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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f1386b2x

Gauge

Tire Radial Runout

f1386a2x

Gauge

Tire Lateral

Runout

3. Thoroughly lubricate the rim ﬂanges and both beads of the tire with tire lubricant. Install RIM PROTECTORS, Part No. HD-01289 to prevent scarring rims.

4. See Figure 2-31. Starting at the valve stem, start the ﬁrst bead into the rim well. Work the bead on as far as possible by hand. Use the tire tool to pry the remaining bead over the rim ﬂange. If tire has colored dot on sidewall, it is a balance mark and should be located next to valve stem hole.

5. Inﬂate tube just enough to round it out. Lubricate thoroughly 360˚ around the tube base. Insert tube in tire with valve stem in hole.

6. See Figure 2-32. Starting 180˚ from valve stem, start the second bead onto the rim. Work the bead onto the rim with tire tools, working toward valve in both directions. Remove the valve core from the rim hole before prying the remaining bead over the rim ﬂange.

Make sure inner tube valve stem moves in and out freely, then inﬂate the tire to recommended pressure to seat the bead. See TIRE DATA at the beginning of this section. Then deﬂate tire to allow inner tube to smooth out. Inﬂate again to recommended pressure to seat the bead.

7. Use the BEAD EXPANDER (Part No. HD-28700) to seat beads on tubeless tires.

Figure 2-33. Checking Tire Radial Runout

11WARNING1WARNING

Do not inﬂate tire over 40 psi (2.8 bars) to seat beads. Inﬂating tire beyond this point can cause the tire rim assembly to burst, which could result in death or serious injury. If the beads fail to seat, deﬂate and relubricate the bead and rim. Reinﬂate to seat beads, but do not exceed 40 psi (2.8 bars).

CAUTION

When mounting tire and tube on the rim, use extreme care so the inner tube is not pinched.

Checking Tire Radial Runout

1. Check runout by turning wheel on axle, measuring amount of radial displacement from a ﬁxed point near the tire. See Figure 2-33.

2. Tire tread runout should be no more than 0.090 inch (2.28 mm) If tire tread runout exceeds this speciﬁcation, remove tire from rim and check rim runout to see if rim is at fault. (See Section 2.5 CHECKING RIM RUNOUT).

Make sure bead is properly seated on rim. Deﬂate and reseat tire if necessary.

3. If rim runout is less than 1/32 inch (0.79 mm), tire is at fault and should be replaced. If rim runout exceeds this speciﬁcation, correct by replacing cast wheel or truing laced wheel.

NOTE

Figure 2-34. Checking Tire Lateral Runout

Checking Tire Lateral Runout

1. Check runout by turning wheel on axle, measuring tread runout. See Figure 2-34.

2. Tire tread runout should be no more than 0.080 inch (2.03 mm). If tire tread runout exceeds this speciﬁcation, remove tire from rim and check rim bead runout to see if rim is at fault (see Section 2.5 CHECKING RIM

RUNOUT).

NOTE

Make sure bead is properly seated on rim. Deﬂate and reseat tire if necessary.

2004 Touring: Chassis 2-25

HOME

3. If rim bead runout is less than 1/32 inch (0.79 mm), tire is at fault and should be replaced. If rim bead runout exceeds this speciﬁcation, correct by replacing cast wheel or truing laced wheel.

Wheel Balancing

Wheel balancing is recommended to improve handling and reduce vibration, especially at high road speeds. Cast aluminum wheels require special self-adhesive weights. Gold Color – 1 oz. (28g) weight, 1/2 oz. (14g) weight, Silver Color 1/2 oz. (14g) and 1/4 oz. (7g), and Black 1/4 oz. (7g) weight.

Laced wheels use balance weights which press over the spoke nipples. 1 oz. (28g), 3/4 oz. (21g) and 1/2 oz. (14g) weights are available.

1. Self adhesive wheel weights should be applied to the ﬂat surface of the rim. Make sure that area of application is completely clean, dry and free of oil and grease.

NOTE

If 1 oz. (28g) or more weight must be added at one location, split the amount so that half is applied to each side of the rim.

2. Remove paper backing from weight and apply three

drops of Loctite SUPERBONDER 420 to the adhe- sive side of the weight. Place the weight on rim, press ﬁrmly in place and hold for 10 seconds. Full adhesive cure takes 8 hours.

3. In most cases, static balancing using WHEEL TRUING STAND, Part No. HD-99500-80, will produce satisfactory results. However, dynamic balancing, utilizing a wheel spinner, should be used to produce ﬁner tolerances for best high and low speed handling characteristics. Follow the instructions supplied with the balance machine you are using. Wheels should be balanced to within 1/2 oz. (14g) at 60 mph (96 km/h). The maximum permissible weight to accomplish balance is 3-1/2 oz. (99g) total.

2-26 2004 Touring: Chassis

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f2117x2x

f2118x2x

Alignment

Screw

Pilot

Alignment

Fixture

VEHICLE ALIGNMENT 2.9

11WARNING1WARNING

Vehicle alignment is very important to ensure proper handling and vibration control. Follow this procedure carefully and in the sequence given. Failure to do so may lead to loss of vehicle control, which could result in death or serious injury.

METHOD A

NOTE Use this procedure to realign the powertrain to the frame whenever major disassembly or engine replacement occurs. For acceptable results, a careful inspection should be performed (wheel and tire runout, laced wheel offset, rubber mount condition, etc.) to ensure that it is conducted with serviceable components. See INSPECTION for more infor- mation.

1. Place the motorcycle on a hydraulic center stand or

place blocking under the frame to support the vehicle and lift the rear wheel off the ground. Be sure the motorcycle is positioned as level as possible.

2. Remove socket screw with lockwasher to remove left

passenger footboard from rear swingarm bracket. Tighten both rear swingarm bracket bolts to 34-42 ft-lbs (46-57 Nm). Repeat step on right side of motorcycle.

3. Remove the decorative chrome plug from both rear

swingarm brackets. While holding the left side pivot shaft locknut, tighten the right side locknut to 40-45 ft-lbs (5461 Nm). Then hold the right side pivot shaft locknut and tighten the left side locknut to 40-45 ft-lbs (54-61 Nm).

4. Verify that belt deﬂection is within speciﬁcation and that

adjuster cams are tight against rear swingarm weld nubs. Holding nut on right side to 95-105 ft-lbs (128.8-142.4 Nm).

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

6. Partially remove fuel tank to gain access to top engine

mounting bracket and stabilizer link. See Section 4.7

FUEL TANK (CARBURETED), PA RTIAL REMOVAL, FLHT/C, or FLHR/S. For fuel injected models, see Sec-

tion 9.4 FUEL TANK (FUEL INJECTED), PA R TIAL

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

7. Top Engine Mount:

a. On left side of motorcycle, tighten the two top

engine mounting bracket to front and rear cylinder head bolts to 35-40 ft-lbs (48-54 Nm). See A of Fig-

ure 2-37.

b. Moving to right side of motorcycle, tighten the top

stabilizer link eyelet to frame weldment bolt to 18-22 ft-lbs (24-30 Nm). See C of Figure 2-37.

weld nut on left side of axle, tighten cone

Figure 2-35. Vehicle Alignment Tool

(Part No. HD-46247)

Figure 2-36. Install Vehicle Alignment Tool (Left Side)

c. Loosen both top stabilizer link jam nuts. d. Remove the top stabilizer link eyelet to top engine

mounting bracket bolt. See B of Figure 2-37.

8. Front Engine Mount: a. Remove ﬂange locknuts from studs on lower frame

crossmember. Remove voltage regulator from studs and allow to hang by cables at front of motorcycle.

b. Tighten two engine to front engine mounting bracket

bolts to 33-38 ft-lbs (45-52 Nm). See H of Figure 2-

37.

c. Tighten front stabilizer link eyelet bolt to block on

front engine mounting bracket to 18-22 ft-lbs (24-30

Nm). See E of Figure 2-37. d. Loosen both front stabilizer link jam nuts. e. Remove front stabilizer link eyelet to frame weld-

ment bolt. See D of Figure 2-37. f. Remove the center front engine mounting bracket to

rubber mount bolt (with washers and nut). See F of

Figure 2-37.

2004 Touring: Chassis 2-27

HOME

LEFT SIDE RIGHT SIDE

Top Stabilizer Link and Engine Mounting Bracket

f2111x2xf2181x2x

Front Engine

Mounting Bracket

ATop Engine Mounting Bracket to Cylinder Heads BEyelet to Top Engine Mounting Bracket CEyelet to Frame Weldment

Front Stabilizer Link and Engine Mounting Bracket

Jam Nut

Front

Stabilizer Link

Bottom DEyelet to Frame Weldment

EEyelet to Front Engine Mounting Bracket FFront Engine Mounting Bracket to Rubber Mount GFront Engine Mount to Frame Crossmember H Engine to Front Engine Mounting Bracket

f1303x2x

Figure 2-37. Engine Mounting Bracket Bolts

9. Obtain Vehicle Alignment Tool (HD-46247). See Figure

2-35. Proceed as follows:

2-28 2004 Touring: Chassis

a. Back off alignment screws and pilot so that no con-

tact is made with pivot shaft during initial installation.

HOME

b. Position alignment ﬁxture so that pilot begins to

engage hole in rear swingarm bracket and then start 5/16 allen head screw (with ﬂat washer) into lower hole of passenger footboard mount. Leave ﬁxture loosely installed. Repeat step on other side of motorcycle.

NOTE Alignment ﬁxtures are stamped L(eft) and R(ight) for easy identiﬁcation. When installing alignment ﬁxture on right side of motorcycle, ﬁrst remove hex screw to free brake hose Pclamp from rear swingarm bracket. The relief in right side ﬁxture accommodates hex screw boss.

c. Holding alignment ﬁxture tight against rear swing-

arm bracket, use knurling to rotate pilot until it bottoms in rear swingarm bracket. Without disturbing setting of pilot, tighten allen head screw to passenger footboard mount to 18-22 ft-lbs (24-30 Nm). Repeat step on other side of motorcycle.

d. Hand turn alignment screw until it bottoms against

end of pivot shaft. Repeat step on other side of motorcycle.

e. Tighten alignment screw to 60-80 in-lbs (6.8-9.0

Nm). Repeat step on other side of motorcycle. See

Figure 2-36.

10. Adjust each stabilizer link as follows:

a. Install bolts removed under steps 7(d) and 8(e), and

using the center hex to maintain equal thread engagement at both eyelets, adjust stabilizer links so that bolts thread in without any stress or engine

movement. See B and D of Figure 2-37. b. Alternately tighten bolts to 18-22 ft-lbs (24-30 Nm). c. Holding the stabilizer link adjuster and mounting

eyelets to prevent movement or binding, tighten jam

nuts on top and front stabilizer links.

11. Remove vehicle alignment tool from rear swingarm brackets.

12. Snap the chrome plugs back into the rear swingarm brackets.

13. Install socket screw with lockwasher to fasten passenger footboard to rear swingarm bracket. Tighten screw to 1518 ft-lbs (20-24 Nm). Repeat step on other side of motorcycle.

14. Verify that front rubber mount is centered under the front mounting plate bolt hole and has not been bound by the plate dragging across the isolator.

a. If the front rubber mount is centered and free of

binding, proceed as follows:

•Tighten the two front engine mount to frame cross-

member bolts to 15-20 ft-lbs (20-27 Nm). See G of

Figure 2-37.

•Install center front engine mounting bracket to rub-

ber mount bolt (with washers and nut) and tighten to 15-20 ft-lbs (20-27 Nm). See F of Figure 2-37.

b. If centering or relaxation of the mount is required,

proceed as follows:

• Loosen the two front engine mount to frame crossmember bolts. See G of Figure 2-37.

• Push on the rubber mount to center it with the thru bolt hole in the mounting plate. It may be necessary to bounce or wiggle the engine to unload any binding of the rubber mount on the mounting plate.

•After the mount is centered, tighten the two front engine mount to frame crossmember bolts to 15-20 ft-lbs (20-27 Nm). See G of Figure 2-37.

•Install center front engine mounting bracket to rubber mount bolt (with washers and nut) and tighten to 15-20 ft-lbs (20-27 Nm). See F of Figure 2-37.

15. Slide voltage regulator over studs on lower frame crossmember at front of vehicle. Install ﬂange locknuts on studs and tighten to 70-100 in-lbs (7.9-11.3 Nm).

16. 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.

17. Verify minim the following frame mounted components:

a. Top Engine/Horn Mounting Bracket to Fuel Tank:

0.328 inch (8.3 mm). b. Rocker Covers to Fuel Tank: 0.375 inch (9.5 mm). c. Carburetor Top Cover to Fuel Tank: 0.375 inch (9.5

mm).

d. Rear Spark Plug Boot to Fuel Valve: 0.250 inch (6.4

mm).

e. To p Stabilizer Link to Induction Module: 0.375 inch

(9.5 mm).

f. Front Stabilizer Link to Voltage Regulator: 0.375

inch (9.5 mm).

g. Inner Primary Chaincase to Lower Frame Tube:

0.187 inch (4.8 mm). h. Exhaust Crossover Pipe to Primary Housing: 0.125

inch (3.2 mm). i. Tire to Rear Fender: 0.100 inch (2.5 mm). j. Perform the procedure under Method B to trouble-

shoot clearance problems and to identify offending

component(s).

18. Install seat. See Section 2.24 SEAT, INSTALLATION.

19. Test ride the motorcycle.

Vehicle leads that require more than 2-lbs pull to correct need further diagnosis. Perform the procedure under Method B in this section.

um clearance between the powertrain and

NOTE

2004 Touring: Chassis 2-29

HOME

METHOD B

NOTE

Use this procedure to determine the cause of vehicle misalignment and to locate clearance problems, or as an alternative to use of the Vehicle Alignment Tool (HD-46247) described under Method A. For acceptable results, a careful inspection should be performed (wheel and tire runout, laced wheel offset, rubber mount condition, etc.) to ensure that it is conducted with serviceable components. See INSPECTION for more information.

1. Place the motorcycle on a hydraulic center stand or place blocking under the frame to support the vehicle and lift the rear wheel off the ground. Be sure the motorcycle is positioned as level as possible.

2. Remove socket screw with lockwasher to remove left passenger footboard from rear swingarm bracket. Tighten both rear swingarm bracket bolts to 34-42 ft-lbs (46-57 Nm). Repeat step on right side of motorcycle.

3. Remove the decorative chrome plug from both rear swingarm brackets. While holding the left side pivot shaft locknut, tighten the right side locknut to 40-45 ft-lbs (5461 Nm). Then hold the right side pivot shaft locknut and tighten the left side locknut to 40-45 ft-lbs (54-61 Nm).

4. Verify that belt deﬂection is within speciﬁcation and that adjuster cams are tight against rear swingarm weld nubs. Holding nut on right side to 95-105 ft-lbs (128.8-142.4 Nm).

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

6. Partially remove fuel tank to gain access to top engine mounting bracket and stabilizer link. See Section 4.7

FUEL TANK (CARBURETED), PA RTIAL REMOVAL, FLHT/C, or FLHR/S. For fuel injected models, see Sec-

tion 9.4 FUEL TANK (FUEL INJECTED), PA R TIAL

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

7. Top Engine Mount: a. On left side of motorcycle, tighten the two top

engine mounting bracket to front and rear cylinder head bolts to 35-40 ft-lbs (48-54 Nm). See A of Fig-

ure 2-37.

b. Moving to right side of motorcycle, tighten the top

stabilizer link eyelet to frame weldment bolt to 18-22

ft-lbs (24-30 Nm). See C of Figure 2-37. c. Loosen both top stabilizer link jam nuts. d. Remove the top stabilizer link eyelet to top engine

mounting bracket bolt. See B of Figure 2-37.

8. Front Engine Mount: a. Remove ﬂange locknuts from studs on lower frame

crossmember. Remove voltage regulator from studs and allow to hang by cables at front of motorcycle.

b. Tighten two engine to front engine mounting bracket

bolts to 33-38 ft-lbs (45-52 Nm). See H of Figure 2-

37.

weld nut on left side of axle, tighten cone

c. Tighten front stabilizer link eyelet to frame weldment

bolt to 18-22 ft-lbs (24-30 Nm). See D of Figure 2-

37.

d. Tighten front stabilizer link eyelet bolt to block on

front engine mounting bracket to 18-22 ft-lbs (24-30 Nm). See E of Figure 2-37.

e. Remove the center front engine mounting bracket to

rubber mount bolt (with washers and nut). See F of

Figure 2-37.

9. To verify alignment, install alignment bars or other suitable device on both the left and right side of motorcycle. Proceed as follows:

NOTE

If the front tire is wider than the rear, then the alignment bars must either be shimmed out equally at the points of contact on the rear tire, notched at the front to clear the front tire, or attached to the front tire with all measurements performed at the rear. For explanatory purposes, the following procedure assumes the alignment bars are secured to the rear tire.

a. Place a set of straightedges on both the left and

right sides of the motorcycle alongside the front and rear tires.

b. Ve rify that both alignment bars ﬁrmly contact the

rear wheel at two points. Use clamp or bungee cords to hold the bars in place. Tension should be equal to avoid spreading or pinching the bars.

c. Verify that the bars are straight by matching the

width measurements at both ends.

d. Straighten the front end and verify that the

measurements from the front wheel to the bar on one side of the motorcycle are equal at two points, both fore and aft.

e. Measure the front wheel to the bar on the other side

of the motorcycle, both fore and aft, and compare the results to the measurements obtained under step 9(d). Measurements from left to right should be equal +/- 0.030 inch (0.76 mm).

f. Loosen jam nuts, and using the center hex, adjust

the front stabilizer link as required to obtain equal measurements at all four points (+/- 0.030 inch or

0.76 mm). See Figure 2-38.

NOTE

After each adjustment, unload any binding of the front rubber mount and verify that the alignment bars and front wheel are still correctly positioned.

g. Holding the front stabilizer link adjuster and

mounting eyelets to prevent movement or binding, tighten both jam nuts.

h. Verify that the front rubber mount is centered under

the thru bolt hole in the mounting plate.

2-30 2004 Touring: Chassis

HOME

FLT0240

To Correct: Adjust top stablizer link.

Chassis

Powertrain

Chassis

Powertrain

To Correct: Adjust front stablizer link.

FLT0239

Figure 2-38. Horizontally Misaligned

i. If the front rubber mount is centered and free of

binding, proceed as follows:

•Tighten the two front engine mount to frame crossmember bolts to 15-20 ft-lbs (20-27 Nm). See G of

Figure 2-37.

•Install center front engine mounting bracket to rubber mount bolt (with washers and nut) and tighten to 15-20 ft-lbs (20-27 Nm). See F of Figure 2-37.

j. If centering or relaxation of the mount is required,

proceed as follows:

•Loosen the two front engine mount to frame crossmember bolts. See G of Figure 2-37.

•After the mount is centered, tighten the two front engine mount to frame crossmember bolts to 15-20 ft-lbs (20-27 Nm). See G of Figure 2-37.

•Install center front engine mounting bracket to rubber mount bolt (with washers and nut) and tighten to 15-20 ft-lbs (20-27 Nm). See F of Figure 2-37.

10. Slide voltage regulator over studs on lower frame crossmember at front of vehicle. Install ﬂange locknuts on studs and tighten to 70-100 in-lbs (7.9-11.3 Nm).

11. Adjust the top stabilizer link as follows:

Figure 2-39. Vertically Misaligned

a. Using the center hex to maintain equal thread

engagement at both eyelets, adjust stabilizer link so that bolt removed under step 7(d) threads in without any stress or engine movement.

b. Tighten the stabilizer link eyelet to top engine

mounting bracket bolt to 18-22 ft-lbs (24-30 Nm). See B of Figure 2-37.

c. Holding the top stabilizer link adjuster and mounting

eyelets to prevent movement or binding, tighten both jam nuts.

12. Lower motorcycle to ﬂoor and remove hydraulic center stand or blocking.

13. After verifying that the motorcycle is level, check vertical alignment placing an inclinometer on both front and rear brake rotors. Front and rear lean angles should be equal +/- 1/2 degree. See Figure 2-39. If vertical alignment exceeds speciﬁcation, proceed as follows:

a. Loosen the top stabilizer link eyelet to top engine

mounting bracket bolt. See B of Figure 2-37. Verify that bolt is unloaded and threads freely in and out of the mounting bracket hole. If necessary, loosen jam nuts and adjust stabilizer link to a achieve a free state. Tighten bolt to 18-22 ft-lbs (24-30 Nm) and then tighten jam nuts before rechecking vertical alignment.

b. Look for components that are worn, damaged or out

of speciﬁcation. See INSPECTION on the next page.

2004 Touring: Chassis 2-31

HOME

14. Remove the alignment bars from both the left and right side of the motorcycle.

15. Snap the chrome plugs back into the rear swingarm brackets.

16. Install socket screw with lockwasher to fasten passenger footboard to rear swingarm bracket. Tighten screw to 1518 ft-lbs (20-24 Nm). Repeat step on other side of motorcycle.

17. 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.

18. Verify minim the following frame mounted components:

a. Top Engine/Horn Mounting Bracket to Fuel Tank:

0.328 inch (8.3 mm).

b. Rocker Covers to Fuel Tank: 0.375 inch (9.5 mm).

c. Carburetor Top Cover to Fuel Tank: 0.375 inch (9.5

mm).

d. Rear Spark Plug Boot to Fuel Valve: 0.250 inch (6.4

mm).

e. Top Stabilizer Link to Induction Module: 0.375 inch

(9.5 mm).

f. Front Stabilizer Link to Voltage Regulator: 0.375

inch (9.5 mm).

g. Inner Primary Chaincase to Lower Frame Tube:

0.187 inch (4.8 mm).

h. Exhaust Crossover Pipe to Primary Housing: 0.125

inch (3.2 mm).

i. Tire to Rear Fender: 0.100 inch (2.5 mm).

19. Install seat. See Section 2.24 SEAT, INSTALLATION.

20. Test ride the motorcycle.

Vehicle leads that require more than 2-lbs pull to correct need further diagnosis. See INSPECTION on this page.

um clearance between the powertrain and

NOTE

INSPECTION

At the 10,000 mile (16,000 km) service interval, and at every 10,000 mile (16,000 km) service interval thereafter, inspect the engine isolators and stabilizer links. Perform inspection sooner if any sag in the powertrain is observed or abnormal handling characteristics/vibrations are experienced.

Front Rubber Mount

1. Verify condition and torque of the mounting hardware. Visually inspect for wear, damage or improper installation. Replace hardware as necessary.

2. Examine carefully at the bottom of the motorcycle paying special attention to the area between the large ﬂat metal washer and the bracket on the frame. There should be a gap between the mounting plate and the cushion portion of the rubber mount.

3. Replace the rubber mount if there are any signs of cracking or shearing.

Rear Swingarm Mounts

1. Verify condition and torque of the mounting hardware. Visually inspect for wear, damage or improper installation. Replace hardware as necessary.

2. Examine rubber mount to be sure there is no twisting or binding at the parting line.

Engine Stabilizer Links

1. Verify condition and torque of the mounting hardware. Visually inspect for wear, damage or improper installation. Replace hardware as necessary.

2. Using ﬂats machined into the stabilizer eyelet, gently rock the link and check for separation of the molded-in sleeve. Replace as necessary.

Wear in the link also can be measured with a dial indicator by hand compressing and then releasing the link. Replace any link that exceeds 0.025 inch (0.64 mm) of play or wear.

2-32 2004 Touring: Chassis

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11WARNING1WARNING

CAUTION

f1284x2x

Dual Disc

Single Disc

Bore Size

Stamp

FRONT BRAKE MASTER CYLINDER 2.10

GENERAL

Master cylinders designed for dual disc (two caliper) operation have an 11/16 inch bore, while those that are designed for single disc (one caliper) operation have a 9/16 inch bore. The bore size is stamped on the master cylinder assembly inboard of the handlebar clamp bracket. See Figure 2-40.

11WARNING1WARNING

Do not use a 9/16 inch bore master cylinder assembly on dual disc (two caliper) models. Likewise, do not use an 11/16 inch bore master cylinder assembly on single disc (one caliper) models. These master cylinder assemblies are not interchangeable. Using the wrong assembly can adversely affect braking efﬁciency or result in brake failure, which could result in death or serious injury.

REMOVAL/DISASSEMBLY

1. Remove banjo bolt and two steel/rubber washers to disconnect ﬁtting of hydraulic brake line from master cylinder housing. Hold paper cup or other suitable container under banjo bolt bore to allow reservoir to drain. Discard steel/rubber washers.

CAUTION

Do not remove the master cylinder assembly without ﬁrst placing the 5/32 inch (4.0 mm) cardboard insert between the brake lever and lever bracket. Removal without the insert may result in damage to the rubber boot and plunger of the Front Stoplight Switch.

NOTE

Use the eyelet of a small cable strap if the cardboard insert is not available.

2. Place the cardboard insert between the brake lever and lever bracket. See Figure 2-41.

3. Using a T27 TORX drive head, remove two screws with ﬂat washers to release handlebar clamp from the master cylinder housing. Remove the clamp and brake lever/ master cylinder assembly from the handlebar. See Fig-

ure 2-42.

4. Remove the cardboard insert (or cable strap eyelet) between the brake lever and lever bracket.

Figure 2-40. Verify Correct Bore Size Before Use

Always wear proper eye protection when removing retaining rings. Use the correct retaining ring pliers. Verify that the tips of the pliers are not damaged or excessively worn. Slippage may propel the ring with enough force to cause eye injury.

5. Remove retaining ring from pivot pin groove at bottom of master cylinder bracket. Discard retaining ring.

6. Remove pivot pin and brake hand lever from master cylinder assembly.

7. Carefully remove wiper with pick or similar tool.

8. Remove piston cap.

9. Remove piston with O-ring and primary cup.

10. Remove spring.

To prevent dirt and other contaminants from entering the master cylinder reservoir, thoroughly clean the cover before removal.

11. Remove two Phillips screws, cover and cover gasket from the master cylinder reservoir.

2004 Touring: Chassis 2-33

HOME

7959

5/32 Inch (4.0 mm)

Cardboard

Insert

Figure 2-41. Install Cardboard Insert

Before Removing Master Cylinder Assembly

CLEANING AND INSPECTION

4. Inspect the piston bore in the master cylinder housing for scoring, pitting or corrosion. Replace the housing if any of these conditions are found.

5. Inspect the outlet port that mates with the brake line ﬁtting. As a critical sealing surface, replace the housing if any scratches, dents or other damage is noted.

6. Inspect the cover gasket for cuts, tears or general deterioration. If gasket and/or sight glass replacement is necessary, proceed as follows:

a. From inboard side, push sight glass toward top of

cover until free.

b. Pull rubber gasket from cover.

c. Fit nipple of new gasket into hole of cover aligning

gasket and cover thru holes.

d. From bottom of gasket, push ﬂat end of sight glass

through nipple until top of glass is ﬂush with top of gasket. Verify that glass is square in bore. If some lubrication is necessary, use a small quantity of clean brake ﬂuid.

ASSEMBLY/INSTALLATION

11WARNING1WARNING

Do not use replacement parts from single caliper repair kits (9/16 inch bore) on dual caliper models. Likewise, do not use replacement parts from dual caliper repair kits (11/16 inch bore) on single caliper models. Parts are not interchangeable. Using the wrong replacement parts can adversely affect braking efﬁciency or result in brake failure, which could result in death or serious injury.

1. Always reassemble the master cylinder using new parts

from the correct repair kit.

2. Clean all parts with denatured alcohol or D.O.T. 5 BRAKE FLUID. Do not contaminate with mineral oil or other solvents. Wipe dry with a clean, lint free cloth. Blow out drilled passages and bore with a clean air supply. Do not use a wire or similar instrument to clean drilled passages in bottom of reservoir.

11WARNING1WARNING

Use denatured alcohol to clean brake system components. Do not use mineral base solvents (such as gasoline and paint thinner) or deterioration of rubber parts may occur after assembly. Deterioration of components may result in premature brake failure, which could result in death or serious injury.

3. Carefully inspect all parts for wear or damage and replace as necessary.

1. Fit O-ring into groove on outboard side of piston (pin side). See Figure 2-42.

2. Fit primary cup over lip on inboard side of piston, so that closed side (smaller OD) contacts shoulder.

3. Coat piston bore of master cylinder reservoir with special lubricant supplied in the service parts kit. Also apply the lubricant to OD of installed O-ring and primary cup.

4. Insert metal retainer end of spring into piston bore, so that it seats against counterbore (recess) at bottom.

5. Slide piston over spring.

6. Fit wiper over piston cap so that ﬂat side of wiper contacts cap shoulder.

7. Fit piston cap over piston pin.

8. Press down on wiper until it contacts the counterbore. Larger OD of wiper must be completely seated in groove on outlet side of piston bore.

9. Note that the angular shape of the master cylinder cover makes one side thicker than the other. Install the cover (with gasket) on the master cylinder reservoir, so that the thicker side is positioned above the brake line ﬁtting. Install two Phillips screws to fasten cover to the reservoir, but do not tighten at this time.

10. Align hole in brake hand lever with hole in master cylinder bracket. From the top of the assembly, slide pivot pin through bracket and hand lever.

2-34 2004 Touring: Chassis

HOME

Phillips

Screw

Provided in Service Parts Kit

9/16 Inch Bore - HD Part No. 45006-96B

11/16 Inch Bore - HD Part No. 45072-96B

T27 TORX

Screw

Handlebar

Clamp

Primary

Cup

Flat

Washer

Spring

Phillips

Screw

Cover

Site Glass

Gasket

Master Cylinder

Reservoir

Brake Line

Seating Surface

Pivot

Bushing

Piston

Cap

Wiper

O-Ring

Flat

Side

Piston

Shoulder

Metal

Retainer

Shoulder

O-Ring

Groove

Lubricant

Figure 2-42. Front Brake Master Cylinder Assembly

Brake

Hand Lever

Retaining

Ring

f1866x2x

2004 Touring: Chassis 2-35

HOME

f1225x2x

Groove

5/32 Inch (4.0 mm)

Cardboard

Insert

Figure 2-43. Install Cardboard Insert

Before Installing Master Cylinder Assembly

11WARNING1WARNING

Always wear proper eye protection when installing retaining rings. Use the correct retaining ring pliers. Verify that the tips of the pliers are not damaged or excessively worn. Slippage may propel the ring with enough force to cause eye injury.

11. Install new retaining ring in pivot pin groove. Verify that

retaining ring is completely seated in groove.

CAUTION

To avoid leakage, verify that the steel/rubber washers, banjo bolt, brake line ﬁtting and master cylinder bore are completely clean.

15. Position new steel/rubber washers on each side of hydraulic brake line ﬁtting. Insert banjo bolt through washers and ﬁtting. Thread bolt into master cylinder housing and tighten to 17-22 ft-lbs (23-30 Nm).

16. Remove the master cylinder reservoir cover. Stand the motorcycle upright so that the master cylinder is in a level position.

NOTE

D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID is non-toxic.

17. Add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID to the master cylinder reservoir until the ﬂuid level is 1/8 inch (3.2 mm) from the top. Do not reuse old brake ﬂuid. Use only D.O.T. 5 ﬂuid from a sealed container.

11WARNING1WARNING

A plugged or covered relief port can cause brake drag or wheel lockup and may lead to loss of vehicle control, which could result in death or serious injury.

18. Verify proper operation of the master cylinder relief port. Actuate the brake hand lever. A slight spurt of ﬂuid will break the ﬂuid surface in the reservoir compartment if all internal components are working properly.

19. Remove cap from bleeder valve on front brake caliper. Install end of a length of clear plastic tubing over caliper bleeder valve, while placing free end in a suitable container.

CAUTION

See Figure 2-43. Do not install the master cylinder assembly without ﬁrst placing the 5/32 inch (4.0 mm) cardboard insert between the brake lever and lever bracket. Installation without the insert may result in damage to the rubber boot and plunger of the Front Stoplight Switch.

12. Place the cardboard insert between the brake lever and lever bracket. Use the eyelet of an ordinary cable strap if the cardboard insert is not available.

13. Position the brake lever/master cylinder assembly inboard of the switch housing assembly engaging the tab on the lower switch housing in the groove at the top of the brake lever bracket. See Figure 2-44.

14. Align the holes in the handlebar clamp with those in the master cylinder housing and start the two screws (with ﬂat washers). Position for rider comfort. Beginning with the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0 Nm) torque using a T27 TORX drive head.

f1785x8x

Tab

Groove

Switch

Housing

Assembly

Figure 2-44. Fit Brake Lever/Master Cylinder to

Right Handlebar Switch Housings

Brake

Lever

Bracket

2-36 2004 Touring: Chassis

HOME

20. Depress and hold the brake hand lever to build up hydraulic pressure.

21. Open bleeder valve about 1/2-turn. Brake ﬂuid will ﬂow from bleeder valve through tubing. Close bleeder valve when brake hand lever has moved 1/2 to 3/4 of its full range of travel. Allow brake hand lever to return slowly to its released position.

22. Add brake ﬂuid to the master cylinder reservoir until the ﬂuid level is about 1/8 inch (3.2 mm) from the top.

23. Repeat steps 20-22 until all air bubbles are purged.

24. Final tighten the bleeder valve to 80-100 in-lbs (9.0-11.3 Nm). Install the bleeder valve cap.

25. Install cover (with gasket) on the master cylinder reservoir, so that the thicker side is positioned above the brake line ﬁtting. Install two Phillips screws to fasten the cover to the reservoir. Tighten the screws to 6-8 in-lbs (0.7-0.9 Nm).

26. With the Ignition/Light Key Switch turned to IGNITION, actuate the front brake hand lever to verify operation of the brake lamp.

11WARNING1WARNING

27. Test ride the motorcycle. If the brake feels spongy, repeat the bleeding procedure.

NOTE

A sight glass enables the rider to visually check the brake ﬂuid level without removing the master cylinder cover. When the reservoir is full, the sight glass is dark. As the ﬂuid level drops, the glass lightens up to indicate this condition to the rider.

After completing repairs or bleeding the system, always test motorcycle brakes at low speed. If brakes are not operating properly or braking efﬁciency is poor, testing at high speeds could result in death or serious injury.

2004 Touring: Chassis 2-37

HOME

REAR BRAKE MASTER CYLINDER 2.11

REMOVAL

PRELIMINARY INSTRUCTIONS

NOTE

If fairing lowers are absent, proceed to step 5.

1. Remove two screws from fairing lower cap on right side of vehicle.

2. Hold nut at bottom of fairing lower, and using a T40 TORX drive head, turn inside screw to free assembly from engine guard clamp. Discard rubber washer.

3. Remove two locknuts to free retainer from upper rail of engine guard. From within glove box, remove U-bolt.

4. Remove glove box from fairing lower. Remove fairing lower from vehicle.

5. Remove two allen head socket screws (with lock washers and ﬂat washers) to release right side front footboard brackets from frame weldment. For best results, approach from left side of vehicle using a 3/8 inch ball allen with extension.

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

DLEBAG, REMOVAL.

7. Gently pull side cover from frame downtube (no tools required).

8. Remove bleeder valve cap on rear brake caliper. Install end of a length of clear plastic tubing over caliper bleeder valve, while placing free end in a suitable container. Open bleeder valve about 1/2-turn. Pump brake pedal to drain brake ﬂuid. Close bleeder valve.

BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, REMOVAL

1. See PRELIMINARY INSTRUCTIONS on this page.

2. Remove banjo bolt and two steel/rubber washers to disconnect brake line front ﬁtting from master cylinder assembly. Discard washers.

3. Release rear brake line as needed to move front ﬁtting forward far enough to access hex nut. For further instructions See REAR BRAKE LINE, REMOVAL, steps 3-6, in this section.

4. Using 1-1/8 inch wrench, remove hex nut to free brake pedal/master cylinder assembly from mounting bracket.

Rear

Brake Pedal

Master Cylinder

Reservoir

f2053x2x

O-Ring

Clevis Pin

Flat

Washer

Cotter Pin

Retaining

Ring

Figure 2-45. Rear Brake Pedal/Master Cylinder Assembly

2-38 2004 Touring: Chassis

HOME

Cable Clips

Top of Rear Swingarm

f2275x2x

Brake Line

Hose

Brake Hose

Crimp

Locating Tab

Screw and

Weld Nut

Frame Weldment

Cable Straps and Anchors

Lower Frame Tube

Figure 2-46. Rear Brake Line Assembly

P-Clamp

and Screw

Swingarm Bracket

Rear Brake

Light Switch

Steel/Rubber

Washers

Brake Line

Tube

Banjo

Bolt

5. Remove locknut with ﬂat washer to free brake pedal/ master cylinder assembly from pedal shaft. Remove assembly from vehicle. Remove and discard O-ring on each side of brake pedal shaft bore. See Figure 2-45.

6. Remove cotter pin and ﬂat washer from clevis pin. Supporting rear brake pedal/master cylinder assembly in vise, tap out clevis pin using a brass drift. Remove master cylinder assembly from brake pedal ﬂange.

7. For further instructions, see MASTER CYLINDER, DIS-

ASSEMBLY, in this section.

BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, INSTALLATION

1. If master cylinder was disassembled, see MASTER

CYLINDER, ASSEMBLY, in this section, for instructions.

2. Install master cylinder assembly on brake pedal ﬂange. Supporting assembly in vise, tap in clevis pin using a brass drift. Install ﬂat washer and cotter pin on clevis pin. See Figure 2-45.

3. Install new O-ring on each side of brake pedal shaft bore.

4. Apply a light coat of Wheel Bearing Grease (Part No. 99855-89) to the brake pedal shaft and bore. Install brake pedal/master cylinder assembly on the pedal shaft

ﬁtting collar on cartridge body into square-shaped hole in mounting bracket. Install ﬂat washer and new locknut on pedal shaft and tighten to 15-20 ft-lbs (20-27 Nm).

5. Apply Loctite Medium Strength Threadlocker 243 (blue) to threads of hex nut. Install hex nut on threaded end of cartridge body and tighten to 30-40 ft-lbs (41-54 Nm).

6. Position new steel/rubber washers on each side of brake line ﬁtting. Insert banjo bolt through washers and ﬁtting. Thread bolt into master cylinder assembly and tighten to 17-22 ft-lbs (23-30 Nm).

7. Secure rear brake line if released during master cylinder removal. For further instructions, see REAR BRAKE

LINE, INSTALLATION, steps 4-7, in this section.

8. See FINAL INSTRUCTIONS on the next page.

REAR BRAKE LINE, REMOVAL

1. See PRELIMINARY INSTRUCTIONS on the previous page.

2. Remove banjo bolt and two steel/rubber washers to disconnect brake line front ﬁtting from master cylinder assembly. Discard washers. See Figure 2-46.

3. Cut cable straps to free rear brake line from two anchors installed on T-studs at top of lower frame tube.

2004 Touring: Chassis 2-39

HOME

4. Remove hex screw to free brake hose P-clamp from rear swingarm bracket (passenger footboard bracket).

5. Remove socket terminals from rear brake light switch spade contacts. Cut cable strap to free rear brake light switch wires from lower frame tube, if necessary.

6. Remove hex screw to free brake light switch bracket from frame weldment. Push on bracket to release locating tab from slot in frame weldment.

7. Open two cable clips on rear swingarm T-studs. Free rear brake line hose from cable clips.

NOTE

For best results, insert blade of small screwdriver into gap at side of clip and gently rotate end of screwdriver to pop open.

8. Remove banjo bolt and two steel/rubber washers to disconnect brake line ﬁtting from rear brake caliper. Discard washers.

9. Feed rear brake line hose forward to area in front of rear swingarm bracket. Remove rear brake line assembly from vehicle.

REAR BRAKE LINE, INSTALLATION

1. Place rear brake line into approximate position along top of lower right frame tube. From area in front of rear swingarm bracket, feed brake line hose rearward following top of rear swingarm.

2. Position new steel/rubber washers on each side of brake line rear ﬁtting. Insert banjo bolt through washers and ﬁtting. Thread bolt into rear brake caliper and tighten to 17-22 ft-lbs (23-30 Nm).

3. Capture rear brake line hose in two cable clips on rear swingarm T-studs. Snap cable clips closed.

4. Index locating tab on brake light switch bracket in slot of frame weldment. Install hex screw to secure brake light switch bracket to frame weldment.

5. Install socket terminals onto rear brake light switch spade contacts. If removed, install new cable strap to secure rear brake light switch wires to lower frame tube.

6. Install hex screw to secure brake hose P-clamp to rear swingarm bracket (passenger footboard bracket).

7. Center rear brake line over two anchors installed on Tstuds at top of lower frame tube. Thread new cable straps through eyelets in anchors to capture brake line. Cut any excess cable strap material.

NOTE

Cable strap anchors also capture voltage regulator cables (front only) and branch of main harness leading to the oil pressure sender and crankshaft position sensor connectors.

8. Position new steel/rubber washers on each side of brake

line front ﬁtting. Insert banjo bolt through washers and ﬁtting. Thread bolt into master cylinder assembly and tighten to 17-22 ft-lbs (23-30 Nm).

9. See FINAL INSTRUCTIONS on this page.

INSTALLATION

FINAL INSTRUCTIONS

NOTE

If fairing lowers are absent, proceed to step 7.

1. Place fairing lower into position on right side of vehicle. Place glove box into fairing lower.

2. Holding screw inside fairing lower, install new rubber washer, clamp and locknut to attach fairing bottom to engine guard. Do not tighten locknut.

3. From within glove box, install U-bolt so that it encircles the upper rail of the engine guard. Loosely install retainer and locknuts.

4. Adjust the fairing lower so that ear at top inboard side is approximately 1/4 inch (6.35 mm) from frame downtube. Verify that fairing lower is square, and then alternately tighten locknuts to 35-40 in-lbs (4.0-4.5 Nm).

5. Hold locknut at bottom of fairing lower, and using a T40 TORX drive head, turn inside screw to fasten assembly to engine guard clamp. Tighten screw to 90-100 in-lbs (10.2-11.3 Nm).

6. Install two screws to secure fairing lower cap to fairing lower. Tighten screws to 10-20 in-lbs (1.1-2.3 Nm).

7. Insert two allen head socket screws (with lockwashers and ﬂat washers) through frame weldment into right side front footboard brackets. For best results, approach from left side of vehicle using a 3/8 inch ball allen with extension. Alternately tighten socket screws to 30-35 ft-lbs (41-48 Nm).

8. Install length of clear plastic tubing over caliper bleeder valve, if removed. Place free end of tube in a suitable container.

9. Remove the master cylinder cover, if installed. Stand the motorcycle upright so that the master cylinder is in a level position.

NOTE

D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID is non-toxic.

10. Add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID to the master cylinder reservoir until the ﬂuid level is 1/8 inch (3.2 mm) from the top. Do not reuse old brake ﬂuid. Use only D.O.T. 5 ﬂuid from a sealed container.

2-40 2004 Touring: Chassis

HOME

11WARNING1WARNING

Cable Clip

2nd

Rear

Swingarm

1st

Frame

Weldment

2nd

Cable Strap

Anchor

Captures Rear Brake Light Switch Wires

Cable Strap

and Lower Frame Tube Only

f2274x8x

1st

Cable Strap

Anchor

Figure 2-47. Rear Brake Line Routing (Right Side View)

11WARNING1WARNING

Verify proper operation of the master cylinder relief port. A plugged or covered relief port can cause brake drag or wheel lockup and may lead to loss of vehicle control, which could result in death or serious injury.

11. Actuate the rear brake pedal. A slight spurt of ﬂuid will break the ﬂuid surface in the reservoir compartment if all internal components are working properly.

12. Add brake ﬂuid to the master cylinder reservoir until the ﬂuid level is 1/8 inch (3.2 mm) from the top.

13. Depress and hold the rear brake pedal to build up hydraulic pressure.

14. Open bleeder valve about 1/2-turn. Brake ﬂuid will ﬂow from bleeder valve through tubing. Close bleeder valve when rear brake pedal has moved 1/2 to 3/4 of its full range of travel. Allow rear brake pedal to return slowly to its released position.

15. Repeat steps 12-14 until all air bubbles are purged.

16. Final tighten the bleeder valve to 80-100 in-lbs (9.0-11.3 Nm). Install the bleeder cap.

17. Add brake ﬂuid to the master cylinder reservoir until the ﬂuid level is about 1/8 inch (3.2 mm) from the top.

18. Install the cover (with gasket) on the master cylinder reservoir. Install two Phillips screws to fasten the cover to the reservoir. Tighten the screws to 6-8 in-lbs (0.7-0.9 Nm).

19. With the Ignition/Light Key Switch turned to IGNITION, actuate the rear brake pedal to verify operation of the brake lamp.

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

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

BAG, INSTALLATION.

22. Test ride the motorcycle. If the brake feels spongy, repeat the bleeding procedure.

NOTE

A sight glass enables the rider to visually check the brake ﬂuid level without removing the master cylinder cover. The sight glass is dark when the reservoir is full, but as the ﬂuid level drops, the glass lightens to alert the rider of this condition.

2004 Touring: Chassis 2-41

HOME

f2050x2x

Figure 2-48. Compress Spring and Remove

Retaining Ring

MASTER CYLINDER

DISASSEMBLY

Clevis

Shop

Cloth

NOTE

The push rod, clevis and spacer washer are a one-piece assembly.

5. Remove the large ﬂat washer, dust boot and spring from the cartridge body. Remove spring and spring retainer from dust boot.

6. Push on threaded end of cartridge body to remove from reservoir adapter. Use hand pressure only. Exercise caution to keep cartridge body free of dirt and grease. See Figure 2-49.

7. Carefully remove two O-rings from cartridge body. Exercise caution to avoid scratching O-ring grooves.

8. Remove small retaining ring from groove in cartridge body bore. Piston assembly is spring loaded so be sure to hold parts together as retaining ring is removed.

9. Remove push rod with captured spacer washer from cartridge body. Remove small retaining ring from push rod, if attached. Discard retaining ring.

NOTE

Do not disassemble the cartridge body. The cartridge body components are not sold separately. If piston seal leakage is evident, replace the entire cartridge body assembly.

NOTE

If installing the Master Cylinder Reservoir Kit (Part No. 42454-99), see steps 1-7 below. If installing the Push Rod Kit (Part No. 41957-97A) or the assembled cartridge body from the Master Cylinder Repair Kit (Part No. 42382-87C), see steps 1-9.

1. See BRAKE PEDAL/MASTER CYLINDER ASSEMBLY,

REMOVAL, in this section.

2. Thoroughly clean exterior of master cylinder assembly with denatured alcohol.

3. Stand master cylinder assembly upright on banjo sealing surface. For best results, suspend reservoir over edge of table. Be sure to lay down a clean shop cloth to protect the sealing surface from damage.

11WARNING1WARNING

4. Push down on large ﬂat washer to compress spring. While holding the spring in a compressed state, remove retaining ring from groove in clevis and then carefully release spring. See Figure 2-48. Discard retaining ring.

f2054x2x

Figure 2-49. Remove Cartridge From Reservoir Adapter

Reservoir

Adapter

Cartridge

Body

2-42 2004 Touring: Chassis

HOME

1. Hex Nut

2. Reservoir

3. O-Ring

4. Cartridge Body

5. Spring

6. Primary Cup

7. Piston

8. O-Ring

9. Push Rod/Clevis/Spacer Washer*

10. Retaining Ring

11. Retaining Ring

12. Spring

13. Spring Retainer

14. Dust Boot

15. Washer

16. Retaining Ring

17. Clevis Pin

18. Flat Washer

19. Cotter Pin

f2100x2x

Banjo

Sealing Surface

*Push rod, clevis and spacer washer are a one-piece assembly

Figure 2-50. Rear Brake Master Cylinder Assembly (Exploded View)

CLEANING AND INSPECTION

11WARNING1WARNING

1. Clean all metal parts, except the cartridge body assembly, and blow dry with compressed air. Clean all rubber parts using denatured alcohol.

2. Inspect the reservoir adapter bore for scratches. Replace the reservoir if scratches are present.

3. Check the dust boot for cuts or tears. Replace as necessary.

4. Inspect the threads on the cartridge body. Replace if threads are damaged.

5. Inspect the spring for distortion, cracks or broken coils. Replace as necessary.

6. Inspect O-ring grooves on the cartridge body for dirt. Carefully clean grooves using a soft cotton cloth moistened with alcohol and allow to dry. Inspect O-ring grooves for scratches. Replace cartridge body if grooves are scratched.

7. Inspect the reservoir cover gasket for cuts, tears or general deterioration. If gasket and/or sight glass replacement is necessary, proceed as follows:

2004 Touring: Chassis 2-43

HOME

a. From inboard side, push sight glass toward top of

cover until free.

b. Pull rubber gasket from cover.

c. Fit nipple of new gasket into hole of cover aligning

gasket and cover thru holes.

d. From bottom of gasket, push ﬂat end of sight glass

through nipple until top of glass is ﬂush with top of gasket. Verify that glass is square in bore. If some lubrication is necessary, use a small quantity of clean brake ﬂuid.

ASSEMBLY

NOTE

If installing assembled cartridge body from Master Cylinder Repair Kit (Part No. 42382-87C), begin at step 2 below. If installing the Push Rod Kit (Part No. 41957-97A), begin at step 3. If installing the Master Cylinder Reservoir Kit (Part No. 42454-99), start at step 7.

1. To install piston in cartridge body, proceed as follows:

a. Install small spring into cartridge body making sure

that spring is seated in counterbore.

b. Lightly lubricate primary cup and O-ring on piston

with D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID.

c. Install piston over spring.

Retaining

Ring

f2049x2x

Figure 2-51. Compress Spring and Install Retaining Ring

Spring

Retainer

Push Rod

Cartridge

Body

Shop Cloth

Dust Boot

2. Install new large retaining ring in groove on push rod

side of cartridge body.

3. Position new retaining ring on push rod between spacer

washer and clevis, or on clevis inboard of the retaining ring groove.

NOTE

The push rod, clevis and spacer washer are a one-piece assembly.

4. Stand cartridge body upright on banjo sealing surface. Lay down a clean shop cloth to protect the sealing surface from damage. See Figure 2-51.

11WARNING1WARNING

5. Insert ball end of push rod into piston cup. Pushing down on push rod to compress spring, ﬁt captured spacer washer into cartridge body. Further compressing spring as necessary, install retaining ring positioned in step 4 in groove of cartridge body bore.

Spring

Reservoir

Figure 2-52. Install Spring, Spring Retainer and Dust Boot

6. Verify that retaining ring is completely seated in groove and that push rod rotates freely.

7. Lubricate new O-rings with D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID and carefully install in grooves on outside of cartridge body.

f2055x2x

2-44 2004 Touring: Chassis

HOME

f2051x2x

Brake Line

Seating Surface

Must Not Be

Scratched or Dented

During Handling

Reservoir

Adapter

O-Ring

Retaining

Ring

Spacer

Washer

Retaining

Ring

Dust Boot

Flat

Washer

Clevis

Mounting

1-1/8 Inch Hex Nut

Spring

Cartridge

Body

Primary

Cup

O-Ring

Piston

*Push rod, clevis and spacer washer are a one-piece assembly

Figure 2-53. Rear Brake Master Cylinder Assembly (Cross Sectional View)

8. Wipe bore of reservoir adapter with D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID.

9. Insert cartridge body into reservoir adapter indexing tab on adapter in slot on threaded end of cartridge. Use hand pressure only. Cartridge body is fully installed when reservoir adapter contacts large retaining ring.

10. Stand master cylinder assembly upright on banjo sealing surface. For best results, suspend reservoir over edge of table. Be sure to lay down a clean shop cloth to protect the sealing surface from damage.

11. Install spring over push rod and cartridge body until it contacts side of large retaining ring. See Figure 2-52.

12. Place concave side of spring retainer over end of spring ﬁtting inside tabs in slot of clevis.

13. Slide dust boot over spring and spring retainer.

Retaining

Ring

Spring

Drain/Air

Hole At Bottom

Push Rod

Spring

Retainer

14. Place large ﬂat washer on top of dust boot ﬁtting inside tabs in slot of clevis.

15. Push down on large ﬂat washer to compress spring. While holding spring in a compressed state, install new retaining ring in groove of clevis.

16. Pull down dust boot as necessary to seat over lip on reservoir adapter.

17. Rotate boot so that drain/air hole is at the bottom.

18. See BRAKE PEDAL/MASTER CYLINDER ASSEMBLY,

INSTALLATION, in this section.

2004 Touring: Chassis 2-45

HOME

FRONT BRAKE CALIPER 2.12

INSPECTION

Caliper

Check brake pads and discs:

● At every scheduled service interval.

● Whenever the components are removed during normal

service procedures.

BRAKE DISC THICKNESS/WARPAGE

The minimum brake disc thickness is stamped on the side of the disc. Replace disc if excessively worn or badly scored. Maximum brake disc lateral runout or warpage is 0.008 inch (0.20 mm) when measured near the outside diameter. Replace disc if warped beyond speciﬁcation. For replacement instructions, see Section 2.3 FRONT WHEEL, DISAS-

SEMBLY.

BRAKE PADS

NOTE

Brake pad inspection can be performed without removing the caliper.

1. Look up at the back of the right side caliper. See Figure

2-54.

2. Place a thin plastic 6 inch rule against the brake disc and measure the friction material of the brake outer pad. Using a small hand mirror, visually check the friction material of the inner pad.

3. Repeat above checks at the front of the right side caliper. Replace both pads If the friction material above the backing plate on either pad is 0.04 inch (1.02 mm) thick or less.

4. Repeat steps 1-3 on the left side of the vehicle.

11WARNING1WARNING

Always replace brake pads in pairs. Never replace just one brake pad. Mismatched brake pads can lead to brake system damage and loss of braking performance, which could result in death or serious injury.

5. See FRONT BRAKE PAD REPLACEMENT on this page.

Right

Front Brake

Bottom View

Friction Material

Outer Pad

Brake

Disc

f1756x2x

Replace both pads if friction material of either pad is

0.04 inch (1.02 mm) or less above the backing plate.

Figure 2-54. Measure Brake Pad Wear

Backing

Plate

FRONT BRAKE PAD REPLACEMENT

PAD REMOVAL

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

2. Loosen two pad pins, but do not remove. See Figure 2-

55.

3. Remove upper and lower caliper mounting bolts from front fork mounting lugs. Lift caliper upward to remove from brake disc.

4. Remove two Phillips screws to release cover from front master cylinder reservoir.

BRAKE LINE/HOSE INSPECTION

When checking brake pads and discs, take the time to inspect the brake lines and hoses for damage or wear. Replace as necessary.

2-46 2004 Touring: Chassis

NOTE

As the pistons are pushed back into the caliper, ﬂuid level may rise more than 1/8 inch (3.2 mm) and overﬂow the reservoir. Watch the ﬂuid level as the pistons are retracted and remove ﬂuid from the reservoir if necessary.

HOME

Upper Caliper

Mounting Bolt

(Long)

Pad

Pins

Lower Caliper

Mounting Bolt

(Short)

f1767x2x

Figure 2-55. Loosen Pad Pins and Remove Caliper

Mounting Bolts (Right Side View)

5. Pry back inner and outer brake pads pushing the four pistons back into their bores.

6. With the pistons retracted, remove two pad pins and both inner and outer brake pads. Inspect pad pins. See

CLEANING AND INSPECTION, step 4.

NOTE

Replacing one pad at a time keeps the anti-rattle spring in place. Remove both pads to remove or replace the spring.

PAD INSTALLATION

NOTE

Both front calipers (as well as the rear brake caliper) use the same brake pad set.

1. Install new brake pads into caliper with the friction mate-

rial facing the brake disc opening. Be sure that the pad is oriented so that the curved side faces the rear of the vehicle when the caliper is installed. See Figure 2-56.

Furthermore, note that the backing plate of each brake pad has either one or two tabs. On the r vehicle, the pad with two tabs is installed on the inboard side of the caliper, the pad with the single tab is installed on the outboard side.

On the left side

of the vehicle, the pad location is reversed. Therefore, the pad with the single tab is installed on the inboard side of the caliper, while the pad with two tabs is installed on the outboard side.

2. Install pad pins, but do not fully tighten at this time.

3. Install calipers as follows: a. Use shop rag or tape to protect fender area adja-

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

b. Place caliper over brake disc with bleeder valve top-

side.

c. Loosely install long caliper mounting bolt into upper

lug of front fork leg.

d. Install short caliper mounting bolt into lower lug of

front 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. Tighten pad pins to 180-200 in-lbs (20.3-22.6 Nm).

ight side of the

Outboard Side

of Caliper

Two Tabs Two Tabs Single

Curved Portion

Left Side of Vehicle Right Side of Vehicle

Inboard Side

Faces Rear

of Caliper

Single

Tab

Inboard Side

of Caliper

Outboard Side

of Caliper

Tab

Curved Portion

Faces Rear

f2156x2xf2156x2x

Figure 2-56. Front Brake Pad Locations

2004 Touring: Chassis 2-47

HOME

Per Caliper Assembly

1. Inside Caliper Housing

2. Square Seal (4)

3. Wiper (4)

4. Piston (4)

5. Crossover O-Ring (2)

6. Inner Brake Pad

7. Outer Brake Pad

8. Anti-Rattle Spring

9. Outside Caliper Housing

10. Lower Mounting Bolt (Short)

11. Upper Mounting Bolt (Long)

12. Decal

13. Pad Pin (2)

14. Bridge Bolt (2)

15. Bleeder Valve

16. Bleeder Valve Cap

Figure 2-57. Front Brake Caliper Assembly (Left Side)

11WARNING1WARNING

After installation of new pads 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 brakes will not be available the ﬁrst time they are used, a situation that could result in death or serious injury.

4. Pump brake hand lever until pistons contact brake pads and pads contact brake discs. Verify piston location against pads. If the front wheel is off the ground, rotate wheel to check for excessive brake pad drag.

5. Verify that brake ﬂuid level is 1/8 inch (3.2 mm) below top of reservoir with master cylinder in a level position. Add D.O.T. 5 SILICONE BRAKE FLUID, if necessary.

6. Install master cylinder reservoir cover. Install two Phillips screws to fasten cover to reservoir and tighten to 6-8 in-

lbs (0.7-0.9 Nm).

f2182x2x

7. Test operation of brake lamp with the front brake applied and the Ignition/Light Key Switch turned to IGNITION.

11WARNING1WARNING

8. Test ride the motorcycle. If the brakes feel spongy, bleed the system. See Section 2.14 BLEEDING HYDRAULIC

BRAKES.

NOTE

To allow new brake pads to “wear in” properly with the brake disc, avoid making hard stops for the ﬁrst 100 miles (160 km).

2-48 2004 Touring: Chassis

HOME

11WARNING1WARNING

Brake Caliper Piston Remover

(Part No. HD-43293A)

CAUTION

To prevent air from escaping through the banjo bolt hole, and to avoid scratching or nicking the banjo seating surface, use only a tapered, rubber tipped nozzle on air hose. Loss of air pressure will keep the pistons from moving, while any damage to the banjo seating surface requires caliper replacement.

Figure 2-58. Direct Compressed Air Into Banjo Bolt Hole to Force Pistons From Bores

f1776x2x

Tapered,

Rubber-Tipped

Nozzle

Low Pressure

Air Hose

Bridge

Bolt

Brake Caliper

Piston Remover

CALIPER REMOVAL

NOTE

If only replacing brake pads, see FRONT BRAKE PAD

REPLACEMENT in this section.

CAUTION

Damaged banjo bolt surfaces will leak when reassembled. Prevent damage to seating surfaces by carefully removing brake line components.

1. Remove banjo bolt and two steel/rubber washers to detach front brake line from caliper. Discard washers.

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

3. Remove upper and lower caliper mounting bolts from front fork mounting lugs. Lift caliper upward to remove from brake disc.

CALIPER DISASSEMBLY

1. See Figure 2-55. Remove two pad pins. Remove brake pads from caliper housings.

2. Remove two bridge bolts and separate inside and outside caliper housings.

3. Remove anti-rattle spring from channel around boss in outside caliper housing.

4. Remove bleeder valve, if damaged.

Pressurized air can blow debris into your face and eyes. Always wear eye protection or a face shield. Failure to do so could result in eye injury.

5. Remove four pistons as follows: a. Obtain BRAKE CALIPER PISTON REMOVER (Part

No. HD-43293A). See inset of Figure 2-58.

b. Seat tool in outside caliper housing aligning outside

holes in tool with bridge bolt holes in housing. Place inside caliper housing over tool aligning bridge bolt

holes with outside holes in tool. c. Install bridge bolts and tighten securely. d. If the bleeder valve was removed, reinstall ﬁnger

tight or place a gloved ﬁnger over the valve hole. e. Using a tapered, rubber-tipped nozzle on the air

hose (to prevent both loss of air pressure and dam-

age to the banjo seating surface), apply low pres-

sure compressed air into the banjo bolt hole to force

pistons into contact with cushion of tool. See Figure

2-58.

2004 Touring: Chassis 2-49

HOME

f1779x2x

Wooden

Toothpick

Wiper

Square

Seal

Figure 2-59. Remove Wipers and Square Seals

From Piston Bores

f. Remove bridge bolts and separate caliper housings.

g. Remove pistons from caliper piston bores. For best

results, wiggle pistons slightly while pulling.

6. Remove two crossover O-rings from inside caliper housing. Discard O-rings.

CAUTION

Do not use metal objects to remove parts from caliper piston bores or damage will occur. Damaged pistons or bores will leak when reassembled. Use a wooden toothpick to assist in the removal of parts, if necessary.

7. Using a wooden toothpick, remove wiper and square seal from each piston bore. Discard wipers and seals. See Figure 2-59.

CLEANING AND INSPECTION

2. Carefully inspect all components. Replace any parts that appear damaged or worn.

a. Check pistons for pitting, scratching or corrosion on

face and also on ground surfaces.

b. Inspect caliper piston bore. Replace caliper if bore

shows signs of pitting or corrosion. Do not hone bore for reuse.

c. Always replace wipers, square seals and crossover

O-rings after caliper disassembly.

11WARNING1WARNING

3. Inspect brake pads and discs. See INSPECTION at the beginning of this section.

4. Inspect pad pins for wear and grooving. Replace both pins if wear of either pin exceeds 0.015 inch (0.38 mm).

CALIPER ASSEMBLY

1. Install new square seals into caliper piston bores.

2. Install new wipers into caliper piston bores.

CAUTION

Do not use D.O.T. 5 brake ﬂuid for lubrication or increased lever travel will result.

3. Lubricate the following areas using a thin ﬁlm of G.E. VERSILUBE “Piston Lube” in the service parts kit):

● Inside diameter of square seals and wipers.

● Caliper piston bores.

● Nose radius and outside diameter of piston.

#G322L SILICONE GREASE (marked

11WARNING1WARNING

1. Clean all parts with denatured alcohol or D.O.T. 5 SILICONE BRAKE FLUID. Wipe parts dry with a clean, lint free cloth. Blow out drilled passages and bores with a clean air supply. Do not use a wire or similar instrument to clean drilled passages.

2-50 2004 Touring: Chassis

NOTE

All other surfaces must be kept clean and dry for assembly.

4. Carefully insert pistons into bores by hand. If resistance is felt, remove piston and verify that both seal and wiper are properly installed.

5. Install new crossover O-rings into two grooves on inside caliper housing.

6. Assemble caliper housings as follows:

a. Install bleeder valve on outside caliper housing, if

removed. Tighten valve to 80-100 in-lbs (9.0-11.3 Nm). Install bleeder valve cap.

HOME

CAUTION

11WARNING1WARNING

Bleeder

Valve

Anti-Rattle

f1780x2x

Figure 2-60. Install Anti-Rattle Spring

b. Place outside caliper housing on workbench with

decal side down. Place anti-rattle spring in channel around boss. Spring is not directional. See Figure 2-

60.

c. Mate inside and outside caliper housings and

loosely install two bridge bolts. d. Verify that anti-rattle spring is still seated. e. Tighten bridge bolts to 28-38 ft-lbs (37.9-51.5 Nm).

NOTE

Both front calipers (as well as the rear brake caliper) use the same brake pad set.

Spring

CALIPER INSTALLATION

1. Install calipers as follows:

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

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

b. Place caliper over brake disc with bleeder valve top-

side.

c. Loosely install long caliper mounting bolt into upper

lug of front fork leg.

d. Install short caliper mounting bolt into lower lug of

front 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 to install second caliper.

To avoid leakage, verify that the washers, banjo bolt, brake line and caliper bore are completely clean.

2. Connect brake line to caliper using two new steel/rubber

washers and banjo bolt. Tighten bolt to 17-22 ft-lbs (23.0-29.8).

3. Remove two Phillips screws to release cover from front brake master cylinder reservoir. Verify that brake ﬂuid level is 1/8 inch (3.2 mm) below top of reservoir with master cylinder in a level position. Add D.O.T. 5 SILICONE BRAKE FLUID, if necessary.

7. Install new brake pads into caliper with the friction mate-

rial facing the brake disc opening. Also, be sure that the pad is oriented so that the curved side faces the rear of the vehicle when the caliper is installed. See Figure 2-

56.

On the left side reversed. Therefore, the pad with the single tab is installed on the inboard side of the caliper, while the pad with two tabs is installed on the outboard side.

8. Install pad pins and tighten to 180-200 in-lbs (20.3-22.6

Nm).

If pad pins do not ﬁt, verify the following: (1) Proper pad set is being used, not two identical pads. (2) Anti-rattle spring is installed as shown in Figure 2-60. (3) Pads are pushed tight against anti-rattle spring.

of the vehicle, the pad location is

NOTE

ight side of the

4. Actuate the brake lever. A slight spurt of ﬂuid will break the surface if all internal components are working properly.

5. Depress front brake hand lever several times to set brake pads to proper operating position within caliper. Bleed brake system. See Section 2.14 BLEEDING

HYDRAULIC BRAKES.

2004 Touring: Chassis 2-51

HOME

6. Install master cylinder reservoir cover. Install two Phillips

screws to fasten cover to reservoir and tighten to 6-8 in- lbs (0.7-0.9 Nm).

7. Test operation of brake lamp with the front brake applied and the Ignition/Light Key Switch turned to IGNITION.

11WARNING1WARNING

8. Test ride the motorcycle. If the brakes feel spongy, bleed the system again. See Section 2.14 BLEEDING

HYDRAULIC BRAKES.

NOTE

To allow new brake pads to “wear in” properly with the brake disc, avoid making hard stops for the ﬁrst 100 miles (160 km).

2-52 2004 Touring: Chassis

HOME

f1757x2x

Caliper

Backing

Plate

Brake

Disc

Friction

Material

Outer Pad

Rear Brake

Top View

Replace both pads if friction material of either pad is

0.04 inch (1.02 mm) or less above the backing plate.

REAR BRAKE CALIPER 2.13

INSPECTION

Check brake pads and discs:

● At every scheduled service interval.

● Whenever the components are removed during service

procedures.

BRAKE DISC THICKNESS/WARPAGE

The minimum brake disc thickness is stamped on the side of the disc. Replace disc if excessively worn or badly scored. Maximum brake disc lateral runout or warpage is 0.008 inch (0.2 mm) when measured near the outside diameter. Replace disc if warped beyond speciﬁcation. For replacement instructions, see Section 2.4 REAR WHEEL, DISAS-

SEMBLY.

BRAKE PADS

NOTE

Brake pad inspection can be performed without removing the caliper.

1. Look down at the back of the rear caliper. See Figure 2-

61.

2. Place a thin plastic 6 inch rule against the brake disc and measure the friction material of the brake outer pad. Using a small hand mirror, visually check the friction material of the inner pad.

3. Repeat above checks at the front of the rear caliper.

Replace both pads If the friction material above the backing plate on either pad is 0.04 inch (1.02 mm) thick or less.

11WARNING1WARNING

4. See REAR BRAKE PAD REPLACEMENT on this page.

BRAKE LINE/HOSE INSPECTION

When checking brake pads and discs, take the time to inspect the brake lines and hoses for damage or wear. Replace as necessary.

Figure 2-61. Measure Brake Pad Wear

REAR BRAKE PAD REPLACEMENT

PAD REMOVAL/INSTALLATION

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

DLEBAG, REMOVAL.

2. Loosen both pad pins, but do not remove. See Figure 2-

62.

3. Remove two Phillips screws to release cover from rear master cylinder reservoir.

NOTE

2004 Touring: Chassis 2-53

HOME

Pad

Pins

f2026x2x

4. Pry the inside pad back pushing the pistons into their bores. Use a putty knife with a wide thin blade to avoid scoring or scratching the brake disc.

Do not completely pull pad pins from caliper during the next step. Completely removing pad pins at this time will make assembly difﬁcult.

5. Once the pistons have been retracted, pull the pad pins part way out until the inside pad drops free. Note the orientation of the pad.

6. Install new inside brake pad using the same orientation. Curved portion of pad must face rear of motorcycle.

7. Install pad pins, but do not fully tighten.

8. Pump rear brake pedal to move inside pistons out until they contact inside brake pad.

9. Pry the outside pad back pushing the pistons into their bores. Use a putty knife with a wide thin blade to avoid scoring or scratching the brake disc.

10. Verify that inside pad is captured between brake disc and pistons. Completely remove pad pins to free outside brake pad. Note the orientation of the pad.

11. Install new outside brake pad using the same orientation. Curved portion of pad must face rear of motorcycle. If the inside pad moved during the previous step, reinstall.

Replacing one pad at a time keeps the anti-rattle spring in place. Remove both pads to remove or replace the spring.

12. Inspect pad pins. See CLEANING AND INSPECTION, step 4.

Bridge

Bolts

Figure 2-62. Loosen Both Pad Pins

NOTE

Anchor

Weldment

13. Install two pad pins and tighten to 180-200 in-lbs (20.3-

22.6 Nm).

11WARNING1WARNING

After installation of new pads 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.

14. Pump rear brake pedal to move pistons out until they contact both brake pads. Verify piston location against pads.

15. Verify that brake ﬂuid level is 1/8 inch (3.2 mm) below top of reservoir with master cylinder in a level position. Add D.O.T. 5 SILICONE BRAKE FLUID, if necessary. Install master cylinder reservoir cover. Install two Phillips screws to fasten cover to reservoir and tighten to 6-8 in- lbs (0.7-0.9 Nm).

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

BAG, INSTALLATION.

17. Test operation of brake lamp with the rear brake applied and the Ignition/Light Key Switch turned to IGNITION.

11WARNING1WARNING

Inboard Side

of Caliper

Two Tabs

Curved Portion

Right Side of Vehicle

Figure 2-63. Rear Brake Pad Locations

Outboard Side

of Caliper

Single

Tab

Faces Rear

f2156x2x

2-54 2004 Touring: Chassis

HOME

CAUTION

1. Bridge Bolt (3)

2. Pad Pin (2)

3. Decal

4. Outside Caliper Housing

5. Rubber Damper

6. Bleeder Valve

7. Bleeder Valve Cap

8. Square Seal (4)

9. Wiper (4)

10. Piston (4)

11. Outer Brake Pad

12. Inner Brake Pad

13. Anti-Rattle Spring

14. Crossover O-Ring (2)

15. Inside Caliper Housing

Figure 2-64. Rear Brake Caliper Assembly (Right Side)

18. Test ride the motorcycle. If the brakes feel spongy, bleed the system again. See Section 2.14 BLEEDING

HYDRAULIC BRAKES.

NOTE

To allow new brake pads to “wear in” properly with the brake disc, avoid making hard stops for the ﬁrst 100 miles (160 km).

CALIPER REMOVAL

NOTE

If only replacing brake pads, see REAR BRAKE PAD

REPLACEMENT in this section.

1. Block motorcycle underneath frame so rear wheel is raised off the ground.

2. Remove saddlebags. See Section 2.25 SADDLEBAG,

REMOVAL.

f2072x2x

Damaged banjo bolt surfaces will leak when reassembled. Prevent damage to seating surfaces by carefully removing brake line components.

3. Remove banjo bolt and two steel/rubber washers to detach rear brake line from caliper. Discard washers.

4. Remove rear wheel. See Section 2.4 REAR WHEEL,

REMOVAL, steps 2-6.

5. Remove caliper from anchor weldment on rear swingarm.

CALIPER DISASSEMBLY

1. See Figure 2-62. Remove two pad pins. Remove brake pads from caliper housings.

2. Remove three bridge bolts and separate inside and outside caliper housings.

2004 Touring: Chassis 2-55

HOME

f1781x2x

Brake Caliper Piston Remover

(Part No. HD-43293A)

Brake Caliper

Piston Remover

Bridge

CAUTION

Bolt

Figure 2-65. Direct Compressed Air Into Banjo Bolt Hole to Force Pistons From Bores

3. Remove anti-rattle spring from channel around boss in outside caliper housing.

4. If damaged, cut anchor of rubber damper and remove.

5. Remove bleeder valve, if damaged.

11WARNING1WARNING

Pressurized air can blow debris into your face and eyes. Always wear eye protection or a face shield. Failure to do so could result in eye injury.

6. Remove four pistons as follows: a. Obtain BRAKE CALIPER PISTON REMOVER (Part

No. HD-43293A). See inset of Figure 2-65.

b. Seat tool in outside caliper housing aligning holes in

tool with three bridge bolt holes in housing. Place inside caliper housing over tool aligning bridge bolt

holes with three holes in tool. c. Install bridge bolts and tighten securely. d. If the bleeder valve was removed, reinstall ﬁnger

tight or place a gloved ﬁnger over the valve hole. e. Using a tapered, rubber-tipped nozzle on the air

hose (to prevent both loss of air pressure and dam-

age to the banjo seating surface), apply low pres-

sure compressed air into the banjo bolt hole to force

pistons into contact with cushion of tool. See Figure

2-65.

f. Remove bridge bolts and separate caliper housings. g. Remove pistons from caliper piston bores. For best

results, wiggle pistons slightly while pulling.

Tape red,

Rubber-Tipped

Low Pressure

Air Hose

Nozzle

7. Remove two crossover O-rings from inside caliper housing. Discard O-rings.

CAUTION

8. Using a wooden toothpick, remove wiper and square seal from each piston bore. Discard wipers and seals. See Figure 2-66.

Wooden

f1779x2x

Toothpick

Wiper

Square

Seal

Figure 2-66. Remove Wipers and Square Seals

From Piston Bores

2-56 2004 Touring: Chassis

f1782x2x

Bleeder

Valve

Anti-Rattle

Spring

Rubber

Damper

Anchor Bead

HOME

CLEANING AND INSPECTION

11WARNING1WARNING

2. Carefully inspect all components. Replace any parts that appear damaged or worn.

a. Check pistons for pitting, scratching or corrosion on

face and also on ground surfaces.

b. Inspect caliper piston bore. Replace caliper if bore

shows signs of pitting or corrosion. Do not hone bore for reuse.

c. Check rubber damper for cuts, tears or signs of

deterioration.

d. Always replace wipers, square seals and crossover

O-rings after caliper disassembly.

11WARNING1WARNING

3. Inspect brake pads and discs. See INSPECTION at the beginning of this section.

4. Inspect pad pins for wear and grooving. Replace both pins if wear of either pin exceeds 0.015 inch (0.38 mm).

CALIPER ASSEMBLY

1. Install new square seals into caliper piston bores.

2. Install new wipers into caliper piston bores.

CAUTION

Do not use D.O.T. 5 brake ﬂuid for lubrication or increased lever travel will result.

3. Lubricate the following areas using a thin ﬁlm of G.E. VERSILUBE “Piston Lube” in the service parts kit):

#G322L SILICONE GREASE (marked

Figure 2-67. Install Anti-Rattle Spring

● Inside diameter of square seals and wipers.

● Caliper piston bores.

● Nose radius and outside diameter of piston.

NOTE

All other surfaces must be kept clean and dry for assembly.

4. Carefully insert pistons into bores by hand. If resistance is felt, remove piston and verify that both seal and wiper are properly installed.

5. Install new crossover O-rings into two grooves on inside caliper housing.

6. Assemble caliper housings as follows:

a. Install bleeder valve on outside caliper housing, if

removed. Tighten valve to 80-100 in-lbs (9.0-11.3 Nm). Install bleeder valve cap.

b. Place outside caliper housing on workbench with

decal side down. Place anti-rattle spring in channel around boss. Spring is not directional. See Figure 2-

67.

c. Mate inside and outside caliper housings and

loosely install two bridge bolts.

d. Tighten bridge bolts to 28-38 ft-lbs (37.9-51.5 Nm).

e. If rubber damper was removed, lubricate anchor of

new damper with isopropyl alcohol or glass cleaner and install by pulling rubber bead through hole in outside caliper housing, as shown in Figure 2-67.

f. Ver ify that anti-rattle spring is still seated.

NOTE

All calipers (both front and rear) use the same brake pad set.

2004 Touring: Chassis 2-57

HOME

7. Install new brake pads into caliper with the friction mate-

rial facing the brake disc opening. Also, be sure that the pad is oriented so that the curved side faces the rear of the vehicle when the caliper is installed. See Figure 2-

63.

Furthermore, note that the backing plate of each brake pad has either one or two tabs. The pad with two tabs is installed on the inboard side of the caliper, the pad with the single tab is installed on the outboard side.

8. Install pad pins and tighten to 180-200 in-lbs (20.3-22.6

Nm).

NOTE

If pad pins do not ﬁt, verify the following: (1) Proper pad set is being used, not two identical pads. (2) Anti-rattle spring is installed as shown in Figure 2-67. (3) Pads are pushed tight against anti-rattle spring.

CALIPER INSTALLATION

1. Install rear wheel. See Section 2.4 REAR WHEEL,

INSTALLATION, steps 1-9.

CAUTION

To avoid leakage, verify that the washers, banjo bolt, brake line and caliper bore are completely clean.

5. Depress rear brake pedal several times to set brake pads to proper operating position within caliper. Bleed brake system. See Section 2.14 BLEEDING HYDRAU-

LIC BRAKES.

6. Install master cylinder reservoir cover. Install two Phillips screws to fasten cover to reservoir and tighten to 6-8 in- lbs (0.7-0.9 Nm).

7. Install saddlebags. See Section 2.25 SADDLEBAG,

INSTALLATION.

8. Test operation of brake lamp with the rear brake applied and the Ignition/Light Key Switch turned to IGNITION.

11WARNING1WARNING

9. Test ride the motorcycle. If the brakes feel spongy, bleed the system again. See Section 2.14 BLEEDING

HYDRAULIC BRAKES.

NOTE

To allow new brake pads to “wear in” properly with the brake disc, avoid making hard stops for the ﬁrst 100 miles (160 km).

2. Connect brake line to caliper using two new steel/rubber

washers and banjo bolt. Tighten bolt to 17-22 ft-lbs (23.0-29.8).

3. Remove two Phillips screws to release cover from rear brake master cylinder reservoir. Verify that brake ﬂuid level is 1/8 inch (3.2 mm) below top of reservoir with master cylinder in a level position. Add D.O.T. 5 SILICONE BRAKE FLUID, if necessary.

11WARNING1WARNING

Verify proper operation of the master cylinder relief port. A plugged or covered relief port can cause brake drag or lockup, which may result in loss of vehicle control and could result in death or serious injury.

4. Actuate the brake pedal with the cover removed. A slight spurt of ﬂuid will break the surface if all internal components are working properly.

11WARNING1WARNING

2-58 2004 Touring: Chassis

HOME

11WARNING1WARNING

f1994x2x

BLEEDING HYDRAULIC BRAKES 2.14

GENERAL

Bleed the hydraulic brake system any time a brake line, master cylinder or brake caliper has been opened or disassembled, or whenever the brake lever/pedal operation feels “spongy.” Bleeding evacuates air from the system leaving only incompressible hydraulic ﬂuid.

NOTE

Harley-Davidson recommends that all brake service be performed by a Harley-Davidson dealer or other qualiﬁed technician.

NOTE

Hydraulic brake ﬂuid bladder-type pressure equipment can be used to ﬁll brake master cylinders through the bleeder valve. Remove master cylinder reservoir cover so that system cannot pressurize. Do not use pressure bleeding equipment when the hydraulic system is sealed with master cylinder reservoir cover and gasket in place.

1. Install end of a length of plastic tubing over caliper bleeder valve. Place free end of tube in a clean container. See Figure 2-68. Stand motorcycle upright.

6. Repeat steps 3-5 until all air bubbles are purged.

7. Final tighten the bleeder valve to 80-100 in-lbs

(9.0-11.3 Nm). Install the bleeder cap.

8. Add brake ﬂuid to the master cylinder reservoir until the ﬂuid level is about 1/8 inch (3.2 mm) from the top. Do not reuse brake ﬂuid.

9. Install the master cylinder reservoir cover. Install two Phillips screws to fasten the cover to the reservoir. Tighten the screws to 6-8 in-lbs (0.7-0.9 Nm).

NOTE

Note that the angular shape of the front brake master cylinder reservoir cover makes one side thicker than the other. Install the cover on the master cylinder reservoir so that the thicker side is positioned above the brake line ﬁtting.

10. Test ride motorcycle. Repeat the bleeding procedure if brakes feel spongy.

CAUTION

To prevent dirt and other contaminants from entering the master cylinder reservoir, thoroughly clean the cover before removal.

2. Remove the two Phillips screws to release cover from the master cylinder reservoir.

3. Add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID to the master cylinder reservoir until the ﬂuid level is 1/8 inch (3.2 mm) from the top. Do not reuse brake ﬂuid.

NOTE

D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID is non-toxic.

4. Depress and hold brake lever/pedal to build up hydraulic pressure.

5. Open bleeder valve about 1/2 turn. Brake ﬂuid will ﬂow from bleeder valve through tubing. Close bleeder valve when brake lever/pedal has moved 1/2 to 3/4 of its full range of travel. Allow brake lever/pedal to return slowly to its released position.

Figure 2-68. Bleeding Hydraulic System

2004 Touring: Chassis 2-59

HOME

FRONT FORKS 2.15

CHANGING FORK OIL

Overhaul the front fork assembly and replace the fork oil at every 50,000 mile (80,000 km) service interval. Proceed as follows:

Table 2-2. Fork Oil Requirements

FORK MODEL TYPE

All models

Left

Right

except

Road King

All models

Cartridge

Conventional

AMOUNT

OZ. ML IN.

10.0 295 4.21 107

See Warning Below

11.1 328 5.24 133

11WARNING1WARNING

Fork oil level in cartridge type forks is carefully measured from top of tube after pumping damper rod. Any deviation from instructions can result in incorrect amount of fork oil. Incorrect amount of fork oil can adversely affect handling and lead to loss of vehicle control, which could result in death or serious injury.

NOTE

All touring models with the exception of Road King have the cartridge type fork on the left side and the conventional type fork on the right. Road King uses the conventional type fork on both sides. To change the fork oil on a cartridge type fork, partial disassembly of the fork is required.

Fork

Cap Bolt

Fork Stop

Pinch Bolt

8312

Figure 2-69. Remove Fork Cap Bolt (FLHR/C/S Shown)

FLHT/C/U, FLTR

1. Remove left fork. See REMOVAL, steps 1-9.

2. Partially disassemble left fork. See DISASSEMBLY,

LEFT FORK, steps 1-13.

3. Position fork assembly upside down over drain pan. Allow sufﬁcient time for fork to thoroughly drain (about 10-15 minutes).

4. Assemble left fork. See ASSEMBLY, LEFT FORK, steps 13-29.

5. Drain and ﬁll right fork. Removal and disassembly of the fork is not required. See FLHR/C/S below, steps 3-7.

NOTE

If removing and inverting right fork is the preferred method of draining, see REMOVAL, steps 4-9.

6. Install fork(s) and assemble motorcycle. See INSTALLA-

TION in this section.

Drain

Plug

f1786x2x

Figure 2-70. Remove Fork Oil Drain Plug

(Right Side Shown)

FLHR/C/S

1. Remove headlamp nacelle. See Section 2.31 WIND-

SHIELD/HEADLAMP NACELLE (FLHR/C/S), NACELLE REMOVAL (FLHR/C) or NACELLE REMOVAL (FLHRS).

2. Place suitable blocking under frame to raise front wheel several inches off the ﬂoor. Use an hydraulic center stand on a level surface.

3. Remove fork cap bolt from fork tube plug at top of fork tube. See Figure 2-69.

4. Remove the drain plug from the bottom of the fork slider. See Figure 2-70.

2-60 2004 Touring: Chassis

HOME

Plastic Knob

Rubber Pad

Vise Grip

f1898x2x

Fork Tube

Plug

Vise

Fork Tube

Holder

Flat

5. When fork oil is fully drained, install drain plug and

tighten to 72-96 in-lbs (8-11 Nm).

6. Using a funnel, pour 11.1 ounces (328 ml) of HarleyDavidson Type E Fork Oil into the fork tube.

7. Install fork cap bolt and tighten to 50-60 ft-lbs (68-81 Nm).

8. Repeat steps 3-7 on other fork.

9. Install headlamp nacelle. See Section 2.31 WIND-

SHIELD/HEADLAMP NACELLE (FLHR/C/S), NACELLE INSTALLATION (FLHR/C) or NACELLE INSTALLATION (FLHRS).

NOTE If fork is leaking or fails visual inspection, completely disassemble following the instructions under REMOVAL and DIS-

ASSEMBLY. Use the occasion to thoroughly examine all

parts and install a new fork oil seal.

REMOVAL

1. Place suitable blocking under frame to raise front wheel

several inches off the ﬂoor. For best results, use an hydraulic center stand on a level surface.

2. Remove the front wheel and fender. See Section 2.32

FRONT FENDER, REMOVAL.

3. FLHT/C/U:

a. Remove fairing cap. See Section 2.29 UPPER

FAIRING/WINDSHIELD (FLHT/C/U), FAI RING CAP, REMOVAL.

b. Move to front of motorcycle. Loosen two upper outer

fairing screws. Remove two lower outer fairing screws.

c. Remove two screws from lower fork bracket to

release passing lamp bracket, chrome skirt and inner fairing. Remove chrome skirt.

FLTR:

a. Remove instrument nacelle. See Section 2.30

UPPER FAIRING/WINDSHIELD (FLTR), INSTRU- MENT NACELLE, REMOVAL.

FLHR/C/S:

a. Remove headlamp nacelle. See Section 2.31

WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S), NACELLE REMOVAL (FLHR/C) or NACELLE REMOVAL (FLHRS).

Figure 2-71. Fork Tube Holder (HD-41177)

Figure 2-72. Install Fork Tube Into Fork Holder

7. Holding fork slider to prevent fork from dropping, remove fork cap bolt from fork tube plug. Slide fork tube down and out of upper fork bracket, fork stop, lower fork bracket, and slider cover.

8. Thread fork cap bolt back into fork tube plug to prevent loss of fork oil while handling.

9. Move front fork to bench area. Place suitable drain pan on ﬂoor beneath vise.

10. Repeat steps 4-9 to remove right fork.

DISASSEMBLY

4. Standing at front of vehicle, loosen pinch bolt (with lockwasher) on left side of lower fork bracket, but do not remove. See Figure 2-69.

5. Loosen fork cap bolt from fork tube plug at top of fork tube, but do not remove.

6. Spray glass cleaner on fork tube above the rubber fork stop. After lubricating surfaces, move fork stop up fork tube until it contacts bottom of upper fork bracket.

LEFT FORK

Cartridge Type - All Models Except Road King

NOTE Since Road King uses the conventional type fork on both sides, see DISASSEMBLY, RIGHT FORK, for Road King instructions.

2004 Touring: Chassis 2-61

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Length

Retaining Pins (3)

Adjuster

Screw

Spring

Compressor

Damper Rod

Extension Tool

Post

f2188x2x

Figure 2-73. Fork Spring Compressing Tool (HD-45966)

Locknut

a. Clamp end of tool in vise in a horizontal position

with plastic knobs facing toward you.

b. With the fork cap bolt topside, clamp fork tube

between rubber pads on inboard side of tool. Tighten knobs until fork tube is securely held.

3. Remove fork cap bolt from fork tube plug. Remove and discard quad ring seal.

4. Using ﬂat, unthread fork tube plug from fork tube. See

Figure 2-72.

5. Pull up on fork slider to compress fork assembly, which causes the damper rod to protrude from the top of the fork tube.

6. Holding locknut, remove fork tube plug from threaded end of damper rod. Remove O-ring from fork tube plug. Discard O-ring.

7. Remove fork assembly from fork tube holder. Turning fork upside down, drain fork oil into drain pan.

8. Remove fork tube holder from vise.

9. Obtain the FORK SPRING COMPRESSING TOOL (HD-

45966) shown in Figure 2-73. Install as follows: a. Clamp tool in vise in a vertical position with length

adjuster screw topside. b. Pull up on fork slider to compress fork assembly. c. Place hole at bottom of fork slider over post at bot-

tom end of tool. d. With the smaller OD topside, place spring compres-

sor over locknut, spring seat and ﬂat washer of fork

assembly.

f2189x2x

Figure 2-74. Compress Fork Spring

1. Remove the fork assembly. See REMOVAL in this sec- tion.

CAUTION

Exercise caution to avoid scratching or nicking fork tube. Damaging tube can result in fork oil leaks after assembly.

2. Obtain the FORK TUBE HOLDER (HD-41177). See Fig-

ure 2-71. Proceed as follows:

CAUTION

Use only hand tools to turn length adjuster screw on fork spring compressing tool. Do not use an air impact wrench or tool damage can occur.

e. Adjust tool as necessary until three retaining pins

engage blind holes in spring compressor. Turn length adjuster screw in a counterclockwise direction to lengthen, a clockwise direction to shorten.

11WARNING1WARNING

Retaining pins must fully engage blind holes or spring compressor may rotate out of position during compression of spring. If spring compressor rotates out of position, sudden extension of spring can cause parts to ﬂy out, possibly resulting in minor or moderate injury.

f. Tu rn retaining pins as necessary to lock position of

spring compressor.

g. Turn length adjuster screw in a clockwise direction

to compress spring.

10. Using deepwell socket to avoid unnecessary spring

compression, remove locknut from end of damper rod. See Figure 2-74.

2-62 2004 Touring: Chassis

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CAUTION

11. Turn length adjuster screw in a counterclockwise direction to release tension on fork spring. Loosen retaining pins and remove spring compressor. Remove spring seat and ﬂat washer.

12. Remove fork assembly from tool and remove tool from vise. Remove fork spring from fork tube.

13. Obtain damper rod extension tool shown in Figure 2-75. Thread extension tool onto end of damper rod. Turn fork assembly upside down over drain pan and slowly pump damper rod at least twenty times until rod moves freely. See Figure 2-76.

NOTE

If just changing the fork oil, continue procedure at ASSEM-

BLY, LEFT FORK, step 13. If overhauling the fork assembly,

continue with step below.

14. Remove extension tool from damper rod. Install fork spring back into fork tube.

f2186x2x

M10 X 1.0

Thread Size

15. Place a shop rag on the ﬂoor, and turning fork assembly upside down, press end of spring against rag. While compressing spring to prevent rotation of damper cartridge, remove 6mm screw from end of fork slider. Use an air impact wrench for best results. Discard 6mm screw and copper crush washer.

16. Remove spring and damper cartridge from fork tube.

Do not expand or stretch retaining clip to remove from fork tube or clip may become bent or distorted.

17. Using pick tool, remove retaining clip between fork slider and fork tube.

18. Remove fork tube from fork slider.

NOTE

To overcome any resistance, use the fork tube as a slide hammer, that is, ﬁrst push fork tube into fork slider and then pull it outward with a moderate amount of force. Repeat this sequence until fork tube separates from fork slider.

19. Slide fork oil seal, slider spacer and slider bushing off end of fork tube. Discard fork oil seal and slider bushing.

20. Gently pry at split line to expand fork leg bushing, and then remove from groove at end of fork tube. Discard fork leg bushing.

21. Remove lower stop from fork slider, or end of damper cartridge if still installed.

Figure 2-75. Damper Rod Extension Tool

f2187x2x

Figure 2-76. Pump Damper Rod Extension Tool

RIGHT FORK

Conventional Type - All Models

1. Remove the fork assembly. See REMOVAL in this sec- tion.

2. Remove nuts, lockwashers, ﬂat washers and axle holder from studs at end of fork slider.

Exercise caution to avoid scratching or nicking fork tube. Damaging tube can result in fork oil leaks after assembly.

3. Obtain the FORK TUBE HOLDER (HD-41177). See Fig-

ure 2-71. Proceed as follows:

a. Clamp end of tool in vise in a horizontal position

with plastic knobs facing toward you.

b. With the fork cap bolt topside, clamp fork tube

between rubber pads on inboard side of tool. Tighten knobs until fork tube is securely held. See

Figure 2-72.

4. Remove fork cap bolt from fork tube plug. Remove and discard O-ring.

2004 Touring: Chassis 2-63

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5. Using ﬂat, slowly unthread fork tube plug from fork tube. Be aware that fork tube plug is under spring pressure, so have a ﬁrm grasp on plug as the last thread is turned. Remove and discard O-ring from fork tube plug.

6. Remove fork spring from fork tube.

7. Remove fork assembly from fork tube holder.

8. Turning fork upside down, drain fork oil into drain pan. For best results, slowly pump fork tube and slider at least ten times.

9. Install fork spring back into fork tube.

10. Place a shop rag on the ﬂoor, and turning fork assembly upside down, press end of spring against rag. While compressing spring to prevent rotation of damper tube, remove 6mm screw from end of fork slider. Use an air impact wrench for best results. Discard 6mm screw and copper crush washer.

11. Remove fork spring and damper tube from fork tube.

12. Remove wear ring and rebound spring from damper tube.

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Figure 2-77. Measure Fork Tube Runout

5. Check the fork tube and slider for scoring, scratches and excessive or abnormal wear. Replace parts as necessary. Set the fork tube on V-blocks and measure the runout using a dial indicator gauge. Replace fork if runout exceeds 0.008 inch (0.2 mm). See Figure 2-77.

CAUTION

Do not expand or stretch retaining clip to remove from fork tube or clip may become bent or distorted.

13. Using pick tool, remove retaining clip between fork slider and fork tube.

14. Remove fork tube from fork slider.

NOTE

15. Slide fork oil seal, slider spacer and slider bushing off end of fork tube. Discard fork oil seal and slider bushing.

16. Gently pry at split line to expand fork leg bushing, and then remove from groove at end of fork tube. Discard fork leg bushing.

17. Remove the lower stop from the fork slider.

CLEANING AND INSPECTION

1. Thoroughly clean and inspect all parts. Replace any parts that are bent, broken or obviously damaged.

2. Inspect fork cap bolt quad ring seal and fork tube plug Oring for cuts, tears or signs of deterioration. Replace if necessary.

3. Replace the retaining clip if bent or distorted.

4. Check the slider and fork leg bushings for scratches or excessive wear. Always replace bushings in a set if either bearing is damaged or worn.

6. Inspect upper fork springs for damage or distortion. Verify that free length is a minimum of 15 inches (381.0 mm) on cartridge type forks, 18.5 inches (469.9 mm) on the conventional type. Replace rebound spring on the conventional type fork if the free length is less than 15/16 inch (23.8 mm) or whenever the upper fork spring requires replacement.

ASSEMBLY

LEFT FORK

Cartridge Type - All Models Except Road King

NOTE

Since Road King uses the conventional type fork on both sides, see ASSEMBLY, RIGHT FORK, for Road King instruc- tions.

CAUTION

Exercise caution to avoid scratching or nicking fork tube. Damaging tubes can result in fork oil leaks after assembly.

1. Coat fork leg bushing ID with clean fork oil. Expand fork leg bushing at split line only so far as required to slip over end and into groove of fork tube.

2. Slide damper cartridge into fork tube, so that cartridge end drops through hole at bottom of fork tube. Install lower stop at end of damper cartridge.

2-64 2004 Touring: Chassis

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CAUTION

f2190x2x

3. Install fork slider in fork tube holder. Slide fork tube into fork slider.

4. Coat slider bushing ID with clean fork oil. Slide slider bushing down fork tube.

5. Slide slider spacer down fork tube until it contacts slider bushing.

6. Obtain the FORK OIL SEAL INSTALLER (HD-34634). See Figure 2-78. Proceed as follows:

a. Slide the fork oil seal installer down the fork tube,

and using the tool like a slide hammer, drive slider bushing into counterbore of fork slider. Remove tool.

NOTE

Place masking tape over edge of fork tube to avoid damaging lip of fork oil seal during installation.

b. Coat new fork oil seal ID with clean fork oil. With the

lip garter spring side facing down (toward the fork slider), slide seal down fork tube until it contacts slider spacer. Remove masking tape from edge of fork tube.

c. Slide the fork oil seal installer down the fork tube

until it contacts the fork oil seal.

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Figure 2-78. Fork Oil Seal Installer (HD-34634)

f1902x2x

Figure 2-80. Pump Damper Rod Extension Tool

d. Using the tool like a slide hammer, drive fork oil seal

down fork tube until retaining clip groove is visible in fork slider ID. See Figure 2-79. Remove tool.

Do not expand or stretch retaining clip to install on fork tube or clip may become bent or distorted.

e. Slide the retaining clip down the fork tube until it

contacts the fork oil seal. Install retaining clip in the fork slider groove.

7. Install fork spring into fork tube.

8. Remove fork assembly from fork tube holder.

9. Place a shop rag on the ﬂoor, and turning fork assembly upside down, press end of spring against rag.

10. Install new 6mm screw with copper crush washer. Slide screw through hole at bottom of fork slider and start into end of damper cartridge.

11. While compressing spring to prevent rotation of damper cartridge, tighten 6mm screw to 132-216 in-lbs (14.9-

24.4 Nm).

12. Remove fork spring from fork tube.

13. With the fork tube topside, clamp fork slider (not the fork tube) into fork tube holder.

Figure 2-79. Install Fork Oil Seal

NOTE

Install the drain plug at the bottom of the fork slider, if removed. Tighten the plug to 72-96 in-lbs (8-11 Nm).

14. Fill the fork tube as follows: a. Obtain damper rod extension tool shown in Figure

2-75. Thread extension tool onto end of damper rod.

b. Pour 5 ounces (147.9 ml) of Harley-Davidson Type

E Fork Oil into the fork tube.

2004 Touring: Chassis 2-65

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c. Grasping extension tool, slowy pump the damper

rod until resistance is felt, and then pump ﬁve more

times. See Figure 2-80. d. Place the damper rod in the fully bottomed position. e. Remove extension tool from end of damper rod. f. Pour 6 more ounces (177.5 ml) of fork oil into the

fork tube.

15. Adjust the fork oil level, so that it is 4.21 inches (107 mm) from the top of the fork tube with the fork compressed. Proceed as follows:

a. Obtain the FRONT FORK OIL LEVEL GAUGE (HD-

59000B). See Figure 2-81.

b. Loosen thumbscrew on metal ring and move it up or

down the rod until the bottom of the ring is 4.21 inches (107 mm) from the end of the rod. Tighten

thumbscrew. c. Push the plunger on the cylinder all the way in.

d. Insert rod into top of fork tube until metal ring rests

ﬂat on top of fork tube. See Figure 2-82.

Figure 2-81. Front Fork Oil Level Gauge (HD-59000B)

f2168x2x

e. Pull out plunger to suck fork oil from fork tube.

Observe fork oil through transparent tube as it is drawn into cylinder. If no oil is drawn through transparent tube, add enough oil so that tool usage sets fork oil level.

f. Remove rod from fork tube. Push plunger into cylin-

der to eject excess fork oil into suitable container.

g. If necessary, repeat steps 15(d) thru 15(f). Level is

correct when no fork oil is observed being drawn through transparent tube.

11WARNING1WARNING

Be sure fork oil level is correct. The incorrect amount of fork oil can adversely affect handling and may lead to loss of vehicle control, which could result in death or serious injury.

16. With the closer spaced coils at the bottom, slide fork spring into fork tube.

17. Pull up on fork slider to compress fork assembly, which causes the damper rod and spring to protrude from the top of the fork tube.

18. Thread damper rod extension tool onto end of damper rod.

19. Remove fork assembly from fork tube holder. Remove fork tube holder from vise.

20. Obtain the FORK SPRING COMPRESSING TOOL (HD-

45966) shown in Figure 2-73. Install as follows: a. Clamp tool in vise in a vertical position with length

adjuster screw topside. b. Pull up on fork slider to compress fork assembly. c. Place hole at bottom of fork slider over post at bot-

tom end of tool. d. Place ﬂat washer rounded side up over damper rod

extension tool and on top of spring. Place spring

seat concave side up on top of ﬂat washer. With the

smaller OD topside, place spring compressor over

spring seat and ﬂat washer.

CAUTION

Figure 2-82. Remove Excess Fork Oil

2-66 2004 Touring: Chassis

Use only hand tools to turn length adjuster screw on fork spring compressing tool. Do not use an air impact wrench or tool damage can occur.

e. Adjust tool as necessary until three retaining pins

engage blind holes in spring compressor. Turn

length adjuster screw in a counterclockwise direc-

tion to lengthen, a clockwise direction to shorten.

11WARNING1WARNING

HOME

CAUTION

f1974x2x

f. Tu rn retaining pins as necessary to lock position of

spring compressor. See Figure 2-74.

g. Tu rn length adjuster screw in a clockwise direction

to compress spring. See Figure 2-74.

21. After a number of turns, pull up on extension tool to raise damper rod. If threaded portion of rod cannot be pulled completely out of spring, compress spring further.

22. Repeat step 21 until threaded portion of rod can be pulled completely out of spring. Remove extension tool, but do not let go of damper rod.

23. Thread locknut onto damper rod until it contacts shoulder. Use a deepwell socket for best results.

24. Install new O-ring onto fork tube plug. Thread fork tube plug onto threaded end of rod until it bottoms. Now turn locknut in a counterclockwise direction until it makes ﬁrm contact with the fork tube plug. Tighten locknut to 13-20 ft-lbs (18-27 Nm).

25. Turn length adjuster screw in a counterclockwise direction to release tension on fork spring. Loosen retaining pins and remove spring compressor. Remove fork assembly from tool and remove tool from vise.

26. Install fork tube holder in vise. Clamp fork tube into fork tube holder.

27. Tighten fork tube plug to 22-58 ft-lbs (30-79 Nm).

28. Install new O-ring onto fork cap bolt. Thread fork cap bolt into fork tube plug to prevent loss of fork oil while handling.

29. Remove fork assembly from fork tube holder.

1. Fork cap bolt

2. Quad ring seal

3. Fork tube plug

4. O-Ring

5. Locknut

6. Spring seat

7. Flat washer

8. Spring

9. Damper cartridge

10. Fork tube

11. Retaining clip

Figure 2-83. Left Side Fork - Cartridge Type

(All Models Except Road King)

12. Lip seal

13. Slider spacer

14. Slider bushing

15. Fork leg bushing

16. Lower stop

17. Fork slider

18. Plug

19. Flat Washer

20. Copper washer

21. Screw (6mm)

RIGHT FORK

Conventional Type - All Models

Exercise caution to avoid scratching or nicking fork tube. Damaging tubes can result in fork oil leaks after assembly.

1. Coat fork leg bushing ID with clean fork oil. Expand fork leg bushing at split line only so far as required to slip over end and into groove of fork tube.

2. Install new wear ring in groove at top of damper tube. Install rebound spring on opposite end.

3. With the wear ring topside, slide damper tube into fork tube, so that tube end drops through hole at bottom of fork tube. Install lower stop at end of damper tube.

4. Install fork slider in fork tube holder. Slide fork tube into fork slider.

5. Coat slider bushing ID with clean fork oil. Slide slider bushing down fork tube.

6. Slide slider spacer down fork tube until it contacts slider bushing.

2004 Touring: Chassis 2-67

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7. Obtain the FORK OIL SEAL INSTALLER (HD-34634). See Figure 2-78. Proceed as follows:

a. Slide the fork oil seal installer down the fork tube,

and using the tool like a slide hammer, drive slider bushing into counterbore of fork slider. Remove tool.

NOTE

Place masking tape over edge of fork tube to avoid damaging lip of fork oil seal during installation.

b. Coat new fork oil seal ID with clean fork oil. With the

lip garter spring side facing down (toward the fork slider), slide seal down fork tube until it contacts slider spacer. Remove masking tape from edge of fork tube.

c. Slide the fork oil seal installer down the fork tube

until it contacts the fork oil seal.

d. Using the tool like a slide hammer, drive fork oil seal

down fork tube until retaining clip groove is visible in fork slider ID. See Figure 2-79. Remove tool.

CAUTION

Do not expand or stretch retaining clip to install on fork tube or clip may become bent or distorted.

f1975x2x

e. Slide the retaining clip down the fork tube until it

contacts the fork oil seal. Install retaining clip in the fork slider groove.

8. Install fork spring into fork tube.

9. Remove fork assembly from fork tube holder.

10. Place a shop rag on the ﬂoor, and turning fork assembly upside down, press end of spring against rag.

11. Install new 6mm screw with copper crush washer. Slide screw through hole at bottom of fork slider and start into end of damper tube.

12. While compressing spring to prevent rotation of damper tube, tighten 6mm screw to 132-216 in-lbs (14.9-24.4 Nm).

13. Remove fork spring from fork tube.

14. With the fork tube topside, clamp fork slider (not the fork tube) into fork tube holder.

NOTE

Install the drain plug at the bottom of the fork slider, if removed. Tighten the plug to 72-96 in-lbs (8-11 Nm).

15. Pour 11.1 ounces (328 ml) of Harley-Davidson Type E Fork Oil into the fork tube.

16. Adjust the fork oil level, so that it is 5.24 inches (133 mm) from the top of the fork tube with the fork compressed. Proceed as follows:

a. Obtain the FRONT FORK OIL LEVEL GAUGE (HD-

59000B). See Figure 2-81.

1. Fork cap bolt

2. Quad ring seal

3. Fork tube plug

4. O-Ring

5. Spring

6. Wear ring

7. Damper tube

8. Rebound spring

9. Fork tube

10. Retaining clip

11. Lip seal

12. Slider spacer

Figure 2-84. Right Side Fork - Conventional Type

(All Models)

13. Slider bushing

14. Fork leg bushing

15. Lower stop

16. Fork slider

17. Plug

18. Flat Washer

19. Copper washer

20. Screw (6mm)

21. Axle holder

22. Flat washer (2)

23. Lockwasher (2)

24. Nut (2)

2-68 2004 Touring: Chassis

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b. Loosen thumbscrew on metal ring and move it up or

down the rod until the bottom of the ring is 5.24 inches (133 mm) from the end of the rod. Tighten thumbscrew.

c. Push the plunger on the cylinder all the way in.

d. Insert rod into top of fork tube until metal ring rests

ﬂat on top of fork tube. See Figure 2-82.

e. Pull out plunger to suck fork oil from fork tube.

Observe fork oil through transparent tube as it is drawn into cylinder. If no oil is drawn through transparent tube, add enough oil so that tool usage sets fork oil level.

f. Remove rod from fork tube. Push plunger into cylin-

der to eject excess fork oil into suitable container.

g. If necessary, repeat steps 16(d) thru 16(f). Level is

correct when no fork oil is observed being drawn through transparent tube.

11WARNING1WARNING

Be sure fork oil level is correct. The incorrect amount of fork oil can adversely affect handling and may lead to loss of vehicle control, which could result in death or serious injury.

17. With the closer spaced coils at the bottom, slide fork spring into fork tube.

18. Install new O-ring onto fork tube plug. Compressing fork spring with end of fork tube plug, thread fork tube plug into fork tube. Tighten fork tube plug to 22-58 ft-lbs (3079 Nm).

19. Install new quad ring seal onto fork cap bolt. Thread fork cap bolt into fork tube plug to prevent loss of fork oil while handling.

20. Loosely install axle holder, ﬂat washers, lockwashers and nuts on studs at end of fork slider.

INSTALLATION

1. Remove fork cap bolt.

2. Standing at front of vehicle, slide fork tube up and into slider cover, lower fork bracket, fork stop, and upper fork bracket. Install fork cap bolt.

3. Move rubber fork stop down fork tube until it contacts top of lower fork bracket. Lubricate surfaces with glass cleaner, if necessary.

4. Install pinch bolt (with lockwasher) on left side of lower fork bracket. See Figure 2-69. Tighten pinch bolt to 3035 ft-lbs (41-48 Nm).

5. Tighten fork cap bolt to 50-60 ft-lbs (68-81 Nm).

6. Repeat steps 1-5 on other fork, if removed.

7. Install the front fender and wheel. See Section 2.32

FRONT FENDER, INSTALLATION.

8. FLHT/C/U: a. Slide chrome skirt into position between passing

lamp bracket and inner fairing. To avoid possible wire damage, be sure that trim strip is installed on top edge of skirt. Install two screws to secure passing lamp bracket, chrome skirt and inner fairing to lower fork bracket.

b. Move to front of motorcycle. Install two lower outer

fairing screws. Tighten two upper outer fairing screws.

c. Install fairing cap. See Section 2.29 UPPER FAIR-

ING/WINDSHIELD (FLHT/C/U), FAIR ING CAP, INSTALLATION

FLTR:

a. Install instrument nacelle. See Section 2.30 UPPER

FAIRING/WINDSHIELD (FLTR), INSTRUMENT NACELLE, INSTALLATION.

FLHR/C/S:

a. Install headlamp nacelle. See Section 2.31 WIND-

SHIELD/HEADLAMP NACELLE (FLHR/C/S), NACELLE INSTALLATION (FLHR/C) or NACELLE INSTALLATION (FLHRS).

2004 Touring: Chassis 2-69

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LOWER FORK BRACKET COVER/AIR DAM 2.16

LOWER FORK BRACKET COVER (FLHRS)

REMOVAL

1. Moving to the back of the lower fork bracket, remove two hex screws (with ﬂat washers) to release cover ﬂange.

2. Holding cover to prevent from dropping, remove T40 TORX screw at bottom.

7590

INSTALLATION

1. With the concave side up, align holes in cover ﬂange with holes at back of the lower fork bracket.

Figure 2-85. Air Dam

NOTE

Plastic plug(s) at back of lower fork bracket will prevent proper cover installation. Remove and discard plug(s), if present.

3. Start two hex screws (with ﬂat washers) to fasten cover ﬂange to bracket.

4. Start T40 TORX screw at bottom of cover engaging offset hole in front brake line bracket.

5. Alternately tighten two hex screws to 70-110 in-lbs (7.9-

12.4 Nm).

6. Tighten T40 TORX screw to 120-180 in-lbs (13.6-20.3 Nm).

7. Verify that cover does not contact brake lines to front brake calipers or master cylinder reservoir. Adjust either brake line bracket or cover if necessary.

AIR DAM (FLTR)

REMOVAL

1. Moving to the back of the lower fork bracket, remove two screws (with ﬂat washers) to release the air dam. See

Figure 2-85.

2. To keep out dirt and debris, reinstall two screws (with ﬂat washers) into holes of lower fork bracket. Tighten screws to 120-144 in-lbs (13.6-16.3 Nm).

INSTALLATION

1. With the concave side down, align holes in air dam with holes at back of the lower fork bracket.

NOTE

Plastic plug(s) at back of lower fork bracket will prevent proper cover installation. Remove and discard plug(s), if present.

2. Install two screws (with ﬂat washers) to fasten dam to bracket. Tighten screws to 120-144 in-lbs (13.6-16.3 Nm).

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f2108x2x

Grease

Fitting

Steering

Head

STEERING HEAD BEARINGS 2.17

LUBRICATION

At the 1000 mile (1600 km) service interval, and at every 10,000 mile (16,000 km) service interval thereafter, grease the steering head bearings using Special Purpose Grease, Part No. 99857-97. Turn handlebar full right to access the grease ﬁtting at the left side of the steering head. Connect grease gun to ﬁtting and inject grease until it exudes from top and bottom of steering head. See Figure 2-86.

At every 25,000 mile (40,000 km) service interval, check the swing-by following the CHECKING procedure below.

At every 50,000 mile (80,000 km) service interval, disassemble the steering head and inspect the bearings for brinelling, scoring, or other damage. Replace and/or repack the bearings as required.

CHECKING

Figure 2-86. Steering Head Bearing Grease Fitting

1. Using an hydraulic center stand on a level surface, raise the vehicle so that the front and rear tires are the same distance from the ﬂoor.

2. Verify that motorcycle is in stock conﬁguration. Remove all non-factory accessories, since they can inﬂuence front end swing momentum (and lead to improper adjustment).

3. Turn the front wheel until contact is made with the left fork stop and then let go. The wheel should swing right, left, then right and stop. The wheel need not stop near the center or straight-forward position, but it must move to the right making a partial third swing. See frame C of

Figure 2-87.

4. To correct a swing pattern that is too short or too long, see ADJUSTMENT below.

ADJUSTMENT

1. On FLHT/C/U models, remove outer fairing and radio (storage box on FLHT). On FLHR/C/S, remove headlamp nacelle. On FLTR models, remove the instrument bezel.

2. Loosen the pinch bolts on the lower fork bracket and slide the rubber fork stops up slightly on the fork tubes. This will prevent any binding of the front end when the adjustment is made. See Figure 2-69.

3. Bend tab on lock plate away from ﬂat of fork stem nut. Loosen the fork stem nut. See Figure 2-88.

4. Fashion a bearing adjuster tool using a drill rod 16 inches long. See lower frame of Figure 2-89.

ABCD

Steering head is set up too tight. The wheel stops in its ﬁ swing.

f1475x2x

Steering head is still set up too

rst

tight. The wheel stops in its

swing. A steering head

second that is too tight can interfere with the vehicle’s ability to absorb a weave.

Steering head adjustment is OK. The wheel need not stop near the center, but it must move to the right making a partial third swing.

CORRECT

Figure 2-87. Check Steering Head Bearing Swing-By

Steering head is set up too loose. The wheel begins its fourth swing. A steering head that is too loose can interfere with the vehicle’s ability to absorb a wobble.

2004 Touring: Chassis 2-71

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f1907x2x

Fork Stem

Nut

Lock Plate

Figure 2-88. Fork Stem Nut

To decrease the number of swings, stand on the left side of the vehicle and insert the rod to engage the notches of the bearing adjuster (star) nut under the fork bracket. Push forward to rotate the nut cloc

kwise.

NOTE

Tu r ning the bearing adjuster nut as little as one notch will make a noticeable difference in the swing pattern.

To increase the number of swings, stand on the r

ight side of the vehicle and insert the rod to engage the notches of the bearing adjuster nut. Push forward to rotate the nut countercloc

kwise.

5. Tighten the fork stem nut to 60-80 ft-lbs (81-109 Nm). The tightness of the nut will affect the swing pattern.

6. Recheck the swing pattern. See step 3 under CHECK-

ING. Repeat steps 4-6 above until swing pattern is cor-

rect.

7. Tighten pinch bolts to 30-35 ft-lbs (41-48 Nm) and properly position the rubber fork stops.

8. Verify that the fork stem nut is tightened to 60-80 ft-lbs (81-109 Nm). Bend tab on lockplate against ﬂat of fork stem nut.

9. On FLHT/C/U models, install radio (storage box on FLHT) and outer fairing. On FLHR/C/S, install headlamp nacelle. On FLTR models, install the instrument bezel.

10. Recheck the swing pattern. See step 3 under CHECK-

ING. Repeat ADJUSTMENT procedure if swing pattern

is not correct.

REMOVAL

1. On FLHT/C/U models, remove the passing lamp bracket, outer fairing and radio (storage box on FLHT). On FLHR/ C, remove headlamp nacelle. On FLTR models, remove the instrument nacelle.

8257

Upper Fork Bracket

Bearing

Adjuster

Star Nut

f1792x2x

Each Rod is 1/4 Inch Diameter

NOTE

by 16 Inches Long.

5/32 Inch goes back for 1-1/4 Inches.

1/8 Inch

2 Inches

Start of

Bend

5/32 Inch

End View

FLTR

All Others

Road Glide

Figure 2-89. Fashion Steering Head Bearing

Adjustment Tool From Drill Rod

2. Remove the front wheel and fork assemblies. Remove brake line from lower fork bracket.

3. Bend tab away from ﬂat of fork stem nut. Remove nut.

4. Remove the bearing adjuster and fork stem assembly. See upper frame of Figure 2-89. Remove dust shield and bearing from top of steering head.

2-72 2004 Touring: Chassis

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1. Install Remover on Upper Race

2. Install Collet on Driver

3. Install Driver in Remover and Remove Upper Race

4. Remove Lower Race

Steering Head Bearing Race Remover

(Part No. HD-39301A)

Remover

Figure 2-90. Steering Head Bearing Race Removal Tools

INSPECTION

1. Check the bearing races in the steering head. If pitted or grooved, replace both the bearings and races.

2. Turn bearings in races. Replace the bearings if they do not move freely and smoothly. Always replace both races and bearings even if one race and bearing appears good.

Collet

Universal Driver

(Part No. HD-33416)

STEERING HEAD BEARING RACE REMOVAL

To remove the upper and lower steering head bearing races, use the Steering Head Bearing Race Remover (Part No. HD39301A) with the Universal Driver (Part No. HD-33416). See

Figure 2-90.

Proceed as follows:

1. With the tapered side down, seat the two-piece remover tool on the upper bearing race leaving a gap in the middle. See Figure 2-91.

2. Install the collet on the driver.

3. Insert the driver at the bottom of the steering head tube, and while holding the remover tool on the race, center the collet in the gap. Tap the driver to remove the upper race.

4. Reverse the tool and repeat the procedure to remove the lower bearing race.

REMOVING BEARING FROM FORK STEM

1. Chisel cage retaining rollers off bearing on fork stem.

2. Turn the stem upside down while heating the inner race. Race will expand and fall free.

NOTE

Figure 2-91. Remove Upper and Lower

Steering Head Bearing Races

2004 Touring: Chassis 2-73

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ASSEMBLY

1. Pack new bearings with Harley-Davidson SPECIAL

PURPOSE GREASE, Part No. 99857-97.

2. Install dust shield on fork stem. Use a sleeve that will contact only the inner race of the new bearing, then press the bearing into place on fork stem.

3. Install new bearing races in steering head using STEERING HEAD BEARING RACE INSTALLATION TOOL, Part No. HD-39302.

INSTALLATION

1. Install the fork stem assembly into the steering head. Install the bearings and dust shield. Install the bearing adjuster nut. Snug the adjuster nut down until bearing play is taken up and the fork stem turns freely. Overtightening the nut will cause excessive bearing wear.

11WARNING1WARNING

Be sure fork stem nut adjustment is correct. An improperly adjusted nut can adversely affect handling and may lead to loss of vehicle control, which could result in death or serious injury.

2. Install upper fork bracket and fork stem nut. Tighten nut to 60-80 ft-lbs (81-109 Nm). Bend the lockplate tab against the nut ﬂat. See Figure 2-88.

3. Install fork assemblies, radio (storage box on FLHT), outer fairing and passing lamp bracket. On FLHR/C/S, install headlamp nacelle. On FLTR models, install the instrument bezel.

4. Install the front wheel and bleed the front brake. Check swing-by under CHECKING in this section.

2-74 2004 Touring: Chassis

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CAUTION

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Frame Cover

Air Valve

REAR AIR SUSPENSION 2.18

GENERAL

All models feature air-adjustable rear suspension. Air pressure may be varied to suit load conditions, riding style and personal comfort. Less initial pressure does not necessarily result in a softer ride. See the table below for the recommended air suspension pressures.

Table 2-3. Rear Air Suspension Pressures

Recommended

Shock Loading

All Models Except FLHRS - Standard Shocks

Solo rider up to 150 lbs. (68 kg), hereafter referred to as “Average”

Solo rider 150-200 lbs. (68-91 kg) 0-10 0-69

Solo rider 200-250 lbs. (91-113 kg) 5-15 35-103

Average rider with passenger up to 150 lbs. (68 kg)

Average rider with passenger up to 200 lbs. (91 kg)

Maximum GVWR (see Section 2.1 Speciﬁcations)

FLHRS Only - Low Proﬁle Shocks

Solo rider up to 160 lbs. (73 kg), hereafter referred to as “Average”

Solo rider 160-200 lbs. (73-91 kg) 0-10 0-69

Solo rider over 200 lbs. (91 kg) 5-10 35-69

Average rider with passenger up to 150 lbs. (68 kg)

Average rider with passenger over 150 lbs. (68 kg)

Maximum GVWR (see Section 2.1 Speciﬁcations)

Pressures

PSI kPa

10-15 69-103

20-25 138-172

20-35 138-241

0-5 0-35

20-30 138-207

25-35 172-241

40-50 276-345

Figure 2-92. Rear Air Suspension Air Valve

(Under Protective Cap)

Improper inﬂation of rear air suspension components also can result in a reduction of available suspension travel, reduced rider comfort and possible damage to shock absorbers.

All air components ﬁll rapidly. Use low air line pressure to avoid possible damage. A small hand or foot operated air pump is the best way to add air to suspension components.

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 50 psi (345 kPa) for FLHRS models and 35 psi (241 kPa) for all others. 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.

11WARNING1WARNING

Use a no-loss air gauge to check air pressure. Check pressure in shocks weekly if in daily use or before each trip if only used occasionally.

NOTE

An AIR SUSPENSION PUMP AND GAUGE (Part No. HD-

34633) is available at your Harley-Davidson dealer.

2004 Touring: Chassis 2-75

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Right

Shock

Air Suspension Air Valve

and Mounting Bracket

Below Left Side Frame Cover

Shock

Air Inlet Tee

Shock

Air Inlet Tube

Hex Nut

Protective

Cap

Compression

Fitting

Left

Shock

Depress collar on ﬁtting and pull out air tube. To install, insert air tube into ﬁtting until it bottoms. Gently tug on tube to verify that it is locked in place.

2-76 2004 Touring: Chassis

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Figure 2-93. Rear Air Suspension System

HOME

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Air Inlet

Tee

Valve Head

11WARNING1WARNING

Exercise caution when bleeding air from the air valve. Moisture combined with lubricant (either from shock assembly or drip oiler in the air compressor lines) may be ejected onto the rear wheel, tire and/or brake components and adversely affect traction and/or braking efﬁciency, which could result in death or serious injury.

REAR AIR SUSPENSION

Adjust the rear shock air suspension pressure by adding or removing air from the air valve located just below the frame cover on the left side of the vehicle. See Figure 2-92. Always adjust pressures with the vehicle on the jiffy stand.

REMOVAL/INSTALLATION

Remove and replace components as necessary. Check for air leaks as follows:

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

DLEBAG, REMOVAL.

2. Remove protective cap from air valve. Install the no-loss air gauge and set to correct pressure. See Tab le 2-3. Remove the gauge and wait overnight.

3. Recheck air pressure. If no leakage is observed, move to step 8. If a loss of 5-10 psi (34.5-68.9 kPa) is noted, then proceed to step 4.

4. Pressurize rear air suspension system and check for leaks as described below.

Compression Fitting

5. Spray or brush a light ﬁlm of soapy water on the compression ﬁtting at the top of each shock absorber. If no leakage is observed, move to step 6. If leakage is noted, proceed as follows:

Figure 2-94. Air Suspension Pump and Gauge

(Part No. HD-34633)

Figure 2-95. Air Valve Assembly

a. Depress pin in valve to bleed air from shocks. To

purge lines of any oil, add 3-5 psi (20.7-34.5 kPa) before releasing air.

b. Remove air tube from compression ﬁtting. Inspect

the tube end for burrs or damage. If either condition is observed, snip off the end of the tube and insert it back into the ﬁtting.

c. Pressurize rear air suspension system and check

for leaks. If leakage continues, proceed to step 5(d).

d. Remove air tube from compression ﬁtting. Remove

compression ﬁtting from shock absorber.

e. Apply PIPE SEALANT WITH TEFLON to the

threads of a new compression ﬁtting and install in

shock absorber. f. Install air tube in compression ﬁtting. g. Pressurize rear air suspension system and check

for leaks. If no leakage is observed, move to step 8.

If leakage continues, proceed to step 6.

Air Valve Assembly

6. Spray or brush a light ﬁlm of soapy water into the valve head and where the air tubes exit the air inlet tee. If leakage is not observed at either location, move to step 7. If leakage is noted, proceed as follows:

a. If leakage is at the air inlet tee, proceed to step 6(b).

If leakage is at the valve head, proceed to step 6(e).

b. Depress pin in valve to bleed air from shocks. To

purge lines of any oil, add 3-5 psi (20.7-34.5 kPa) before releasing air.

c. Remove air tubes from air inlet tee. Inspect the tube

ends for burrs or damage. If either condition is observed, snip off the end of the tube and insert it back into the ﬁtting.

d. Pressurize rear air suspension system and check

for leaks. If no leakage is observed, move to step 8. If leakage continues, proceed to step 6(e).

2004 Touring: Chassis 2-77

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e. Using a valve core tool, verify that valve core is

properly tightened. If leakage continues, proceed to step 6(f).

f. Depress pin in valve to bleed air from shocks. To

purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)

before releasing air. g. Remove hex nut from valve head. See Figure 2-93. h. Push on valve head to free air valve assembly from

mounting bracket. See Figure 2-95. i. Remove air tubes from air inlet tee. j. Insert air tubes into air inlet tee of new air valve

assembly. k. From inboard side, insert valve head through hole in

mounting bracket. Install hex nut on valve head (ﬂat

side facing inboard). Tighten nut to 40-50 in-lbs

(4.5-5.6 Nm). l. Pressurize rear air suspension system and check

for leaks. m. If no leakage is observed, move to step 8. If leakage

continues, reinstall old air valve assembly and pro-

ceed to step 7.

Air Tubes

d. Cut bulk tube to proper length. e. Insert new tubes into air inlet tee. Install opposite

end of tubes into compression ﬁttings. f. Pressurize rear air suspension system. g. Install seat. See Section 2.24 SEAT, INSTALLA-

TION.

8. Install protective cap on air valve.

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

BAG, INSTALLATION.

7. Inspect air tubes for kinks, cuts, holes, chaﬁng or other damage that may result in air leaks. If tube replacement is necessary, proceed as follows:

a. Remove seat. See Section 2.24 SEAT, REMOVAL. b. Depress pin in valve to bleed air from shocks. To

purge lines of any oil, add 3-5 psi (20.7-34.5 kPa) before releasing air.

c. Remove air tubes from air inlet tee. Remove oppo-

site end of tubes from compression ﬁttings. See Fig-

ure 2-93.

2-78 2004 Touring: Chassis

Harley Davidson Touring 2004 Service Manual sm02a

Specifications and Main Features

Frequently Asked Questions

User Manual

SPECIFICATIONS 2.1

DIMENSIONS (IN.)

WEIGHT (LBS.)

DIMENSIONS (MM)

WEIGHT (KG)

CAPACITIES (U.S.)

CAPACITIES (METRIC)

TIRE DATA

REAR WHEEL SPROCKET

TORQUE VALUES

TORQUE VALUES (CONT.’D)

VEHICLE IDENTIFICATION NUMBER (VIN) 2.2

FRONT WHEEL 2.3

GENERAL

PRELIMINARY INSPECTION

REMOVAL

DISASSEMBLY

CLEANING AND INSPECTION

ASSEMBLY

INSTALLATION

REAR WHEEL 2.4

GENERAL

PRELIMINARY INSPECTION

REMOVAL

DISASSEMBLY

CLEANING AND INSPECTION

ASSEMBLY

INSTALLATION

CHECKING RIM RUNOUT 2.5

INSPECTION

WHEEL LACING - 16 INCH RIM 2.6

GENERAL

WHEEL LACING

SPOKE TIGHTNESS

TRUING LACED WHEEL 2.7

PROCEDURE

TIRES AND TUBES 2.8

GENERAL

REMOVAL

CLEANING AND INSPECTION

INSTALLATION

Checking Tire Radial Runout

Checking Tire Lateral Runout

Wheel Balancing

VEHICLE ALIGNMENT 2.9

METHOD A

METHOD B

INSPECTION

Front Rubber Mount

Rear Swingarm Mounts

Engine Stabilizer Links

FRONT BRAKE MASTER CYLINDER 2.10

GENERAL

REMOVAL/DISASSEMBLY

CLEANING AND INSPECTION

ASSEMBLY/INSTALLATION

REAR BRAKE MASTER CYLINDER 2.11

REMOVAL

PRELIMINARY INSTRUCTIONS

BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, REMOVAL

BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, INSTALLATION

REAR BRAKE LINE, REMOVAL

REAR BRAKE LINE, INSTALLATION

INSTALLATION

FINAL INSTRUCTIONS

MASTER CYLINDER

DISASSEMBLY

CLEANING AND INSPECTION

ASSEMBLY

FRONT BRAKE CALIPER 2.12

INSPECTION

BRAKE PADS

FRONT BRAKE PAD REPLACEMENT

BRAKE LINE/HOSE INSPECTION

PAD INSTALLATION

CALIPER REMOVAL