Harley Davidson 2005 touring models. Service repair manual — page 8
HOME
10. Lift inner ramp out of clutch release cover and turn the
assembly over so that ball sockets are facing outboard.
Right Frame
f1472b2x
Remove hook of ramp from button on coupling. Remove
Downtube
coupling from clutch cable end.
11. Remove balls from outer ramp sockets. Remove outer
ramp from clutch release cover.
12. Unscrew the cable fitting from the clutch release cover.
Remove clutch cable and fitting.
13. Cut cable strap in hole of crossbrace to free clutch cable
from right frame downtube. See Figure 2-117. Continue
as follows:
FLHR/C/S: Remove T40 TORX screw with flat washer
(FLHRS) or acorn nut (FLHR/C) to release clutch cable
from P-clamp fastened to upper fork bracket. See Figure
2-118.
FLTR: Release clutch cable from cable clip anchored in
hole on left side of instrument nacelle.
FLHT/C/U: Remove the outer fairing. See Section 2.29
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
FAIRING/WINDSHIELD, REMOVAL. Cut cable strap to
Clutch Cable
Cable Strap
release clutch cable from left fairing bracket. See Figure
2-119.
Figure 2-117. Clutch Cable Routing (Right Side View)
14. Remove clutch cable from motorcycle.
NOTE
Clutch Cable
f2257x2x
If ball and ramp or throwout bearing and clutch pushrod need
service, see Section 7.5 CLUTCH RELEASE COVER.
INSTALLATION
1. See Figure 2-115. Insert clutch cable eyelet into groove
of clutch hand lever aligning eyelet with hole without
bushing. Insert anchor pin through lever and eyelet.
2. Insert lever into groove of clutch lever bracket fitting
sleeve at end of cable housing into bore on inboard side
of bracket.
3. Align hole in hand lever with hole in bracket and install
Clamp
pivot pin. Install retaining ring in pivot pin groove.
4. If removed, use a T27 TORX drive head and install two
screws (with flat washers) to secure handelbar clamp to
clutch lever bracket. See Figure 2-115. Starting with the
Figure 2-118. Clutch Cable Routing - FLHR/C
top screw, tighten screws to 60-80 in-lbs (6.8-9.0 Nm).
(Left Side View)
5. Start clutch cable routing as follows:
FLHR/C/S: Capture clutch cable in P-clamp and fasten
FLHT/C/U: Feed clutch cable through grommet on left
to upper fork bracket using T40 TORX screw with flat
side of inner fairing. Route cable on inboard side of left
washer (FLHRS) or acorn nut (FLHR/C). Orient P-clamp
fairing bracket between upper and lower wings of radio
as shown in Figure 2-118. On left side of steering head,
(or storage box) support bracket. Cable strap clutch
run cable downward between engine guard and front of
cable to left fairing bracket using oblong hole at this loca-
left frame downtube.
tion. See Figure 2-119. Run cable downward along left
FLTR: Capture clutch cable in cable clip and anchor clip
side of steering head, and then between engine guard
in hole on left side of instrument nacelle. Run cable for-
and front of left frame downtube. Install the outer fairing.
ward and then rearward beneath instrument nacelle fol-
See Section
2.29 UPPER FAIRING/WINDSHIELD
lowing left side of steering head. Run cable downward
(FLHT/C/U), OUTER FAIRING/WINDSHIELD, INSTAL-
between engine guard and front of left frame downtube.
LATION.
2-96
2005 Touring: Chassis
HOME
12. Install the retaining ring so that the opening is to the right
9421
of the outer ramp tang slot in the clutch release cover.
13. Verify that the two locating dowels are in place on the
right side of the transmission case. Hang a new gasket
on the dowels.
14. Holding the clutch release cover in position, install six
socket head screws. Tighten screws to 84-132 in-lbs
(9.5-14.9 Nm).
15. Tighten clutch cable fitting to 36-60 in-lbs (4-7 Nm).
16. Check the O-ring on the transmission drain plug for
tears, cuts or general deterioration. Replace as nec-
Cable
essary.
Strap
CAUTION
Do not overtighten filler plugs or drain plugs. Overtight-
Figure 2-119. Secure Clutch Cable to Fairing Bracket
ening plugs can cause leaks.
17. Install transmission the drain plug. Tighten the plug to
6.
Complete clutch cable routing as follows:
14-21 ft-lbs (19-28 Nm).
All Models: Continue downward progression while
crossing to right side of motorcycle and then run cable
between outboard side of voltage regulator and inboard
side of right frame downtube. Threading cable strap
8496
Clutch
through hole in crossbrace, secure clutch cable to down-
Release
tube as shown in Figure 2-117. Following inboard side of
Cover
frame downtube, route cable between bottom of cam
cover and top of lower frame tube to area of clutch
release cover.
7.
Inspect cable fitting O-ring and replace if damaged or
deformed. Install clutch cable fitting into clutch release
cover. See Figure 2-116. Do not tighten cable fitting at
this time.
Filler
8.
Place outer ramp in clutch release cover recess with
Plug
tang in cover slot.
9.
Apply a multi-purpose grease to the balls and outer
ramp sockets. Place a ball in each of three outer ramp
sockets.
Figure 2-120. Transmission Case (Right Side)
10.
Hold coupling with button facing outboard. Place cable
end in recess of coupling. With ball sockets facing out-
OMF50
board, place hook of inner ramp on button of couplng.
Holding inner ramp and coupling together, turn the
assembly over.
11.
Place inner ramp (ball socket side down) over balls in
outer ramp sockets.
1WARNING
Always wear proper eye protection when installing re-
O-Ring
taining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
worn. Slippage may propel the ring with enough force to
cause eye injury.
Figure 2-121. Transmission Lubricant Filler Plug/Dipstick
2005 Touring: Chassis
2-97
HOME
18. Remove the filler plug from the clutch release cover, if
21. Adjust the clutch cable. See Section
6.3 CLUTCH,
installed. See Figure 2-120. Check the O-ring for tears,
ADJUSTMENT.
cuts or general deterioration. Replace as necessary.
22. Install right side exhaust system. See Section
3.8
See Figure 2-121.
INSTALLING ENGINE IN CHASSIS, steps 46-52.
19. Fill the transmission with
20-24 oz. (590-710 ml) of
23. Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
transmission lubricant or until the lubricant level on the
MAXI-FUSE, INSTALLATION.
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
TRANSMISSION LUBRICANT, Part No.
99892-84
(quart) or Part No. 99891-84 (gallon).
20. Install the transmission filler plug/dipstick in the clutch
release cover. Tighten the plug to 25-75 in-lbs (2.8-8.5
Nm).
2-98
2005 Touring: Chassis
HOME
HANDLEBARS
2.23
10. If necessary, adjust left and right handlebar switch con-
HANDLEBAR ADJUSTMENT
trols as follows:
a. Using a T27 TORX drive head, loosen the two
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
screws securing the handlebar clamp to the clutch
MAXI-FUSE, REMOVAL.
lever bracket
(left) or master cylinder housing
2. FLHR/C/S: Remove the handlebar clamp shroud. See
(right).
Section
2.31 WINDSHIELD/HEADLAMP NACELLE
b. Position switch controls for rider posture and com-
(FLHR/C/S), NACELLE REMOVAL (FLHR/C), steps 1-
fort.
11, or NACELLE REMOVAL (FLHRS), steps 1-7.
c. Beginning with the top screw, tighten the screws to
FLTR: Remove the instrument bezel. See Section 2.30
60-80 in-lbs (6.8-9.0 Nm).
UPPER FAIRING/WINDSHIELD
(FLTR), BEZEL,
REMOVAL.
11. Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
MAXI-FUSE, INSTALLATION.
FLHT/C/U: Remove the fairing cap. See Section 2.29
UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING
CAP, REMOVAL.
HANDLEBAR REMOVAL
3. Loosen rear screws on the upper handlebar clamps. On
FLTR models, loosen the front screws instead.
1.
Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
4. Position handlebars for rider posture and comfort.
MAXI-FUSE, REMOVAL.
5. To be sure that the handlebars are centered, verify that
2.
Place blanket or protective cover over front of fuel tank to
the knurled area on the outboard side of the left side
protect against scratches or other damage.
handlebar clamp is equal to that on the right side.
3.
FLHR/C/S: Remove the handlebar clamp shroud. See
Section
2.31 WINDSHIELD/HEADLAMP NACELLE
6. Snug upper handlebar clamp screws.
(FLHR/C/S), NACELLE REMOVAL (FLHR/C), steps 1-
11, or NACELLE REMOVAL (FLHRS), steps 1-7.
1WARNING
FLTR: Remove the instrument nacelle. See Section 2.30
Improperly aligned handlebars can contact the fuel tank
UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT
when turned to the left or right fork stops. Contact with
NACELLE, REMOVAL.
the fuel tank while riding can cause loss of vehicle con-
FLHT/C/U: Remove the fairing cap. See Section 2.29
trol resulting in death or serious injury.
UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING
CAP, REMOVAL. Remove the radio (or storage box).
7.
Slowly turn handlebars to the full right fork stop and then
See Section 8.31 PREMIUM SOUND SYSTEM (FLHTC/
the full left fork stop to be sure there is no contact with
U, FLTR), RADIO (FLHTC/U), REMOVAL, steps 3-7.
the fuel tank. If contact occurs and handlebars are prop-
erly aligned, raise handlebars as necessary until the
4.
Remove the left and right handlebar switch controls. See
proper clearance is obtained.
Section 8.21 HANDLEBAR SWITCHES, REMOVAL.
8. Tighten the upper handlebar clamp screws to 12-16 ft-
5.
Remove upper handlebar clamp screws (with flat wash-
lbs (16.3-21.7 Nm).
ers). Remove upper handlebar clamps and handlebar.
9. FLHR/C/S: Install the handlebar clamp shroud. See
Section
2.31 WINDSHIELD/HEADLAMP NACELLE
(FLHR/C/S), NACELLE INSTALLATION
(FLHR/C),
HANDLEBAR INSTALLATION
steps
3-15, or NACELLE INSTALLATION (FLHRS),
steps 5-13.
1.
Place new handlebars on lower handlebar clamps.
FLTR: Install the instrument bezel. See Section 2.30
Install upper handlebar clamps and loosely install clamp
UPPER FAIRING/WINDSHIELD
(FLTR), BEZEL,
screws (with flat washers).
INSTALLATION.
2.
To be sure that the handlebars are centered, verify that
FLHT/C/U: Install the fairing cap. See Section
2.29
the knurled area on the outboard side of the left side
UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING
handlebar clamp is equal to that on the right side.
CAP, INSTALLATION.
3.
Snug upper handlebar clamp screws.
2005 Touring: Chassis
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HOME
5. Tighten upper handlebar clamp screws as follows:
f2056x2x
1
a. Tighten front screws until upper and lower handle-
bar clamps make contact.
2
b. Tighten rear screws to 12-16 ft-lbs (16.3-21.7 Nm).
c. Tighten front screws to 12-16 ft-lbs (16.3-21.7 Nm).
3
NOTE
A slight gap will exist between the upper and lower clamps at
the rear of the handlebars after tightening.
6.
Install the left hand grip. See LEFT HAND GRIP,
INSTALLATION, in this section.
*9
4
7.
Install the left and right handlebar switch controls. See
Section
8.21 HANDLEBAR SWITCHES, INSTALLA-
TION.
8.
FLHR/C/S: Install the handlebar clamp shroud. See
5
Section
2.31 WINDSHIELD/HEADLAMP NACELLE
**10
(FLHR/C/S), NACELLE INSTALLATION
(FLHR/C),
6
steps
3-15, or NACELLE INSTALLATION (FLHRS),
steps 5-13.
7
FLTR: Install the instrument nacelle. See Section 2.30
UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT
NACELLE, INSTALLATION.
5
**11
FLHT/C/U: Install the fairing cap. See Section
2.29
UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING
CAP, INSTALLATION. Install the radio (or storage box).
8
See Section 8.31 PREMIUM SOUND SYSTEM (FLHTC/
U, FLTR), RADIO (FLHTC/U), INSTALLATION, steps 1-
6.
1.
Screw
2.
Flat washer
*LEFT CLAMP ONLY
9.
Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
3.
Upper clamp
MAXI-FUSE, INSTALLATION.
9. Ground cable
4.
Lower clamp
10.
Turn the ignition/light key switch to IGNITION and test
5.
Cup washer
**RIGHT CLAMP ONLY
each handlebar switch for proper operation.
6.
Spacer
7.
Rubber bushing
10. Flat washer
11.
Apply front brake hand lever to test operation of brake
8.
Bolt
11. Large flat washer
lamp.
12.
Adjust idle and throttle control cables as follows:
Figure 2-122. Handlebar Clamp Assemblies
Non-Cruise: See Section 2.21 THROTTLE CABLES
(NON-CRUISE), ADJUSTMENT.
Cruise Equipped: See Section 8.30 CRUISE CON-
1WARNING
TROL (FLHRC, FLTR, FLHTCU), CABLE ADJUST-
MENT.
Improperly aligned handlebars can contact the fuel tank
when turned to the left or right fork stops. Contact with
the fuel tank while riding can cause loss of vehicle con-
trol resulting in death or serious injury.
LEFT HAND GRIP
4. Slowly turn handlebars to the full right fork stop and then
the full left fork stop to be sure there is no contact with
REMOVAL
the fuel tank. If contact occurs and handlebars are prop-
erly aligned, raise handlebars as necessary until the
1.
Remove the left handlebar switch controls. See Section
proper clearance is obtained.
8.21 HANDLEBAR SWITCHES, REMOVAL.
2-100
2005 Touring: Chassis
HOME
2. Use a sharp blade to carefully cut rubber and then peel
Right Side
off handlebar.
3.
Holding lower handlebar clamp to prevent rotation, turn
3. Thoroughly clean handlebar to remove all residual adhe-
bolt at bottom of upper fork bracket until free.
sive.
4. Remove lower handlebar clamp, flat washer and cup
washer at top of upper fork bracket. See Figure 2-123.
INSTALLATION
5.
Pull bushing from fork bracket bore and discard. See
Figure 2-124.
1WARNING
6.
Moving to bottom of upper fork bracket, remove bolt,
HARLEY-DAVIDSON ADHESIVE contains METHYL
large flat washer and cup washer. See Figure 2-125.
ETHYL KETONE, a chemical known to the State of Cali-
7.
Pull bushing and spacer from fork bracket bore. Remove
fornia to cause cancer or other reproductive harm.
spacer from bushing. See Figure 2-126. Discard bush-
ing.
1WARNING
Use HARLEY-DAVIDSON ADHESIVE in well ventilated
Left Side
areas only. Vapors are flammable and can be harmful to
breath. Avoid contact with eyes, mucous membranes, or
8.
Holding lower handlebar clamp to prevent rotation, turn
prolonged contact with skin. Keep out of reach of chil-
bolt at bottom of upper fork bracket until free.
dren.
9.
Remove lower handlebar clamp, ground wire ring termi-
1. Obtain a new left hand grip and HARLEY-DAVIDSON
nal and cup washer at top of upper fork bracket.
ADHESIVE (Part No. 99839-95). Apply a coat of the
adhesive to the inside surface of the grip one inch (25.4
mm) from the open end. Apply a coat to the end of the
handlebar.
f2077x2x
2.
Immediately push grip completely onto end of handlebar
using a twisting motion. Do not hesitate when installing
grip or adhesive may dry before installation is complete.
NOTE
If the left hand grip is patterned, align it with the pattern on
the right grip with the throttle in the fully closed position.
3.
Let 6-8 hours elapse (at 70° F.) to allow adhesive to fully
cure.
4. Install the left handlebar switch controls. See Section
8.21 HANDLEBAR SWITCHES, INSTALLATION.
Figure 2-123. Remove Flat Washer and
Upper Cup Washer (Right Side)
RUBBER MOUNTS
f2076x2x
NOTE
For complete disassembly of the handlebar clamp assem-
blies and/or to replace the rubber mounts, proceed as fol-
lows.
REMOVAL
General
1.
Turn fork to left fork stop and loosen right side bolt at
bottom of upper fork bracket. Turn fork to right fork stop
and loosen left side bolt at bottom of upper fork bracket.
2.
Remove handlebars. See HANDLEBAR REMOVAL in
Figure 2-124. Remove Upper Bushing (Right Side)
this section.
2005 Touring: Chassis
2-101
HOME
5. Install cup washer over threaded end of bolt fitting con-
f2058x2x
cave side over collar of bushing. Install flat washer. See
Figure 2-123.
6. Apply two or three drops of Loctite Medium Strength
Threadlocker 243 (blue) to threads of bolt and start lower
handlebar clamp. Holding clamp to prevent rotation, turn
bolt at bottom of upper fork bracket until snug.
Left Side
7.
Insert spacer into new bushing until flush with outboard
side of collar. See Figure 2-126.
Figure 2-125. Remove Bolt, Large Washer
and Lower Cup Washer (Right Side)
8.
Insert bushing into bore at bottom of upper fork bracket
fitting collar of bushing over lip of boss.
f2057x2x
9.
Install cup washer on bolt. Insert bolt into bushing fitting
concave side of cup washer over collar of bushing.
10. Moving to top of upper fork bracket, insert bushing into
bore fitting collar of bushing over lip of boss. See Figure
2-124.
11. Install cup washer over threaded end of bolt fitting con-
cave side over collar of bushing. Install ground wire ring
terminal.
12. Apply two or three drops of Loctite Medium Strength
Threadlocker 243 (blue) to threads of bolt and start lower
Figure 2-126. Remove Spacer From Lower Bushing
handlebar clamp. Holding clamp to prevent rotation, turn
bolt at bottom of upper fork bracket until snug.
General
10. Pull bushing from fork bracket bore and discard. See
Figure 2-124.
13. Install handlebars and upper handlebar clamps. See
11. Moving to bottom of upper fork bracket, remove bolt and
HANDLEBAR INSTALLATION in this section, steps 1-5.
cup washer.
14. Turn fork to left fork stop and tighten right side bolt at
12. Pull bushing and spacer from fork bracket bore. Remove
bottom of upper fork bracket to 30-40 ft-lbs (40.7-54.2
spacer from bushing. See Figure 2-126. Discard bush-
Nm). Turn fork to right fork stop and tighten left side bolt
ing.
to the same torque value.
15. Complete assembly of motorcycle. See HANDLEBAR
INSTALLATION in this section, steps 7-12.
INSTALLATION
Right Side
1.
Insert spacer into new bushing until flush with outboard
side of collar. See Figure 2-126.
2.
Insert bushing into bore at bottom of upper fork bracket
fitting collar of bushing over lip of boss.
3.
Install large flat washer and cup washer on bolt. See Fig-
ure 2-125. Insert bolt into bushing fitting concave side of
cup washer over collar of bushing.
4.
Moving to top of upper fork bracket, insert bushing into
bore fitting collar of bushing over lip of boss. See Figure
2-124.
2-102
2005 Touring: Chassis
HOME
SEAT
2.24
FLHR
Seat
Bottom
Tongue
REMOVAL
1. Remove Phillips screw to detach passenger seat mount-
ing bracket from top of rear fender. See Figure 2-127.
Slightly lift up back of passenger seat and carefully slide
toward rear of vehicle to detach from front seat mounting
bracket nuts.
NOTE
The FLHR seat can be converted to a solo seat by removal of
the passenger section. When the solo seat configuration is
desired, turn the passenger seat upside down and locate the
chrome plug pressed into the seat frame hole. See inset of
Figure 2-127. Remove the plug and press into the seat reten-
tion nut hole using finger pressure only.
2.
Using the 5/8 hex, remove two nuts from studs to free
f1416x2x
front seat mounting bracket from rear fender.
f2171x2x
3.
Push front seat rearward to free tongue
from slot in
frame backbone. See Figure 2-128.
Slot
f1091d2x
Screw
Passenger
Seat
Nut
Frame
Backbone
Front Seat
Figure 2-128. Seat Mounting
INSTALLATION
1.
Position front seat on frame with mounting bracket at
Stud Plate
rear.
2.
Firmly push front of seat downward and rearward until
tongue engages slot in frame backbone. See Figure 2-
128. Push seat forward until studs are centered in slots
of mounting bracket.
3.
Using the 5/8 hex, install two nuts on studs to secure
Passenger Seat
front seat mounting bracket to rear fender.
f1456x2x
Retention Nut Plug
4.
Install passenger seat fitting slots on passenger seat
front mounting bracket between rounded caps and hex
Figure 2-127. Seat Assembly - FLHR
of front seat mounting bracket nuts.
2005 Touring: Chassis
2-103
HOME
5.
Push passenger seat forward until rear fender seat
retention nut is centered in hole of rear mounting
f1550x2x
bracket. Install Phillips screw.
Slot
NOTE
If seat retention nut is damaged or lost, see SEAT RETEN-
TION NUT REPLACEMENT for instructions.
1WARNING
Pull up on seat to verify that it is properly secured, front
and rear. A loose seat may shift during vehicle operation
and startle the rider, possibly causing loss of vehicle
control resulting in death or serious injury.
FLHRC
Figure 2-129. Route Passenger Seat Strap Through
Slots in Seat - FLHRC
REMOVAL
1.
Remove right side saddlebag. See Section 2.25 SAD-
4. Using slots in seat, route free end of passenger seat
DLEBAG, REMOVAL.
strap to right side of vehicle. See Figure 2-129.
2.
Remove bolt (with flat washer) to remove passenger
5. Insert bolt with flat washer through passenger seat strap
seat strap and saddlebag front mounting bracket from
and slotted hole of saddlebag front mounting bracket.
chrome frame tube cover.
Insert bolt into forward hole in chrome frame tube cover.
3.
Using slots in seat, carefully pull passenger seat strap
Snug saddlebag front mounting bracket bolt, but do not
from seat. See Figure 2-129.
tighten.
6.
Install right side saddlebag. See Section 2.25 SADDLE-
4.
Remove Phillips screw to detach seat mounting bracket
BAG, INSTALLATION.
from top of rear fender.
7.
Using an open end/box wrench, tighten saddlebag front
5.
Push seat rearward to free tongue at front of seat from
mounting bracket bolt.
slot in frame backbone. See Figure 2-128.
6.
Remove seat from frame.
FLHRS, FLTR
INSTALLATION
1.
Place seat on frame backbone.
REMOVAL
2.
Firmly push front of seat downward and rearward until
tongue engages slot in frame backbone. See Figure 2-
CAUTION
128.
Removing seat without first removing passenger seat
3.
Push seat forward until rear fender seat retention nut is
strap will result in damage to rear fender paint.
centered in hole of mounting bracket. Install Phillips
screw.
1.
Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
NOTE
2.
Remove bolt (with flat washer) to remove passenger
If seat retention nut is damaged or lost, see SEAT RETEN-
seat strap and saddlebag front mounting bracket from
TION NUT REPLACEMENT for instructions.
chrome frame tube cover. Draw free end of passenger
seat strap to left side of vehicle.
3.
Remove Phillips screw to detach seat mounting bracket
1WARNING
from top of rear fender.
Pull up on seat to verify that it is properly secured, front
4.
Push seat rearward to free tongue at front of seat from
and rear. A loose seat may shift during vehicle operation
slot in frame backbone. See Figure 2-128.
and startle the rider, possibly causing loss of vehicle
5.
Remove seat from frame.
control resulting in death or serious injury.
2-104
2005 Touring: Chassis
HOME
INSTALLATION
1
WARNING
1. Place seat on frame backbone.
Pull up on seat to verify that it is properly secured, front
2. Firmly push front of seat downward and rearward until
and rear. A loose seat may shift during vehicle operation
tongue engages slot in frame backbone. See Figure 2-
and startle the rider, possibly causing loss of vehicle
128.
control resulting in death or serious injury.
3. Push seat forward until rear fender seat retention nut is
centered in hole of mounting bracket. Install Phillips
screw.
NOTE
FLHTC/U
If seat retention nut is damaged or lost, see SEAT RETEN-
TION NUT REPLACEMENT for instructions.
REMOVAL
1WARNING
1.
Open Tour-Pak to move passenger seat backrest out of
the way.
Pull up on seat to verify that it is properly secured, front
and rear. A loose seat may shift during vehicle operation
NOTE
and startle the rider, possibly causing loss of vehicle
The Tour-Pak must be positioned to the rear to access the
control resulting in death or serious injury.
seat mounting bracket screw. If the Tour-Pak is in the forward
4.
Draw free end of passenger seat strap to right side of
position, remove Tour-Pak and install in rearward position.
vehicle. Insert bolt with flat washer through passenger
See Section 2.26 TOUR-PAK for more information.
seat strap and slotted hole of saddlebag front mounting
bracket. Insert bolt into forward hole in chrome frame
2.
Remove Phillips screw to detach seat mounting bracket
tube cover. Snug saddlebag front mounting bracket bolt,
from top of rear fender.
but do not tighten.
3.
To protect finish of Tour-Pak, cover rear seat mounting
5. Install right side saddlebag. See Section 2.25 SADDLE-
bracket with palm of hand.
BAG, INSTALLATION.
4.
While pushing seat forward, raise rear of seat until
6. Using an open end/box wrench, tighten saddlebag front
bracket clears top of Tour-Pak. Push seat rearward
mounting bracket bolt.
slightly to free tongue at front of seat from slot in frame
backbone. See Figure 2-128.
5.
Remove seat from frame.
FLHT
INSTALLATION
REMOVAL
1.
Place seat on frame backbone.
1. Remove Phillips screw to detach seat mounting bracket
2.
To protect finish of Tour-Pak, cover rear seat mounting
from top of rear fender.
bracket with palm of hand.
2. Push seat rearward to free tongue at front of seat from
3.
While raising rear of seat approximately 3 inches (76.2
slot in frame backbone. See Figure 2-128.
mm), use other hand to firmly push front of seat down-
3. Remove seat from frame.
ward and rearward until tongue engages slot in frame
backbone. See Figure 2-128.
4.
Push seat forward until rear fender seat retention nut is
INSTALLATION
centered in hole of mounting bracket. Install Phillips
screw.
1. Place seat on frame backbone.
NOTE
2. Firmly push front of seat downward and rearward until
tongue engages slot in frame backbone. See Figure 2-
If seat retention nut is damaged or lost, see SEAT RETEN-
128.
TION NUT REPLACEMENT for instructions.
3. Push seat forward until rear fender seat retention nut is
centered in hole of mounting bracket. Install Phillips
1WARNING
screw.
Pull up on seat to verify that it is properly secured, front
NOTE
and rear. A loose seat may shift during vehicle operation
If seat retention nut is damaged or lost, see SEAT RETEN-
and startle the rider, possibly causing loss of vehicle
TION NUT REPLACEMENT for instructions.
control resulting in death or serious injury.
2005 Touring: Chassis
2-105
HOME
SEAT RETENTION NUT REPLACEMENT
Rear
Retention
1.
Slide retention nut over tapered end of cable strap so
Washer
Fender
that larger OD of nut rests on cable strap eyelet. From
bottom of rear fender, feed cable strap up through fender
hole.
2.
See Figure 2-130. With tab on retention nut seated in
notch of fender hole, pull up on cable strap to hold nut
snug against underside of rear fender. From the side
Tab
opposite the tab, slide on the retention washer to lock
Retention
the position of the retention nut. Remove cable strap.
Nut
f1897x2x
Figure 2-130. Seat Retention Nut and Washer
2-106
2005 Touring: Chassis
HOME
SADDLEBAG
2.25
OPENING
NOTE
Maximum recommended load for each saddlebag is 15 lbs.
FLHRC
1. Raise the decorative buckle and press tabs on both
Hinge
sides of catch to release from receptacle. Repeat step to
Latch
release second catch. See upper frame of Figure 2-131.
2. Rotate hinge on outboard side of saddlebag to open lid.
FLHRS
1. Depress button on front inboard side of saddlebag, and
f1554x2x
while holding button in, raise lid. See lower frame of Fig-
ure 2-131.
Check Strap
Anchor Brackets
f1552x2x
Catch
Receptacle
Anchor Tabs
f1553x2x
FLHRC
Figure 2-132. Open Saddlebag (FLHR, FLTR, FLHT/C/U)
Button
2.
Rotate hinge on inboard side of saddlebag to open lid.
FLHR, FLTR, FLHT/C/U
1.
Use key to unlock lid latch if locked.
2.
Pull bottom of latch outward and then lift upward raising
outboard corners of saddlebag lid. See upper frame of
Figure 2-132.
3.
With top of lid tilted toward motorcycle, carefully lift
inboard side of lid upward disengaging front and rear
anchor tabs from anchor brackets.
4.
Pivot lid on latch hinge to open. A nylon check strap sus-
FLHRS
f2228x3x
pends the lid in the open position. See lower frame of
Figure 2-132.
Figure 2-131. Open Saddlebag (FLHRC/S)
2005 Touring: Chassis
2-107
HOME
f1451x2x
Front Mounting
Front
Bracket Bolt
Rear
Mounting
Mounting
Bracket
Bracket
Quick-Release
Stud
Wire
Form
Spring
Flat
Plate
Washer
Bail
Wire
f1075axx
Figure 2-133. Saddlebag Quick-Release Fasteners
CLOSING
FLHRC
1. Rotate hinge on outboard side of saddlebag to close lid.
2.
Insert catch into receptacle until tabs fully engage.
Repeat step to secure second catch. See upper frame of
Figure 2-131.
FLHRS
Rear Mounting
f1450x2x
Bracket Bolt
1.
Rotate hinge on inboard side of saddlebag to close lid.
Lid latches automatically.
Figure 2-134. Saddlebag Mounting Bracket Bolts
(Right Side View)
FLHR, FLTR, FLHT/C/U
1.
Rotate lid to closed position engaging both anchor tabs
NOTE
with bottom of anchor brackets. Press bottom of latch
On some HDI vehicles, the bail wire has been removed from
inward until it snaps closed. See lower frame of Figure 2-
the quick release stud. In these cases, turn the stud by
132.
engaging the slotted end with a large screwdriver.
2.
Use key to lock lid latch.
3. Remove saddlebag.
REMOVAL
INSTALLATION
1.
Open saddlebag. See OPENING in this section.
2.
Grasp bail wire inside saddlebag and rotate each stud a
1.
Position saddlebag on vehicle.
full
1/4 turn in a counter-clockwise direction. Remove
2.
Place flat washers on bail head studs.
bail head studs with flat washers. See Figure 2-133.
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2005 Touring: Chassis
HOME
3. With groove at end of stud held in a horizontal position,
insert stud through holes in saddlebag and front mount-
Rub Bar
ing bracket. When groove engages wire form of spring
plate on inboard side of bracket, turn stud clockwise a
full 1/4 turn until it snaps in place. Install rear bail head
stud in the same manner.
NOTE
On some HDI vehicles, the bail wire has been removed from
the quick release stud. In these cases, turn the stud by
engaging the slotted end with a large screwdriver.
NOTE
8862
Molded rubber insert at bottom of saddlebag must fit snugly
on lower saddlebag support rail. If saddlebag is not fully
seated, use an open end/box wrench to loosen bolts secur-
ing mounting brackets to saddlebag support and frame. See
Figure 2-134. Alternately tighten bolts to 60-96 in-lbs (7-11
Nm) after seating saddlebag.
4. Close saddlebag. See CLOSING in this section.
LATCH SPRING REPLACEMENT
(FLHR, FLTR, FLHT/C/U)
8863
REMOVAL
Figure 2-135. Lid Right Side Up With Latch on Near Side
1. Lay clean pad or blanket on work bench to protect
painted surfaces of saddlebag.
Opening
2. Remove saddlebag from motorcycle leaving lid open.
See REMOVAL in this section.
3. Lay saddlebag flat on pad with the inboard side facing
up and the lid closest to you.
4. Remove two T20 TORX screws to release check strap
from lid.
5. Remove two T15 TORX screws to release check strap
from saddlebag.
8864
6. Remove two remaining T15 TORX screws to remove
latch from saddlebag. Move saddlebag back and out of
the way.
CAUTION
This procedure assumes that the latch is NOT removed
from the saddlebag lid. If there is doubt as to whether the
procedure can be accomplished without scratching
painted surfaces of the lid, then remove the five remain-
ing T15 TORX screws to completely remove latch.
7. Position lid right side up with latch closest to you.
8865
8.
Raise latch slightly and rotate hinge on inboard side so
Figure 2-136. Lid Up Side Down With Latch on Far Side
that it is topside with the two plastic rub bars pointed
upward. See upper frame of Figure 2-135.
2005 Touring: Chassis
2-109
HOME
9.
Rotate rub bar section of hinge to expose hinge pin and
CABLE ASSEMBLY/LATCH/SCRIPT
spring. Using a flat tip screwdriver, carefully bend
crimped end link outward. See lower frame of Figure 2-
(FLHRS)
135.
NOTE
CABLE ASSEMBLY
The end link on opposite side of hinge has a weld spot that
prevents pin removal.
Removal
10. Reposition lid so that it is upside down with the latch
1.
Open saddlebag. See OPENING in this section.
farthest from you. Rotate hinge so that plastic rub bars
are positioned beneath latch and spring is topside.
2.
Remove two screws on inboard side of saddlebag to
11. Using a needle nose pliers, grasp pin through opening
release plastic shroud. See upper frame of Figure 2-137.
just outboard of the spring and push toward the crimped
3.
Depress wireform and pull button from hole in saddle-
link side. Work pin in this manner until end can be seen
bag. See lower frame of Figure 2-137.
exiting crimped link. See upper frame of Figure 2-136. If
necessary, pry crimped link outward a little more to
4.
Remove sleeve from hole in saddlebag.
achieve the desired result.
5.
Moving to inboard side of saddlebag lid, remove lock
12. Grasping end with needle nose pliers, slowly pull pin
ring from hole at end of latch pin. See upper frame of
from links until spring can be slid off opposite end. Only
Figure 2-138.
pull pin as far as necessary to remove spring. See lower
frame of Figure 2-136.
6.
Pull latch pin from metal shroud, saddlebag bracket and
latch. Remove metal shroud.
INSTALLATION
7.
Depress spring and pull on cable ball end to remove
from slot in latch. Remove latch.
1.
Slide new spring onto end of pin. Orient spring as shown
in lower frame of Figure 2-136.
8.
Remove spring from cable. See lower frame of Figure 2-
138.
2.
Slide pin back through links. Using tapered end of
needle nose pliers, push end of pin into crimped link
3.
Reposition lid so that it is right side up with latch closest
to you. As before, raise latch slightly and rotate hinge on
inboard side so that it is topside with plastic rub bars
pointing upward. Now rotate rub bar section of hinge to
expose hinge pin and spring. See Figure 2-135.
4.
Holding lid down with elbow, if necessary, use a pliers to
bend crimped link back into its original position, so that
pin is captured and will not back out of hinge.
5.
Reposition lid so that it is upside down with the latch
farthest from you. Move saddlebag forward for
Plastic
Shroud
reinstallation of lid. Align four holes in saddlebag with
f2229x2x
those in latch.
6.
Install two inboard T15 TORX screws to fasten latch to
saddlebag. Alternately tighten screws to 20-25 in-lbs
(2.3-2.8 Nm).
7.
Align holes in check strap with those in lid and
saddlebag. Orient check strap so that logo is topside
with the bottom of the bar and shield on the lid side.
8.
Install two T15 TORX screws to fasten check strap and
latch to saddlebag. Alternately tighten screws to 20-25
in-lbs (2.3-2.8 Nm).
9.
Install two T20 TORX screws to fasten check strap to lid.
Wireform
Alternately tighten screws to 18-20 in-lbs (2.0-2.3 Nm).
f2232x2x
10.
Close saddlebag and install on motorcycle. See
Figure 2-137. Remove Button Assembly
INSTALLATION in this section.
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2005 Touring: Chassis
HOME
5.
Install cable end fitting into hole in saddlebag bracket.
f2233x2x
6.
With the rounded edge of the e-clip on the same side as
the rounded edge of the saddlebag bracket, install e-clip
into groove in cable end fitting.
7.
Pull up on cable ball end and install spring on cable. See
lower frame of Figure 2-138.
2
NOTE
1.
Lock Ring
2.
Metal Shroud
Verify that ball end on opposite side of cable is installed in
3.
Latch Slot
pivot of button assembly. See Figure 2-139.
1
4.
Saddlebag
3
Bracket
8.
Position latch between saddlebag bracket with the cable
5.
Spring
slot inline with the cable ball end. Depress spring and
6.
E-Clip
capture cable ball end in slot of latch.
9.
Install metal shroud over latch and saddlebag bracket. At
rear of assembly, insert latch pin through metal shroud,
saddlebag bracket and latch until end exits front hole in
shroud.
4
10. Install lock ring into hole at end of latch pin. See upper
frame of Figure 2-138.
11. Close and open saddlebag lid several times to verify that
latch locks every time. Adjust cable if necessary.
Adjustment
5
1.
Open saddlebag. See OPENING in this section.
6
f2234x2x
2.
Remove two screws on inboard side of saddlebag to
release plastic shroud. See upper frame of Figure 2-137.
Figure 2-138. Remove Latch Assembly
3.
Back jam nut away from body hex. See Figure 2-139.
4.
Turn body hex toward or away from jam nut until closest
9. Remove e-clip from groove in cable end fitting.
part of latch is approximately 3/8 inch (9.5 mm) from
inboard side of saddlebag lid.
10. Pull cable end fitting from hole in saddlebag bracket.
5.
Turn jam nut until it makes firm contact with body hex.
11. Release cable from channel running along inboard edge
of saddlebag.
Installation
Body Hex
1. From the outboard side, insert sleeve into hole in saddle-
bag.
2. On the inboard side, depress wireform and slide button
into sleeve. Release wireform. Gently tug on assembly
to verify that wireform has engaged groove in sleeve to
lock button in place. See lower frame of Figure 2-137.
3. Holding plastic shroud with the relief positioned over the
cable adjuster, install two screws from inboard side of
Jam Nut
saddlebag. See upper frame of Figure 2-137.
f2235x2x
4. Capture cable in channel running along inboard edge of
saddlebag.
Figure 2-139. Cable Adjustment
2005 Touring: Chassis
2-111
HOME
6.
Holding plastic shroud with the relief positioned over the
cable adjuster, install two screws from inboard side of
CAUTION
saddlebag. See upper frame of Figure 2-137.
Always install push nuts on the end studs first. If center
7.
Close and open saddlebag lid several times to verify that
stud is not done last, end stud can sometimes come out
latch locks every time. Readjust if necessary.
of saddlebag hole during installation of the second push
nut. If this occurs, forcing the last stud in can bend stud
or script and enlarge saddlebag hole.
LATCH
2.
From inside saddlebag, install new push nuts onto
studs. For best results, install push nuts on the end
Removal
studs first.
1.
Open saddlebag. See OPENING in this section.
3.
Close saddlebag. See CLOSING in this section.
2.
Moving to inboard side of saddlebag lid, remove lock
ring from hole at end of latch pin. See upper frame of
Figure 2-138.
3.
Pull latch pin from metal shroud, saddlebag bracket and
SADDLEBAG GUARD/SUPPORT
latch. Remove metal shroud.
RAIL
4.
Depress spring and pull on cable ball end to remove
from slot in latch. Remove latch.
REMOVAL
Installation
1.
Remove saddlebag from motorcycle. See REMOVAL in
1.
Position new latch between saddlebag bracket with the
this section.
cable slot inline with the cable ball end. Depress spring
and capture cable ball end in slot of latch.
2.
Disassemble saddlebag guard, support and/or rails as
necessary. See Figure 2-140.
2.
Install metal shroud over latch and saddlebag bracket. At
rear of assembly, insert latch pin through metal shroud,
saddlebag bracket and latch until end exits front hole in
INSTALLATION
shroud.
3.
Install lock ring into hole at end of latch pin. See upper
1.
Assemble saddlebag guard, support and/or rails as nec-
frame of Figure 2-138.
essary. Replace any damaged parts. See Figure 2-140.
4.
Close saddlebag. See CLOSING in this section.
2.
Install saddlebag on motorcycle. See INSTALLATION in
this section.
SCRIPT
Removal
1.
Open saddlebag. See OPENING in this section.
CAUTION
Do not remove push nuts unless script replacement is
necessary. Push nuts are damaged during removal and
studs on script may be bent or broken.
2.
From inside saddlebag, pry push nuts from studs. Dis-
card push nuts.
3.
Remove script from side of saddlebag.
Installation
1.
Install new script on side of saddlebag inserting studs
through holes.
2-112
2005 Touring: Chassis
HOME
2
1
3
1
7
4
FLHTC/U
Multi-Rail
Saddlebag Guard
3
f2247x2x
Torque:
6
1. Saddlebag mounting bracket screws: 60-96 in-lbs (7-11 Nm)
2. Saddlebag support to fender screws: 15-20 ft-lbs (20-27 Nm)
3. Rail to saddlebag support screws: 15-20 ft-lbs (20-27 Nm)
4
4. Guard/support rail to frame screws: 15-20 ft-lbs (20-27 Nm)
5
4
5. Support rail to guard screw: 70-100 in-lbs (8-11 Nm)
6. Guard mount to rail screws: 72-120 in-lbs (8-14 Nm)
7. Rail clamp screws: 30-50 in-lbs (3-6 Nm)
3
Saddlebag Guard
FLHT, FLHR/C
f2248x2x
4
5
3
FLTR, FLHRS
Saddlebag Support Rail
f2249x2x
4
Figure 2-140. Saddlebag Guards/Support Rail
2005 Touring: Chassis
2-113
HOME
TOUR-PAK
2.26
FLHTC
Tour-Pak
Hole
Radio Antenna
NOTE
Cable Connector
For instructions covering riveted components, such as hinges
and catches, refer to the Instruction Sheet included with the
RIVET TOOL, HD-39787A.
REMOVAL
1.
Open Tour-Pak. Remove rubber mat.
2.
Rotate knurled lock ring in a counter-clockwise direction
to separate pin and socket halves of Radio antenna
cable connector. Release cable from two clips at bottom
of Tour-Pak.
3.
Pull Tour-Pak lights connector [12], 3-place Multilock,
Grommet
from cavity inside Tour-Pak. Depress button and sepa-
rate pin and socket halves. See Figure 2-141.
Cable
Tour-Pak
Clip
Mounting Bolt
4.
Pull grommet into Tour-Pak and remove from main har-
ness conduit.
Figure 2-142. Feed Main Harness Thru Tour-Pak Hole
5.
Feed main harness conduit and connectors through hole
in Tour-Pak. See Figure 2-142.
INSTALLATION
6.
Holding nylon cap locknuts at bottom of Tour-Pak,
remove five bolts (with flat washers) to release Tour-Pak
1.
Place Tour-Pak on luggage rack and open lid.
from luggage rack. Luggage rack spacers will become
free as nuts are removed. Be sure to have a firm grasp
2.
Align rear center hole in Tour-Pak with same hole in lug-
on the Tour-Pak as the last bolt is removed. See Figure
gage rack. Slide 2 inch bolt (with flat washer) through
2-143.
ring terminal of radio antenna ground, and then through
Tour-Pak and luggage rack holes. At bottom of luggage
rack, install spacer (concave side up) and nylon cap
locknut on bolt. With concavity on spacer inline with the
rail, hold nut and tighten bolt until snug.
f1466a2x
Cable
Clip
CAUTION
Grommet
Always install the mounting bolts from inside the Tour-
Pak. If the bolts are installed upside down, then the ends
of the bolts can tear the molded liner and scratch
objects, such as helmets, stored inside the Tour-Pak.
3.
Install remaining
2 inch bolts (with flat washers and
nylon cap locknuts) in two front Tour-Pak and luggage
Cavity
rack holes (one each side) in the manner described
under step 2 above.
Tour-Pak Lights
4.
Position two spacers between bottom of luggage rack
Connector [12]
and tabs of license plate bracket. Slide 2-1/4 inch bolts
(with flat washers) through two center holes in Tour-Pak
Tour-Pak
and luggage rack, and then through spacers and tabs of
Radio Antenna
Mounting Bolt
license plate bracket. If necessary, loosen two hex bolts
Cable
at back of license plate bracket to align holes in tabs with
bolts. Install flat washers and nylon cap locknuts on bolts
Figure 2-141.
Disconnect Tour-Pak Lights Connector
and tighten until snug. See inset of Figure 2-143.
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2005 Touring: Chassis
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6.
Standing on left side of vehicle, feed socket connectors
and main harness conduit through hole in Tour-pak.
f1850x2x
Capture conduit in grommet. Install grommet in hole with
the larger OD facing inside.
7.
Mate pin and socket halves of Tour-pak lights connector
Rear Center Hole
Mounting Bolt
[12], 3-place Multilock, and tuck into cavity inside Tour-
(Cap side Up)
Pak. See Figure 2-141.
8.
Rotate knurled lock ring in a clockwise direction to mate
pin and socket halves of Radio antenna cable con-nec-
Flat
tor. Capture cable in two clips at bottom of Tour-Pak.
Washer
9.
Install rubber mat. Close Tour-Pak.
FLHTCU
REMOVAL
Spacer
1.
Open Tour-Pak. Open map pocket and remove acorn
nuts
(with flat washers). Remove map pocket and
molded liner from Tour-Pak.
2.
Depress external latch and rotate housing to release
Nylon Cap
bulb socket from left side of Tour-Pak.
Locknut
3.
Rotate knurled lock ring in a counterclockwise direction
to separate pin and socket halves of Radio antenna
cable connector. Release cable from two clips at bottom
Flat
of Tour-Pak.
Washer
4.
Pull Tour-Pak lights connector [12], 3-place Multilock,
Luggage
from cavity inside Tour-Pak. Depress button and sepa-
Rack Rail
rate pin and socket halves. See Figure 2-141.
5.
Pull grommet into Tour-Pak and remove from main har-
Spacer
ness conduit.
Nylon Cap
Locknut
6.
Feed main harness conduit and connectors through hole
in Tour-Pak. See Figure 2-142.
7.
Release rear headset receptacle from bracket at bottom
of left side speaker box.
8.
Remove trim ring and gently pull on wire harness to
draw 6-place Mini-Deutsch connector out of left side
speaker box. Depress external latch and use a rocking
motion to separate pin and socket halves.
f1851x2x
Stackup at License Plate Bracket
9.
Moving to right side of vehicle, disconnect 1-place CB
antenna cable connector. Release cable from two clips
Figure 2-143. Install Tour-Pak Mounting Bolts
at bottom of Tour-Pak. See Figure 2-144.
10.
Pull right side grommet into Tour-Pak and remove from
CB antenna cable. Feed CB antenna cable through hole
in Tour-Pak.
5.
In a crosswise pattern, alternately tighten five bolts to
11.
Remove trim ring and gently pull on wire harness to
96-120 in-lbs (10.8-13.5 Nm). Be sure that concavity on
draw 6-place Mini-Deutsch connector out of right side
each spacer is inline with the rail and has not rotated out
speaker box. Depress external latch and use a rocking
of position.
motion to separate pin and socket halves.
2005 Touring: Chassis
2-115
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