HOME
f1641x3x
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
HOME
COLD CHECK
HOT CHECK
f1254b3x
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
f1210x6x
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
HOME
CAUTION
f1508b6x
Lubricant
Primary
Chaincase Cover
f1841x6x
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
HOME
f1440x6x
Rubber
Boot
Figure 1-6. Clutch Cable Adjuster Mechanism
Clutch
Cable
Ferrule
f1421x6x
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.
f1509b6x
Clutch
Adjuster
Screw
Locknut
Figure 1-8. Clutch Assembly
1-18 2004 Touring: Maintenance
HOME
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
HOME
o0250xox
Sidewall
Arrow
Indicator Bar on
Tread Surface
o0249xox
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,
f2108x2x
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
HOME
10 lbs. (4.5 kg)
of Force
f1652x6x
See Tabl e 1-4.
Transmission
Sprocket
Rear Wheel
Sprocket
Belt Tension Gauge Adapter
Part No. HD-35381-3
Belt Tension Gauge
Part No. HD-35381A
BRAKE FLUID
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect the
brake fluid condition and level. Proceed as follows:
CAUTION
To prevent dirt from entering the master cylinder reservoir, thoroughly clean the cover before removal.
1. Remove two Phillips screws from cover of master cylinder reservoir. Remove cover (with gasket).
2. Stand the vehicle upright so that the master cylinder reservoir is in a level position. Fluid level should be 1/ 8 inch
(3.2 mm) from the top. Add fluid as necessary.
NOTE
Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID,
Part No. 99902-77 (12 oz.) or Part No. 99901-77 (gallon).
3. Install cover (with gasket) on the master cylinder reservoir. Install two Phillips screws and tighten to 6-8
(0.7-0.9 Nm).
in-lbs
11WARNING1WARNING
Whenever the brake system is serviced, it should be
tested on dry, clean pavement at slow speeds before putting the motorcycle into regular service. Improperly serviced brakes can lead to an accident that could result in
death or serious injury.
DRIVE BELT
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect drive
belt for damage and proper deflection. Proceed as follows:
1. Remove left side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
2. Check deflection at the loosest spot in the belt with the
transmission in neutral and the motorcycle cold. Use
BELT TENSION GAUGE (HD-35381A), or install narro
saddle (HD-35381-3) on existing gauge, and apply 10
lbs. (4.5 kg) of force at the midpoint of the bottom belt
strand. See Figure 1-13. Belt deflection should be as follows:
Table 1-4. Belt Deflection
Orientation
On Jiffy Stand
Without Rider or Luggage
10 psi (69 kPa) in Rear Shocks
Motorcycle Upright
With Rear Wheel in the Air
If belt deflection is within specification, install left side
saddlebag. If adjustment is necessary, move to step 3.
3. Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
4. Remove right side muffler as follows:
Inches Millimeters
1/4 - 5/16 6.4 - 7.9
3/16 - 1/4 4.8 - 6.4
w
BRAKE PADS AND DISCS
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect the
brake pads and discs as follows:
Brake Pads
If brake pad friction material is worn to 0.04 inch (1.02 mm) or
less, replace the entire set of pads.
For correct and safe brake operation, brake pads must
be replaced in sets at the same time. Mismatched brake
pads could lead to an accident resulting in death or serious injury.
Brake Discs
The minimum brake disc thickness is stamped on the side of
the disc.
When checking the brake pads and discs, inspect the brake
lines and hoses for damage or leaks.
11WARNING1WARNING
Figure 1-13. Check and Adjust Belt Deflection
2004 Touring: Maintenance 1-21
HOME
RIGHT SIDELEFT SIDE
Increase
Belt
Deflection
Reduce
Belt
Deflection
Weld
Weld
Nut
Nub
8398
Figure 1-14. Move Rear Wheel Forward Until Adjuster Cams Just Contact Weld Nubs
a. Open worm drive clamps to remove heat shield
from rear header pipe in front of muffler.
b. Using a bungee cord, tie the muffler to the lower
saddlebag support rail.
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.
5. Standing on right side of vehicle, remove E-clip from
groove at end of axle. Loosen cone nut, and then snug
to 15-20 ft-lbs (20-27 Nm). See Figure 1-14.
6. If belt is too tight, move to step 7 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 1-4.
c. If belt is still too loose, repeat steps 6(a) through
6(b). If belt is now too tight, move to step 7.
7. If belt is too tight, increase belt deflection as follows:
a. Using a hydraulic center stand, raise motorcycle so
that the rear wheel is off the ground.
b. Rotate weld nut on left side of axle in a counter-
clockwise direction.
Cone
Nut
Weld
Nub
E-Clip
Adjuster
8407
Cam
c. Push wheel forward slightly so that adjuster cam
just contacts weld nub on both sides of rear swingarm. See Figure 1-14.
d. 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 ble 1-4.
e. If belt is still too tight, repeat steps 7(b) through 7(d).
If belt is now too loose, move to step 6.
8.
Holding
weld nut on left side of axle, tighten cone nut on
right side to 95-105 ft-lbs (128.8-142.4 Nm).
NOTE
If the axle moves during tightening of the cone nut, then the
the belt deflection procedure must be restarted.
9. 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 6.
10. With the flat side out, install
new
E-clip in groove on right
side of axle.
11. Install right side muffler as follows:
NOTE
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.
a. Slide
new
TORCA clamp onto free end of rear
header pipe.
1-22 2004 Touring: Maintenance
HOME
CAUTION
b. Using a bungee cord, tie muffler to lower saddlebag
support rail. Install muffler on rear header pipe.
Place TORCA clamp into position between rear
header pipe and muffler.
c. Tighten the two bolts (with lockwashers) to fasten
the muffler to the lower saddlebag support rail.
CAUTION
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
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
rear header pipe. Position clamp so that screw is on
the outboard side in the most accessible position.
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.
12. Install saddlebags. See Section 2.25 SADDLEBAG,
INSTALLATION.
REAR SHOCK ABSORBERS
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect the
rear shock absorbers for signs of leakage or damage, and
replace if necessary. For adjustment of rear air suspension
pressures, see Section 2.18 REAR AIR SUSPENSION.
AIR CLEANER
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect the
air cleaner filter element, and clean or replace as necessary.
1. Remove large allen head socket screw in center of air
cleaner cover. Remove air cleaner cover with rubber
seal. See Figure 1-15.
2. Remove three T27 TORX screws to release cover
bracket from filter element.
Never run the engine with the filter element removed.
The filter prevents dirt and dust from entering the
engine.
3. Remove filter element pulling two breather tubes from
holes on inboard side.
4. Remove gasket from sleeve on inboard side of filter element. Discard gasket.
5. Remove breather tubes from fittings on two cylinder
head breather bolts.
6. Remove two cylinder head breather bolts from backplate
using a 7/16 inch deepwell socket.
Gasket
O-Ring
Cylinder Head
Breather Bolt
Backplate
Breather
Tube
Cover
Bracket
Gasket
Filter
Element
Figure 1-15. Air Cleaner Assembly
f1650x4x
T27 Torx
Screw
2004 Touring: Maintenance 1-23
Air Cleaner
Cover
Cover Screw
HOME
7. Remove backplate from cylinder heads. On carbureted
California models, pull clean air inlet tube (to charcoal
canister) from hole on inboard side of backplate.
8. Remove two O-rings from grooves around breather bolt
holes on inboard side of backplate. Discard O-rings.
9. Remove gasket from inboard side of backplate. Discard
gasket.
10. Thoroughly clean air cleaner cover and backplate.
11. Replace the filter element if damaged or if filter media
cannot be adequately cleaned.
12. Wash the filter element and breather tubes in warm,
soapy water. To remove soot and carbon, soak element
for 30 minutes in warm water with mild detergent.
11WARNING1WARNING
Do not use gasoline or solvents to clean the filter element. Volatile or flammable cleaning agents may cause
an intake system fire, which could result in death or serious injury.
11WARNING1WARNING
Compressed air can pierce the skin and cause injury.
Never use your hand to check for leaks or to determine
air flow rates. Wear safety glasses to shield your eyes
from flying dirt and debris. Failure to comply could result
in death or serious injury.
13. Dry the filter element using low pressure compressed air
(32 psi/221 kPa maximum). Rotate the element while
moving air nozzle up and down the element interior. Do
not rap the element on a hard surface.
14. Hold the filter element up to a strong light source. The
element can be considered sufficiently clean if light is
uniformly visible through the media.
15. Inspect the breather tubes for cuts, tears, holes or signs
of deterioration. Replace as necessary. Direct compressed air through the breather tubes to verify that they
are not plugged.
16. Install
17. Aligning flat edge of gasket with molded tab, install
18. On California models, push clean air inlet tube (to char-
19. Align holes in backplate with those in cylinder heads and
20. Slide
new
O-rings in grooves around breather bolt
holes on inboard side of backplate.
new
gasket on inboard side of backplate. On California models, install gasket by aligning small holes with plastic
pins.
coal canister) into hole on inboard side of backplate.
install cylinder head breather bolts. Using a 7/16 inch
deepwell socket, alternately tighten bolts to 10-12 ft-lbs
(13.6-16.3 Nm).
new
gasket over sleeve on inboard side of filter
element. Be sure holes in gasket are aligned with those
in filter.
21. Insert breather tubes about 1/4 inch (6.4 mm) into holes
on inboard side of filter element.
22. Install breather tubes onto fittings of two cylinder head
breather bolts.
NOTE
Air cleaner mounting without installation of the breather
tubes allows crankcase vapors to be vented into the atmosphere in violation of legal emissions standards.
23. Place filter element onto backplate with the flat side
down, so that hole on inboard side of element fits over
molded boss in backplate.
24. Align holes in cover bracket with those in filter element
and start three T27 TORX screws. Stamp on cover
bracket points to downside. Alternately tighten screws to
20-40
in-lbs
(2.3-4.5 Nm) in a crosswise pattern.
25. Verify that rubber seal is properly seated around perime-
ter of air cleaner cover. Replace seal if cut, torn or shows
signs of deterioration.
26. Fit air cleaner cover into backplate. Apply a small dab of
Loctite Medium Strength Threadlocker 243 (blue) to
threads of large allen head socket screw. Install screw in
center of air cleaner cover. Tighten screw to 36-60
(4.1-6.8 Nm).
in-lbs
FUEL SYSTEM LINES AND FITTINGS
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect the
fuel system lines and fittings for leaks or damage.
FUEL TANK FILTER (CARBURETED)
At every 25,000 mile (40,000 km) service interval, remove
and inspect the fuel tank filter as follows:
11WARNING1WARNING
Gasoline is extremely flammable and highly explosive.
When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Inadequate safety
precautions could result in death or serious injury.
1. Turn the handle of the fuel valve to OFF.
11WARNING1WARNING
A small amount of gasoline may drain from the carburetor fuel inlet hose when disconnected from the fuel valve
fitting. Thoroughly wipe up any spilled fuel immediately
and dispose of rags in a suitable manner. Gasoline is
extremely flammable and highly explosive. Inadequate
safety precautions could result in death or serious
injury.
1-24 2004 Touring: Maintenance
HOME
11WARNING1WARNING
CAUTION
f1960x4x
Filter
Strainer
Carburetor
Fuel Inlet
Hose
Convoluted
Tubing
Figure 1-16. Vacuum Operated Fuel Valve
2. Using a side cutters, cut clamp and remove hose from
fuel outlet fitting at the front of the fuel valve. See Figure
1-16. Drain free end of hose into a suitable container.
3. Remove elbow of intake manifold vacuum tube from fitting on inboard side of the fuel valve.
4. Attach a length of fuel hose to the fuel outlet fitting. The
hose must be long enough to reach a suitable gasoline
container.
5. Turn the handle of the fuel valve to RES(ERVE).
6. Using the correct hose adapter, connect the Mity-Vac®
Hand Pump (HD-23738A) to the vacuum fitting.
To avoid damage to the diaphragm of the fuel valve, do
not apply a vacuum greater than 25 inches of Mercury
(Hg) to the vacuum fitting.
7. Gently apply a vacuum of 1-10 inches of Mercury (Hg) to
the vacuum fitting to get a good flow of gasoline through
the valve.
Clamp
Fuel
Outlet
Fitting
Hose
CAUTION
Jam
Nut
Gasket
Valve
Handle
Vacuum
Fitting
Atmospheric
Pressure
Port
8. When the fuel tank is completely drained, remove the
Mity-Vac® Hand Pump from the vacuum fitting.
9. Holding fuel tank adapter, turn the hex jam nut in a
clockwise direction to remove the fuel valve assembly.
10. Remove the fuel filter strainer from the valve head.
Clean or replace.
11. Remove the hex jam nut from the fuel valve.
12. Remove the gasket from the valve head. Discard the
gasket.
13. Install a
14. Install the fuel filter strainer fitting the internal tube into
the larger hole in the valve head.
15. Apply Loctite Pipe Sealant with Teflon 565 to threads of
fuel valve and fuel tank adapter.
16. With the hex side down, turn the jam nut two full turns in
a counterclockwise direction to thread onto fuel tank
adapter.
17. Insert fuel filter strainer into fuel tank. Holding the hex
jam nut to prevent rotation, turn the fuel valve two full
turns in a clockwise direction to thread onto hex jam nut.
Do not thread fuel valve onto hex jam nut more than two
turns or nut may “bottom” on valve, a condition which
may result in a gasoline leak. Any gasoline leak is a
potential fire hazard that could result in death or serious
injury.
18. Holding the fuel valve to prevent rotation, turn the hex
jam nut in a counterclockwise direction until snug.
Tighten the hex jam nut to 15-20 ft-lbs (20.3-27.1 Nm).
Do not allow dirt or fluids to get into the vacuum tube
that connects the fuel valve to the intake manifold. Contaminants can block the vacuum signal which could
cause the fuel valve to malfunction.
19. Connect elbow of intake manifold vacuum tube to fitting
on inboard side of the fuel valve.
20. Slide
hose. Install hose onto fuel outlet fitting at front of fuel
valve. Crimp clamp using HOSE CLAMP PLIERS (HD97087-65B).
21. Turn the handle of the fuel valve to OFF and fill the fuel
tank. Carefully inspect for leaks at fitting.
22. Turn the valve handle to ON and start engine. No priming or special procedures are required to start fuel flow.
Carefully inspect for leaks at fitting.
23. Stop engine and return the valve to the OFF position.
new
gasket on the valve head.
new
clamp onto free end of carburetor fuel inlet
2004 Touring: Maintenance 1-25
HOME
f1438x4x
Enrichener
Knob
Knurled
Nut
Mounting
Bracket
Figure 1-17. Enrichener Control
Flat
Lockwasher
Hex
Nut
Enrichener
Cable
ENRICHENER CONTROL
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect the
enrichener control as follows:
The fuel enrichener knob should open, remain open and then
close without binding. The knurled plastic nut next to the
enrichener knob controls the ease at which the cable slides
within the conduit.
f1225x2x
Cardboard
Figure 1-18. Install Cardboard Insert
Ferrule
5/32 Inch
(4.0 mm)
Insert
Notch
Groove
If adjustment is needed, proceed as follows:
1. See Figure 1-17. Loosen hex nut at backside of mounting bracket.
2. Move cable assembly free of slot in mounting bracket.
3. Hold cable assembly at flat with adjustable wrench.
Hand turn knurled nut counterclockwise to reduce sliding
resistance until knob slides inward unaided.
4. Turn knurled nut clockwise to increase sliding resistance
until knob remains fully out without holding and then
closes with relative ease.
5. Slide enrichener cable into slot of mounting bracket.
With external tooth lockwasher and hex nut positioned
on the inboard side of the mounting bracket, tighten hex
nut to 20-35
Do not lubricate the cable or inside of conduit. The cable
must have sliding resistance to work properly.
in-lbs
(2.3-4.0 Nm).
CAUTION
THROTTLE CABLES
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect and
lubricate the throttle and clutch cables as follows:
Idle
Cable
f1474x2x
Figure 1-19. Remove Throttle/Idle Cables
Throttle
Grip
Throttle
Cable
Lubrication
CAUTION
Do not remove the switch housing 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 an ordinary cable strap if the cardboard
insert is not available.
1. Place the cardboard insert between the brake lever and
lever bracket. See Figure 1-18.
1-26 2004 Touring: Maintenance
HOME
f1376b2x
Throttle Control
Grip
Jam Nut
Throttle Cable
Adjuster
Idle Cable
Adjuster
Tension
Adjuster
Screw
Insert
Lubricant
Here
7958
Figure 1-20. Lubricate Throttle/Idle Cables
2. Using a T25 TORX drive head, remove the upper and
lower switch housing screws.
3. Using a T27 TORX drive head, loosen the upper screw
securing the handlebar clamp to the master cylinder
housing. Remove the lower clamp screw with flat
washer.
4. Remove the brass ferrules from the notches on the
inboard side of the throttle control grip. Remove the ferrules from the cable end fittings. See Figure 1-19.
NOTE
On non cruise equipped models, remove the friction shoe
from the end of the tension adjuster screw. The friction shoe
is a loose fit and may fall out or become dislodged if the lower
switch housing is turned upside down or shaken.
5. Remove the throttle control grip from the end of the han-
dlebar.
6. Move upper switch housing to the side in order to access
lower housing.
9. Apply a light coating of graphite to the handlebar.
10. Slide the throttle control grip over the end of the right
handlebar until it bottoms against the closed end. Rotate
the grip so that the ferrule notches are at the top. To prevent binding, pull the grip back about 1/8 inch (3.2 mm).
11. Position the lower switch housing beneath the throttle
control grip. Install the brass ferrules onto the cables so
that the end fittings seat in the ferrule recess. Seat the
ferrules in their respective notches on the throttle control
grip. Verify that the cables are captured in the grooves
molded into the grip. See Figure 1-19.
12. Position the upper switch housing over the handlebar
and lower switch housing. Verify that the wire harness
conduit runs in the depression at the bottom of the handlebar.
13. Start the upper and lower switch housing screws, but do
not tighten.
14. 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.
15. Align the holes in the handlebar clamp with those in the
master cylinder housing and start the lower screw (with
flat washer). 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.
16. Using a T25 TORX drive head, tighten the lower and
upper switch housing screws to 35-45
in-lbs
(4-5 Nm).
NOTE
Always tighten the lower switch housing screw first so that
any gap between the upper and lower housings is at the front
of the switch assembly.
1CAUTION
Lubit-8 Tufoil Chain and Cable Lube contains detergents.
Avoid contact with eyes. Keep out of reach of children.
7. Obtain tube of Lubit-8 Tufoil Chain and Cable Lube (HD
Part No. 94968-85TV- 1/4 fl. oz.). Insert pin of tube
between throttle cable and cable housing inside lower
switch housing. Squeeze tube to squirt a quantity of
lubricant into cable housing moving pin around cable
OD. See Figure 1-20.
8. Repeat the procedure squirting a quantity of lubricant
between the idle cable and cable housing.
On non cruise equipped models, install the friction shoe with
the concave side up so that the pin hole is over the point of
the adjuster screw. The friction shoe is a loose fit and may fall
out or become dislodged if the lower switch housing is turned
upside down or shaken.
NOTE
Figure 1-21. Throttle Cable Assembly - Throttle Side
(FLHR/S)
2004 Touring: Maintenance 1-27
HOME
Throttle
Cable Guide
Barrel End
Stop Plate
Figure 1-22. Throttle Cable Assembly - Carburetor Side
Throttle
Cam Stop
Throttle
Wheel
Idle
Cable Guide
Cable
Cable
Housing
Spring
f1381a2x
17. Remove the cardboard insert between the brake lever
and lever bracket.
18. Turn the Ignition/Light Key Switch to IGNITION and
apply brake lever to test operation of brake lamp.
Adjustment
NOTE
For throttle and idle cable adjustment on cruise equipped
models, see Section 8.30 CRUISE CONTROL (FLHRC,
FLTR, FLHTCU).
1. Slide rubber boot off throttle cable adjuster. See Figure
1-21. Holding cable adjuster with a 3/8 inch wrench,
loosen jam nut turning in a clockwise direction. Back jam
nut away from cable adjuster until it stops. Turn adjuster
clockwise until it contacts jam nut. Repeat procedure on
idle cable adjuster.
2. Point the front wheel straight ahead. Turn the throttle
control grip so that the throttle is wide open (fully counterclockwise) and then hold in position. Now turn the
throttle cable adjuster counterclockwise until the throttle
cam stop just touches the stop plate on the carburetor.
See Figure 1-22. Tighten jam nut against the throttle
cable adjuster and then release the throttle control grip.
Cover cable adjuster mechanism with rubber boot.
3. Turn the front wheel full right. Turn the idle cable adjuster
counterclockwise until the cable housing just touches
the spring in the longer cable guide. Work the throttle
grip to verify that the throttle cable returns to the idle
position when released. If the cable does not return to
idle, turn the adjuster clockwise slightly until the correct
response is achieved. Tighten jam nut against the idle
cable adjuster and cover cable adjuster mechanism with
rubber boot.
4. Verify that the throttle control operates freely without
binding. With the tension adjuster screw backed off, the
throttle control grip must freely return to the closed (idle)
position. The throttle control also must open and close
freely when the front wheel is turned to both the right
and left fork stops.
If the throttle grip does not return to the idle position
freely, check the adjuster screw tension. If the adjuster
screw is backed off, inspect the cables for short bends.
SPARK PLUGS
Inspect the spark plugs at every 5000 mile (8,000 km) service interval. Replace the spark plugs at every 10,000 mile
(16,000 km) service interval. Proceed as follows:
1-28 2004 Touring: Maintenance
HOME
f1381d2x
Throttle
Stop Screw
The HD-6R12 plug has a resistor element to reduce radio
interference originating in the motorcycle ignition system.
Only resistor type plugs should be used with the electronic
ignition system.
Table 1-5. Spark Plug Data
SIZE 12 mm
GAP 0.038-0.043 in. (0.97-1.09 mm)
TYPE HD-6R12 (No Substitute)
1. Remove plugs and examine immediately. The deposits
on the plug base are an indication of the plug efficiency
and are a guide to the general condition of rings, valves,
carburetor and ignition system.
a. A wet black and shiny deposit on plug base, elec-
trodes and ceramic insulator tip indicate an oil
fouled plug. The condition may be caused by worn
rings and pistons, loose valves, weak battery or
faulty ignition.
b. A dry fluffy or sooty black deposit indicates a too
rich carburetor air/fuel mixture or long periods of
engine idling.
c. An overheated plug can be identified by a light
brown, glassy deposit. This condition may be
accompanied by cracks in the insulator or by erosion of the electrodes. This condition is caused by
too lean an air/fuel mixture, a hot running engine,
valves not seating or improper ignition timing. The
glassy deposit on the spark plug is a conductor
when hot and may cause high speed misfiring. A
plug with eroded electrodes, heavy deposits or a
cracked insulator should be replaced.
d. A plug with a white, yellow or light tan to rusty brown
powdery deposit indicates balanced combustion.
The deposits may be cleaned off at regular intervals
if desired.
2. Set the spark plug gap using a wire-type gauge. Bend
the outside of the electrode so only a slight drag on the
gauge is felt when passing it between electrodes. Never
make adjustments by bending the center electrode. Set
gap on all plugs at 0.038-0.043 in. (0.97-1.09 mm)
3. Before installing spark plugs, check condition of threads
in cylinder head and on plug. If necessary soften deposits with penetrating oil and clean out with a thread
chaser.
4. Install spark plug finger tight and then torque to 12-18 ftlbs (16-24 Nm).
ELECTRICAL COMPONENTS
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect the
operation of all electrical components and switches.
Figure 1-23. Idle Speed Adjustment
ENGINE IDLE SPEED
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect the
engine idle speed as follows:
NOTES
●
The C.V. carburetor has an enrichener circuit that will
cause the engine to idle at approximately 1500 rpm with
the engine at normal operating temperature and the
enrichener knob pulled fully out.
The increase in idle speed is intended to alert the rider
●
that the engine is warmed up to normal operating temperature and the enrichener knob should be pushed all
the way in.
Continuing to use the enrichener when the engine is at
●
full operating temperature WILL CAUSE FOULED
PLUGS.
●
TECHNICIAN – Be sure the engine is warmed up to normal operating temperature and the enrichener knob is
pushed all the way in BEFORE adjusting engine idle
speed. Be aware that because there are variations in
individual components, it is possible for a properly
warmed up engine to idle at 2000 rpm with the
enrichener knob pulled PARTIALLY OUT.
1. See Figure 1-23. With the engine at normal operating
temperature and the enrichener all the way in
(enrichener valve closed) adjust the throttle stop screw
so the engine idles at 950-1050 rpm.
2004 Touring: Maintenance 1-29
HOME
NOTE
To me asure engine rpm on models without tachometers, use
a test tachometer connected to the negative ignition coil terminal.
CRITICAL FASTENERS
At the 1000 mile (1600 km) service interval, and at every
10,000 mile (16,000 km) service interval thereafter, inspect
the tightness of all critical fasteners. Replace fastener if damaged or missing.
Table 1-6. Critical Fastener Torque
Axle
Front axle nut 50-55 ft-lbs 68-75 Nm
Rear axle cone nut 95-105 ft-lbs 129-142 Nm
Brakes
Banjo Bolts 17-22 ft-lbs 23-30 Nm
Front Brake Disc Mounting
Screws
Front Brake Caliper Mounting
Bolts
Brake Caliper Pad Pins 180-200 in-lbs 20-23 Nm
Rear Brake Disc Mounting
Screws
Rear Master Cylinder Mounting
Nut
Reservoir Cover Screws 6-8 in-lbs 0.7-0.9 Nm
Front Forks
Axle Holder Nuts 132-180 in-lbs 14.9-20.3 Nm
Hand Controls
Clutch Lever/Handlebar Clamp 60-80 in-lbs 6.8-9.0 Nm
Master Cylinder/Handlebar
Clamp Screws
Upper/Lower Switch Housing
Screws
Handlebars
Lower Clamp (Riser) Bolts 30-40 ft-lbs 40.7-54.2 Nm
Pivot Shaft
Locknuts 40-45 ft-lbs 54-61 Nm
Swingarm Bracket Bolts 34-42 ft-lbs 46-57 Nm
Fastener ft/in-lbs Nm
16-24 ft-lbs 22-33 Nm
28-38 ft-lbs 38-52 Nm
30-45 ft-lbs 41-61 Nm
30-40 ft-lbs 41-54 Nm
60-80 in-lbs 6.8-9.0 Nm
35-45 in-lbs 4-5 Nm
ENGINE MOUNTS
At every 10,000 mile (16,000 km) service interval, inspect the
condition and tightness of the stabilizer links and engine
mounts. Proceed as follows:
NOTE
Raise fuel tank to access top engine stabilizer bolts and jam
nuts. For carbureted models, see Section 4.7 FUEL TANK
(CARBURETED), PARTIAL REMOVAL, FLHT/C, or FLHR/S.
For fuel injected models, see Section 9.4 FUEL TANK (FUEL
INJECTED), PARTIAL REMOVAL, FLHT/C/U/I, FLTRI, or
FLHR/C/S/I.
Top
On left side of vehicle, tighten top engine mounting
●
bracket bolts to front and rear cylinder heads to 35-40 ftlbs (48-54 Nm). See A of Figure 1-24.
●
To p stabilizer link - tighten eyelet bolt to top engine
mounting bracket to 18-22 ft-lbs (24-30 Nm). See B of
Figure 1-24.
●
Moving to right side of vehicle, tighten eyelet bolt to
frame weldment to 18-22 ft-lbs (24-30 Nm). See C of Fig-
ure 1-24.
Verify tightness of jam nuts on top stabilizer link.
●
Bottom
●
Front stabilizer link - on left side of vehicle, tighten eyelet
bolt to frame weldment to 18-22 ft-lbs (24-30 Nm). See D
of Figure 1-24.
●
Moving to right side of vehicle, tighten eyelet bolt to
block on front engine mounting bracket to 18-22 ft-lbs
(24-30 Nm). See E of Figure 1-24.
●
Verify tightness of jam nuts on front stabilizer link.
● Tighten center front engine mounting bracket to rubber
mount bolt to 15-20 ft-lbs (20-27 Nm). See F of Figure 1-
24.
● Tighten the two front engine mount to frame crossmem-
ber bolts to 15-20 ft-lbs (20-27 Nm). See G of Figure 1-
24.
● Tighten two engine to front engine mounting bracket
bolts to 33-38 ft-lbs (45-52 Nm). See H of Figure 1-24.
● Tighten four engine to transmission bolts to 30-35 ft-lbs
(41-48 Nm).
NOTE
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.
1-30 2004 Touring: Maintenance
HOME
B
C
A
LEFT SIDE RIGHT SIDE
Top Stabilizer Link and Engine Mounting Bracket
f2111x2xf2181x2x
H
Front Engine
Mounting Bracket
T
op
ATop Engine Mounting Bracket to Cylinder Heads
BEyelet to Top Engine Mounting Bracket
CEyelet to Frame Weldment
F
Front Stabilizer Link and Engine Mounting Bracket
Jam Nut
E
D
Front
Stabilizer Link
G
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 1-24. Engine Mounting Bracket Bolts
2004 Touring: Maintenance 1-31
HOME
FRONT FORK OIL
Overhaul the front fork assembly and replace the fork oil at
every 50,000 mile (80,000 km) service interval. For detailed
instructions, see Section 2.15 FRONT FORKS.
ROAD TEST
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, perform a
road test after all work is complete.
1-32 2004 Touring: Maintenance
Loading...