Harley Davidson 2005 touring models. Service repair manual — page 3
HOME
6.
Oil pan overfilled.
3.
Inlet valve and/or valve seat worn or damaged.
7.
Rocker housing gasket (bottom) installed upside down.
4.
Float misadjusted.
5. Leaky or damaged float.
Low Oil Pressure
6.
Excessive “pumping” of hand throttle grip.
1.
Oil pan underfilled.
7.
See TROUBLESHOOTING CHART in Section 4.
2.
Faulty low oil pressure switch.
3.
Oil pump O-ring(s) damaged or missing.
4.
Oil pressure relief valve stuck in open position.
TRANSMISSION
5.
Ball or clean out plug missing from cam support plate.
Transmission Shifts Hard
High Oil Pressure
1.
Clutch dragging slightly.
1.
Oil pan overfilled.
2.
Primary chaincase overfilled with lubricant.
2.
Oil pressure relief valve stuck in closed position.
3.
Corners worn off shifter clutch dogs.
4.
Shifter return spring bent or broken.
5.
Bent shifter rod.
ELECTRICAL SYSTEM
6.
Shifter forks sprung.
7.
Transmission lubrication too heavy (winter operation).
Alternator Does Not Charge
1.
Module not grounded.
Jumps Out Of Gear
2.
Engine ground wire loose or broken.
1.
Shifter rod improperly adjusted.
3.
Faulty regulator-rectifier module.
2.
Shifter drum damaged.
4.
Loose or broken wires in charging circuit.
3.
Shifter engaging parts (inside transmission) badly worn
5.
Faulty stator and/or rotor.
and rounded.
4.
Shifter forks bent.
Alternator Charge Rate Is Below Normal
5.
Damaged gears.
1.
Weak or damaged battery.
2.
Loose connections.
Clutch Slips
3.
Faulty regulator-rectifier module.
1.
Clutch controls improperly adjusted.
4.
Faulty stator and/or rotor.
2.
Insufficient clutch spring tension.
3.
Worn friction discs.
Speedometer Operates Erratically
1.
Contaminated speedometer sensor (remove sensor and
Clutch Drags Or Does Not Release
clean off metal particles).
2.
Loose connections.
1.
Clutch controls improperly adjusted.
2.
Lubricant level too high in primary chaincase.
3.
Primary chain badly misaligned.
CARBURETOR
4.
Clutch discs warped.
5.
Insufficient clutch spring tension.
Carburetor Floods
Clutch Chatters
1.
Dirt or other foreign matter between valve and its seat.
2.
Inlet valve sticking.
1.
Friction discs or steel discs worn or warped.
1-38
2005 Touring: Maintenance
HOME
BRAKES
HANDLING
Brake Does Not Hold Normally
Irregularities
1.
Master cylinder reservoir low on fluid.
1.
Improperly loaded motorcycle. Non-standard equipment
on the front end such as heavy radio receivers, extra
2.
Brake system contains air bubbles.
lighting equipment or luggage tends to cause unstable
3.
Master or wheel cylinder piston worn or parts damaged.
handling.
2.
Incorrect air suspension pressure.
4.
Brake pads contaminated with grease or oil.
3.
Damaged tire(s) or improper front-rear tire combination.
5.
Brake pads badly worn- friction material 0.04 inch (1.02
mm) thick or less.
4.
Irregular or peaked front tire tread wear.
6.
Brake disc badly worn or warped.
5.
Incorrect tire pressure.
7.
Brake fades due to heat build up - brake pads dragging
6.
Shock absorber not functioning normally.
or excessive braking.
7.
Loose wheel axle nuts. Tighten to recommended tight-
8.
Brake drags - insufficient brake pedal free play.
ness.
8.
Excessive wheel hub bearing play.
9.
Improper vehicle alignment.
10.
Steering head bearings improperly adjusted. Correct
adjustment and replace pitted or worn bearings and
races.
11.
Tire and wheel unbalanced.
12.
Rims and tires out-of-round or eccentric with hub.
13.
Rims and tires out-of-true sideways.
14.
Shock absorber improperly adjusted.
15.
Worn engine stabilizer links.
16.
Damaged rear engine isolation mounts.
17.
Swingarm pivot shaft nut improperly tightened or assem-
bled.
2005 Touring: Maintenance
1-39
HOME
NOTES
1-40
2005 Touring: Maintenance
Table Of Contents
CHASSIS
2
SUBJECT
PAGE NO.
2.1 Specifications
2-1
2.2 Vehicle Identification Number (V.I.N.)
2-5
2.3 Front Wheel
2-6
2.4 Rear Wheel
2-11
2.5 Checking Rim Runout
2-17
2.6 Wheel Lacing-16 Inch Rim
2-18
2.7 Truing Laced Wheel
2-21
2.8 Tires And Tubes
2-23
2.9 Vehicle Alignment
2-27
2.10 Front Brake Master Cylinder
2-33
2.11 Rear Brake Master Cylinder
2-38
2.12 Front Brake Caliper
2-46
2.13 Rear Brake Caliper
2-53
2.14 Bleeding Hydraulic Brake System
2-59
2.15 Front Forks
2-61
2.16 Lower Fork Bracket Cover/Air Dam
2-71
2.17 Steering Head Bearings
2-72
2.18 Rear Air Suspension
2-76
2.19 Rear Shock Absorbers
2-81
2.20 Rear Swingarm
2-83
2.21 Throttle Cables (Non-Cruise)
2-90
2.22 Clutch Cable
2-95
2.23 Handlebars
2-99
2.24 Seat
2-103
2.25 Saddlebag
2-107
2.26 Tour-Pak
2-114
2.27 Tour-Pak Lights/Backrest/Speaker Box
2-117
2.28 Lower Fairing/Engine Guard
2-121
2.29 Upper Fairing/Windshield (FLHT/C/U)
2-123
2.30 Upper Fairing/Windshield (FLTR)
2-131
2.31 Windshield/Headlamp Nacelle (FLHR/C/S)
2-141
2.32 Front Fender
2-145
2.33 Rear Fender
2-147
2.34 Jiffy Stand
2-150
2.35 Footboards/Footrests
2-152
2.36 Exhaust System
2-156
HOME
SPECIFICATIONS
2.1
DIMENSIONS (IN.)
DIMENSIONS (MM)
FLHT/C/U
FLHR/C/S
FLTR
FLHT/C/U
FLHR/C/S
FLTR
Wheel Base
63.5
63.5
63.5
Wheel Base
1613
1613
1613
Overall Length
93.7/97.5/98.3
93.7
93.7
Overall Length
2380/2476/2497
2380
2380
Overall Width
39.0
34.45/34.45/39.40
35.75
Overall Width
990
875/875/1001
908
Road Clearance
5.12
5.12/5.12/4.70
5.12
Road Clearance
130
130/130/119
130
Overall Height
61.0
55.06/55.06/46.40
55.0
Overall Height
1549
1399/1399/1179
1397
Saddle Height*
27.3
27.3/26.9/26.1
26.9
Saddle Height*
693
693/683/663
683
* With 180 Lb. Rider
* With 81.6 kg Rider
WEIGHT (LBS.)
WEIGHT (KG)
FLHT/C/U
FLHR/C/S
FLTR
FLHT/C/U
FLHR/C/S
FLTR
DRY WEIGHT**
758/776/788
723/710/721
731
DRY WEIGHT**
344/352/358
328/322/327
332
GVWR
1259
1259
1259
GVWR
571
571
571
GAWR - Front
500
500
500
GAWR - Front
227
227
227
GAWR - Rear
827
827
827
GAWR - Rear
375
375
375
** As shipped from the factory
** As shipped from the factory
NOTE
Gross Vehicle Weight Rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding Gross Axle Weight
Ratings (GAWR) are given on a label located on the inside of
the right front frame downtube.
CAPACITIES (U.S.)
CAPACITIES (METRIC)
FLHT/C/U
FLHR/C/S
FLTR
FLHT/C/U
FLHR/C/S
FLTR
Fuel Tank (gallons)
Fuel Tank (liters)
Total***
5
5
5
Total***
18.9
18.9
18.9
Reserve
0.9
0.9
0.9
Reserve
3.4
3.4
3.4
Oil Tank (quarts)
Oil Tank (liters)
with filter
4
4
4
with filter
3.78
3.78
3.78
Transmission
Transmission
(Ounces, approximate)
20-24
20-24
20-24
(Milliliters)
591-710
591-710
591-710
Primary Chaincase
Primary Chaincase
(Ounces, approximate)
32
32
32
(Milliliters)
946
946
946
Left
Right
Left
Right
Left
Right
Left
Right
Left
Right
Left
Right
Front Fork (Ounces)
Front Fork (Milliliters)
10.0
11.1
11.1
11.1
10.0
11.1
295
328
328
328
295
328
*** Includes Reserve on Carbureted Models
*** Includes Reserve on Carbureted Models
2005 Touring: Chassis
2-1
HOME
TIRE DATA
TORQUE VALUES
1WARNING
Item
ft/in-lbs
Nm
Tires, rims and air valves must be correctly matched to
Front brake disc TORX
16-24 ft-lbs
22-33 Nm
screws
wheel rims. See your Harley-Davidson dealer for service.
Mismatching tires, tubes, rims and air valves may result
Front axle nut
50-55 ft-lbs
68-75 Nm
in damage to the tire bead during mounting or may allow
Front axle holder nuts
132-180 in-lbs
14.9-20.3 Nm
the tire to slip on the rim, possibly causing tire failure,
which could result in death or serious injury.
Front brake caliper
28-38 ft-lbs
37.9-51.5 Nm
mounting bolts
1WARNING
Rear brake disc TORX
30-45 ft-lbs
41-61 Nm
screws
Using tires in ways other than those specified below may
Rear wheel sprocket bolts
55-65 ft-lbs
75-88 Nm
adversely affect motorcycle stability. Instability may lead
to loss of vehicle control, which could result in death or
Rear axle cone nut
95-105 ft-lbs
129-142 Nm
serious injury.
Wheel spokes
40-50 in-lbs
4.5-5.6 Nm
Front engine mount to
● Use tubeless tires on all Harley-Davidson cast and
15-20 ft-lbs
20-27 Nm
frame bolts
disc wheels.
Front engine mounting
● Tubeless tires fitted with the correct size inner tubes
bracket to rubber mount
15-20 ft-lbs
20-27 Nm
also may be used on all Harley-davidson laced
bolt
wheels, but protective rubber rim strips must be
Voltage regulator locknuts
70-100 in-lbs
7.9-11.3 Nm
installed to prevent damage to the inner tubes.
Handlebar clamp to
● Do not use inner tubes in radial tires. Do not use
master cylinder housing
60-80 in-lbs
6.8-9.0 Nm
TORX screws
radial tires on laced wheels.
Brake caliper bleeder
80-100 in-lbs
9.0-11.3 Nm
● Always use the correct size tires and tubes. Tire
valve
sizes are molded on the tire sidewall. Tube sizes are
Rear brake pedal shaft
printed on the tube.
15-20 ft-lbs
20-27 Nm
locknut
Brake pedal/master
1WARNING
cylinder assembly to
30-40 ft-lbs
41-54 Nm
mounting bracket hex nut
Maximum inflation pressure must not exceed specifica-
Banjo bolt to master
tion on tire sidewall. Exceeding inflation specifications
17-22 ft-lbs
23-30 Nm
cylinder
can adversely affect handling or result in tire failure,
Banjo bolt to brake caliper
17-22 ft-lbs
23-30 Nm
which could result in death or serious injury.
Fairing
lower
U-bolt
35-40 in-lbs
4.0-4.5 Nm
retainer locknuts
Tire Pressure (Cold)
Fairing lower to engine
90-100 in-lbs
10.2-11.3 Nm
Dunlop Tires
guard clamp TORX screw
Front
Rear
Only
Fairing lower cap screws
10-15 in-lbs
1.1-1.7 Nm
PSI
BARS
PSI
BARS
Front brake master
Solo Rider
36
2.5
36
2.5
cylinder reservoir cover
6-8 in-lbs
0.7-0.9 Nm
screws
Rider & One Passenger
36
2.5
40
2.8
Rear brake master
cylinder reservoir cover
6-8 in-lbs
0.7-0.9 Nm
screws
Brake caliper pad pins
180-200 in-lbs
20-23 Nm
REAR WHEEL SPROCKET
Brake caliper bridge bolts
28-38 ft-lbs
38-52 Nm
70 teeth
Continued ...
2-2
2005 Touring: Chassis
HOME
TORQUE VALUES (CONT.’D)
Item
ft/in-lbs
Nm
Item
ft/in-lbs
Nm
Fork oil drain plugs
72-96 in-lbs
8-11 Nm
Short fairing screws
6-12 in-lbs
0.7-1.4 Nm
(FLTR)
Fork pinch bolts
30-35 ft-lbs
41-48 Nm
Long fairing screws (FLTR)
10-15 in-lbs
1.1-1.7 Nm
Fork stem nut
60-80 ft-lbs
81-109 Nm
Instrument bezel TORX
Fork tube plug
22-58 ft-lbs
30-79 Nm
25-35 in-lbs
2.8-4.0 Nm
screws (FLTR)
Fork cap bolt
50-60 ft-lbs
68-81 Nm
Instrument nacelle to fork
15-20 ft-lbs
20-27 Nm
bracket TORX bolts (FLTR)
Damper rod/cartridge
132-216 in-lbs
14.9-24.4 Nm
6mm screw
Fairing bracket/steering
20-30 ft-lbs
27.1-40.7 Nm
head thru bolt (FLTR)
Damper rod locknut
13-20 ft-lbs
18-27 Nm
(cartridge type fork)
Radio bracket/inner fairing
to fairing bracket stud lock-
96-144 in-lbs
10.9-16.3 Nm
Shock bottom mounting
35-40 ft-lbs
47-54 Nm
nuts (FLTR)
bolt
Headlamp nacelle handle-
Shock top mounting bolt
33-35 ft-lbs
45-48 Nm
bar clamp shroud Phillips
10-20 in-lbs
1.1-2.3 Nm
Rear swingarm bracket
screw
34-42 ft-lbs
46-57 Nm
bolts
Headlamp nacelle trim
15-20 in-lbs
1.7-2.3 Nm
Rear swingarm pivot shaft
strip flange nut
40-45 ft-lbs
54-61 Nm
locknut
Auxiliary lamp bracket to
Handlebar switch
fork bracket stud acorn
72-108 in-lbs
8.1-12.2 Nm
35-45 in-lbs
4-5 Nm
housing TORX screws
nuts
Handlebar clamp to clutch
60-80 in-lbs
6.8-9.0 Nm
Front fender mounting
lever bracket screws
16-20 ft-lbs
22-27 Nm
bolts
Clutch release cover
84-132 in-lbs
9.5-14.9 Nm
Rear fender TORX bolts
15-20 ft-lbs
20-27 Nm
socket head screws
Jiffy stand leg stop flange
Clutch cable fitting
36-60 in-lbs
4-7 Nm
43-53 ft-lbs
58-72 Nm
nut
Transmission lubricant
14-21 ft-lbs
19-28 Nm
Intake flange adapter
drain plug
96-144 in-lbs
10.9-16.3 Nm
screws
Transmission filler plug/
25-75 in-lbs
2.8-8.5 Nm
Exhaust flange adapter
dipstick
100-120 in-lbs
11.3-13.6 Nm
nuts
Battery cable bolt
60-96 in-lbs
6.8-10.9 Nm
Exhaust pipe TORCA
45-60 ft-lbs
61-81 Nm
Tour-Pak mounting bolts
96-120 in-lbs
10.8-13.5 Nm
clamps
Inner fairing screws
20-30 in-lbs
2.3-3.4 Nm
Heat shield worm drive
20-40 in-lbs
2.3-4.5 Nm
clamps
Outer fairing screws
25-30 in-lbs
2.8-3.4 Nm
Transmission exhaust
(below windshield)
60-96 in-lbs
6.8-10.8 Nm
bracket clamp bolt
Fairing cap TORX screws
25-30 in-lbs
2.8-3.4 Nm
Passenger footboard/
15-18 ft-lbs
20-24 Nm
Speedometer/tachometer
footrest socket screws
10-20 in-lbs
1.1-2.3 Nm
bracket socket screws
Rider footboard
84-108 in-lbs
9.5-12.2 Nm
2 inch diameter gauge
pivot bolt nut
10-20 in-lbs
1.1-2.3 Nm
nuts
Air valve mount hex nut
40-50 in-lbs
4.5-5.6 Nm
Auxiliary lamp bracket to
15-20 ft-lbs
20-27 Nm
Handlebar upper clamp
fork bracket TORX bolts
12-16 ft-lbs
16.3-21.7 Nm
screws
Windshield wellnut
6-13 in-lbs
0.7-1.5 Nm
Handlebar lower clamp
screws (FLTR)
30-40 ft-lbs
40.7-54.2 Nm
bolts (risers)
Front turn signal lamp
Ignition switch
DOM
50-70 in-lbs
5.7-7.9 Nm
bracket stud acorn nuts
40-50 in-lbs
4.5-5.7 Nm
(FLTR)
nut
HDI
125-150 in-lbs
14.1-16.9 Nm
Continued ...
Speaker box to
25-35 in-lbs
2.8-4.0 Nm
Tour-Pak bolts
Throttle cable J-clamp
9-18 in-lbs
1.0-2.0 Nm
screw to wellnut (FLHR/C)
2005 Touring: Chassis
2-3
HOME
NOTES
2-4
2005 Touring: Chassis
HOME
VEHICLE IDENTIFICATION NUMBER (V.I.N.)
2.2
See Figure 2-1. The full 17-digit serial number, or Vehicle
Sample V.I.N. as it appears on the steering head
-
Identification Number (V.I.N.), is stamped on the right side of
1HD1DJV135Y110000
the frame backbone at the rear of the steering head (and
Sample abbreviated V.I.N. as it appears on the crankcase -
under the main harness conduit). A label bearing the V.I.N.
DJV5110000
code is also affixed to the left side of the steering head. An
NOTE
abbreviated V.I.N. is stamped between the front and rear cyl-
Always give the complete V.I.N. when ordering parts or mak-
inders on the left side of the crankcase.
ing an inquiry about your motorcycle.
1
2
3
4
5
6
7
8
9
10
1
HD
1
DJ V
1
3
5
Y
110000
Figure 2-1. Vehicle Identification Number (V.I.N.)
Table 2-1. V.I.N. Description
ITEM
DESCRIPTION
VALUE
1=Domestic
1
Market destination
5=International
2
Manufacturer
HD=Harley-Davidson
3
Motorcycle type
1=Heavyweight
4
Model designation
See Table 2-2.
V=Carbureted
5
Engine type
W=Fuel injected
1=Regular
3=California
6
Introduction
2=Mid-year
4=Anniversary
7
V.I.N. check digit
Can be 0-9 or X
8
Model year
5=2005
K=Kansas City, MO
9
Assembly plant
Y=York, PA
10
Sequential number (last 6 digits)
Varies
Table 2-2. Model Designation
CODE
MODEL
CODE
MODEL
DD
FLHT
FL
FLHTCUI Shrine
DJ
FLHTC
FR
FLHRCI
FB
FLHRI
FS
FLTRI
FC
FLHTCUI
FV
FLHTI
FD
FLHR
FW
FLHRI Shrine
FF
FLHTCI
FX
FLHRS
FG
FLHTCUI W/SC
FY
FLHRSI
FK
FLHTCI Shrine
2005 Touring: Chassis
2-5
HOME
FRONT WHEEL
2.3
2.
Remove both the upper and lower mounting bolts from
GENERAL
lugs of front fork leg to release brake caliper assembly.
Maximum tire mileage and good handling qualities are
3.
Lift caliper upward to remove from brake disc. Allow the
directly related to care given wheels and tires. Wheels and
caliper to hang loose.
tires should be regularly inspected for wear. If handling prob-
4.
Repeat steps 1 thru 3 to release caliper on opposite side
lems occur, see Section 1.21 TROUBLESHOOTING, HAN-
DLING, for possible causes.
of wheel.
Always keep tires inflated to the recommended pressure and
NOTE
balance the wheel whenever a tire or tube is replaced.
Do not operate the front brake hand lever with the front wheel
removed or the caliper pistons may be forced out. Reseating
pistons requires disassembly of the caliper.
PRELIMINARY INSPECTION
5.
Insert screwdriver or steel rod through hole in axle on
1.
Measure brake disc thickness for excessive wear. Mini-
right side of vehicle. While holding axle stationary,
mum acceptable thickness is stamped on side of disc.
remove the axle nut, lockwasher and flat washer on the
Also replace discs if warped or badly scored. Obtain
left side.
new T40 TORX screws if brake discs were removed.
6.
Loosen the two axle holder nuts at bottom of right side
2.
Whenever the wheel is removed for tire replacement or
fork leg.
any other purpose, inspect the wheel bearings as fol-
lows:
7.
With soft mallet, tap axle toward right side of vehicle until
a. Insert finger into wheel bearing and rotate the inner
loose. Catching external spacers on left and right side,
race in both directions. Repeat step on opposite
pull axle from hub while supporting wheel.
side of wheel.
8.
Move wheel to bench area and inspect bearings. See
b. Replace the wheel bearings if there is rough rota-
PRELIMINARY INSPECTION on this page.
tion, abnormal noise or anything unusual. Always
replace wheel bearings as a set. Never replace just
one wheel bearing.
DISASSEMBLY
REMOVAL
1.
If wheel bearing replacement is necessary, proceed as
follows:
1. Use shop rag or tape to protect fender area adjacent to
caliper, as incidental contact can occur during caliper
a. Obtain the WHEEL BEARING REMOVER/IN-
removal.
STALLER (HD-44060). Pick out the wheel bearing
remover tools for the front wheel. See Figure 2-3.
b. To prolong service life and ensure smooth opera-
9428
tion, sparingly apply graphite lubricant to threads of
forcing screw.
c. Install hex nut, flat washer and Nice bearing on forc-
ing screw. Insert end of forcing screw through hole
in bridge.
d. Install steel ball inside larger collet. Install collet at
end of forcing screw.
e. Insert collet into bearing ID. Feel for inside edge of
bearing using lip at end of collet and then back off
slightly.
f.
Holding forcing screw to prevent rotation, turn hex
on collet until lip makes firm contact with inside
edge of bearing. See upper frame of Figure 2-4.
Figure 2-2. Inspect Wheel Bearings
2-6
2005 Touring: Chassis
HOME
Bridge
f1769x2x
f1774x2x
Forcing
Screw
Larger Collet
1 Inch
Nice Bearing
Steel Ball
Hex
Flat
Nut
Washer
Flat Washer
Hex Nut
Nice
Forcing Screw
Bearing
Graphite Lubricant
Figure 2-3. Front Wheel Bearing Remover Tools
(Part No. HD-44060)
g. Holding forcing screw, turn hex nut until bearing is
free. See lower frame of Figure 2-4.
h. Remove spacer sleeve from wheel hub.
Collet Hex
Bridge
with Ball Bearing
i.
Repeat procedure to remove bearing on opposite
side of wheel. Discard bearings.
Hold Forcing Screw and Turn Hex on Collet to Expand.
2.
If brake disc replacement is necessary, use a T40 TORX
drive head and remove five screws securing brake disc
f1775x2x
to hub. Discard TORX screws. Repeat procedure to
remove disc on opposite side of wheel. If the wheel is to
be assembled with the same discs, mark both the wheel
and discs, so that they can be installed in their original
positions.
3.
If tire replacement is necessary, see Section 2.8 TIRES
AND TUBES.
4.
If the wheel is laced, and hub, spoke or rim replacement
is necessary, loosen all spoke nipples and disassemble
hub from rim.
CLEANING AND INSPECTION
1. Thoroughly clean all parts in solvent.
2. Inspect all parts for damage or excessive wear.
3. Always replace bearing assemblies as a complete set.
4. Inspect brake discs. Replace discs if warped or badly
scored. Measure disc thickness for excessive wear. Min-
Wheel
imum acceptable thickness is stamped on side of disc.
Bearing
Hold Forcing Screw and Turn Hex Nut to Pull Out Bearing.
ASSEMBLY
Figure 2-4. Remove Sealed Wheel Bearings
1. On laced wheels, if the hub and rim were disassembled,
assemble the hub, spokes and rim. See Section 2.6
WHEEL LACING-16 INCH RIM.
2005 Touring: Chassis
2-7
HOME
1. Axle Nut
2. Lockwasher
13
3. Flat Washer
4. T40 Torx Screw (10)
5. Brake Disc (Left Side)
Left Side
6. External Spacer (Long)
7. Sealed Bearing (2)
8. Cast Wheel
9. Spacer Sleeve
10. Brake Disc (Right Side)
11. External Spacer (Short)
4
1
12. Axle
13. Laced Wheel
2
3
Right Side
6
5
7
4
8
9
7
12
11
10
f2042x2x
Figure 2-5. Front Wheel (Exploded View)
a. Obtain the WHEEL BEARING REMOVER/IN-
1WARNING
STALLER (HD-44060). Pick out the wheel bearing
installer tools for the front wheel. See Figure 2-6.
Do not allow brake fluid or other lubricants to contact
the brake disc. Such contact can adversely affect brak-
b. To prolong service life and ensure smooth opera-
ing ability, which could result in death or serious injury.
tion, sparingly apply graphite lubricant to threads of
threaded rod.
2. Using a T40 TORX drive head, install brake discs on hub
using new screws. Be sure to install discs in their origi-
c. Slide support plate onto threaded rod. Slide rod
nal positions. Alternately tighten screws to 16-24 ft-lbs
through hub on the valve stem side of the wheel.
(22-33 Nm).
See upper frame of Figure 2-7.
3. Install new wheel bearings as follows:
d. On opposite side of wheel, slide bearing onto
threaded rod with lettered side facing outboard.
NOTE
Always install first of two bearings on the left side (opposite
e. Install larger pilot, Nice bearing, flat washer and
the valve stem side of the wheel).
hex nut onto rod.
2-8
2005 Touring: Chassis
HOME
Larger Pilot
1 Inch
Support Plate
Nice Bearing
Support
Plate
Flat Washer
Hex Nut
Threaded Rod
Graphite Lubricant
f1771x2x
Figure 2-6. Front Wheel Bearing Installer Tools
Threaded
(Part No. HD-44060)
Rod
f.
Holding threaded rod on opposite side of wheel to
f1777x2x
prevent rotation, turn hex nut to install bearing. See
lower frame of Figure 2-7. Bearing is fully seated
when it makes firm contact with the counterbore.
Slide Threaded Rod (with Support Plate) Through Hub.
g. Disassemble and remove tool, but leave support
plate on threaded rod.
Wheel
Bearing
h. Slide threaded rod through installed wheel bearing
and hub of wheel.
Nice
i.
On the valve stem side of the wheel, slide spacer
Bearing
sleeve down threaded rod until it contacts installed
wheel bearing.
j.
Repeat steps 3(d) through 3(g) to complete installa-
tion of second wheel bearing. Bearing is fully seated
when hex nut can no longer be turned.
4.
Verify that wheel is true. See CHECKING CAST RIM
RUNOUT or TRUING LACED WHEEL, whichever
Pilot
applies.
Threaded
5.
Install rim strip on wheel rim, if applicable. Install tube
Rod
Flat
and tire, if applicable. Verify that wheel is balanced.
Hex
Washer
f1773x2x
Nut
Hold Threaded Rod and Turn Hex Nut to Push In Bearing.
INSTALLATION
Figure 2-7. Install Sealed Wheel Bearings
1. Place wheel into position between forks with the valve
stem on the right side of the vehicle.
5. Install flat washer, lockwasher and axle nut.
2. Coat the axle with ANTI-SEIZE LUBRICANT.
6. Insert screwdriver or steel rod through hole in axle on
3. Supporting wheel, insert threaded end of axle through
right side of vehicle. While holding axle stationary,
right fork leg. Push axle through fork, short external
tighten axle nut to 50-55 ft-lbs (68-75 Nm).
spacer and wheel hub until it begins to emerge from left
side.
7. Insert 7/16 inch drill bit into hole in axle. See Figure 2-8.
4. With the three notches on the bearing side, push axle
8. Pull fork leg so that it just contacts drill bit, and then
through long external spacer and left fork leg until axle
tighten axle holder nuts to 132-180 in-lbs (14.9-20.3
shoulder contacts external spacer on right fork side.
Nm).
2005 Touring: Chassis
2-9
HOME
f1783x2x
1WARNING
After installation of calipers and BEFORE moving motor-
Fork Leg
cycle, pump front brake hand lever until pistons push
Right Side
pads against the brake discs. If fluid pressure is not
pumped up, the brake will not be available the first time it
is used, a situation that could result in death or serious
injury.
11.
Depress front brake hand lever several times to set
Short
Spacer
brake pads to proper operating position within caliper.
Axle
Drill Bit
Axle Holder
Nuts
Figure 2-8. Align Front Wheel
9.
Remove drill bit from axle hole.
10.
Install brake caliper as follows:
a. Use shop rag or tape to protect fender area adja-
cent to caliper, as incidental contact can occur dur-
ing caliper installation.
b. With the bleeder valve topside, position caliper so
that brake disc is situated between friction pads. Pry
inner and outer brake pads back for additional clear-
ance, if necessary.
c. Align upper mounting hole in caliper with upper
mounting lug on fork leg. Loosely install long caliper
mounting bolt into upper lug of fork leg.
d. Install short caliper mounting bolt into lower lug of
fork leg. Tighten lower mounting bolt to 28-38 ft-lbs
(37.9-51.5 Nm).
e. Tighten upper caliper mounting bolt to 28-38 ft-lbs
(37.9-51.5 Nm).
f.
Repeat step 10 to install caliper on opposite side of
wheel.
2-10
2005 Touring: Chassis
HOME
REAR WHEEL
2.4
c. Loosen TORCA clamp between rear header pipe
GENERAL
and muffer.
Maximum tire mileage and good handling qualities are
d. Remove two bolts (with lockwashers) to detach muf-
directly related to care given wheels and tires. Wheels and
fler from the lower saddlebag support rail.
tires should be regularly inspected for wear. If handling prob-
e. Remove bungee cord to release muffler from lower
lems occur, see Section 1.21 TROUBLESHOOTING, HAN-
saddlebag support rail.
DLING, for possible causes.
Always keep tires inflated to the recommended pressure and
3.
Standing on right side of vehicle, remove E-clip from
balance the wheel whenever a tire or tube is replaced.
groove at end of axle.
4.
Remove cone nut and adjuster cam from axle.
PRELIMINARY INSPECTION
5.
Using a soft mallet, gently tap end of axle towards left
side to loosen. Catching external spacers on right and
1. Measure brake disc thickness for excessive wear. Mini-
left side of hub, pull axle free of wheel and rear
mum acceptable thickness is stamped on side of disc.
swingarm.
Also replace disc if warped or badly scored.
6.
Pull wheel to release brake disc from caliper. Pry inner
2. Whenever the wheel is removed for tire replacement or
and outer brake pads back for additional clearance, if
any other purpose, inspect the wheel bearings as fol-
necessary. Use a putty knife with a wide thin blade to
lows:
avoid scoring or scratching the brake disc.
a. Insert finger into wheel bearing and rotate the inner
7.
Remove caliper from anchor weldment on rear swing-
race. Repeat step on opposite side of wheel.
arm, and carefully hang over lower saddlebag support
b. Replace the wheel bearings if there is rough rota-
rail.
tion, abnormal noise or anything unusual. Always
8.
Move wheel forward and slip belt off sprocket.
replace wheel bearings as a set. Never replace just
one wheel bearing.
9.
Move wheel to bench area and inspect bearings. See
PRELIMINARY INSPECTION on this page.
NOTE
REMOVAL
Do not operate the rear brake pedal with the rear wheel
1. Remove saddlebags. See Section 2.25 SADDLEBAG,
removed or the caliper pistons may be forced out. Reseating
REMOVAL.
pistons requires disassembly of the caliper.
2. Remove both mufflers as follows:
Left Side
DISASSEMBLY
a. Open worm drive clamps to remove heat shield
from crossover pipe.
1. If wheel bearing replacement is necessary, proceed as
b. Using a bungee cord, tie the muffler to the lower
follows:
saddlebag support rail.
a. Remove five bolts (with flat washers) securing belt
c. Loosen TORCA clamp between crossover pipe and
sprocket to hub.
muffer.
d. Remove two bolts (with lockwashers) to detach muf-
b. Obtain the WHEEL BEARING REMOVER/IN-
fler from the lower saddlebag support rail.
STALLER (HD-44060). Pick out the wheel bearing
remover tools for the rear wheel. See Figure 2-9.
e. Remove bungee cord to release muffler from lower
saddlebag support rail.
NOTE
The smaller 3/4 inch collet (and pilot) is only used to replace
Right Side
the rear wheel bearings on 2000-01 Touring models.
a. Open worm drive clamps to remove heat shield
from rear header pipe.
c. To prolong service life and ensure smooth opera-
tion, sparingly apply graphite lubricant to threads of
b. Using a bungee cord, tie the muffler to the lower
forcing screw.
saddlebag support rail.
2005 Touring: Chassis
2-11
HOME
Bridge
f1769x2x
f1774x2x
Forcing
Screw
Larger Collet
1 Inch
Nice Bearing
Steel Ball
Hex
Flat
Nut
Washer
Flat Washer
Hex Nut
Nice
Forcing Screw
Bearing
Graphite Lubricant
Figure 2-9. Rear Wheel Bearing Remover Tools
(Part No. HD-44060)
d. Install nut, flat washer and Nice bearing on forcing
screw. Insert end of forcing screw through hole in
bridge.
Collet Hex
Bridge
with Ball Bearing
e. Install steel ball inside larger collet. Install collet at
end of forcing screw.
Hold Forcing Screw and Turn Hex on Collet to Expand.
f.
Insert collet into bearing ID. Feel for inside edge of
bearing using lip at end of collet and then back off
f1775x2x
slightly.
g. Holding forcing screw to prevent rotation, turn hex
on collet until lip makes firm contact with inside
edge of bearing. See upper frame of Figure 2-10.
h. Holding forcing screw, turn hex nut until bearing is
free. See lower frame of Figure 2-10.
i.
Remove spacer sleeve from wheel hub.
j.
Repeat procedure to remove bearing on opposite
side of wheel. Discard bearings.
2.
If brake disc replacement is necessary, use a T45 TORX
drive head and remove five screws securing brake disc
to hub. If the wheel is to be assembled with the same
disc, mark both the wheel and disc, so that it can be
installed in its original position.
3.
Remove tire, if necessary. Remove tube from the rim, if
applicable. See Section 2.8 TIRES AND TUBES.
Wheel
4.
If it is necessary to remove the hub from a laced wheel,
Bearing
loosen all spoke nipples and remove the rim and spokes.
Hold Forcing Screw and Turn Hex Nut to Pull Out Bearing.
CLEANING AND INSPECTION
Figure 2-10. Remove Sealed Wheel Bearings
1. Thoroughly clean all parts in solvent.
2. Inspect all parts for damage or excessive wear.
3. Always replace bearings as a complete set.
2-12
2005 Touring: Chassis
HOME
1. Axle
2. External Spacer (Large)
3. Bolt (5)
15
4. Flat Washer (5)
5.
Belt Sprocket
6.
Sealed Bearing (2)
Left Side
7.
Spacer Sleeve
8.
Cast Wheel
9.
Brake Disc
10. T45 TORX Screw (5)
11. External Spacer (Small)
1
12. Adjuster Cam
3
13. Cone Nut
14. E-Clip
4
15. Laced Wheel
2
7
Right Side
6
5
6
8
11
13
9
12
f2044x2x
14
10
Figure 2-11. Rear Wheel (Exploded View)
4. Inspect brake disc. Replace disc if warped or badly
2. Verify that wheel is true. See Section 2.5 CHECKING
scored. Measure disc thickness for excessive wear. Min-
RIM RUNOUT or Section 2.7 TRUING LACED WHEEL,
imum acceptable thickness is stamped on side of disc.
whichever applies.
5. Check the belt sprocket for wear, tooth damage, cracks
or pitting. Replace if necessary.
1WARNING
6. On laced wheels, replace spokes, rim or hub if dam-
Do not allow brake fluid or other lubricants to contact
aged.
the brake disc. Such contact can adversely affect brak-
ing ability, which could result in death or serious injury.
ASSEMBLY
3. Using a T45 TORX drive head, install five screws (and
locknuts on laced wheels) to secure brake disc to hub.
1. On laced wheels, if the hub and rim were disassembled,
Always install brake disc in its original position. Use new
assemble the hub, spokes and rim. See Section 2.6
screws after three use cycles. Alternately tighten screws
WHEEL LACING-16 INCH RIM.
to 30-45 ft-lbs (41-61 Nm).
2005 Touring: Chassis
2-13
HOME
Larger Pilot
1 Inch
Support Plate
Nice Bearing
Support
Plate
Flat Washer
Hex Nut
Threaded Rod
Graphite Lubricant
f1771x2x
Figure 2-12. Rear Wheel Bearing Installer Tools
Threaded
(Part No. HD-44060)
Rod
4.
Install new wheel bearings as follows:
f1777x2x
NOTE
Always install first of two bearings on the right side (the valve
Slide Threaded Rod (with Support Plate) Through Hub.
stem side of the wheel).
a.
Obtain the WHEEL BEARING REMOVER/IN-
Wheel
STALLER (HD-44060). Pick out the wheel bearing
Bearing
installer tools for the rear wheel. See Figure 2-12.
b.
To prolong service life and ensure smooth opera-
Nice
tion, sparingly apply graphite lubricant to threads of
Bearing
threaded rod.
c.
Slide support plate onto threaded rod. Slide rod
through hub on the sprocket side of the wheel. See
upper frame of Figure 2-13.
d.
On the valve stem side of the wheel, slide bearing
onto threaded rod with lettered side facing out-
board.
Pilot
e.
Install larger pilot, Nice bearing, flat washer and
Threaded
hex nut onto rod.
Rod
Flat
Hex
f.
Holding threaded rod on opposite side of wheel to
Washer
f1773x2x
Nut
prevent rotation, turn hex nut to install bearing. See
lower frame of Figure 2-13. Bearing is fully seated
Hold Threaded Rod and Turn Hex Nut to Push In Bearing.
when it makes firm contact with the counterbore.
g.
Disassemble and remove tool, but leave support
Figure 2-13. Install Sealed Wheel Bearings
plate on threaded rod.
h.
Slide threaded rod through installed wheel bearing
6. Apply two drops of Loctite High Strength Threadlocker
and hub of wheel.
271 (red) to threads of five belt sprocket bolts. Always
i.
On the other side of the wheel, slide spacer sleeve
use new bolts after three use cycles. Install bolts with
down threaded rod until it contacts installed wheel
flat washers to secure sprocket to hub. Alternately
bearing.
tighten bolts to 55-65 ft-lbs (75-88 Nm).
j.
Repeat steps 4(d) through 4(g) to complete installa-
tion of second wheel bearing. Bearing is fully seated
INSTALLATION
when hex nut can no longer be turned.
5.
Install rim strip on wheel rim, if applicable. Install tube
1. Place wheel in rear swingarm. Slide wheel far enough
and tire, if applicable. Verify that wheel is balanced.
forward to slip belt over sprocket and then slide the
wheel back.
2-14
2005 Touring: Chassis
HOME
kg) of force at the midpoint of the bottom belt strand. Belt
CAUTION
deflection should be as follows:
Do not bend or fold belt backward or into loops smaller
Table 2-3. Belt Deflection in the Air
than 5 inches (127 mm) in diameter. Sharp bending can
weaken the belt and cause premature failure.
Orientation
Inches
Millimeters
2.
Seat caliper on anchor weldment of rear swingarm. Posi-
Motorcycle Upright
3/16 - 1/4
4.8
- 6.4
tion wheel in swingarm, so that brake disc is centered
With Rear Wheel in the Air
between brake pads.
NOTE
See Section 1.10 DRIVE BELT for belt deflection specification
3.
Coat the axle with ANTI-SEIZE LUBRICANT.
with motorcycle on jiffy stand.
4.
With the larger OD on the outboard side, hold external
spacer between rear swingarm and belt sprocket. Slide
10.
If belt is too tight, move to step
11 to increase belt
axle through left side of rear swingarm, external spacer,
deflection. If belt is too loose, reduce belt deflection as
and belt sprocket into wheel hub.
described below:
5.
When axle emerges from hub on brake disc side of
a. Rotate weld nut on left side of axle in a clockwise
wheel, push axle through short external spacer, caliper
direction.
bracket and right side of rear swingarm.
b. Check belt deflection. Apply 10 lbs. (4.5 kg) of force
6.
Rotate axle so that the flat on the threaded end is top-
at the midpoint of the bottom belt strand. Belt
side. With the thumb down and the cam forward, install
deflection should be within the range specified in
adjuster cam on end of axle.
Table 2-3.
7.
Apply a thin film of ANTI-SEIZE LUBRICANT to the
c. If belt is still too loose, repeat steps 10(a) through
inboard side of the cone nut avoiding contact with
10(b). If belt is now too tight, move to step 11.
threads. Install cone nut on axle, but finger tighten only.
8.
Verify that adjuster cam just contacts weld nub on both
11.
If belt is too tight, increase belt deflection as follows:
sides of rear swingarm. If necessary, push wheel for-
ward slightly to achieve the desired result. Snug the
a. Rotate weld nut on left side of axle in a counter-
cone nut to 15-20 ft-lbs (20-27 Nm). See Figure 2-14.
clockwise direction.
9.
Check deflection at the loosest spot in the belt. Use
b. Push wheel forward slightly so that adjuster cam
BELT TENSION GAUGE (HD-35381A), or install adapter
just contacts weld nub on both sides of rear swing-
(HD-35381-3) on old style gauge, and apply 10 lbs. (4.5
arm. See Figure 2-14.
LEFT SIDE
RIGHT SIDE
Increase
Reduce
Belt
Belt
Deflection
Deflection
Cone
Nut
Weld
Nub
Weld
Weld
Nut
E-Clip
Nub
Adjuster
8398
8407
Cam
Figure 2-14. Move Rear Wheel Forward Until Adjuster Cams Just Contact Weld Nubs
2005 Touring: Chassis
2-15
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