Harley Davidson Touring 2004 Service Manual sm01a
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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
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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
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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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