Harley Davidson Touring 2004 Service Manual sm01b
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SCHEDULED MAINTENANCE PROCEDURES 1.5
BATTERY
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect the
battery as follows:
1. Battery top must be clean and dry. Dirt on the top of the
battery may cause the battery to self-discharge at a
faster than normal rate.
2. Inspect battery screws, clamps, and cables for breakage, loose connections and corrosion. Clean clamps.
Coat terminals with grease.
3. Inspect battery for discoloration, raised top, or warped
case which may indicate battery has been overheated or
overcharged.
4. Inspect the battery case for cracks or leaks.
NOTE
For charging information, see Section 8.10 BATTERY, BAT-
TERY CHARGING.
ENGINE OIL/ENGINE OIL FILTER
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, change the
engine oil and engine oil filter as follows:
NOTE
If the motorcycle is ridden hard, under dusty conditions, or in
cold weather, the oil and filter should be changed more often.
1. Ride vehicle until engine is at normal operating tempera-
ture.
2. Locate oil filler plug/dipstick on right side of vehicle at top
of transmission case. To remove the oil filler plug, pull
steadily while moving plug back and forth.
3. Locate oil drain plug at front left side of the oil pan.
Remove the oil drain plug and allow oil to drain completely.
4. Inspect the oil drain plug O-ring for cuts, tears or signs of
deterioration. Replace as necessary.
5. Remove the oil filter as follows:
a. Obtain the OIL FILTER WRENCH (HD-42311). The
tool allows easy removal of the oil filter without risk
of damage to the crankshaft position sensor or
cable.
b. Place the jaws of the wrench over the oil filter with
the tool oriented vertically. See Figure 1-1.
c. Using a 3/8 inch drive with a 4 inch extension, turn
wrench in a counterclockwise direction. Do not use
with air tools.
NOTE
Use OIL FILTER WRENCH (HD-44067) if HD-42311 is not
available.
Figure 1-1. Remove Engine Oil Filter
6. Clean the oil filter mount flange of any old gasket material.
7. Lubricate gasket with clean engine oil and install
new
oil
filter on filter mount. Hand tighten oil filter 1/2-3/4 turn
after gasket first contacts filter mounting surface. Do
NOT
use OIL FILTER WRENCH for oil filter installation.
NOTE
Use of the Premium 10 micron synthetic media oil filter is
highly recommended, Part No. 63798-99 (Chrome) or 6373199 (Black).
8. Install engine oil drain plug and tighten to 14-21 ft-lbs
(19-28 Nm).
9. With vehicle resting on jiffy stand, add 3-1/2 quarts (3.3
liters) engine oil as specified in Ta bl e 1-1. Use the proper
grade of oil for the lowest temperature expected before
the next oil change.
Table 1-1. Recommended Engine Oils
Harley-Davidson
Type
HD Multi-grade
HD Multi-grade
HD Regular Heavy
HD Extra Heavy
Viscosity
SAE
10W40
SAE
20W50
SAE
50
SAE
60
Harley-
Davidson
Rating
HD 360
HD 360
HD 360
HD 360
Lowest
Ambient
Temperature
Below 40˚F
(4˚C)
Above 40˚F
(4˚C)
Above 60˚F
(16˚C)
Above 80˚F
(27˚C)
Cold Weather
Starts Below
50˚F (10˚C)
Excellent
Good
Poor
Poor
2004 Touring: Maintenance 1-15
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COLD CHECK
HOT CHECK
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Figure 1-2. Engine Oil Dipstick
CAUTION
Oil level cannot be accurately measured on a cold
engine. For preride inspection, with motorcycle leaning
on jiffy stand on level ground, oil should register on dipstick between arrows when engine is cold. Do NOT add
oil to bring the level to the FULL mark on a COLD
10. Perform engine oil level
COLD CHECK
as follows:
engine.
a. With the vehicle resting on the jiffy stand on level
ground, wipe off the dipstick and insert it back into
the oil pan with the plug pushed completely into the
fill spout.
b. Remove the dipstick and note the level of the oil. Oil
level should register between the two arrows on the
dipstick. See Figure 1-2. If oil level is at or below the
lower arrow, add only enough oil to bring the level
between the two arrows on the dipstick.
11. Perform engine oil level
HOT CHECK
as follows:
a. Ride vehicle until engine is at normal operating tem-
perature.
b. With the vehicle resting on the jiffy stand on level
ground, allow engine to idle for 1-2 minutes. Turn
engine off.
c. Wipe off the dipstick and insert it back into the oil
pan with the plug pushed completely into the fill
spout.
d. Remove the dipstick and note the level of the oil.
Add only enough oil to bring the level to the FULL
mark on the dipstick. See Figure 1-2. Do not overfill.
12. Start engine and carefully check for leaks around hoses,
drain plug and oil filter.
PRIMARY CHAIN
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect the
primary chain tension and adjust if necessary.
Proceed as follows:
1. Remove seat. See Section 2.24 SEAT, REMOVAL.
11WARNING1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
2. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
3. See Figure 1-3. Using a T27 TORX drive head, remove
four screws to free the primary chain inspection cover
from the primary chaincase cover.
4. Check the primary chain tension. Push on the upper
strand to verify that it has free up and down movement
midway between the engine compensating sprocket
(front) and the clutch sprocket (rear).
Table 1-2. Primary Chain Adjustment
(Free Play)
COLD ENGINE
HOT ENGINE
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4
Inspection
Figure 1-3. Primary Chaincase Cover
Inches Millimeters
5/8-7/8 inch 15.9-22.2 mm
3/8-5/8 inch 9.5-15.9 mm
1
43
Clutch
Inspection
Cover
2
Primary
Chain
Cover
1
32
Drain Plug
5
1-16 2004 Touring: Maintenance
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CAUTION
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Lubricant
Primary
Chaincase Cover
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Top
Center
Nut
Chain Inspection
Cover Opening
Figure 1-4. Primary Chaincase Cover
5. Measure the free play to be sure that it falls within the
range specified for a hot or cold engine. See Ta bl e 1-2.
6. If the chain is too tight or too loose, then adjust as follows:
a. Locate the chain tensioner assembly and loosen the
top center nut a maximum of two turns. See Figure
1-4.
b. Raise or lower the chain tensioner assembly as
necessary to obtain the specified free play.
NOTE
As chains stretch and wear, they run tighter at one spot than
another. Always adjust the free play at the tightest spot in the
chain. Replace the primary chain if it is worn to the point
where it cannot be properly adjusted.
PRIMARY CHAIN LUBRICANT
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, replace the
primary chain lubricant as follows:
1. Using a T27 TORX drive head, remove five screws (with
captive washers) to free clutch inspection cover from primary chaincase cover.
2. Remove magnetic drain plug at bottom of primary chaincase cover. Drain lubricant into suitable container. See
Figure 1-3.
3. Clean drain plug. If plug has accumulated a lot of debris,
inspect the condition of chaincase components.
4. Inspect drain plug O-ring for cuts, tears or signs of deterioration. Replace as necessary.
5. Install drain plug back into primary chaincase cover.
Tighten plug to 36-60
6. Pour 32 ounces (946 ml) of Harley-Davidson PRIMARY
CHAINCASE LUBRICANT through the clutch inspection
cover opening, Part No. 99887-84 (quart) or Part No.
99886-84 (gallon). See Figure 1-5.
Do not overfill the primary chaincase with lubricant.
Overfilling may cause rough clutch engagement, incomplete disengagement, clutch drag and/or difficulty in
finding neutral at engine idle.
7. Remove quad ring from groove in primary chaincase
cover. Wipe all lubricant from the quad ring and inspect
for cuts, tears or signs of deterioration. Replace as necessary.
in-lbs
(4.1-6.8 Nm).
CAUTION
Always keep the primary chain properly adjusted. Allowing the chain to run too tight or too loose will result in
excessive chain and sprocket wear.
c. Tighten the top center nut of the chain tensioner
assembly to 21-29 ft-lbs (29-39 Nm).
7. Align holes in
new
gasket with holes in the primary
chaincase cover. Using a T27 TORX drive head, install
four screws to secure primary chain inspection cover to
primary chaincase cover. Alternately tighten screws to
84-108
in-lbs
(10-12 Nm) in a crosswise pattern. See
Figure 1-3.
8. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96
in-lbs
(6.8-10.9 Nm).
9. Install seat. See Section 2.24 SEAT, INSTALLATION.
Figure 1-5. Fill Primary Chaincase With Lubricant
2004 Touring: Maintenance 1-17
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Rubber
Boot
Figure 1-6. Clutch Cable Adjuster Mechanism
Clutch
Cable
Ferrule
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Figure 1-7. Adjust Clutch Free Play
Jam
Nut
Cable
Adjuster
Adjust for 1/16-1/8 inch
(1.6-3.2 mm) gap
between ferrule
and bracket
Clutch Lever
Bracket
Cable
End
CLUTCH ADJUSTMENT
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, adjust the
clutch as follows:
CAUTION
Perform the clutch adjustment with the motorcycle at
room temperature. The clearance at the adjuster screw
will increase as the powertrain temperature increases. If
adjuster screw is adjusted while the powertrain is hot,
clearance at push rod bearing could be insufficient with
powertrain cold and clutch slippage could occur.
NOTE
Perform adjustment procedure whenever clutch components
are replaced during normal servicing. Repeat adjustment
after 500 miles (800 km) of use.
1. Stand vehicle upright and level.
2. Using a T27 TORX drive head, remove five screws (with
captive washers) to free clutch inspection cover from primary chaincase cover.
3. See Figure 1-6. Slide rubber boot off cable adjuster.
Holding cable adjuster with 1/2 inch wrench, loosen jam
nut using a 9/16 inch wrench. Back jam nut away from
cable adjuster. Move adjuster toward jam nut to introduce a large amount of free play at hand lever.
4. See Figure 1-8. Loosen locknut on clutch adjuster screw.
To take up all free play in push rods, turn screw inward
(clockwise) until lightly seated.
8. Swab all lubricant from the quad ring groove. Install
quad ring in primary chaincase cover with the nubs contacting the ring groove walls.
NOTE
If lubricant is not thoroughly removed from both the quad ring
and groove, compression of the ring during installation of the
clutch inspection cover can cause lubricant to be squeezed
to the outboard side of the ring groove, resulting in some
temporary weepage around the inspection cover.
9. Using a T27 TORX drive head, install five screws (with
captive washers) to secure clutch inspection cover to the
primary chaincase cover. Alternately tighten screws to
84-108
in-lbs
(10-12 Nm) in the pattern shown in Figure
1-3.
11WARNING1WARNING
When adding lubricant, do not allow dirt, debris or other
contaminants to enter the primary chaincase. Exercise
caution so that lubricant does not contact rear wheel,
tire and brake components. Such contact can adversely
affect traction and may lead to loss of vehicle control,
which could result in death or serious injury.
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Clutch
Adjuster
Screw
Locknut
Figure 1-8. Clutch Assembly
1-18 2004 Touring: Maintenance
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8496
Clutch
Release
Cover
Filler
Plug
OMF50
O-Ring
5. Back out adjuster screw 1/2 to 1 turn. While holding
adjuster screw with an allen wrench, tighten locknut to
72-120
in-lbs
(8-14 Nm).
6. Squeeze clutch lever to maximum limit three times to set
ball and ramp release mechanism.
7. Turn cable adjuster away from jam nut until slack is eliminated at hand lever. Pull clutch cable ferrule away from
clutch lever bracket to check free play. Turn cable
adjuster as necessary to obtain 1/16 to 1/8 inch (1.6 -
3.2 mm) free play between end of cable ferrule and
clutch lever bracket, as shown in Figure 1-7.
8. Hold adjuster with 1/2 inch wrench. Using 9/16 inch
wrench, tighten jam nut against cable adjuster. Cover
cable adjuster mechanism with rubber boot.
9. Remove quad ring from groove in primary chaincase
cover. Wipe all lubricant from the quad ring and inspect
for cuts, tears or signs of deterioration. Replace as necessary.
10. Swab all lubricant from the quad ring groove. Install
quad ring in primary chaincase cover with the nubs contacting the ring groove walls.
11. Using a T27 TORX drive head, install five screws (with
captive washers) to secure clutch inspection cover to the
primary chaincase cover. Alternately tighten screws to
84-108
in-lbs
(10-12 Nm) in the pattern shown in Figure
1-3.
Figure 1-9. Transmission Case (Right Side)
TRANSMISSION LUBRICANT
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, replace the
transmission lubricant as follows:
1. Remove the filler plug from the clutch release cover on
the right side of the transmission case. See Figure 1-9.
Check the O-ring for tears, cuts or general deterioration.
Replace as necessary. See Figure 1-10.
2. Locate transmission drain plug on the right side of the oil
pan. Remove the magnetic plug and drain the transmission lubricant into a suitable container.
3. Remove any foreign material from the drain plug. Check
the O-ring on the drain plug for tears, cuts or general
deterioration. Replace as necessary.
4. Install the transmission lubricant drain plug and tighten
to 14-21 ft-lbs (19-28 Nm).
11WARNING1WARNING
When adding lubricant, do not allow dirt, debris or other
contaminants to enter the transmission case. Exercise
caution so that lubricant does not contact rear wheel,
tire and brake components. Such contact can adversely
affect traction and may lead to loss of vehicle control,
which could result in death or serious injury.
Figure 1-10. Transmission Lubricant Filler Plug/Dipstick
5. Fill the transmission with 20-24 oz. (590-710 ml) of
transmission lubricant or until the lubricant level on the
dipstick of the filler plug is at the F(ULL) mark with the
motorcycle in a level, upright position and the filler plug
resting on the threads.
Use only Harley-Davidson SEMI-SYNTHETIC TRANSMISSION LUBRICANT: Part No.’s 99892-84 (quart),
98853-96 (case of quarts), 99891-84 (gallon), or 9885296 (case of gallons).
6. Install the transmission filler plug/dipstick in the clutch
release cover. Tighten the plug to 25-75
Nm).
in-lbs
(2.8-8.5
TIRES
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect both
the tire condition and pressure.
1. Inspect for wear as follows:
a. Locate the arrows on the tire sidewalls. The arrows
point to location of the tread wear indicator bars.
See upper frame of Figure 1-11.
2004 Touring: Maintenance 1-19
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Sidewall
Arrow
Indicator Bar on
Tread Surface
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Figure 1-11. Tread Wear Indicator Bars
b. Immediately replace tires if any tread wear indicator
bar is on the tire tread surface, indicating that 1/32
inch (0.8 mm) or less of tire tread pattern remains.
See lower frame of Figure 1-11.
NOTE
Harley-Davidson recommends that the tires be replaced
BEFORE
surface.
2. Inspect for damage. Replace tires if:
3. Check tire pressure.
the tread wear indicator bars are on the tire tread
Cords or fabric become visible through cracked
●
sidewalls, snags or deep cuts.
Bump, bulge or split line is observed.
●
●
Puncture, deep cut or other damage is present that
is not repairable.
Table 1-3. Tire Pressure (Cold)
WHEEL SPOKES
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
spokes are loose, true the entire wheel following the procedure under Section 2.7 TRUING LACED WHEEL.
in-lbs
(4.5-5.6 Nm). If more than a few
STEERING HEAD BEARINGS
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
Part No. 99857-97
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 1-12.
At every 25,000 mile (40,000 km) service interval, check the
swing-by following the procedure under Section 2.17
STEERING HEAD BEARINGS and adjust as necessary.
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. See Section 2 for more information.
Steering
Head
. Tu rn handlebar full right to access the
Special Purpose Grease,
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DUNLOP TIRES ONLY
Solo Rider 36 2.5 36 2.5
Rider & One Passenger 36 2.5 40 2.8
FRONT REAR
PSI
BARS PSI BARS
11WARNING1WARNING
Do not inflate tires beyond the maximum inflation pressure specified on tire sidewall. Overinflation can lead to
tire failure while vehicle is in operation, which could
result in death or serious injury.
1-20 2004 Touring: Maintenance
Grease
Fitting
Figure 1-12. Steering Head Bearing Grease Fitting
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