Harley Davidson 2004 Touring Models. Service Manual — page 36
HOME
3.
Using a T40 TORX drive head, remove four screws to
Passing Lamp
Turn Signal Lamp
release passing lamp bracket from upper and lower fork
Connector [73]
Connector [31]
brackets. Remove passing lamp assembly from the
motorcycle.
4.
Remove the fairing cap. See FAIRING CAP, REMOVAL,
in this section.
5.
Pull chrome skirt from inner fairing. See Figure 2-152.
6.
Slide rubber boot off clutch cable adjuster. Holding cable
adjuster with 1/2 inch wrench, loosen jam nut using 9/16
inch wrench. Back jam nut away from cable adjuster.
Move adjuster toward jam nut to introduce free play at
hand lever.
7.
Remove retaining ring from pivot pin groove at bottom of
clutch lever bracket. Remove pivot pin.
8.
Using a T27 TORX drive head, remove two screws (with
flat washers) to release handlebar clamp from clutch
lever bracket. Remove clutch hand lever from clutch
lever bracket.
9.
Remove anchor pin and clutch cable eyelet from clutch
hand lever. See Figure 2-114.
10.
Feed clutch cable and cable eyelet through inner fairing
grommet to front of motorcycle.
Chrome
f2238x8x
Skirt
CAUTION
Figure 2-152. Inner Fairing (Front View)
Do not remove the switch housing assembly without first
placing a 5/32 inch (4.0 mm) cardboard insert between
the brake lever and lever bracket. Removal without the
c. With the red arrow pointing toward the ACCESS
insert may result in damage to the rubber boot and
position, install the ignition switch knob. Turn key
plunger of the front stoplight switch.
clockwise to UNLOCK position and then turn knob
to OFF.
NOTE
6.
Using a T27 TORX drive head, tighten two fairing cap
Use the eyelet of a small cable strap if the cardboard insert is
screws to 25-30 in-lbs (2.8-3.4 Nm).
not available.
INNER FAIRING
7959
REMOVAL
CAUTION
To avoid scratches or other damage, place protective
material over front fender, fuel tank and fairing lowers, if
present.
1.
Remove the outer fairing. See OUTER FAIRING/WIND-
SHIELD, REMOVAL, in this section.
5/32 Inch
(4.0 mm)
2.
Locate passing lamp (white 2-place Multilock) and front
Cardboard
turn signal lamp (6-place Multilock) connectors. Depress
Insert
button on socket terminal side and pull apart pin and
socket halves of both connectors. See Figure 2-152.
Figure 2-153. Install Cardboard Insert
2-122
2004 Touring: Chassis
HOME
Speedometer
[39]
Voltmeter
Fuel Gauge
Indicator Lamps
Tachometer
[21]
Speaker
[108]
Adapter
Speaker
Adapter
Ambient
Temperature
Gauge
Oil Pressure
Cigarette
Gauge
Lighter
f2238x8x
Figure 2-154. Inner Fairing Connections (FLHTC/U)
11. Place the cardboard insert between the brake lever and
15. Remove the throttle control grip from the end of the han-
lever bracket. See Figure 2-153.
dlebar.
12. Using a T25 TORX drive head, remove
the upper and
16. Remove two-sided plastic clip inboard of cable adjuster
lower switch housing screws.
boots to separate throttle and idle control cable hous-
ings. Pull the crimped inserts at the end of the cable
13. Using a T27 TORX drive head, loosen the upper screw
housings from the lower handlebar switch housing. For
securing the handlebar clamp to the master cylinder
best results, place a drop of light oil on the retaining
housing. Remove the lower clamp screw with flat
rings and use a rocking motion while pulling.
washer.
14. Remove the brass ferrules from the notches on the
17. Feed the throttle and idle control cables through the
inboard side of the throttle control grip. For best results,
inner fairing grommet to front of motorcycle.
place flat tip screwdriver in slot on outboard side and
18. See Figure 2-154. Pull socket terminals from spade con-
rotate ferrule in notch. Remove the ferrules from the
tacts on the cigarette lighter. Remove cigarette lighter
cable end fittings.
from socket. Holding socket to prevent rotation, unscrew
outer shell. Remove socket from inner fairing.
NOTE
On non cruise equipped models, remove the friction shoe
19. Pull socket terminals from speaker spade contacts.
from the end of the tension adjuster screw. The friction shoe
Using a T25 TORX drive head, remove three screws to
is a loose fit and may fall out or become dislodged if the lower
release the speaker adapter from the inner fairing.
switch housing is turned upside down or shaken.
Repeat step on opposite side of motorcycle.
2004 Touring: Chassis
2-123
HOME
23.
Pull the interconnect harness connectors from the volt-
Hex Nut
meter and fuel gauge.
Lamp
24.
Remove four socket head screws to free inner fairing
Connector
from fairing bracket. See Figure 2-157.
25.
Spread bottom of inner fairing to free from dowels in
lower fork bracket. Spread bottom of fairing bracket to
release from same dowels.
26.
Raise inner fairing and fairing bracket slightly to prevent
reengagement with dowels. On Classic and Ultra mod-
Mounting
els, remove the connectors from the oil pressure and
Bracket
ambient air temperature gauges.
Stud
Tab
27.
Raise inner fairing and fairing bracket together and then
separate by pulling fairing bracket toward the front and
inner fairing toward the rear.
Gauge
f1345x2x
28.
When inner fairing becomes free of the radio, remove
from motorcycle and move to bench area.
Figure 2-155. Voltmeter Gauge Assembly
29.
Install fairing bracket (with radio and interconnect har-
ness) back onto motorcycle aligning holes with dowels in
Indicator Lamp
lower fork bracket. Loosely install T40 TORX screws.
Connector [21]
10-Place Multilock
30.
At bench area, remove hex nuts from studs at back of
voltmeter and fuel gauges. Remove mounting brackets
from gauges and remove gauges from inner fairing. See
Figure 2-155. On Classic and Ultra models, repeat step
Bulb
to remove oil pressure and ambient air temperature
Housing
gauges.
31.
Remove clutch and throttle cable grommets from the
inner fairing.
Rubber
Boot
Fairing Bracket
Screws
Paddle
Lense
f2262x8x
Figure 2-156. Indicator Lamp Assembly
20.
Unthread rubber boot from odometer reset switch. Pull
switch from hole in inner fairing.
21.
Bend back the external latches slightly and remove con-
nectors at back of speedometer and tachometer gauges.
See Figure 2-154. Leaving anchors on interconnect har-
ness installed in outboard ears of brackets, remove allen
head socket screws to remove brackets from gauges.
Push gauges toward rear of motorcycle to remove from
inner fairing.
Fairing Bracket
Screws
22.
Separate pin and socket halves of indicator lamps con-
nector (10-place Multilock). See Figure 2-154. Release
f2238x8x
four paddles to free indicator bulb housing from lense
assembly. See Figure 2-156. Remove lense assembly
from inner fairing.
Figure 2-157.
Remove Fairing Bracket Screws
2-124
2004 Touring: Chassis
HOME
INSTALLATION
11. With the widest edge at the top, align holes in speaker
adapter with those in inner fairing. Install two long
1. At bench area, install clutch and throttle cable grommets
screws to fasten top of speaker adapter. Capturing fair-
in inner fairing.
ing support brace, install short screw in lower outboard
hole (positioning flat washer between adapter and sup-
2. Install voltmeter and fuel gauges in inner fairing. Slide
port brace). Using a T25 TORX drive head, tighten the
mounting brackets over studs. Verify that tabs on top and
lower screw to 22-28 in-lbs (2.5-3.2 Nm). Tighten the
bottom of brackets engage slots in inner fairing. Loosely
two upper screws to 35-50 in-lbs (4.0-5.7 Nm).
install hex nuts on studs. Verify that gauge is properly
aligned and tighten nuts to 10-20 in-lbs (1.1-2.3 Nm).
NOTE
See Figure 2-155. On Classic and Ultra models, repeat
The screw hole on the lower inboard side of the speaker
step to install ambient air temperature and oil pressure
adapter is not used.
gauges.
12. Push the socket terminals onto the speaker spade con-
tacts. Different size spade contacts prevent improper
CAUTION
assembly.
To avoid scratches or other damage, place protective
13. Repeat steps 11-12 on opposite side of motorcycle.
material over front fender, fuel tank and fairing lowers, if
14. From rear of inner fairing, slide socket of cigarette lighter
present.
through bore in fairing. Thread outer shell onto socket
3.
Remove T40 TORX screws to free fairing bracket (with
until tight. Install cigarette lighter in socket. Connect the
radio and interconnect harness) from lower fork bracket.
orange/white wire terminal to the socket spade contact,
Raise fairing bracket and then tilt forward at about a 45
the black wire terminal to the outer shell contact.
degree angle.
15. Feed the throttle and idle control cables through the right
4.
Position inner fairing at rear of fairing bracket. Tilting
side inner fairing grommet.
inner fairing rearward at about a 45 degree angle, align
NOTE
upper and lower fork bracket thru holes with those in fair-
On non cruise equipped models, install the friction shoe with
ing bracket. Draw fairing bracket and inner fairing
the concave side up so that the pin hole is over the point of
together fitting radio into slot in inner fairing.
the adjuster screw. The friction shoe is a loose fit and may fall
5.
Align upper thru holes in fairing bracket and inner fairing
out or become dislodged if the lower switch housing is turned
with threaded holes in upper fork bracket and start T40
upside down or shaken.
TORX screws. Align lower thru holes in fairing bracket
16. Push the throttle and idle control cables into the lower
and inner fairing with dowels in lower fork bracket and
start screws. Alternately tighten four T40 TORX screws
handlebar switch housing until they snap in place. Pro-
ceed as follows:
until snug.
a. Note the different diameter inserts crimped into the
6.
Install four socket head screws to attach inner fairing to
end of the throttle and idle control cable housings.
fairing brackets. See Figure 2-157.
b. Push the larger diameter insert (silver) on the throt-
7.
Install the interconnect harness connectors onto the volt-
tle cable housing into the larger hole (front).
meter and fuel gauge. On Classic and Ultra models,
install the connectors onto the oil pressure and ambient
c. Push the smaller diameter insert (gold) on the idle
air temperature gauges.
cable housing into the smaller hole (rear).
8.
Place indicator lamp lense assembly into inner fairing.
NOTE
Slot at bottom of lense engages tab in inner fairing to
To aid assembly, place a drop of light oil on the retaining
prevent improper orientation. Engage all four paddles on
rings of the crimped inserts. Always replace the retaining
lense assembly with slots on indicator bulb housing.
rings if damaged or distorted.
Mate pin and socket halves of indicator lamps connector
17. Slide the throttle control grip over the end of the right
(10-place Multilock). See Figure 2-156.
handlebar until it bottoms against the closed end. Rotate
9.
Install speedometer and tachometer gauges in inner fair-
the grip so that the ferrule notches are at the top. To pre-
ing. Align holes in brackets with those at back of gauges
vent binding, pull the grip back about 1/8 inch (3.2 mm).
and start two allen head socket screws. Rotate gauges
18. Position the lower switch housing beneath the throttle
until tabs at top and bottom of brackets engage slots in
control grip. Install the brass ferrule onto the throttle
inner fairing. Verify that gauge is properly aligned and
cable so that the end fitting seats in the ferrule recess.
tighten allen head socket screws to 10-20 in-lbs (1.1-2.3
Be sure that ferrule is oriented so that when installed in
Nm). Install speedometer and tachometer connectors at
notch of throttle control grip, slotted end is on the out-
back of gauges.
board side. Install ferrule in notch of throttle control grip.
10.
Slide odometer reset switch through hole in inner fairing.
Verify that cable is captured in groove molded into the
Install rubber boot to secure.
grip. Repeat step to install idle control cable. See Figure
2-158.
2004 Touring: Chassis
2-125
HOME
23. Align the holes in the handlebar clamp with those in the
Ferrule
Notch
Groove
master cylinder housing and start the two screws (with
flat washers). Position for rider comfort. Beginning with
the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0
Nm) using a T27 TORX drive head.
24. Using a T25 TORX drive head, tighten the lower and
upper switch housing screws to 35-45 in-lbs (4-5 Nm).
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.
25.
Remove the cardboard insert between the brake lever
and lever bracket.
26.
Install two-sided plastic clip inboard of cable adjuster
boots to hold throttle and idle control cable housings
together.
27.
Moving to other side of motorcycle, feed clutch cable
Throttle
through left side inner fairing grommet.
Grip
28.
Insert clutch cable eyelet into groove of clutch hand lever
aligning eyelet with hole without bushing. Insert anchor
pin through lever and eyelet.
Idle
Throttle
f1474x2x
29.
Insert lever into groove of clutch lever bracket fitting
Cable
Cable
sleeve at end of cable housing into bore on inboard side
of bracket.
Figure 2-158. Install Throttle/Idle Control Cables on
30.
Align hole in hand lever with hole in bracket and install
Throttle Control Grip
pivot pin. Install retaining ring in pivot pin groove.
31.
Using a T27 TORX drive head, install two screws (with
flat washers) to secure handelbar clamp to clutch lever
19. Position the upper switch housing over the handlebar
bracket. Starting with the top screw, tighten screws to
and lower switch housing.
60-80 in-lbs (6.8-9.0 Nm).
20. Verify that the wire harness conduit runs in the depres-
32.
Adjust the clutch. See Section 6.3 CLUTCH, ADJUST-
sion at the bottom of the handlebar. Also be sure that the
MENT.
upper switch housing harness will not be pinched
33.
Install the fairing cap. See FAIRING CAP, INSTALLA-
against the handlebar when the switch housing screws
TION, in this section.
are tightened.
34.
Remove two T40 TORX screws from lower fork bracket.
21. Start the upper and lower switch housing screws, but do
Install chrome skirt aligning thru holes with screws just
not tighten.
removed. Start T40 TORX screws back into lower fork
bracket.
35.
Loosen two T40 TORX screws from upper fork bracket.
CAUTION
36.
Slide slots of passing lamp bracket onto upper and lower
See Figure 2-153. Do not remove the 5/32 inch (4.0 mm)
fork bracket screws. Alternately tighten four T40 TORX
cardboard insert (or cable strap eyelet) wedged between
screws to 15-20 ft-lbs (20-27 Nm) in a crosswise pattern.
the brake lever and lever bracket. Removal will result in
37.
Route passing lamp conduit upward in front of chrome
damage to the rubber boot and plunger of the Front
skirt and then rearward using relief in upper outboard
Stoplight Switch during installation of the master cylin-
corner (in front of fairing bracket). Route conduit of other
der assembly.
passing lamp in the same manner. Mate pin and socket
22. Position the brake lever/master cylinder assembly
halves of passing lamp connector (white 2-place Mul-
inboard of the switch housing assembly engaging the
tilock) and front turn signal lamp connector (6-place Mul-
tab on the lower switch housing in the groove at the top
tilock).
of the brake lever bracket.
38.
Install the outer fairing. See OUTER FAIRING/WIND-
SHIELD, INSTALLATION, in this section.
2-126
2004 Touring: Chassis
HOME
UPPER FAIRING/WINDSHIELD (FLTR)
2.30
WINDSHIELD ONLY
Wellnut
Flat Washer
Phillips
Plastic
Screw
REMOVAL
1. Standing at front of motorcycle, locate five Phillips
screws at base of windshield. Alternately loosen and
Windshield
then remove screws (with plastic flat washers).
2. Remove windshield from outer fairing.
3. Carefully remove wellnuts from holes in outer fairing.
See Figure 2-159. Exercise caution to avoid pushing
wellnuts into fairing during removal. Inspect wellnuts for
cuts, tears or signs of deterioration. Replace as neces-
sary.
Outer
Fairing
f1528x2x
INSTALLATION
1. Preinstall hardware on windshield as follows:
Figure 2-160. Install Windshield
a. Slide plastic flat washers onto Phillips screws.
(Decal Removed for Illustration Purposes)
b. Slide Phillips screws through holes in decal to orient
hardware in slots of windshield.
2.
Moving to front of motorcycle, push wellnuts into holes in
outer fairing. See Figure 2-160.
NOTE
3.
Starting with center screw, alternately tighten the five
If installing new windshield, poke holes in decal from inboard
Phillips screws to 6-13 in-lbs (0.7-1.5 Nm).
side of windshield. Punching holes from outboard side will
dislocate or tear decal on windshield.
c. Start wellnuts onto Phillips screws.
OUTER FAIRING
Wellnuts
f1525x2x
REMOVAL
NOTE
Windshield may be left in place during outer fairing removal.
1.
Place protective material on top of front fender to protect
paint from scratches or other damage.
2.
Standing on left side of motorcycle, use a T25 TORX
drive head to remove screw at edge of fairing outboard
of the left speaker. See Figure 2-161. Remove screw
outboard of the right speaker.
3.
Loosen top left and right screws just outboard of the fuel
and volt gauges, respectively.
4.
Remove screw just below left side glove compartment.
Remove screw below right side glove compartment.
5. On inboard side of right fairing support, remove rear
acorn nut (with flat washer) from stud of front turn signal
Figure 2-159. Remove Wellnuts From Outer Fairing
lamp bracket. Remove front acorn nut with flat washer.
2004 Touring: Chassis
2-127
HOME
2
2
50
60
70
30
40
50
3040
MPH
8090
20
RPMx100
60
10
20
100110
10
70
0
120
0
80
CERTIFIEDN
N
1
1
HARLEY-DAVIDSON
Long Screw
Long Screw
3
3
f2169x2x
Figure 2-161. Remove/Install Six Outer Fairing Screws
Pull front turn signal lamp assembly from motorcycle
and allow to hang at front of engine guard. Repeat step
to remove front turn signal lamp assembly on left side.
See Figure 2-162.
Acorn Nuts
6.
Remove top left and right screws just outboard of the
fuel and volt gauges, respectively (previously loosened).
7.
Raise outer fairing slightly and then rest on protective
fender pad.
8.
Squeeze two external tabs to disconnect headlamp
jumper harness connector.
9.
To avoid possible wire damage, separate pin and socket
halves of front turn signal lamp connectors [31L] and
[31R], 3-place Multilocks, and move to bench area. See
Figure 2-163.
9424
INSTALLATION
Figure 2-162. Remove Acorn Nuts to Release
Turn Signal Lamp and Bracket
1. Place protective material on top of front fender to protect
paint from scratches or other damage.
2.
Mate pin and socket halves of front turn signal lamp con-
NOTE
nectors [31L] and [31R], 3-place Multilocks. Verify that
The front turn signal lamp assemblies are not interchange-
conduit is captured in flexible clips on inner fairing. Allow
able. Note that the letters R(ight) or L(eft) are stamped on the
front turn signal lamp assemblies to hang at front of
inboard side of the turn signal lamp bracket to help ensure
engine guard until outer fairing installation is complete.
proper assembly.
2-128
2004 Touring: Chassis
HOME
10. Alternately tighten four short fairing screws to 6-12 in-
lbs (0.7-1.4 Nm). Alternately tighten two long fairing
screws to 10-15 in-lbs (1.1-1.7 Nm). Use the torque pat-
tern shown in Figure 2-161.
11. Slide studs on front turn signal lamp bracket through
holes in fairings and fairing support. Loosely install
acorn nuts with flat washers. Alternately tighten acorn
nuts to 40-50 in-lbs (4.5-5.7 Nm).
12. Repeat step 11 to install front turn signal lamp assembly
on opposite side of motorcycle.
9408
BEZEL
Figure 2-163. Front Turn Signal Lamp
REMOVAL
1.
Using a T25 TORX drive head, remove screw on left and
3. Rest outer fairing on front fender pad and connect head-
right side of instrument bezel. See Figure 2-164.
lamp jumper harness connector.
2.
Use thumbs to push tab at rear of bezel from slot in front
4. To avoid chafing wires of interconnect harness, verify
of ignition switch. Gently raise free side of bezel until
that trim strips are installed inboard of hooks on radio
tabs at front of instrument nacelle become disengaged
bracket.
from slot at front of bezel (concealed behind decorative
adhesive strip).
CAUTION
3.
Raising bezel slightly, remove anchor on ambient tem-
perature sensor from hole
in bottom
inboard ear
of
If windshield is attached during outer fairing installation,
speedometer bracket.
exercise caution to avoid scratching or damaging inner
fairing with windshield screws and wellnuts.
5. Place outer fairing against inner fairing. Two slots in
outer fairing must engage hooks on radio bracket. Move
harness conduit and wiring as necessary to ensure full
Bezel Screws
engagement between outer and inner fairings.
T25 TORX
6. Move to side of outer fairing to verify that alignment tabs
are properly engaged. Alignment tabs on inner fairing
must be positioned outboard of those on the outer fair-
ing. Repeat step on opposite side of motorcycle.
NOTE
Although the tightening sequence described below begins on
the left side of the motorcycle, if the left side of the outer fair-
ing fits the inner fairing better than the right, then start the
50
60 70
30
40
first screw on the right side. In other words, install the first
40
80
50
30
MPH
90
20
RPMx100
60
20
100
10
70
screw on the side that does not have the best fit.
10
110
0
120
0
80
CERTIFIEDN
N
7. Using a T25 TORX drive head, install screw at edge of
fairing outboard of the left speaker. Install screw out-
board of the right speaker. Mounting bosses on inner
fairing are painted white for easier alignment of holes.
8. Install the top left and right screws just outboard of the
Bezel
fuel and volt gauges, respectively.
Instrument
9. Moving to left side of motorcycle, install the first of two
Nacelle
long screws just below the glove compartment. Install
f2167x2x
the second long screw below the right side glove com-
partment.
Figure 2-164.
Remove Instrument Bezel Screws
2004 Touring: Chassis
2-129
HOME
Instrument Nacelle
Indicator
f2219x8x
Switches [105]
Lamps [21]
Tachometer
Gauge [108]
Speedometer
Gauge [39]
Throttle
Cables
Clutch
Cable
Speaker
Ambient
Switch [105]
Temperature
Sensor [107]
Figure 2-165. Instrument Nacelle (Bezel Removed)
4.
See Figure 2-165. Disconnect instruments and indicator
NOTE
lamps from interconnect harness as follows:
If tabs do not properly engage slot at front of bezel, then a
● Speedometer connector [39], 12-place Packard.
loose fit will result. Remove decorative adhesive strip by gen-
● Tachometer connector [108], 12-place Packard.
tly prying up outer edges, and using a flat bladed screwdriver,
carefully raise tabs so that they engage lip in slot. If dam-
● Indicator lamps connector [21], 10-place Multilock.
aged, install new decorative adhesive strip.
5.
Remove bezel from motorcycle.
5.
Using a T25 TORX drive head, install screw on each
side of bezel. Tighten screws to 25-35 in-lbs (2.8-4.0
Nm). See Figure 2-164.
INSTALLATION
1.
See Figure 2-165. Looking into the instrument nacelle,
connect instruments and indicator lamps to interconnect
harness as follows:
INSTRUMENT NACELLE
● Speedometer connector [39], 12-place Packard.
● Tachometer connector [108], 12-place Packard.
REMOVAL
● Indicator lamps connector [21], 10-place Multilock.
1.
Remove bezel. See BEZEL, REMOVAL, in this section.
2.
Install anchor on ambient temperature sensor into hole
in bottom inboard ear of speedometer bracket.
2.
Partially disassemble domestic ignition switch as follows:
3.
Verify that left and right sides of instrument nacelle are
NOTE
properly mated. Pins on left side of nacelle must fully
For partial disassembly of HDI ignition switch, see Section
engage holes on right.
8.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK,
4.
Insert tab at rear of bezel into slot of instrument nacelle
FLHT/C/U, FLTR (INTERNATIONAL), REMOVAL, steps 1-4.
(just in front of ignition switch). Holding left and right
sides of nacelle together, place bezel over instrument
a. To remove the ignition switch knob, insert the Igni-
nacelle flange. When properly mated, tabs at front of
tion Switch key and turn to the UNLOCK position.
instrument nacelle engage lip in slot at front of bezel
Leaving the key installed, rotate the knob to
(behind decorative adhesive strip).
ACCESS. Depressing the release button at bottom
2-130
2004 Touring: Chassis
HOME
6.
Unthread rubber boot from odometer reset switch, and
TOP VIEW
BOTTOM VIEW
while carefully removing left side instrument nacelle from
motorcycle, pull odometer reset switch from hole. See
Figure 2-167.
7.
See Figure
2-168. Disconnect instrument nacelle
switches from interconnect harness as follows:
● Instrument nacelle switch connector [105], 12-place
Multilock.
8.
Pull throttle cable clip from hole on right side of instru-
ment nacelle.
Button
9.
Using a T40 TORX drive head, remove two bolts (with
Button
f1240x2x
f1476x8x
flat washers) to release right side of instrument nacelle
from upper and lower fork brackets.
f1297b2x
INSTALLATION
1.
Install right side of instrument nacelle on motorcycle.
2.
See Figure 2-168. Connect instrument nacelle switches
Knob
to interconnect harness as follows:
● Instrument nacelle switch connector [105], 12-place
Nut
Multilock.
3.
While carefully placing left side of instrument nacelle on
Tab
Collar
motorcycle, slide odometer reset switch through hole
Down and Forward
and install rubber boot.
4.
See Figure 2-168. Connect left side switch to instrument
nacelle switch harness as follows:
● Speaker Switch connector [105], 4-place Multilock.
Spacer
5.
Verify that left and right sides of nacelle are properly
Figure 2-166. Ignition Switch Knob (Domestic)
mated. Four pins on left side of nacelle must fully
engage holes on right.
6.
Using a T40 TORX drive head, install two bolts (with flat
(left side) with a small screwdriver, push key down
washers) to fasten left side instrument nacelle to upper
and turn an additional 60 degrees in a counter-
and lower fork brackets. Alternately tighten bolts to 15-
clockwise direction. Lift and remove knob. See
20 ft-lbs (20-27 Nm).
upper frame of Figure 2-166.
7.
Capture clutch cable in cable clip. Insert cable clip into
b. Using a 7/8 inch wrench on flats, loosen switch nut
hole in left side of instrument nacelle.
and remove from threaded post of ignition switch
8.
Using a T40 TORX drive head, install two bolts (with flat
housing. Remove collar and spacer. See lower
washers) to fasten right side instrument nacelle to upper
frame of Figure 2-166.
and lower fork brackets. Tighten bolts to 15-20 ft-lbs (20-
c. Remove the switch position plate from threaded
27 Nm).
post of ignition switch housing.
9.
Capture throttle cables in cable clip. Insert cable clip into
hole in right side of instrument nacelle.
3.
See Figure 2-165. Disconnect left side switch from
10.
Assemble domestic ignition switch as follows:
instrument nacelle switch harness as follows:
● Speaker Switch connector [105], 4-place Multilock.
NOTE
For assembly of HDI ignition switch, see Section 8.18 IGNI-
4.
Pull clutch cable clip from hole on left side of instrument
TION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U,
nacelle.
FLTR (INTERNATIONAL), INSTALLATION, steps 5-10.
5.
Using a T40 TORX drive head, remove two bolts (with
a. Install the switch position plate over threaded post
flat washers) to release left side of instrument nacelle
of ignition switch housing. Tabs on plate fit in holes
from upper and lower fork brackets.
at top of instrument nacelle.
2004 Touring: Chassis
2-131
HOME
f2214x8x
CONNECTOR
DESCRIPTION
NUMBER
[A, C] = Pin
[B, D] = Socket
LEFT SIDE
[105A, 105B]
Interconnect to Nacelle Switch Harness
[105]
[105C, 105D]
Nacelle Switch Harness to Speaker Switch
Throttle
Cable Clip
RIGHT SIDE
Speaker
Switch [105D]
4-Place Multilock
Clutch
Cable Clip
Instrument Nacelle
Switches [105B]
12-Place Multilock
Speaker
Switch [105C]
4-Place Multilock
f2213x8x
Figure 2-167. Instrument Nacelle Halves
b. Slide spacer over threaded post of ignition switch
INNER FAIRING
housing until it contacts switch position plate. Slide
collar over post with the tab side down (and for-
ward). Install nut, and using a 7/8 inch wrench on
REMOVAL
flats, tighten to
50-70 in-lbs
(5.7-7.9 Nm). See
lower frame of Figure 2-166.
1.
Place protective material on top of front fender to protect
paint from scratches or other damage.
c. With the red arrow pointing toward the ACCESS
2.
Remove the outer fairing. See OUTER FAIRING,
position, install the ignition switch knob. Turn key
REMOVAL, in this section.
clockwise to UNLOCK position and then turn knob
to OFF.
3.
Carefully cut two cable straps and allow wire bundles
and conduit to hang naturally.
11. Install bezel. See BEZEL, INSTALLATION, in this sec-
4.
See Figure 2-168. Disconnect main harness from inter-
tion.
connect harness as follows:
2-132
2004 Touring: Chassis
HOME
Main to Interconnect
Harness [1]
Radio Antenna
Left Handlebar
Cable [51]
Switch Controls [24]
Right Handlebar
Switch Controls [22]
Main to Interconnect
Harness [156]
Radio
Ground
Main to Interconnect
Harness [2]
Right Turn
Left Turn
Signal [31R]
Signal [31L]
Headlamp [38]
Main to Interconnect
Harness [15]
Ignition
Switch [33]
f2269x8x
Figure 2-168. Inner Fairing Connections (FLTR)
● Main to interconnect harness connector [1], 12-
● Radio antenna cable connector [51]; back of radio
place Deutsch (black); below radio (right side).
(left side).
● Main to interconnect harness connector [2], 12-
place Deutsch (gray); below radio (right side).
6.
See Figure 2-168. Disconnect handlebar switch controls
from interconnect harness. Disconnect radio ground.
● Main to interconnect harness connector [15], 4-
Proceed as follows:
place Packard (black); below radio (right side).
● Main to interconnect harness connector [156], 6-
● Left handlebar switch controls connector [24], 12-
place Deutsch (gray); below radio (right side).
place Deutsch (gray); T-stud on left side of radio
bracket.
5. See Figure 2-168. Disconnect ignition switch from main
● Right handlebar switch controls connector [22], 12-
harness. Disconnect radio antenna cable. Proceed as
place Deutsch (black); T-stud on left side of radio
follows:
bracket.
● Ignition switch connector
[33],
4-place Packard
● Radio ground; single spade and socket terminal;
(black); inside fairing bracket tunnel (right side).
below radio (left side).
2004 Touring: Chassis
2-133
HOME
15. Remove right side instrument nacelle. See INSTRU-
f2237x2x
MENT NACELLE, REMOVAL, in this section, steps 8-9.
16. Remove shop towels and masking tape from around the
harness bundle. Separate radio ground and main har-
ness, ignition switch and handlebar switch control con-
duit.
Interconnect
17. Remove screw to release main harness ground ring ter-
Harness
minal and brake line P-clamp from front of upper fork
bracket.
18. Pull main harness and both radio ground and harness
ground ring terminals through opening on right side of
fairing bracket allowing conduit and connectors to hang
over top of engine guard.
19. Pull ignition switch and handlebar switch control conduit
out through opening at top of fairing bracket.
20. Remove locknuts and bolts to release fairing bracket
Figure 2-169. Wrap Main Harness in Shop Towels
from holes at rear of steering head.
7.
Draw the main harness conduit, handlebar switch con-
INSTALLATION
trol conduit, radio ground wire and radio antenna cable
as far forward as possible. Rest the connectors of the
NOTE
longer harnesses on the front fender.
To install the fairing bracket, begin at step 1. If only the inner
fairing was removed, start at step 7.
8.
Remove left side of instrument nacelle. See INSTRU-
MENT NACELLE, REMOVAL, in this section, steps 1-6.
1.
Align holes in fairing bracket with those at rear of steer-
9.
See Figure
2-165. Disconnect instrument nacelle
ing head. Standing on right side, insert bolts until they
switches and ambient temperature sensor from intercon-
exit fairing bracket on left side of motorcycle. Install lock-
nect harness as follows:
nuts and tighten to 20-30 ft-lbs (27.1-40.7 Nm).
● Instrument nacelle switch connector [105], 12-place
2.
Route ignition switch and handlebar switch control con-
Multilock.
duit through opening at top of fairing bracket. See Figure
2-171.
● Ambient temperature sensor connector [107], 3-
place Multilock.
3.
Route main harness and both radio ground and harness
ground ring terminals through opening on right side of
10.
See Figure 2-165. Draw branches of interconnect har-
fairing bracket. See Figure 2-171.
ness (terminating in odometer reset switch and speed-
4.
Install screw to fasten harness ground ring terminal and
ometer, tachometer, indicator lamps, instrument nacelle
switch and ambient temperature sensor connectors)
brake line P-clamp to front of upper fork bracket.
from instrument nacelle through tunnel of fairing bracket
5.
Draw wire harnesses and conduit out tunnel of fairing
to front of inner fairing.
bracket and pull as far forward as possible. Tightly wrap
clean shop towels around all conduit and connectors
11.
Separate any branches of the interconnect harness that
and secure with masking tape. See Figure 2-169.
may be intermingled with the main harness conduit.
Allow the interconnect harness to hang along the left
6.
Install right side instrument nacelle. See INSTRUMENT
side of the front fender.
NACELLE, INSTALLATION, in this section, steps 8-9.
12.
Capturing all connectors, tightly wrap clean shop towels
7.
Place protective material on top of front fender to protect
around the main harness conduit, handlebar switch con-
paint from scratches or other damage. Rest inner fairing
trol conduit, radio ground wire and radio antenna cable,
(with attached radio bracket and interconnect harness)
and secure with masking tape. See Figure 2-169.
on front fender.
13.
Remove four locknuts to release radio bracket and inner
8.
Place inner fairing over four fairing bracket studs while
fairing from studs of fairing bracket. See Figure 2-170.
feeding end of harness bundle through opening beneath
radio. See Figure 2-170. Verify that sides of inner fairing
14.
Lift inner fairing (with attached radio bracket and inter-
are positioned outboard of both fairing supports
(on
connect harness) from fairing bracket studs and move to
engine guards).
bench area.
9.
Install four locknuts to secure radio bracket and inner
NOTE
fairing to fairing bracket studs. Tighten locknuts to 96-
To remove the fairing bracket, proceed with steps 15-20.
144 in-lbs (10.9-16.3 Nm).
2-134
2004 Touring: Chassis
HOME
f2105x2x
Inner
Fairing
Outer Fairing
Hooks
Fairing
Stud
Bracket
Trim
Strip
Bolt
Locknut
Slot
Locknut
Radio
Opening
Bracket
Figure 2-170. Inner Fairing Assembly
10.
Draw the harness bundle as far forward as possible,
resting the end of the bundle on the front fender. See
f2231x2x
Left and Right
Figure 2-169.
Handlebar Controls
11.
Find branch of interconnect harness terminating in
odometer reset switch and speedometer, tachometer,
Ignition
indicator lamps, instrument nacelle switch and ambient
Switch
temperature sensor connectors. Feed connectors and
conduit from front of inner fairing through tunnel of fair-
ing bracket and then out through opening at top of fairing
bracket to instrument nacelle.
12.
See Figure 2-165. Connect instrument nacelle switches
and ambient temperature sensor to interconnect har-
ness as follows:
● Instrument nacelle switch connector [105], 12-place
Multilock.
● Ambient temperature sensor connector [107], 3-
place Multilock.
13.
Returning to front of inner fairing, remove shop towels
and masking tape from around the harness bundle. Sep-
arate radio ground and main harness, ignition switch and
Radio
handlebar switch control conduit.
Main
Ground
Harness
14.
See Figure 2-168. Connect handlebar switch controls to
interconnect harness. Connect radio ground. Proceed
Figure 2-171. Route Main Harness and Conduit
as follows:
Thru Fairing Bracket
● Left handlebar switch controls connector [24], 12-
place Deutsch (gray); T-stud on left side of radio
bracket.
● Radio ground; single spade and socket terminal;
● Right handlebar switch controls connector [22], 12-
below radio (left side).
place Deutsch (black); T-stud on left side of radio
15.
See Figure 2-168. Connect main harness to intercon-
bracket.
nect harness as follows:
2004 Touring: Chassis
2-135
HOME
● Main to interconnect harness connector [1], 12-
INSTALLATION
place Deutsch (black); below radio (right side).
● Main to interconnect harness connector [2], 12-
1.
Place spring inside hinge inserting spring pin into clos-
place Deutsch (gray); below radio (right side).
est hole. With coil and one spring pin positioned inside
● Main to interconnect harness connector [15], 4-
hinge, second spring pin is outside.
place Packard (black); below radio (right side).
2.
Place hinge into position capturing free end of external
● Main to interconnect harness connector [156], 6-
spring pin between ribs molded into glove box door.
place Deutsch (gray); below radio (right side).
3.
Install plastic barrels to hold hinge in door. Slot in barrel
16. See Figure 2-168. Connect ignition switch to main har-
prevents interference with spring pin installed between
ness. Connect radio antenna cable. Proceed as follows:
ribs of door. Push barrels in until tight.
● Ignition switch connector
[33],
4-place Packard
(black); inside fairing bracket tunnel (right side).
NOTE
● Radio antenna cable connector [51]; back of radio
Install new glove box door bumpers in inner fairing if dam-
(left side).
aged or missing. Insert tail of rubber bumper into hole, and
moving to front of inner fairing, pull anchor through hole.
17. Loop wire bundles and conduit as necessary to orient
connectors as shown in Figure 2-168. Install two new
4.
Place glove box door into position against inner fairing.
cable straps, one near the end of the left side loop and
Holding locknuts (with flat washers) at front of inner fair-
another near the end of the right side loop. Cut any
ing, use a T25 TORX drive head to tighten hinge screws.
excess cable strap material.
5.
To conceal glove door fasteners, snap screw cap cover
into place below hinge.
CAUTION
6.
Install the outer fairing. See OUTER FAIRING, INSTAL-
To avoid chafing wires of interconnect harness and pos-
LATION, in this section.
sible damage to slots of outer fairing during installation,
verify that trim strips are installed on hooks of radio
bracket.
18. Install the outer fairing. See OUTER FAIRING, INSTAL-
LATION, in this section.
19. Install left side of instrument nacelle. See INSTRUMENT
NACELLE, INSTALLATION, in this section, steps 5-7
and 9-10.
20. Install bezel. See BEZEL, INSTALLATION, in this sec-
tion.
GLOVE BOX DOOR/HINGE
REMOVAL
1.
Remove the outer fairing. See OUTER FAIRING,
REMOVAL, in this section.
2.
To access glove box door fasteners, pull out screw cap
cover below hinge.
3.
Holding locknuts at front of inner fairing, use a T25
TORX drive head to loosen hinge screws.
4. Hold glove box door closed as hinge screws are com-
pletely removed. If not held closed, door will pop open as
spring loaded hinge is released and door may be
dropped to the floor.
5. If hinge replacement is necessary, remove plastic bar-
rels to release hinge from door.
2-136
2004 Touring: Chassis
HOME
WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S)
2.31
1.
Standing at the front of the motorcycle, carefully insert
WINDSHIELD REMOVAL
the windshield brackets between the headlamp nacelle
and the passing bracket. Lower the windshield into posi-
1. See Figure 2-172. Standing at the front of the motorcy-
tion until the lower notches on the windshield brackets
cle, use a finger to raise the wireform latch springs on
are seated on the lower grommets.
both sides of the windshield.
2.
Gently push the top of the windshield toward the rear
2. Gently pull on the top of the windshield until the upper
until the upper notches fully engage the upper grom-
notches on the windshield brackets are free of the upper
mets. See Figure 2-172.
grommets.
3.
Push down on the wireform latch springs, so that they
overhang the rubber grommets. If some adjustment is
3. Carefully raise the windshield until the lower notches are
necessary, loosen the retaining screws and rotate the
free of the lower grommets.
latch springs into the proper position.
4. Remove windshield from motorcycle.
NACELLE REMOVAL (FLHR/C)
WINDSHIELD INSTALLATION
1.
Remove the windshield. See WINDSHIELD REMOVAL
on this page.
CAUTION
2.
Remove the Phillips screw at the bottom of the head-
lamp door (chrome ring). Remove the headlamp door.
To avoid scratching headlamp nacelle or passing lamp
bracket, be sure that all four notches on the windshield
3.
Remove the eight Phillips screws to free the headlamp
brackets are firmly seated on a rubber grommet.
housing from the headlamp nacelle.
Wireform
Headlamp
Latch Spring
Nacelle
Windshield
Clutch
Cable
Passing
Lamp Bracket
Upper
Grommet
f2278x2x
Figure 2-172. Windshield (FLHR/C)
2004 Touring: Chassis
2-137
HOME
10. Remove the grommets (and clutch cable clamp) from the
left and right side fork bracket studs.
Fork Lock
Plate
11. Raise the handlebar clamp shroud, and after separating
the halves of the headlamp nacelle slightly, slide the
Phillips
shroud forward running the shaft of the Phillips screw
Screw
down the gap. See Figure 2-174.
Handlebar
12. Reaching inside the headlamp nacelle, separate the pin
Clamp Shroud
and socket halves of the Accessory Switch and Passing
Lamp Switch connectors.
13. Carefully separate the halves of the headlamp nacelle
and remove from motorcycle.
Headlamp
Chrome
Nacelle
Strip
Left Side
NACELLE INSTALLATION (FLHR/C)
Trim
Strip
1.
Fit halves of the headlamp nacelle together engaging
the holes in the nacelle with the left and right side fork
bracket studs.
Flange
2.
Reaching inside the headlamp nacelle, mate pin and
Nut
socket halves of the Accessory Switch and Passing
Lamp Switch connectors.
Flat
3.
If disassembled, install screw assembly on the handle-
Washer
bar clamp shroud as shown in Figure 2-174.
4.
Part the halves of the headlamp nacelle slightly. With the
flat washer on the inboard side of the nacelle, slide the
Keps
shroud rearward running the shaft of the Phillips screw
Nut
down the gap. Position the shroud over the flange at the
top of the nacelle.
f2195x2x
5.
Mate the halves of the headlamp nacelle and tighten the
Phillips screw to 10-20 in-lbs (1.1-2.3 Nm).
Figure 2-173. Headlamp Nacelle Assembly
6.
Install two Phillips screws to secure the handlebar clamp
shroud to the fork lock mechanism. Install the fork lock
plate.
4.
Squeeze the two external tabs (if present) to remove the
wire connector at the back of the headlamp bulb.
Remove the headlamp housing assembly from the
motorcycle.
5.
Reaching inside the headlamp nacelle, remove the
flange nut to release the chrome strip at the top of the
nacelle. See Figure 2-173.
6.
Carefully pry off the fork lock plate at the rear of the han-
dlebar clamp shroud. Remove two Phillips screws
beneath the lock plate.
7.
Loosen the Phillips screw from tab at the front of the
handlebar clamp shroud (but do not remove).
8.
Remove the two acorn nuts from the left side fork
bracket studs. Remove acorn nuts from the right side
fork bracket studs.
Screw
Assembly
f1458b2x
9.
Cover the front fender with suitable material to protect
the fender paint. Remove the passing lamp bracket from
Figure 2-174. Handlebar Clamp Shroud and Screw
the left and right side fork bracket studs and carefully set
Assembly
on front fender.
2-138
2004 Touring: Chassis
HOME
1WARNING
To avoid possible damage to the brake hose, throttle
cables and/or handlebar switch wires, verify that trim
strips are installed on inside edges of the headlamp
nacelle. Cutting or severe chafing of the brake hose,
throttle cables and/or handlebar switch wires could
cause loss of function while riding, possibly resulting in
death or serious injury.
7.
Verify that trim strips are installed on inside edges of
headlamp nacelle. Install new trim strips if cracked, bro-
ken or missing.
f2194x2x
8.
Inserting the weld stud on the chrome strip into the hole
at the top of the headlamp nacelle, reach inside the
Figure 2-175. Remove Screw From Slot in Wind Deflector
nacelle to install flange nut. Tighten flange nut to 15-20
in-lbs (1.7-2.3 Nm).
9.
Install the grommets on the left and right side fork studs.
Screw
Assembly
10.
Slide the passing lamp bracket onto the left and right
side fork bracket studs. Verify that the four grommets are
in place on the inboard side of the passing lamp brack-
ets.
11.
Install the acorn nuts on the fork bracket studs and
tighten to 72-108 in-lbs (8.1-12.2 Nm). Be sure to cap-
ture the clutch cable clamp on the upper left stud before
installing the acorn nut.
12.
Install the wire connector at the back of headlamp bulb.
13.
Align holes in headlamp housing with those in headlamp
nacelle (headlamp door bracket at bottom). Install the
f2193x2x
eight Phillips screws.
14.
Fit the square-shaped portion of the headlamp door
Figure 2-176. Handlebar Clamp Shroud/Wind Deflector
spring into the slot at the top of the headlamp housing
and Screw Assembly
and then snap the headlamp door (chrome ring) into
place. Install the Phillips screw at the bottom of the
headlamp door.
5.
Carefully pry off the fork lock plate at the rear of the han-
15.
Install the windshield. See WINDSHIELD INSTALLA-
TION in this section.
dlebar clamp shroud. Remove two Phillips screws
beneath the lock plate.
6.
Loosen Phillips screw at front of wind deflector (but do
not remove). Reaching inside the headlamp nacelle,
NACELLE REMOVAL (FLHRS)
release screw head from slot in tab and then draw screw
assembly down and out through headlamp nacelle. See
1. Remove the Phillips screw at the bottom of the head-
Figure 2-175.
lamp door (chrome ring). Remove the headlamp door.
7.
Raise handlebar clamp shroud/wind deflector and
2. Remove the eight Phillips screws to free the headlamp
housing from the headlamp nacelle.
remove from motorcycle. See Figure 2-176.
3. Squeeze the two external tabs (if present) to remove the
NOTE
wire connector at the back of the headlamp bulb.
Remove the headlamp housing assembly from the
If damage requires separation of parts, remove three flange
motorcycle.
bolts to remove handlebar clamp shroud from wind deflector.
4. Reaching inside the headlamp nacelle, remove the
8.
Reaching inside the headlamp nacelle, separate the pin
flange nut to release the chrome strip at the top of the
and socket halves of the Accessory Switch connector.
nacelle.
2004 Touring: Chassis
2-139
HOME
9.
Using a T-40 TORX drive head, remove the left side fork
11.
Install the wire connector at the back of headlamp bulb.
bracket bolts (with flat washers). Remove the right side
fork bracket bolts (with flat washers).
12.
Align holes in headlamp housing with those in headlamp
nacelle (headlamp door bracket at bottom). Install the
10. Carefully separate the halves of the headlamp nacelle
eight Phillips screws.
and remove from motorcycle.
13.
Fit the square-shaped portion of the headlamp door
spring into the slot at the top of the headlamp housing
and then snap the headlamp door (chrome ring) into
NACELLE INSTALLATION (FLHRS)
place. Install the
Phillips
screw
at
the bottom of
the
headlamp door.
1.
Fit halves of the headlamp nacelle together aligning the
holes in the nacelle with those in the upper and lower
fork brackets.
2.
Start right side fork bracket bolts (with flat washers).
Start left side fork bracket bolts (with flat washers). Be
sure to capture clutch cable clamp when installing upper
fork bracket bolt on left side of motorcycle (open side of
clamp faces forward).
3.
Using a T-40 TORX drive head, alternately tighten the
fork bracket bolts to 15-20 ft-lbs (20-27 Nm) in a cross-
wise pattern.
4.
Reaching inside the headlamp nacelle, mate pin and
socket halves of the Accessory Switch connector.
5.
Position the handlebar clamp shroud/wind deflector on
flange at top of headlamp nacelle.
NOTE
If separated, install three flange bolts to fasten handlebar
clamp shroud to wind deflector. Alternately tighten bolts to
12-18 ft-lbs (16.3-24.4 Nm).
6.
If disassembled, assemble screw assembly as shown in
Figure 2-176.
7.
Holding screw assembly, reach inside headlamp nacelle
and insert head of Phillips screw up through opening to
engage slot in tab at front of wind deflector. See Figure
2-175. Tighten screw to 10-20 in-lbs (1.1-2.3 Nm).
8.
Install two Phillips screws to secure the handlebar clamp
shroud to the fork lock mechanism. Install the fork lock
plate.
1WARNING
To avoid possible damage to the brake hose, throttle
cables and/or handlebar switch wires, verify that trim
strips are installed on inside edges of the headlamp
nacelle. Cutting or severe chafing of the brake hose,
throttle cables and/or handlebar switch wires could
cause loss of function while riding, possibly resulting in
death or serious injury.
9. Verify that trim strips are installed on inside edges of
headlamp nacelle. Install new trim strips if cracked, bro-
ken or missing.
10. Inserting the weld stud on the chrome strip into the hole
at the top of the headlamp nacelle, reach inside the
nacelle to install flange nut. Tighten flange nut to 15-20
in-lbs (1.7-2.3 Nm).
2-140
2004 Touring: Chassis
HOME
FRONT FENDER
2.32
REMOVAL
Front Fender Tip Lamp [32]
NOTE
If fender tip lamp is absent, start procedure at step 5.
1.
FLHT/C/U: Reaching in below the fairing cap on the left
side of the steering head, locate the front fender tip lamp
connector (black 2-place Multilock). See Figure 2-177.
Remove the outer fairing only if necessary. See Section
2.29 UPPER FAIRING/WINDSHIELD
(FLHT/C/U),
OUTER FAIRING/WINDSHIELD, REMOVAL.
FLHR: Remove the Phillips screw at the bottom of the
headlamp door (chrome ring). Remove the headlamp
door. Remove the eight Phillips screws to free the head-
lamp housing from the headlamp nacelle. Squeeze the
two external tabs to remove the wire connector at the
back of the headlamp bulb. Remove the headlamp hous-
ing assembly from the vehicle. Locate the front fender tip
f2238x8x
lamp connector (black 2-place Multilock). See Figure 2-
178.
Figure 2-177. Inner Fairing (FLHT/C/U)
2.
Depress the button on the socket terminal side of the
connector and pull apart the pin and socket halves.
3.
Draw socket connector down to fender area.
4.
Carefully cut cable strap to release front fender tip lamp
wires from brake line hose.
5.
Place the motorcycle on a hydraulic center stand with
the front wheel raised off the ground.
6.
Use shop rag or tape to protect fender area adjacent to
caliper, as incidental contact can occur during caliper
removal.
7.
Remove both the upper and lower mounting bolts from
lugs of front fork leg to release brake caliper assembly.
Lift caliper upward to remove from brake disc. Using thru
hole, cable strap caliper to rail of engine guard. Repeat
step to release caliper on opposite side of wheel.
Front Fender
NOTE
Tip Lamp [32]
Do not operate the front brake hand lever with the front wheel
f2212x8x
Used on FLHR Only
removed or the caliper pistons may be forced out. Reseating
pistons requires disassembly of the caliper.
Figure 2-178. Headlamp Nacelle (FLHRC)
8. Insert screwdriver or steel rod through hole in axle on
right side of vehicle. While holding axle stationary,
remove the axle nut, lockwasher and flat washer on the
left side.
10. With soft mallet, tap axle toward right side of vehicle until
9. Loosen the two axle holder nuts at bottom of right side
loose. Pull axle from hub while supporting wheel.
fork leg.
Remove wheel.
2004 Touring: Chassis
2-141
Большое спасибо!
Ваше мнение очень важно для нас.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст