Harley Davidson 2005 touring models. Service repair manual — page 12
HOME
STRIPPING MOTORCYCLE FOR SERVICE
3.5
e.
Pull and twist on crossover pipe to remove left side
PROCEDURE
exhaust from vehicle. For best results, be sure to
allow sufficient time for the penetrating oil to work.
NOTE
f.
Remove TORCA clamp assembly from crossover
If performing top end service (or both cam compartment and
pipe and discard.
top end), follow steps 1-21. If servicing cam compartment
NOTE
components only, perform steps 1-12.
To ensure sealing integrity of TORCA clamps and prevent the
1.
Drain and remove fuel tank. Proceed as follows:
possibility of leakage, Harley-Davidson recommends that
TORCA assemblies be discarded and replaced each time
Carbureted: See Section 4.7 FUEL TANK (CARBU-
they are removed.
RETED), COMPLETE REMOVAL, FLHT/C, or FLHR/S.
g.
Moving to right side of vehicle, open two worm drive
Fuel Injected: See Section
9.4 FUEL TANK (FUEL
clamps and release heat shield from front header
INJECTED), COMPLETE REMOVAL, FLHT/C/U/I,
pipe. Using an impact wrench with long 1/2 inch
FLTRI, or FLHR/C/S/I.
swivel socket, remove two exhaust flange nuts to
release front header pipe from studs of front cylin-
2.
Remove left side saddlebag. See Section 2.25 SAD-
der head. Slide exhaust flange down header pipe to
DLEBAG, REMOVAL.
improve clearance around exhaust port.
3.
Gently pull left side cover from frame downtubes (no
h.
Open two worm drive clamps and release heat
tools required).
shield from rear header pipe. Remove two exhaust
4.
On Ultra models, hold locknut at bottom of left fairing
flange nuts to release rear header pipe from studs
lower, and using a T40 TORX drive head, turn inside
of rear cylinder head.
screw to free assembly from engine guard clamp. Dis-
i.
Open two worm drive clamps to release heat shield
card rubber washer.
over front header pipe to rear header pipe connec-
5.
Repeat steps 2-4 to remove saddlebag, side cover and
tion (outboard of transmission side door).
fairing lower on right side of vehicle.
j.
Remove bolt (with flat washer and locknut) from
transmission exhaust bracket clamp on front header
6.
Remove the air cleaner and backplate. See Section 4.5
pipe. Use a channel lock to open clamp and then
AIR CLEANER, REMOVAL.
remove from header pipe and transmission exhaust
7.
Remove two allen head socket screws (with lockwashers
bracket.
and flat washers) to release right side front footboard
k.
Remove two bolts (with lockwashers) to detach right
brackets from frame weldment. For best results,
side muffler from the lower saddlebag support rail.
approach from left side of vehicle using a 3/8 inch ball
allen with extension.
l.
Depressing rear brake pedal, remove right side
exhaust from vehicle.
8.
Remove exhaust system in two sections as follows:
m.
Remove and discard gaskets from front and rear
a. Open two worm drive clamps to release heat shield
exhaust ports.
over rear header pipe to crossover pipe connection
(above starter).
9.
Moving to left side of vehicle, pull boots on spark plug
cables to release from spark plug and ignition coil tow-
b. Loosen TORCA clamp between rear header pipe
ers. Release cables from three cable clips at bottom of
and crossover pipe. Remove Keps nut and pull
frame backbone.
bracket tab and stud from slots in TORCA clamp
10.
Remove spark plugs.
and exhaust support bracket.
11.
Pull external latch outward and use rocking motion to
c. Spray PB Blaster or other suitable penetrating oil in
remove electrical connector from left side of ignition coil.
and around joint between rear header pipe and
crossover pipe.
12.
Pull sides of ignition coil bracket outward to remove from
bosses of front fuel tank mount.
d. Moving to left side of vehicle, remove two bolts (with
lockwashers) to detach left side muffler from the
13.
Remove connections to carburetor or induction module.
lower saddlebag support rail.
Proceed as follows:
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2005 Touring: Engine
HOME
Carbureted:
a. Remove right side allen head socket screws from
front and rear cylinder head flange adapters. For
a. Standing on left side of vehicle, remove electrical
best results, use the INTAKE MANIFOLD WRENCH
connector from manifold absolute pressure (MAP)
(HD-47250), or a long
1/4 inch ball allen head
sensor at top of intake manifold.
socket with end driver 4 inches long.
b. Locate the fuel enrichener knob under the left side
b. Moving to opposite side of vehicle, just loosen left
of the fuel tank, and loosen hex nut at backside of
side allen head socket screws from flange adapters.
mounting bracket. Slide cable assembly free of slot
Slots in flanges make removal of left side screws
in mounting bracket.
unnecessary.
c. Remove intake manifold/carburetor or induction
Fuel Injected:
module from right side of vehicle.
a. Standing on right side of vehicle, remove idle air
control and manifold absolute pressure sensor con-
18.
Standing on left side of vehicle, remove two hex head
nectors. Pull external latch(es) outward and use
bolts (with flat washers) to release top engine mounting
rocking motion to separate pin and socket halves.
bracket from cylinder heads.
b. Depress wire form to remove electrical connectors
19.
Leaving ground wire ring terminal in place, detach
from front and rear fuel injectors.
socket terminal of yellow lead from spade contact at
back of horn. Release wire conduit from J-clamp.
c. Remove throttle position sensor and intake air tem-
perature sensor connectors.
20.
Moving to right side of vehicle, turn hex head bolt to
release stabilizer link from frame weldment.
d. Moving to left side of vehicle, pull back boot to
reveal engine temperature sensor at back of front
21.
Remove horn, top engine mounting bracket and stabi-
cylinder. Pull external latch outward and remove
lizer link as an assembly.
connector. Cut cable strap to release conduit from
horn bracket.
e. Tuck free ends of EFI wire harness under main wire
harness on frame backbone to keep conduit and
connectors out of the way.
14.
Remove idle and throttle control cables as follows:
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.
Release idle and throttle cables from guides in throttle
cable bracket.
Fuel Injected: Using a needle nose pliers, carefully pull
idle cable barrel from upper hole in throttle wheel. Pull
throttle cable barrel from lower hole. Using slots, release
idle and throttle cables from guides in throttle cable
bracket.
15.
Free idle and throttle control cables from J-clamp fas-
tened to right side of frame backbone. Move cables up
and out of the way.
16.
If equipped with cruise control, remove E-clip from
sleeve at end of cruise cable housing. Using slot,
remove cable housing from cable guide in throttle cable
bracket. Push the plastic end fitting on the cruise cable
to the outboard side to release from wheel pin. Move
cable up and out of the way.
17.
Remove intake manifold/carburetor or induction module.
Proceed as follows:
2005 Touring: Engine
3-17
HOME
ASSEMBLING MOTORCYCLE AFTER STRIPPING
3.6
2.
Install horn, top engine mounting bracket and stabilizer
PROCEDURE
link as an assembly. Proceed as follows:
a. Moving to right side of vehicle, turn hex head bolt to
NOTE
secure stabilizer link to frame weldment. Tighten
If top end service was performed (or both cam compartment
bolt to 18-22 ft-lbs (24-30 Nm).
and top end), follow steps 1-19. If only cam compartment
b. Attach socket terminal of yellow lead to spade con-
components were serviced, perform steps 8-18.
tact at back of horn. Capture wire conduit in J-
1.
Install intake manifold/carburetor or induction module.
clamp.
Proceed as follows:
c. Standing on left side of vehicle, install two hex head
a.
With the counterbore facing outward, slide cylinder
bolts
(with flat washers) to secure top engine
head flange adapters onto outlet ports of intake
mounting bracket to front and rear cylinder heads.
manifold/induction module. The flange adapters are
Alternately tighten bolts to 35-40 ft-lbs (48-54 Nm).
not interchangeable. Look next to the slotted bolt
3.
If equipped with cruise control, slide groove in cruise
hole for a stamp that indicates F(ront) and R(ear)
cable end fitting over cap of wheel pin. Push on end fit-
cylinder.
ting until it snaps in place. Using slot, slip cruise cable
b.
Place a new seal in each flange adapter with the
housing into cable guide in throttle cable bracket. Install
beveled side in against the counterbore.
new E-clip on sleeve at end of cruise cable housing.
c.
Standing on right side of engine, slide intake mani-
4.
Route idle and throttle control cables through J-clamp
fold/induction module toward installed position so
fastened to right side of frame backbone.
that open-ended slots on flange adapters begin to
5.
Install idle and throttle control cables as follows:
engage allen head socket screws loosely installed
Carbureted: Install sleeve on throttle cable housing into
on left side.
shorter cable guide in throttle cable bracket. Drawing
d.
Align fixed holes in flange adapters with those in
throttle cable downward, fit barrel end into lower out-
cylinder heads and start allen head socket screws.
board hole in throttle wheel. Install sleeve and spring on
For best results, use the INTAKE MANIFOLD
idle cable housing into longer cable guide inserting bar-
WRENCH (HD-47250), or a long 1/4 inch ball allen
rel end into upper inboard hole in throttle wheel.
head socket with end driver 4 inches long.
Induction Module:Install sleeve on throttle cable hous-
e.
Use the air cleaner backplate or INDUCTION SYS-
ing into shorter cable guide at top of throttle cable
TEM ALIGNMENT BRACKET
(P&A Part No.
bracket. Drawing throttle cable downward, fit barrel end
40054-01) to properly locate carburetor/induction
into lower hole in throttle wheel. Install sleeve and spring
module. Proceed as follows:
on idle cable housing into longer cable guide at bottom
Backplate: Install two breather bolts to fasten back-
of throttle cable bracket inserting barrel end into upper
plate to front and rear cylinder heads. Install three
hole in throttle wheel.
T27 TORX screws to secure backplate to face of
6.
Adjust cables as necessary to keep barrel ends from dis-
carburetor/induction module.
lodging. Verify that cables are seated in channel of throt-
tle wheel. Verify operation by turning throttle grip and
Alignment bracket: Fitting pins on inboard side
observing cable action.
into holes in face of carburetor/induction module,
install two breather bolts to fasten bracket to front
7.
Install connections to carburetor or induction module.
and rear cylinder heads.
Standing on left side of vehicle, proceed as follows:
f.
Tighten allen head socket screw in fixed holes of
Carbureted:
flange adapters until snug. Moving to left side of
engine, tighten screws in slotted holes to 96-144 in-
a. Moving to left side of vehicle, install electrical con-
lbs (10.9-16.3 Nm).
nector to manifold absolute pressure (MAP) sensor
at top of intake manifold.
g.
Remove breather bolts and T27 TORX screws to
b. Slide threaded portion of enrichener cable into slot
remove backplate, if installed.
of mounting bracket. Flat on threads must face rear
h.
Tighten allen head socket screws in fixed holes of
of vehicle for script on enrichener knob to be right
side up. With the external tooth lockwasher and hex
flange adapters to 96-144 in-lbs (10.9-16.3 Nm).
nut positioned on the inboard side of the mounting
i.
Remove breather bolts to remove alignment
bracket, tighten hex nut to 20-35 in-lbs (2.3-4.0
bracket, if installed.
Nm).
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2005 Touring: Engine
HOME
Fuel Injected:
●
Using a long 1/2 inch swivel socket, tighten the top
nut of the front cylinder head exhaust flange to 9-18
a. Install electrical connectors on fuel injectors.
in-lbs (1-2 Nm). Tighten the bottom nut to 100-120
b. Install manifold absolute pressure sensor and idle
in-lbs (11.3-13.6 Nm). Final tighten the top nut to
air control connectors.
100-120 in-lbs (11.3-13.6 Nm).
●
Tighten the bottom nut of the rear cylinder head
c. Install intake air temperature sensor and throttle
exhaust flange to 9-18 in-lbs (1-2 Nm). Tighten the
position sensor connectors.
top nut to
100-120 in-lbs (11.3-13.6 Nm). Final
d. Moving to left side of vehicle, install connector to
tighten the bottom nut to 100-120 in-lbs (11.3-13.6
engine temperature sensor at back of front cylinder.
Nm).
Pull boot over sensor to keep out dirt and debris.
●
Tighten the transmission exhaust bracket clamp bolt
Install new cable strap to secure connector conduit
to 60-96 in-lbs (6.8-10.8 Nm).
to horn bracket.
●
Tighten the two bolts (with lockwashers) to fasten
8.
Install exhaust system as follows:
the right side muffler to the lower saddlebag support
rail.
a. Install new gaskets in both the front and rear cylin-
der head exhaust ports (with the tapered side out).
●
Tighten the two bolts (with lockwashers) to fasten
the left side muffler to the lower saddlebag support
b. Place right side exhaust into position on vehicle and
rail.
start two exhaust flange nuts to secure front header
●
Verify that all exhaust pipes are in alignment and do
pipe to studs of front cylinder head.
not contact the vehicle frame or mounted compo-
c. Start two bolts (with lockwashers) to secure right
nents.
side muffler to the lower saddlebag support rail.
●
Tighten the TORCA clamp between the rear header
pipe and crossover pipe to 45-60 ft-lbs (61-81 Nm).
d. Start two exhaust flange nuts to secure rear header
pipe to studs of rear cylinder head.
●
Tighten Keps nut securing bracket tab to exhaust
support bracket.
e. Engaging transmission exhaust bracket, capture
front header pipe in transmission exhaust bracket
clamp. Use a channel lock to close clamp, if neces-
CAUTION
sary. Finger tighten clamp bolt (with flat washer and
Verify that the heat shields do not contact the vehicle
locknut).
frame or any mounted components. Contact will cancel
the effect of the rubber isolation mounts and transmit
NOTE
vibration to the rider via the vehicle frame.
To ensure sealing integrity of TORCA clamps and prevent the
possibility of leakage, Harley-Davidson recommends that
NOTE
TORCA assemblies be discarded and replaced each time
Position worm drive clamps so that screws are on the out-
they are removed.
board side in the most accessible position.
f.
Moving to left side of vehicle, slide new TORCA
k. Open worm drive clamps and install heat shields as
clamp assembly onto crossover pipe.
follows:
g. Twist and push left side exhaust onto crossover
● Over front header pipe (below exhaust port).
pipe.
● Over rear header pipe (below exhaust port).
h. Start two bolts (with lockwashers) to secure left side
● Over front header pipe to rear header pipe connec-
muffler to the lower saddlebag support rail.
tion (outboard of transmission side door).
i.
Returning to left side of vehicle, position TORCA
● Over rear header pipe to crossover pipe connection
clamp between rear header pipe and crossover
(above starter).
pipe. Fit bracket tab into slot of TORCA clamp
engaging stud in slot of exhaust support bracket.
l.
Position each worm drive clamp so that screw is on
Start Keps nut on stud.
the outboard side in the most accessible position
and then tighten to 20-40 in-lbs (2.3-4.5 Nm).
CAUTION
9.
Insert two allen head socket screws (with lockwashers
and flat washers) through frame weldment into right side
Verify that the exhaust pipes do not contact the vehicle
front footboard brackets. For best results, approach from
frame or any mounted components. Contact will cancel
left side of vehicle using a 3/8 inch ball allen with exten-
the effect of the rubber isolation mounts and transmit
sion.
vibration to the rider via the vehicle frame.
10. Install the backplate and air cleaner. See Section 4.5
j.
Tighten the exhaust system as follows:
AIR CLEANER, INSTALLATION.
2005 Touring: Engine
3-19
HOME
11.
On Ultra models, place fairing lower into position on right
17.
Install the fuel tank. Proceed as follows:
side of vehicle. Holding T40 TORX screw inside fairing
Carbureted: See Section 4.7 FUEL TANK (CARBU-
lower, install new rubber washer, clamp and locknut to
RETED), INSTALLATION
(AFTER COMPLETE
attach fairing bottom to engine guard. Do not tighten
REMOVAL), FLHT/C, or FLHR/S.
locknut.
12.
Align barbed studs in right side cover with grommets in
Fuel Injected: See Section
9.4 FUEL TANK (FUEL
frame downtubes and push firmly into place (no tools
INJECTED), INSTALLATION
(AFTER COMPLETE
REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
required).
13.
Install right side saddlebag. See Section 2.25 SADDLE-
18.
On Ultra models, hold locknut at bottom of fairing lower,
BAG, INSTALLATION.
and using a T40 TORX drive head, turn inside screw to
fasten assembly to engine guard clamp. Tighten screw
14.
Repeat steps 11-13 to install side cover, saddlebag and
to 90-100 in-lbs (10.2-11.3 Nm). Repeat step on oppo-
fairing lower on left side of vehicle.
site side of vehicle.
15.
Install spark plugs in front and rear cylinder heads.
19.
Adjust idle and throttle control cables as follows:
Install the plugs finger tight and then tighten to 12-18 ft-
lbs (16-24 Nm).
Non-Cruise: See Section 2.21 THROTTLE CABLES
(NON-CRUISE), ADJUSTMENT.
16.
Install ignition coil and spark plug cables as follows:
a. With the coil towers facing rear of vehicle, hold igni-
Cruise Equipped: See Section 8.30 CRUISE CON-
tion coil and bracket at bottom of frame backbone.
TROL (FLHRC, FLTR, FLHTCU), CABLE ADJUST-
Pull sides of bracket outward and install on bosses
MENT.
of front fuel tank mount. See Figure 3-11.
b. Install electrical connector on left side of ignition
coil.
c. Install spark plug cable to front cylinder onto left
side coil tower. Verify that spark plug cable is cap-
tured in double-sided cable clip at bottom left side of
frame backbone. Install new cable clip on T-stud if
damaged or missing.
d. Install spark plug cable to rear cylinder onto right
side coil tower. Verify that spark plug cable is cap-
tured in two single-sided cable clips at bottom left
side of frame backbone. Install new cable clips on T-
studs if damaged or missing.
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2005 Touring: Engine
HOME
REMOVING ENGINE FROM CHASSIS
3.7
NOTE
PROCEDURE
To ensure sealing integrity of TORCA clamps and prevent the
possibility of leakage, Harley-Davidson recommends that
1.
Drain and remove fuel tank. Proceed as follows:
TORCA assemblies be discarded and replaced each time
Carbureted: See Section 4.7 FUEL TANK (CARBU-
they are removed.
RETED), COMPLETE REMOVAL, FLHT/C, or FLHR/S.
g.
Moving to right side of vehicle, open two worm drive
Fuel Injected: See Section
9.4 FUEL TANK (FUEL
clamps and release heat shield from front header
INJECTED), COMPLETE REMOVAL, FLHT/C/U/I,
pipe. Using an impact wrench with long 1/2 inch
FLTRI, or FLHR/C/S/I.
swivel socket, remove two exhaust flange nuts to
release front header pipe from studs of front cylin-
2.
Remove the primary chaincase. See Section 6.5 PRI-
der head. Slide exhaust flange down header pipe to
MARY CHAINCASE, REMOVAL, steps 2-18.
improve clearance around exhaust port.
3.
Remove left side saddlebag. See Section 2.25 SAD-
h.
Open two worm drive clamps and release heat
DLEBAG, REMOVAL.
shield from rear header pipe. Remove two exhaust
4.
Gently pull left side cover from frame downtubes (no
flange nuts to release rear header pipe from studs
tools required).
of rear cylinder head.
5.
On Ultra models, hold locknut at bottom of left fairing
i.
Open two worm drive clamps to release heat shield
lower, and using a T40 TORX drive head, turn inside
over front header pipe to rear header pipe connec-
screw to free assembly from engine guard clamp. Dis-
tion (outboard of transmission side door).
card rubber washer.
j.
Remove bolt (with flat washer and locknut) from
6.
Repeat steps 3-5 to remove saddlebag, side cover and
transmission exhaust bracket clamp on front header
fairing lower on right side of vehicle.
pipe. Use a channel lock to open clamp and then
remove from header pipe and transmission exhaust
7.
Remove the air cleaner and backplate. See Section 4.5
bracket.
AIR CLEANER, REMOVAL.
k.
Remove two bolts (with lockwashers) to detach right
8.
Remove two allen head socket screws (with lockwashers
side muffler from the lower saddlebag support rail.
and flat washers) to release right side front footboard
l.
Depressing rear brake pedal, remove right side
brackets from frame weldment. For best results,
exhaust from vehicle.
approach from left side of vehicle using a 3/8 inch ball
allen with extension.
m.
Remove and discard gaskets from front and rear
exhaust ports.
9.
Remove exhaust system in two sections as follows:
10.
Remove connections to carburetor or induction module.
a. Open two worm drive clamps to release heat shield
Proceed as follows:
over rear header pipe to crossover pipe connection
(above starter).
Carbureted:
b. Loosen TORCA clamp between rear header pipe
a. Moving to left side of vehicle, pull external latch out-
and crossover pipe. Remove Keps nut and pull
ward and use rocking motion to remove electrical
bracket tab and stud from slots in TORCA clamp
connector from manifold absolute pressure (MAP)
and exhaust support bracket.
sensor at top of intake manifold.
c. Spray PB Blaster or other suitable penetrating oil in
b. Locate the fuel enrichener knob under the left side
and around joint between rear header pipe and
of the fuel tank, and loosen hex nut at backside of
crossover pipe.
mounting bracket. Slide cable assembly free of slot
in mounting bracket.
d. Moving to left side of vehicle, remove two bolts (with
lockwashers) to detach left side muffler from the
Fuel Injected:
lower saddlebag support rail.
a. Standing on right side of vehicle, remove idle air
e. Pull and twist on crossover pipe to remove left side
control and manifold absolute pressure sensor con-
exhaust from vehicle. For best results, be sure to
nectors. Pull external latch(es) outward and use
allow sufficient time for the penetrating oil to work.
rocking motion to separate pin and socket halves.
f.
Remove TORCA clamp assembly from crossover
b. Depress wire form to remove electrical connectors
pipe and discard.
from front and rear fuel injectors.
2005 Touring: Engine
3-21
HOME
16.
Pull external latch outward and use rocking motion to
8316
remove electrical connector from left side of ignition coil.
17.
Pull sides of ignition coil bracket outward to remove from
bosses of front fuel tank mount. See Figure 3-11.
18.
Moving to right side of vehicle, remove two allen head
socket screws to release oil hose cover.
19.
Using a side cutters, cut and remove clamps on engine
side of oil hoses. Pull hoses from crankcase fittings.
20.
Cut and remove clamp on breather hose behind rear
lifter cover. Pull hose from crankcase fitting and tuck
behind transmisson to engine flange to keep out of the
way.
21.
Remove the voltage regulator. See Section 8.9 VOLT-
Figure 3-11. Remove Ignition Coil Bracket From Vehicle
AGE REGULATOR, REMOVAL.
22.
To release stator cable conduit, remove P-clip from left
c. Remove throttle position sensor and intake air tem-
side stud on lower frame crossmember. Remove P-clip
perature sensor connectors.
from cable conduit. Draw stator connector and cable
conduit to rear of engine stabilizer link and then up to
d. Moving to left side of vehicle, pull back boot to
area in front of primary chaincase.
reveal engine temperature sensor at back of front
cylinder. Pull external latch outward and remove
23.
Depress tangs inside socket housing and back out sock-
connector. Cut cable strap to release conduit from
ets through wire end of connector. Proceed as follows:
horn bracket.
a.
Looking into the socket housing, take note of the
e. Tuck free ends of EFI wire harness under main wire
cavity on each side of the terminal.
harness on frame backbone to keep conduit and
connectors out of the way.
b.
Gently insert pick (Snap-On TT600-3) into the cavity
about 1/4 inch (6.4 mm) or until it stops, and pivot
11.
Remove idle and throttle control cables as follows:
the side of the pick toward the terminal body.
Carbureted: Using a needle nose pliers, carefully pull
Repeat step on other cavity. See Figure 3-12.
idle cable barrel from upper inboard hole in throttle
c.
Gently tug on cable to pull terminal from chamber. If
wheel. Pull throttle cable barrel from remaining hole.
terminal is still locked, one or both tangs are not
Release idle and throttle cables from guides in throttle
fully depressed. Repeat steps 24(b) and 24(c) as
cable bracket.
necessary.
Fuel Injected: Using a needle nose pliers, carefully pull
d.
Repeat procedure to release second terminal.
idle cable barrel from upper hole in throttle wheel. Pull
throttle cable barrel from lower hole. Using slots, release
idle and throttle cables from guides in throttle cable
bracket.
f1911x8x
12.
Free idle and throttle control cables from J-clamp fas-
tened to right side of frame backbone. Move cables up
and out of the way.
13.
If equipped with cruise control, remove E-clip from
sleeve at end of cruise cable housing. Using slot,
Pick
remove cable housing from cable guide in throttle cable
bracket. Push the plastic end fitting on the cruise cable
to the outboard side to release from wheel pin. Move
cable up and out of the way.
14.
Moving to left side of vehicle, pull boots on spark plug
cables to release from spark plug and ignition coil tow-
ers. Release cables from three cable clips at bottom of
frame backbone.
Figure 3-12. Remove Socket Terminals
15.
Remove spark plugs.
From Stator/Voltage Regulator Connector
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2005 Touring: Engine
HOME
24.
Remove conduit from stator cables. For best results, pull
one cable and socket terminal through conduit at a time.
Tape cables to crankcase so that they are out of the way
and will not be pinched or cut during engine removal.
25.
Remove crankshaft position sensor and oil pressure
switch/sender as follows:
a. Locate crankshaft position sensor connector [79], 2-
place Mini-Deutsch, next to oil filter mount. Depress
button on socket terminal side and pull apart pin
and socket halves.
b. Remove allen head socket screw to free crank posi-
tion sensor mount from crankcase. Pull sensor from
Figure 3-13. Engine/Transmission Bench Stand
bore. Remove O-ring from groove on sensor body.
(Part No. HD-42310)
Discard O-ring.
c. Locate the oil pressure switch/sender at the front
35.
Cover lower frame tubes (both left and right side) with
right side of the crankcase. On FLHR/C/S models,
foam padding or bubble pack. Split loom conduit or a half
pull elbow from post of oil pressure switch. On
shell of PVC tubing will also produce good results. Pro-
FLHT/C/U and FLTR models, pull external latch out-
tection is necessary to prevent nicks or paint damage to
ward and use rocking motion to remove Packard
left frame tube and chafing, cutting or kinking of the
connector from oil pressure sender.
brake line, wire cables and conduit at the top of the right
d. On FLHR/C/S models, use a 15/16 inch Open End
frame tube.
Crow Foot (Snap-On FC30B) to remove oil pressure
36.
Cover rocker covers of front and rear cylinders with foam
switch from crankcase. On FLHT/C/U and FLTR
padding or bubble pack.
models, use
1-1/16 inch Open End Crow Foot
(Snap-On FC34A) to remove oil pressure sender.
1CAUTION
26.
Coil main harness conduit and allow to hang below
lower frame tube at front of vehicle. If harness is not
The engine weighs approximately 165 pounds (74.8 kg).
moved out of the way, it may be damaged during engine
Use a suitable lifting device, if necessary. Exercise cau-
removal.
tion to avoid personal injury.
27.
Place jack under oil pan at rear of vehicle. Using a block
37. Move engine forward far enough to clear two ring dowels
of wood to distribute pressure across the length of the
in lower flange of transmission housing. Raise engine
casting, raise the jack until firm contact is made with the
and remove from right side of vehicle. Exercise caution
bottom of the oil pan.
to avoid contact with rear brake master cylinder reservoir
and brake line, wire cables and conduit at top of lower
28.
Standing on left side of vehicle, remove two hex head
frame tube.
bolts (with flat washers) to release top engine mounting
bracket from cylinder heads.
38. Using the TWIN CAM 88 CRADLE (HD-42310-2), install
engine in BENCH STAND (HD-42310) or ROLLING
29.
Remove elbow terminals from spade contacts at back of
STAND (HD-43646A). See Figure 3-13.
horn. Release wire harness conduit from J-clamp.
39. Remove intake manifold/carburetor or induction module.
30.
Moving to right side of vehicle, turn hex head bolt to
Proceed as follows:
release stabilizer link from frame weldment.
a. Remove right side allen head socket screws from
31.
Remove horn, top engine mounting bracket and stabi-
front and rear cylinder head flange adapters. For
lizer link as an assembly.
best results, use the INTAKE MANIFOLD WRENCH
(HD-47250), or a long
1/4 inch ball allen head
32.
Remove four bolts (with flat washers) to free rear of
socket with end driver 4 inches long.
crankcase from transmission housing. Loosen and
remove bolts in a crosswise pattern.
b. Moving to opposite side of vehicle, just loosen left
side allen head socket screws from flange adapters.
33.
Remove two bolts (with flat washers) to free front of
Slots in flanges make removal of left side screws
crankcase from front engine mounting bracket.
unnecessary.
34.
Wrap rear master cylinder reservoir with foam padding
c. Remove intake manifold/carburetor or induction
or bubble pack.
module from right side of vehicle.
2005 Touring: Engine
3-23
HOME
40. Remove the rotor as follows:
Capped
f1634x8x
Stator
Rib
1CAUTION
The high-output rotor is used on FLHTCI, FLHTCUI and
FLTRI models only. Since the high-output rotor contains
magnets that are considerably more powerful than those
used on low-output rotors, the ROTOR REMOVER/
INSTALLER and SHAFT PROTECTOR SLEEVE (HD-
41771) must be used to prevent parts damage and possi-
ble hand injury during removal and installation.
High Output Rotor - 45 Amp
a. Verify that threads of engine sprocket shaft are
clean, especially of old Loctite material. Thread the
Shaft Protector Sleeve onto the shaft.
b. Turn thumbscrews of Rotor Remover/Installer into
Awl
Opening
threaded holes in rotor face.
c. Rotate handle of forcing screw in a clockwise direc-
tion to remove rotor from shaft.
Figure 3-14. Remove Grommet From Crankcase
Low Output Rotor - 38 Amp
c. Using a 3/8 inch drive with a 4 inch extension, turn
CAUTION
wrench in a counterclockwise direction until loose.
Do not strike or drop rotor. Damage to magnet adhesive
Do not use with air tools.
may result in rotor failure.
NOTE
a. Fabricate wire hooks or use the ends of two allen
wrenches to carefully pull rotor at holes in rotor
Use OIL FILTER WRENCH (HD-44067) if HD-42311 is not
available.
face.
b. Pull rotor from stator. Magnets in rotor cause some
43. Remove oil filter mount as follows:
resistance during removal.
41.
Remove stator as follows:
a. Carefully bend corners on lockplate away from
heads of top and bottom bolts in oil filter mount.
a. Using a T27 TORX drive head, remove four screws
Remove top and bottom bolts, lockplate and flat
to free stator from crankcase. Discard screws.
washers. Discard lockplate.
b. Using point of awl, carefully lift capped rib on grom-
b. Remove middle bolt with flat washer to free filter
met away from crankcase and then insert into bore
mount from crankcase.
between grommet and casting. See Figure 3-14. Tilt
awl slightly squirting isopropyl alcohol or glass
c. Remove two O-rings from inboard side of filter
cleaner into opening. Repeat this step at one or two
mount. Discard O-rings.
other locations around grommet.
c. While pushing on capped rib from outside of crank-
NOTES
case, draw grommet through bore by pulling on
Remove and clean the oil pan under any of the following con-
cable stop with needle nose pliers. Rock grommet
ditions:
back and forth to facilitate removal, if necessary.
Exercise caution to avoid damaging ribs on grom-
● Metal debris is found in the engine or crankcase.
met if stator is to be reused.
● Oil contamination is suspected.
42.
Remove the oil filter as follows:
a. Obtain the OIL FILTER WRENCH (HD-42311). The
● A complete engine overhaul is being performed as a
tool allows easy removal of the oil filter without risk
result of a major engine failure.
of damage to the crankshaft position sensor or
cable.
● The engine is being replaced with a new one.
b. Place the jaws of the wrench over the oil filter with
the tool oriented vertically.
44. To remove the oil pan, proceed as follows:
3-24
2005 Touring: Engine
HOME
RIGHT SIDE
f2025x3x
LEFT SIDE
Strap
Strap
Frame
Backbone
Mainshaft
Hook
Rubber Coated
Hook
Transmission
Rubber Coated
Bracket
f1791x2x
Figure 3-15. Secure Transmission Using Transmission Exhaust Bracket and Mainshaft
a. Use a tie down strap to hold the transmission. Lay
d. Locate transmission drain plug on right side of the
strap over frame backbone placing one rubber
oil pan. See Figure 3-16. Remove the plug and
coated hook through the transmission exhaust
drain the transmission lubricant into a suitable con-
bracket on the right side of the vehicle and the other
tainer.
around the mainshaft on the left. Using buckle,
tighten strap until taut. See Figure 3-15.
e. Alternately loosen and then remove the twelve allen
head socket screws to release the oil pan from the
b. Lower and remove jack under oil pan.
transmission housing. Follow the pattern shown in
c. Locate oil drain plug at front of the oil pan. See Fig-
Figure 3-16.
ure 3-16. Remove the plug and allow oil to drain
f.
Remove gasket from oil pan and discard.
completely.
2005 Touring: Engine
3-25
HOME
INSTALLING ENGINE IN CHASSIS
3.8
PROCEDURE
f1677x3x
9
NOTE
11
3
If oil pan was drained and removed, start at step 1. If oil pan
LEFT
was neither drained nor removed, move to step 13.
7
2
SIDE
1.
Coat gasket surface of oil pan with a thin coat of HYLO-
6
MAR® gasket sealer.
2.
Place gasket on oil pan and allow sealer to dry until
5
tacky.
8
3.
Position oil pan under transmission housing and start the
twelve allen head socket screws. Tighten each screw
1
RIGHT
about two turns after initial thread engagement.
SIDE
4
4.
Inspect the oil pan gasket to verify that it is properly posi-
tioned.
12
Transmission
10
Engine Oil
5.
Alternately tighten oil pan screws to 84-132 in-lbs (9.5-
Drain Plug
Drain Plug
14.9 Nm) following the pattern shown in Figure 3-16.
6.
Remove any foreign material from magnet of oil drain
Figure 3-16. Oil Pan Torque Sequence
plug. Also check the O-ring for tears, cuts or general
deterioration. Replace as necessary.
12.
Install the transmission filler plug/dipstick in the clutch
7.
Install the engine oil drain plug in front of the oil pan.
release cover. Tighten the plug to 25-75 in-lbs (2.8-8.5
Tighten plug to 14-21 ft-lbs (19-28 Nm).
Nm).
8.
Remove the transmission filler plug from the clutch
13.
Place jack under oil pan at rear of vehicle. Using a block
release cover on the right side of the transmission case.
of wood to distribute pressure across the length of the
Check the O-ring for tears, cuts or general deterioration.
casting, raise the jack until firm contact is made with the
Replace as necessary.
bottom of the oil pan.
9.
Remove any foreign material from magnet of transmis-
14.
Remove strap from frame backbone disengaging hooks
sion drain plug. Also check the O-ring for tears, cuts or
from mainshaft and transmission exhaust bracket.
general deterioration. Replace as necessary.
15.
Install spark plugs in front and rear cylinder heads.
10.
Install the transmission lubricant drain plug in right side
Install the plugs finger tight and then tighten to 12-18 ft-
of the oil pan and tighten to 14-21 ft-lbs (19-28 Nm).
lbs (16-24 Nm).
16.
Install oil filter mount as follows:
1WARNING
a. Install two new O-rings on inboard side of filter
When draining or adding lubricant, do not allow dirt,
mount.
debris or other contaminants to enter the transmission
b. Place flat washers in recessed bolt holes at top and
case. Exercise caution so that lubricant does not contact
bottom of filter mount flange.
rear wheel, tire and brake components. Such contact
can adversely affect traction and may lead to loss of
c. Align holes in lockplate with holes in flat washers.
vehicle control, which could result in death or serious
d. Slide two hex head bolts through lockplate, flat
injury.
washers and filter mount flange. Apply Loctite
11. Fill the transmission with
20-24 oz. (590-710 ml) of
Medium Strength Threadlocker
243
(blue) to
transmission lubricant or until the lubricant level on the
threads of installed bolts.
dipstick of the filler plug is at the F(ULL) mark with the
motorcycle in a level, upright position and the filler plug
CAUTION
resting on the threads.
To avoid cross threading tapped holes, exercise care
Use only Harley-Davidson TRANSMISSION LUBRI-
when starting hex head bolts in crankcase.
CANT: Part No.’s 99892-84 (quart), 98853-96 (case of
quarts), 99891-84 (gallon), or 98852-96 (case of gal-
e. Align holes in filter mount flange with holes in crank-
lons).
case and tighten bolts until snug.
3-26
2005 Touring: Engine
HOME
f.
Install flat washer on remaining bolt, apply Loctite
Medium Strength Threadlocker
243
(blue) to
1CAUTION
threads, and install in middle hole of filter mount
The high-output rotor is used on FLHTCI, FLHTCUI and
flange.
FLTRI models only. Since the high-output rotor contains
g. Starting at the top, alternately tighten three hex
magnets that are considerably more powerful than those
used on low-output rotors, the ROTOR REMOVER/
head bolts to 12-16 ft-lbs (16-22 Nm). Re-tighten
INSTALLER and SHAFT PROTECTOR SLEEVE (HD-
middle bolt when done.
41771) must be used to prevent parts damage and possi-
h. To prevent rotation, carefully bend outside corners
ble hand injury during removal and installation.
of lockplate against heads of top and bottom bolts.
High Output Rotor - 45 Amp
17. Clean oil filter mount flange of any old gasket material.
a. Install the Shaft Protector Sleeve and Rotor
Lubricate gasket of new oil filter with clean engine oil
Remover/Installer, if removed.
and install on filter mount. Hand tighten oil filter 1/2-3/4
turn after gasket first contacts filter mounting surface. Do
NOTE
NOT use OIL FILTER WRENCH for oil filter installation.
The Shaft Protector Sleeve not only protects the threads from
the splines of the rotor, but acts as a guide to ensure that the
NOTE
rotor is properly centered.
Use of the Premium 10 micron synthetic media oil filter is
highly recommended, Part No. 63798-99 (Chrome) or 63731-
b. Center ball on forcing screw in recess at end of
engine sprocket shaft. Rotate the handle of the tool
99 (Black).
in a counterclockwise direction to ease rotor into
position over stator.
18. Install stator as follows:
c. Loosen thumbscrews and remove Rotor Remover/
a. From inside crankcase, feed socket terminals and
Installer. Remove Shaft Protector Sleeve.
stator cable through hole in crankcase.
d. Install the shaft extension on the engine sprocket
b. Thoroughly lubricate grommet with isopropyl alco-
shaft. (No alternator rotor spacer is provided.)
hol or glass cleaner. To avoid leakage, ribs of grom-
met must be free of dirt and oily residue.
Low Output Rotor - 38 Amp
c. Carefully grasp cable stop behind grommet with a
needle nose pliers. Push grommet into crankcase
a. Slide rotor over stator with the concave side
inboard.
bore while carefully pulling on outside cable. Instal-
lation is complete when cable stop contacts casting
and capped rib of grommet exits crankcase bore.
1CAUTION
d. If necessary, carefully run awl around edge of
When installing rotor, keep fingers away from edge that
capped rib so that it rests flat against seating sur-
mates with crankcase. Since rotor is magnetized, as it
face on crankcase.
nears the crankcase it may be pulled in with consider-
able force, resulting in pinched fingers or other hand
injury.
CAUTION
b. Install the 0.020 inch (0.508 mm) thick alternator
Do not reuse T27 TORX screws. The threads of the
rotor spacer and the shaft extension on the engine
screws contain a locking compound in pellet form. When
sprocket shaft.
the screw is started, the pellet breaks releasing the com-
pound.
20. Install intake manifold/carburetor or induction module.
Proceed as follows:
e. Using a T27 TORX drive head, install four new
a. With the counterbore facing outward, slide cylinder
screws to fasten stator to crankcase. Alternately
head flange adapters onto outlet ports of intake
tighten screws to 55-75 in-lbs (6.2-8.5 Nm).
manifold/induction module. The flange adapters are
not interchangeable. Look next to the slotted bolt
f.
Coil stator connector cable lengths so that they are
hole for a stamp that indicates F(ront) and R(ear)
out of the way and will not be pinched or cut during
cylinder.
engine installation.
b. Place a new seal in each flange adapter with the
19. Install the rotor as follows:
beveled side in against the counterbore.
2005 Touring: Engine
3-27
HOME
21. Cover rocker covers of front and rear cylinders with foam
f1684x3x
padding or bubble pack.
22. Cover lower frame tubes (both left and right side) with
2
foam padding or bubble pack. Split loom conduit or a half
4
shell of PVC tubing will also produce good results. Pro-
tection is necessary to prevent nicks or paint damage to
RIGHT
left frame tube and chafing, cutting or kinking of the
SIDE
brake line, wire cables and conduit at the top of the right
frame tube.
23. Wrap rear master cylinder reservoir with foam padding
or bubble pack.
3
24. Remove engine from BENCH STAND (HD-42310) or
ROLLING STAND (HD-43646A) and set on floor on right
1
side of chassis.
1CAUTION
The engine weighs approximately 165 pounds (74.8 kg).
Figure 3-17. Transmission Housing to Crankcase
Use a suitable lifting device, if necessary. Exercise cau-
Torque Sequence
tion to avoid personal injury.
25. Raise engine and install in chassis from right side of
c.
Standing on right side of engine, slide intake mani-
vehicle setting front of crankcase onto front engine
fold/induction module toward installed position so
mounting bracket. Engine must be set forward far
that open-ended slots on flange adapters begin to
enough to clear two ring dowels in lower flange of trans-
engage allen head socket screws loosely installed
mission housing. Exercise caution to avoid contact with
on left side.
rear brake master cylinder reservoir and brake line, wire
d.
Align fixed holes in flange adapters with those in
cables and conduit at top of lower right frame tube.
cylinder heads and start allen head socket screws.
26. Move engine rearward to fully engage two ring dowels in
For best results, use the INTAKE MANIFOLD
lower flange of transmission housing.
WRENCH (HD-47250), or a long 1/4 inch ball allen
27. Secure the engine as follows:
head socket with end driver 4 inches long.
e.
Use the air cleaner backplate or INDUCTION SYS-
a. Hand tighten four bolts (with flat washers) to secure
TEM ALIGNMENT BRACKET
(P&A Part No.
transmission housing to rear of crankcase.
40054-01) to properly locate carburetor/induction
b. Hand tighten two bolts (with flat washers) to secure
module. Proceed as follows:
front of crankcase to front engine mounting bracket.
Backplate: Install two breather bolts to fasten back-
c. Tighten the four transmission housing to crankcase
plate to front and rear cylinder heads. Install three
bolts to 15 ft-lbs (20.3 Nm) in the sequence shown
T27 TORX screws to secure backplate to face of
in Figure 3-17.
carburetor/induction module.
Alignment bracket: Fitting pins on inboard side
NOTE
into holes in face of carburetor/induction module,
For best results, use Open End Crowfoot (Snap-On FC018)
install two breather bolts to fasten bracket to front
on upper left and upper right transmission housing to
and rear cylinder heads.
crankcase bolts.
f.
Tighten allen head socket screw in fixed holes of
d. Following the same sequence, final tighten the four
flange adapters until snug. Moving to left side of
transmission housing to crankcase bolts to 30-35 ft-
engine, tighten screws in slotted holes to 96-144 in-
lbs (40.7-47.5 Nm).
lbs (10.9-16.3 Nm).
e. Tighten the two crankcase to front engine mounting
g.
Remove breather bolts and T27 TORX screws to
bracket bolts to 33-38 ft-lbs (44.8-51.5 Nm).
remove backplate, if installed.
28. Install horn, top engine mounting bracket and stabilizer
h.
Tighten allen head socket screws in fixed holes of
link as an assembly. Proceed as follows:
flange adapters to 96-144 in-lbs (10.9-16.3 Nm).
a. Moving to right side of vehicle, turn hex head bolt to
i.
Remove breather bolts to remove alignment
secure stabilizer link to frame weldment. Tighten
bracket, if installed.
bolt to 18-22 ft-lbs (24-30 Nm).
3-28
2005 Touring: Engine
HOME
b. On FLHR/C/S models, install elbow on post of oil
pressure switch. On FLHT/C/U and FLTR models,
install Packard connector to oil pressure sender .
c. Install new O-ring in groove on crank position sen-
sor body. Apply a very thin film of clean H-D 20W50
engine oil to O-ring before installation.
X-Acto Knife
d. Push sensor into bore aligning hole in sensor mount
with hole in spot face. Install allen head socket
Tang
screw (1/4 x 1 inch) and tighten to 90-120 in-lbs
(10.2-13.6 Nm).
e. Locate crankshaft position sensor connector [79], 2-
f1913x8x
place Mini-Deutsch, next to oil filter mount. Mate pin
and socket halves of connector.
Figure 3-18. Bend Tangs Outward on Socket Terminals
of Stator/Voltage Regulator Connector
35.
Install the voltage regulator. See Section 8.9 VOLTAGE
REGULATOR, INSTALLATION.
36.
Slide new clamp onto free end of breather hose behind
b. Install elbow terminals onto spade contacts at back
rear lifter cover. Install hose onto crankcase fitting.
of horn. Capture wire harness conduit in J-clamp.
Crimp clamp using HOSE CLAMP PLIERS (HD-97087-
65B).
c. Standing on left side of vehicle, install two hex head
bolts
(with flat washers) to secure top engine
37.
Slide new clamps onto free ends of oil hoses. Install
mounting bracket to front and rear cylinder heads.
hoses onto crankcase fittings. Crimp clamps.
Alternately tighten bolts to 35-40 ft-lbs (48-54 Nm).
38.
Install two allen head socket screws to secure oil hose
29.
Lower and remove jack under oil pan.
cover to transmission and engine housings. Longer
30.
Install conduit onto stator cables. For best results, feed
screw goes to engine housing. Alternately tighten
one socket terminal and cable through conduit at a time.
screws to 84-108 in-lbs (10-12 Nm).
31.
Install sockets into stator connector as follows:
39.
Install ignition coil and spark plug cables as follows:
a. Using a fingernail or a thin flat blade, like that on an
a. With the coil towers facing rear of vehicle, hold igni-
X-Acto knife, carefully bend the tangs outward away
tion coil and bracket at bottom of frame backbone.
from each terminal body. See Figure 3-18.
Pull sides of bracket outward and install on bosses
of front fuel tank mount. See Figure 3-11.
b. Feed each socket into wire end of stator connector
until it “clicks” in place.
b. Install electrical connector on left side of ignition
c. Verify that sockets will not back out of chambers. A
coil.
slight tug on each cable will confirm that it is locked.
c. Install spark plug cable to front cylinder onto left
32.
Install P-clip on stator cable conduit approximately five
side coil tower. Verify that spark plug cable is cap-
inches (127 mm) from socket housing. Slide P-clip over
tured in double-sided cable clip at bottom left side of
left side stud on lower frame crossmember. Properly ori-
frame backbone. Install new cable clip on T-stud if
ented, P-clip is positioned at front of stud with the open
damaged or missing.
side up and angled so that it is inline with the lower rail of
d. Install spark plug cable to rear cylinder onto right
the engine guard.
side coil tower. Verify that spark plug cable is cap-
33.
Uncoil main harness conduit and allow to hang below
tured in two single-sided cable clips at bottom left
lower frame tube at front of vehicle.
side of frame backbone. Install new cable clips on T-
studs if damaged or missing.
34.
Install oil pressure switch/sender and crankshaft position
sensor as follows:
40.
If equipped with cruise control, slide groove in cruise
cable end fitting over cap of wheel pin. Push on end fit-
a. Start oil pressure switch/sender into crankcase bore
ting until it snaps in place. Using slot, slip cruise cable
at the front right side of the crankcase. On FLHR/C/
housing into cable guide in throttle cable bracket. Install
S models, use a 15/16 inch Open End Crow Foot
new E-clip on sleeve at end of cruise cable housing.
(Snap-On FC30B) to tighten oil pressure switch to
96-120 in-lbs (11-14 Nm). On FLHT/C/U and FLTR
41.
Route idle and throttle control cables through J-clamp
models, use
1-1/16 inch Open End Crow Foot
fastened to right side of frame backbone.
(Snap-On FC34A) to tighten oil pressure sender to
same torque.
42.
Install idle and throttle control cables as follows:
2005 Touring: Engine
3-29
HOME
Carbureted: Install sleeve on throttle cable housing into
d. Start two exhaust flange nuts to secure rear header
shorter cable guide in throttle cable bracket. Drawing
pipe to studs of rear cylinder head.
throttle cable downward, fit barrel end into lower out-
e. Engaging transmission exhaust bracket, capture
board hole in throttle wheel. Install sleeve and spring on
front header pipe in transmission exhaust bracket
idle cable housing into longer cable guide inserting bar-
clamp. Use a channel lock to close clamp, if neces-
rel end into upper inboard hole in throttle wheel.
sary. Finger tighten clamp bolt (with flat washer and
Induction Module: Install sleeve on throttle cable hous-
locknut).
ing into shorter cable guide at top of throttle cable
NOTE
bracket. Drawing throttle cable downward, fit barrel end
into lower hole in throttle wheel. Install sleeve and spring
To ensure sealing integrity of TORCA clamps and prevent the
on idle cable housing into longer cable guide at bottom
possibility of leakage, Harley-Davidson recommends that
of throttle cable bracket inserting barrel end into upper
TORCA assemblies be discarded and replaced each time
hole in throttle wheel.
they are removed.
43. Tighten cables as necessary to keep barrel ends from
f.
Moving to left side of vehicle, slide new TORCA
clamp assembly onto crossover pipe.
dislodging. Verify that cables are seated in channel of
throttle wheel. Verify operation by turning throttle grip
g. Twist and push left side exhaust onto crossover
and observing cable action.
pipe.
44. Install connections to carburetor or induction module.
h. Start two bolts (with lockwashers) to secure left side
Standing on left side of vehicle, proceed as follows:
muffler to the lower saddlebag support rail.
Carbureted:
i.
Returning to left side of vehicle, position TORCA
clamp between rear header pipe and crossover
a. Moving to left side of vehicle, install electrical con-
pipe. Fit bracket tab into slot of TORCA clamp
nector to manifold absolute pressure (MAP) sensor
engaging stud in slot of exhaust support bracket.
at top of intake manifold.
Start Keps nut on stud.
b. Slide threaded portion of enrichener cable into slot
of mounting bracket. Flat on threads must face rear
CAUTION
of vehicle for script on enrichener knob to be right
side up. With the external tooth lockwasher and hex
Verify that the exhaust pipes do not contact the vehicle
nut positioned on the inboard side of the mounting
frame or any mounted components. Contact will cancel
bracket, tighten hex nut to 20-35 in-lbs (2.3-4.0
the effect of the rubber isolation mounts and transmit
Nm).
vibration to the rider via the vehicle frame.
Fuel Injected:
j.
Tighten the exhaust system as follows:
a. Install electrical connectors on fuel injectors.
● Using a long 1/2 inch swivel socket, tighten the top
nut of the front cylinder head exhaust flange to 9-18
b. Install manifold absolute pressure sensor and idle
in-lbs (1-2 Nm). Tighten the bottom nut to 100-120
air control connectors.
in-lbs (11.3-13.6 Nm). Final tighten the top nut to
c. Install intake air temperature sensor and throttle
100-120 in-lbs (11.3-13.6 Nm).
position sensor connectors.
● Tighten the bottom nut of the rear cylinder head
exhaust flange to 9-18 in-lbs (1-2 Nm). Tighten the
d. Moving to left side of vehicle, install connector to
top nut to
100-120 in-lbs (11.3-13.6 Nm). Final
engine temperature sensor at back of front cylinder.
tighten the bottom nut to 100-120 in-lbs (11.3-13.6
Pull boot over sensor to keep out dirt and debris.
Nm).
Install new cable strap to secure connector conduit
● Tighten the transmission exhaust bracket clamp bolt
to horn bracket.
to 60-96 in-lbs (6.8-10.8 Nm).
45. Install the primary chaincase. See Section
6.5 PRI-
● Tighten the two bolts (with lockwashers) to fasten
MARY CHAINCASE, INSTALLATION, steps 1-29.
right side muffler to lower saddlebag support rail.
46. Install exhaust system as follows:
● Tighten the two bolts (with lockwashers) to fasten
left side muffler to lower saddlebag support rail.
a. Install new gaskets in both the front and rear cylin-
● Verify that all exhaust pipes are in alignment and do
der head exhaust ports (with the tapered side out).
not contact the vehicle frame or mounted compo-
b. Place right side exhaust into position on vehicle and
nents.
start two exhaust flange nuts to secure front header
● Tighten the TORCA clamp between the rear header
pipe to studs of front cylinder head.
pipe and crossover pipe to 45-60 ft-lbs (61-81 Nm).
c. Start two bolts (with lockwashers) to secure right
● Tighten Keps nut securing bracket tab to exhaust
side muffler to the lower saddlebag support rail.
support bracket.
3-30
2005 Touring: Engine
HOME
COLD CHECK
HOT CHECK
f1254b3x
Figure 3-19. Engine Oil Dipstick
52.
Repeat steps 49-51 to install side cover, saddlebag and
CAUTION
fairing lower on left side of vehicle.
53.
Install the fuel tank. Proceed as follows:
Verify that the heat shields do not contact the vehicle
frame or any mounted components. Contact will cancel
Carbureted: See Section 4.7 FUEL TANK (CARBU-
the effect of the rubber isolation mounts and transmit
RETED), INSTALLATION
(AFTER COMPLETE
vibration to the rider via the vehicle frame.
REMOVAL), FLHT/C, or FLHR/S.
Fuel Injected: See Section
9.4 FUEL TANK (FUEL
NOTE
INJECTED), INSTALLATION
(AFTER COMPLETE
Position worm drive clamps so that screws are on the out-
REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
board side in the most accessible position.
54.
On Ultra models, hold locknut at bottom of fairing lower,
k. Open worm drive clamps and install heat shields as
and using a T40 TORX drive head, turn inside screw to
follows:
fasten assembly to engine guard clamp. Tighten screw
to 90-100 in-lbs (10.2-11.3 Nm). Repeat step on oppo-
● Over front header pipe (below exhaust port).
site side of vehicle.
● Over rear header pipe (below exhaust port).
55.
Adjust idle and throttle control cables as follows:
● Over front header pipe to rear header pipe connec-
tion (outboard of transmission side door).
Non-Cruise: See Section 2.21 THROTTLE CABLES
● Over rear header pipe to crossover pipe connection
(NON-CRUISE), ADJUSTMENT.
(above starter).
Cruise Equipped: See Section 8.30 CRUISE CON-
TROL (FLHRC, FLTR, FLHTCU), CABLE ADJUST-
l.
Position each worm drive clamp so that screw is on
MENT.
the outboard side in the most accessible position
and then tighten to 20-40 in-lbs (2.3-4.5 Nm).
NOTE
47.
Insert two allen head socket screws (with lockwashers
If oil pan was not drained, move to step 57.
and flat washers) through frame weldment into right side
front footboard brackets. For best results, approach from
56.
With vehicle resting on jiffy stand, add 3-1/2 quarts (3.3
left side of vehicle using a 3/8 inch ball allen with exten-
liters) engine oil as specified in Table 3-2. Use the proper
sion. Alternately tighten screws to 30-35 ft-lbs (41-48
grade of oil for the lowest temperature expected before
Nm).
the next oil change.
48.
Install the backplate and air cleaner. See Section 4.5
Table 3-2. Recommended Engine Oils
AIR CLEANER, INSTALLATION.
49.
On Ultra models, place fairing lower into position on right
Harley-
Lowest
Cold Weather
Harley-Davidson
side of vehicle. Holding T40 TORX screw inside fairing
Viscosity
Davidson
Ambient
Starts Below
Type
lower, install new rubber washer, clamp and locknut to
Rating
Temperature
50˚F (10˚C)
attach fairing bottom to engine guard. Do not tighten
SAE
Below 40˚F
HD Multi-grade
HD 360
Excellent
locknut.
10W40
(4˚C)
50.
Align barbed studs in right side cover with grommets in
SAE
Above 40˚F
HD Multi-grade
HD 360
Good
20W50
(4˚C)
frame downtubes and push firmly into place (no tools
SAE
Above 60˚F
required).
HD Regular Heavy
HD 360
Poor
50
(16˚C)
51.
Install right side saddlebag. See Section 2.25 SADDLE-
SAE
Above 80˚F
HD Extra Heavy
HD 360
Poor
BAG, INSTALLATION.
60
(27˚C)
2005 Touring: Engine
3-31
HOME
58. Perform engine oil level HOT CHECK as follows:
CAUTION
a. Ride vehicle until engine is at normal operating tem-
perature.
Oil level cannot be accurately measured on a cold
engine. For preride inspection, with motorcycle leaning
b. With the vehicle resting on the jiffy stand on level
on jiffy stand on level ground, oil should register on dip-
ground, allow engine to idle for 1-2 minutes. Turn
stick between arrows when engine is cold. Do NOT add
engine off.
oil to bring the level to the FULL mark on a COLD engine.
c. Wipe off the dipstick and insert it back into the oil
pan with the plug pushed completely into the fill
57. Perform engine oil level COLD CHECK as follows:
spout.
a. With the vehicle resting on the jiffy stand on level
d. Remove the dipstick and note the level of the oil.
ground, wipe off the dipstick and insert it back into
Add only enough oil to bring the level to the FULL
the oil pan with the plug pushed completely into the
mark on the dipstick. See Figure 3-19. Do not over-
fill spout.
fill.
59. Start engine and carefully check for oil leaks around
b. Remove the dipstick and note the level of the oil. Oil
level should register between the two arrows on the
drain plug and oil filter.
dipstick. See Figure 3-19. If oil level is at or below
the lower arrow, add only enough oil to bring the
level between the two arrows on the dipstick.
3-32
2005 Touring: Engine
HOME
TOP END OVERHAUL
3.9
DISASSEMBLY
1. Use low pressure spray to thoroughly clean exterior sur-
faces of engine prior to disassembly. Dirt caked on cool-
ing fins and other areas can fall into crankcase bore or
stick to subassemblies as parts are removed. Abrasive
particles can damage machined surfaces or plug oil pas-
sageways.
NOTE
It is assumed that each step performed on one cylinder is
automatically repeated on the other.
2. Alternately loosen the six rocker cover bolts following the
pattern shown in A of Figure 3-22. Remove the rocker
cover bolts.
NOTE
If the engine is left in the chassis for service, use the
f1603x3x
ROCKER COVER WRENCH (HD-47258) and ROCKER
HOUSING WRENCH (HD-47248) to remove the rocker cover
Figure 3-21. Remove Spring Cap Retainer
and rocker housing bolts, respectively. These tools are
especially useful when removing the bolts on the left side of
the engine (particularly the rear) where there is close proxim-
6. To remove the rocker arm support plate, both lifters of
ity to the frame. With both an external and internal hex, the
the cylinder being serviced must be on the base circle
bolts also can be removed with either a 7/16 inch socket or
(or lowest position) of the cam.
open end/box wrench (open spaces), or a short 3/16 inch
allen wrench (tight spaces). See Figure 3-20.
CAUTION
3. Remove the rocker cover and gasket. Discard the gas-
Removing the rocker arms with the valve train loaded
ket.
can result in bent push rods, damaged bushings or
4. Insert the blade of a small screwdriver into cast loop of
warped support plate.
spring cap retainer (at top of upper push rod cover), and
while pushing down on spring cap, rotate bottom of
To find the base circle, it is first necessary to rotate the
screwdriver toward outboard side to remove. See Figure
engine. Based on the level of disassembly required,
3-21. Repeat step on second push rod cover.
three methods of engine rotation are presented below.
5. Collapse upper and lower push rod covers.
a. With primary cover installed - With vehicle on center
stand, place the transmission in 5th gear and rotate
rear wheel in a clockwise direction (as viewed from
right side) until the base circle is found. See step
Internal Hex
6(d) to find the base circle.
Part No. HD-47258 or
Lock Patch
3/16 Inch Allen Wrench
b. With primary cover removed
- Remove primary
cover. Place the transmission in neutral. Fit a 1-1/2
inch socket on the compensating sprocket shaft nut.
Rotate nut in a counterclockwise direction until the
base circle is found. See step 6(d) to find the base
circle.
CAUTION
External Hex
Captive
Do not attempt to rotate engine by removing cam cover
Part No. HD-47248 or
Washer
7/16 Inch Open End Wrench
and placing socket on crank or primary cam sprocket
f1570x3x
flange bolt. Head of flange bolt can break off possibly
resulting in damage to flywheel or camshaft.
Figure 3-20. Rocker Cover Bolt (1-1/4 Inch)
2005 Touring: Engine
3-33
HOME
4
f2164x3x
5
1
3
f2163x3x
Breather
Assembly
2
1
FRONT
2
6
3
4
6
2
3
4
2
1
REAR
3
4
1
5
Remove Two Breather Assembly Bolts.
Alternately Loosen Four Rocker Arm Bolts
A
Loosen Six Rocker Cover Bolts.
B
1/4 Turn in Pattern Shown.
f2165x3x
2
f2166x3x
6
4
4
2
O-Ring
FRONT
1
3
3
5
1
3
5
1
3
1
REAR
2
4
2
6
4
Alternately Loosen Four Cylinder Head
Loosen Six Rocker Housing Bolts.
C
D
Bolts 1/4 Turn in Pattern Shown.
Figure 3-22. Top End Disassembly
3-34
2005 Touring: Engine
HOME
10.
Remove the intake and exhaust push rods. Tag the push
rods as they are removed, so that they can be installed
in their original locations. Also take note of their orienta-
tion to be able to discern top from bottom at time of
installation.
11.
Remove push rod covers from cylinder head and lifter
cover bores. Remove three O-rings from push rod cov-
ers and discard. If O-ring is missing from upper push rod
cover, be sure to dislodge it from the cylinder head bore.
12.
Using a crosswise pattern, remove the four allen head
Figure 3-23. Engine Rotation Wrench (Part No. HD-47257)
socket screws to release the lifter cover. Remove the
lifter cover and gasket. Discard the gasket.
13.
Remove the anti-rotation pin. Remove the hydraulic lift-
c. With engine mounted in engine stand - Obtain the
ers. Tag lifters as they are removed, so that they can be
ENGINE ROTATION WRENCH (HD-47257). See
installed in their original locations. Also take note of their
Figure 3-23. Install tool on sprocket shaft and rotate
orientation (by observing location of the oil hole) to be
in a counterclockwise direction until the base circle
able to discern front from rear at time of installation.
is found. See step 6(d) to find the base circle.
14.
Place the lifters in clean plastic bags to keep out dust,
d. Finding the base circle: Using one of the methods
dirt and debris. See Section 3.11 SUBASSEMBLY SER-
above, rotate engine until piston is at Top Dead
VICE AND REPAIR, PUSH RODS/LIFTERS/COVERS.
Center (TDC) of compression stroke. To accomplish
this, first raise lower push rod cover to access intake
15.
Remove O-ring from groove around breather baffle hole
lifter (inside hole of lifter cover). Place index finger
in rocker housing. Discard the O-ring.
on top of the intake lifter. While rotating engine, feel
lifter rise (valve open) and fall (valve closed). Now
16.
Alternately loosen the six rocker housing bolts following
place finger tightly over spark plug hole and rotate
the pattern shown in C of Figure 3-22. Remove the
engine again. In the compression stroke, air will be
rocker housing bolts.
forced out against your finger until the piston
reaches the TDC position. Stop engine rotation
NOTE
when the flow of air through the spark plug hole
If the engine is left in the chassis for service, use the
stops. Direct the beam of a small flashlight into
ROCKER HOUSING WRENCH (HD-47248) for best results.
spark plug hole to verify piston is at TDC. Both
intake and exhaust valves are now closed and the
17. Remove the rocker housing and gasket. Discard the
push rods are in the unloaded position (and should
gasket.
turn freely).
7.
Remove two bolts to release breather assembly from the
CAUTION
rocker arm support plate. See B of Figure 3-22. See
To prevent distortion of the cylinder head, cylinder and
Section 3.11 SUBASSEMBLY SERVICE AND REPAIR,
cylinder studs, gradually loosen the cylinder head bolts
BREATHER ASSEMBLY.
in the specified pattern.
8.
Alternately loosen each of the four rocker arm support
18. Alternately loosen each of the four cylinder head bolts
plate bolts just 1/4 turn following the pattern shown in B
just 1/4 turn following the pattern shown in D of Figure 3-
of Figure
3-22. Continue turning the bolts in these
22. Continue turning the bolts in these increments until
increments until loose.
loose. Remove the cylinder head bolts.
9.
When the rocker arm support plate bolts are free of the
cylinder head, lift the support plate assembly from the
NOTE
rocker housing. See Section 3.11 SUBASSEMBLY SER-
Save the cylinder head gasket if not damaged. The gasket is
VICE AND REPAIR, ROCKER ARM ASSEMBLY.
needed to install the CYLINDER TORQUE PLATES (HD-
42324A) when measuring, boring or honing of the cylinder is
NOTE
required.
Always service each cylinder separately. After the first cylin-
der is serviced the engine must be rotated to find the base
19. Remove cylinder head and head gasket. See Section
circle on the second cam. Service on the remaining cylinder
3.11 SUBASSEMBLY SERVICE AND REPAIR, CYLIN-
can then proceed.
DER HEAD.
2005 Touring: Engine
3-35
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