HOME
TROUBLESHOOTING 1.1
GENERAL
The following check list of possible operating troubles and
their probable causes will be helpful in keeping your motorcycle in good operating condition. More than one of these conditions may be causing the trouble and all should be carefully
checked.
11WARNING1WARNING
The troubleshooting section of this manual is intended
solely as a guide to diagnosing problems. Carefully read
the appropriate sections of this manual before performing any work. Improper repair and/or maintenance could
result in death or serious injury.
ENGINE
Starter Motor Does Not Operate or Does Not Turn Engine Over
1. Ignition/Light Key Switch not in IGNITION position.
2. Engine Stop switch in the OFF position.
3. Discharged battery, loose or corroded connections
(solenoid chatters).
4. TSM/TSSM BAS tripped and Ignition/Light Key Switch
not cycled to OFF and then back to IGNITION.
5. Starter control circuit, relay or solenoid faulty.
6. Electric starter shaft pinion gear not engaging or overrunning clutch slipping.
Engine Turns Over But Does Not Start
1. Fuel tank empty.
2. Fuel supply valve turned to OFF.
3. Fouled spark plugs.
4. Engine flooded with gasoline as a result of over use of
enrichener.
5. Fuel valve or filter clogged.
6. Vacuum hose to automatic fuel supply valve disconnected, leaking or pinched.
7. Discharged battery, loose or broken battery terminal
connections.
8. Loose wire connection at coil, battery or plug between
ignition sensor and module.
9. Spark plug cables in bad condition and shorting, cable
connections loose, or cables connected to wrong cylinders.
10. Ignition timing incorrect due to faulty ignition coil, ignition
module or sensors (MAP, CKP and/or TSM/TSSM).
11. Engine lubricant too heavy (winter operation).
NOTE
Always disengage clutch for cold weather starts.
12. Sticking or damaged valve or push rod wrong length.
13. Primary cam sprocket spline sheared or missing spacer.
Starts Hard
1. Spark plugs in bad condition, have improper gap or are
partially fouled.
2. Spark plug cables in bad condition.
3. Battery nearly discharged.
4. Loose wire connection at one of the battery terminals,
ignition coil or plug between ignition sensor and module.
5. Carburetor controls not adjusted correctly.
6. Water or dirt in fuel system and carburetor.
7. Intake air leak.
8. Fuel tank vent hose and vapor valve plugged, or carburetor fuel line closed off and restricting fuel flow.
9. Enrichener valve inoperative.
10. Engine lubricant too heavy (winter operation).
NOTE
Always disengage clutch for cold weather starts.
11. Ignition not functioning properly (possible sensor failure).
12. Faulty ignition coil.
13. Valves sticking.
Starts But Runs Irregularly or Misses
1. Spark plugs in bad condition or partially fouled.
2. Spark plug cables in bad condition and leaking.
3. Spark plug gap too close or too wide.
4. Faulty ignition coil, module and/or sensor.
5. Battery nearly discharged.
6. Damaged wire or loose connection at battery terminals,
ignition coil, or plug between ignition sensor and module.
7. Intermittent short circuit due to damaged wire insulation.
8. Water or dirt in fuel system, carburetor or filter.
9. Fuel tank vent system plugged or carburetor vent line
closed off.
10. Carburetor controls misadjusted.
11. Damaged carburetor.
2004 Touring: Maintenance 1-1
HOME
12. Loose or dirty ignition module connector at crankcase.
13. Faulty MAP and/or CKP Sensor.
14. Incorrect valve timing.
15. Weak or broken valve springs.
16. Damaged intake or exhaust valve.
A Spark Plug Fouls Repeatedly
1. Fuel mixture too rich or enrichener left out too long.
2. Incorrect spark plug for the kind of service.
3. Piston rings badly worn or broken.
4. Valve guides or seals badly worn.
Pre-Ignition or Detonation (Knocks or Pings)
1. Fuel octane rating too low.
2. Faulty spark plugs.
3. Incorrect spark plug for the kind of service.
4. Excessive carbon deposit on piston head or in combustion chamber.
5. Ignition timing advanced due to faulty sensor inputs
(MAP, CKP).
Overheating
1. Insufficient oil supply or oil not circulating.
2. Insufficient air flow over engine.
3. Heavy carbon deposit.
4. Ignition timing retarded due to faulty MAP and/or CKP
Sensor.
5. Leaking valve.
Valve Train Noise
1. Low oil pressure caused by oil feed pump not functioning
properly or oil passages obstructed.
2. Faulty hydraulic lifters.
3. Bent push rod.
4. Incorrect push rod length.
5. Rocker arm binding on shaft.
6. Valve sticking in guide.
7. Chain tensioner spring or shoe worn.
Excessive Vibration
1. Wheels and/or tires worn or damaged.
2. Engine/transmission/motorcycle not aligned properly.
3. Primary chain badly worn or links tight as a result of
insufficient lubrication or misalignment.
4. Engine to transmission mounting bolts loose.
5. Upper engine mounting bracket loose.
6. Ignition timing incorrect/poorly tuned engine.
7. Internal engine problem.
8. Broken frame.
9. Stabilizer links worn or loose.
10. Rubber mounts loose or worn.
11. Rear fork pivot shaft nuts loose.
12. Front engine mounting bolts loose.
Check Engine Lamp Illuminates During Operation
1. Fault detected. Check for trouble codes.
LUBRICATION SYSTEM
Oil Does Not Return To Oil Pan
1. Oil pan empty.
2. Oil pump not functioning.
3. Restricted oil lines or fittings.
4. Restricted oil filter.
5. Oil pump misaligned or in poor condition.
6. O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).
Engine Uses Too Much Oil Or Smokes Excessively
1. Oil pan overfilled.
2. Restricted oil return line to pan.
3. Restricted breather operation.
4. Restricted oil filter.
5. Oil pump misaligned or in poor condition.
6. Piston rings badly worn or broken.
7. Valve guides or seals worn.
8. O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).
Engine Leaks Oil From Case, Push Rods, Hoses, Etc.
1. Loose parts.
2. Imperfect seal at gaskets, push rod cover, washers, etc.
3. Restricted oil return line to pan.
4. Restricted breather hose to air cleaner.
5. Restricted oil filter.
1-2 2004 Touring: Maintenance
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6. Oil pan overfilled.
7. Rocker housing gasket (bottom) installed upside down.
Low Oil Pressure
1. Oil pan underfilled.
2. Faulty low oil pressure switch.
3. Oil pump O-ring(s) damaged or missing.
4. Oil pressure relief valve stuck in open position.
5. Ball or clean out plug missing from cam support plate.
High Oil Pressure
1. Oil pan overfilled.
2. Oil pressure relief valve stuck in closed position.
ELECTRICAL SYSTEM
Alternator Does Not Charge
1. Module not grounded.
2. Engine ground wire loose or broken.
3. Faulty regulator-rectifier module.
4. Loose or broken wires in charging circuit.
5. Faulty stator and/or rotor.
Alternator Charge Rate Is Below Normal
1. Weak or damaged battery.
2. Loose connections.
3. Faulty regulator-rectifier module.
4. Faulty stator and/or rotor.
Speedometer Operates Erratically
3. Inlet valve and/or valve seat worn or damaged.
4. Float misadjusted.
5. Leaky or damaged float.
6. Excessive “pumping” of hand throttle grip.
7. See TROUBLESHOOTING CHART in Section 4.
TRANSMISSION
Transmission Shifts Hard
1. Clutch dragging slightly.
2. Primary chaincase overfilled with lubricant.
3. Corners worn off shifter clutch dogs.
4. Shifter return spring bent or broken.
5. Bent shifter rod.
6. Shifter forks sprung.
7. Transmission lubrication too heavy (winter operation).
Jumps Out Of Gear
1. Shifter rod improperly adjusted.
2. Shifter drum damaged.
3. Shifter engaging parts (inside transmission) badly worn
and rounded.
4. Shifter forks bent.
5. Damaged gears.
Clutch Slips
1. Clutch controls improperly adjusted.
2. Insufficient clutch spring tension.
3. Worn friction discs.
1. Contaminated speedometer sensor (remove sensor and
clean off metal particles).
2. Loose connections.
CARBURETOR
Carburetor Floods
1. Dirt or other foreign matter between valve and its seat.
2. Inlet valve sticking.
Clutch Drags Or Does Not Release
1. Clutch controls improperly adjusted.
2. Lubricant level too high in primary chaincase.
3. Primary chain badly misaligned.
4. Clutch discs warped.
5. Insufficient clutch spring tension.
Clutch Chatters
1. Friction discs or steel discs worn or warped.
2004 Touring: Maintenance 1-3
HOME
BRAKES
Brake Does Not Hold Normally
1. Master cylinder reservoir low on fluid.
2. Brake system contains air bubbles.
3. Master or wheel cylinder piston worn or parts damaged.
4. Brake pads contaminated with grease or oil.
5. Brake pads badly worn- friction material 0.04 inch (1.02
mm) thick or less.
6. Brake disc badly worn or warped.
7. Brake fades due to heat build up – brake pads dragging
or excessive braking.
8. Brake drags – insufficient brake pedal free play.
HANDLING
Irregularities
1. Improperly loaded motorcycle. Non-standard equipment
on the front end such as heavy radio receivers, extra
lighting equipment or luggage tends to cause unstable
handling.
2. Incorrect air suspension pressure.
3. Damaged tire(s) or improper front-rear tire combination.
4. Irregular or peaked front tire tread wear.
5. Incorrect tire pressure.
6. Shock absorber not functioning normally.
7. Loose wheel axle nuts. Tighten to recommended tightness.
8. Excessive wheel hub bearing play.
9. Improper vehicle alignment.
10. Steering head bearings improperly adjusted. Correct
adjustment and replace pitted or worn bearings and
races.
11. Tire and wheel unbalanced.
12. Rims and tires out-of-round or eccentric with hub.
13. Rims and tires out-of-true sideways.
14. Shock absorber improperly adjusted.
15. Worn engine stabilizer links.
16. Damaged rear engine isolation mounts.
17. Swingarm pivot shaft nut improperly tightened or assembled.
1-4 2004 Touring: Maintenance
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SHOP PRACTICES 1.2
REPAIR NOTES
General maintenance practices are given in this section. All
special tools and torque values are noted at the point of use
and all required parts or materials can be found in the appropriate PARTS CATALOG.
Safety
Safety is always the most important consideration when performing any job. Be sure you have a complete understanding
of the task to be performed. Use common sense. Use the
proper tools. Don’t just do the job – do the job safely.
Removing Parts
Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. A hoist
and adjustable lifting beam or sling are needed to remove
some parts. The lengths of chains or cables from the hoist to
the part should be equal and parallel, and should be positioned directly over the center of the part. Be sure that no
obstructions will interfere with the lifting operation. Never
leave a part suspended in mid-air.
Always use blocking or proper stands to support the part that
has been hoisted. If a part cannot be removed, verify that all
bolts and attaching hardware have been removed. Check to
see if any parts are in the way of the part being removed.
When removing hoses, wiring or tubes, always tag each part
to ensure proper installation.
Disassembly and Assembly
Always assemble or disassemble one part at a time. Do not
work on two assemblies simultaneously. Be sure to make all
necessary adjustments. Recheck your work when finished.
Be sure that everything is done.
Operate the motorcycle to perform any final check or adjustments. If all is correct, the motorcycle is ready to go back to
the customer.
Checking Torques on Fasteners with Lock Patches
To c heck the torque on a fastener that has a lock patch:
1. Set the torque wrench for the lowest setting in the specified torque range.
2. Attempt to tighten fastener to set torque. If fastener does
not move and lowest setting is satisfied (torque wrench
clicks), then the proper torque has been maintained.
REPAIR AND REPLACEMENT PROCEDURES
Hardware and Threaded Parts
Install helical thread inserts when inside threads in castings
are stripped, damaged or not capable of withstanding specified torque.
Cleaning
If you intend to reuse parts, follow good shop practice and
thoroughly clean the parts before assembly. Keep all dirt out
of parts; the unit will perform better and last longer. Seals, filters and covers are used in this motorcycle to keep out environmental dirt and dust. These items must be kept in good
condition to ensure satisfactory operation.
Clean and inspect all parts as they are removed. Be sure all
holes and passages are clean and open. After cleaning,
cover all parts with clean lint-free cloth, paper or other material. Be sure the part is clean when it is installed.
Always clean around lines or covers before they are
removed. Plug, tape or cap holes and openings to keep out
dirt, dust and debris.
Always verify cleanliness of blind holes before assembly.
Tightening screws with dirt, water or oil in the holes can
cause castings to crack or break.
Replace bolts, nuts, studs, washers, spacers and small common hardware if missing or in any way damaged. Clean up or
repair minor thread damage with a suitable tap or die.
Replace all damaged or missing lubrication fittings.
Use Teflon tape on pipe fitting threads.
Wiring, Hoses and Lines
Replace hoses, clamps, electrical wiring, electrical switches
or fuel lines if they do not meet specifications.
Instruments and Gauges
Replace broken or defective instruments and gauges.
Replace dials and glass that are so scratched or discolored
that reading is difficult.
2004 Touring: Maintenance 1-5
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Bearings
Anti-friction bearings must be handled in a special way. To
keep out dirt and abrasives, cover the bearings as soon as
they are removed from the package.
Wash bearings in a non-flammable cleaning solution. Knock
out packed lubricant inside by tapping the bearing against a
wooden block. Wash bearings again. Cover bearings with
clean material after setting them down to dry. Never use compressed air to dry bearings.
Coat bearings with clean oil. Wrap bearings in clean paper.
Be sure that the chamfered side of the bearing always faces
the shoulder (when bearings installed against shoulders).
Lubricate bearings and all metal contact surfaces before
pressing into place. Only apply pressure on the part of the
bearing that makes direct contact with the mating part.
Always use the proper tools and fixtures for removing and
installing bearings.
Bearings do not usually need to be removed. Only remove
bearings if necessary.
Bushings
Do not remove a bushing unless damaged, excessively worn
or loose in its bore. Press out bushings that must be
replaced.
When pressing or driving bushings, be sure to apply pressure in line with the bushing bore. Use a bearing/bushing
driver or a bar with a smooth, flat end. Never use a hammer
to drive bushings.
Inspect the bushing and the mated part for oil holes. Be sure
all oil holes are properly aligned.
Seals should not be removed unless necessary. Only remove
seals if required to gain access to other parts or if seal damage or wear dictates replacement.
Leaking oil or grease usually means that a seal is damaged.
Replace leaking seals to prevent overheated bearings.
Always discard seals after removal. Do not use the same
seal twice.
O-Rings (Preformed Packings)
Always discard O-rings after removal. Replace with new Orings. To prevent leaks, lubricate the O-rings before installation. Apply the same type of lubricant as that being sealed.
Be sure that all gasket, O-ring and seal mating surfaces are
thoroughly clean before installation.
Gears
Always check gears for damaged or worn teeth.
Remove burrs and rough spots with a honing stone or crocus
cloth before installation. Lubricate mating surfaces before
pressing gears on shafts.
Shafts
If a shaft does not come out easily, check that all nuts, bolts
or retaining rings have been removed. Check to see if other
parts are in the way before using force.
Shafts fitted to tapered splines should be very tight. If shafts
are not tight, disassemble and inspect tapered splines. Discard parts that are worn. Be sure tapered splines are clean,
dry and free of burrs before putting them in place. Press mating parts together tightly.
Clean all rust from the machined surfaces of new parts.
Gaskets
Always discard gaskets after removal. Replace with new gaskets. Never use the same gasket twice (unless instructed
otherwise). Be sure that gasket holes match up with holes in
the mating part.
If a gasket must be made, be sure to cut holes that match up
with the mating part. Serious damage can occur if any flange
holes are blocked by the gasket. Use material that is the right
type and thickness.
Lip Type Seals
Lip seals are used to seal oil or grease and are usually
installed with the sealing lip facing the contained lubricant.
Seal orientation, however, may vary under different applications.
Part Replacement
Always replace worn or damaged parts with new parts.
CLEANING
Part Protection
Before cleaning, protect rubber parts (such as hoses, boots
and electrical insulation) from cleaning solutions. Use a
grease-proof barrier material. Remove the rubber part if it
cannot be properly protected.
Cleaning Process
Any cleaning method may be used as long as it does not
result in parts damage. Thorough cleaning is necessary for
proper parts inspection. Strip rusted paint areas to bare
metal before repainting.
1-6 2004 Touring: Maintenance
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Rust or Corrosion Removal
Remove rust and corrosion with a wire brush, abrasive cloth,
sand blasting, vapor blasting or rust remover. Use buffing
crocus cloth on highly polished parts that are rusted.
Bearings
Remove shields and seals from bearings before cleaning.
Clean bearings with permanent shields and seals in solution.
Clean open bearings by soaking them in a petroleum cleaning solution. Never use a solution that contains chlorine.
Let bearings stand and dry. Do not dry using compressed air.
Do not spin bearings while they are drying.
2004 Touring: Maintenance 1-7
HOME
TOOL SAFETY 1.3
AIR TOOLS
●
Always use approved eye protection equipment when
performing any task using air-operated tools.
●
On all power tools, use only recommended accessories
with proper capacity ratings.
●
Do not exceed air pressure ratings of any power tools.
●
Bits should be placed against work surface before air
hammers are operated.
●
Disconnect the air supply line to an air hammer before
attaching a bit.
●
Never point an air tool at yourself or another person.
Protect bystanders with approved eye protection.
●
WRENCHES
Never use an extension on a wrench handle.
●
●
If possible, always pull on a wrench handle and adjust
your stance to prevent a fall if something lets go.
●
Never cock a wrench.
Never use a hammer on any wrench other than a Strik-
●
ing Face wrench.
Discard any wrench with broken or battered points.
●
Never use a pipe wrench to bend, raise, or lift a pipe.
●
PUNCHES/CHISELS
Never use a punch or chisel with a chipped or mush-
●
roomed end; dress mushroomed chisels and punches
with a file.
Hold a chisel or a punch with a tool holder if possible.
●
When using a chisel on a small piece, clamp the piece
●
firmly in a vise, and chip toward the stationary jaw.
●
Wear approved eye protection when using these tools.
Protect bystanders with approved eye protection.
●
SCREWDRIVERS
●
Don’t use a screwdriver for prying, punching, chiseling,
scoring, or scraping.
Use the right type of screwdriver for the job; match the
●
tip to the fastener.
●
Don’t interchange POZIDRIV®, PHILLIPS®, or REED
AND PRINCE screwdrivers.
Screwdriver handles are not intended to act as insula-
●
tion; don’t use on live electrical circuits.
●
Don’t use a screwdriver with rounded edges because it
will slip – redress with a file.
PLIERS/CUTTERS/PRYBARS
●
Plastic or vinyl covered pliers handles are not intended
to act as insulation; don’t use on live electrical circuits.
●
Don’t use pliers or cutters for cutting hardened wire
unless they were designed for that purpose.
●
Always cut at right angles.
●
Don’t use any prybar as a chisel, punch, or hammer.
HAMMERS
Never strike one hammer against a hardened object,
●
such as another hammer.
Always grasp a hammer handle firmly, close to the end.
●
●
Strike the object with the full face of the hammer.
●
Never work with a hammer which has a loose head.
Discard hammer if face is chipped or mushroomed.
●
Wear approved eye protection when using striking tools.
●
●
Protect bystanders with approved eye protection.
RATCHETS AND HANDLES
●
Periodically clean and lubricate ratchet mechanisms with
a light grade oil. Do not replace parts individually; ratchets should be rebuilt with the entire contents of service
kit.
●
Never hammer or put a pipe extension on a ratchet or
handle for added leverage.
Always support the ratchet head when using socket
●
extensions, but do not put your hand on the head or you
may interfere with the action of its reversing mechanism.
●
When breaking loose a fastener, apply a small amount
of pressure as a test to be sure the ratchet’s gear wheel
is engaged with the pawl.
SOCKETS
●
Never use hand sockets on power or impact wrenches.
Select the right size socket for the job.
●
Never cock any wrench or socket.
●
1-8 2004 Touring: Maintenance
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Select only impact sockets for use with air or electric
●
impact wrenches.
Replace sockets showing cracks or wear.
●
Keep sockets clean.
●
Always use approved eye protection when using power
●
or impact sockets.
STORAGE UNITS
Don’t open more than one loaded drawer at a time.
●
Close each drawer before opening up another.
●
Close lids and lock drawers and doors before moving
storage units.
●
Don’t pull on a tool cabinet; push it in front of you.
●
Set the brakes on the locking casters after the cabinet
has been rolled to your work.
2004 Touring: Maintenance 1-9
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NOTES
1-10 2004 Touring: Maintenance
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SCHEDULED MAINTENANCE TABLE 1.4
The scheduled maintenance table beginning on this page
lists the maintenance requirements for Touring models. If you
are familiar with the procedures, just reference the table for
the recommended maintenance interval as well as the
required specifications. On the other hand, if more information is needed, turn to page 14 for the start of more detailed
service procedures. For your added convenience, the adjacent chart lists the part numbers of required lubricants.
SCHEDULED MAINTENANCE TABLE
1
1
2
1
5
0
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
mi
mi
mi
mi
Service
Operation
km
1
1
8
6
6
0
0
0
0
0
0
0
0
km
km
km
mi
2
3
4
2
0
0
0
0
0
0
km
Tr ansmission Lubricant
2
5
0
0
0
mi
mi
4
0
0
0
0
km
km
Lubricant
Engine Oil See Ta ble 1-1.
Hydraulic Fork Oil, Type “E” 99884-80 (16 oz.)
D.O.T. 5 Hydraulic Brake Fluid 99902-77 (12 oz.)
Quart 99892-84
Semi-Synthetic
Primary Chaincase
Lubricant
Clutch and Throttle Cable Lubricant
Steering Head Bearing Lubricant
Electrical Contact Grease 99861-90
3
3
0
5
0
0
0
0
0
0
mi
4
5
8
6
0
0
0
0
0
0
km
Case of Quarts 98853-96
Gallon 99891-84
Case of Gallons 98852-96
Quart 99887-84
Gallon 99886-84
4
4
5
0
5
0
0
0
0
0
0
0
0
0
0
mi
mi
mi
6
7
8
4
2
0
0
0
0
0
0
0
0
0
0
km
km
km
Part Number
94968-85TV
Special Purpose Grease
99857-97 (cartridge)
Super Oil
Service
Data
Battery
Engine Oil
Engine
Oil Filter
R
– Replace or changeI – Inspect (adjust, clean or replace as required)
X
– Perform
I
IIIIIIIIII
R
RRRRRRRRRR
R
RRRRRRRRRR
T
– Tighten to proper torque
1-11 2004 Touring: Maintenance
Check condition and
clean connections.
Oil level
Separate HOT and
COLD checks per
procedure.
Oil capacity
4 qt. (3.8 L) per
chart in procedure.
Hand tighten
1/2-3/4 turn after
gasket contact.
L
– Lubricate (with specified lubricant)
D
– Disassemble (lube and inspect as required)
HOME
Service
Operation
Primary Chain
Tension
Primary Chain
Lubricant
mi
km
R
1
1
2
2
3
3
4
1
5
0
5
0
5
0
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
mi
mi
mi
mi
mi
mi
mi
mi
1
2
3
4
4
5
6
1
8
6
4
2
0
8
6
4
6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
km
km
km
km
km
km
km
km
IIIIIIIIII
I
RRRRRRRRRR
mi
km
4
5
5
0
0
0
0
0
0
0
mi
7
8
2
0
0
0
0
0
0
0
km
Service
Data
Deflection
Cold: 5/8-7/8 in.
(15.9-22.2 mm)
Hot: 3/8-5/8 in.
(9.5-15.9 mm)
Lubricant capacity
32 oz (946 mL)
Part No.’s
99887-84 (qt)
99886-84 (gal)
Clutch
Adjustment
Tr ansmission
Lubricant
Tire Condition
and Pressure
XL
XL XL XL XL XL XL XL XL XL XL
R
RRRRRRRRRR
I
IIIIIIIIII
Free play at
adjuster screw
1/2-1 turn
Free play at hand
lever
1/16-1/8 in.
(1.6-3.2 mm)
Lubricant level
Dipstick at FULL
with motorcycle
level and filler plug
resting on threads.
Lubricant capacity
20-24 oz (590-710
mL) Part No.’s
99892-84 (qt),
99891-84 (gal)
Tr ansmission drain
plug torque
14-21 ft-lbs
(19-28 Nm).
Filler plug torque
25-75
in-lbs
(2.8-8.5 Nm)
See Ta bl e 1-3.
Wheel Spokes
R
– Replace or changeI – Inspect (adjust, clean or replace as required)
X
– Perform
I I I I
I
T
– Tighten to proper torque
1-12 2004 Touring: Maintenance
Spoke nipple
torque
40-50
in-lbs
(4.5-5.6 Nm)
L
– Lubricate (with specified lubricant)
D
– Disassemble (lube and inspect as required)
HOME
Service
Operation
Steering
Head Bearings
mi
km
L
1
1
2
2
3
3
4
4
5
1
5
0
5
0
5
0
5
0
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
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0
mi
mi
mi
mi
mi
mi
mi
mi
mi
mi
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3
4
4
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6
7
8
1
8
6
4
2
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8
6
4
2
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0
0
0
0
0
0
0
0
0
0
0
0
0
0
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0
0
0
0
0
0
0
0
0
0
0
km
km
km
km
km
km
km
km
km
km
Service
Data
Lubricate through
neck fitting with
Special
Purpose Grease
,
Part No. 99857-
L L IL L D
97 (cartridge)
For swing-by
inspection or
disassembly
instructions, see
Section 2.17.
Brake Fluid
Reservoir Level
and Condition
Brake Pad
Linings and Discs
Drive Belt
Rear Shock
Absorbers
Air Cleaner
Fuel Valve, Lines
and Fittings
Fuel Tank Filter
Enrichener Control
I
IIIIIIIIII
I
IIIIIIIIII
I
IIIIIIIIII
I
IIIIIIIIII
IIIIIIIIII
I
I
IIIIIIIIII
I
I
IIIIIIIIII
D.O.T. 5 Brake fluid
Part No.’s 9990277 (12 oz),
99901-77 (gal)
Minimum brake
pad thickness
0.04 in.
(1.02 mm)
On ground without
rider
5/16-3/8 in.
(7.9-9.5 mm) in
bottom strand
with 10 lb. (4.5
kg) upward force
See Section 2.19.
Air cleaner cover
screw torque
36-60
(4-7 Nm)
Check for leaks.
Hex fitting torque
I
15-20 ft-lbs
(20-27 Nm)
See Section 4.3.
in-lbs
R
– Replace or changeI – Inspect (adjust, clean or replace as required)
X
– Perform
T
– Tighten to proper torque
L
– Lubricate (with specified lubricant)
D
– Disassemble (inspect and repack as required)
2004 Touring: Maintenance 1-13
HOME
Service
Operation
Throttle Cables
1
0
0
0
mi
1
6
0
0
km
IL
1
1
2
2
3
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4
4
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km
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km
km
km
IL IL IL IL IL IL IL IL IL IL
5
0
0
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mi
8
0
0
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0
km
Lubricant
Part No. 9496885TV- 1/4 fl. oz.
Handlebar clamp
screw torque
60-80
(6.8-9.0 Nm)
Switch housing
screw torque
35-45
(4-5 Nm)
Service
Data
in-lbs
in-lbs
Spark Plugs
Electrical
Components
Engine Idle Speed
Critical Fastener
Torque
I IRIRIRIRIR
I
IIIIIIIIII
I
IIIIIIIIII
T
T T T T T
Stabilizer Links
and Engine
T
T T T T
Mounts
Front Fork Oil
Road Test
R
– Replace or changeI – Inspect (adjust, clean or replace as required)
X
– Perform
X
XXXXXXXXXX
T
– Tighten to proper torque
Plug type
HD-6R12
Plug gap
0.038-0.043 in.
(0.97-1.09 mm)
Plug torque
12-18 ft-lbs
(16-24 Nm)
Check for proper
operation.
Idle speed
950-1050 rpm
Verify tightness.
See Ta bl e 1-6.
See ENGINE
MOUNTS in
Section 1.5.
Fork oil (Type E)
D
Part No. 9988480 (16 oz)
-
L
– Lubricate (with specified lubricant)
D
– Disassemble (lube and inspect as required)
1-14 2004 Touring: Maintenance
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