Harley Davidson 2004 Touring Models. Service Manual — page 48
HOME
MAIN DRIVE GEAR
7.7
REMOVAL
7970
NOTE
Leave the transmission case in the frame unless the case
itself requires replacement. For illustration purposes, some
photographs may show the case removed.
1. Remove the exhaust system in two sections. See Sec-
tion 3.7 REMOVING ENGINE FROM CHASSIS, steps 3-
9.
2.
Remove the shifter cam and shifter fork assemblies. See
Section
7.4 SHIFTER CAM ASSEMBLY/SHIFTER
FORKS, DISASSEMBLY.
3. Remove the primary chaincase cover. Remove the
clutch assembly, primary chain, and compensating
sprocket components. Remove the starter jackshaft
assembly and primary chaincase. See Section 6.5 PRI-
Side
Rear
MARY CHAINCASE, REMOVAL.
Indent
Door
4. Remove oil filler spout and starter. See Section
5.4
Figure 7-27. Remove Transmission Side Door
STARTER, REMOVAL, steps 6-12.
5. Remove the bearing inner race from the transmission
mainshaft. See Section
6.5 PRIMARY CHAINCASE,
MAINSHAFT BEARING INNER RACE, REMOVAL.
1WARNING
6. See Figure 7-27. Remove the six socket head screws
Always wear proper eye protection when removing re-
(bottom four with flat washers) to free both the side door
taining rings. Use the correct retaining ring pliers. Verify
and transmission exhaust bracket from the transmission
that the tips of the pliers are not damaged or excessively
case. Pull the side door, mainshaft and countershaft
from the transmission case as a single assembly.
worn. Slippage may propel the ring with enough force to
Remove and discard the door gasket.
cause eye injury.
NOTE
10. Remove the retaining ring from the roller bearing bore.
DO NOT USE A HAMMER TO REMOVE THE SIDE DOOR.
If the side door sticks or binds on the locating dowels, gently
11. Pull the main drive gear using HD-35316B, MAIN DRIVE
pry open using the indents at each side of the door. See Fig-
GEAR REMOVER AND INSTALLER. See instructions
ure 7-27.
provided with the tool.
7. Remove the two socket screws and lockplate to free the
12. Using a block of wood and a hammer, remove the roller
sprocket nut. Remove the sprocket nut. Use an air
bearing from the transmission case. Discard the bearing.
impact wrench for best results.
NOTE
NOTE
Always replace the main drive gear bearing when the main
The transmission sprocket nut has left handed threads. Turn
the nut clockwise to remove from the main drive gear.
drive gear is removed. The bearing will be damaged during
the removal procedure.
8. Moving to rear wheel, remove E-clip and loosen hex nut
on right side of axle. Moving to left side, turn adjuster
cam in a counterclockwise direction until belt tension is
CLEANING AND INSPECTION
relieved. Remove the belt from the transmission
sprocket.
1. Clean all parts in solvent except the transmission case
9. Remove the transmission sprocket, spacer sleeve, main-
shaft oil seal and quad seal.
and needle bearings. Blow dry with compressed air.
7-22
2004 Touring: Transmission
HOME
shown in Figure 7-28. The tool will bottom on the gear
when the correct depth is obtained.
Needle
Ram
3.
Turn over tool and press on oil seal using the 0.080 inch
Bearing
step (garter spring side toward main drive gear). See
Installer
Figure 7-29.
NOTE
0.315 In. Step
An alternative method is provided which allows the oil seal to
Outer
be pressed into place after installation of the main drive gear.
Needle
Bearing
For detailed information, see Section
7.7 MAIN DRIVE
GEAR, INSTALLATION, step 14.
Main Drive
4.
See Figure 7-30. Turn over the main drive gear in the
Gear
arbor press. Using the step a second time (0.080 inch
step), press in inner (transmission side) needle bearing.
8254
8252
Oil Seal
0.080 In. Step
Figure 7-28. Press Clutch Side Needle Bearing into
Main Drive Gear
CAUTION
The transmission case and needle bearings must not be
cleaned. Normal cleaning methods will wash dirt or other
contaminants into the bearing case (behind the needles)
and lead to bearing failure.
2. When replacing seals, lightly coat outside diameter of
seal with Loctite RETAINING COMPOUND No. 609.
3. Inspect the main drive gear for pitting and wear. Replace
if necessary.
Figure 7-29. Press Oil Seal on Main Drive Gear
4. Replace the sprocket if the teeth are rounded or dam-
aged.
8253
5. Inspect the needle bearings on the inside of the main
drive gear. If the mainshaft race surface appears pitted
Inner
or grooved, replace the needle bearings.
Needle
Bearing
0.080 In. Step
Needle Bearing Replacement
NOTE
If the main drive gear needle bearings and/or oil seal need to
be replaced, proceed as follows.
1. Remove old oil seal and needle bearings.
NOTE
To install the main drive gear needle bearings and seal, use
the INNER/OUTER MAIN DRIVE GEAR NEEDLE BEARING
and SEAL INSTALLER, Part No. HD- 37842A.
2. Install outer (clutch side) needle bearing using an arbor
Figure 7-30. Press Transmission Side Needle
press and the 0.315 inch step end of tool HD-37842A as
Bearing into Main Drive Gear
2004 Touring: Transmission
7-23
HOME
Figure 7-31. Main Drive Gear Large Oil Seal Installer
Figure 7-33. Final Drive Sprocket Locking Tool
(Part No. HD-41496)
(Part No. HD-41184)
Transmission
f2273x7x
Sprocket
Transmission
Case
Right Side View
Main Drive
f1172a6x
Gear
Mainshaft
Oil Seal
Spacer
Lockplate
Sleeve
Sprocket
Sprocket
Nut
Locking Tool
f1855x7x
Pivot Shaft
f1856x7x
Quad Seal
Transmission
Sprocket
Lubricate
Socket
Contact Surfaces
Screw
Figure 7-32. Install Transmission Sprocket Components
INSTALLATION
1.
Install new main drive gear bearing using the MAIN
DRIVE GEAR REMOVER/INSTALLER (Part No. HD-
Sprocket
35316B). To prevent damage, always apply force to the
Sprocket
Nut
bearing outer race during installation. Install a new
Locking Tool
retaining ring with the beveled side out and the 90°
opening facing the rear. See inset of Figure 7-32. Install
Figure 7-34. Install Final Drive Sprocket Locking Tool
the main drive gear in the transmission case using the
special tool.
drive gear, place the side door against the case. Tighten
2.
Verify that the two locating dowels are in place on the
the 5/16 inch mounting screws to 13-16 ft-lbs (18-22
right side of the transmission case. Hang a new gasket
Nm). Tighten the 1/4 inch screw to 84-108 in-lbs (9-12
on the dowels. Inserting the mainshaft through the main
Nm).
7-24
2004 Touring: Transmission
HOME
3. With the garter spring side out (toward the transmission
case), place a new seal on lip of MAIN DRIVE GEAR
Wrench
LARGE OIL SEAL INSTALLER (Part No. HD-41496).
See Figure 7-31. Slide the tool over the mainshaft so
that it is positioned squarely over the bearing bore in the
transmission housing. Hand press the seal into the bore;
a rubber mallet may be used to lightly tap the driver, if
necessary. Install the quad seal. See Figure 7-32.
Pilot
4. Apply a small amount of the appropriate H-D transmis-
sion lubricant to outside diameter of spacer sleeve.
Figure 7-35. Mainshaft Locknut Wrench/Pilot
5. Install spacer sleeve on the main drive gear with cham-
(Part No. HD-94660-37B )
fer facing inboard. Install the transmission sprocket.
Install the belt on the sprocket as the sprocket is
installed on the main drive gear.
6. Install the sprocket nut. The procedure is based on
whether a new or used nut is being installed.
CAUTION
Exercise caution to avoid getting oil on the threads of
the sprocket nut or the integrity of the lock patch may be
compromised.
New sprocket nut: smear a small quantity of clean
engine oil on the inside face of both the sprocket nut and
the sprocket. Limit the application to where the surfaces
of the two parts contact each other. Install the sprocket
nut until finger tight.
Sprocket
Pilot
f1857x7x
Nut
NOTE
f1858x7x
The transmission sprocket nut has left handed threads. Turn
Mainshaft
the nut counterclockwise to install on the main drive gear.
Locknut
Wrench
Used sprocket nut: apply Loctite
262 (red) to the
threads of the sprocket nut. Also smear a small quantity
of Loctite or clean engine oil on the inside face of both
the sprocket nut and the sprocket. Limit the application
to where the surfaces of the two parts contact each
other. Install the sprocket nut until finger tight.
7. Lock transmission sprocket with FINAL DRIVE
SPROCKET LOCKING TOOL, Part No. HD-41184. See
Figure
7-33. Insert handle of tool below pivot shaft
inboard of bottom frame tube and attach to sprocket.
Snug thumbscrew to lock position of tool on sprocket.
See Figure 7-34.
8. Install pilot of MAINSHAFT LOCKNUT WRENCH (Part
No. HD-94660-37B) on threaded end of mainshaft. See
Torque
Wrench
Figure 7-35. Slide sleeve of locknut wrench over pilot
and onto sprocket nut. Tighten sprocket nut to 60 ft-lbs
(81 Nm). As the nut is tightened the handle of the
Figure 7-36. Install Mainshaft Locknut Pilot/Wrench
sprocket locking tool rises to contact the pivot shaft,
and Torque Sprocket Nut
thereby preventing sprocket/mainshaft rotation. See Fig-
ure 7-36.
9. Scribe a straight line on the transmission sprocket nut
10. Install lockplate over nut so that two diagonally opposite
continuing the line over onto the transmission sprocket
holes align with two tapped holes in sprocket. To find the
as shown in Figure
7-37. Tighten the transmission
best fit, lockplate can be rotated to a number of positions
sprocket nut an additional 35° to 40°.
and can be placed with either side facing sprocket.
2004 Touring: Transmission
7-25
HOME
f1977x6x
Seal Protector
Sprocket Nut
Sleeve
Driver
45°
35°
Figure 7-38. Main Drive Gear Seal Installer
(Part No. HD-41405 )
Scribe Line
Transmission
f1853x7x
on Nut and Sprocket
Sprocket
Oil Seal
Figure 7-37. Tighten/Secure Sprocket Nut
11. If holes in lockplate do not align with those in sprocket,
tighten sprocket nut as necessary (up to the 45° maxi-
mum) until sprocket and lockplate holes are in align-
ment. See Figure 7-37.
CAUTION
Seal Protector
Sleeve
Maximum allowable tightening of sprocket nut is 45° of
counterclockwise rotation after a torque of 60 ft-lbs (81
Figure 7-39. Slide Protector Sleeve/Oil Seal on Mainshaft
Nm). Do not loosen sprocket nut when attempting to
align holes.
12. Insert two socket head screws through lockplate into
f1854x7x
sprocket holes. Tighten screws to 90-110 in-lbs.
Seal
Driver
NOTE
The socket head screws have a thread locking compound
that allows them to be reused up to three times. The fourth
time the screws are removed, replace with new screws (H-D
Part No. 3594).
13. Adjust the belt tension and complete installation of rear
wheel. See Section
6.4 SECONDARY DRIVE BELT
AND SPROCKETS, ADJUSTMENT, steps 6-10.
14. If the main drive gear oil seal was not installed with the
needle bearings (or if a faulty seal is discovered with the
main drive gear installed in the transmission case), an
Figure 7-40. Install Oil Seal Using Driver
alternative method is provided using the MAIN DRIVE
GEAR SEAL INSTALLER, HD-41405. See Figure 7-38.
NOTE
b.
Place the seal protector sleeve over the end of the
If a serviceable seal is already installed, proceed to step 15.
mainshaft. Lightly lubricate the protector sleeve and
To install the oil seal with the main drive gear in the
seal ID with clean transmission oil.
transmission case, proceed as follows:
c.
Squarely seat the oil seal on the seal protector
a. Verify that the garter spring is in place on the lip of
sleeve with the garter spring facing the transmission
the oil seal.
case. See Figure 7-39.
7-26
2004 Touring: Transmission
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d. Using the seal driver, hand press the seal onto the
Countershaft Needle Bearing
mainshaft. A rubber mallet may be used to lightly
Replacement
tap the driver, if necessary.
1.
Find a suitable bearing driver 1-1/4 inch (31.75 mm) in
15. Install the bearing inner race on the transmission main-
diameter.
shaft. See Section 6.5 PRIMARY CHAINCASE, MAIN-
SHAFT BEARING INNER RACE, INSTALLATION.
2.
From the outside of the transmission case place the nee-
dle bearing open end first next to the bearing bore. Hold
16. Install shifter cam and fork assemblies. See Section 7.4
the driver squarely against the closed end of the bearing
SHIFTER CAM ASSEMBLY/SHIFTER FORKS,
and tap the bearing into place. The bearing is properly
ASSEMBLY.
positioned when it is driven inward flush with the outside
17. Install the starter and oil filler spout. See Section 5.4
surface of the case or to a maximum depth of 0.030 inch
STARTER, INSTALLATION, steps 1-3 and 5-7.
(0.76 mm).
18. Install the primary chaincase and starter jackshaft
3.
Lubricate the bearing with TransLube.
assembly. Install the clutch assembly, primary chain, and
compensating sprocket components. Install the primary
chaincase cover. See Section 6.5 PRIMARY CHAIN-
CASE, INSTALLATION.
19. Install the exhaust system. See Section 3.8 INSTALL-
ING ENGINE IN CHASSIS, steps 46-52.
2004 Touring: Transmission
7-27
HOME
TRANSMISSION CASE/OIL PAN
7.8
GENERAL
REMOVAL
The transmission case and oil pan can be removed as an
assembly if the transmission case must be replaced.
Transmission Case and Oil Pan
If necessary, the oil pan can be removed without removing
1.
See Figure 7-41. Remove both the engine oil and trans-
the transmission case. Once the rear wheel is removed, the
mission lubricant drain plugs from the oil pan. Drain the
oil pan can be slid out from the rear.
fluids into suitable containers.
2.
Remove the mainshaft and countershaft assemblies.
See Section
7.6 MAINSHAFT/COUNTERSHAFT,
REMOVAL.
f2267x7x
13
14
12
1.
Screw
9
2.
Screw
3.
Oil hose cover
4.
Oil hose (2)
5.
Hose clamp (6)
11
15
6.
Straight fitting (3)
10
7.
Crankcase
breather hose
8.
Screw (4)
16
9.
Oil filler cap/dipstick
10.
Oil filler spout
6
17
11.
Filler spout gasket
8
12.
Transmission
5
housing
7
13.
Dowel pin
4
14.
Bolt (4)
5
15.
Washer (4)
2
6
16.
Ring dowel
17.
Baffle spring
18.
Serpentine baffle
18
5
19.
Oil pan gasket
20.
Oil pan
19
21.
O-ring (2)
22.
Magnetic plug (2)
23.
Pipe plug
1
3
24.
Screw (12)
20
24
21
Transmission
Drain Plug
21
23
Engine Oil
22
22
Drain Plug
Figure 7-41. Transmission Case and Oil Pan
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2004 Touring: Transmission
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7.
Using a side cutters, cut and remove clamps on trans-
7968
mission side of oil supply and return hoses. Pull hoses
Centering
from fittings on transmission housing.
Screw
8.
Cut and remove clamp on transmission side of crank-
case breather hose. Pull hose from fitting on oil filler
spout.
9.
Remove four bolts (with flat washers) to free front of
Washer
transmission from rear of crankcase. Loosen and
remove bolts in a crosswise pattern. Move transmission
Retaining
rearward until two ring dowels in lower flange are free of
Ring
crankcase.
NOTE
If the main drive gear was not removed from the transmission
Splined
Shifter Shaft
case, then it may be removed at this time. See Section 7.7
MAIN DRIVE GEAR, REMOVAL.
Figure 7-42. Shifter Pawl Centering Screw
10. Remove the transmission case from the right side of the
vehicle.
NOTE
Shifter
If removal is difficult, remove the twelve socket head bolts to
Lever Spring
separate the oil pan from the transmission case. For best
Shifter
Pawl
results, use a long 3/16 inch ball hex socket driver. Holes in
the lower frame crossmember allow access to bolts which
would not otherwise be accessible.
Slot
Oil Pan Only
Splined
Centering
Shifter Shaft
NOTE
Spring
Perform the following procedure if only the oil pan must be
removed.
7967
1.
See Figure 7-44. Remove both the engine oil and trans-
mission lubricant drain plugs from the oil pan. Drain the
Figure 7-43. Shifter Pawl Assembly
fluids into suitable containers.
3. Remove rear wheel and rear swingarm. See Section
2.20 REAR SWINGARM, REMOVAL.
f1677x3x
9
NOTE
11
The main drive gear and bearing may be removed with the
3
transmission case in the frame. See Section
7.7 MAIN
LEFT
7
DRIVE GEAR, REMOVAL.
2
SIDE
6
4. Remove the socket screw from the shifter lever. Remove
the lever from the splined end of the shifter shaft. Mark
splines on shaft and lever as they are removed to assist
5
8
in assembly. See Figure 7-42.
5. Using a T50 TORX drive head, turn the centering screw
out until it clears the centering spring slot of the shifter
RIGHT
1
pawl assembly. Remove the retaining ring and flat
SIDE
4
washer from the splined end of the shifter shaft. See Fig-
12
ure 7-43. Push on end of shaft to free shifter pawl
10
Transmission
Engine Oil
assembly from transmission case.
Drain Plug
Drain Plug
6. Remove two allen head socket screws to release oil
hose cover. See Figure 7-41.
Figure 7-44. Oil Pan Torque Sequence
2004 Touring: Transmission
7-29
HOME
2.
Install lifting strap around frame backbone, and using
3.
It is normal for the baffle springs to hold the oil pan away
overhead jack, support vehicle from the top.
from transmission housing. Use a long screwdriver to
compress the springs as the pan enters the housing.
3.
Remove rear wheel. See Section 2.4 REAR WHEEL,
Exercise caution to avoid cocking or distorting the
REMOVAL.
springs.
4.
With a long 3/16 inch ball hex socket driver (Snap-On
stock number FABL6 or equal), remove the twelve
4.
Position oil pan under transmission and install the twelve
socket head bolts from the bottom of the oil pan.
oil pan bolts, but only tighten about two turns after initial
thread engagement.
NOTE
Holes in the frame crossmember allow access to bolts which
would not otherwise be accessible.
CAUTION
Inspect the oil pan gasket to ensure that gasket is prop-
CAUTION
erly positioned. If gasket was moved out of position,
remove bolts and repeat step 3 to ensure that gasket is
Remove the engine oil dipstick before attempting to
properly positioned.
slide the oil pan rearward. Contact with the oil pan will
result in damage to the dipstick.
5.
Tighten the oil pan bolts to 84-108 in-lbs (9-12 Nm) fol-
lowing the numerical sequence shown in Figure 7-44.
5.
Slide oil pan rearward and remove from underside of
transmission.
6.
Install rear wheel. See Section
2.4 REAR WHEEL,
INSTALLATION.
7.
Remove lifting strap to release frame backbone from
CLEANING AND INSPECTION
overhead jack.
1.
Clean all parts in solvent except the transmission case
and needle bearings. Blow dry with compressed air.
Transmission Case and Oil Pan
CAUTION
NOTE
The transmission case and needle bearings must not be
If the main drive gear was assembled prior to mounting of the
cleaned. Normal cleaning methods will wash dirt or other
transmission, place belt on transmission sprocket as trans-
contaminants into the bearing case (behind the needles)
mission is placed in position.
and lead to bearing failure.
2.
Inspect the shifter pawl and centering spring for wear.
1. From right side of vehicle, place the transmission case
Replace lever assembly if pawl ends are damaged.
(with oil pan) in the motorcycle frame. Move transmis-
Replace centering spring if elongated.
sion forward until two ring dowels in lower flange fully
engage holes in crankcase. Support the engine and
3.
Inspect the shifter lever spring. Replace the spring if it
transmission, so that they do not sag at their mating sur-
fails to hold the pawl on the cam pins.
faces.
4.
Thoroughly clean the oil pan with solvent, if removed.
2. Install the transmission-to-engine mounting bolts as fol-
5.
Inspect the hoses for nicks, cuts or general deterioration.
lows:
Replace as necessary. Used compressed air to verify
that hoses and fittings are unobstructed.
a. Using a crosswise pattern, hand tighten four bolts
(with flat washers) to secure transmission housing
to rear of crankcase.
INSTALLATION
b. Alternately tighten the four bolts to 15 ft-lbs (20.3
Nm) in the same crosswise pattern.
Oil Pan Only
NOTE
For best results, use Open End Crowfoot (Snap-On FC018)
NOTE
on upper left and upper right transmission housing to
The following procedure describes installation of the oil pan
crankcase bolts.
with the transmission case mounted in the motorcycle frame.
Follow the applicable steps to install the oil pan with the
c. Repeating the pattern again, final tighten the four
transmission case removed from the motorcycle frame.
bolts to 30-35 ft-lbs (40.7-47.5 Nm).
1. Coat gasket surface of oil pan with a thin coat of HYLO-
3. Slide new clamps onto free ends of oil supply and return
MAR® gasket sealer.
hoses. See Figure 7-41. Install hoses onto transmission
2. Place gasket on oil pan and allow sealer to dry until
fittings. Crimp clamps using the Hose Clamp Pliers (HD-
tacky.
41137).
7-30
2004 Touring: Transmission
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10. Install the primary chaincase and starter jackshaft
f1894x7x
assembly. Install clutch assembly, primary chain, and
compensating sprocket components. Install the primary
chaincase cover. See Section 6.5 PRIMARY CHAIN-
CASE, INSTALLATION.
11. Install rear swingarm and rear wheel. Adjust belt ten-
sion. See Section 2.20 REAR SWINGARM, INSTALLA-
TION.
12. Install engine oil drain plug and tighten to 14-21 ft-lbs
(19-28 Nm).
13. Add engine oil. See Section 3.3 GENERAL INFORMA-
TION, CHANGING ENGINE OIL AND FILTER, steps 9-
12.
Figure 7-45. Shifter Pawl Assembly
4.
Slide new clamp onto free end of crankcase breather
hose. Install hose onto fitting of oil filler spout. Crimp
clamp using HOSE CLAMP PLIERS (HD-97087-65B).
5.
Install two allen head socket screws (with captive wash-
ers) to secure oil hose cover to transmission and engine
housings. Longer screw goes to engine housing. Alter-
nately tighten screws to 84-108 in-lbs (10-12 Nm).
6.
Slide splined end of shifter shaft through sleeved bore
until it protrudes from left side of case. Install flat washer
and retaining ring on splined end of shaft. Hold the
shifter pawl assembly inside the transmission case so
that the centering spring slot is aligned with the center-
ing screw. Using a T50 TORX drive head, tighten center-
ing screw until snug. See Figure 7-45.
7.
Install the shifter lever onto the splined end of the shifter
shaft taking note to align marks placed on splines during
disassembly. Install socket head screw and tighten to
18-22 ft-lbs (24-30 Nm). Make sure screw registers in
slot of shifter lever.
8.
Install the mainshaft and countershaft assemblies. See
Section
7.6 MAINSHAFT/COUNTERSHAFT, INSTAL-
LATION.
9.
Install belt on transmission sprocket.
2004 Touring: Transmission
7-31
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NOTES
7-32
2004 Touring: Transmission
HOME
SPECIFICATIONS
8.1
IGNITION TIMING
System Fuse Block (Under Left Side Cover)
8
ALL FL Models
FLHR/C/S
RANGE
TDC - 50˚ BTDC
9
10
START
TDC
5
11
ALTERNATOR SYSTEM
Output Voltage @ 3600 rpm 14.3-14.7
4
38 Amp:
12
FLHR, FLHRI, FLHRCI, FLHRS, FLHRSI, FLHT, FLHTC
45 Amp:
f2210x8x
1
2
3
FLHTI, FLHTCI, FLHTCUI, FLTRI
8
7
FLTR, FLHT/C/U
BATTERY
9
6
10
5
Voltage 12V
11
Amperes - 28 AH @ 20 Hour Rate
FUSES
4
Rating
Circuit
Color
(Amperes)
f2204x8x
2
3
1
System Fuses
1.
Headlamp
7.
Radio Power
Maxi-Fuse
40
Orange
2.
Ignition
8.
Accessory
3.
Lighting
9.
Battery
Headlamp
15
Blue
4.
Instruments
10.
Brake Light Relay
5.
Brakes/Cruise
11.
P&A
Ignition
15
Blue
6.
Radio Memory
12.
Starter Relay
Lighting
15
Blue
Instruments
15
Blue
EFI Fuse Block (Under Right Side Cover)
Brakes/Cruise
15
Blue
EFI System
Radio Memory
15
Blue
Relay
Spare
Radio Power
10
Red
Accessory
15
Blue
Fuel Pump
Battery
15
Blue
P & A
15
Blue
ECM Power
EFI Fuses
f2223x9x
Fuel Pump
15
Blue
ECM Power
15
Blue
Figure 8-1. Fuse Locations
2004 Touring: Electrical
8-1
HOME
SPARK PLUG
Item
ft/in-lbs
Nm
Part No.
No.
Size
Gap
Fork lock to upper fork
36-60 in-lbs
4.1-6.8 Nm
bracket (FLHR/C/S)
0.038-0.043 in.
32317-86A
6R12
12 mm
0.97-1.09 mm
Ignition switch screws
20-30 in-lbs
2.3-3.4 Nm
(FLHR/C/S)
Instrument bezel TORX
NOTE
25-35 in-lbs
2.8-4.0 Nm
screws
Be sure spark plugs are gapped to specification before instal-
Handlebar clamp to
lation.
master cylinder housing
60-80 in-lbs
6.8-9.0 Nm
screws
Lower and upper handle-
bar switch housing TORX
35-45 in-lbs
4-5 Nm
TORQUE VALUES
screws
Handlebar clamp to
clutch lever bracket TORX
60-80 in-lbs
6.8-9.0 Nm
Item
ft/in-lbs
Nm
screws
Ignition module socket
Neutral switch
120-180 in-lbs
13.6-20.3 Nm
50-60 in-lbs
5.7-6.8 Nm
head screws
Horn stud flange nut
80-100 in-lbs
9.0-11.3 Nm
(10mm)
MAP sensor TORX screw
25-35 in-lbs
2.8-4.0 Nm
Ignition coil bracket
Horn bracket acorn nut to
80-100 in-lbs
9.0-11.3 Nm
84-144 in-lbs
9.5-16.3 Nm
rubber mount stud
socket screws
2 inch diameter gauge
Spark plug
12-18 ft-lbs
16-24 Nm
10-20 in-lbs
1.1-2.3 Nm
nuts
Stator to crankcase TORX
55-75 in-lbs
6.2-8.5 Nm
Tachometer bracket
screws
10-20 in-lbs
1.1-2.3 Nm
socket screws
Battery cable bolt
60-96 in-lbs
6.8-10.9 Nm
Speedometer speed
84-108 in-lbs
9-12 Nm
Voltage regulator locknuts
70-100 in-lbs
7.9-11.3 Nm
sensor screw
Battery hold-down clamp
Speedometer bracket
15-20 ft-lbs
20-27 Nm
10-20 in-lbs
1.1-2.3 Nm
TORX bolt
socket screws
Headlamp door screw
9-18 in-lbs
1.0-2.0 Nm
Console mounting bolt
50-90 in-lbs
5.7-10.2 Nm
Passing lamp bracket fork
acorn nut (FLHR/C/S)
15-20 ft-lbs
20-27 Nm
bracket TORX bolts
Console pod Phillips
6-11 in-lbs
0.7-1.2 Nm
Passing lamp bracket fork
screws
72-108 in-lbs
8.1-12.2 Nm
bracket stud acorn nuts
Fuel tank canopy TORX
18-24 in-lbs
2.0-2.7 Nm
Tail lamp lense screws
20-24 in-lbs
2.3-2.7 Nm
screws
Tail lamp circuit board/
Cruise module locknuts
60-96 in-lbs
6.8-10.9 Nm
40-48 in-lbs
4.5-5.4 Nm
plastic bracket
Radio to support bracket
35-45 in-lbs
4.0-5.1 Nm
Rear fender tip lamp nuts
20-25 in-lbs
2.3-2.8 Nm
socket screws
Front fender tip lamp nuts
20-25 in-lbs
2.3 - 2.8 Nm
Upper fairing speaker
22-28 in-lbs
2.5-3.2 Nm
lower TORX screw
Front fender trim strip tee
10-15 in-lbs
1.1-1.7 Nm
bolt nuts
Upper fairing speaker
35-50 in-lbs
4.0-5.7 Nm
upper TORX screws
Ignition switch to upper
36-60 in-lbs
4.1-6.8 Nm
fork bracket
Throttle cable J-clamp
screw to wellnut
9-18 in-lbs
1.0-2.0 Nm
Fairing cap TORX screws
25-30 in-lbs
2.8-3.4 Nm
(FLHR/C/S)
Ignition
switch button
18-23 in-lbs
2.0-2.6 Nm
Ground post flange nuts
50-90 in-lbs
5.7-10.2 Nm
head screws
Ignition switch
DOM
50-70 in-lbs
5.7-7.9 Nm
nut
HDI
125-150 in-lbs
14.1-16.9 Nm
Continued ...
8-2
2004 Touring: Electrical
HOME
BULB CHART
8.2
Lamp Description,
Number of
Current Draw
Harley-Davidson
Wattage
All Lamps 12V
Bulbs
(Amperage)
Part No.
HEADLAMP
FLHT/C/U, FLHR/C/S
1
4.58/5
55/60
68329-03
FLTR
2
4.58/5
55/60
68329-03
POSITION LAMP (HDI)
1
0.32
3.9
53438-92
PASSING LAMPS
(DOM)
2
2.50
30
68674-69B
(HDI)
2
2.92
35
68847-98A
TAIL AND STOP LAMP
1
Tail Lamp
0.59
6
68167-88
Stop Lamp
2.10
24
68167-88
Tail Lamp (HDI)
0.59
6
68167-88
Stop Lamp(HDI)
2.10
24
68167-88
License Plate (HDI)
1
0.37
5.2
53436-97
TURN SIGNAL LAMP
Front/Running
2
2.25/.59
27/7
68168-89
Front (HDI)
2
1.75
21
68163-84
Rear
2
2.25
27
68572-64B
Rear (HDI)
2
1.75
21
68163-84
TOUR-PAK
Side Marker Lamps *
4
0.3
3.7
53439-79
Tail/Brake Lamps (Ultra)
2
0.59
7
68168-89A
FENDER TIP LAMPS *
2
0.3
3.7
53439-79
INSTRUMENT PANEL LAMPS
FLHT/C/U, FLTR
High Beam
1
0.15
2.1
68024-94
Oil Pressure
1
0.15
2.1
68024-94
Neutral
1
0.15
2.1
68024-94
Turn Signal
2
0.15
2.1
68024-94
GAUGE LAMPS
FLHT/C/U, FLTR
Speedometer **
Tachometer **
Voltmeter
1
0.24
3.4
67445-00
Oil Pressure Gauge
1
0.24
3.4
67445-00
Air Temperature Gauge
1
0.24
3.4
67445-00
Fuel Gauge
1
0.24
3.4
67445-00
Engine **
INSTRUMENT PANEL/
GAUGE LAMPS
FLHR/C/S
High Beam **
Oil Pressure **
Neutral **
Turn Signal **
Fuel Gauge **
Speedometer **
Odometer **
Engine **
* Not Applicable to HDI
** LED Illuminated. LEDs are not repairable. Assembly must be replaced if LED fails.
2004 Touring: Electrical
8-3
HOME
NOTES
8-4
2004 Touring: Electrical
HOME
SYSTEM FUSES
8.3
MAXI-FUSE
REMOVAL
1.
Remove left side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
2.
Gently pull side cover from frame downtubes (no tools
required).
3.
Depress latches on maxi-fuse holder and then slide
cover rearward to disengage tongue from groove in fuse
block cover. See Figure 8-2.
Maxi-Fuse
4.
Pull maxi-fuse from maxi-fuse holder. See Figure 8-3.
f2207x8x
Figure 8-3. Remove Maxi-Fuse
INSTALLATION
MAXI-FUSE HOLDER
1. Insert maxi-fuse into maxi-fuse holder. See Figure 8-3.
2. Slide cover forward to engage tongue in groove of fuse
block cover and then insert maxi-fuse holder into cover
REMOVAL
until latches engage. See Figure 8-2.
1.
Remove maxi-fuse. See MAXI-FUSE, REMOVAL, in this
3. Align barbed studs in side cover with grommets in frame
section.
downtubes and push firmly into place
(no tools
required).
2.
Remove socket terminals from maxi-fuse holder. See
Section B.3 PACKARD ELECTRICAL CONNECTORS,
4. Install left side saddlebag. See Section 2.25 SADDLE-
800 METRI-PACK SERIES.
BAG, INSTALLATION.
INSTALLATION
3. Install socket terminals into maxi-fuse holder. See
Section B.3 PACKARD ELECTRICAL CONNECTORS,
800 METRI-PACK SERIES.
4. Install maxi-fuse. See MAXI-FUSE, INSTALLATION, in
this section.
SYSTEM FUSES/RELAYS
REMOVAL
Fuse
Maxi-Fuse
1.
Remove maxi-fuse. See MAXI-FUSE, REMOVAL, in this
Block
Cover
section.
f2206x8x
2.
Pull fuse block from tabs on mounting bracket. Tabs on
Figure 8-2. Remove Left Side Cover
bracket fit into slots on each side of fuse block cover.
2004 Touring: Electrical
8-5
HOME
INSTALLATION
Spare Fuse
Holder
1. Install system fuse/relay in fuse block. See lower frame
Fuse Block
of Figure 8-4.
Cover
NOTE
For FLHR/C/S configuration, see upper frame of Figure 8-1 in
Section 8.1 SPECIFICATIONS.
2. Slide cover over fuse block until slots fully engage tabs
on block. See upper frame of Figure 8-4.
3. Slide fuse block into position on mounting bracket. Tabs
on bracket fit into slots on each side of fuse block cover.
4. Install maxi-fuse. See MAXI-FUSE, INSTALLATION, in
this section.
f2209x8x
f2203x8x
8
7
FUSE BLOCK
9
6
10
REMOVAL
5
1. Remove system fuses and relay(s). See SYSTEM
11
FUSES/RELAYS, REMOVAL, in this section.
5. Remove socket terminals from fuse block. See Section
B.3 PACKARD ELECTRICAL CONNECTORS,
280
4
METRI-PACK SERIES.
INSTALLATION
1
2
3
1.
Install socket terminals into fuse block. See Section B.3
PACKARD ELECTRICAL CONNECTORS, 280 METRI-
1.
Headlamp
7.
Radio Power
PACK SERIES.
2.
Ignition
8.
Accessory
2.
Install system fuses and relay(s). See SYSTEM FUSES/
3.
Lighting
9.
Battery
RELAYS, INSTALLATION, in this section.
4.
Instruments
10.
Brake Light Relay
5.
Brakes/Cruise
11.
P&A
6.
Radio Memory
EFI FUSES
Figure 8-4. Fuse Block (FLTR, FLHTC/U)
See Section 9.2 ELECTRICAL BRACKET ASSEMBLY, EFI
FUSES.
NOTE
The fuse block cover also serves as the spare fuse holder.
One spare 10 amp and 15 amp fuse are provided.
3. Remove the fuse block cover. Raise lipped side slightly
to disengage slots from tabs on fuse block. See upper
frame of Figure 8-4.
4. Remove system fuse/relay from fuse block. Replace
fuse if the element is burned or broken. Automotive type
ATO fuses are used. See lower frame of Figure 8-4.
NOTE
For FLHR/C/S configuration, see upper frame of Figure 8-1 in
Section 8.1 SPECIFICATIONS.
8-6
2004 Touring: Electrical
HOME
IGNITION CONTROL MODULE (CARBURETED)
8.4
REMOVAL
f2191x8x
1. Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
2. Gently pull side cover from frame downtubes (no tools
required).
3. Depress external latches and use a rocking motion to to
remove electrical connector. See Figure 8-5.
4. Remove two socket screws to detach ignition control
module from electrical bracket.
INSTALLATION
1. Align holes in ignition control module with those in elec-
Ignition Control Module
trical bracket. Install two socket screws and tighten to
Connector [10]
50-60 in-lbs (5.7-6.8 Nm).
2. Align tabs on socket housing with grooves on pin hous-
Figure 8-5. Electrical Bracket (Under Right Side Cover)
ing and push connector halves together until latches
click.
3. Align barbed studs in side cover with grommets in frame
4.
Install right side saddlebag. See Section 2.25 SADDLE-
downtubes and push firmly into place
(no tools re-
BAG, INSTALLATION.
quired).
2004 Touring: Electrical
8-7
HOME
SENSORS (CARBURETED)
8.5
MANIFOLD ABSOLUTE
PRESSURE SENSOR
MAP Sensor
T20 TORX
Removal
Screw
1. Partially remove fuel tank. See Section 4.7 FUEL TANK
(CARBURETED), PARTIAL REMOVAL, FLHT/C, or
FLHR/S.
2.
Pull external latch outward and use rocking motion to
remove electrical connector.
3.
Remove T20 TORX screw to release retaining clip from
intake manifold. See Figure 8-6.
4.
Carefully pull pressure port (enveloped in rubber seal)
Retaining
from hole in intake manifold.
Clip
5.
If reusing sensor, inspect condition of rubber seal.
Figure 8-6. Intake Manifold
Replace the seal if it is cut, torn or shows signs of deteri-
oration.
3.
Install T20 TORX screw and tighten to 25-35 in-lbs (2.8-
4.0 Nm). See Figure 8-6.
Installation
4.
Align latch on socket housing with locking tab on pin
housing and push connector halves together until latch
1. Install rubber seal on pressure port, if removed.
clicks.
2. With port side down, slide end of retaining clip in slot at
5.
Install fuel tank. See Section 4.7 FUEL TANK (CARBU-
side of sensor. Aligning hole in retaining clip with
RETED), INSTALLATION (AFTER PARTIAL REMOVAL),
threaded hole in intake manifold, carefully press pres-
FLHT/C, or FLHR/S.
sure port into bore,
CRANKSHAFT POSITION SENSOR
See Section
9.3 SENSORS, CRANKSHAFT POSITION
SENSOR.
8-8
2004 Touring: Electrical
HOME
IGNITION COIL
8.6
6.
Install fuel tank. For carbureted models, see Section 4.7
REMOVAL
FUEL TANK (CARBURETED), INSTALLATION (AFTER
PARTIAL REMOVAL), FLHT/C or FLHR/S. For fuel
1. Partially remove fuel tank. For carbureted models, see
injected models, see Section 9.4 FUEL TANK (FUEL
Section
4.7 FUEL TANK (CARBURETED), PARTIAL
INJECTED), INSTALLATION
(AFTER PARTIAL
REMOVAL, FLHT/C or FLHR/S. For fuel injected mod-
REMOVAL), FLHT/C/U/I, FLTRI or FLHR/C/S/I.
els, see Section 9.4 FUEL TANK (FUEL INJECTED),
PARTIAL REMOVAL, FLHT/C/U/I, FLTRI or FLHR/C/S/I.
2. Unplug spark plug cables from ignition coil towers.
8316
3. Pull external latch outward and use rocking motion to
remove electrical connector from left side of ignition coil.
4. Pull sides of ignition coil bracket outward to remove from
bosses of front fuel tank mount. See Figure 8-7.
5. Remove two socket screws to free ignition coil from
bracket.
INSTALLATION
1.
Align holes in new ignition coil with holes in bracket.
Properly positioned, connector pin housing should be
positioned at cut in bracket. Install two socket screws
and tighten to 84-144 in-lbs (9.5-16.3 Nm). See Figure
8-8.
Figure 8-7. Remove Ignition Coil Bracket From Vehicle
2. With the coil towers facing rear of vehicle, hold ignition
coil and bracket at bottom of frame backbone. Pull sides
f1925x8x
of bracket outward and install on bosses of front fuel
tank mount. See Figure 8-7.
3. Install electrical connector on left side of ignition coil.
Align latch on socket housing with locking tab on pin
housing and push connector halves together until latch
clicks.
4. Install spark plug cable to front cylinder onto left side coil
tower. Verify that spark plug cable is captured in double-
sided cable clip at bottom left side of frame backbone.
Install new cable clip on T-stud if damaged or missing.
See Figure 8-10.
Front
5. Install spark plug cable to rear cylinder onto right side
coil tower. Verify that spark plug cable is captured in two
single-sided cable clips at bottom left side of frame back-
Rear
bone. Install new cable clips on T-studs if damaged or
missing. See Figure 8-10.
Figure 8-8. Install Bracket to Ignition Coil
2004 Touring: Electrical
8-9
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