Harley Davidson 2005 touring models. Service repair manual — page 7

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REAR AIR SUSPENSION

2.18

GENERAL

Frame

All models feature air-adjustable rear suspension. Air pres-

Cover

sure may be varied to suit load conditions, riding style and

personal comfort. Less initial pressure does not necessarily

result in a softer ride. See the table below for the recom-

mended air suspension pressures.

Table 2-6. Rear Air Suspension Pressures

Recommended

Shock Loading

Pressures

PSI

kPa

All Models Except FLHRS - Standard Shocks

Solo rider up to 150 lbs. (68 kg),

hereafter referred to as “Average”

Solo rider 150-200 lbs. (68-91 kg)

0-10

0-69

Solo rider 200-250 lbs. (91-113 kg)

5-15

35-103

Air Valve

Average rider with passenger

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10-15

69-103

up to 150 lbs. (68 kg)

Average rider with passenger

Figure 2-93. Rear Air Suspension Air Valve

20-25

138-172

up to 200 lbs. (91 kg)

(Under Protective Cap)

Maximum GVWR

20-35

138-241

(see Section 2.1 Specifications)

FLHRS Only - Low Profile Shocks

CAUTION

Solo rider up to 160 lbs. (73 kg),

0-5

0-35

hereafter referred to as “Average”

Improper inflation of rear air suspension components

also can result in a reduction of available suspension

Solo rider 160-200 lbs. (73-91 kg)

0-10

0-69

travel, reduced rider comfort and possible damage to

Solo rider over 200 lbs. (91 kg)

5-10

35-69

shock absorbers.

Average rider with passenger

20-30

138-207

up to 150 lbs. (68 kg)

CAUTION

Average rider with passenger

25-35

172-241

All air components fill rapidly. Use low air line pressure

over 150 lbs. (68 kg)

to avoid possible damage. A small hand or foot operated

Maximum GVWR

air pump is the best way to add air to suspension com-

40-50

276-345

(see Section 2.1 Specifications)

ponents.

1WARNING

CAUTION

Use this table as a starting point in determining suit-

Use a no-loss air gauge to check air pressure. Check

able rear air suspension pressures. Do not exceed

pressure in shocks weekly if in daily use or before each

maximum GVWR when loading vehicle and do not

trip if only used occasionally.

pressurize system in excess of 50 psi (345 kPa) for

FLHRS models and 35 psi (241 kPa) for all others.

NOTE

Excessive load weight and/or air suspension pres-

sure can adversely affect handling and lead to loss

An AIR SUSPENSION PUMP AND GAUGE (Part No. HD-

of vehicle control, which could result in death or

34633) is available at your Harley-Davidson dealer.

serious injury.

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Air Suspension Air Valve

Right

and Mounting Bracket

Shock

Below Left Side Frame Cover

Shock

Air Inlet Tee

Shock

Hex Nut

Air Inlet Tube

Protective

Cap

Compression

Fitting

Left

Shock

Depress collar on fitting and pull out air tube.

To install, insert air tube into fitting until it bottoms.

Gently tug on tube to verify that it is locked in place.

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Figure 2-94. Rear Air Suspension System

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1WARNING

Air Inlet

Tee

Exercise caution when bleeding air from the air valve.

Moisture combined with lubricant (either from shock

assembly or drip oiler in the air compressor lines) may

be ejected onto the rear wheel, tire and/or brake compo-

nents and adversely affect traction and/or braking effi-

ciency, which could result in death or serious injury.

REAR AIR SUSPENSION

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Valve Head

Adjust the rear shock air suspension pressure by adding or

removing air from the air valve located just below the frame

Figure 2-96. Air Valve Assembly

cover on the left side of the vehicle. See Figure 2-93. Always

adjust pressures with the vehicle on the jiffy stand.

Depress pin in valve to bleed air from shocks. To

purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)

before releasing air.

REMOVAL/INSTALLATION

Remove air tube from compression fitting. Inspect

the tube end for burrs or damage. If either condition

Remove and replace components as necessary. Check for

is observed, snip off the end of the tube and insert it

air leaks as follows:

back into the fitting.

Remove left side saddlebag. See Section 2.25 SAD-

Pressurize rear air suspension system and check

DLEBAG, REMOVAL.

for leaks. If leakage continues, proceed to step 5(d).

Remove protective cap from air valve. Install the no-loss

Remove air tube from compression fitting. Remove

air gauge and set to correct pressure. See Table 2-6.

compression fitting from shock absorber.

Remove the gauge and wait overnight.

Recheck air pressure. If no leakage is observed, move

Apply PIPE SEALANT WITH TEFLON to the

threads of a new compression fitting and install in

to step 8. If a loss of 5-10 psi (34.5-68.9 kPa) is noted,

then proceed to step 4.

shock absorber.

Pressurize rear air suspension system and check for

Install air tube in compression fitting.

leaks as described below.

Pressurize rear air suspension system and check

for leaks. If no leakage is observed, move to step 8.

If leakage continues, proceed to step 6.

Compression Fitting

Spray or brush a light film of soapy water on the com-

Air Valve Assembly

pression fitting at the top of each shock absorber. If no

leakage is observed, move to step 6. If leakage is noted,

Spray or brush a light film of soapy water into the valve

proceed as follows:

head and where the air tubes exit the air inlet tee. If leak-

age is not observed at either location, move to step 7. If

leakage is noted, proceed as follows:

a. If leakage is at the air inlet tee, proceed to step 6(b).

If leakage is at the valve head, proceed to step 6(e).

b. Depress pin in valve to bleed air from shocks. To

purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)

before releasing air.

c. Remove air tubes from air inlet tee. Inspect the tube

ends for burrs or damage. If either condition is

observed, snip off the end of the tube and insert it

back into the fitting.

d. Pressurize rear air suspension system and check

Figure 2-95. Air Suspension Pump and Gauge

for leaks. If no leakage is observed, move to step 8.

(Part No. HD-34633)

If leakage continues, proceed to step 6(e).

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Using a valve core tool, verify that valve core is

d. Cut bulk tube to proper length.

properly tightened. If leakage continues, proceed to

e. Insert new tubes into air inlet tee. Install opposite

step 6(f).

end of tubes into compression fittings.

Depress pin in valve to bleed air from shocks. To

Pressurize rear air suspension system.

purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)

g. Install seat. See Section

2.24 SEAT, INSTALLA-

before releasing air.

TION.

Remove hex nut from valve head. See Figure 2-94.

Install protective cap on air valve.

Push on valve head to free air valve assembly from

mounting bracket. See Figure 2-96.

Install left side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

Remove air tubes from air inlet tee.

Insert air tubes into air inlet tee of new air valve

assembly.

From inboard side, insert valve head through hole in

mounting bracket. Install hex nut on valve head (flat

side facing inboard). Tighten nut to 40-50 in-lbs

(4.5-5.6 Nm).

Pressurize rear air suspension system and check

for leaks.

If no leakage is observed, move to step 8. If leakage

continues, reinstall old air valve assembly and pro-

ceed to step 7.

Air Tubes

7. Inspect air tubes for kinks, cuts, holes, chafing or other

damage that may result in air leaks. If tube replacement

is necessary, proceed as follows:

a. Remove seat. See Section 2.24 SEAT, REMOVAL.

b. Depress pin in valve to bleed air from shocks. To

purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)

before releasing air.

c. Remove air tubes from air inlet tee. Remove oppo-

site end of tubes from compression fittings. See Fig-

ure 2-94.

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NOTES

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REAR SHOCK ABSORBERS

2.19

ADJUSTMENT

Depress Collar on Fitting

and Pull Out Air Inlet Tube.

For the correct air pressure, see Section 2.18 REAR AIR

SUSPENSION.

REMOVAL

NOTE

If replacing both shock absorbers, remove and install one

shock at a time. Remove and install the second shock only

after the first shock is installed, but before the air suspension

system is pressurized.

1. Place the motorcycle on a hydraulic center stand with

the rear wheel raised off the ground.

Remove saddlebags. See Section 2.25 SADDLEBAG,

REMOVAL.

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1WARNING

Air Inlet

Tube

Frame

Exercise caution when bleeding air from the air valve.

Boss

Moisture combined with lubricant (either from shock

assembly or drip oiler in the air compressor lines) may

be ejected onto the rear wheel, tire and/or brake compo-

nents and adversely affect traction and/or braking effi-

ciency, which could result in death or serious injury.

Remove protective cap from air valve. Using a no-loss

AIR SUSPENSION PUMP AND GAUGE (Part No. HD-

34633), add 3-5 psi (20.7-34.5 kPa) to purge lines of any

oil.

Depress pin in valve to bleed air from shocks.

Depress collar on compression fitting to release air tube.

See upper frame of Figure 2-97.

Remove the upper shock mounting bolt with lockwasher

Shock

and flat washer. See lower frame of Figure 2-97.

Absorber

Remove the lower shock mounting bolt with lockwasher

and flat washer. Remove the shock absorber assembly

Compression

from the motorcycle.

Fitting

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CAUTION

Figure 2-97. Remove Air Inlet Tube and

Upper Shock Mounting Bolt (Left Side View)

Never lay the shock absorber down. Always keep the

shock absorber upright in a fully vertical position. Lay-

ing the shock absorber down with the air line removed

can cause the oil to drain out through the compression

fitting. Any loss of oil requires replacement of the shock

absorber.

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DISASSEMBLY

INSTALLATION

NOTE

CAUTION

Air shocks are not repairable. Replace the shocks if dam-

aged, worn or any sign of leakage is observed.

Never lay the shock absorber down. Always keep the

shock absorber upright in a fully vertical position. Lay-

ing the shock absorber down with the air line removed

can cause the oil to drain out through the compression

CLEANING AND INSPECTION

fitting. Any loss of oil requires replacement of the shock

absorber.

1. Examine the rubber mounting bushings for cracks or

Install lockwasher and flat washer on the lower shock

wear. Examine the shock for leaks. The unit should not

mounting bolt. Insert bolt through the shock bottom

leak and should compress slightly easier than it extends.

bushing.

Compare the action of the shock with a new one to judge

if it is worn. Replace the shock if necessary.

Apply two or three drops of Loctite Medium Strength

Threadlocker 243 (blue) to threads.

2. Clean and examine the shock mounting hardware.

Replace parts that are worn or damaged.

Start bolt into rear swingarm mount. Tighten bolt to 35-

40 ft-lbs (47-54 Nm).

Install lockwasher and flat washer on the upper shock

mounting bolt. Insert bolt through the shock upper bush-

ASSEMBLY

ing

Apply two or three drops of Loctite Medium Strength

NOTE

Threadlocker 243 (blue) to threads.

If the compression fittings were removed, apply PIPE SEAL-

Start bolt into frame boss. Tighten bolt to 33-35 ft-lbs

ANT WITH TEFLON to the threads before assembly.

(45-48 Nm).

Insert air tube into compression fitting until it bottoms.

Gently tug on tube to verify that it is locked in place.

NOTE

If replacing both shock absorbers, remove and install the

other shock at this time.

Pressurize rear air suspension system and check for

leaks. For the correct air pressure, see Section 2.18

REAR AIR SUSPENSION.

Install saddlebags. See Section

2.25 SADDLEBAG,

INSTALLATION.

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REAR SWINGARM

2.20

REMOVAL

1. Remove saddlebags. See Section 2.25 SADDLEBAG,

REMOVAL.

Rear

Rubber

Swingarm

Mount

2. Remove socket screw with lockwasher to remove pas-

senger footboard from rear swingarm bracket. Repeat

step on opposite side of vehicle.

3. Remove both mufflers as follows:

Left Side

a. Open worm drive clamps to remove heat shield

Slot

from crossover pipe in front of muffler.

b. Using a bungee cord, tie the muffler to the lower

saddlebag support rail.

Locknut

c. Loosen TORCA clamp between crossover pipe and

muffer.

Pivot

Shaft

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.

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Right Side

Figure 2-98. Remove Rear Swingarm Bracket

a. Open worm drive clamps to remove heat shield

(Left Side View)

from rear header pipe in front of muffler.

b. Using a bungee cord, tie the muffler to the lower

Remove caliper from anchor weldment on rear swing-

saddlebag support rail.

arm, and carefully hang over lower saddlebag support

c. Loosen TORCA clamp between rear header pipe

rail.

and muffer.

10.

Roll wheel forward and slip belt off sprocket. Move wheel

d. Remove two bolts (with lockwashers) to detach muf-

out from beneath rear fender.

fler from the lower saddlebag support rail.

11.

Remove belt guard from bottom of left side swingarm.

e. Remove bungee cord to release muffler from lower

First remove two rear screws, and then loosen front

saddlebag support rail.

screw. Push belt guard toward the front of the vehicle

until screw engages large end of slot, and then remove.

Place the motorcycle on a hydraulic center stand. Slide

a block of wood beneath the oil pan to support the

12.

Remove lower shock mounting bolt (with lockwasher and

flat washer) to release shock absorber from rear swing-

weight of the transmission once the pivot shaft is

removed.

arm mount. Repeat step on opposite side of vehicle.

Standing on right side of vehicle, remove E-clip from

13.

Remove two bolts (with lockwashers) to free rear swing-

groove at end of axle.

arm bracket from left side of vehicle frame. See Figure 2-

98.

Remove cone nut and adjuster cam from axle.

14.

Moving to right side of vehicle, leave rear swingarm

Using a soft mallet, gently tap end of axle towards left

bracket installed, but remove decorative chrome plug.

side to loosen. Catching external spacers on right and

left side of hub, pull axle free of wheel and rear

15.

Open two cable clips on T-studs at top of right side swin-

swingarm.

garm. Free rear brake line hose from cable clips.

Pull wheel to release brake disc from caliper. Pry inner

NOTE

and outer brake pads back for additional clearance, if

necessary. Use a putty knife with a wide thin blade to

For best results, insert blade of small screwdriver into gap at

avoid scoring or scratching the brake disc.

side of clip and gently rotate end of screwdriver to pop open.

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Ram

Socket

Extension

Anchor

Weldment

Socket

Wood

Block

Figure 2-99. Press Out Drive Side Bearing

16. Holding left side nut within rubber mount, remove right

side locknut from end of pivot shaft. Remove cup

f1967x2x

washer.

Spacer

17. Using a suitable drift, tap pivot shaft toward left side of

vehicle.

18. Moving to left side, pull pivot shaft assembly (pivot shaft,

locknut, cup washer, rubber mount and outer spacer) out

of transmission mount and left side swingarm. See

Bearing

Figure 2-103.

19. Standing at rear of vehicle, work rear swingarm free of

transmission mount and rear swingarm brackets.

20. Remove outer spacer from right side swingarm tube.

21. Remove rubber mount from behind right side swingarm

bracket.

DISASSEMBLY/ASSEMBLY

Figure 2-100. Press Spacer Into Bearing

Bearing Removal

Move rear swingarm to an hydraulic press.

4. Slide driver handle (or long socket extension) through

the brake side swingarm tube and bearing until it con-

Place swingarm on its side, so that the brake side is on

tacts driver (or large socket) placed on inboard side of

top. The brake side is easily recognized by the anchor

drive side bearing.

weldment for mounting of the brake caliper.

5. Center driver handle (or long socket extension) under

Support the swingarm with a block of wood and a large

ram and press drive side bearing from rear swingarm.

socket as shown in Figure 2-99. Verify that assembly is

6. Remove tools from rear swingarm. Turn swingarm over

square and the bearing bore is completely vertical.

and repeat steps 3-5 to press out brake side bearing.

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a. Place swingarm on its side, so that the brake side is

on top. The brake side is easily recognized by the

anchor weldment for mounting of the brake caliper.

Drive Side

Brake Side

Driver

b. With the spacer inboard, insert bearing into out-

board side of brake side swingarm tube.

c. Insert driver stamped “Brake Side” into swingarm

tube until it contacts installed bearing. Center driver

under ram and press on brake side bearing until

shoulder on tool makes contact with casting of swin-

garm. See Figure 2-102.

d. Remove tool and turn rear swingarm over. With the

spacer inboard, insert bearing into outboard side of

drive side swingarm tube.

Figure 2-101. Rear Swingarm Bearing Installer (HD-

e. Insert driver stamped “Drive Side” into swingarm

45327)

tube until it contacts installed bearing. Center driver

under ram and press on drive side bearing until it

bottoms. Shoulder on tool will not make contact

Brake Side

f1909x2x

with casting of swingarm.

Driver

Remove tool from swingarm. Remove swingarm

from hydraulic press.

Pivot Shaft Disassembly

Anchor

1. Partially install locknut on right side of pivot shaft. Install

Weldment

second locknut on right side until it contacts the first.

Holding first locknut to prevent rotation of shaft, remove

left side locknut. See Figure 2-103.

2. Remove cup washer, rubber mount and outer spacer.

3. Remove right side locknuts from pivot shaft.

Pivot Shaft Assembly

With larger OD outboard, slide outer spacer onto left

side of pivot shaft until counterbore contacts shoulder on

shaft.

Figure 2-102. Press In Brake Side Bearing

Install rubber mount with the flat side inboard toward

outer spacer.

Install cup washer with the concave side facing in toward

Bearing Installation

the rubber mount.

1. Obtain new rear swingarm bearings. Bearings and spac-

ers must be assembled before installation. Proceed as

follows:

Right Side

Locknut and

a. Obtain REAR SWINGARM BEARING INSTALLER

Cup Washer

(HD-45327). See Figure 2-101.

b. With the nose topside, center one of the drivers

under ram of hydraulic press.

c. Place bearing over nose of driver. With the collar

topside, place spacer over nose and into bearing.

Pivot

See Figure 2-100.

Spacer

Shaft

d. Apply pressure to spacer until it bottoms in bearing.

Rubber

e. Repeat step to assemble second swingarm bearing.

Mount

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2. Install assembled bearings into rear swingarm. Proceed

as follows:

Figure 2-103. Pivot Shaft Assembly

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Apply two drops of Loctite Medium Strength Thread-

Install lockwasher and flat washer on the lower shock

locker 243 (blue) to threads of left side locknut, and then

mounting bolt. Insert bolt through the shock bottom

start on shaft.

bushing. Apply two or three drops of Loctite Medium

Strength Threadlocker 243 (blue) to threads. Start bolt

Partially install locknut on right side of pivot shaft. Install

into rear swingarm mount. Tighten bolt to 35-40 ft-lbs

second locknut on right side until it contacts the first.

(47-54 Nm). Repeat step on opposite side of vehicle.

Holding second locknut to prevent rotation of shaft,

tighten left side locknut to 40-45 ft-lbs (54-61 Nm).

Install belt guard at bottom of left side swingarm. Push

belt guard toward the rear of the vehicle until front screw

Remove right side locknuts from pivot shaft.

engages small end of slot. Install two rear screws, and

then tighten front screw.

Capture rear brake line hose in two cable clips at top of

INSTALLATION

right side swingarm. Snap cable clips closed.

Place wheel in rear swingarm. Slide wheel far enough

With the slot on the outboard side between the twelve

forward to slip belt over sprocket and then slide the

and one o’clock positions, install rubber mount behind

wheel back.

rear swingarm bracket on right side of vehicle. Be sure

that index tab cast on inboard side of bracket fully

engages slot in rubber mount.

CAUTION

Place outer spacer into right side swingarm tube.

Do not bend or fold belt backward or into loops smaller

than 5 inches (127 mm) in diameter. Sharp bending can

With the belt on the inboard side of the left side swing-

arm, work the rear swingarm into position between the

weaken the belt and cause premature failure.

transmission mount and the rear swingarm brackets.

Seat caliper on anchor weldment of rear swingarm. Posi-

Use a rubber mallet and carefully tap swingarm into

tion wheel in swingarm, so that brake disc is centered

position, if necessary.

between brake pads.

The pivot shaft secures the rear swingarm and transmis-

10.

Coat the axle with Loctite ANTI-SEIZE LUBRICANT.

sion to the vehicle frame. See Figure 2-103. Install the

11.

With the larger OD on the outboard side, hold external

pivot shaft as follows:

spacer between rear swingarm and belt sprocket. Slide

axle through left side of rear swingarm, external spacer,

Coat pivot shaft with Loctite ANTI-SEIZE LUBRI-

and belt sprocket into wheel hub.

CANT.

12.

When axle emerges from hub on brake disc side of

From left side of vehicle, slide pivot shaft assembly

wheel, push axle through short external spacer, caliper

(pivot shaft, locknut, cup washer, rubber mount and

bracket and right side of rear swingarm.

outer spacer) through left side swingarm and trans-

mission mount. After exiting right side swingarm,

13.

Rotate axle so that the flat on the threaded end is top-

guide end of pivot shaft through holes in rubber

side. With the thumb down and the cam forward, install

mount and right side swingarm bracket.

adjuster cam on end of axle.

With the concave side inboard, slide cup washer

14.

Apply a thin film of ANTI-SEIZE LUBRICANT to the

onto end of pivot shaft.

inboard side of the cone nut avoiding contact with

threads. Install cone nut on axle, but finger tighten only.

Install locknut on pivot shaft. Holding left side nut on

pivot shaft, tighten locknut to 40-45 ft-lbs (54-61 Nm).

15.

Verify that adjuster cam just contacts weld nub on both

Now hold right side nut and tighten left side locknut

sides of rear swingarm. If necessary, push wheel for-

using the same torque value.

ward slightly to achieve the desired result. Snug the

cone nut to 15-20 ft-lbs (20-27 Nm). See Figure 2-104.

Carefully raise swingarm up and down slightly to

verify movement (and that assembly is not in a

16.

Check deflection at the loosest spot in the belt. Use

bind).

BELT TENSION GAUGE (HD-35381A), or install adapter

(HD-35381-3) on old style gauge, and apply 10 lbs. (4.5

Install decorative chrome plug in right side rear

kg) of force at the midpoint of the bottom belt strand.

swingarm bracket.

See Figure 2-105. Belt deflection should be as follows:

Moving to left side of vehicle, rotate the rubber

mount so that the slot is between the eleven and

Table 2-7. Belt Deflection in the Air

twelve o’clock positions. Install left side swingarm

bracket fitting index tab into rubber mount slot. See

Orientation

Inches

Millimeters

Figure 2-98.

Motorcycle Upright

Install two bolts (with lockwashers) to secure left

3/16 - 1/4

4.8

- 6.4

With Rear Wheel in the Air

side swingarm bracket to vehicle frame. Tighten

NOTE

bolts to 34-42 ft-lbs (46-57 Nm).

See Section 1.10 DRIVE BELT for belt deflection specification

with motorcycle on jiffy stand.

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LEFT SIDE

RIGHT SIDE

Increase

Reduce

Belt

Deflection

Cone

Nut

Weld

Nub

Weld

Nut

E-Clip

Nub

Adjuster

Cam

8398

8407

Figure 2-104. Move Rear Wheel Forward Until Adjuster Cams Just Contact Weld Nubs

17.

If belt is too tight, move to step

18 to increase belt

20. Recheck belt deflection to verify that it is still within spec-

deflection. If belt is too loose, reduce belt deflection as

ification.

described below:

If the belt deflection is not within specification, loosen

cone nut and then snug to 15-20 ft-lbs (20-27 Nm)

a. Rotate weld nut on left side of axle in a clockwise

before returning to step 17.

direction.

21. With the flat side out, install new E-clip in groove on right

b. Check belt deflection. Apply 10 lbs. (4.5 kg) of force

side of axle.

at the midpoint of the bottom belt strand. Belt

22. Depress rear brake pedal several times to set brake

deflection should be within the range specified in

pads to proper operating position within caliper.

Table 2-7.

c. If belt is still too loose, repeat steps 17(a) through

17(b). If belt is now too tight, move to step 18.

Transmission

Rear Wheel

Sprocket

18.

If belt is too tight, increase belt deflection as follows:

a. Rotate weld nut on left side of axle in a counter-

clockwise direction.

b. Push wheel forward slightly so that adjuster cam

just contacts weld nub on both sides of rear swing-

arm. See Figure 2-104.

10 lbs. (4.5 kg)

of Force

c. Check belt deflection. Apply 10 lbs. (4.5 kg) of force

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See Table 2-7.

at the midpoint of the bottom belt strand. Belt

deflection should be within the range specified in

Table 2-7.

Belt Tension Gauge

d. If belt is still too tight, repeat steps 18(a) through

Part No. HD-35381A

18(c). If belt is now too loose, move to step 17.

19.

Holding weld nut on left side of axle, tighten cone nut on

right side to 95-105 ft-lbs (128.8-142.4 Nm).

Belt Tension Gauge Adapter

NOTE

Part No. HD-35381-3

If the axle moves during tightening of the cone nut, then the

belt deflection procedure must be restarted.

Figure 2-105. Check and Adjust Belt Deflection

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1WARNING

Passenger

After installation of caliper and BEFORE moving motor-

Footboard

cycle, pump rear brake pedal until pistons push pads

Bracket

against the brake disc. If fluid pressure is not pumped

up, the rear brake will not be available the first time it is

used, a situation that could result in death or serious

injury.

23. Install both mufflers 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, Har-

ley-Davidson recommends that TORCA clamp assemblies be

discarded and replaced each time they are removed.

Chrome

Plug

Left Side

Rear

a. Slide new TORCA clamp onto free end of crossover

Swingarm

pipe.

Bracket

b. Using a bungee cord, tie muffler to lower saddlebag

support rail. Install muffler on crossover pipe. Place

f1787x2x

TORCA clamp into position between crossover 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.

Locknut

d. Verify that exhaust pipes are in alignment and do

not contact the vehicle frame or mounted compo-

nents.

e. Tighten the TORCA clamp to 45-60 ft-lbs (61-81

Nm).

Open worm drive clamps and install heat shield on

crossover pipe. Position clamp so that screw is on

the outboard side in the most accessible position.

Pivot

Shaft

CAUTION

Verify that the heat shields do not contact the vehicle

frame or any mounted components. Contact will cancel

L(eft) Side

the effect of the rubber isolation mounts and transmit

Casting Stamp

vibration to the rider via the vehicle frame.

g. Remove bungee cord from muffler.

f2073x2x

Right Side

a. Slide new TORCA clamp onto free end of rear

Figure 2-106. Remove Chrome Plugs and Check

header pipe.

Pivot Shaft Locknut Torque (Left Side View)

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b. Using a bungee cord, tie muffler to lower saddlebag

25. Install saddlebags. See Section

2.25 SADDLEBAG,

support rail. Install muffler on rear header pipe.

INSTALLATION.

Place TORCA clamp into position between rear

NOTE

header pipe and muffler.

At the required service interval (see Section 1.2 MAINTE-

c. Tighten the two bolts (with lockwashers) to fasten

NANCE SCHEDULE), remove the decorative chrome plugs

the muffler to the lower saddlebag support rail.

in the rear swingarm brackets and check the torque on the

pivot shaft locknuts. See Figure 2-106. Holding right side nut

CAUTION

on the pivot shaft, tighten left side locknut to 40-45 ft-lbs (54-61

Nm). Then hold left side nut and tighten right

side locknut

Verify that the exhaust pipes do not contact the vehicle

using the same torque value.

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 compo-

nents.

e. Tighten the TORCA clamp to 45-60 ft-lbs (61-81

Nm).

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.

24. Install socket screw with lockwasher to fasten passenger

footboard to rear swingarm bracket. Tighten screw to 15-

18 ft-lbs (20-24 Nm). Repeat step on opposite side of

vehicle.

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HOME

THROTTLE CABLES (NON-CRUISE)

2.21

1. Slide rubber boot off throttle cable adjuster. See Figure

ADJUSTMENT

2-107. Holding cable adjuster with a 3/8 inch wrench,

loosen jam nut turning in a clockwise direction. Back jam

NOTE

nut away from cable adjuster until it stops. Turn adjuster

For throttle and idle cable adjustment or replacement on

clockwise until it contacts jam nut. Repeat procedure on

cruise equipped models, see Section 8.30 CRUISE CON-

idle cable adjuster.

TROL (FLHRC, FLTR, FLHTCU).

2. Point the front wheel straight ahead. Turn the throttle

The throttle control must operate freely without binding. With

control grip so that the throttle is wide open (fully coun-

the tension adjuster screw backed off, the throttle control grip

terclockwise) and then hold in position. Now turn the

must freely return to the closed (idle) position. The throttle

throttle cable adjuster counter-clockwise until the throttle

control also must open and close freely when the front wheel

cam stop just touches the stop plate. See Figure 2-108.

is turned to both the right and left fork stops. If the throttle

Release the throttle control grip and then tighten the jam

grip does not return to the idle position freely, check the

nut against the throttle cable adjuster. Cover cable

adjuster screw tension. If the adjuster screw is backed off,

adjuster mechanism with rubber boot.

inspect the cables for short bends.

3. Turn the front wheel full right. Turn the idle cable adjuster

counterclockwise until the cable housing just touches

the spring in the cable guide (as seen through slot).

1WARNING

Work the throttle grip to verify that the throttle cable

Do not overtighten the tension adjuster screw. An over-

returns to the idle position when released. If the cable

tightened screw will prevent the engine from automati-

does not return to idle, turn the adjuster clockwise

cally returning to idle in an emergency situation. This

slightly until the correct response is achieved. Tighten

can lead to loss of vehicle control, which could result in

jam nut against the idle cable adjuster and cover cable

death or serious injury.

adjuster mechanism with rubber boot.

Throttle Control

Grip

Jam Nut

Tension

Adjuster

Screw

Throttle Cable

Idle Cable

Adjuster

f1376b2x

Figure 2-107. Throttle Cable Assembly - Throttle Side (FLHR)

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Throttle

Cable Guide

Idle

Cable Guide

Cable

Housing

Spring

Cable

Barrel End

Throttle

Stop Plate

Throttle

Wheel

Cam Stop

f1381a2x

Figure 2-108. Throttle Cable Assembly - Carburetor Side

REMOVAL

f1225x2x

THROTTLE SIDE

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.

5/32 Inch

(4.0 mm)

1. Place the cardboard insert between the brake lever and

Cardboard

lever bracket. See Figure 2-109.

Insert

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.

Figure 2-109. Install Cardboard Insert

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HOME

Remove the brass ferrules from the notches on the

inboard side of the throttle control grip. Remove the fer-

7961

rules from the cable end fittings.

Lower

Remove the friction shoe from the end of the tension

Switch

adjuster screw.

Housing

NOTE

The friction shoe is a loose fit and may fall out or become dis-

lodged if the lower switch housing is turned upside down or

shaken.

Throttle

Cable Insert

(Silver)

6. Remove the throttle control grip from the end of the han-

dlebar.

Idle

Cable Insert

Pull the crimped inserts at the end of the throttle and idle

(Gold)

cable housings from the lower switch housing.

For best results, use a rocking motion while pulling.

Figure 2-110. Install Throttle/Idle Cables

Place a drop of light oil on the retaining rings, if neces-

in Lower Switch Housing

sary. Remove the cables from the switch housing.

2. Inspect the cables for damage or wear. Replace the

cables if frayed, kinked or bent.

CARBURETOR/INDUCTION MODULE SIDE

3. Obtain tube of Lubit-8 Tufoil Chain and Cable Lube (HD

Part No. 94968-85TV- 1/4 fl. oz.). Insert pin of tube

Remove the air cleaner and backplate. See Section 4.5

between throttle cable and cable housing. Squirt a few

AIR CLEANER, REMOVAL.

drops of lubricant into cable housing moving pin around

Raise fuel tank to access cables in area of frame back-

cable OD. Repeat the procedure squirting a few drops

bone. For carbureted models, see Section 4.7 FUEL

between the idle cable and cable housing.

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.

INSTALLATION

Carbureted: Using a needle nose pliers, carefully pull

idle cable barrel from upper inboard hole in throttle

wheel. Pull throttle cable barrel from remaining hole.

THROTTLE SIDE

Release idle and throttle cables from guides in throttle

cable bracket. See Figure 2-108.

1. Apply a light coating of graphite to the handlebar and

inside surface of the switch housings.

Induction Module: Using a needle nose pliers, carefully

pull idle cable barrel from upper hole in throttle wheel.

2. Push the throttle and idle cables into the lower switch

Pull throttle cable barrel from lower hole. Using slots,

housing until they snap in place. See Figure 2-110. Pro-

release idle and throttle cables from guides in throttle

ceed as follows:

cable bracket. See Figure 2-112.

Note the different diameter inserts crimped into the end

Free cables from J-clamp riveted to right side of frame

of the throttle and idle cable housings.

backbone.

Push the larger diameter insert (silver) on the throttle

If present, remove screw (with flat washer) to release J-

cable housing into the larger hole in front of the tension

clamp from wellnut in right side of steering head.

adjuster screw.

Remove J-clamp from cables.

Push the smaller diameter insert (gold) on the idle cable

housing into the smaller hole at the rear of the tension

adjuster screw.

CLEANING AND INSPECTION

NOTE

To aid assembly, place a drop of light oil on the retaining

1. Clean all parts in a non-flammable cleaning solvent and

rings of the crimped inserts. Always replace the retaining

blow dry with compressed air.

rings if damaged or distorted.

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2005 Touring: Chassis

HOME

Position the brake lever/master cylinder assembly

Ferrule

Notch

Groove

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.

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.

10. 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.

Throttle

Grip

11. Remove the cardboard insert between the brake lever

and lever bracket.

12. Turn the Ignition/Light Key Switch to IGNITION and

Idle

Throttle

f1474x2x

apply brake lever to test operation of brake lamp.

Cable

Figure 2-111. Install Throttle/Idle Control Cables on

Throttle Control Grip

CARBURETOR/INDUCTION MODULE SIDE

Route the throttle and idle cables as follows:

3. With the concave side facing upward, install the friction

shoe so that the pin hole is over the point of the adjuster

FLHT/C: Route the cables downward following the brake

screw.

line to the inner fairing. Pass the cables through the

inner fairing grommet and then loop them toward the

NOTE

rear along the right side of the steering head.

The friction shoe is a loose fit and may fall out or become dis-

FLHR/C: Route the cables downward following the right

lodged if the lower switch housing is turned upside down or

handlebar to the handlebar clamp shroud. Pass the

shaken.

cables through the opening in the shroud and then loop

them toward the rear along the right side of the steering

4. Slide the throttle control grip over the end of the right

handlebar until it bottoms against the closed end. Rotate

head. Capture cables in J-clamp and then start screw

the grip so that the ferrule notches are at the top. To pre-

(with flat washer) to fasten J-clamp to wellnut in right

vent binding, pull the grip back about 1/8 inch (3.2 mm).

side of steering head. Tighten screw to 9-18 in-lbs (1.0-

2.0 Nm).

5. Position the lower switch housing beneath the throttle

control grip. Install the brass ferrules onto the cables so

Route the throttle and idle cables rearward along the

that the end fittings seat in the ferrule recess. Seat the

right side of the frame backbone. After passing through

ferrules in their respective notches on the throttle control

J-clamp riveted to frame backbone, route cables down-

grip. Verify that the cables are captured in the grooves

ward to carburetor/induction module.

molded into the grip. See Figure 2-111.

Carbureted: Install sleeve on throttle cable housing into

6. Position the upper switch housing over the handlebar

shorter cable guide in throttle cable bracket. Drawing

and lower switch housing. Verify that the wire harness

throttle cable downward, fit barrel end into lower out-

conduit runs in the depression at the bottom of the han-

board hole in throttle wheel. Install sleeve and spring on

dlebar.

idle cable housing into longer cable guide inserting bar-

7. Start the upper and lower switch housing screws, but do

rel end into upper inboard hole in throttle wheel. See

not tighten.

Figure 2-108.

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LUBRICATION

f2162x9x

Idle Cable

Guide

1. See REMOVAL, THROTTLE SIDE, in this section, steps

1-5.

Throttle Cable

Guide

2. Move upper switch housing to the side in order to access

lower housing.

1CAUTION

Lubit-8 Tufoil Chain and Cable Lube contains detergents.

Keep out of reach of children. Contact with eyes may

result in minor or moderate injury.

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 2-113.

Repeat the procedure squirting a quantity of lubricant

between the idle cable and cable housing.

Figure 2-112. Throttle Cable Assembly -

Induction Module Side

See INSTALLATION, THROTTLE SIDE, in this section,

steps 3-12.

Turn the Ignition/Light Key Switch to IGNITION and

Induction Module: Install sleeve on throttle cable hous-

apply brake lever to test operation of brake lamp.

ing into shorter cable guide at top of throttle cable

bracket. Drawing throttle cable downward, fit barrel end

into lower hole in throttle wheel. Install sleeve and spring

on idle cable housing into longer cable guide at bottom

of throttle cable bracket inserting barrel end into upper

hole in throttle wheel. See Figure 2-112.

Insert

Tighten cables as necessary to keep barrel ends from

Lubricant

Here

dislodging. Verify that cables are seated in channel of

throttle wheel. Verify operation by turning throttle grip

and observing cable action. Adjust throttle cables as

described under ADJUSTMENT.

Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER

PARTIAL REMOVAL), FLHT/C, or FLHR/S. For fuel

injected models, see Section 9.4 FUEL TANK (FUEL

7958

INJECTED), INSTALLATION

(AFTER PARTIAL

REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

Figure 2-113. Right Handlebar Lower Switch Housing

Install the air cleaner assembly. See Section 4.5 AIR

CLEANER, INSTALLATION.

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CLUTCH CABLE

2.22

ADJUSTMENT

f1140axx

Flat

Screw

Washer

See Section 6.3 CLUTCH, ADJUSTMENT.

Pivot Pin

Clutch Cable

Clutch

Lever

Handlebar

REMOVAL

Bracket

Clamp

Bushing

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

Hand Lever

MAXI-FUSE, REMOVAL.

Retaining

Ring

To access the clutch release cover assembly, remove

right side exhaust system. See Section 3.7 REMOVING

Anchor

Pin

ENGINE FROM CHASSIS, steps 3-9.

Rubber Boot

Anti-Rattle

Remove the magnetic drain plug at the bottom right side

Spring

of the oil pan and drain the transmission lubricant into a

and Screw

O-Ring

suitable container. Remove the filler plug/dipstick.

Slide rubber boot off clutch cable adjuster. Holding cable

Figure 2-115. Clutch Hand Lever Assembly

adjuster with 1/2 inch wrench, loosen jam nut using 9/16

inch wrench. Back jam nut away from cable adjuster.

Move adjuster toward jam nut to introduce free play at

Inner

hand lever. See Figure 2-114.

Retaining

Ramp

Ring

Remove retaining ring from pivot pin groove at bottom of

clutch lever bracket. Remove pivot pin.

Cable

Fitting

Remove clutch hand lever from clutch lever bracket. If

necessary, use a T27 TORX drive head and remove two

screws (with flat washers) to release handelbar clamp

from clutch lever bracket.

Remove anchor pin and clutch cable eyelet from clutch

hand lever. See Figure 2-115.

Remove six socket head screws and washers to free

clutch release cover from transmission case. Remove

and discard gasket. See Figure 2-116.

Clutch Cable

Coupling

f1896x7x

Figure 2-116. Clutch Release Cover Assembly

f1440x6x

Jam

Nut

Rubber

Boot

1WARNING

Always wear proper eye protection when removing re-

Cable

End

taining rings. Use the correct retaining ring pliers. Verify

that the tips of the pliers are not damaged or excessively

worn. Slippage may propel the ring with enough force to

Cable

Adjuster

cause eye injury.

Remove retaining ring securing ball and ramp mech-

Figure 2-114. Clutch Cable Adjuster Mechanism

anism to clutch release cover.

2005 Touring: Chassis

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Harley Davidson 2005 touring models. Service repair manual — page 7

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