Harley Davidson 2004 Touring Models. Service Manual — page 38
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ENGINE OIL FLOW
Gauge
CAUTION
The oiling system is carefully designed for optimum effi-
ciency. All oil holes and passageways are specially
sized. Exercise caution to avoid enlarging oil holes dur-
ing cleaning. Any modification of the oiling system will
adversely affect oil pressure or cooling and lubrication
Banjo
Adapter
efficiency.
Bolt
Part No. HD-96921-110
Oil Feed (Figures 3-6, 3-7)
Washers
Oil flows from the oil pan through a passageway at the front
of the transmission housing into a flexible hose clamped to
Figure 3-4. Oil Pressure Gauge
the lower fitting (A1) at the rear right side of the crankcase.
(Part No. HD-96921-52B)
Running through a passageway in the crankcase, the oil exits
a hole in the crankcase flange (B2) and enters a hole on the
f1646x3x
inboard side of the cam support plate. Passing through a
channel in the cam support plate (A3), the oil enters the feed
side of the oil pump. See OIL PUMP OPERATION. The feed
Adapter
gerotors of the pump direct the flow up a second channel in
the cam support plate (A4).
A drilling in this channel connects to a pressure relief valve
mounted in the bypass port of the cam support plate (A5).
When the oil pressure exceeds the setting of the valve spring
Oil
Filter
(35 psi), the orifice opens to bypass excess oil back to the
feed side of the pump (A3).
Oil not returned to the feed side exits a hole on the inboard
side of the cam support plate and passes through a hole in
the crankcase flange (B6). Flowing through a passageway in
the crankcase, where a reading is taken by the oil pressure
sender (B7), the oil exits the lower hole in the oil filter mount
(D8).
Figure 3-5. Install Adapter and Oil Pressure Gauge
After circulating through the oil filter, the flow of oil is directed
back into the crankcase through the upper hole in the oil filter
mount (D9). Exiting a passageway in the crankcase through
NOTE
a hole in the crankcase flange (B10), the flow of oil reenters
If reusing oil pressure switch/sender, apply Loctite Pipe Seal-
the cam support plate.
ant with Teflon 565 to threads.
Filtered oil is then routed to the top and bottom ends of the
engine, as described below.
11. Start oil pressure switch/sender into crankcase bore.
12. On FLHR/C/S models, use a 15/16 inch Open End Crow
Top End (Figures 3-6, 3-7)
Foot (Snap-On FC30B) to tighten oil pressure switch to
96-120 in-lbs (11-14 Nm). On FLHT/C/U and FLTR
Oil passes through a channel in the cam support plate exiting
models, use 1-1/16 inch Open End Crow Foot (Snap-On
the inboard side through two holes near the top (A11, A12).
FC34A) to tighten oil pressure sender to same torque.
Entering two holes in the crankcase flange (B13, B14), one
leading to the front cylinder and the other to the rear, the oil
13. On FLHR/C/S models, install elbow on post of oil pres-
travels through passageways in the crankcase to the hydrau-
sure switch. On FLHT/C/U and FLTR models, install
lic lifter bores (D15).
Packard connector to oil pressure sender.
Exiting a hole in each lifter bore (E16), the oil flows around
NOTE
the lifter and enters a hole at the side of the lifter body. As the
If wire socket terminal requires replacement, see APPENDIX
chamber inside the lifter body is filled, the push rod socket
B.5 SEALED BUTT SPLICE CONNECTORS.
rises to achieve the no-lash fit of the valve train components.
The flow of oil then exits a hole centered in the lifter socket
14. Test oil pressure switch/sender for proper operation.
and runs up the hollow push rods.
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2004 Touring: Engine
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f1581b3x
A
Cam Support Plate
12
11
26
4
38
36
1
3
5
Crankshaft
Bushing
13
14
10
B
24
23
7
37
6
2
f1573b3x
Oil Pump
35
25
Cam Needle Bearings
C
Crankshaft
Bearing
34
f1580b3x
Figure 3-6. Engine Oil Flow - Cam Support Plate/Right Crankcase Half
2004 Touring: Engine
3-9
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NOTE
Oil spray from each piston jet also enters a hole at the bottom
Note that there is one additional hole drilled into the inside
of each pin boss (O30) for lubrication of the piston pin.
lifter bores- while the oblong hole circulates oil around the
Another hole at the top of the connecting rod (D31) allows a
lifter body as described, the round hole (E17) feeds oil to the
portion of the oil to reach the upper rod bushing.
piston jets in the flywheel compartment.
Surplus oil falls back to the bottom of the flywheel compart-
Exiting holes at the top of the hollow push rods, oil enters a
ment where it collects in the sump area (P32). Oil in the
hole at the bottom of the intake and exhaust rocker arms.
sump is drawn to the cam compartment through an internal
Lubricating the rocker arm bushings, oil flows down the
channel (P33, C34) that connects with the second scavenge
rocker arm shafts and exits a pin hole in the outboard side of
lobe of the oil pump (B35).
each rocker arm housing (F18) where it sprays the valve
springs and the top of the valve stem.
Oil Return (Figures 3-6, 3-8)
Oil runs down to the low side of the rocker housing and
enters the exhaust valve spring pocket where a drain hole
The “dual kidney” designation given to the oil pump refers to
(G19) leads to a passageway in the cylinder head casting.
its two scavenging functions, whereby it simultaneously
Oil exits the bottom of the cylinder head and passes through
draws oil from both the cam and flywheel compartments.
a ring dowel (H20) on the “down side” of the cylinder flange.
The oil runs through a vertical passageway in the cylinder,
Oil sucked up by the scavenge lobes passes through the
passes through a second ring dowel on the “down side” of
scavenge gerotors of the oil pump and is directed through a
the cylinder deck (I21) and enters the left crankcase half.
return channel in the cam support plate (A36). See OIL
PUMP OPERATION.
Flowing through a horizontal passageway in the left crank-
case half (J22), oil runs through a third ring dowel (K23) to
Exiting a hole on the inboard side of the cam support plate,
the right crankcase half where it travels through another pas-
the oil enters a hole in the crankcase flange (B37).
sageway before emptying into the cam compartment (B23,
B24).
The oil flows through a passageway in the crankcase and
Oil collecting in the cam compartment is picked up by one of
exits the upper fitting at the rear right side of the crankcase
two scavenge lobes on the oil pump (B25).
(A38). Passing through a flexible hose connection, the flow of
oil runs through a passageway at the front of the transmis-
Bottom End (Figures 3-6, 3-7, 3-8)
sion housing (Q39) before emptying into the oil pan at the
front of the baffle (R40).
Oil travels down the center passage of the cam support plate
(A26) and sprays out through pin holes on each side of the
The oil flows to the rear of the oil pan along each side of the
casting to lubricate both the primary and secondary cam
chains. Oil also passes through a hole in the crankshaft
baffle. Spring tension holds the unit tight against the bottom
of the pan to prevent oil from entering or escaping around the
bushing where the flow enters a drilling in the crankshaft
(L27).
perimeter of the baffle. At the back of the oil pan, the oil
enters the open side of the baffle where it is redirected for-
Oil runs down the center of the crankshaft and then up a
ward. The baffle plates slow the circulation of the oil through
cross drilling into the right side of the flywheel. The flow exits
the pan to enhance cooling.
a drilling in the crank pin bore, enters the crank pin and then
sprays out through three holes to lubricate the lower rod
Oil pickup occurs in the front compartment of the baffle
bearing set.
where a passageway in the casting (S41) directs the flow
The oil splash and mist created by the action of the flywheel
upward. Passing through a second passageway in the trans-
lubricates the crankshaft bearing and the camshaft needle
mission housing (Q42), the flow of oil enters the flexible hose
bearings in the right crankcase half. This same action serves
connection (A1) to repeat the circuit.
to lubricate the sprocket shaft bearing in the left crankcase
half (M28).
Also note that a third flexible hose clamped to a fitting behind
the rear lifter cover connects the cam compartment with the
Since the oil mist also lubricates the cylinder walls, three
oil filler spout. This crankcase breather connection provides
holes on each side of the piston (in the area of the third ring
the pressure balance necessary for oil circulation.
land) evacuate excess oil scraped from the walls on the pis-
ton downstroke.
Oil Pump Operation
The piston jets (N29), which receive a supply of oil from the
intake lifter bores, spray the underside of the piston for cool-
The oil pump consists of a housing containing two gerotor
ing of the piston crown and skirt area. A check valve in each
gear sets, one feed and the other scavenge. Driven by the
jet opens only when the oil pressure reaches 12-15 psi, at
crankshaft, the feed gerotor set distributes oil to the engine,
which point the engine is operating above idle speed. At idle
while the scavenge gerotor set draws oil from the cam and
speeds (9-12 psi), the valve remains closed to prevent over
flywheel compartments and returns it to the oil pan.
oiling and to ensure proper system operating pressure.
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2004 Touring: Engine
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15
D
31
H
20
9
8
E
I
17
16
21
F
J
22
18
G
K
19
23
Figure 3-7. Engine Oil Flow - Top End
2004 Touring: Engine
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L
P
27
32
33
M
Q
28
42
39
40
N
R
29
O
30
S
41
Figure 3-8. Engine Oil Flow - Bottom End
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2004 Touring: Engine
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Each gerotor gear set has two parts, an inner and outer gero-
tor. The inner and outer gerotors have fixed centers that are
f1562x3x
slightly offset to one another. Also, the inner gerotor has one
Seal
less tooth.
As the crankshaft rotates, the cavity between the inner and
Inner
outer gerotors on the inlet side of the pump increases in vol-
Oil In
Gerotor
ume. This creates a vacuum causing oil to be drawn in. The
cavity continues to increase until the volume is equivalent to
that of the missing tooth on the inner gerotor. Also note that
the inlet and outlet sides of the pump are sealed by the tips
A
and lobes of the inner and outer gerotors. See A of Figure 3-
9.
Continued rotation moves the pocket of oil to the outlet side
of the pump. In this area, the cavity decreases in volume as
the gerotor teeth mesh causing the oil to be squeezed out the
Outer
discharge port. As the cavity on the outlet side is emptied, a
Gerotor
second seal formed by the tips and lobes of the inner and
outer gerotors prevents oil on the outlet side (high pressure)
from being transferred to the inlet side (low pressure). See B
of Figure 3-9.
In operation, the gerotors provide a continuous flow of oil.
See C of Figure 3-9.
Breather Operation
Oil Out
NOTE
The crankcase breather system relieves crankcase pressure
B
produced by the downstroke of the pistons and allows crank-
case vapors vacated from each cylinder to be directed into
the air filter element. Through effective recirculation of crank-
case vapors, the system serves to eliminate the pollutants
Seal
normally discharged from the crankcase.
As each piston pushes downward on its power and intake
stroke, displaced air in the flywheel compartment is vented
through the crankshaft bearing into the cam compartment
and then up the push rod covers into the rocker housing.
Air rushes under the rocker arm support plate, which is ele-
vated slightly, and passes through an opening at the bottom
of the plate to enter the breather baffle compartment.
C
In the baffle compartment, the flow of air passes upward
through the oil filter gauze, where the oil is removed from the
air. Two pin holes in the rocker arm support plate act as drain
holes to rid the baffle compartment of the oil separated from
the air.
Passing through the oil filter gauze, the flow of air passes
through the umbrella valve into the breather compartment.
Figure 3-9. Gerotor Operation
The flaps of the umbrella valve only allow air to be vented
one way, rising to allow the passage of air, but then falling
back into place to seal the vent holes as the flow of air stops.
Flowing
through the cylinder head passageway, the
air
passes through a drilling in the air cleaner backplate bolt and
In the breather compartment, the flow of air reverses direc-
then through a breather tube into the air filter element.
tion passing downward through holes aligned in the breather
baffle, rocker arm support plate and rocker housing. Exiting
NOTE
the rocker housing, the air enters a passageway cast into the
top of the cylinder head. Proper orientation of the rocker
Air cleaner mounting without installation of the breather
housing gasket is critical for effective sealing of this passage-
tubes allows crankcase vapors to be vented into the atmo-
way.
sphere in violation of legal emissions standards.
2004 Touring: Engine
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HOW TO USE THIS SECTION
3.4
GENERAL
TOP END SERVICE
Three basic levels of service are presented in this section:
Engine in Chassis
Engine Removed
top end overhaul, bottom end overhaul and subassembly ser-
vice and repair. The manner in which these instructions are
used depends upon the level of disassembly required.
Stripping
Removing Engine
Motorcycle for
From Chassis.
Service.
Top End Overhaul
Top End Overhaul,
Top End Overhaul,
Disassembly.
If servicing only cylinder head components, pistons, cylinders
Disassembly.
and/or upper rod bushings, see Section 3.5 STRIPPING
Subassembly
MOTORCYCLE FOR SERVICE, and then proceed to Section
Subassembly
Service and Repair-
3.9 TOP END OVERHAUL, DISASSEMBLY. During top end
Service and Repair-
Top End.
disassembly, the engine may be left in the chassis for ser-
Top End.
vice.
Top End Overhaul,
Top End Overhaul,
Assembly.
NOTE
Assembly.
If the engine is to be removed from the chassis, see Section
Installing Engine
3.7 REMOVING ENGINE FROM CHASSIS in lieu of Section
Assembling
In Chassis.
3.5 STRIPPING MOTORCYCLE FOR SERVICE.
Motorcycle After
In the top end disassembly instructions, references are made
Stripping.
to Section 3.11 SUBASSEMBLY SERVICE AND REPAIR for
service of all top end subassemblies.
BOTTOM END SERVICE
To rebuild the engine after a top end overhaul is complete,
perform the steps under Section 3.9 TOP END OVERHAUL,
Engine in Chassis
Engine Removed
ASSEMBLY, immediately following the disassembly instruc-
tions. Then, refer to Section 3.6 ASSEMBLING MOTORCY-
Cam
Flywheel Compartment
CLE AFTER STRIPPING to complete the project.
Compartment.
or Complete Engine
Overhaul.
NOTE
Stripping
For clarity, all artwork in this section shows the engine
Motorcycle for
removed from the chassis for service.
Removing Engine
Service.
From Chassis.
Top End Overhaul,
Bottom End Overhaul
Top End Overhaul,
Disassembly,
Disassembly.
Bottom end service may require either partial or complete
Steps 1-11.
disassembly of the engine. Servicing components in the cam
Bottom End
Bottom End
compartment requires only partial disassembly, while servic-
Overhaul,
Overhaul,
ing those in the flywheel compartment requires complete dis-
Disassembly.
Disassembly,
assembly. An easy rule to remember is that any time the
Steps 1-14.
crankcase halves must be split, complete disassembly needs
Subassembly
Service and Repair-
to occur. The cam compartment can be accessed through
Subassembly
Top End.
removal of the cam cover making complete engine disassem-
Service and Repair-
bly unnecessary.
Bottom End.
Subassembly
During bottom end service that requires complete disassem-
Service and Repair-
Bottom End
bly, the engine must be removed from the chassis and placed
Bottom End.
Overhaul,
in an engine stand. To begin, see Section 3.7 REMOVING
Assembly,
ENGINE FROM CHASSIS.
Bottom End
Steps 6-25.
Overhaul,
After the motorcycle has been stripped and the engine
Assembly.
Top End Overhaul,
removed, follow all of the steps under Section 3.9 TOP END
Assembly,
OVERHAUL, DISASSEMBLY. When finished, continue with
Top End Overhaul,
Steps 29-39.
disassembly of the bottom half by performing those steps
Assembly.
listed under Section 3.10 BOTTOM END OVERHAUL, DIS-
Assembling
ASSEMBLY.
Installing Engine
Motorcycle After
In Chassis.
Stripping.
Figure 3-10. Top/Bottom End Service
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2004 Touring: Engine
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As with the top end disassembly instructions, references are
For example, if just installing new cams, then refer to Section
made to Section
3.11 SUBASSEMBLY SERVICE AND
3.11 SUBASSEMBLY SERVICE AND REPAIR, CAM SUP-
REPAIR for service of bottom end subassemblies.
PORT PLATE.
Since it is standard practice to inspect and clean all oil pas-
The steps under Section 3.9 TOP END OVERHAUL and Sec-
sages when the engine is completely disassembled, a
tion 3.10 BOTTOM END OVERHAUL that need to be fol-
detailed explanation of the engine oil circuit is presented
lowed for the removal and installation of the cam support
under Section 3.3 GENERAL INFORMATION, ENGINE OIL
plate are given.
FLOW.
Furthermore, detailed instructions for disassembling, clean-
To rebuild the engine after a bottom end overhaul is com-
ing, inspecting, replacing and assembling cam support plate
plete, perform the steps under Section 3.10 BOTTOM END
components are provided.
OVERHAUL, ASSEMBLY, and then proceed to Section 3.9
TOP END OVERHAUL, ASSEMBLY, to rebuild the upper
end.
Once the engine is assembled, refer to Section 3.8 INSTALL-
ING ENGINE IN CHASSIS to complete the project.
The flow charts on the preceding page show how the same
subsections are used for various levels of service.
Subassembly Service and Repair
Finally, if the task entails servicing of only one particular sub-
assembly, then move directly to Section 3.11 SUBASSEM-
BLY SERVICE AND REPAIR for all service instructions.
2004 Touring: Engine
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STRIPPING MOTORCYCLE FOR SERVICE
3.5
e.
Pull and twist on crossover pipe to remove left side
PROCEDURE
exhaust from vehicle. For best results, be sure to
allow sufficient time for the penetrating oil to work.
NOTE
f.
Remove TORCA clamp assembly from crossover
If performing top end service (or both cam compartment and
pipe and discard.
top end), follow steps 1-21. If servicing cam compartment
NOTE
components only, perform steps 1-12.
To ensure sealing integrity of TORCA clamps and prevent the
1.
Drain and remove fuel tank. Proceed as follows:
possibility of leakage, Harley-Davidson recommends that
TORCA assemblies be discarded and replaced each time
Carbureted: See Section 4.7 FUEL TANK (CARBU-
they are removed.
RETED), COMPLETE REMOVAL, FLHT/C, or FLHR/S.
g.
Moving to right side of vehicle, open two worm drive
Fuel Injected: See Section
9.4 FUEL TANK (FUEL
clamps and release heat shield from front header
INJECTED), COMPLETE REMOVAL, FLHT/C/U/I,
pipe. Using an impact wrench with long 1/2 inch
FLTRI, or FLHR/C/S/I.
swivel socket, remove two exhaust flange nuts to
release front header pipe from studs of front cylin-
2.
Remove left side saddlebag. See Section 2.25 SAD-
der head. Slide exhaust flange down header pipe to
DLEBAG, REMOVAL.
improve clearance around exhaust port.
3.
Gently pull left side cover from frame downtubes (no
h.
Open two worm drive clamps and release heat
tools required).
shield from rear header pipe. Remove two exhaust
4.
On Ultra models, hold locknut at bottom of left fairing
flange nuts to release rear header pipe from studs
lower, and using a T40 TORX drive head, turn inside
of rear cylinder head.
screw to free assembly from engine guard clamp. Dis-
i.
Open two worm drive clamps to release heat shield
card rubber washer.
over front header pipe to rear header pipe connec-
5.
Repeat steps 2-4 to remove saddlebag, side cover and
tion (outboard of transmission side door).
fairing lower on right side of vehicle.
j.
Remove bolt (with flat washer and locknut) from
transmission exhaust bracket clamp on front header
6.
Remove the air cleaner and backplate. See Section 4.5
pipe. Use a channel lock to open clamp and then
AIR CLEANER, REMOVAL.
remove from header pipe and transmission exhaust
7.
Remove two allen head socket screws (with lockwashers
bracket.
and flat washers) to release right side front footboard
k.
Remove two bolts (with lockwashers) to detach right
brackets from frame weldment. For best results,
side muffler from the lower saddlebag support rail.
approach from left side of vehicle using a 3/8 inch ball
allen with extension.
l.
Depressing rear brake pedal, remove right side
exhaust from vehicle.
8.
Remove exhaust system in two sections as follows:
m.
Remove and discard gaskets from front and rear
a. Open two worm drive clamps to release heat shield
exhaust ports.
over rear header pipe to crossover pipe connection
(above starter).
9.
Moving to left side of vehicle, pull boots on spark plug
cables to release from spark plug and ignition coil tow-
b. Loosen TORCA clamp between rear header pipe
ers. Release cables from three cable clips at bottom of
and crossover pipe. Remove Keps nut and pull
frame backbone.
bracket tab and stud from slots in TORCA clamp
10.
Remove spark plugs.
and exhaust support bracket.
11.
Pull external latch outward and use rocking motion to
c. Spray PB Blaster or other suitable penetrating oil in
remove electrical connector from left side of ignition coil.
and around joint between rear header pipe and
crossover pipe.
12.
Pull sides of ignition coil bracket outward to remove from
bosses of front fuel tank mount.
d. Moving to left side of vehicle, remove two bolts (with
lockwashers) to detach left side muffler from the
13.
Remove connections to carburetor or induction module.
lower saddlebag support rail.
Proceed as follows:
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2004 Touring: Engine
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Carbureted:
a. Remove right side allen head socket screws from
front and rear cylinder head flange adapters. For
a. Standing on left side of vehicle, remove electrical
best results, use a long 1/4 inch ball allen head
connector from manifold absolute pressure (MAP)
socket with end driver 4 inches long.
sensor at top of intake manifold.
b. Moving to opposite side of vehicle, just loosen left
b. Locate the fuel enrichener knob under the left side
side allen head socket screws from flange adapters.
of the fuel tank, and loosen hex nut at backside of
Slots in flanges make removal of left side screws
mounting bracket. Slide cable assembly free of slot
unnecessary.
in mounting bracket.
c. Remove intake manifold/carburetor or induction
Fuel Injected:
module from right side of vehicle.
a. Standing on right side of vehicle, remove idle air
18.
Standing on left side of vehicle, remove two hex head
control and manifold absolute pressure sensor con-
bolts (with flat washers) to release top engine mounting
nectors. Pull external latch(es) outward and use
bracket from cylinder heads.
rocking motion to separate pin and socket halves.
19.
Leaving ground wire ring terminal in place, detach
b. Depress wire form to remove electrical connectors
socket terminal of yellow lead from spade contact at
from front and rear fuel injectors.
back of horn. Release wire conduit from J-clamp.
c. Remove throttle position sensor and intake air tem-
20.
Moving to right side of vehicle, turn hex head bolt to
perature sensor connectors.
release stabilizer link from frame weldment.
d. Moving to left side of vehicle, pull back boot to
21.
Remove horn, top engine mounting bracket and stabi-
reveal engine temperature sensor at back of front
lizer link as an assembly.
cylinder. Pull external latch outward and remove
connector. Cut cable strap to release conduit from
horn bracket.
e. Tuck free ends of EFI wire harness under main wire
harness on frame backbone to keep conduit and
connectors out of the way.
14.
Remove idle and throttle control cables as follows:
Carbureted: Using a needle nose pliers, carefully pull
idle cable barrel from upper inboard hole in throttle
wheel. Pull throttle cable barrel from remaining hole.
Release idle and throttle cables from guides in throttle
cable bracket.
Fuel Injected: Using a needle nose pliers, carefully pull
idle cable barrel from upper hole in throttle wheel. Pull
throttle cable barrel from lower hole. Using slots, release
idle and throttle cables from guides in throttle cable
bracket.
15.
Free idle and throttle control cables from J-clamp fas-
tened to right side of frame backbone. Move cables up
and out of the way.
16.
If equipped with cruise control, remove E-clip from
sleeve at end of cruise cable housing. Using slot,
remove cable housing from cable guide in throttle cable
bracket. Push the plastic end fitting on the cruise cable
to the outboard side to release from wheel pin. Move
cable up and out of the way.
17.
Remove intake manifold/carburetor or induction module.
Proceed as follows:
2004 Touring: Engine
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HOME
ASSEMBLING MOTORCYCLE AFTER STRIPPING
3.6
2.
Install horn, top engine mounting bracket and stabilizer
PROCEDURE
link as an assembly. Proceed as follows:
a. Moving to right side of vehicle, turn hex head bolt to
NOTE
secure stabilizer link to frame weldment. Tighten
If top end service was performed (or both cam compartment
bolt to 18-22 ft-lbs (24-30 Nm).
and top end), follow steps 1-19. If only cam compartment
b. Attach socket terminal of yellow lead to spade con-
components were serviced, perform steps 8-18.
tact at back of horn. Capture wire conduit in J-
clamp.
1.
Install intake manifold/carburetor or induction module.
Proceed as follows:
c. Standing on left side of vehicle, install two hex head
bolts
(with flat washers) to secure top engine
a.
With the counterbore facing outward, slide cylinder
mounting bracket to front and rear cylinder heads.
head flange adapters onto outlet ports of intake
Alternately tighten bolts to 35-40 ft-lbs (48-54 Nm).
manifold/induction module. The flange adapters are
not interchangeable. Look next to the slotted bolt
3.
If equipped with cruise control, slide groove in cruise
hole for a stamp that indicates F(ront) and R(ear)
cable end fitting over cap of wheel pin. Push on end fit-
cylinder.
ting until it snaps in place. Using slot, slip cruise cable
housing into cable guide in throttle cable bracket. Install
b.
Place a new seal in each flange adapter with the
new E-clip on sleeve at end of cruise cable housing.
beveled side in against the counterbore.
4.
Route idle and throttle control cables through J-clamp
c.
Standing on right side of engine, slide intake mani-
fastened to right side of frame backbone.
fold/induction module toward installed position so
that open-ended slots on flange adapters begin to
5.
Install idle and throttle control cables as follows:
engage allen head socket screws loosely installed
Carbureted: Install sleeve on throttle cable housing into
on left side.
shorter cable guide in throttle cable bracket. Drawing
d.
Align fixed holes in flange adapters with those in
throttle cable downward, fit barrel end into lower out-
board hole in throttle wheel. Install sleeve and spring on
cylinder heads and start allen head socket screws.
For best results, use a long 1/4 inch ball allen head
idle cable housing into longer cable guide inserting bar-
rel end into upper inboard hole in throttle wheel.
socket with end driver 4 inches long.
Induction Module:Install sleeve on throttle cable hous-
e.
Use the air cleaner backplate or INDUCTION SYS-
ing into shorter cable guide at top of throttle cable
TEM ALIGNMENT BRACKET
(P&A Part No.
bracket. Drawing throttle cable downward, fit barrel end
40054-01) to properly locate carburetor/induction
into lower hole in throttle wheel. Install sleeve and spring
module. Proceed as follows:
on idle cable housing into longer cable guide at bottom
Backplate: Install two breather bolts to fasten back-
of throttle cable bracket inserting barrel end into upper
plate to front and rear cylinder heads. Install three
hole in throttle wheel.
T27 TORX screws to secure backplate to face of
6.
Adjust cables as necessary to keep barrel ends from dis-
carburetor/induction module.
lodging. Verify that cables are seated in channel of throt-
Alignment bracket: Fitting pins on inboard side
tle wheel. Verify operation by turning throttle grip and
into holes in face of carburetor/induction module,
observing cable action.
install two breather bolts to fasten bracket to front
7.
Install connections to carburetor or induction module.
and rear cylinder heads.
Standing on left side of vehicle, proceed as follows:
f.
Tighten allen head socket screw in fixed holes of
Carbureted:
flange adapters until snug. Moving to left side of
engine, tighten screws in slotted holes to 96-144 in-
a. Moving to left side of vehicle, install electrical con-
lbs (10.9-16.3 Nm).
nector to manifold absolute pressure (MAP) sensor
at top of intake manifold.
g.
Remove breather bolts and T27 TORX screws to
b. Slide threaded portion of enrichener cable into slot
remove backplate, if installed.
of mounting bracket. Flat on threads must face rear
h.
Tighten allen head socket screws in fixed holes of
of vehicle for script on enrichener knob to be right
flange adapters to 96-144 in-lbs (10.9-16.3 Nm).
side up. With the external tooth lockwasher and hex
nut positioned on the inboard side of the mounting
i.
Remove breather bolts to remove alignment
bracket, tighten hex nut to 20-35 in-lbs (2.3-4.0
bracket, if installed.
Nm).
3-18
2004 Touring: Engine
HOME
Fuel Injected:
●
Using a long 1/2 inch swivel socket, tighten the top
nut of the front cylinder head exhaust flange to 9-18
a. Install electrical connectors on fuel injectors.
in-lbs (1-2 Nm). Tighten the bottom nut to 100-120
b. Install manifold absolute pressure sensor and idle
in-lbs (11.3-13.6 Nm). Final tighten the top nut to
air control connectors.
100-120 in-lbs (11.3-13.6 Nm).
●
Tighten the bottom nut of the rear cylinder head
c. Install intake air temperature sensor and throttle
exhaust flange to 9-18 in-lbs (1-2 Nm). Tighten the
position sensor connectors.
top nut to
100-120 in-lbs (11.3-13.6 Nm). Final
d. Moving to left side of vehicle, install connector to
tighten the bottom nut to 100-120 in-lbs (11.3-13.6
engine temperature sensor at back of front cylinder.
Nm).
Pull boot over sensor to keep out dirt and debris.
●
Tighten the transmission exhaust bracket clamp bolt
Install new cable strap to secure connector conduit
to 60-96 in-lbs (6.8-10.8 Nm).
to horn bracket.
●
Tighten the two bolts (with lockwashers) to fasten
8.
Install exhaust system as follows:
the right side muffler to the lower saddlebag support
rail.
a. Install new gaskets in both the front and rear cylin-
der head exhaust ports (with the tapered side out).
●
Tighten the two bolts (with lockwashers) to fasten
the left side muffler to the lower saddlebag support
b. Place right side exhaust into position on vehicle and
rail.
start two exhaust flange nuts to secure front header
●
Verify that all exhaust pipes are in alignment and do
pipe to studs of front cylinder head.
not contact the vehicle frame or mounted compo-
c. Start two bolts (with lockwashers) to secure right
nents.
side muffler to the lower saddlebag support rail.
●
Tighten the TORCA clamp between the rear header
pipe and crossover pipe to 45-60 ft-lbs (61-81 Nm).
d. Start two exhaust flange nuts to secure rear header
pipe to studs of rear cylinder head.
●
Tighten Keps nut securing bracket tab to exhaust
support bracket.
e. Engaging transmission exhaust bracket, capture
front header pipe in transmission exhaust bracket
clamp. Use a channel lock to close clamp, if neces-
CAUTION
sary. Finger tighten clamp bolt (with flat washer and
Verify that the heat shields do not contact the vehicle
locknut).
frame or any mounted components. Contact will cancel
the effect of the rubber isolation mounts and transmit
NOTE
vibration to the rider via the vehicle frame.
To ensure sealing integrity of TORCA clamps and prevent the
possibility of leakage, Harley-Davidson recommends that
NOTE
TORCA assemblies be discarded and replaced each time
Position worm drive clamps so that screws are on the out-
they are removed.
board side in the most accessible position.
f.
Moving to left side of vehicle, slide new TORCA
k. Open worm drive clamps and install heat shields as
clamp assembly onto crossover pipe.
follows:
g. Twist and push left side exhaust onto crossover
● Over front header pipe (below exhaust port).
pipe.
● Over rear header pipe (below exhaust port).
h. Start two bolts (with lockwashers) to secure left side
● Over front header pipe to rear header pipe connec-
muffler to the lower saddlebag support rail.
tion (outboard of transmission side door).
i.
Returning to left side of vehicle, position TORCA
● Over rear header pipe to crossover pipe connection
clamp between rear header pipe and crossover
(above starter).
pipe. Fit bracket tab into slot of TORCA clamp
engaging stud in slot of exhaust support bracket.
l.
Position each worm drive clamp so that screw is on
Start Keps nut on stud.
the outboard side in the most accessible position
and then tighten to 20-40 in-lbs (2.3-4.5 Nm).
CAUTION
9.
Insert two allen head socket screws (with lockwashers
and flat washers) through frame weldment into right side
Verify that the exhaust pipes do not contact the vehicle
front footboard brackets. For best results, approach from
frame or any mounted components. Contact will cancel
left side of vehicle using a 3/8 inch ball allen with exten-
the effect of the rubber isolation mounts and transmit
sion.
vibration to the rider via the vehicle frame.
10. Install the backplate and air cleaner. See Section 4.5
j.
Tighten the exhaust system as follows:
AIR CLEANER, INSTALLATION.
2004 Touring: Engine
3-19
HOME
11.
On Ultra models, place fairing lower into position on right
17.
Install the fuel tank. Proceed as follows:
side of vehicle. Holding T40 TORX screw inside fairing
Carbureted: See Section 4.7 FUEL TANK (CARBU-
lower, install new rubber washer, clamp and locknut to
RETED), INSTALLATION
(AFTER COMPLETE
attach fairing bottom to engine guard. Do not tighten
REMOVAL), FLHT/C, or FLHR/S.
locknut.
12.
Align barbed studs in right side cover with grommets in
Fuel Injected: See Section
9.4 FUEL TANK (FUEL
frame downtubes and push firmly into place (no tools
INJECTED), INSTALLATION
(AFTER COMPLETE
REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
required).
13.
Install right side saddlebag. See Section 2.25 SADDLE-
18.
On Ultra models, hold locknut at bottom of fairing lower,
BAG, INSTALLATION.
and using a T40 TORX drive head, turn inside screw to
fasten assembly to engine guard clamp. Tighten screw
14.
Repeat steps 11-13 to install side cover, saddlebag and
to 90-100 in-lbs (10.2-11.3 Nm). Repeat step on oppo-
fairing lower on left side of vehicle.
site side of vehicle.
15.
Install spark plugs in front and rear cylinder heads.
19.
Adjust idle and throttle control cables as follows:
Install the plugs finger tight and then tighten to 12-18 ft-
lbs (16-24 Nm).
Non-Cruise: See Section 2.21 THROTTLE CABLES
(NON-CRUISE), ADJUSTMENT.
16.
Install ignition coil and spark plug cables as follows:
a. With the coil towers facing rear of vehicle, hold igni-
Cruise Equipped: See Section 8.30 CRUISE CON-
tion coil and bracket at bottom of frame backbone.
TROL (FLHRC, FLTR, FLHTCU), CABLE ADJUST-
Pull sides of bracket outward and install on bosses
MENT.
of front fuel tank mount. See Figure 3-11.
b. Install electrical connector on left side of ignition
coil.
c. Install spark plug cable to front cylinder onto left
side coil tower. Verify that spark plug cable is cap-
tured in double-sided cable clip at bottom left side of
frame backbone. Install new cable clip on T-stud if
damaged or missing.
d. Install spark plug cable to rear cylinder onto right
side coil tower. Verify that spark plug cable is cap-
tured in two single-sided cable clips at bottom left
side of frame backbone. Install new cable clips on T-
studs if damaged or missing.
3-20
2004 Touring: Engine
HOME
REMOVING ENGINE FROM CHASSIS
3.7
NOTE
PROCEDURE
To ensure sealing integrity of TORCA clamps and prevent the
possibility of leakage, Harley-Davidson recommends that
1.
Drain and remove fuel tank. Proceed as follows:
TORCA assemblies be discarded and replaced each time
Carbureted: See Section 4.7 FUEL TANK (CARBU-
they are removed.
RETED), COMPLETE REMOVAL, FLHT/C, or FLHR/S.
g.
Moving to right side of vehicle, open two worm drive
Fuel Injected: See Section
9.4 FUEL TANK (FUEL
clamps and release heat shield from front header
INJECTED), COMPLETE REMOVAL, FLHT/C/U/I,
pipe. Using an impact wrench with long 1/2 inch
FLTRI, or FLHR/C/S/I.
swivel socket, remove two exhaust flange nuts to
release front header pipe from studs of front cylin-
2.
Remove the primary chaincase. See Section 6.5 PRI-
der head. Slide exhaust flange down header pipe to
MARY CHAINCASE, REMOVAL, steps 2-18.
improve clearance around exhaust port.
3.
Remove left side saddlebag. See Section 2.25 SAD-
h.
Open two worm drive clamps and release heat
DLEBAG, REMOVAL.
shield from rear header pipe. Remove two exhaust
4.
Gently pull left side cover from frame downtubes (no
flange nuts to release rear header pipe from studs
tools required).
of rear cylinder head.
5.
On Ultra models, hold locknut at bottom of left fairing
i.
Open two worm drive clamps to release heat shield
lower, and using a T40 TORX drive head, turn inside
over front header pipe to rear header pipe connec-
screw to free assembly from engine guard clamp. Dis-
tion (outboard of transmission side door).
card rubber washer.
j.
Remove bolt (with flat washer and locknut) from
6.
Repeat steps 3-5 to remove saddlebag, side cover and
transmission exhaust bracket clamp on front header
fairing lower on right side of vehicle.
pipe. Use a channel lock to open clamp and then
remove from header pipe and transmission exhaust
7.
Remove the air cleaner and backplate. See Section 4.5
bracket.
AIR CLEANER, REMOVAL.
k.
Remove two bolts (with lockwashers) to detach right
8.
Remove two allen head socket screws (with lockwashers
side muffler from the lower saddlebag support rail.
and flat washers) to release right side front footboard
l.
Depressing rear brake pedal, remove right side
brackets from frame weldment. For best results,
exhaust from vehicle.
approach from left side of vehicle using a 3/8 inch ball
allen with extension.
m.
Remove and discard gaskets from front and rear
exhaust ports.
9.
Remove exhaust system in two sections as follows:
10.
Remove connections to carburetor or induction module.
a. Open two worm drive clamps to release heat shield
Proceed as follows:
over rear header pipe to crossover pipe connection
(above starter).
Carbureted:
b. Loosen TORCA clamp between rear header pipe
a. Moving to left side of vehicle, pull external latch out-
and crossover pipe. Remove Keps nut and pull
ward and use rocking motion to remove electrical
bracket tab and stud from slots in TORCA clamp
connector from manifold absolute pressure (MAP)
and exhaust support bracket.
sensor at top of intake manifold.
c. Spray PB Blaster or other suitable penetrating oil in
b. Locate the fuel enrichener knob under the left side
and around joint between rear header pipe and
of the fuel tank, and loosen hex nut at backside of
crossover pipe.
mounting bracket. Slide cable assembly free of slot
in mounting bracket.
d. Moving to left side of vehicle, remove two bolts (with
lockwashers) to detach left side muffler from the
Fuel Injected:
lower saddlebag support rail.
a. Standing on right side of vehicle, remove idle air
e. Pull and twist on crossover pipe to remove left side
control and manifold absolute pressure sensor con-
exhaust from vehicle. For best results, be sure to
nectors. Pull external latch(es) outward and use
allow sufficient time for the penetrating oil to work.
rocking motion to separate pin and socket halves.
f.
Remove TORCA clamp assembly from crossover
b. Depress wire form to remove electrical connectors
pipe and discard.
from front and rear fuel injectors.
2004 Touring: Engine
3-21
HOME
16.
Pull external latch outward and use rocking motion to
8316
remove electrical connector from left side of ignition coil.
17.
Pull sides of ignition coil bracket outward to remove from
bosses of front fuel tank mount. See Figure 3-11.
18.
Moving to right side of vehicle, remove two allen head
socket screws to release oil hose cover.
19.
Using a side cutters, cut and remove clamps on engine
side of oil hoses. Pull hoses from crankcase fittings.
20.
Cut and remove clamp on breather hose behind rear
lifter cover. Pull hose from crankcase fitting and tuck
behind transmisson to engine flange to keep out of the
way.
21.
Remove the voltage regulator. See Section 8.9 VOLT-
Figure 3-11. Remove Ignition Coil Bracket From Vehicle
AGE REGULATOR, REMOVAL.
22.
To release stator cable conduit, remove P-clip from left
c. Remove throttle position sensor and intake air tem-
side stud on lower frame crossmember. Remove P-clip
perature sensor connectors.
from cable conduit. Draw stator connector and cable
conduit to rear of engine stabilizer link and then up to
d. Moving to left side of vehicle, pull back boot to
area in front of primary chaincase.
reveal engine temperature sensor at back of front
cylinder. Pull external latch outward and remove
23.
Depress tangs inside socket housing and back out sock-
connector. Cut cable strap to release conduit from
ets through wire end of connector. Proceed as follows:
horn bracket.
a.
Looking into the socket housing, take note of the
e. Tuck free ends of EFI wire harness under main wire
cavity on each side of the terminal.
harness on frame backbone to keep conduit and
connectors out of the way.
b.
Gently insert pick (Snap-On TT600-3) into the cavity
about 1/4 inch (6.4 mm) or until it stops, and pivot
11.
Remove idle and throttle control cables as follows:
the side of the pick toward the terminal body.
Carbureted: Using a needle nose pliers, carefully pull
Repeat step on other cavity. See Figure 3-12.
idle cable barrel from upper inboard hole in throttle
c.
Gently tug on cable to pull terminal from chamber. If
wheel. Pull throttle cable barrel from remaining hole.
terminal is still locked, one or both tangs are not
Release idle and throttle cables from guides in throttle
fully depressed. Repeat steps 24(b) and 24(c) as
cable bracket.
necessary.
Fuel Injected: Using a needle nose pliers, carefully pull
d.
Repeat procedure to release second terminal.
idle cable barrel from upper hole in throttle wheel. Pull
throttle cable barrel from lower hole. Using slots, release
idle and throttle cables from guides in throttle cable
bracket.
f1911x8x
12.
Free idle and throttle control cables from J-clamp fas-
tened to right side of frame backbone. Move cables up
and out of the way.
13.
If equipped with cruise control, remove E-clip from
sleeve at end of cruise cable housing. Using slot,
Pick
remove cable housing from cable guide in throttle cable
bracket. Push the plastic end fitting on the cruise cable
to the outboard side to release from wheel pin. Move
cable up and out of the way.
14.
Moving to left side of vehicle, pull boots on spark plug
cables to release from spark plug and ignition coil tow-
ers. Release cables from three cable clips at bottom of
frame backbone.
Figure 3-12. Remove Socket Terminals
15.
Remove spark plugs.
From Stator/Voltage Regulator Connector
3-22
2004 Touring: Engine
HOME
24.
Remove conduit from stator cables. For best results, pull
one cable and socket terminal through conduit at a time.
Tape cables to crankcase so that they are out of the way
and will not be pinched or cut during engine removal.
25.
Remove crankshaft position sensor and oil pressure
switch/sender as follows:
a. Locate crankshaft position sensor connector [79], 2-
place Mini-Deutsch, next to oil filter mount. Depress
button on socket terminal side and pull apart pin
and socket halves.
b. Remove allen head socket screw to free crank posi-
tion sensor mount from crankcase. Pull sensor from
Figure 3-13. Engine/Transmission Bench Stand
bore. Remove O-ring from groove on sensor body.
(Part No. HD-42310)
Discard O-ring.
c. Locate the oil pressure switch/sender at the front
35.
Cover lower frame tubes (both left and right side) with
right side of the crankcase. On FLHR/C/S models,
foam padding or bubble pack. Split loom conduit or a half
pull elbow from post of oil pressure switch. On
shell of PVC tubing will also produce good results. Pro-
FLHT/C/U and FLTR models, pull external latch out-
tection is necessary to prevent nicks or paint damage to
ward and use rocking motion to remove Packard
left frame tube and chafing, cutting or kinking of the
connector from oil pressure sender.
brake line, wire cables and conduit at the top of the right
d. On FLHR/C/S models, use a 15/16 inch Open End
frame tube.
Crow Foot (Snap-On FC30B) to remove oil pressure
36.
Cover rocker covers of front and rear cylinders with foam
switch from crankcase. On FLHT/C/U and FLTR
padding or bubble pack.
models, use
1-1/16 inch Open End Crow Foot
(Snap-On FC34A) to remove oil pressure sender.
1CAUTION
26.
Coil main harness conduit and allow to hang below
lower frame tube at front of vehicle. If harness is not
The engine weighs approximately 165 pounds (74.8 kg).
moved out of the way, it may be damaged during engine
Use a suitable lifting device, if necessary. Exercise cau-
removal.
tion to avoid personal injury.
27.
Place jack under oil pan at rear of vehicle. Using a block
37. Move engine forward far enough to clear two ring dowels
of wood to distribute pressure across the length of the
in lower flange of transmission housing. Raise engine
casting, raise the jack until firm contact is made with the
and remove from right side of vehicle. Exercise caution
bottom of the oil pan.
to avoid contact with rear brake master cylinder reservoir
and brake line, wire cables and conduit at top of lower
28.
Standing on left side of vehicle, remove two hex head
frame tube.
bolts (with flat washers) to release top engine mounting
bracket from cylinder heads.
38. Using the TWIN CAM 88 CRADLE (HD-42310-2), install
engine in BENCH STAND (HD-42310) or ROLLING
29.
Remove elbow terminals from spade contacts at back of
STAND (HD-43646A). See Figure 3-13.
horn. Release wire harness conduit from J-clamp.
39. Remove intake manifold/carburetor or induction module.
30.
Moving to right side of vehicle, turn hex head bolt to
Proceed as follows:
release stabilizer link from frame weldment.
31.
Remove horn, top engine mounting bracket and stabi-
a. Remove right side allen head socket screws from
lizer link as an assembly.
front and rear cylinder head flange adapters. For
best results, use a long 1/4 inch ball allen head
32.
Remove four bolts (with flat washers) to free rear of
socket with end driver 4 inches long.
crankcase from transmission housing. Loosen and
remove bolts in a crosswise pattern.
b. Moving to opposite side of vehicle, just loosen left
side allen head socket screws from flange adapters.
33.
Remove two bolts (with flat washers) to free front of
Slots in flanges make removal of left side screws
crankcase from front engine mounting bracket.
unnecessary.
34.
Wrap rear master cylinder reservoir with foam padding
c. Remove intake manifold/carburetor or induction
or bubble pack.
module from right side of vehicle.
2004 Touring: Engine
3-23
HOME
40. Remove the rotor as follows:
Capped
f1634x8x
Stator
Rib
1CAUTION
The high-output rotor is used on fuel injected vehicles,
FLHR/C/S/I excepted. Since the high-output rotor con-
tains magnets that are considerably more powerful than
those used on low-output rotors, the ROTOR REMOVER/
INSTALLER and SHAFT PROTECTOR SLEEVE (HD-
41771) must be used to prevent parts damage and possi-
ble hand injury during removal and installation.
High Output Rotor - 45 Amp
a. Verify that threads of engine sprocket shaft are
clean, especially of old Loctite material. Thread the
Shaft Protector Sleeve onto the shaft.
b. Turn thumbscrews of Rotor Remover/Installer into
Awl
Opening
threaded holes in rotor face.
c. Rotate handle of forcing screw in a clockwise direc-
tion to remove rotor from shaft.
Figure 3-14. Remove Grommet From Crankcase
Low Output Rotor - 38 Amp
c. Using a 3/8 inch drive with a 4 inch extension, turn
CAUTION
wrench in a counterclockwise direction until loose.
Do not strike or drop rotor. Damage to magnet adhesive
Do not use with air tools.
may result in rotor failure.
NOTE
a. Fabricate wire hooks or use the ends of two allen
wrenches to carefully pull rotor at holes in rotor
Use OIL FILTER WRENCH (HD-44067) if HD-42311 is not
available.
face.
b. Pull rotor from stator. Magnets in rotor cause some
43. Remove oil filter mount as follows:
resistance during removal.
41.
Remove stator as follows:
a. Carefully bend corners on lockplate away from
heads of top and bottom bolts in oil filter mount.
a. Using a T27 TORX drive head, remove four screws
Remove top and bottom bolts, lockplate and flat
to free stator from crankcase. Discard screws.
washers. Discard lockplate.
b. Using point of awl, carefully lift capped rib on grom-
b. Remove middle bolt with flat washer to free filter
met away from crankcase and then insert into bore
mount from crankcase.
between grommet and casting. See Figure 3-14. Tilt
awl slightly squirting isopropyl alcohol or glass
c. Remove two O-rings from inboard side of filter
cleaner into opening. Repeat this step at one or two
mount. Discard O-rings.
other locations around grommet.
c. While pushing on capped rib from outside of crank-
NOTES
case, draw grommet through bore by pulling on
Remove and clean the oil pan under any of the following con-
cable stop with needle nose pliers. Rock grommet
ditions:
back and forth to facilitate removal, if necessary.
Exercise caution to avoid damaging ribs on grom-
● Metal debris is found in the engine or crankcase.
met if stator is to be reused.
● Oil contamination is suspected.
42.
Remove the oil filter as follows:
a. Obtain the OIL FILTER WRENCH (HD-42311). The
● A complete engine overhaul is being performed as a
tool allows easy removal of the oil filter without risk
result of a major engine failure.
of damage to the crankshaft position sensor or
cable.
● The engine is being replaced with a new one.
b. Place the jaws of the wrench over the oil filter with
the tool oriented vertically.
44. To remove the oil pan, proceed as follows:
3-24
2004 Touring: Engine
HOME
RIGHT SIDE
f2025x3x
LEFT SIDE
Strap
Strap
Frame
Backbone
Mainshaft
Hook
Rubber Coated
Hook
Transmission
Rubber Coated
Bracket
f1791x2x
Figure 3-15. Secure Transmission Using Transmission Exhaust Bracket and Mainshaft
a. Use a tie down strap to hold the transmission. Lay
d. Locate transmission drain plug on right side of the
strap over frame backbone placing one rubber
oil pan. See Figure 3-16. Remove the plug and
coated hook through the transmission exhaust
drain the transmission lubricant into a suitable con-
bracket on the right side of the vehicle and the other
tainer.
around the mainshaft on the left. Using buckle,
tighten strap until taut. See Figure 3-15.
e. Alternately loosen and then remove the twelve allen
head socket screws to release the oil pan from the
b. Lower and remove jack under oil pan.
transmission housing. Follow the pattern shown in
c. Locate oil drain plug at front of the oil pan. See Fig-
Figure 3-16.
ure 3-16. Remove the plug and allow oil to drain
f.
Remove gasket from oil pan and discard.
completely.
2004 Touring: Engine
3-25
HOME
INSTALLING ENGINE IN CHASSIS
3.8
PROCEDURE
f1677x3x
9
NOTE
11
3
If oil pan was drained and removed, start at step 1. If oil pan
LEFT
was neither drained nor removed, move to step 13.
7
2
SIDE
1.
Coat gasket surface of oil pan with a thin coat of HYLO-
6
MAR® gasket sealer.
2.
Place gasket on oil pan and allow sealer to dry until
5
tacky.
8
3.
Position oil pan under transmission housing and start the
twelve allen head socket screws. Tighten each screw
1
RIGHT
about two turns after initial thread engagement.
SIDE
4
4.
Inspect the oil pan gasket to verify that it is properly posi-
tioned.
12
Transmission
10
Engine Oil
5.
Alternately tighten the oil pan screws to 84-108 in-lbs
Drain Plug
Drain Plug
(9-12 Nm) following the pattern shown in Figure 3-16.
6.
Remove any foreign material from magnet of oil drain
Figure 3-16. Oil Pan Torque Sequence
plug. Also check the O-ring for tears, cuts or general
deterioration. Replace as necessary.
12.
Install the transmission filler plug/dipstick in the clutch
7.
Install the engine oil drain plug in front of the oil pan.
release cover. Tighten the plug to 25-75 in-lbs (2.8-8.5
Tighten plug to 14-21 ft-lbs (19-28 Nm).
Nm).
8.
Remove the transmission filler plug from the clutch
13.
Place jack under oil pan at rear of vehicle. Using a block
release cover on the right side of the transmission case.
of wood to distribute pressure across the length of the
Check the O-ring for tears, cuts or general deterioration.
casting, raise the jack until firm contact is made with the
Replace as necessary.
bottom of the oil pan.
9.
Remove any foreign material from magnet of transmis-
14.
Remove strap from frame backbone disengaging hooks
sion drain plug. Also check the O-ring for tears, cuts or
from mainshaft and transmission exhaust bracket.
general deterioration. Replace as necessary.
15.
Install spark plugs in front and rear cylinder heads.
10.
Install the transmission lubricant drain plug in right side
Install the plugs finger tight and then tighten to 12-18 ft-
of the oil pan and tighten to 14-21 ft-lbs (19-28 Nm).
lbs (16-24 Nm).
16.
Install oil filter mount as follows:
1WARNING
a. Install two new O-rings on inboard side of filter
When draining or adding lubricant, do not allow dirt,
mount.
debris or other contaminants to enter the transmission
b. Place flat washers in recessed bolt holes at top and
case. Exercise caution so that lubricant does not contact
bottom of filter mount flange.
rear wheel, tire and brake components. Such contact
can adversely affect traction and may lead to loss of
c. Align holes in lockplate with holes in flat washers.
vehicle control, which could result in death or serious
d. Slide two hex head bolts through lockplate, flat
injury.
washers and filter mount flange. Apply Loctite
11. Fill the transmission with
20-24 oz. (590-710 ml) of
Medium Strength Threadlocker
243
(blue) to
transmission lubricant or until the lubricant level on the
threads of installed bolts.
dipstick of the filler plug is at the F(ULL) mark with the
motorcycle in a level, upright position and the filler plug
CAUTION
resting on the threads.
To avoid cross threading tapped holes, exercise care
Use only Harley-Davidson TRANSMISSION LUBRI-
when starting hex head bolts in crankcase.
CANT: Part No.’s 99892-84 (quart), 98853-96 (case of
quarts), 99891-84 (gallon), or 98852-96 (case of gal-
e. Align holes in filter mount flange with holes in crank-
lons).
case and tighten bolts until snug.
3-26
2004 Touring: Engine
HOME
f.
Install flat washer on remaining bolt, apply Loctite
Medium Strength Threadlocker
243
(blue) to
1CAUTION
threads, and install in middle hole of filter mount
The high-output rotor is used on fuel injected vehicles,
flange.
FLHR/C/S/I excepted. Since the high-output rotor con-
g. Starting at the top, alternately tighten three hex
tains magnets that are considerably more powerful than
those used on low-output rotors, the ROTOR REMOVER/
head bolts to 12-16 ft-lbs (16-22 Nm). Re-tighten
INSTALLER and SHAFT PROTECTOR SLEEVE (HD-
middle bolt when done.
41771) must be used to prevent parts damage and possi-
h. To prevent rotation, carefully bend outside corners
ble hand injury during removal and installation.
of lockplate against heads of top and bottom bolts.
High Output Rotor - 45 Amp
17. Clean oil filter mount flange of any old gasket material.
a. Install the Shaft Protector Sleeve and Rotor
Lubricate gasket of new oil filter with clean engine oil
Remover/Installer, if removed.
and install on filter mount. Hand tighten oil filter 1/2-3/4
turn after gasket first contacts filter mounting surface. Do
NOTE
NOT use OIL FILTER WRENCH for oil filter installation.
The Shaft Protector Sleeve not only protects the threads from
the splines of the rotor, but acts as a guide to ensure that the
NOTE
rotor is properly centered.
Use of the Premium 10 micron synthetic media oil filter is
highly recommended, Part No. 63798-99 (Chrome) or 63731-
b. Center ball on forcing screw in recess at end of
engine sprocket shaft. Rotate the handle of the tool
99 (Black).
in a counterclockwise direction to ease rotor into
position over stator.
18. Install stator as follows:
c. Loosen thumbscrews and remove Rotor Remover/
a. From inside crankcase, feed socket terminals and
Installer. Remove Shaft Protector Sleeve.
stator cable through hole in crankcase.
d. Install the shaft extension on the engine sprocket
b. Thoroughly lubricate grommet with isopropyl alco-
shaft. (No alternator rotor spacer is provided.)
hol or glass cleaner. To avoid leakage, ribs of grom-
met must be free of dirt and oily residue.
Low Output Rotor - 38 Amp
c. Carefully grasp cable stop behind grommet with a
needle nose pliers. Push grommet into crankcase
a. Slide rotor over stator with the concave side
inboard.
bore while carefully pulling on outside cable. Instal-
lation is complete when cable stop contacts casting
and capped rib of grommet exits crankcase bore.
1CAUTION
d. If necessary, carefully run awl around edge of
When installing rotor, keep fingers away from edge that
capped rib so that it rests flat against seating sur-
mates with crankcase. Since rotor is magnetized, as it
face on crankcase.
nears the crankcase it may be pulled in with consider-
able force, resulting in pinched fingers or other hand
injury.
CAUTION
b. Install the 0.020 inch (0.508 mm) thick alternator
Do not reuse T27 TORX screws. The threads of the
rotor spacer and the shaft extension on the engine
screws contain a locking compound in pellet form. When
sprocket shaft.
the screw is started, the pellet breaks releasing the com-
pound.
20. Install intake manifold/carburetor or induction module.
Proceed as follows:
e. Using a T27 TORX drive head, install four new
a. With the counterbore facing outward, slide cylinder
screws to fasten stator to crankcase. Alternately
head flange adapters onto outlet ports of intake
tighten screws to 55-75 in-lbs (6.2-8.5 Nm).
manifold/induction module. The flange adapters are
not interchangeable. Look next to the slotted bolt
f.
Coil stator connector cable lengths so that they are
hole for a stamp that indicates F(ront) and R(ear)
out of the way and will not be pinched or cut during
cylinder.
engine installation.
b. Place a new seal in each flange adapter with the
19. Install the rotor as follows:
beveled side in against the counterbore.
2004 Touring: Engine
3-27
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