Harley Davidson 2005 touring models. Service repair manual — page 2

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Hold adjuster with 1/2 inch wrench. Using 9/16 inch

b. Insert screw (with captive washer) through clutch

wrench, tighten jam nut against cable adjuster. Cover

inspection cover and carefully thread it all the way

cable adjuster mechanism with rubber boot.

through triangular shaped hole in gasket. Do not

push screw through hole.

To avoid punching holes in the clutch inspection cover

gasket or enlarging existing holes, install clutch inspec-

c. Hang the clutch inspection cover on the primary

tion cover and new gasket as follows:

chaincase cover flange by starting the top cover

screw.

a. Align the triangular shaped hole in the gasket with

d. Start the remaining four screws (with captive wash-

the top hole in the clutch inspection cover. Be sure

ers).

the rubber molding and the words “towards clutch”

face the motorcycle.

e. Using a T27 TORX drive head, alternately tighten

screws to 84-108 in-lbs (10-12 Nm) in the pattern

shown in Figure 1-5.

1-18

2005 Touring: Maintenance

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TRANSMISSION LUBRICANT

1.9

GENERAL

8496

Clutch

Release

See Section

1.2 MAINTENANCE SCHEDULE for the

Cover

required service interval.

PROCEDURE

1. Remove the filler plug from the clutch release cover on

the right side of the transmission case. See Figure 1-11.

Check the O-ring for tears, cuts or general deterioration.

Filler

Replace as necessary. See Figure 1-12.

Plug

2. Locate transmission drain plug on the right side of the oil

pan. Remove the magnetic plug and drain the transmis-

sion lubricant into a suitable container.

3. Remove any foreign material from the drain plug. Check

Figure 1-11. Transmission Case (Right Side)

the O-ring on the drain plug for tears, cuts or general

deterioration. Replace as necessary.

OMF50

4. Install the transmission lubricant drain plug and tighten

to 14-21 ft-lbs (19-28 Nm).

1WARNING

When adding lubricant, do not allow dirt, debris or other

contaminants to enter the transmission case. Exercise

caution so that lubricant does not contact rear wheel,

O-Ring

tire and brake components. Such contact can adversely

affect traction and may lead to loss of vehicle control,

which could result in death or serious injury.

Figure 1-12. Transmission Lubricant Filler Plug/Dipstick

5. Fill the transmission with

20-24 oz. (590-710 ml) of

transmission lubricant or until the lubricant level on the

dipstick of the filler plug is at the F(ULL) mark with the

motorcycle in a level, upright position and the filler plug

resting on the threads.

Use only Harley-Davidson SEMI-SYNTHETIC TRANS-

MISSION LUBRICANT: Part No.’s 99892-84 (quart),

98853-96 (case of quarts), 99891-84 (gallon), or 98852-

96 (case of gallons).

Install the transmission filler plug/dipstick in the clutch

release cover. Tighten the plug to 25-75 in-lbs (2.8-8.5

Nm).

2005 Touring: Maintenance

1-19

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DRIVE BELT

1.10

GENERAL

Transmission

Rear Wheel

Sprocket

See Section

1.2 MAINTENANCE SCHEDULE for the

required service interval.

PROCEDURE

10 lbs. (4.5 kg)

Remove left side saddlebag. See Section 2.25 SAD-

of Force

DLEBAG, REMOVAL.

f1652x6x

See Table 1-6.

Check deflection at the loosest spot in the belt with the

transmission in neutral and the motorcycle cold. Use

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

Belt Tension Gauge

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

Part No. HD-35381A

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

See Figure 1-13. Belt deflection should be as follows:

Table 1-6. Belt Deflection

Belt Tension Gauge Adapter

Orientation

Inches

Millimeters

Part No. HD-35381-3

On Jiffy Stand

Without Rider or Luggage

1/4 - 5/16

6.4

- 7.9

Figure 1-13. Check and Adjust Belt Deflection

10 psi (69 kPa) in Rear Shocks

Motorcycle Upright

3/16 - 1/4

4.8

- 6.4

With Rear Wheel in the Air

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

direction.

If belt deflection is within specification, install left side

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

saddlebag. If adjustment is necessary, move to step 3.

at the midpoint of the bottom belt strand. Belt

deflection should be within the range specified in

Remove right side saddlebag. See Section 2.25 SAD-

Table 1-6.

DLEBAG, REMOVAL.

c. If belt is still too loose, repeat steps 6(a) through

Remove right side muffler as follows:

6(b). If belt is now too tight, move to step 7.

a. Open worm drive clamps to remove heat shield

from rear header pipe in front of muffler.

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

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

a. Using a hydraulic center stand, raise motorcycle so

saddlebag support rail.

that the rear wheel is off the ground.

c. Loosen TORCA clamp between rear header pipe

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

and muffer.

clockwise direction.

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

fler from the lower saddlebag support rail.

c. Push wheel forward slightly so that adjuster cam

just contacts weld nub on both sides of rear swing-

e. Remove bungee cord to release muffler from lower

arm. See Figure 1-14.

saddlebag support rail.

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

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

at the midpoint of the bottom belt strand. Belt

deflection should be within the range specified in

groove at end of axle. Loosen cone nut, and then snug

to 15-20 ft-lbs (20-27 Nm). See Figure 1-14.

Table 1-6.

If belt is too tight, move to step 7 to increase belt deflec-

e. If belt is still too tight, repeat steps 7(b) through 7(d).

tion. If belt is too loose, reduce belt deflection as follows:

If belt is now too loose, move to step 6.

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2005 Touring: Maintenance

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LEFT SIDE

RIGHT SIDE

Increase

Reduce

Belt

Deflection

Cone

Nut

Weld

Nub

Weld

Nut

E-Clip

Nub

Adjuster

Cam

8398

8407

Figure 1-14. Move Rear Wheel Forward Until Adjuster Cams Just Contact Weld Nubs

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

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

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

the muffler to the lower saddlebag support rail.

NOTE

CAUTION

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

belt deflection procedure must be restarted.

Verify that the exhaust pipes do not contact the motorcy-

cle frame or any mounted components. Contact will can-

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

cel the effect of the rubber isolation mounts and transmit

ification.

vibration to the rider via the motorcycle frame.

If the belt deflection is not within specification, loosen

d. Verify that exhaust pipes are in alignment and do

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

not contact the motorcycle frame or mounted com-

before returning to step 6.

ponents.

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

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

side of axle.

Nm).

Open worm drive clamps and install heat shield on

11. Install right side muffler as follows:

rear header pipe. Position clamp so that screw is on

the outboard side in the most accessible position.

NOTE

TORCA muffler clamps have eliminated the need for silicone

or graphite tape during assembly. To ensure sealing integrity

CAUTION

of muffler clamps and prevent the possibility of leakage, Har-

Verify that the heat shields do not contact the motorcy-

ley-Davidson recommends that TORCA clamp assemblies be

cle frame or any mounted components. Contact will can-

discarded and replaced each time they are removed.

cel the effect of the rubber isolation mounts and transmit

vibration to the rider via the motorcycle frame.

a. Slide new TORCA clamp onto free end of rear

header pipe.

g. Remove bungee cord from muffler.

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

support rail. Install muffler on rear header pipe.

12. Install saddlebags. See Section

2.25 SADDLEBAG,

Place TORCA clamp into position between rear

INSTALLATION.

header pipe and muffler.

2005 Touring: Maintenance

1-21

HOME

THROTTLE CABLES

1.11

GENERAL

f1225x2x

See Section

1.2 MAINTENANCE SCHEDULE for the

required service interval.

PROCEDURE

LUBRICATION

CAUTION

5/32 Inch

Do not remove the switch housing assembly without first

(4.0 mm)

placing the 5/32 inch (4.0 mm) cardboard insert between

Cardboard

the brake lever and lever bracket. Removal without the

Insert

insert may result in damage to the rubber boot and

plunger of the Front Stoplight Switch.

NOTE

Figure 1-15. Install Cardboard Insert

Use the eyelet of an ordinary cable strap if the cardboard

insert is not available.

Notch

Ferrule

Place the cardboard insert between the brake lever and

lever bracket. See Figure 1-15.

2. Using a T25 TORX drive head, remove the upper and

Groove

lower switch housing screws.

3. Using a T27 TORX drive head, loosen the upper screw

securing the handlebar clamp to the master cylinder

housing. Remove the lower clamp screw with flat

washer.

Remove the brass ferrules from the notches on the

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

Idle

rules from the cable end fittings. See Figure 1-16.

Cable

Throttle

Grip

Cable

NOTE

f1474x2x

On non cruise equipped models, remove the friction shoe

from the end of the tension adjuster screw. The friction shoe

Figure 1-16. Remove Throttle/Idle Cables

is a loose fit and may fall out or become dislodged if the lower

switch housing is turned upside down or shaken.

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

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

dlebar.

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

between throttle cable and cable housing inside lower

Move upper switch housing to the side in order to access

lower housing.

switch housing. Squeeze tube to squirt a quantity of

lubricant into cable housing moving pin around cable

OD. See Figure 1-17.

1CAUTION

Repeat the procedure squirting a quantity of lubricant

Lubit-8 Tufoil Chain and Cable Lube contains detergents.

between the idle cable and cable housing.

Avoid contact with eyes. Keep out of reach of children.

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2005 Touring: Maintenance

HOME

NOTE

Always tighten the lower switch housing screw first so that

any gap between the upper and lower housings is at the front

of the switch assembly.

Insert

Lubricant

17. Remove the cardboard insert between the brake lever

Here

and lever bracket.

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

apply brake lever to test operation of brake lamp.

ADJUSTMENT

7958

NOTE

Figure 1-17. Lubricate Throttle/Idle Cables

For throttle and idle cable adjustment on cruise equipped

models, see Section

8.30 CRUISE CONTROL (FLHRC,

FLTR, FLHTCU).

NOTE

Slide rubber boot off throttle cable adjuster. See Figure

On non cruise equipped models, install the friction shoe with

1-18. Holding cable adjuster with a 3/8 inch wrench,

the concave side up so that the pin hole is over the point of

loosen jam nut turning in a clockwise direction. Back jam

the adjuster screw. The friction shoe is a loose fit and may fall

nut away from cable adjuster until it stops. Turn adjuster

out or become dislodged if the lower switch housing is turned

clockwise until it contacts jam nut. Repeat procedure on

upside down or shaken.

idle cable adjuster.

Apply a light coating of graphite to the handlebar.

Point the front wheel straight ahead. Turn the throttle

10.

Slide the throttle control grip over the end of the right

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

handlebar until it bottoms against the closed end. Rotate

terclockwise) and then hold in position. Now turn the

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

throttle cable adjuster counterclockwise until the throttle

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

cam stop just touches the stop plate on the carburetor.

See Figure 1-19. Tighten jam nut against the throttle

11.

Position the lower switch housing beneath the throttle

cable adjuster and then release the throttle control grip.

control grip. Install the brass ferrules onto the cables so

Cover cable adjuster mechanism with rubber boot.

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

ferrules in their respective notches on the throttle control

grip. Verify that the cables are captured in the grooves

molded into the grip. See Figure 1-16.

f1376b2x

Throttle Control

12.

Position the upper switch housing over the handlebar

Grip

and lower switch housing. Verify that the wire harness

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

dlebar.

13.

Start the upper and lower switch housing screws, but do

not tighten.

14.

Position the brake lever/master cylinder assembly

Jam Nut

inboard of the switch housing assembly engaging the

tab on the lower switch housing in the groove at the top

of the brake lever bracket.

Tension

15.

Align the holes in the handlebar clamp with those in the

Adjuster

master cylinder housing and start the lower screw (with

Screw

flat washer). Position for rider comfort. Beginning with

Idle Cable

Throttle Cable

the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0

Adjuster

Nm) torque using a T27 TORX drive head.

16.

Using a T25 TORX drive head, tighten the lower and

Figure 1-18. Throttle Cable Assembly - Throttle Side

upper switch housing screws to 35-45 in-lbs (4-5 Nm).

(FLHR/S)

2005 Touring: Maintenance

1-23

HOME

Idle

Throttle

Cable Guide

Cable

Housing

Spring

Cable

Barrel End

Throttle

Stop Plate

Throttle

Wheel

Cam Stop

f1381a2x

Figure 1-19. Throttle Cable Assembly - Carburetor Side

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

4. Verify that the throttle control operates freely without

counterclockwise until the cable housing just touches

binding. With the tension adjuster screw backed off, the

the spring in the longer cable guide. Work the throttle

throttle control grip must freely return to the closed (idle)

grip to verify that the throttle cable returns to the idle

position. The throttle control also must open and close

position when released. If the cable does not return to

freely when the front wheel is turned to both the right

idle, turn the adjuster clockwise slightly until the correct

and left fork stops.

response is achieved. Tighten jam nut against the idle

If the throttle grip does not return to the idle position

cable adjuster and cover cable adjuster mechanism with

freely, check the adjuster screw tension (if present). If

rubber boot.

the adjuster screw is backed off, inspect the cables for

short bends.

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2005 Touring: Maintenance

HOME

ENRICHENER CONTROL

1.12

GENERAL

f1438x4x

See Section

1.2 MAINTENANCE SCHEDULE for the

required service interval.

PROCEDURE

NOTE

The fuel enrichener knob should open, remain open and then

close without binding. The knurled plastic nut next to the

enrichener knob controls the ease at which the cable slides

within the conduit.

Enrichener Knob

Lockwasher

Knurled Nut

Hex Nut

If adjustment is needed, proceed as follows:

Mounting Bracket

Enrichener Cable

Flat

1. See Figure 1-20. Loosen hex nut at backside of mount-

ing bracket.

Figure 1-20. Enrichener Control

2. Move cable assembly free of slot in mounting bracket.

3. Hold cable assembly at flat with adjustable wrench.

Hand turn knurled nut counterclockwise to reduce sliding

resistance until knob slides inward unaided.

4. Turn knurled nut clockwise to increase sliding resistance

until knob remains fully out without holding and then

closes with relative ease.

5. Slide enrichener cable into slot of mounting bracket. Flat

on threads must face rear of motorcycle for script on

enrichener knob to be right side up. With external tooth

lockwasher and hex nut positioned on the inboard side

of the mounting bracket, tighten hex nut to 20-35 in-lbs

(2.3-4.0 Nm).

CAUTION

Do not lubricate the cable or inside of conduit. The cable

must have sliding resistance to work properly.

2005 Touring: Maintenance

1-25

HOME

FUEL SYSTEM

1.13

GENERAL

f1723x4x

See Section

1.2 MAINTENANCE SCHEDULE for the

required service interval.

PROCEDURE

LINES AND FITTINGS

Carefully inspect the fuel system lines and fittings for leaks or

damage.

FUEL FILTER (CARBURETED)

1WARNING

Gasoline is extremely flammable and highly explosive.

When servicing the fuel system, do not smoke or allow

open flame or sparks in the vicinity. Inadequate safety

precautions could result in death or serious injury.

1. Turn the handle of the fuel valve to OFF.

1WARNING

A small amount of gasoline may drain from the carbure-

tor fuel inlet hose when disconnected from the fuel valve

fitting. Thoroughly wipe up any spilled fuel immediately

and dispose of rags in a suitable manner. Gasoline is

extremely flammable and highly explosive. Inadequate

Valve Handle

Vacuum Fitting

safety precautions could result in death or serious

Fuel Outlet Fitting

Jam Nut

injury.

Hose Clamp

Filter Strainer

Carburetor Fuel

Gasket

2. Using a side cutters, cut clamp and remove hose from

Inlet Hose

10.

Atmospheric

fuel outlet fitting at the front of the fuel valve. See Figure

Convoluted Tubing

Pressure Port

1-21. Drain free end of hose into a suitable container.

3. Remove elbow of intake manifold vacuum tube from fit-

ting on inboard side of the fuel valve.

Figure 1-21. Vacuum Operated Fuel Valve

4. Attach a length of fuel hose to the fuel outlet fitting. The

hose must be long enough to reach a suitable gasoline

Gently apply a vacuum of 1-10 inches of Mercury (Hg) to

container.

the vacuum fitting to get a good flow of gasoline through

5. Turn the handle of the fuel valve to RES(ERVE).

the valve.

6. Using the correct hose adapter, connect the Mity-Vac®

When the fuel tank is completely drained, remove the

Hand Pump (HD-23738A) to the vacuum fitting.

Mity-Vac® Hand Pump from the vacuum fitting.

Holding fuel tank adapter, turn the hex jam nut in a

CAUTION

clockwise direction to remove the fuel valve assembly.

To avoid damage to the diaphragm of the fuel valve, do

10. Remove the fuel filter strainer from the valve head.

not apply a vacuum greater than 25 inches of Mercury

Clean or replace.

(Hg) to the vacuum fitting.

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2005 Touring: Maintenance

HOME

11. Remove the hex jam nut from the fuel valve.

CAUTION

12. Remove the gasket from the valve head. Discard the

gasket.

Do not allow dirt or fluids to get into the vacuum tube

that connects the fuel valve to the intake manifold. Con-

13. Install a new gasket on the valve head.

taminants can block the vacuum signal which could

cause the fuel valve to malfunction.

14. Install the fuel filter strainer fitting the internal tube into

the larger hole in the valve head.

19. Connect elbow of intake manifold vacuum tube to fitting

on inboard side of the fuel valve.

15. Clean threads and sealing surface of fuel tank adapter

and inspect for damage. Replace if necessary.

20. Slide new clamp onto free end of carburetor fuel inlet

hose. Install hose onto fuel outlet fitting at front of fuel

16. With the hex side down, turn the jam nut two full turns in

valve. Crimp clamp using HOSE CLAMP PLIERS (HD-

a counterclockwise direction to thread onto fuel tank

97087-65B).

adapter.

21. Turn the handle of the fuel valve to OFF and fill the fuel

17. Insert fuel filter strainer into fuel tank. Holding the hex

tank. Carefully inspect for leaks at fitting.

jam nut to prevent rotation, turn the fuel valve two full

turns in a clockwise direction to thread onto hex jam nut.

22. Turn the valve handle to ON and start engine. No prim-

ing or special procedures are required to start fuel flow.

Carefully inspect for leaks at fitting.

1WARNING

23. Stop engine and return the valve to the OFF position.

Do not thread fuel valve onto hex jam nut more than two

turns or nut may “bottom” on valve, a condition which

may result in a gasoline leak. Any gasoline leak is a

potential fire hazard that could result in death or serious

FUEL FILTER CANISTER

injury.

(FUEL INJECTED)

18. Holding the fuel valve to prevent rotation, turn the hex

See Section 9.4 FUEL TANK (FUEL INJECTED), FUEL FIL-

jam nut in a counterclockwise direction until snug.

TER CANISTER, for replacement procedure.

Tighten the hex jam nut to 15-20 ft-lbs (20.3-27.1 Nm).

2005 Touring: Maintenance

1-27

HOME

BRAKES

1.14

NOTE

GENERAL

Use only DOT 4 BRAKE FLUID, Part No. 99953-99A (12 oz.).

See Section

1.2 MAINTENANCE SCHEDULE for the

3. Install cover (with gasket) on the master cylinder reser-

required service interval.

voir. Install two Phillips screws and tighten to 6-8 in-lbs

(0.7-0.9 Nm).

PROCEDURE

WARNING

Whenever the brake system is serviced, it should be

BRAKE FLUID

tested on dry, clean pavement at slow speeds before put-

ting the motorcycle into regular service. Improperly ser-

Inspect the brake fluid condition and level. Proceed as fol-

viced brakes can lead to an accident that could result in

lows:

death or serious injury.

CAUTION

BRAKE PADS AND DISCS

To prevent dirt and other contaminants from entering the

master cylinder reservoir, thoroughly clean the cover

Inspect the brake pads and discs as follows:

before removal.

Brake Pads

If brake pad friction material is worn to 0.04 inch (1.02 mm) or

CAUTION

less, replace the entire set of pads.

Cover adjacent surfaces when removing, draining, filling

and/or bleeding brake system components. Spilling DOT

4 brake fluid on painted or other finished surfaces can

1WARNING

result in cosmetic damage. Immediately wipe up any

For correct and safe brake operation, brake pads must

spilled brake fluid and thoroughly clean affected area

be replaced in sets at the same time. Mismatched brake

with water or 50/50 mix of water and denatured alcohol.

pads could lead to an accident resulting in death or seri-

ous injury.

Remove two Phillips screws from cover of master cylin-

der reservoir. Remove cover (with gasket).

Brake Discs

The minimum brake disc thickness is stamped on the side of

1WARNING

the disc.

Never mix DOT 4 with other brake fluids (such as DOT 5).

When checking the brake pads and discs, inspect the brake

Mixing different types of fluid may adversely affect brak-

lines and hoses for damage or leaks.

ing ability and lead to brake failure which could result in

death or serious injury.

1WARNING

Use only fresh, uncontaminated DOT 4 brake fluid. Fluid

containers that have been opened may have been con-

taminated by dirt or moisture. Use of contaminated

brake fluid may adversely affect braking ability and lead

to brake failure which could result in death or serious

injury.

2. Stand the motorcycle upright so that the master cylinder

reservoir is in a level position. Fluid level should be 1/ 8

inch (3.2 mm) from the top. Add fluid as necessary.

1-28

2005 Touring: Maintenance

HOME

SPARK PLUGS

1.15

Before installing spark plugs, check condition of threads

GENERAL

in cylinder head and on plug. If necessary soften depos-

its with penetrating oil and clean out with a thread

See Section

1.2 MAINTENANCE SCHEDULE for the

chaser.

required service interval.

Apply a very light coating of ANTISEIZE LUBRICANT to

spark plug threads.

PROCEDURE

Install spark plug finger tight and then torque to 12-18 ft-

lbs (16-24 Nm).

NOTE

1WARNING

If a torque wrench is not available, finger tighten spark plug

Never disconnect a spark plug cable with the engine run-

and then using a spark plug wrench, tighten plug an addi-

ning. Doing so will result in an electric shock from the

tional 1/4 turn.

ignition system that could result in death or serious

injury.

Table 1-7. Spark Plug Data

Disconnect spark plug cables from spark plug terminals.

SIZE

12 mm

Remove spark plug using a 5/8 inch spark plug socket.

Examine plugs as soon as they have been removed. The

GAP

0.038-0.043 in. (0.97-1.09 mm)

deposits on the plug base are an indication of the plug

efficiency and are a guide to the general condition of

TYPE

HD-6R12 (No Substitute)

rings, valves, carburetor and ignition system.

a. A wet black and shiny deposit on plug base, elec-

NOTE

trodes and ceramic insulator tip indicate an oil

fouled plug. The condition may be caused by worn

The number 6R12 plug is supplied as original equipment and

rings and pistons, loose valves or seals, weak bat-

is the only plug that should be used. The resistor plug

tery or faulty ignition.

reduces radio interference created by the ignition system and

will not adversely affect performance or fuel economy.

b. A dry fluffy or sooty black deposit indicates a too

rich carburetor air-fuel mixture or long periods of

Install spark plug cable from left side coil tower onto front

engine idling. Excessive use of the enrichener may

cylinder spark plug. Install spark plug cable from right

also cause this condition.

side coil tower onto rear cylinder spark plug.

c. An overheated plug can be identified by a light

brown, glassy deposit. This condition may be

accompanied by cracks in the insulator or by ero-

sion of the electrodes. This condition is caused by

too lean an air-fuel mixture, a hot running engine,

valves not seating or improper ignition timing. The

glassy deposit on the spark plug is a conductor

when hot and may cause high speed misfiring. A

plug with eroded electrodes, heavy deposits or a

cracked insulator should be replaced.

d. A plug with white, yellow or light tan to rusty brown

powdery deposit indicates balanced combustion.

The deposits may be cleaned off at regular intervals

if desired.

Set the spark plug gap using a wire-type gauge. Bend

the outside electrode so only a slight drag on the gauge

is felt when passing it between electrodes. Never make

adjustments by bending the center electrode. Set gap on

all plugs at 0.038-0.043 in. (0.97-1.09 mm)

2005 Touring: Maintenance

1-29

HOME

ENGINE IDLE SPEED

1.16

GENERAL

Throttle

Stop Screw

See Section

1.2 MAINTENANCE SCHEDULE for the

required service interval.

PROCEDURE

Inspect the engine idle speed as follows:

NOTES

●

The C.V. carburetor has an enrichener circuit that will

cause the engine to idle at approximately 1500 rpm with

the engine at normal operating temperature and the

enrichener knob pulled fully out.

●

The increase in idle speed is intended to alert the rider

that the engine is warmed up to normal operating tem-

perature and the enrichener knob should be pushed all

the way in.

●

Continuing to use the enrichener when the engine is at

f1381d2x

full operating temperature WILL CAUSE FOULED

PLUGS.

Figure 1-22. Idle Speed Adjustment

●

TECHNICIAN - Be sure the engine is warmed up to nor-

mal operating temperature and the enrichener knob is

pushed all the way in BEFORE adjusting engine idle

NOTE

speed. Be aware that because there are variations in

To measure engine rpm on models without tachometers, use

individual components, it is possible for a properly

a test tachometer connected to the negative ignition coil ter-

warmed up engine to idle at

2000 rpm with the

minal.

enrichener knob pulled PARTIALLY OUT.

See Figure 1-22. With the engine at normal operating

temperature and the enrichener all the way in

(enrichener valve closed) adjust the throttle stop screw

so the engine idles at 950-1050 rpm.

1-30

2005 Touring: Maintenance

HOME

FRONT FORK OIL

1.17

GENERAL

See Section

1.2 MAINTENANCE SCHEDULE for the

required service interval.

PROCEDURE

See Section 2.15 FRONT FORKS for detailed instructions.

2005 Touring: Maintenance

1-31

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STEERING HEAD BEARINGS

1.18

GENERAL

f2108x2x

See Section

1.2 MAINTENANCE SCHEDULE for the

Steering

required service interval.

Head

PROCEDURE

GREASING

Turn handlebar full right to access the grease fitting at

the left side of the steering head. See Figure 1-23.

Grease

Fitting

Using SPECIAL PURPOSE GREASE (Part No. 99857-97),

connect grease gun to fitting and inject grease until it

exudes from top and bottom of steering head.

Figure 1-23. Steering Head Bearing Grease Fitting

CHECKING

Check the swing-by and adjust as necessary. See Section

2.17 STEERING HEAD BEARINGS for more information.

INSPECTING/REPLACING

Disassemble the steering head and inspect the bearings for

brinelling, scoring, or other damage. Replace and/or repack

the bearings as required. See Section

2.17 STEERING

HEAD BEARINGS for more information.

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2005 Touring: Maintenance

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CRITICAL FASTENERS

1.19

● Tighten four engine to transmission bolts to 30-35 ft-lbs

GENERAL

(41-48 Nm).

See Section

1.2 MAINTENANCE SCHEDULE for the

NOTE

required service interval.

Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER

PROCEDURE

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

models, see Section 9.4 FUEL TANK (FUEL INJECTED),

INSTALLATION (AFTER PARTIAL REMOVAL), FLHT/C/U/I,

ENGINE MOUNTS

FLTRI, or FLHR/C/S/I.

Inspect the condition and tightness of the stabilizer links and

engine mounts. Replace fastener if damaged. Proceed as fol-

lows:

OTHER FASTENERS

NOTE

Inspect the condition and tightness of other critical fasteners.

Raise fuel tank to access top engine stabilizer bolts and jam

Replace fastener if damaged. Proceed as follows:

nuts. For carbureted models, see Section 4.7 FUEL TANK

(CARBURETED), PARTIAL REMOVAL, FLHT/C, or FLHR/S.

For fuel injected models, see Section 9.4 FUEL TANK (FUEL

Table 1-8. Critical Fastener Torque

INJECTED), PARTIAL REMOVAL, FLHT/C/U/I, FLTRI, or

FLHR/C/S/I.

Fastener

ft/in-lbs

Axle

Top

Front axle nut

50-55 ft-lbs

68-75 Nm

● On left side of motorcycle, tighten top engine mounting

Rear axle cone nut

95-105 ft-lbs

129-142 Nm

bracket bolts to front and rear cylinder heads to 35-40 ft-

Brakes

lbs (48-54 Nm). See A of Figure 1-24.

Banjo Bolts

17-22 ft-lbs

23-30 Nm

● Top stabilizer link - tighten eyelet bolt to top engine

Front Brake Disc Mounting

16-24 ft-lbs

22-33 Nm

mounting bracket to 18-22 ft-lbs (24-30 Nm). See B of

Screws

Figure 1-24.

Front Brake Caliper Mounting

28-38 ft-lbs

38-52 Nm

Bolts

● Moving to right side of motorcycle, tighten eyelet bolt to

frame weldment to 18-22 ft-lbs (24-30 Nm). See C of Fig-

Brake Caliper Pad Pins

180-200 in-lbs

20-23 Nm

ure 1-24.

Rear Brake Disc Mounting

30-45 ft-lbs

41-61 Nm

Screws

● Verify tightness of jam nuts on top stabilizer link.

Rear Master Cylinder Mounting

30-40 ft-lbs

41-54 Nm

Nut

Bottom

Reservoir Cover Screws

6-8 in-lbs

0.7-0.9 Nm

● Front stabilizer link - on left side of motorcycle, tighten

Front Forks

eyelet bolt to frame weldment to 18-22 ft-lbs (24-30 Nm).

See D of Figure 1-24.

Axle Holder Nuts

132-180 in-lbs

14.9-20.3 Nm

● Moving to right side of motorcycle, tighten eyelet bolt to

Hand Controls

block on front engine mounting bracket to 18-22 ft-lbs

Clutch Lever/Handlebar Clamp

60-80 in-lbs

6.8-9.0 Nm

(24-30 Nm). See E of Figure 1-24.

Master Cylinder/Handlebar

60-80 in-lbs

6.8-9.0 Nm

● Verify tightness of jam nuts on front stabilizer link.

Clamp Screws

Upper/Lower Switch Housing

● Tighten center front engine mounting bracket to rubber

35-45 in-lbs

4-5 Nm

Screws

mount bolt to 15-20 ft-lbs (20-27 Nm). See F of Figure 1-

24.

Handlebars

● Tighten the two front engine mount to frame crossmem-

Lower Clamp (Riser) Bolts

30-40 ft-lbs

40.7-54.2 Nm

ber bolts to 15-20 ft-lbs (20-27 Nm). See G of Figure 1-

Pivot Shaft

24.

Locknuts

40-45 ft-lbs

54-61 Nm

● Tighten two engine to front engine mounting bracket

Swingarm Bracket Bolts

34-42 ft-lbs

46-57 Nm

bolts to 33-38 ft-lbs (45-52 Nm). See H of Figure 1-24.

2005 Touring: Maintenance

1-33

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LEFT SIDE

RIGHT SIDE

Top Stabilizer Link and Engine Mounting Bracket

f2181x2x

f2111x2x

Jam Nut

Front

Stabilizer Link

Front Engine

Mounting Bracket

f1303x2x

Front Stabilizer Link and Engine Mounting Bracket

Top

Bottom

A Top Engine Mounting Bracket to Cylinder Heads

D Eyelet to Frame Weldment

B Eyelet to Top Engine Mounting Bracket

E Eyelet to Front Engine Mounting Bracket

C Eyelet to Frame Weldment

F Front Engine Mounting Bracket to Rubber Mount

G Front Engine Mount to Frame Crossmember

H Engine to Front Engine Mounting Bracket

Figure 1-24. Engine Mounting Bracket Bolts

1-34

2005 Touring: Maintenance

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BATTERY

1.20

Inspect battery for discoloration, raised top, or warped

GENERAL

case, which may indicate that battery has been over-

heated or overcharged. Inspect battery case for cracks

See Section

1.2 MAINTENANCE SCHEDULE for the

or leaks. Replace battery if any of these conditions are

required service interval.

found.

NOTE

For testing or charging information, see Section 8.10 BAT-

PROCEDURE

TERY.

Coat battery terminals with ELECTRICAL CONTACT

1. Verify that battery top is clean and dry. Dirt on top of bat-

LUBRICANT, Part No. 99861-02 (1 oz tube).

tery may cause it to self-discharge at a faster than nor-

mal rate.

2. Inspect battery clamp, screws and cables for breakage,

loose connections and corrosion. Clean or replace as

necessary.

2005 Touring: Maintenance

1-35

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TROUBLESHOOTING

1.21

10. Ignition timing incorrect due to faulty ignition coil, ignition

GENERAL

module or sensors (MAP, CKP and/or TSM/TSSM).

The following check list of possible operating troubles and

11. Engine lubricant too heavy (winter operation).

their probable causes will be helpful in keeping your motorcy-

NOTE

cle in good operating condition. More than one of these con-

Always disengage clutch for cold weather starts.

ditions may be causing the trouble and all should be carefully

checked.

12. Sticking or damaged valve or push rod wrong length.

13. Primary cam sprocket spline sheared or missing spacer.

1WARNING

The troubleshooting section of this manual is intended

Starts Hard

solely as a guide to diagnosing problems. Carefully read

Spark plugs in bad condition, have improper gap or are

the appropriate sections of this manual before perform-

partially fouled.

ing any work. Improper repair and/or maintenance could

result in death or serious injury.

Spark plug cables in bad condition.

Battery nearly discharged.

ENGINE

Loose wire connection at one of the battery terminals,

ignition coil or plug between ignition sensor and module.

Carburetor controls not adjusted correctly.

Starter Motor Does Not Operate or Does

Water or dirt in fuel system and carburetor.

Not Turn Engine Over

Intake air leak.

Ignition/Light Key Switch not in IGNITION position.

Fuel tank vent hose and vapor valve plugged, or carbu-

Engine Stop switch in the OFF position.

retor fuel line closed off and restricting fuel flow.

Discharged battery, loose or corroded connections

Enrichener valve inoperative.

(solenoid chatters).

10. Engine lubricant too heavy (winter operation).

TSM/TSSM BAS tripped and Ignition/Light Key Switch

NOTE

not cycled to OFF and then back to IGNITION.

Always disengage clutch for cold weather starts.

Starter control circuit, relay or solenoid faulty.

11. Ignition not functioning properly (possible sensor failure).

Electric starter shaft pinion gear not engaging or over-

running clutch slipping.

12. Faulty ignition coil.

13. Valves sticking.

Engine Turns Over But Does Not Start

Starts But Runs Irregularly or Misses

Fuel tank empty.

Fuel supply valve turned to OFF.

Spark plugs in bad condition or partially fouled.

Fouled spark plugs.

Spark plug cables in bad condition and leaking.

Engine flooded with gasoline as a result of over use of

Spark plug gap too close or too wide.

enrichener.

Faulty ignition coil, module and/or sensor.

Fuel valve or filter clogged.

Battery nearly discharged.

Vacuum hose to automatic fuel supply valve discon-

Damaged wire or loose connection at battery terminals,

nected, leaking or pinched.

ignition coil, or plug between ignition sensor and module.

Discharged battery, loose or broken battery terminal

Intermittent short circuit due to damaged wire insulation.

connections.

Water or dirt in fuel system, carburetor or filter.

Loose wire connection at coil, battery or plug between

Fuel tank vent system plugged or carburetor vent line

ignition sensor and module.

closed off.

Spark plug cables in bad condition and shorting, cable

10. Carburetor controls misadjusted.

connections loose, or cables connected to wrong cylin-

ders.

11. Damaged carburetor.

1-36

2005 Touring: Maintenance

HOME

12. Loose or dirty ignition module connector at crankcase.

Engine to transmission mounting bolts loose.

13. Faulty MAP and/or CKP Sensor.

Upper engine mounting bracket loose.

14. Incorrect valve timing.

Ignition timing incorrect/poorly tuned engine.

15. Weak or broken valve springs.

Internal engine problem.

16. Damaged intake or exhaust valve.

Broken frame.

Stabilizer links worn or loose.

A Spark Plug Fouls Repeatedly

10. Rubber mounts loose or worn.

11. Rear fork pivot shaft nuts loose.

1. Fuel mixture too rich or enrichener left out too long.

12. Front engine mounting bolts loose.

2. Incorrect spark plug for the kind of service.

3. Piston rings badly worn or broken.

Check Engine Lamp Illuminates During

4. Valve guides or seals badly worn.

Operation

Fault detected. Check for trouble codes.

Pre-Ignition or Detonation (Knocks or

Pings)

1. Fuel octane rating too low.

LUBRICATION SYSTEM

2. Faulty spark plugs.

3. Incorrect spark plug for the kind of service.

4. Excessive carbon deposit on piston head or in combus-

Oil Does Not Return To Oil Pan

tion chamber.

Oil pan empty.

5. Ignition timing advanced due to faulty sensor inputs

Oil pump not functioning.

(MAP, CKP).

Restricted oil lines or fittings.

Restricted oil filter.

Overheating

Oil pump misaligned or in poor condition.

1. Insufficient oil supply or oil not circulating.

O-ring damaged or missing from oil pump/crankcase

2. Insufficient air flow over engine.

junction (also results in poor engine performance).

3. Heavy carbon deposit.

4. Ignition timing retarded due to faulty MAP and/or CKP

Engine Uses Too Much Oil Or Smokes

Sensor.

Excessively

5. Leaking valve.

Oil pan overfilled.

Restricted oil return line to pan.

Valve Train Noise

Restricted breather operation.

1. Low oil pressure caused by oil feed pump not functioning

Restricted oil filter.

properly or oil passages obstructed.

Oil pump misaligned or in poor condition.

2. Faulty hydraulic lifters.

Piston rings badly worn or broken.

3. Bent push rod.

Valve guides or seals worn.

4. Incorrect push rod length.

O-ring damaged or missing from oil pump/crankcase

5. Rocker arm binding on shaft.

junction (also results in poor engine performance).

6. Valve sticking in guide.

7. Chain tensioner spring or shoe worn.

Engine Leaks Oil From Case, Push Rods,

Hoses, Etc.

Excessive Vibration

Loose parts.

1. Wheels and/or tires worn or damaged.

Imperfect seal at gaskets, push rod cover, washers, etc.

2. Engine/transmission/motorcycle not aligned properly.

Restricted oil return line to pan.

Restricted breather hose to air cleaner.

3. Primary chain badly worn or links tight as a result of

insufficient lubrication or misalignment.

Restricted oil filter.

2005 Touring: Maintenance

1-37

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Harley Davidson 2005 touring models. Service repair manual — page 2

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