Harley Davidson 2005 touring models. Service repair manual — page 68
HOME
cse0008x2x
9
6
5
4
1
3
2
21
24
11
22
15
25
20
14
23
10
19
2
12
13
7
8
14
20
15
18
14
15
17
16
1.
Right passenger footboard insert
13.
Left front rider footboard support bracket
(left-side not shown)
14.
Washer (3)
2.
Pivot pin
15.
Lockwasher (3)
3.
Spring
16.
Right front rider footboard support bracket
4.
Ball
17.
Right rider footboard bottom assembly
5.
Screw (2)
18.
Right rider footboard insert
6.
Lockwasher (2)
19.
Right rear rider footboard support bracket
7.
Passenger footboard support bracket
20.
Screw (3)
8.
Passenger footboard bottom assembly
21.
Screw (2)
9.
Left rider footboard insert
22.
Left rear rider footboard support bracket
10.
Left rider footboard bottom assembly
23.
Lockwasher
11.
Locknut (4)
24.
Nut
12.
Pivot bolt (4)
25.
Locating pin
Figure 2-7. Rider and Passenger Footboard Components
2-8
2005 FLHTCSE2: Chassis
HOME
PASSENGER FOOTBOARDS
SHIFT LEVER
Removal
Replacement
1.
See Figure 2-7. Remove screw (5) and lockwasher (6) to
1.
Remove and replace shift lever pegs. Tighten fasteners
remove footboard bracket
(7) from rear fork pivot
to 12-14 ft-lbs (16.3-18.9 Nm).
bracket.
2.
If necessary, replace shift levers as follows:
2.
Repeat for other passenger footboard assembly.
a. loosen clamp bolts and pull shift levers off splined
shaft.
Disassembly
b. Position shift levers on splined shaft for comfortable
NOTE
rider position.
If only replacing the rubber pad, refer to step 1 below and
c. Tighten clamp bolts to
90-110 in-lbs (10.2-12.4
then see step 3. under ASSEMBLY.
Nm).
1.
See Figure 2-7. Tilt footboard bottom assembly
(8)
upward. From bottom side, use a small blade screw-
REAR BRAKE PEDAL
driver to push rubber beads on pad up through holes in
footboard bottom assembly. Remove footboard insert
(1).
Replacement
2.
Using a brass drift and rubber mallet, tap two pivot pins
1.
See Figure 2-8. Remove screws (5), brake pedal cover
(2) toward center of footboard and remove.
(8) and pad (7) from metal backing plate (4).
3.
Remove footboard bottom assembly from footboard
2.
Remove acorn nut (1), offset washer (2) and metal back-
bracket (7).
ing plate from foot brake lever (3).
4.
Remove ball (4) and spring (3) from hole in footboard
bracket.
5.
Repeat for other passenger footboard assembly.
cse0009x2x
Assembly
8
1.
See Figure 2-7. Place spring (3) into hole in footboard
7
bracket (7). Place ball (4) on top of spring.
5
2.
Place footboard bottom assembly (8) into position on
bracket and install pivot pins (2) from the outboard side.
6
Using a brass drift and rubber mallet, tap pins until cen-
tered in lugs of bracket.
4
3.
Moisten rubber beads on new insert assembly with
soapy water. Place footboard insert (1) into position on
2
footboard bottom assembly. Press firmly on footboard
3
insert in areas of rubber beads.
1
4.
Repeat for other passenger footboard assembly.
Installation
1.
Acorn nut
1.
See Figure 2-7. Insert locating pin (25) on footboard
2.
Offset washer
bracket (7) into hole in rear fork pivot bracket.
3.
Foot brake lever
4.
Metal backing plate
NOTE
5.
Screw (2)
Passenger footboards can be adjusted to one of three posi-
6.
Screw
tions. To move footboards to a new position, remove plastic
7.
Rubber pad
plugs from holes in rear fork pivot bracket as necessary.
8.
Metal brake pedal cover
2.
Install screw (5) and lockwasher (6). Tighten screw to
15-18 ft-lbs (20.4-24.4 Nm).
Figure 2-8. Rear Brake Pedal
3.
Install metal backing plate (4) to foot brake lever (3).
Secure with offset washer (2) and acorn nut (1). Tighten
nut to 25-29 ft-lbs (33.9-39.4 Nm).
4.
Assemble metal brake pedal cover (8) and rubber pad
(7) to metal backing plate. Secure with screws
(5).
Tighten screws to 20-22 in-lbs (2.3-2.5 Nm).
2005 FLHTCSE2: Chassis
2-9
HOME
FRONT AXLE COVERS
2.7
REPLACEMENT
10522
1.
See Figure 2-9. Loosen but do not remove set screw
under cover. Remove cover.
2.
Remove set screws from cover.
3.
Liberally apply LOCTITE THREADLOCKER 262 (red)
(Part No. 94759-77) to threads of set screw.
4.
Orient cover over axle end so that set screw is on the
bottom and will tighten down against a flat on the axle
nut.
5.
Install and tighten set screw to 60-84 in-lbs (6.8-9.5
Nm).
6.
Repeat for opposite side.
Figure 2-9. Front Axle Cover Set Screw
2-10
2005 FLHTCSE2: Chassis
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LOWER TRIPLE CLAMP COVER
2.8
REPLACEMENT
cse0012x2x
1
2
1.
See Figure 2-10. Loosen but do not remove the two
3
screws (1) on the backside of the lower triple clamp
cover (3).
2.
Remove screw (4) through brake line manifold on bottom
5
of triple clamp cover.
3.
Remove two screws loosened in step 1, with washers (2)
and remove cover.
4.
To replace cover, fit cover inside bottom of nacelle and
around lower triple clamp (5). Hold in place.
5.
Install screws (1) and washers (2). Tighten finger-tight
only. Install screw (4) through brake line manifold and
cover. Tighten finger-tight only. Verify that cover is snug
against rear surface of lower triple clamp.
4
NOTE
Plastic plugs in locator holes in rear surface of triple clamp
can cause interference with cover. Verify that center plug has
been removed.
1.
Screw (2)
2.
Washer (2)
6.
Tighten screws (1) to 70-110 in-lbs (7.9-12.4 Nm).
3.
Lower triple clamp cover
7.
Tighten screw (4) to 120-180 in-lbs (13.6-20.4Nm).
4.
Screw
5.
Lower triple clamp
8.
Verify that brake line does not rub on cover. Adjust line
or cover as necessary.
Figure 2-10. Lower Triple Clamp Cover
2005 FLHTCSE2: Chassis
2-11
HOME
HANDLEBARS
2.9
REMOVAL/REPLACEMENT
f1915x8x
1
2
3
1WARNING
To prevent accidental vehicle start-up, which could
4
cause death or serious injury, remove maxi-fuse before
proceeding. (00251a)
5
1.
Remove left side cover.
2.
Remove Maxi-Fuse.
7
3.
Remove outer fairing and fairing cap. See FAIRING CAP
in Touring Models Service Manual.
6
4.
Remove radio chassis. See RADIO REMOVAL in Tour-
ing Models Service Manual.
1.
Locking wedge
2.
Internal seal
5.
See Figure 2-11. Separate handlebar switch connectors
3.
Socket housing
[22] and [24] and turn signal multilock connector [31].
4.
Wire seal
6.
See Figure 2-12. Remove wires from socket side hous-
5.
Seal pin
ings from socket terminal wires:
6.
Socket terminal
a. Use a screw driver to pry out the secondary locking
7.
External latch
wedges. See DEUTSCH ELECTRICAL CONNEC-
TORS in Touring Models Service Manual.
Figure 2-12. 12-place Deutsch Socket Side Connector
b. See Figure 2-13. Depress internal terminal latches
and pull socket terminals out of the wire seal.
o0031x0x
f2238x8a
3
1
2
Figure 2-13. Internal Deutsch Terminal Latches
7.
Using mechanic’s wire, neatly wrap the socket terminals
and wires with 1 or 2 twists to form leaders for turn sig-
1.
Right
handlebar switch connector [22]
nal and handlebar switch connector wires.
2.
Left handlebar switch connector [24]
3.
Turn signal multilock connector [31]
8.
String wire along the turn signal wire. String sufficient
wire to pull conduits through handlebars.
Figure 2-11. Turn Signal and Cruise Switch Connectors
9.
Wrap with electrical tape from the open end of the con-
duit past the turn signal lamp sockets to form a leader.
2-12
2005 FLHTCSE2: Chassis
HOME
10. Shorten throttle and idle cable adjustors and pull idle
f1225x2x
and throttle cable inserts and elbows from switch hous-
ing.
11. Remove upper and lower fasteners holding right turn
signal and cruise control housings to handlebars.
12. See Figure 2-14. Use a screwdriver to rotate cable fer-
1
rules in throttle grip notches. Remove cables from
notches on inboard side of throttle grip and remove
throttle grip from handlebar.
13. Remove the cables from the housing.
10521
2
1.
Notch for switch housing
2.
5/32 in. (4 mm) cardboard
Figure 2-15. Cardboard Insert
Figure 2-14. Throttle and Idle Cable Ferrules
18. Remove upper and lower fasteners holding left turn sig-
nal and cruise control housings to handlebars.
14. Protect chrome and painted surfaces and tie idle and
19. Remove fasteners and washers securing the handlebar
throttle cables away from chrome and paint finishes.
clamp to the clutch lever bracket.
Maintain the routing of the cables.
20. Protect chrome and painted surfaces and tie the master
15. See Figure 2-15. Insert a 5/32 in. (4 mm) cardboard
cylinder, reservoir and clutch fluid line out of the way.
between front brake lever and lever bracket.
21. Remove upper handlebar clamps and lift handlebars,
turn signal housings, and wire harness from motorcycle.
CAUTION
NOTE
If handlebar rubber mounts require service, see HANDLE-
Do not remove or install the master cylinder assembly
BARS in the Touring Models Service Manual.
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
22. Place handlebars and wiring on work bench.
installing the master cylinder assembly without the
23. Cut wire tie at handlebar.
insert in place may result in damage to the rubber boot
and plunger on the front stoplight switch. (00324a)
16. Remove fasteners securing handlebar clamp to master
cylinder and front brake lever.
17. Protect chrome and painted surfaces and tie the master
cylinder, reservoir and brake line out of the way.
2005 FLHTCSE2: Chassis
2-13
HOME
24. See Figure 2-16. Lightly lubricate conduits and tape with
HANDGRIPS
glass cleaner then pull the left and right side wiring and
conduits from the handgrip ends through the handlebar
and handlebar grommets.
NOTE
It is not necessary to remove the handlebars from the motor-
25. If installing original handlebars, leave the wire leader in
cycle to replace the handgrips. Remove the control levers
each handlebar half. If installing new bars, string wire
and control housings according to the instructions in this sec-
leader through grommets on outside ends of bars and
tion and replace the hand grips.
through the center hole.
26. If necessary to repair wires, unwrap the electrical tape
1.
Replace right hand throttle grip. Slide throttle grip on in
and wire from the socket terminals.
operating position.
27. Repair and replace switches and socket wires as neces-
2.
Pry off end cap from left hand grip and using a sharp
sary.
blade carefully cut rubber between metal sleeve until the
metal sleeve can be pulled off the bars.
NOTE
3.
Clean left handlebar end.
For handlebar switch repair procedures, see HANDLEBAR
SWITCHES in Touring Models Service Manual.
NOTE
Before installing left hand grip, remove end cap to prevent
trapping air.
8689
1WARNING
FLAMMABLE, INJURIOUS TO EYES, HARMFUL IF SWAL-
LOWED, VAPOR HARMFUL. FLAMMABLE: CONTAINS
METHYL ETHYL KETONE. Use only in well ventilated
areas. Avoid contact with eyes, mucous membranes, and
prolonged skin contact. KEEP OUT OF REACH OF CHIL-
DREN. If swallowed, do not induce vomiting. Call a phy-
sician immediately. This product contains a chemical(s)
known to the State of California to cause cancer or other
reproductive harm.
4.
Apply a coat of HARLEY-DAVIDSON ADHESIVE (Part
no. 99839-95) to inside surface of new left hand grip at a
point 1 in. (25.4 mm) from open end. Apply a coat of
adhesive to handlebar end.
8688
5.
Immediately push grip completely onto the handlebar
end. Install grip with a twisting motion while aligning the
horizontal pattern on the left hand grip to the pattern on
the right hand grip in the closed position.
NOTE
Do not hesitate when installing left grip or adhesive will dry
before installation is complete. Allow 6-8 hours at 70° F (21˚
C) to achieve full cure of the adhesive.
6.
Install end caps.
Figure 2-16. Wire Leader in Handlebars
2-14
2005 FLHTCSE2: Chassis
HOME
NOTE
ASSEMBLY/INSTALLATION
An ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-
1.
Using mechanic’s wire, neatly wrap the socket terminals
39965) can be used to install Deutsch pin and socket termi-
and wires with a few twists to form leaders for turn signal
nals on wires.
and cruise control wires and conduit.
NOTE
If installing the original handlebars, use the wire end left in
f1270x2x
the handlebar half to wrap the socket terminals.
2.
String wire along the turn signal lamp wire. String suffi-
cient wire to pull conduits through handlebars.
3.
Wrap socket wires with electrical tape.
1WARNING
Without protective grommets around wire entry open-
ings in handlebars, wires can rub against sharp metal
edges of opening. A short or broken connection can
cause loss of electrical control which can lead to death
or serious injury.
4.
Lubricate wire conduits with glass cleaner. With the wire
leader, pull wire bundles through grommets and handle-
bar to the handlebars center hole.
5.
See Figure 2-17. and Figure 2-18. Orient wires in switch-
Figure 2-17. Run/Stop Switch Wiring in
housings. The right hand RUN and STOP wires are
Upper Right Hand Control Housing
wrapped over the front of the bars and back and into the
handlebar through the grommet. The wires should be to
the outside of the clamping post inside the housing.
6.
Loosely install left and right switch housings.
f1328x2x
7.
Pull wire leaders and unwrap the tape and mechanic’s
wire.
8.
Cable wrap wire conduits at exit from handlebars.
9.
See Figure 2-12. Fit wire seal into back of Deutsch
socket housings.
2
10. Insert wire color coded socket terminals into numbered
chambers in socket housings:
1
a. Hold socket terminal 1 in. (25.4 mm) behind contact
barrel.
4
b. Gently push socket terminal through hole in wire
3
seal into chamber until it “clicks” in place.
c. Verify that socket will not back out of chamber. Tug
5
on the wire to confirm that is locked.
1.
Right turn signal control and wiring
2.
Cruise control switch
3.
Mode select switch
4.
Lower bracket
5.
Clamping post
Figure 2-18. Wiring in Lower Right Hand Control Housing
2005 FLHTCSE2: Chassis
2-15
HOME
Table 2-4. Handlebar Deutsch Connectors
CAUTION
Wire Color
Chamber No.
Improperly aligned handlebars can hit tank when turned
lock to lock. Verify turning clearance before maneuvering
RH Connector (12 socket) (BLACK)
or riding motorcycle.
Orange/White (O/W)
1
14. Carry handlebars with internal wire harness and control
Red/Blue (R/BE)
2
housings to the motorcycle.
Gray (GY)
3
15. Set handlebars on lower clamps and loosely install
upper handlebar clamps and fasteners. Position wires so
White/Black (W/BK)
4
they exit under radio to front of vehicle from between ris-
White/Brown (W/BN)
5
ers.
Black/Red (BK/R)
6
CAUTION
Brown/White (BN/W)
7
Never adjust handlebars using excessive force. Doing so
Gray/White (GY/W)
8
may result in damage to handlebar.
Pink/White (PK/W)
9
NOTE
Violet/Black (V/BK)
10
If handlebars are positioned for a rider of normal size, post-
pone adjustment until rider has checked their position. If cus-
White/Blue (W/BE)
11
tomer requests changing handlebar position, perform the
Blue/Black (BE/BK)
12
adjustment before delivering the motorcycle.
LH Connector (12 socket) (GRAY)
16. Center handlebars laterally (sideways) in clamps.
17. Snug front fasteners until upper clamp contacts lower
Orange/White (O/W)
1
clamps.
Yellow (Y)
2
18. Position handlebars in normal rider posture.
Blue/White (BE)
3
19. Tighten fasteners in the following order:
White (W)
4
a. Rear fasteners: 12-16 ft-lbs (16.3-20.3 Nm).
b. Front fasteners: 12-16 ft-lbs (16.3-20.3 Nm).
White/Violet (W/V)
5
20. Push left and right harness Deutsch connectors into the
Yellow/Black (Y/BK)
6
pin side housings.
BLANK
7
21. Remove loosely installed control housing fasteners.
Brown/Black (BN/BK)
8
22. Push throttle and idle control cable inserts into lower
switch housing.
Pink/White (PK/W)
9
NOTE
Green/Blue (GN/BE)
10
The smaller idle cable insert is gold while the larger throttle
Gray/Green (GY/GN)
11
cable insert is silver. The inserts only fit their corresponding
hold in switch housing.
BLANK
12
23. Slide throttle control grip onto handlebar until it bottoms.
Pull grip back about 1/8 in. (3.2 mm).
11. Install internal seals on lip of socket housings.
24. Use a screwdriver to rotate barrels and fit cables through
12. Snap tapered end of locking wedges into socket hous-
notches in throttle control grip. Be sure cables ride in
ings.
grooves of throttle control grip.
NOTE
If the locking wedge does not snap into position, verify that all
terminals are fully seated in the socket housing.
13. Gently tug on wire ends to verify that all terminals are
locked.
2-16
2005 FLHTCSE2: Chassis
HOME
30. Install but do not tighten switch housing fasteners.
CAUTION
31. Position controls for rider posture and tighten fasteners:
a. Clutch master cylinder/reservoir clamp beginning
Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
with top fastener to 60-80 in-lbs (6.8-9.0 Nm). Top
between the brake lever and lever bracket. Removing or
gap, if any, must be at handlebar clearance.
installing the master cylinder assembly without the
b. Turn signal and cruise control housings beginning
insert in place may result in damage to the rubber boot
with bottom fastener to 35-45 in-lbs (4.0-5.1 Nm).
and plunger on the front stoplight switch. (00324a)
Rear gap, if any, should be tighter.
25.
Assemble upper and lower control housing to handle-
32. Verify routing of wire conduits, brake line and clutch fluid
bars and brake lever bracket.
line. See FRONT BRAKE LINE in Touring Models Ser-
vice Manual and 2.12 CLUTCH FLUID LINE in this book.
a. Position upper switch housing so wire conduit wraps
around outside of handlebar and sets in clearance
33. Install right rear view mirror stem through mirror spacer,
at bottom of handlebar.
and the brake control lever bracket. Install lock washer
and acorn nut on mirror stem.
b. Verify that wires will not be pinched when fasteners
are tightened.
34. Install left rear view mirror stem through tapered spacer
and clutch master cylinder. Install lock washer and acorn
c. Verify that throttle and idle control cables work
nut.
freely.
35. With motorcycle upright and with front fork pointed
d. Install switch housing fasteners.
straight ahead, adjust mirrors to clearly reflect area
26.
Loosely assemble handlebar clamp to front brake control
behind motorcycle.
lever bracket master cylinder and reservoir.
NOTE
a. Engage tab on switch with notch at top of brake
Adjust mirrors so a small portion of riders’ shoulder is visible
lever bracket.
in each mirror. This visually establishes the distance of vehi-
b. Alternately tighten housing and bracket fasteners
cles to rear of motorcycle.
until all components fit and wires route without inter-
36.
Tighten acorn nuts to 12 ft-lbs (16.3 Nm).
ference. fasteners should only be snug.
37.
Install radio according to procedure in Touring Models
c. Verify housing and bracket clamp are tight against
Service Manual.
handgrip shoulder/edge of bar.
38.
Install outer fairing, wind deflector and fairing cap
27.
Remove cardboard insert between brake lever and
according to procedure in touring Models Service Man-
bracket.
ual.
a. Control lever clamps beginning with top fastener to
39.
Install Maxi-Fuse and side cover.
60-80 in-lbs (6.8-9.0 Nm). The gap, if any must be
at clearance flat on handlebar.
40.
Test clutch lever and front brake lever for pressure and
operation.
b. Turn signal and cruise control housings beginning
with bottom fastener to 35-45 in-lbs (4.0-5.1 Nm).
41.
Turn throttle and idle adjusters out.
Rear gap, if any, should be tighter.
42.
Verify throttle and idle cable routing. Test for correct
28.
Loosely assemble clutch master cylinder/reservoir and
operation Adjust as required. See CRUISE CONTROL in
clamp to handlebar. Alternately tighten fasteners until
the Touring Models Service Manual.
clamp is snug to bracket.
43.
Verify brake and clutch fluid line routing.
29.
Install left turn signal and cruise control housings.
44.
Turn ignition/light key switch to IGNITION and test
a. Position upper switch housing so wire conduit wraps
switches for proper operation.
around front of handlebar.
45.
Apply brake lever to test stop lamp.
b. Verify wires will not be pinched when fasteners are
tightened.
c. Position upper switch housing to wire conduit sets in
clearance at bottom of handlebar and upper har-
ness will not be pinched when fasteners are tight-
ened.
d. Engage lower switch housing tab with notch in
clutch master cylinder reservoir.
2005 FLHTCSE2: Chassis
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HOME
CLUTCH MASTER CYLINDER/RESERVOIR
2.10
GENERAL
REMOVAL
The clutch is hydraulically actuated. Squeezing the clutch
1.
Remove acorn nut, washer and rear view mirror with
hand lever causes the clutch master cylinder to apply pres-
tapered spacer. Support turn sign bullet housing and
sure via the clutch fluid in the clutch line to the secondary
bracket.
clutch actuator mounted in the clutch release cover. The sec-
2.
Remove electrical controls.
ondary clutch actuator piston extends and contacts the clutch
release bearing which disengages the clutch.
CAUTION
A bleeder valve at the secondary clutch actuator is used to
bleed air from the clutch line. D.O.T. 4 HYDRAULIC BRAKE
To prevent dirt and other contaminants from entering the
FLUID (Part No. 99953-99A) is used in the clutch system and
master cylinder reservoir, thoroughly clean the cover
is referred to as clutch fluid in this manual.
before removal.
Check the clutch fluid level in the clutch fluid reservoir on left
3.
See Figure 2-19. Loosen, but do not remove, screws
handlebar. If the sight glass is dark, the fluid level in the res-
with flat washers that detach handlebar clamp from
ervoir is above the sight glass prism and the reservoir is full.
clutch master cylinder/reservoir.
If the sight glass appears clear, the fluid level is below the
4.
Loosen both screws on cover to relieve pressure in mas-
sight glass prism and the fluid level should be checked.
ter cylinder reservoir.
Clutch fluid should be level with the internal shelf marked
FILL LEVEL with the motorcycle upright and the gasket sur-
1WARNING
face level.
Be sure no clutch fluid gets on tires, wheels or brakes
when adding fluid. Traction can be adversely affected,
CAUTION
which could result in loss of control and death or serious
D.O.T. 4 hydraulic brake fluid is used in the hydraulic
injury. (00294a)
clutch. Do not use other types of fluids as they are not
NOTE
compatible and could cause equipment damage.
Place a large cup under the banjo fitting. Hydraulic fluid will
(00353a)
begin draining from the reservoir as the banjo bolt is
removed.
CAUTION
Clutch fluid volume increases with clutch wear. Do not
CAUTION
overfill clutch reservoir.
Damaged banjo bolt surfaces will leak when reassembled.
Prevent damage to seating surfaces by carefully remov-
ing clutch line components.
5.
Slowly loosen banjo bolt and allow clutch fluid from res-
ervoir to drain into cup.
2-18
2005 FLHTCSE2: Chassis
HOME
IMPORTANT NOTE
DISASSEMBLY
Dispose of clutch fluid in accordance with local regula-
tions.
CAUTION
6.
Remove banjo bolt and two steel/rubber washers to dis-
connect fitting of hydraulic clutch fluid line from clutch
To prevent dirt and other contaminants from entering the
reservoir and master cylinder. Discard steel/rubber
master cylinder reservoir, thoroughly clean the cover
washers.
before removal.
NOTE
1.
Drain additional clutch fluid from master cylinder/reser-
To prevent the rest of the clutch fluid from draining from the
voir.
clutch line and secondary clutch actuator, support the banjo
2.
Remove screws securing master cylinder cover.
fitting and clutch fluid line upright. Plug the banjo bolt hole
Remove cover and gasket. Turn housing upside down to
with a finger to transfer the assembly to a workbench without
remove remaining clutch fluid from reservoir.
spilling clutch fluid.
7.
Remove handlebar clamp screws and take clamp and
1WARNING
clutch master cylinder/reservoir assembly to a work-
bench.
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from
v0035x2xb
the pliers and could be propelled with enough force to
1
2
cause serious eye injury. (00312a)
3.
Remove retaining ring from pivot pin groove.
NOTE
To take the piston spring load off the pin and remove the pivot
pin, gently force the clutch lever toward the piston (as if oper-
ating the clutch).
10
7
4.
Remove pivot pin through top of housing. Remove and
3
save pivot pin and clutch lever.
4
5.
See Figure 2-20. Using a toothpick or small screwdriver,
9
8
gently pry outer edge of piston boot out of piston bore.
6.
Remove piston and spring.
1WARNING
5
Use denatured alcohol to clean clutch system compo-
6
nents. Do not use mineral-based solvents (such as gaso-
line or paint thinner), which will deteriorate rubber parts
1.
Cover
even after assembly. Deterioration of these components
2.
Clutch hand lever
can cause clutch failure, which could result in death or
3.
Cover hold down screws
serious injury. (00296a)
4.
Banjo fitting
7.
Wipe the housing with a lint free cloth. With a clean air
5.
Clutch fluid line
supply, blow out drilled passages and bore in the master
6.
Banjo bolt
cylinder housing.
7.
Steel/rubber washers
8.
Handlebar clamp
NOTE
9.
Washer
Do not use a wire or sharp instrument to clean drilled oil pas-
10.
Clamp screw
sages.
Figure 2-19. Clutch Master Cylinder/Reservoir
8.
Inspect cylinder housing bore for scoring, pitting or cor-
rosion. Also check outlet port for damage. Replace
housing if necessary.
9.
Inspect the cover, sight glass, and gasket for cuts, tears
or general deterioration.
2005 FLHTCSE2: Chassis
2-19
HOME
ASSEMBLY
9370
1
To rebuild clutch master cylinder, use the components found
in the SERVICE PARTS KIT No. 46244-01.
2
1.
See Figure 2-20. Lightly lubricate inside of primary cup
and fit over lip on spring end of piston so the closed end
(small ID) contacts evenly with the shoulder in primary
cup grove.
2.
Lightly lubricate inside of secondary cup (steep taper
7
8
from center to outside diameter) and fit over the lip on
outboard end of piston so that flared end is open toward
the shoulder of the secondary cup groove.
3.
Install boot, large sealing ID first, on piston until seal on
smaller ID fits snugly into thin groove in piston.
NOTE
3
See Figure 2-21. The flared ends of the primary cup and the
5
secondary cup face the spring end of the piston.
6
4.
Using lubricant in SERVICE PARTS KIT
(Part No.
3
46244-01) thoroughly coat outside diameters of primary
and secondary cups. Coat master cylinder piston bore.
5.
With tapered end out, install spring into opening on
inboard side of piston assembly.
6.
Align and install piston assembly into bore. Firmly press
on flat end of piston, compressing spring, until the entire
4
assembly slides into cylinder bore.
NOTE
When fitting the piston sealing boot, be careful not to tear,
perforate or damage the piston sealing boot.
7.
Compress piston until it is even with the end of bore.
Using a small dull bladed screwdriver or similar tool,
gently work around sealing edges of boot until entire cir-
cumference of boot is seated in cylinder bore groove.
8.
If cover gasket and/or sight glass replacement is neces-
sary. Proceed as follows:
a. From inboard side, push sight glass toward top of
cover until free.
b. Pull rubber gasket from cover.
c. Fit nipple of new gasket into hole of cover aligning
gasket and cover thru holes.
d. From bottom of gasket, push flat end of sight glass
through nipple until top of glass is flush with top of
gasket. Verify that glass is square in bore. If lubrica-
tion is necessary, use clean D.O.T. 4 HYDRAULIC
BRAKE FLUID (Part No. 99953-99A).
1.
Boot
2.
Piston
3.
Shoulder
4.
Spring
5.
Primary cup
6.
Groove - primary cup
7.
Secondary cup
8.
Groove - secondary cup
Figure 2-20. Clutch Master Cylinder Components
2-20
2005 FLHTCSE2: Chassis
HOME
9.
Install cover with gasket on master cylinder reservoir.
INSTALLATION
Install two screws to fasten the cover to reservoir, but do
not tighten.
1.
See Figure 2-19. Attach master cylinder/reservoir to
handlebars with handlebar clamp. Orient lever to rider
1WARNING
position and tighten two clamp screws to 60-80 in-lbs
(6.8-9.0 Nm).
Wear safety glasses or goggles when removing or
2.
Attach banjo fitting of clutch fluid line to master cylinder
installing retaining rings. Retaining rings can slip from
with new steel/rubber washers. Install electrical controls.
the pliers and could be propelled with enough force to
cause serious eye injury. (00312a)
3.
Loosen bleeder valve on clutch release cover. See 7.4
CLUTCH RELEASE COVER.
10. To install existing clutch hand lever, install clutch hand
4.
Fill reservoir with D.O.T. 4 HYDRAULIC BRAKE FLUID
lever, pivot pin, and a new retaining ring.
(Part No. 99953-99A). Allow fluid to fill clutch line until a
11. To install a replacement clutch hand lever, use SERVICE
steady flow of clutch fluid flows from bleeder valve. Fin-
PARTS KIT (Part No. 46243-01). See 2.11 CLUTCH
ger tighten bleeder valve.
HAND LEVER.
5.
Bleed clutch line. See BLEEDING CLUTCH FLUID
LINE.
9686
6.
Verify that fluid level in clutch fluid reservoir is at FILL
1
2
LEVEL with motorcycle upright and gasket surface level.
3
CAUTION
Clutch fluid volume increases with clutch wear. Do not
overfill clutch reservoir.
7.
Verify pressure by squeezing clutch hand lever.
8.
Tighten fasteners as follows:
a. Banjo bolt to 17-22 ft-lbs (23.1-29.9 Nm).
b. Bleeder screw to 80-100 in-lbs (9.0-11.3 Nm).
1.
Boot in piston groove
c. Reservoir cover screws to 6-8 in-lbs (0.7-0.9 Nm).
2.
Secondary cup flare
9.
Install rear view mirror and turn signals with bracket. See
3.
Primary cup
8.1 TURN SIGNALS.
Figure 2-21. Assembled Cups and Piston
1WARNING
Check for proper turn signal lamp operation before
riding motorcycle. Visibility is a major concern for motor-
cyclists. Failure to have proper lamp operation could
result in death or serious injury.
10. Test ride motorcycle.
2005 FLHTCSE2: Chassis
2-21
HOME
CLUTCH HAND LEVER
2.11
INSTALLATION
9477
2
1.
See Figure 2-22. Slide bushing cups onto pins of roller
with cup flanges against roller.
3
NOTE
Be careful when handling the bushing cups. The bushing
cups are hard plastic and can be easily broken.
2.
With connector bow portion of the bushing cups parallel
1
with groove in clutch handle, snap roller pin with the
bushing cups installed into clutch lever roller groove. If
bushing is positioned correctly, roller/bushing assembly
4
will install with a snap and will be held securely.
3.
Lightly grease pivot bushing and install into clutch hand
lever pivot hole. Position bushing until it is flush with both
sides of lever.
NOTE
1.
Clutch hand lever
If the clutch master cylinder/reservoir is full of clutch fluid
2.
Pivot bushing
under pressure, it may be necessary to apply force to the
3.
Bushing cups connector bow
hydraulic piston (in the clutch hand lever mount) in order to
4.
Roller pin
align the clutch hand lever and to allow the pivot pin to be
inserted.
Figure 2-22. Clutch Hand Lever
4.
Orient clutch lever in lever mounting bracket. Insert pivot
pin from top and tap into place.
5.
Install new retaining ring on pivot pin.
2-22
2005 FLHTCSE2: Chassis
HOME
CLUTCH FLUID LINE
2.12
REPLACEMENT
9994
1.
Remove outer fairing. See Touring Models Service Man-
ual for procedure.
1WARNING
Be sure no clutch fluid gets on tires, wheels or brakes
when adding fluid. Traction can be adversely affected,
which could result in loss of control and death or seri-
ous injury. (00294a)
2.
Loosen the clutch master cylinder/reservoir cover.
3.
See Figure 2-23. Place a suitable container under clutch
release cover (4).
4.
Loosen flare nut (2) and allow clutch fluid to drain.
5.
Remove flare nut on outside of the clutch release cover.
6.
Drain clutch fluid line (3).
Figure 2-24. Clutch Fluid Line O-ring
9930
1
8.
See Figure 2-25. Remove banjo bolt (5) and two wash-
4
ers (4) to disconnect fitting of hydraulic clutch fluid line
(3) from clutch master cylinder/reservoir
(2). Discard
washers.
2
3
cse0003x2x
1
2
1.
Bleeder valve (cap removed)
4
2.
Flare nut
3.
Clutch fluid line
3
4.
Clutch release cover
Figure 2-23. Clutch Release Cover
5
(exhaust system removed)
NOTE
Dispose of clutch fluid in accordance with local regulations.
7.
See Figure 2-24. Remove and discard o-ring.
NOTE
1.
Clutch lever
Clutch fluid line o-ring may stick to inside of clutch release
2.
Clutch master cylinder/reservoir
cover. Use a pick to remove old o-ring and other debris.
3.
Clutch fluid line assembly
4.
Banjo bolt washer (2)
5.
Banjo bolt
Figure 2-25. Clutch Master Cylinder Assembly
and Fluid Line
2005 FLHTCSE2: Chassis
2-23
HOME
9.
See Figure 2-26. Carefully pull banjo fitting end of clutch
10555
fluid line out through inner fairing grommet.
10. Route new clutch fluid line back through fairing retracing
path of old line.
10947
Figure 2-27. Clamp Locations on Frame Down Tube
9991
Figure 2-26. Clutch Fluid Line Inner Fairing Grommet
11.
Loosely install banjo bolt and tie free end of clutch fluid
line away from chrome and painted surfaces.
12.
See Figure 2-27. See Figure 2-28. Loosen clamps and
cut cable ties around old clutch fluid line along right side
frame down tube and behind cam cover around the rear
brake line in front of the clamp.
13.
Remove old clutch fluid line.
14.
Route new clutch fluid line down right side frame tube,
under cam cover and up to clutch release cover. See
CLUTCH FLUID LINE ROUTING.
15.
See Figure 2-24. Install new o-ring on end of clutch fluid
line.
16.
Thread in and finger tighten flare nut fastening clutch
fluid line to clutch release cover.
17.
See Figure 2-25. Attach banjo fitting of the clutch fluid
line (3) to master cylinder (2) with new washers (4).
Figure 2-28. Cable Wrap Locations around
Clutch Fluid Line
18.
Cable wrap clutch fluid line in original places on inner
fairing bracket and behind cam cover around the rear
brake line in front of the clamp.
19. Install outer fairing assembly. See Touring Models Ser-
vice Manual for procedure.
1WARNING
Be sure no clutch fluid gets on tires, wheels or brakes
when adding fluid. Traction can be adversely affected,
which could result in loss of control and death or seri-
ous injury. (00294a)
1WARNING
Do not allow dirt or debris to enter the clutch master cyl-
inder reservoir. Dirt or debris in the reservoir can cause
improper operation of the clutch and equipment dam-
age. (00205a)
2-24
2005 FLHTCSE2: Chassis
HOME
CLUTCH FLUID LINE ROUTING
1WARNING
1.
Remove outer fairing. See Touring Models Service Man-
Direct contact of D.O.T. 4 brake fluid with eyes can cause
ual for procedure.
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
2.
Route clutch fluid line:
Swallowing large amounts of D.O.T. 4 brake fluid can
a.
Route line through inner fairing grommet.
cause digestive discomfort. If swallowed, obtain medical
b.
Route line around top of steering head and back out
attention. Use in well ventilated area. KEEP OUT OF
to P-clamp used for throttle cables.
REACH OF CHILDREN. (00240a)
c. Run clutch fluid line behind engine guard and in
20. Loosen bleeder valve.
front of right frame downtube.
21. Remove clutch master cylinder/reservoir cover and fill
d.
Run line behind foot controls bracket.
reservoir with D.O.T. 4 HYDRAULIC BRAKE FLUID (Part
e.
Following inboard side of frame downtube, route
No. 99953-99A). Allow fluid to fill clutch line until a
cable between bottom of cam cover and top of lower
steady flow of clutch fluid flows from bleeder screw. Fin-
frame tube.
ger tighten bleed screw.
f.
See Figure 2-28. Line is cable wrapped along rear
NOTE
brake line just in front of main wire harness conduit.
A Snap-on BASIC VACUUM BRAKE BLEEDER with a fitting
g. Route line up to clutch release cover.
that mates to the bleeder valve can be used to draw the fluid
down the clutch line.
3.
See Figure 2-27. Install clamps to retain clutch fluid line
at two locations on right frame downtube.
22. Bleed clutch fluid line. See BLEEDING CLUTCH FLUID
4.
Install outer fairing. See Touring Models Service Manual
LINE.
for procedure.
CAUTION
BLEEDING CLUTCH FLUID LINE
Clutch fluid volume increases with clutch wear. Do not
overfill clutch reservoir.
23. Verify that fluid level in clutch fluid reservoir is at FILL
1WARNING
LEVEL with motorcycle upright and gasket surface level.
Be sure no clutch fluid gets on tires, wheels or brakes
24. Test pressure by squeezing clutch hand lever.
when adding fluid. Traction can be adversely affected,
25. Tighten fasteners as follows:
which could result in loss of control and death or serious
a. Clutch master cylinder banjo bolt to 17-22 ft-lbs
injury. (00294a)
(23.1-29.9 Nm).
b. Clutch line flare nut to 80-115 in-lbs (9.0-13.0 Nm).
CAUTION
c. Actuator bleeder valve to 80-100 in-lbs (9.0-11.3
Do not allow dirt or debris to enter the clutch master cyl-
Nm).
inder reservoir. Dirt or debris in the reservoir can cause
d. Reservoir cover screws to 6-8 in-lbs (0.7-0.9 Nm).
improper operation of the clutch and equipment dam-
26. Test ride motorcycle. Incorrect pressure or fluid level can
age. (00205a)
cause:
a. Dragging clutch.
1WARNING
b. Hard shifting.
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can
cause digestive discomfort. If swallowed, obtain medical
attention. Use in well ventilated area. KEEP OUT OF
REACH OF CHILDREN. (00240a)
2005 FLHTCSE2: Chassis
2-25
HOME
NOTE
IMPORTANT NOTE
When filling an empty clutch fluid line, a Snap-on BASIC
Dispose of clutch fluid in accordance with local regula-
VACUUM BRAKE BLEEDER with a fitting that mates to the
tions.
secondary clutch actuator bleeder valve can be used to ini-
tially draw the fluid down the clutch line.
6.
While holding reservoir cover in place:
a. Pump clutch hand lever 5 times.
1.
Stand motorcycle upright and turn handlebars to right as
required to place clutch reservoir in a level position.
b. Hold clutch hand lever against handlebar.
Remove reservoir cover.
c. Loosen secondary clutch actuator bleed valve.
d. Run hose from bleeder valve to suitable container.
CAUTION
e. Watch bleeder valve for air bubbles.
Clutch fluid volume actually increases with clutch wear.
f.
Tighten bleeder valve.
Do not overfill reservoir.
g. Release hand lever.
2.
If necessary, add D.O.T. 4 HYDRAULIC BRAKE FLUID
7.
With reservoir level, fill reservoir to FILL LEVEL and
(Part No. 99953-99A) to clutch master cylinder reservoir.
repeat the previous step three times or more until only a
Initial fluid level should not exceed FILL LEVEL with res-
steady flow of clutch fluid escapes bleeder valve and
ervoir in a level position.
fluid level in reservoir is at FILL LEVEL with motorcycle
in an upright position.
1CAUTION
CAUTION
Loosen banjo bolt only enough to allow air bubbles to
escape. Clutch fluid under pressure can squirt a steady
Clutch fluid volume actually increases with clutch wear.
stream several feet.
Do not overfill reservoir.
3.
While holding reservoir cover in place:
8.
Test pressure by squeezing clutch hand lever.
a. Pump clutch hand lever 5 times.
9.
Tighten fasteners as follows:
b. Hold clutch hand lever against handlebar.
a. Clutch master cylinder banjo bolt to 17-22 ft-lbs
(23.1-29.9 Nm).
c. Hold shop towel under fitting and loosen banjo bolt.
b. Clutch line flare nut to 80-115 in-lbs (9.0-13.0 Nm).
d. Watch banjo fitting for air bubbles.
c. Actuator bleeder valve to 80-100 in-lbs (9.0-11.3
e. Retighten banjo fitting.
Nm).
f.
Release hand lever.
d. Reservoir cover screws to 6-8 in-lbs (0.7-0.9 Nm).
4.
Fill reservoir to FILL LEVEL and repeat the previous
10. Replace cap on actuator bleeder valve.
step three times or more until only a steady flow of clutch
fluid escapes banjo fitting and fluid level in reservoir is at
11. Test ride motorcycle. Incorrect pressure or fluid level can
FILL LEVEL with motorcycle in an upright position.
cause:
5.
Cover exhaust with towel and place a suitable pan under
a. Dragging clutch.
clutch release cover to catch excess clutch fluid.
b. Hard shifting.
2-26
2005 FLHTCSE2: Chassis
HOME
SEAT
2.13
REMOVAL
cse0010x2x
1.
Remove rider and passenger backrests.
1
2.
Remove saddlebag.
3.
Remove fastener with flat washer holding one side of
3
passenger grabstrap.
2
4.
See Figure 2-29. Remove screw (3) holding seat to
fender.
5.
Slide seat backward to free tongue (4) on bottom front of
seat from slot in frame backbone. Remove seat.
7
5
CLEANING AND INSPECTION
6
8
CAUTION
4
1.
Passenger grabstrap
Do not use bleach or detergents containing bleach on
2.
Seat
saddlebags, seats, tank panels or painted surfaces.
3.
Screw
Doing so can result in equipment damage. (00229a)
4.
Tongue
● Do not use ordinary soap to clean leather. It could dry or
5.
Mounting bracket
remove the oils from the leather.
6.
Retention nut
7.
Retention washer
● Use ONLY a good quality saddle soap to clean leather.
8.
Screw (2)
Be sure to rinse saddle soap off thoroughly before treat-
ing leather.
Figure 2-29. Seat Components
● Never try to dry leather quickly, using artificial means.
Always let leather dry naturally at room temperature.
INSTALLATION
NOTE
HARLEY-DAVIDSON LEATHER DRESSING
(Part No.
1.
See Figure 2-29. Set seat on frame and slide seat for-
98261-91V) has been tested and approved for materials
ward until tongue (4) engages slot in frame backbone.
used in FLHTCSE2 seats.
2.
Push seat forward until retention nut (6) in fender is cen-
tered in hole of mounting bracket (5). Install screw (3)
1.
Inspect seat for wear or damage.
and tighten securely.
2.
Clean underside of pillion and seat. Clean fender and
frame mounting surfaces.
1WARNING
After installing seat, pull upward on front of seat to be
sure it is in locked position. While riding, a loose seat
can shift causing loss of control, which could result in
death or serious injury. (00070a)
3.
Pull up on seat to verify that it is properly secured.
4.
Install passenger grabstrap to saddlebag mounting
bracket.
5.
Install rider and passenger backrests.
2005 FLHTCSE2: Chassis
2-27
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