex Nut to Pull Out Bearing.

Bridge

ger Collet

Lar 1 Inch

Steel Ball

Forcing Screw

Figure 2-3. Front Wheel Bearing Remover Tools

(Part No. HD-44060)

g. Holding forcing screw, turn hex nut until bearing is

free. See lower frame of Figure 2-4. h. Remove spacer sleeve from wheel hub. i. Repeat procedure to remove bearing on opposite

side of wheel. Discard bearings.

2. If brake disc replacement is necessary, use a T40 TORX drive head and remove ﬁve screws securing brake disc to hub. Discard TORX screws. Repeat procedure to remove disc on opposite side of wheel. If the wheel is to be assembled with the same discs, mark both the wheel and discs, so that they can be installed in their original positions.

3. If tire replacement is necessary, see Section 2.8 TIRES

AND TUBES.

4. If the wheel is laced, and hub, spoke or rim replacement is necessary, loosen all spoke nipples and disassemble hub from rim.

Nice Bearing

Hex Nut

Graphite Lubricant

f1769x2x

Flat Washer

CLEANING AND INSPECTION

1. Thoroughly clean all parts in solvent.

2. Inspect all parts for damage or excessive wear.

3. Always replace bearing assemblies as a complete set.

4. Inspect brake discs. Replace discs if warped or badly scored. Measure disc thickness for excessive wear. Minimum acceptable thickness is stamped on side of disc.

ASSEMBLY

1. On laced wheels, if the hub and rim were disassembled, assemble the hub, spokes and rim. See Section 2.6

WHEEL LACING - 16 INCH RIM.

Figure 2-4. Remove Sealed Wheel Bearings

2004 Touring: Chassis 2-7

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1. Axle Nut

2. Lockwasher

3. Flat Washer

4. T40 Torx Screw (10)

5. Brake Disc (Left Side)

6. External Spacer (Long)

7. Sealed Bearing (2)

8. Cast Wheel

9. Spacer Sleeve

10. Brake Disc (Right Side)

11. External Spacer (Short)

12. Axle

13. Laced Wheel

Left Side

Right Side

Figure 2-5. Front Wheel (Exploded View)

11WARNING1WARNING

Do not allow brake ﬂuid or other lubricants to contact the brake disc. Such contact can adversely affect braking ability, which could result in death or serious injury.

2. Using a T40 TORX drive head, install brake discs on hub using

new

screws. Be sure to install discs in their original positions. Alternately tighten screws to 16-24 ft-lbs (22-33 Nm).

3. Install

Always install ﬁrst of two bearings on the left side (opposite the valve stem side of the wheel).

new

wheel bearings as follows:

NOTE

f2042x2x

a. Obtain the WHEEL BEARING REMOVER/IN-

STALLER (HD-44060). Pick out the wheel bearing installer tools for the front wheel. See Figure 2-6.

b. To prolong service life and ensure smooth opera-

tion, sparingly apply graphite lubricant to threads of threaded rod.

c. Slide support plate onto threaded rod. Slide rod

through hub on the valve stem side of the wheel. See upper frame of Figure 2-7.

d. On opposite side of wheel, slide bearing onto

threaded rod with lettered side facing outboard.

e. Install

lar

pilot, Nice bearing, ﬂat washer and

ger

hex nut onto rod.

2-8 2004 Touring: Chassis

HOME

f1777x2x

Support

Plate

Threaded

Rod

f1773x2x

Nice

Bearing

Hex Nut

Threaded

Rod

Flat

Washer

Wheel

Bearing

Pilot

Slide Threaded Rod (with Support Plate) Through Hub.

Hold Threaded Rod and Turn Hex Nut to Push In Bearing.

Nice Bearing

Larger Pilot 1 Inch

Support Plate

Hex Nut

Graphite Lubricant

Flat Washer

Threaded Rod

f1771x2x

Figure 2-6. Front Wheel Bearing Installer Tools

(Part No. HD-44060)

f. Holding threaded rod on opposite side of wheel to

prevent rotation, turn hex nut to install bearing. See lower frame of Figure 2-7. Bearing is fully seated when it makes ﬁrm contact with the counterbore.

g. Disassemble and remove tool, but leave support

plate on threaded rod.

h. Slide threaded rod through installed wheel bearing

and hub of wheel.

i. On the valve stem side of the wheel, slide spacer

sleeve down threaded rod until it contacts installed wheel bearing.

j. Repeat steps 3(d) through 3(g) to complete installa-

tion of second wheel bearing. Bearing is fully seated when hex nut can no longer be turned.

4. Verify that wheel is true. See CHECKING CAST RIM RUNOUT or TRUING LACED WHEEL, whichever applies.

5. Install rim strip on wheel rim, if applicable. Install tube and tire, if applicable. Verify that wheel is balanced.

INSTALLATION

1. Place wheel into position between forks with the valve stem on the right side of the vehicle.

2. Coat the axle with ANTI-SIEZE LUBRICANT.

right fork leg. Push axle through fork, spacer and wheel hub until it begins to emerge from left side.

3. Supporting wheel, insert threaded end of axle through

4. With the three notches on the bearing side, push axle through

long

external spacer and left fork leg until axle

shoulder contacts external spacer on right fork side.

shor

external

Figure 2-7. Install Sealed Wheel Bearings

5. Install ﬂat washer, lockwasher and axle nut.

6. Insert screwdriver or steel rod through hole in axle on right side of vehicle. While holding axle stationary, tighten axle nut to 50-55 ft-lbs (68-75 Nm).

7. Insert 7/16 inch drill bit into hole in axle. See Figure 2-8.

8. Pull fork leg so that it just contacts drill bit, and then tighten axle holder nuts to 132-180

in-lbs

(14.9-20.3

Nm).

2004 Touring: Chassis 2-9

HOME

f1783x2x

Fork Leg

Right Side

Axle

Drill Bit

Axle Holder

Nuts

Figure 2-8. Align Front Wheel

9. Remove drill bit from axle hole.

10. Install brake caliper as follows:

Short

Spacer

11WARNING1WARNING

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

11. Depress front brake hand lever several times to set brake pads to proper operating position within caliper.

a. Use shop rag or tape to protect fender area adja-

cent to caliper, as incidental contact can occur during caliper installation.

b. With the bleeder valve topside, position caliper so

that brake disc is situated between friction pads. Pry inner and outer brake pads back for additional clearance, if necessary.

c. Align upper mounting hole in caliper with upper

mounting lug on fork leg. Loosely install long caliper mounting bolt into upper lug of fork leg.

d. Install short caliper mounting bolt into lower lug of

fork leg. Tighten lower mounting bolt to 28-38 ft-lbs (37.9-51.5 Nm).

e. Tighten upper caliper mounting bolt to 28-38 ft-lbs

(37.9-51.5 Nm).

f. Repeat step 10 to install caliper on opposite side of

wheel.

2-10 2004 Touring: Chassis

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REAR WHEEL 2.4

GENERAL

DLING, for possible causes.

Always keep tires inﬂated to the recommended pressure and balance the wheel whenever a tire or tube is replaced.

PRELIMINARY INSPECTION

1. Measure brake disc thickness for excessive wear. Minimum acceptable thickness is stamped on side of disc. Also replace disc if warped or badly scored.

2. Whenever the wheel is removed for tire replacement or any other purpose, inspect the wheel bearings as follows:

a. Insert ﬁnger into wheel bearing and rotate the inner

race. Repeat step on opposite side of wheel.

b. Replace the wheel bearings if there is rough rota-

tion, abnormal noise or anything unusual. Always replace wheel bearings as a set. Never replace just one wheel bearing.

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.

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

4. Remove cone nut and adjuster cam from axle.

5. 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.

6. 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.

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

8. Move wheel forward and slip belt off sprocket.

9. Move wheel to bench area and inspect bearings. See

PRELIMINARY INSPECTION on this page.

REMOVAL

1. Remove saddlebags. See Section 2.25 SADDLEBAG,

REMOVAL.

2. Remove both mufﬂers as follows:

Left Side

a. Open worm drive clamps to remove heat shield

from crossover pipe.

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.

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

saddlebag support rail.

NOTE

Do not operate the rear brake pedal with the rear wheel removed or the caliper pistons may be forced out. Reseating pistons requires disassembly of the caliper.

DISASSEMBLY

1. If wheel bearing replacement is necessary, proceed as follows:

a. Remove ﬁve bolts (with ﬂat washers) securing belt

sprocket to hub.

b. Obtain the WHEEL BEARING REMOVER/IN-

STALLER (HD-44060). Pick out the wheel bearing remover tools for the rear wheel. See Figure 2-9.

NOTE

The smaller 3/4 inch collet (and pilot) is only used to replace the rear

wheel bearings on 2000-01 Touring models.

c. To prolong service life and ensure smooth opera-

tion, sparingly apply graphite lubricant to threads of forcing screw.

2004 Touring: Chassis 2-11

HOME

Bridge

Forcing Screw

Steel Ball

ger Collet

Lar 1 Inch

Hex Nut

Graphite Lubricant

f1769x2x

Nice Bearing

Flat Washer

Figure 2-9. Rear Wheel Bearing Remover Tools

(Part No. HD-44060)

d. Install nut, ﬂat washer and Nice bearing on forcing

screw. Insert end of forcing screw through hole in bridge.

e. Install steel ball inside

lar

collet. Install collet at

ger

end of forcing screw.

f. Insert collet into bearing ID. Feel for inside edge of

bearing using lip at end of collet and then back off slightly.

Forcing

Screw

Hex Nut

Flat

Washer

Nice

Bearing

Collet Hex

with Ball Bearing

Hold Forcing Screw and Turn Hex on Collet to Expand.

Bridge

f1774x2x

f1775x2x

g. Holding forcing screw to prevent rotation, turn hex

on collet until lip makes ﬁrm contact with inside edge of bearing. See upper frame of Figure 2-10.

h. Holding forcing screw, turn hex nut until bearing is

free. See lower frame of Figure 2-10.

i. Remove spacer sleeve from wheel hub.

j. Repeat procedure to remove bearing on opposite

side of wheel. Discard bearings.

2. If brake disc replacement is necessary, use a T45 TORX drive head and remove ﬁve screws securing brake disc to hub. If the wheel is to be assembled with the same disc, mark both the wheel and disc, so that it can be installed in its original position.

3. Remove tire, if necessary. Remove tube from the rim, if applicable. See Section 2.8 TIRES AND TUBES.

4. If it is necessary to remove the hub from a laced wheel, loosen all spoke nipples and remove the rim and spokes.

CLEANING AND INSPECTION

1. Thoroughly clean all parts in solvent.

Wheel

Bearing

Hold Forcing Screw and Turn Hex Nut to Pull Out Bearing.

Figure 2-10. Remove Sealed Wheel Bearings

2. Inspect all parts for damage or excessive wear.

2-12 2004 Touring: Chassis

3. Always replace bearings as a complete set.

HOME

11WARNING1WARNING

1. Axle

2. External Spacer (Large)

3. Bolt (5)

4. Flat Washer (5)

5. Belt Sprocket

6. Sealed Bearing (2)

7. Spacer Sleeve

8. Cast Wheel

9. Brake Disc

10. T45 TORX Screw (5)

11. External Spacer (Small)

12. Adjuster Cam

13. Cone Nut

14. E-Clip

15. Laced Wheel

Right Side

Left Side

4. Inspect brake disc. Replace disc if warped or badly scored. Measure disc thickness for excessive wear. Minimum acceptable thickness is stamped on side of disc.

5. Check the belt sprocket for wear, tooth damage, cracks or pitting. Replace if necessary.

6. On laced wheels, replace spokes, rim or hub if damaged.

Figure 2-11. Rear Wheel (Exploded View)

ASSEMBLY

1. On laced wheels, if the hub and rim were disassembled, assemble the hub, spokes and rim. See Section 2.6

WHEEL LACING - 16 INCH RIM.

f2044x2x

2. Verify that wheel is true. See Section 2.5 CHECKING

RIM RUNOUT or Section 2.7 TRUING LACED WHEEL,

whichever applies.

Do not allow brake ﬂuid or other lubricants to contact the brake disc. Such contact can adversely affect braking ability, which could result in death or serious injury.

3. Using a T45 TORX drive head, install ﬁve screws (and locknuts on laced wheels) to secure brake disc to hub. Always install brake disc in its original position. Use screws after three use cycles. Alternately tighten screws to 30-45 ft-lbs (41-61 Nm).

new

2004 Touring: Chassis 2-13

HOME

Nice Bearing

Larger Pilot 1 Inch

Support Plate

Support

Plate

Hex Nut

Graphite Lubricant

Flat Washer

Threaded Rod

f1771x2x

Figure 2-12. Rear Wheel Bearing Installer Tools

(Part No. HD-44060)

4. Install

new

wheel bearings as follows:

NOTE

Always install ﬁrst of two bearings on the right side (the valve stem side of the wheel).

a. Obtain the WHEEL BEARING REMOVER/IN-

STALLER (HD-44060). Pick out the wheel bearing installer tools for the rear wheel. See Figure 2-12.

b. To prolong service life and ensure smooth opera-

tion, sparingly apply graphite lubricant to threads of threaded rod.

c. Slide support plate onto threaded rod. Slide rod

through hub on the sprocket side of the wheel. See upper frame of Figure 2-13.

d. On the valve stem side of the wheel, slide bearing

onto threaded rod with lettered side facing outboard.

e. Install

lar

pilot, Nice bearing, ﬂat washer and

ger

hex nut onto rod.

f. Holding threaded rod on opposite side of wheel to

prevent rotation, turn hex nut to install bearing. See lower frame of Figure 2-13. Bearing is fully seated when it makes ﬁrm contact with the counterbore.

g. Disassemble and remove tool, but leave support

plate on threaded rod.

h. Slide threaded rod through installed wheel bearing

and hub of wheel.

i. On the other side of the wheel, slide spacer sleeve

down threaded rod until it contacts installed wheel bearing.

j. Repeat steps 4(d) through 4(g) to complete installa-

tion of second wheel bearing. Bearing is fully seated when hex nut can no longer be turned.

5. Install rim strip on wheel rim, if applicable. Install tube and tire, if applicable. Verify that wheel is balanced.

Threaded

Rod

f1777x2x

Slide Threaded Rod (with Support Plate) Through Hub.

Wheel

Bearing

Nice

Bearing

Pilot

Threaded

Rod

f1773x2x

Hold Threaded Rod and Turn Hex Nut to Push In Bearing.

Hex Nut

Flat

Washer

Figure 2-13. Install Sealed Wheel Bearings

6. Apply two drops of Loctite High Strength Threadlocker 271 (red) to threads of ﬁve belt sprocket bolts. Always use

new

bolts after three use cycles. Install bolts with ﬂat washers to secure sprocket to hub. Alternately tighten bolts to 55-65 ft-lbs (75-88 Nm).

INSTALLATION

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

2-14 2004 Touring: Chassis

HOME

CAUTION

lbs. (4.5 kg) of force at the midpoint of the bottom belt strand. Belt deﬂection should be as follows:

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.

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

3. Coat the axle with ANTI-SIEZE LUBRICANT.

4. 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.

5. When axle emerges from hub on brake disc side of wheel, push axle through

shor

external spacer, caliper

bracket and right side of rear swingarm.

6. 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.

7. 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.

8. 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 2-14.

9. 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

Table 2-1. 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

10. If belt is too tight, move to step 11 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 bl e 2-1.

c. If belt is still too loose, repeat steps 10(a) through

10(b). If belt is now too tight, move to step 11.

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

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 2-14.

Inches Millimeters

3/16 - 1/4 4.8 - 6.4

Increase

Belt

Deflection

Weld

Nub

Reduce

Belt

Deflection

Cone

Nut

Weld

Nub

Weld

Nut

8398

E-Clip

8407

Figure 2-14. Move Rear Wheel Forward Until Adjuster Cams Just Contact Weld Nubs

RIGHT SIDELEFT SIDE

Adjuster

Cam

2004 Touring: Chassis 2-15

HOME

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 bl e 2-1.

d. If belt is still too tight, repeat steps 11(a) through

11(c). If belt is now too loose, move to step 10.

12.

Holding

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

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

13. 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 10.

14. With the ﬂat side out, install side of axle.

15. Install both mufﬂers as follows:

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.

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

NOTE

new

E-clip in groove on right

NOTE

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 and mufﬂer.

the mufﬂer to the lower saddlebag support rail.

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

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

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

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

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

f. Open worm drive clamps and install heat shield on

g. Remove bungee cord from mufﬂer.

new

TORCA clamp onto free end of rear

header pipe.

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

the mufﬂer to the lower saddlebag support rail.

CAUTION

not contact the vehicle frame or mounted components.

Nm).

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

CAUTION

d. Verify that exhaust pipes are in alignment and do

not contact the vehicle frame or mounted components.

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

Nm).

f. Open worm drive clamps and install heat shield on

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

2-16 2004 Touring: Chassis

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.

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

17. Install saddlebags. See Section 2.25 SADDLEBAG,

INSTALLATION.

HOME

f1379x2x

Gauge

Radial

Runout

CHECKING RIM RUNOUT 2.5

INSPECTION

Check wheels for lateral and radial runout before installing a new tire or tube.

1. Install truing arbor in wheel hub and place wheel in WHEEL TRUING STAND, Part No. HD-99500-80.

2. See Figure 2-15. To check rim lateral runout, place a gauge rod or dial indicator near the rim bead. If lateral runout exceeds 0.040 inch (1.02 mm), replace the wheel if cast. Retrue the wheel if laced.

3. See Figure 2-16. Check the rim radial runout as shown. If radial runout exceeds 0.030 inch (0.76 mm), replace the wheel if cast. Retrue the wheel if laced.

NOTE

Rim lateral and radial runout is adjustable on laced wheels. See Section 2.7 TRUING LACED WHEEL.

f1378x2x

Lateral Runout

Gauge

Figure 2-15. Checking Rim Lateral Runout

Figure 2-16. Checking Rim Radial Runout

4. If working with a laced wheel, proceed to Section 2.7 TRUING LACED WHEEL to check the wheel offset

dimension.

2004 Touring: Chassis 2-17

HOME

WHEEL LACING - 16 INCH RIM 2.6

GENERAL

The 16 inch wheel uses only one type of spoke, rather than the separate inner and outer spokes (with differing head angles) seen in the old style.

Exercise caution to avoid mixing old and new parts. The head angle of the spoke is closer to 90 degrees, which makes it very difﬁcult to differentiate from the outer spoke of the old style.

The nipple ﬁtting of the spoke uses a TORX style fastener (instead of the straight slotted) and requires a special T-30 I.P. (TORX Plus) driver (HD-42135) for removal and installation. See A of Figure 2-17. Use of a standard T-30 TORX bit will result in nipple damage.

The 16 inch hub can be easily identiﬁed by its aluminum construction. The 16 inch rim can be quickly identiﬁed by the shape of the ﬂat around the valve stem. The ﬂat is tombstone shaped on the rim (square shaped on the old style rim). See B and C of Figure 2-17.

f1150a2x

WHEEL LACING

1. If front wheel, place the hub on a table with the wider ﬂange side up. If rear wheel, place hub so that brake disc side is up. Insert a spoke in each hole of the lower row as shown below. Angle the spokes in a clockwise direction .

f1150d2x

Figure 2-18.

2. Place the rim on the table with the valve stem side up. Using any lower row spoke, place the ﬁrst spoke into the rim hole to the left of the valve stem hole on the upper half of the rim centerline.

Narrow Flange

Belt Sprocket Side

f1150c2x

Figure 2-17. Parts Identiﬁcation

Valve Stem Flat

Tombstone Shaped

Wide Flange

f1150b2x

First

Lower Row Spoke

Valve Stem Hole

f1150e2x

Figure 2-19.

2-18 2004 Touring: Chassis

HOME

f1150h2x f1150i2x

First

Lower Row Spoke

3. Install the rest of the lower row spokes in every fourth hole.

f1150f2x

Figure 2-20.

5. Install the nine remaining upper row spokes into every fourth hole remaining above the rim centerline.

Figure 2-22.

4. Place the ﬁrst upper row spoke into the hub as shown below. Angle the spoke counterclockwise crossing four lower row spokes. The spoke must enter the hole to the left of the valve stem hole.

First

Upper Row Spoke

f1150g2x

6. Turn the wheel over. Place any lower row spoke into the hub. Angle the spoke clockwise and place into rim hole angled to accept it.

Figure 2-21.

Figure 2-23.

2004 Touring: Chassis 2-19

HOME

7. Angled clockwise, place the nine remaining lower row spokes into hub and rim.

f1150j2x

Figure 2-24.

9. Install the nine remaining upper row spokes into hub and rim.

f1150l2x

Figure 2-26.

8. Insert any upper row spoke into the hub and angle spoke counterclockwise. Place spoke into appropriate rim hole crossing four lower row spokes.

First

Upper Row Spoke

f1150k2x

Figure 2-25.

CAUTION

The hub is made of aluminum alloy and should not be clamped in a vise or gripped with pliers, or the hub material may be damaged.

10. Verify that wheel is true. See Section 2.7 TRUING

LACED WHEEL for truing procedure and spoke torque

speciﬁcation.

SPOKE TIGHTNESS

At the 1000 mile (1600 km) service interval, the 5000 mile (8000 km) service interval, and then every 15,000 mile (24,000 km) service interval thereafter, inspect spoke tightness, if applicable. Proceed as follows:

1. Raise wheel off the ground.

CAUTION

If nipples require more than one full turn to tighten spoke, remove tire to check that spoke protrusion has not damaged tube.

2. Lightly tap each spoke with a spoke wrench. Loose spokes will sound dull and must be tightened. Tighten spokes to 40-50 in-lbs (4.5-5.6 Nm). If more than a few spokes are loose, true the entire wheel following the procedure on the next page.

2-20 2004 Touring: Chassis

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CAUTION

f1379x2x

Gauge

Radial

Runout

TRUING LACED WHEEL 2.7

PROCEDURE

1. Divide the wheel spokes into ten groups of four and mark the center of each group with a piece of tape. The groups should be directly across from one another and approximately 90 four groups ﬁnger tight, leaving all others loose.

2. See Figure 2-28. Install truing arbor in wheel hub and place wheel in WHEEL TRUING STAND, Part No. HD99500-80. Tighten arbor nuts so hub will turn on its bearings.

3. Lay a straightedge across the hub brake disc ﬂange (valve stem side of dual disc front wheel) and one of the marked spoke groups. Measure the distance from the straightedge to the edge of the rim as shown in Figure 2-

27. Be sure to subtract the thickness of the straightedge.

The offset dimension must be as follows:

● Front Wheel: 1.555- 1.575 inches (39.5- 40.0 mm).

● Rear Wheel: 1.472- 1.492 inches (37.4- 37.9 mm).

apart. Tighten the spokes in these

If the dimension is not correct, tighten the four spokes accordingly. Use the special T-30 I.P. (TORX Plus) driver (HD-42135). For example, If the measurement on the right rim edge side is less than it should be, loosen the two spokes attached to the hub right side and tighten the two spokes attached to the hub left side. Turn all four spokes an equal number of turns until offset dimension is correct.

f1155b2x

Figure 2-28. Truing Rim Radially

Always loosen the appropriate spokes before tightening the other two. Reversing this procedure will cause the rim to become out-of-round.

4. Repeat Step 3 for all four groups on the wheel.

5. See Figure 2-28. After rim has been trued sideways it must be checked and trued radially. Adjust truing stand gauge to the rim's tire bead seat as shown. The rim should be trued within 1/32 inch (0.79 mm).

6. Spin the rim slowly. If the rim contacts the gauge on or near a marked group of spokes, loosen the spokes in the marked group on the opposite side of the rim. Now tighten the spokes in the group where the rim makes contact. Loosen and tighten spokes an equal number of turns.

7. If the rim contacts the gauge between two marked groups, loosen the spokes in both opposite groups and tighten the spoke groups on the side of the rim that makes contact.Figure 2-27. Checking Laced Hub Offset Dimension

2004 Touring: Chassis 2-21

HOME

8. When the wheel is centered and trued, start at the valve stem hole and tighten the rest of the spoke nipples one turn at a time until they are snug. Repeat step tightening each spoke nipple to 40-50 in-lbs (4.5-5.6 Nm).

11WARNING1WARNING

Do not tighten spokes too tight, or nipples may be drawn through rim, or hub ﬂanges may be distorted. If spokes are left too loose, they will continue to loosen when wheel is put into service. This could adversely affect handling, or cause spoke breakage, possibly leading to loss of vehicle control, which could result in death or serious injury.

9. File or grind off ends of spokes protruding through nipples to prevent puncturing tube when tire is mounted.

10. Check the rim lateral and radial runout as described under Section 2.5 CHECKING RIM RUNOUT.

NOTE

After installation of front wheel, visually check the relationship of the front wheel to the fork fender bosses. The front wheel should be approximately centered between the bosses.

2-22 2004 Touring: Chassis

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1634

TIRES AND TUBES 2.8

GENERAL

Tires should be inspected for punctures, cuts, breaks and wear at least weekly.

Whenever a tube type tire is replaced, the tube should also be replaced. Inner tubes should be patched only as an emergency measure. Replace a damaged tube as soon as possible. Inner tubes must be used on all Harley-Davidson laced wheels.

11WARNING1WARNING

Excessively worn tires are more susceptible to penetrations. Always remove tires from service before they reach the tread wear indicator bars, which indicates that 1/32 inch (0.79 mm) tread pattern depth remains. Worn/ unworn tire combinations and worn tires used in wet conditions can ad-versely affect handling and lead to loss of vehicle control, which could result in death or serious injury.

11WARNING1WARNING

Tubeless tires may be repaired in the tread area only and then the puncture must be 1/4 inch (6.4 mm) or smaller. Never repair a tire with less than 1/16 inch (1.6 mm) tread depth. All repairs must be made from inside the tire. Use of faulty or defective tires can adversely affect handling and lead to loss of vehicle control, which could result in death or serious injury.

NOTE

Acceptable repair methods include a patch and plug combination, chemical or hot vulcanizing patches or head-type plugs.

When repairing tubeless tires, use TIRE SPREADER, Part No. HD-21000 to spread the tire sidewalls.

11WARNING1WARNING

Always check both tire sidewalls for arrows indicating proper forward tire rotation. Some tires require different tire rotation depending on whether tire is used on front or rear wheel. Improper mounting can result in poor tire mileage. In wet weather, improper mounting can adversely affect handling and lead to loss of vehicle control, which could result in death or serious injury.

Figure 2-29. Starting Bead Off Rim

2. Loosen both tire beads from rim ﬂange. See Figure 2-29. In most cases, a bead breaker machine will be required to loosen the bead from the rim.

3. Using tire tools (not sharp instruments), and RIM PROTECTORS, Part No. HD-01289, start upper bead over edge of rim at valve. Do not use excessive force when starting bead over rim. Bead wires may be damaged ruining the tire. Repeat all around rim until ﬁrst bead is over rim. Remove the tube.

NOTE

It is not necessary to use tools to remove tubeless tires. Make sure beads are well lubricated before removing from rim.

4. Push lower bead into rim well on one side and insert tire tool underneath bead from opposite side. Pry bead over rim edge. Remove tire from rim.

NOTE

It is not always necessary to completely remove tire from rim. Removing one side allows the tube to be replaced and allows for inspection of tire.

REMOVAL

1. Remove wheel from motorcycle. Let the air out of the tube or tire.

CLEANING AND INSPECTION

1. Clean the inside of tire, rim and tube. If rim is dirty or rusty, clean with a stiff wire brush.

2004 Touring: Chassis 2-23

HOME

Indicator

Ring

Figure 2-30. Snap-in Tubeless Tire Valves

2. Inspect the tire and tube for wear.

1635

INSTALLATION

11WARNING1WARNING

Use the correct inner tube and tire. See TIRE DATA in SPECIFICATIONS. Use of incorrect tires or tubes can adversely affect handling or result in tire failure, which could result in death or serious injury.

11WARNING1WARNING

Do not interchange tire valves from one type to another. Always replace valves with the same type as originally furnished, either the threaded valve stem or snap-in type. The rim conﬁguration is designed to ﬁt one type only. Use of the wrong valve can lead to tire failure, which could result in death or serious injury.

1. On tubeless wheels, damaged or leaking valves must be replaced. To replace a snap-in type valve proceed as follows:

a. See Figure 2-30. Moisten the valve with water and

insert valve stem through rim hole.

b. Thread plug tool on valve stem and pull valve

through rim until all of the indicator ring is visible.

11WARNING1WARNING

Only install original equipment tire valves and valve caps. A valve, or valve and cap combination, that is too long may strike adjacent components, damage the valve and cause rapid tire deﬂation. Rapid tire deﬂation can cause loss of vehicle control, which could result in death or serious injury.

Figure 2-31. Starting Bead on Rim

1636

Figure 2-32. Starting Second Bead on Rim

11WARNING1WARNING

Aftermarket valve caps that are heavier than the original equipment cap may have clearance at slow speeds, but at high speed the valve/cap will be moved outward by centrifugal force. This movement could cause the valve/ cap to strike adjacent components, damage the valve and cause rapid tire deﬂation. Rapid tire deﬂation can cause loss of vehicle control, which could result in death or serious injury.

2. On laced wheels, install a rim strip into the rim well. Make sure no spokes protrude through nipples and be sure to align the valve stem hole in rim strip with hole in rim.

2-24 2004 Touring: Chassis

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