Harley Davidson Touring 2004 Service Manual spb01a
CAUTION
1. Clutch Master Cylinder Reservoir
2. Reservoir Cover
3. Cover Gasket
4. Screws (2) @ 6-8 in-lbs (0.68-0.90 Nm)
8834
4
2
1
3
8835
2
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HYDRAULIC CLUTCH 1.1
GENERAL
The clutch is hydraulically actuated. A hand lever actuated
master cylinder creates pressure in a clutch fluid line that
activates a secondary clutch actuator mounted in the clutch
release cover. The secondary clutch actuator piston extends
and contacts a pushrod which releases the clutch.
CAUTION
D.O.T. 5 SILICONE BRAKE FLUID is used for the hydraulic clutch and is referred to as clutch fluid in this manual.
Do not use other types of fluid as they are not compatible.
CHECKING AND CORRECTING CLUTCH FLUID LEVEL
Even though a clear sight glass in the reservoir cover indicates a low clutch fluid, it is also possible to remove the cover
to verify fluid level.
Figure 1-1. Clutch Master Cylinder Reservoir (Typical)
11WARNING1WARNING
D.O.T. 5 silicone hydraulic brake fluid is used in the
hydraulic clutch. Do not use other types of fluids as they
are not compatible and could cause equipment damage.
(00204a)
11WARNING1WARNING
Do NOT allow dirt or debris to enter the clutch master cylinder reservoir. Dirt or debris in the reservoir can cause
improper operation of the clutch and equipment damage.
(00205a)
11WARNING1WARNING
Direct contact of D.O.T. 5 brake fluid with eyes can cause
eye irritation, swelling, and redness. Avoid eye contact. In
case of eye contact flush with large amounts of water and
get medical attention. Swallowing large amounts of D.O.T.
5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated
area. KEEP OUT OF REACH OF CHILDREN. (00144a)
1. Stand motorcycle upright (not leaning on jiffy stand) on a
level surface. Turn handlebars to the right if necessary,
so top of clutch master cylinder reservoir is level.
2. See Figure 1-1. Clean and remove reservoir cover.
3. Remove two clutch master cylinder screws, cover and
cover gasket.
4. See Figure 1-2. Verify fluid level in the clutch master cylinder is at FILL LEVEL mark at top of ledge on rear
inside wall of reservoir.
Figure 1-2. Fill Level (reservoir cover removed as viewed
from front of motorcycle)
Clutch fluid volume actually increases with clutch wear.
Do NOT overfill reservoir.
5. If necessary, add D.O.T. 5 SILICONE BRAKE FLUID,
(HD-99902-77) to master cylinder reservoir. Fluid level
should not exceed FILL LEVEL.
6. Carefully place cover gasket and cover on clutch master
cylinder reservoir and secure with two cover screws.
7. Tighten reservoir cover screws to 6-8
(
0.68-0.90 Nm).
in-lbs
2004 FLHTCSE: Maintenance 1-1
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ENGINE LUBRICATION 1.2
GENERAL
Your motorcycle comes equipped with Screamin’ Eagle
ENGINE LUBRICATION
SYN3 Synthetic Motorcycle Lubricant. If SYN3 is not available and addition of motor oil is required, the first choice
would be to add H-D
engine lubrication. Although H-D 360 is compatible with
SYN3, we suggest the mixture of the fluids be changed as
soon as possible.
If H-D 360 is not available, the second choice would be to add
an acceptable diesel engine oil. We again suggest the mixture of the fluids be changed as soon as possible. DO NOT
add diesel engine oil to the primary chaincase or transmission.
To switch lubricant to H-D 360, completely drain the SYN3
before filling with H-D 360. A residual amount of fluid will
remain. It is not required to flush out the residual fluid.
®
360 SAE 20W50 to the SYN3 for
1CAUTION
Prolonged or repeated contact with used motor oil may
be harmful to skin and could cause skin cancer. Promptly
wash affected areas with soap and water.
1CAUTION
If swallowed, do not induce vomiting. Contact a physician immediately. In case of contact with eyes, immediately flush with water. Contact a physician if irritation
persists.
CAUTION
Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)
Refer to Ta bl e 1-1. If it is necessary to add oil and Screamin’
®
Eagle
SYN3 Synthetic Motorcycle Lubricant is not available,
use an oil certified for diesel engines.
Acceptable diesel engine oil designations include:
• CF-4
• CG-4
• CH-4
•CI-4
The preferred viscosities for the diesel engine oils, in
descending order are:
• 20W50
• 15W40
• 10W40
At the first opportunity, see a Harley-Davidson dealer to
change back to 100 percent Harley-Davidson oil.
Table 1-1. Recommended Engine Oils
HARLEY-DAVIDSON
TYPE
Screamin’ Eagle
SYN3 Synthetic
Motorcycle Lubricant
HD Multi-grade SAE 10W40 HD 360 Below 40˚ F (4˚ C) Excellent
HD Multi-grade SAE 20W50 HD 360 Above 40˚ F (4˚ C) Good
HD Regular heavy SAE 50 HD 360 Above 60˚ F (16˚ C) Poor
HD Extra heavy SAE 60 HD 360 Above 80˚ F (27˚ C) Poor
®
VISCOSITY
SAE 20W50 HD 360 Above 40˚ F (4˚ C) Excellent
HARLEY-DAVIDSON
RATING
LOWEST AMBIENT
TEMPERATURE
COLD WEATHER STARTS
BELOW 50˚ F (10˚ C)
1-2 2004 FLHTCSE: Maintenance
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