Harley Davidson 2004 Touring Models. Service Manual — page 33
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a. Clamp end of tool in vise in a horizontal position
with plastic knobs facing toward you.
Length
Retaining Pins (3)
b. With the fork cap bolt topside, clamp fork tube
Adjuster
between rubber pads on inboard side of tool.
Screw
Tighten knobs until fork tube is securely held.
3.
Remove fork cap bolt from fork tube plug. Remove and
discard quad ring seal.
4.
Using flat, unthread fork tube plug from fork tube. See
Figure 2-72.
Spring
Compressor
5.
Pull up on fork slider to compress fork assembly, which
causes the damper rod to protrude from the top of the
fork tube.
6.
Holding locknut, remove fork tube plug from threaded
end of damper rod. Remove O-ring from fork tube plug.
Discard O-ring.
7.
Remove fork assembly from fork tube holder. Turning
fork upside down, drain fork oil into drain pan.
Damper Rod
8.
Remove fork tube holder from vise.
Extension Tool
Post
9.
Obtain the FORK SPRING COMPRESSING TOOL (HD-
45966) shown in Figure 2-73. Install as follows:
a. Clamp tool in vise in a vertical position with length
f2188x2x
adjuster screw topside.
b. Pull up on fork slider to compress fork assembly.
Figure 2-73. Fork Spring Compressing Tool (HD-45966)
c. Place hole at bottom of fork slider over post at bot-
tom end of tool.
Locknut
d. With the smaller OD topside, place spring compres-
sor over locknut, spring seat and flat washer of fork
assembly.
CAUTION
Use only hand tools to turn length adjuster screw on fork
spring compressing tool. Do not use an air impact
wrench or tool damage can occur.
e. Adjust tool as necessary until three retaining pins
engage blind holes in spring compressor. Turn
length adjuster screw in a counterclockwise direc-
tion to lengthen, a clockwise direction to shorten.
f2189x2x
1WARNING
Figure 2-74. Compress Fork Spring
Retaining pins must fully engage blind holes or spring
compressor may rotate out of position during compres-
sion of spring. If spring compressor rotates out of posi-
1.
Remove the fork assembly. See REMOVAL in this sec-
tion, sudden extension of spring can cause parts to fly
tion.
out, possibly resulting in minor or moderate injury.
f.
Turn retaining pins as necessary to lock position of
CAUTION
spring compressor.
Exercise caution to avoid scratching or nicking fork
g. Turn length adjuster screw in a clockwise direction
tube. Damaging tube can result in fork oil leaks after
to compress spring.
assembly.
10. Using deepwell socket to avoid unnecessary spring
2. Obtain the FORK TUBE HOLDER (HD-41177). See Fig-
compression, remove locknut from end of damper rod.
ure 2-71. Proceed as follows:
See Figure 2-74.
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2004 Touring: Chassis
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11. Turn length adjuster screw in a counterclockwise direc-
15. Place a shop rag on the floor, and turning fork assembly
tion to release tension on fork spring. Loosen retaining
upside down, press end of spring against rag. While
pins and remove spring compressor. Remove spring
compressing spring to prevent rotation of damper car-
seat and flat washer.
tridge, remove 6mm screw from end of fork slider. Use
an air impact wrench for best results. Discard
6mm
12. Remove fork assembly from tool and remove tool from
screw and copper crush washer.
vise. Remove fork spring from fork tube.
16. Remove spring and damper cartridge from fork tube.
13. Obtain damper rod extension tool shown in Figure 2-75.
Thread extension tool onto end of damper rod. Turn fork
CAUTION
assembly upside down over drain pan and slowly pump
damper rod at least twenty times until rod moves freely.
Do not expand or stretch retaining clip to remove from
See Figure 2-76.
fork tube or clip may become bent or distorted.
NOTE
17. Using pick tool, remove retaining clip between fork slider
and fork tube.
If just changing the fork oil, continue procedure at ASSEM-
18. Remove fork tube from fork slider.
BLY, LEFT FORK, step 13. If overhauling the fork assembly,
continue with step below.
NOTE
To overcome any resistance, use the fork tube as a slide
14. Remove extension tool from damper rod. Install fork
hammer, that is, first push fork tube into fork slider and then
spring back into fork tube.
pull it outward with a moderate amount of force. Repeat this
sequence until fork tube separates from fork slider.
19. Slide fork oil seal, slider spacer and slider bushing off
end of fork tube. Discard fork oil seal and slider bushing.
f2186x2x
M10 X 1.0
20. Gently pry at split line to expand fork leg bushing, and
Thread Size
then remove from groove at end of fork tube. Discard
fork leg bushing.
21. Remove lower stop from fork slider, or end of damper
cartridge if still installed.
RIGHT FORK
Conventional Type - All Models
Figure 2-75. Damper Rod Extension Tool
1.
Remove the fork assembly. See REMOVAL in this sec-
tion.
f2187x2x
2.
Remove nuts, lockwashers, flat washers and axle holder
from studs at end of fork slider.
CAUTION
Exercise caution to avoid scratching or nicking fork
tube. Damaging tube can result in fork oil leaks after
assembly.
3.
Obtain the FORK TUBE HOLDER (HD-41177). See Fig-
ure 2-71. Proceed as follows:
a. Clamp end of tool in vise in a horizontal position
with plastic knobs facing toward you.
b. With the fork cap bolt topside, clamp fork tube
between rubber pads on inboard side of tool.
Tighten knobs until fork tube is securely held. See
Figure 2-72.
4.
Remove fork cap bolt from fork tube plug. Remove and
Figure 2-76. Pump Damper Rod Extension Tool
discard O-ring.
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5.
Using flat, slowly unthread fork tube plug from fork tube.
Be aware that fork tube plug is under spring pressure, so
f2045x2x
have a firm grasp on plug as the last thread is turned.
Remove and discard O-ring from fork tube plug.
6.
Remove fork spring from fork tube.
7.
Remove fork assembly from fork tube holder.
8.
Turning fork upside down, drain fork oil into drain pan.
For best results, slowly pump fork tube and slider at least
ten times.
9.
Install fork spring back into fork tube.
10. Place a shop rag on the floor, and turning fork assembly
upside down, press end of spring against rag. While
compressing spring to prevent rotation of damper tube,
Figure 2-77. Measure Fork Tube Runout
remove 6mm screw from end of fork slider. Use an air
impact wrench for best results. Discard 6mm screw and
copper crush washer.
5.
Check the fork tube and slider for scoring, scratches and
11. Remove fork spring and damper tube from fork tube.
excessive or abnormal wear. Replace parts as neces-
sary. Set the fork tube on V-blocks and measure the
12. Remove wear ring and rebound spring from damper
runout using a dial indicator gauge. Replace fork if
tube.
runout exceeds 0.008 inch (0.2 mm). See Figure 2-77.
CAUTION
6.
Inspect upper fork springs for damage or distortion. Ver-
ify that free length is a minimum of 15 inches (381.0 mm)
Do not expand or stretch retaining clip to remove from
on cartridge type forks, 18.5 inches (469.9 mm) on the
fork tube or clip may become bent or distorted.
conventional type. Replace rebound spring on the con-
ventional type fork if the free length is less than 15/16
13. Using pick tool, remove retaining clip between fork slider
inch
(23.8 mm) or whenever the upper fork spring
and fork tube.
requires replacement.
14. Remove fork tube from fork slider.
NOTE
To overcome any resistance, use the fork tube as a slide
ASSEMBLY
hammer, that is, first push fork tube into fork slider and then
pull it outward with a moderate amount of force. Repeat this
sequence until fork tube separates from fork slider.
LEFT FORK
15. Slide fork oil seal, slider spacer and slider bushing off
end of fork tube. Discard fork oil seal and slider bushing.
Cartridge Type - All Models Except Road King
16. Gently pry at split line to expand fork leg bushing, and
NOTE
then remove from groove at end of fork tube. Discard
fork leg bushing.
Since Road King uses the conventional type fork on both
sides, see ASSEMBLY, RIGHT FORK, for Road King instruc-
17. Remove the lower stop from the fork slider.
tions.
CLEANING AND INSPECTION
CAUTION
Exercise caution to avoid scratching or nicking fork
1.
Thoroughly clean and inspect all parts. Replace any
tube. Damaging tubes can result in fork oil leaks after
parts that are bent, broken or obviously damaged.
assembly.
2.
Inspect fork cap bolt quad ring seal and fork tube plug O-
ring for cuts, tears or signs of deterioration. Replace if
1.
Coat fork leg bushing ID with clean fork oil. Expand fork
necessary.
leg bushing at split line only so far as required to slip
over end and into groove of fork tube.
3.
Replace the retaining clip if bent or distorted.
2.
Slide damper cartridge into fork tube, so that cartridge
4.
Check the slider and fork leg bushings for scratches or
excessive wear. Always replace bushings in a set if
end drops through hole at bottom of fork tube. Install
lower stop at end of damper cartridge.
either bearing is damaged or worn.
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3. Install fork slider in fork tube holder. Slide fork tube into
fork slider.
f2190x2x
4. Coat slider bushing ID with clean fork oil. Slide slider
bushing down fork tube.
5. Slide slider spacer down fork tube until it contacts slider
bushing.
6. Obtain the FORK OIL SEAL INSTALLER (HD-34634).
See Figure 2-78. Proceed as follows:
a. Slide the fork oil seal installer down the fork tube,
and using the tool like a slide hammer, drive slider
bushing into counterbore of fork slider. Remove tool.
NOTE
Place masking tape over edge of fork tube to avoid damaging
lip of fork oil seal during installation.
b. Coat new fork oil seal ID with clean fork oil. With the
Figure 2-80. Pump Damper Rod Extension Tool
lip garter spring side facing down (toward the fork
slider), slide seal down fork tube until it contacts
slider spacer. Remove masking tape from edge of
d. Using the tool like a slide hammer, drive fork oil seal
fork tube.
down fork tube until retaining clip groove is visible in
fork slider ID. See Figure 2-79. Remove tool.
c. Slide the fork oil seal installer down the fork tube
until it contacts the fork oil seal.
CAUTION
Do not expand or stretch retaining clip to install on fork
tube or clip may become bent or distorted.
f1901x2x
e. Slide the retaining clip down the fork tube until it
contacts the fork oil seal. Install retaining clip in the
fork slider groove.
7.
Install fork spring into fork tube.
8.
Remove fork assembly from fork tube holder.
9.
Place a shop rag on the floor, and turning fork assembly
upside down, press end of spring against rag.
Figure 2-78. Fork Oil Seal Installer (HD-34634)
10. Install new 6mm screw with copper crush washer. Slide
screw through hole at bottom of fork slider and start into
end of damper cartridge.
f1902x2x
11. While compressing spring to prevent rotation of damper
cartridge, tighten 6mm screw to 132-216 in-lbs (14.9-
24.4 Nm).
12. Remove fork spring from fork tube.
13. With the fork tube topside, clamp fork slider (not the fork
tube) into fork tube holder.
NOTE
Install the drain plug at the bottom of the fork slider, if
removed. Tighten the plug to 72-96 in-lbs (8-11 Nm).
14. Fill the fork tube as follows:
a. Obtain damper rod extension tool shown in Figure
2-75. Thread extension tool onto end of damper rod.
b. Pour 5 ounces (147.9 ml) of Harley-Davidson Type
Figure 2-79. Install Fork Oil Seal
E Fork Oil into the fork tube.
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c. Grasping extension tool, slowy pump the damper
e. Pull out plunger to suck fork oil from fork tube.
rod until resistance is felt, and then pump five more
Observe fork oil through transparent tube as it is
times. See Figure 2-80.
drawn into cylinder. If no oil is drawn through trans-
parent tube, add enough oil so that tool usage sets
d. Place the damper rod in the fully bottomed position.
fork oil level.
e. Remove extension tool from end of damper rod.
f.
Remove rod from fork tube. Push plunger into cylin-
der to eject excess fork oil into suitable container.
f.
Pour 6 more ounces (177.5 ml) of fork oil into the
fork tube.
g. If necessary, repeat steps 15(d) thru 15(f). Level is
correct when no fork oil is observed being drawn
15.
Adjust the fork oil level, so that it is 4.21 inches (107
through transparent tube.
mm) from the top of the fork tube with the fork com-
pressed. Proceed as follows:
1WARNING
a. Obtain the FRONT FORK OIL LEVEL GAUGE (HD-
Be sure fork oil level is correct. The incorrect amount of
59000B). See Figure 2-81.
fork oil can adversely affect handling and may lead to
b. Loosen thumbscrew on metal ring and move it up or
loss of vehicle control, which could result in death or
down the rod until the bottom of the ring is 4.21
serious injury.
inches (107 mm) from the end of the rod. Tighten
16. With the closer spaced coils at the bottom, slide fork
thumbscrew.
spring into fork tube.
c. Push the plunger on the cylinder all the way in.
17. Pull up on fork slider to compress fork assembly, which
d. Insert rod into top of fork tube until metal ring rests
causes the damper rod and spring to protrude from the
top of the fork tube.
flat on top of fork tube. See Figure 2-82.
18. Thread damper rod extension tool onto end of damper
rod.
19. Remove fork assembly from fork tube holder. Remove
fork tube holder from vise.
20. Obtain the FORK SPRING COMPRESSING TOOL (HD-
45966) shown in Figure 2-73. Install as follows:
a. Clamp tool in vise in a vertical position with length
adjuster screw topside.
b. Pull up on fork slider to compress fork assembly.
c. Place hole at bottom of fork slider over post at bot-
tom end of tool.
d. Place flat washer rounded side up over damper rod
extension tool and on top of spring. Place spring
Figure 2-81. Front Fork Oil Level Gauge (HD-59000B)
seat concave side up on top of flat washer. With the
smaller OD topside, place spring compressor over
spring seat and flat washer.
f2168x2x
CAUTION
Use only hand tools to turn length adjuster screw on fork
spring compressing tool. Do not use an air impact
wrench or tool damage can occur.
e. Adjust tool as necessary until three retaining pins
engage blind holes in spring compressor. Turn
length adjuster screw in a counterclockwise direc-
tion to lengthen, a clockwise direction to shorten.
1WARNING
Retaining pins must fully engage blind holes or spring
compressor may rotate out of position during compres-
sion of spring. If spring compressor rotates out of posi-
tion, sudden extension of spring can cause parts to fly
Figure 2-82. Remove Excess Fork Oil
out, possibly resulting in minor or moderate injury.
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2004 Touring: Chassis
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f.
Turn retaining pins as necessary to lock position of
f1974x2x
spring compressor. See Figure 2-74.
g. Turn length adjuster screw in a clockwise direction
to compress spring. See Figure 2-74.
21.
After a number of turns, pull up on extension tool to raise
1
damper rod. If threaded portion of rod cannot be pulled
2
completely out of spring, compress spring further.
10
22.
Repeat step 21 until threaded portion of rod can be
3
pulled completely out of spring. Remove extension tool,
4
but do not let go of damper rod.
23.
Thread locknut onto damper rod until it contacts shoul-
5
6
der. Use a deepwell socket for best results.
24.
Install new O-ring onto fork tube plug. Thread fork tube
plug onto threaded end of rod until it bottoms. Now turn
7
locknut in a counterclockwise direction until it makes firm
contact with the fork tube plug. Tighten locknut to 13-20
11
ft-lbs (18-27 Nm).
12
25.
Turn length adjuster screw in a counterclockwise direc-
8
tion to release tension on fork spring. Loosen retaining
pins and remove spring compressor. Remove fork
13
assembly from tool and remove tool from vise.
26.
Install fork tube holder in vise. Clamp fork tube into fork
14
15
tube holder.
16
27.
Tighten fork tube plug to 22-58 ft-lbs (30-79 Nm).
28.
Install new O-ring onto fork cap bolt. Thread fork cap
bolt into fork tube plug to prevent loss of fork oil while
handling.
29.
Remove fork assembly from fork tube holder.
17
9
RIGHT FORK
18
Conventional Type - All Models
CAUTION
19
20
Exercise caution to avoid scratching or nicking fork
tube. Damaging tubes can result in fork oil leaks after
assembly.
21
1.
Coat fork leg bushing ID with clean fork oil. Expand fork
leg bushing at split line only so far as required to slip
1.
Fork cap bolt
12. Lip seal
over end and into groove of fork tube.
2.
Quad ring seal
13. Slider spacer
2.
Install new wear ring in groove at top of damper tube.
3.
Fork tube plug
14. Slider bushing
Install rebound spring on opposite end.
4.
O-Ring
15. Fork leg bushing
5.
Locknut
16. Lower stop
3.
With the wear ring topside, slide damper tube into fork
6.
Spring seat
17. Fork slider
tube, so that tube end drops through hole at bottom of
7.
Flat washer
18. Plug
fork tube. Install lower stop at end of damper tube.
8.
Spring
19. Flat Washer
4.
Install fork slider in fork tube holder. Slide fork tube into
9.
Damper cartridge
20. Copper washer
fork slider.
10.
Fork tube
21. Screw (6mm)
5.
Coat slider bushing ID with clean fork oil. Slide slider
11.
Retaining clip
bushing down fork tube.
6.
Slide slider spacer down fork tube until it contacts slider
Figure 2-83. Left Side Fork - Cartridge Type
bushing.
(All Models Except Road King)
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7.
Obtain the FORK OIL SEAL INSTALLER (HD-34634).
See Figure 2-78. Proceed as follows:
1
f1975x2x
2
a. Slide the fork oil seal installer down the fork tube,
and using the tool like a slide hammer, drive slider
bushing into counterbore of fork slider. Remove tool.
3
4
NOTE
Place masking tape over edge of fork tube to avoid damaging
lip of fork oil seal during installation.
b. Coat new fork oil seal ID with clean fork oil. With the
lip garter spring side facing down (toward the fork
5
slider), slide seal down fork tube until it contacts
slider spacer. Remove masking tape from edge of
fork tube.
10
c. Slide the fork oil seal installer down the fork tube
until it contacts the fork oil seal.
11
6
d. Using the tool like a slide hammer, drive fork oil seal
12
down fork tube until retaining clip groove is visible in
fork slider ID. See Figure 2-79. Remove tool.
13
7
14
CAUTION
Do not expand or stretch retaining clip to install on fork
8
15
tube or clip may become bent or distorted.
e. Slide the retaining clip down the fork tube until it
contacts the fork oil seal. Install retaining clip in the
fork slider groove.
16
8.
Install fork spring into fork tube.
17
9.
Remove fork assembly from fork tube holder.
10. Place a shop rag on the floor, and turning fork assembly
9
upside down, press end of spring against rag.
11. Install new 6mm screw with copper crush washer. Slide
18
21
screw through hole at bottom of fork slider and start into
end of damper tube.
19
22
12. While compressing spring to prevent rotation of damper
tube, tighten 6mm screw to 132-216 in-lbs (14.9-24.4
23
Nm).
20
24
13. Remove fork spring from fork tube.
14. With the fork tube topside, clamp fork slider (not the fork
1.
Fork cap bolt
13.
Slider bushing
tube) into fork tube holder.
2.
Quad ring seal
14.
Fork leg bushing
3.
Fork tube plug
15.
Lower stop
NOTE
4.
O-Ring
16.
Fork slider
Install the drain plug at the bottom of the fork slider, if
5.
Spring
17.
Plug
removed. Tighten the plug to 72-96 in-lbs (8-11 Nm).
6.
Wear ring
18.
Flat Washer
7.
Damper tube
19.
Copper washer
15. Pour 11.1 ounces (328 ml) of Harley-Davidson Type E
8.
Rebound spring
20.
Screw (6mm)
Fork Oil into the fork tube.
9.
Fork tube
21.
Axle holder
10. Retaining clip
22.
Flat washer (2)
16. Adjust the fork oil level, so that it is 5.24 inches (133
11. Lip seal
23.
Lockwasher (2)
mm) from the top of the fork tube with the fork com-
12. Slider spacer
24.
Nut (2)
pressed. Proceed as follows:
a. Obtain the FRONT FORK OIL LEVEL GAUGE (HD-
Figure 2-84. Right Side Fork - Conventional Type
59000B). See Figure 2-81.
(All Models)
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b. Loosen thumbscrew on metal ring and move it up or
INSTALLATION
down the rod until the bottom of the ring is 5.24
inches (133 mm) from the end of the rod. Tighten
1.
Remove fork cap bolt.
thumbscrew.
2.
Standing at front of vehicle, slide fork tube up and into
c. Push the plunger on the cylinder all the way in.
slider cover, lower fork bracket, fork stop, and upper fork
bracket. Install fork cap bolt.
d. Insert rod into top of fork tube until metal ring rests
3.
Move rubber fork stop down fork tube until it contacts top
flat on top of fork tube. See Figure 2-82.
of lower fork bracket. Lubricate surfaces with glass
e. Pull out plunger to suck fork oil from fork tube.
cleaner, if necessary.
Observe fork oil through transparent tube as it is
4.
Install pinch bolt (with lockwasher) on left side of lower
drawn into cylinder. If no oil is drawn through trans-
fork bracket. See Figure 2-69. Tighten pinch bolt to 30-
parent tube, add enough oil so that tool usage sets
35 ft-lbs (41-48 Nm).
fork oil level.
5.
Tighten fork cap bolt to 50-60 ft-lbs (68-81 Nm).
f.
Remove rod from fork tube. Push plunger into cylin-
6.
Repeat steps 1-5 on other fork, if removed.
der to eject excess fork oil into suitable container.
7.
Install the front fender and wheel. See Section 2.32
g. If necessary, repeat steps 16(d) thru 16(f). Level is
FRONT FENDER, INSTALLATION.
correct when no fork oil is observed being drawn
8.
FLHT/C/U:
through transparent tube.
a. Slide chrome skirt into position between passing
lamp bracket and inner fairing. To avoid possible
1WARNING
wire damage, be sure that trim strip is installed on
top edge of skirt. Install two screws to secure pass-
Be sure fork oil level is correct. The incorrect amount of
ing lamp bracket, chrome skirt and inner fairing to
fork oil can adversely affect handling and may lead to
lower fork bracket.
loss of vehicle control, which could result in death or
b. Move to front of motorcycle. Install two lower outer
serious injury.
fairing screws. Tighten two upper outer fairing
screws.
17. With the closer spaced coils at the bottom, slide fork
spring into fork tube.
c. Install fairing cap. See Section 2.29 UPPER FAIR-
ING/WINDSHIELD
(FLHT/C/U), FAIRING CAP,
18. Install new O-ring onto fork tube plug. Compressing fork
INSTALLATION
spring with end of fork tube plug, thread fork tube plug
FLTR:
into fork tube. Tighten fork tube plug to 22-58 ft-lbs (30-
79 Nm).
a. Install instrument nacelle. See Section 2.30 UPPER
FAIRING/WINDSHIELD
(FLTR), INSTRUMENT
19. Install new quad ring seal onto fork cap bolt. Thread fork
NACELLE, INSTALLATION.
cap bolt into fork tube plug to prevent loss of fork oil
FLHR/C/S:
while handling.
a. Install headlamp nacelle. See Section 2.31 WIND-
20. Loosely install axle holder, flat washers, lockwashers
SHIELD/HEADLAMP NACELLE
(FLHR/C/S),
and nuts on studs at end of fork slider.
NACELLE INSTALLATION (FLHR/C) or NACELLE
INSTALLATION (FLHRS).
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LOWER FORK BRACKET COVER/AIR DAM
2.16
LOWER FORK BRACKET COVER
(FLHRS)
REMOVAL
1.
Moving to the back of the lower fork bracket, remove two
hex screws (with flat washers) to release cover flange.
2.
Holding cover to prevent from dropping, remove T40
TORX screw at bottom.
7590
INSTALLATION
Figure 2-85. Air Dam
1.
With the concave side up, align holes in cover flange
with holes at back of the lower fork bracket.
NOTE
AIR DAM (FLTR)
Plastic plug(s) at back of lower fork bracket will prevent
proper cover installation. Remove and discard plug(s), if
present.
REMOVAL
3.
Start two hex screws (with flat washers) to fasten cover
1.
Moving to the back of the lower fork bracket, remove two
flange to bracket.
screws (with flat washers) to release the air dam. See
4.
Start T40 TORX screw at bottom of cover engaging off-
Figure 2-85.
set hole in front brake line bracket.
2.
To keep out dirt and debris, reinstall two screws (with flat
washers) into holes of lower fork bracket. Tighten screws
5.
Alternately tighten two hex screws to 70-110 in-lbs (7.9-
to 120-144 in-lbs (13.6-16.3 Nm).
12.4 Nm).
6.
Tighten T40 TORX screw to 120-180 in-lbs (13.6-20.3
Nm).
INSTALLATION
7.
Verify that cover does not contact brake lines to front
1.
With the concave side down, align holes in air dam with
brake calipers or master cylinder reservoir. Adjust either
holes at back of the lower fork bracket.
brake line bracket or cover if necessary.
NOTE
Plastic plug(s) at back of lower fork bracket will prevent
proper cover installation. Remove and discard plug(s), if
present.
2.
Install two screws (with flat washers) to fasten dam to
bracket. Tighten screws to 120-144 in-lbs (13.6-16.3
Nm).
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STEERING HEAD BEARINGS
2.17
LUBRICATION
At the 1000 mile (1600 km) service interval, and at every
Steering
10,000 mile (16,000 km) service interval thereafter, grease
Head
the steering head bearings using Special Purpose Grease,
Part No. 99857-97. Turn handlebar full right to access the
grease fitting at the left side of the steering head. Connect
grease gun to fitting and inject grease until it exudes from top
and bottom of steering head. See Figure 2-86.
At every 25,000 mile (40,000 km) service interval, check the
swing-by following the CHECKING procedure below.
At every 50,000 mile (80,000 km) service interval, disassem-
Grease
ble the steering head and inspect the bearings for brinelling,
Fitting
scoring, or other damage. Replace and/or repack the bear-
ings as required.
f2108x2x
CHECKING
Figure 2-86. Steering Head Bearing Grease Fitting
1. Using an hydraulic center stand on a level surface, raise
the vehicle so that the front and rear tires are the same
ADJUSTMENT
distance from the floor.
2. Verify that motorcycle is in stock configuration. Remove
1.
On FLHT/C/U models, remove outer fairing and radio
all non-factory accessories, since they can influence
(storage box on FLHT). On FLHR/C/S, remove head-
front end swing momentum (and lead to improper adjust-
lamp nacelle. On FLTR models, remove the instrument
ment).
bezel.
3. Turn the front wheel until contact is made with the left
2.
Loosen the pinch bolts on the lower fork bracket and
fork stop and then let go. The wheel should swing right,
slide the rubber fork stops up slightly on the fork tubes.
left, then right and stop. The wheel need not stop near
This will prevent any binding of the front end when the
the center or straight-forward position, but it must move
adjustment is made. See Figure 2-69.
to the right making a partial third swing. See frame C of
3.
Bend tab on lock plate away from flat of fork stem nut.
Figure 2-87.
Loosen the fork stem nut. See Figure 2-88.
4. To correct a swing pattern that is too short or too long,
4.
Fashion a bearing adjuster tool using a drill rod
16
see ADJUSTMENT below.
inches long. See lower frame of Figure 2-89.
A
B
C
D
Steering head is set up too
Steering head is still set up too
Steering head adjustment is
Steering head is set up too
tight. The wheel stops in its first
tight. The wheel stops in its
OK. The wheel need not stop
loose. The wheel begins its
swing.
second swing. A steering head
near the center, but it must
fourth swing. A steering head
that is too tight can interfere
move to the right making a
that is too loose can interfere
with the vehicle’s ability to
partial third swing.
with the vehicle’s ability to
absorb a weave.
absorb a wobble.
CORRECT
f1475x2x
Figure 2-87. Check Steering Head Bearing Swing-By
2004 Touring: Chassis
2-71
HOME
f1907x2x
Fork Stem
8257
Nut
Upper Fork Bracket
Bearing
Adjuster
Star Nut
Lock
Plate
Figure 2-88. Fork Stem Nut
f1792x2x
5/32 Inch goes back
for 1-1/4 Inches.
To decrease the number of swings, stand on the left side
5/32 Inch
A
of the vehicle and insert the rod to engage the notches
1/8 Inch
of the bearing adjuster (star) nut under the fork bracket.
NOTE
2 Inches
Each Rod is 1/4 Inch Diameter
Start of
Push forward to rotate the nut clockwise.
by 16 Inches Long.
Bend
A
End View
NOTE
Turning the bearing adjuster nut as little as one notch will
A
make a noticeable difference in the swing pattern.
To increase the number of swings, stand on the right
side of the vehicle and insert the rod to engage the
notches of the bearing adjuster nut. Push forward to
rotate the nut counterclockwise.
5. Tighten the fork stem nut to 60-80 ft-lbs (81-109 Nm).
The tightness of the nut will affect the swing pattern.
6. Recheck the swing pattern. See step 3 under CHECK-
ING. Repeat steps 4-6 above until swing pattern is cor-
rect.
7. Tighten pinch bolts to 30-35 ft-lbs (41-48 Nm) and prop-
erly position the rubber fork stops.
FLTR
8. Verify that the fork stem nut is tightened to 60-80 ft-lbs
All Others
Road Glide
(81-109 Nm). Bend tab on lockplate against flat of fork
stem nut.
9.
On FLHT/C/U models, install radio
(storage box on
FLHT) and outer fairing. On FLHR/C/S, install headlamp
nacelle. On FLTR models, install the instrument bezel.
Figure 2-89. Fashion Steering Head Bearing
10. Recheck the swing pattern. See step 3 under CHECK-
Adjustment Tool From Drill Rod
ING. Repeat ADJUSTMENT procedure if swing pattern
is not correct.
2.
Remove the front wheel and fork assemblies. Remove
brake line from lower fork bracket.
REMOVAL
3.
Bend tab away from flat of fork stem nut. Remove nut.
1.
On FLHT/C/U models, remove the passing lamp bracket,
outer fairing and radio (storage box on FLHT). On FLHR/
4.
Remove the bearing adjuster and fork stem assembly.
See upper frame of Figure 2-89. Remove dust shield
C, remove headlamp nacelle. On FLTR models, remove
the instrument nacelle.
and bearing from top of steering head.
2-72
2004 Touring: Chassis
HOME
Steering Head Bearing Race Remover
1. Install Remover on Upper Race
(Part No. HD-39301A)
Remover
Collet
Universal Driver
(Part No. HD-33416)
2. Install Collet on Driver
Figure 2-90. Steering Head Bearing Race Removal Tools
INSPECTION
1. Check the bearing races in the steering head. If pitted or
grooved, replace both the bearings and races.
2. Turn bearings in races. Replace the bearings if they do
not move freely and smoothly. Always replace both races
and bearings even if one race and bearing appears
good.
STEERING HEAD BEARING RACE REMOVAL
3. Install Driver in Remover
and Remove Upper Race
NOTE
To remove the upper and lower steering head bearing races,
use the Steering Head Bearing Race Remover (Part No. HD-
39301A) with the Universal Driver (Part No. HD-33416). See
Figure 2-90.
Proceed as follows:
1. With the tapered side down, seat the two-piece remover
tool on the upper bearing race leaving a gap in the mid-
dle. See Figure 2-91.
2. Install the collet on the driver.
3. Insert the driver at the bottom of the steering head tube,
and while holding the remover tool on the race, center
the collet in the gap. Tap the driver to remove the upper
race.
4. Reverse the tool and repeat the procedure to remove the
f1279x2x
4. Remove Lower Race
lower bearing race.
Figure 2-91. Remove Upper and Lower
REMOVING BEARING FROM FORK STEM
Steering Head Bearing Races
1. Chisel cage retaining rollers off bearing on fork stem.
2. Turn the stem upside down while heating the inner race.
Race will expand and fall free.
2004 Touring: Chassis
2-73
HOME
ASSEMBLY
1
WARNING
1.
Pack new bearings with Harley-Davidson SPECIAL
Be sure fork stem nut adjustment is correct. An improp-
PURPOSE GREASE, Part No. 99857-97.
erly adjusted nut can adversely affect handling and may
lead to loss of vehicle control, which could result in
2.
Install dust shield on fork stem. Use a sleeve that will
death or serious injury.
contact only the inner race of the new bearing, then
press the bearing into place on fork stem.
2.
Install upper fork bracket and fork stem nut. Tighten nut
to
60-80 ft-lbs
(81-109 Nm). Bend the lockplate tab
3.
Install new bearing races in steering head using STEER-
against the nut flat. See Figure 2-88.
ING HEAD BEARING RACE INSTALLATION TOOL,
3.
Install fork assemblies, radio (storage box on FLHT),
Part No. HD-39302.
outer fairing and passing lamp bracket. On FLHR/C/S,
install headlamp nacelle. On FLTR models, install the
instrument bezel.
INSTALLATION
4.
Install the front wheel and bleed the front brake. Check
swing-by under CHECKING in this section.
1.
Install the fork stem assembly into the steering head.
Install the bearings and dust shield. Install the bearing
adjuster nut. Snug the adjuster nut down until bearing
play is taken up and the fork stem turns freely. Overtight-
ening the nut will cause excessive bearing wear.
2-74
2004 Touring: Chassis
HOME
REAR AIR SUSPENSION
2.18
GENERAL
Frame
All models feature air-adjustable rear suspension. Air pres-
Cover
sure may be varied to suit load conditions, riding style and
personal comfort. Less initial pressure does not necessarily
result in a softer ride. See the table below for the recom-
mended air suspension pressures.
Table 2-3. Rear Air Suspension Pressures
Recommended
Shock Loading
Pressures
PSI
kPa
All Models Except FLHRS - Standard Shocks
Solo rider up to 150 lbs. (68 kg),
0
0
hereafter referred to as “Average”
Solo rider 150-200 lbs. (68-91 kg)
0-10
0-69
Solo rider 200-250 lbs. (91-113 kg)
5-15
35-103
Air Valve
Average rider with passenger
f2018x2x
10-15
69-103
up to 150 lbs. (68 kg)
Average rider with passenger
Figure 2-92. Rear Air Suspension Air Valve
20-25
138-172
up to 200 lbs. (91 kg)
(Under Protective Cap)
Maximum GVWR
20-35
138-241
(see Section 2.1 Specifications)
FLHRS Only - Low Profile Shocks
CAUTION
Solo rider up to 160 lbs. (73 kg),
0-5
0-35
hereafter referred to as “Average”
Improper inflation of rear air suspension components
also can result in a reduction of available suspension
Solo rider 160-200 lbs. (73-91 kg)
0-10
0-69
travel, reduced rider comfort and possible damage to
Solo rider over 200 lbs. (91 kg)
5-10
35-69
shock absorbers.
Average rider with passenger
20-30
138-207
up to 150 lbs. (68 kg)
CAUTION
Average rider with passenger
25-35
172-241
All air components fill rapidly. Use low air line pressure
over 150 lbs. (68 kg)
to avoid possible damage. A small hand or foot operated
Maximum GVWR
air pump is the best way to add air to suspension com-
40-50
276-345
(see Section 2.1 Specifications)
ponents.
1WARNING
CAUTION
Use this table as a starting point in determining suit-
Use a no-loss air gauge to check air pressure. Check
able rear air suspension pressures. Do not exceed
pressure in shocks weekly if in daily use or before each
maximum GVWR when loading vehicle and do not
trip if only used occasionally.
pressurize system in excess of 50 psi (345 kPa) for
FLHRS models and 35 psi (241 kPa) for all others.
NOTE
Excessive load weight and/or air suspension pres-
sure can adversely affect handling and lead to loss
An AIR SUSPENSION PUMP AND GAUGE (Part No. HD-
of vehicle control, which could result in death or
34633) is available at your Harley-Davidson dealer.
serious injury.
2004 Touring: Chassis
2-75
HOME
Air Suspension Air Valve
Right
and Mounting Bracket
Shock
Below Left Side Frame Cover
Shock
Air Inlet Tee
Shock
Hex Nut
Air Inlet Tube
Protective
Cap
Compression
Fitting
Left
Shock
Depress collar on fitting and pull out air tube.
To install, insert air tube into fitting until it bottoms.
Gently tug on tube to verify that it is locked in place.
f2017x2x
Figure 2-93. Rear Air Suspension System
2-76
2004 Touring: Chassis
HOME
1WARNING
Air Inlet
Tee
Exercise caution when bleeding air from the air valve.
Moisture combined with lubricant (either from shock
assembly or drip oiler in the air compressor lines) may
be ejected onto the rear wheel, tire and/or brake compo-
nents and adversely affect traction and/or braking effi-
ciency, which could result in death or serious injury.
REAR AIR SUSPENSION
f2041x2x
Valve Head
Adjust the rear shock air suspension pressure by adding or
removing air from the air valve located just below the frame
Figure 2-95. Air Valve Assembly
cover on the left side of the vehicle. See Figure 2-92. Always
adjust pressures with the vehicle on the jiffy stand.
a.
Depress pin in valve to bleed air from shocks. To
purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)
before releasing air.
REMOVAL/INSTALLATION
b.
Remove air tube from compression fitting. Inspect
the tube end for burrs or damage. If either condition
Remove and replace components as necessary. Check for
is observed, snip off the end of the tube and insert it
air leaks as follows:
back into the fitting.
1. Remove left side saddlebag. See Section 2.25 SAD-
c.
Pressurize rear air suspension system and check
DLEBAG, REMOVAL.
for leaks. If leakage continues, proceed to step 5(d).
2. Remove protective cap from air valve. Install the no-loss
d.
Remove air tube from compression fitting. Remove
air gauge and set to correct pressure. See Table 2-3.
compression fitting from shock absorber.
Remove the gauge and wait overnight.
e.
Apply PIPE SEALANT WITH TEFLON to the
3. Recheck air pressure. If no leakage is observed, move
to step 8. If a loss of 5-10 psi (34.5-68.9 kPa) is noted,
threads of a new compression fitting and install in
shock absorber.
then proceed to step 4.
4. Pressurize rear air suspension system and check for
f.
Install air tube in compression fitting.
leaks as described below.
g.
Pressurize rear air suspension system and check
for leaks. If no leakage is observed, move to step 8.
If leakage continues, proceed to step 6.
Compression Fitting
5. Spray or brush a light film of soapy water on the com-
Air Valve Assembly
pression fitting at the top of each shock absorber. If no
leakage is observed, move to step 6. If leakage is noted,
6.
Spray or brush a light film of soapy water into the valve
proceed as follows:
head and where the air tubes exit the air inlet tee. If leak-
age is not observed at either location, move to step 7. If
leakage is noted, proceed as follows:
a. If leakage is at the air inlet tee, proceed to step 6(b).
If leakage is at the valve head, proceed to step 6(e).
b. Depress pin in valve to bleed air from shocks. To
purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)
before releasing air.
c. Remove air tubes from air inlet tee. Inspect the tube
ends for burrs or damage. If either condition is
observed, snip off the end of the tube and insert it
back into the fitting.
d. Pressurize rear air suspension system and check
Figure 2-94. Air Suspension Pump and Gauge
for leaks. If no leakage is observed, move to step 8.
(Part No. HD-34633)
If leakage continues, proceed to step 6(e).
2004 Touring: Chassis
2-77
HOME
e.
Using a valve core tool, verify that valve core is
d. Cut bulk tube to proper length.
properly tightened. If leakage continues, proceed to
e. Insert new tubes into air inlet tee. Install opposite
step 6(f).
end of tubes into compression fittings.
f.
Depress pin in valve to bleed air from shocks. To
f.
Pressurize rear air suspension system.
purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)
g. Install seat. See Section
2.24 SEAT, INSTALLA-
before releasing air.
TION.
g.
Remove hex nut from valve head. See Figure 2-93.
8.
Install protective cap on air valve.
h.
Push on valve head to free air valve assembly from
mounting bracket. See Figure 2-95.
9.
Install left side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
i.
Remove air tubes from air inlet tee.
j.
Insert air tubes into air inlet tee of new air valve
assembly.
k.
From inboard side, insert valve head through hole in
mounting bracket. Install hex nut on valve head (flat
side facing inboard). Tighten nut to 40-50 in-lbs
(4.5-5.6 Nm).
l.
Pressurize rear air suspension system and check
for leaks.
m.
If no leakage is observed, move to step 8. If leakage
continues, reinstall old air valve assembly and pro-
ceed to step 7.
Air Tubes
7.
Inspect air tubes for kinks, cuts, holes, chafing or other
damage that may result in air leaks. If tube replacement
is necessary, proceed as follows:
a. Remove seat. See Section 2.24 SEAT, REMOVAL.
b. Depress pin in valve to bleed air from shocks. To
purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)
before releasing air.
c. Remove air tubes from air inlet tee. Remove oppo-
site end of tubes from compression fittings. See Fig-
ure 2-93.
2-78
2004 Touring: Chassis
HOME
REAR SHOCK ABSORBERS
2.19
ADJUSTMENT
Depress Collar on Fitting
and Pull Out Air Inlet Tube.
For the correct air pressure, see Section 2.18 REAR AIR
SUSPENSION.
REMOVAL
NOTE
If replacing both shock absorbers, remove and install one
shock at a time. Remove and install the second shock only
after the first shock is installed, but before the air suspension
system is pressurized.
1. Place the motorcycle on a hydraulic center stand with
the rear wheel raised off the ground.
2.
Remove saddlebags. See Section 2.25 SADDLEBAG,
REMOVAL.
f1449a2x
1WARNING
Air Inlet
Tube
Frame
Exercise caution when bleeding air from the air valve.
Boss
Moisture combined with lubricant (either from shock
assembly or drip oiler in the air compressor lines) may
be ejected onto the rear wheel, tire and/or brake compo-
nents and adversely affect traction and/or braking effi-
ciency, which could result in death or serious injury.
3.
Remove protective cap from air valve. Using a no-loss
AIR SUSPENSION PUMP AND GAUGE (Part No. HD-
34633), add 3-5 psi (20.7-34.5 kPa) to purge lines of any
oil.
4.
Depress pin in valve to bleed air from shocks.
5.
Depress collar on compression fitting to release air tube.
See upper frame of Figure 2-96.
6.
Remove the upper shock mounting bolt with lockwasher
Shock
and flat washer. See lower frame of Figure 2-96.
Absorber
7.
Remove the lower shock mounting bolt with lockwasher
and flat washer. Remove the shock absorber assembly
Compression
from the vehicle.
Fitting
f2010x2x
Figure 2-96. Remove Air Inlet Tube and
Upper Shock Mounting Bolt (Left Side View)
DISASSEMBLY
NOTE
Air shocks are not repairable. Replace the shocks if dam-
aged or worn.
2004 Touring: Chassis
2-79
HOME
CLEANING AND INSPECTION
INSTALLATION
1. Examine the rubber mounting bushings for cracks or
1. Install lockwasher and flat washer on the lower shock
wear. Examine the shock for leaks. The unit should not
mounting bolt. Insert bolt through the shock bottom
leak and should compress slightly easier than it extends.
bushing.
Compare the action of the shock with a new one to judge
2. Apply two or three drops of Loctite Medium Strength
if it is worn. Replace the shock if necessary.
Threadlocker 243 (blue) to threads.
2. Clean and examine the shock mounting hardware.
3. Start bolt into rear swingarm mount. Tighten bolt to 35-
Replace parts that are worn or damaged.
40 ft-lbs (47-54 Nm).
4. Install lockwasher and flat washer on the upper shock
mounting bolt. Insert bolt through the shock upper bush-
ASSEMBLY
ing
5. Apply two or three drops of Loctite Medium Strength
NOTE
Threadlocker 243 (blue) to threads.
If the compression fittings were removed, apply PIPE SEAL-
6. Start bolt into frame boss. Tighten bolt to 33-35 ft-lbs
ANT WITH TEFLON to the threads before assembly.
(45-48 Nm).
7. Insert air tube into compression fitting until it bottoms.
Gently tug on tube to verify that it is locked in place.
NOTE
If replacing both shock absorbers, remove and install the
other shock at this time.
8. Pressurize rear air suspension system and check for
leaks. For the correct air pressure, see Section 2.18
REAR AIR SUSPENSION.
9. Install saddlebags. See Section
2.25 SADDLEBAG,
INSTALLATION.
2-80
2004 Touring: Chassis
HOME
REAR SWINGARM
2.20
REMOVAL
1.
Remove saddlebags. See Section 2.25 SADDLEBAG,
REMOVAL.
Rear
Rubber
Swingarm
Mount
2.
Remove socket screw with lockwasher to remove pas-
senger footboard from rear swingarm bracket. Repeat
step on opposite side of vehicle.
3. Remove both mufflers as follows:
Left Side
a. Open worm drive clamps to remove heat shield
Slot
from crossover pipe in front of muffler.
b. Using a bungee cord, tie the muffler to the lower
saddlebag support rail.
Locknut
c. Loosen TORCA clamp between crossover pipe and
muffer.
Pivot
Shaft
d. Remove two bolts (with lockwashers) to detach muf-
fler from the lower saddlebag support rail.
e. Remove bungee cord to release muffler from lower
saddlebag support rail.
f2006x2x
Right Side
Figure 2-97. Remove Rear Swingarm Bracket
a. Open worm drive clamps to remove heat shield
(Left Side View)
from rear header pipe in front of muffler.
b. Using a bungee cord, tie the muffler to the lower
9.
Remove caliper from anchor weldment on rear swing-
saddlebag support rail.
arm, and carefully hang over lower saddlebag support
c. Loosen TORCA clamp between rear header pipe
rail.
and muffer.
10.
Roll wheel forward and slip belt off sprocket. Move wheel
d. Remove two bolts (with lockwashers) to detach muf-
out from beneath rear fender.
fler from the lower saddlebag support rail.
11.
Remove belt guard from bottom of left side swingarm.
e. Remove bungee cord to release muffler from lower
First remove two rear screws, and then loosen front
saddlebag support rail.
screw. Push belt guard toward the front of the vehicle
until screw engages large end of slot, and then remove.
4.
Place the motorcycle on a hydraulic center stand. Slide
a block of wood beneath the oil pan to support the
12.
Remove lower shock mounting bolt (with lockwasher and
flat washer) to release shock absorber from rear swing-
weight of the transmission once the pivot shaft is
removed.
arm mount. Repeat step on opposite side of vehicle.
5.
Standing on right side of vehicle, remove E-clip from
13.
Remove two bolts (with lockwashers) to free rear swing-
groove at end of axle.
arm bracket from left side of vehicle frame. See Figure 2-
97.
6.
Remove cone nut and adjuster cam from axle.
14.
Moving to right side of vehicle, leave rear swingarm
7.
Using a soft mallet, gently tap end of axle towards left
bracket installed, but remove decorative chrome plug.
side to loosen. Catching external spacers on right and
left side of hub, pull axle free of wheel and rear
15.
Open two cable clips on T-studs at top of right side swin-
swingarm.
garm. Free rear brake line hose from cable clips.
8.
Pull wheel to release brake disc from caliper. Pry inner
NOTE
and outer brake pads back for additional clearance, if
necessary. Use a putty knife with a wide thin blade to
For best results, insert blade of small screwdriver into gap at
avoid scoring or scratching the brake disc.
side of clip and gently rotate end of screwdriver to pop open.
2004 Touring: Chassis
2-81
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