Harley Davidson 2004 Touring Models. Service Manual — page 58

HOME

Service

Operation

Data

Lubricant level

Dipstick at FULL

with motorcycle

level and filler plug

resting on threads.

Lubricant capacity

20-24 oz (590-710

mL) Part No.’s

Transmission

99892-84 (qt),

Lubricant

99891-84 (gal)

Transmission drain

plug torque

14-21 ft-lbs

(19-28 Nm).

Filler plug torque

25-75 in-lbs

(2.8-8.5 Nm)

Tire Condition

See page 2-3 in

and Pressure

this document

Spoke nipple

torque

Wheel Spokes

40-50 in-lbs

(4.5-5.6 Nm)

Lubricate through

neck fitting with

Special

Purpose Grease,

Part No. 99857-

97 (cartridge)

Steering

For swing-by in-

Head Bearings

spection or dis-

assembly in-

structions, see

page 2-71 of the

2004 Touring

Models Service

Manual

Minimum brake pad

Brake Pad

thickness

Linings and Discs

0.04 in.

(1.02 mm)

R - Replace or change

I - Inspect (adjust, clean or replace as required)

L - Lubricate (with specified lubricant)

X - Perform

T - Tighten to proper torque

D - Disassemble (lube and inspect as required)

1-2

2004 FLT Police: Maintenance

HOME

Service

Operation

Data

D.O.T. 5 Brake fluid

Brake Fluid

Part No.’s 99902-

Reservoir Level

77 (12 oz),

and Condition

99901-77 (gal)

On ground without

rider

1/4-5/16 in.

Drive Belt

(6.4-7.9 mm) on

bottom strand

with 10 lb. (4.5

kg) upward force

See page 2-79 of

Rear Shock

the 2004 Touring

Absorbers

Models Service

Manual

Air cleaner cover

screw torque

Air Cleaner

36-60 in-lbs

(4-7 Nm)

Fuel Valve, Lines

Check for leaks.

and Fittings

Hex fitting torque

Fuel Tank Filter

15-20 ft-lbs

(20-27 Nm)

See page 4-5 of

the 2004 Touring

Enrichener Control

Models Service

Manual

Lubricant

Part No. 94968-

85TV- 1/4 fl. oz.

Handlebar clamp

screw torque

Throttle Cables

60-80 in-lbs

(6.8-9.0 Nm)

Switch housing

screw torque

35-45 in-lbs

(4-5 Nm)

R - Replace or change I - Inspect (adjust, clean or replace as required)

L - Lubricate (with specified lubricant)

X - Perform

T - Tighten to proper torque

D - Disassemble (inspect and repack as required)

2004 FLT Police: Maintenance

1-3

HOME

Service

Operation

Data

Electrical

Check for proper

Components

operation.

Plug type

HD-6R12

Plug gap

0.038-0.043 in.

Spark Plugs

(0.97-1.09 mm)

Plug torque

12-18 ft-lbs

(16-24 Nm)

Idle speed

Engine Idle Speed

950-1050 rpm

Verify tightness.

See CRITICAL

FASTENERS on

Critical Fastener

page 1-30 of the

Torque

2004

Touring

Models

Service

Manual

Verify tightness.

See ENGINE

Stabilizer Links

MOUNTS on page

and Engine

1-30 of the 2004

Mounts

Touring Models

Service Manual

Fork oil (Type E)

Front Fork Oil

Part No. 99884-

80 (16 oz)

Windshield

Grommets (FLHP)

Road Test

R - Replace or change

I - Inspect (adjust, clean or replace as required)

L - Lubricate (with specified lubricant)

X - Perform

T - Tighten to proper torque

D - Disassemble (lube and inspect as required)

1-4

2004 FLT Police: Maintenance

HOME

SPECIFICATIONS

2.1

FUEL TANK

OIL TANK

TRANSMISSION

PRIMARY

TOTAL

RESERVE

W/FILTER

(APPROX.)

CHAINCASE

MODEL

gal.

liter

gal.

liter

qt.

liter

oz.

liter

oz.

liter

FLHTP

5.0

18.92

4.0

3.79

0.71

0.95

FLHP

OVERALL

ROAD

OVERALL

SADDLE

WHEEL BASE

LENGTH

WIDTH

CLEARANCE

HEIGHT

HEIGHT (Laden)

MODEL

in.

FLHTP

63.5

1612.9

93.70

2379.9

39.0

990.6

5.1

129.5

61.0

1549.4

27.3

693.4

FLHP

63.5

1612.9

93.70

2379.9

34.5

876.3

5.1

129.5

55.1

1399.5

27.3

693.4

DRY WEIGHT

GVWR

GAWR FRONT

GAWR REAR

MODEL

lb.

FLHTP

758.0

343.8

1200

544.3

500

226.8

770

349.3

FLHP

723.0

327.9

1200

544.3

500

226.8

770

349.3

NOTE

Gross vehicle weight rating (GVWR) (maximum allowable

See Section 2.3 TIRES for important information regarding

loaded vehicle weight) and corresponding gross axle weight

tire data and tire inflation.

rating (GAWR) are printed on a label fixed to the bottom of

the right front frame downtube.

2004 FLT Police: Chassis

2-1

HOME

VEHICLE IDENTIFICATION NUMBER

2.2

between the front and rear cylinders on the left side of the

GENERAL

crankcase.

A 17-digit serial number, or Vehicle Identification Number

NOTE

(VIN), is stamped on the right side of the frame backbone at

Always give the complete VIN when ordering parts or making

the rear of the steering head (and under the main harness

an inquiry about your motorcycle.

conduit). A label bearing the VIN code is also affixed to the

left side of the steering head. An abbreviated VIN is stamped

Market Designation

1 = Domestic

Manufacturer and Make

Engine Type

Harley-Davidson

Model Designation

5 = International (HDI)

V - Carbureted

FH - FLHPI

W - Fuel Injected

FM - FLHTPI

Motorcycle Type

FT - FLHPEI

1 - Heavyweight

Introduction Date/Special Models

1 = Regular introduction date

2 = Mid-year introduction date

3 = California model

4 = Anniversary model

Vin Check Digit

Varies; can be 0 thru 9, or X.

Model Year

Assembly Plant

4 - 2004

Y - York, PA

K - Kansas City, MO

Serial Number

FM W

110000

Sample VIN as it appears on the steering head - 1HD1FMW134Y110000

Sample abbreviated VIN as it appears on the engine - FMW4110000

Figure 2-1. Vehicle Identification Number (VIN)

2-2

2004 FLT Police: Chassis

HOME

TIRES

2.3

NOTE

GENERAL

Use the tires recommended for civilian/pleasure vehicles of

the same year and model family.

The rear tire on FL police motorcycles is fit for solo riding

only. If converted to a two-up bike, that is, configured for pas-

senger use (with luggage), then the rear tire needs to be

1WARNING

changed to one with a higher weight rating. Since it has long

been Harley-Davidson policy not to mix different types of tires

The Dunlop front and rear tires on Harley-Davidson

on the same vehicle, we strongly recommend that both front

motorcycles are not interchangeable. DO NOT put a front

and rear tires be replaced. In order to alert the customer to

tire at the rear of the vehicle or a rear tire at the front.

this safety issue, the following warning appears on a label fit-

Improper placement of tires can adversely affect motor-

ted to the rear fender approximately 1/4 inch (6.4 mm) behind

cycle stability and handling, which may lead to loss of

the domestic seat mounting hole.

vehicle control resulting in death or serious injury.

(00026a)

1WARNING

Tire size, manufacturer’s description and inflation pressure

are listed below.

This vehicle has tires with weight ratings for one person

operation. If this vehicle is modified to carry two people,

the tires must be changed. See your local Harley-David-

son dealer for the proper replacement tires. Failure to fol-

low this warning could cause tire failure which could

result in death or serious injury. (00096a)

Table 2-1. Tire Data

TIRE

MANUFACTURER’S

MODEL

SIZE

PRESSURE

LOCATION

DESIGNATION

(Cold)

Dunlop

36 psi

Front

MT90B1672H

D402F PT

(248 kPa)

FLHTP/FLHP

Dunlop

36 psi

Rear

MT90B1671H

D402 PT

(248 kPa)

2004 FLT Police: Chassis

2-3

HOME

SEAT

2.4

OPERATION

5872

Quick Release

Pin

CAUTION

Maximum seat air pressure is 100 psi (689 kPa). Normal

air pressure is between 30-45 psi (207-310 kPa). Minimum

air pressure is determined by rider weight. Do not oper-

ate with pressure so low that system bottoms out on

bumpy roads. (00167a)

NOTE

Support

Post

Rear Seat

To set minimum air pressure, have rider sit on seat and

Bracket

bounce to simulate riding conditions. Visually check for any

contact between air spring and frame components. Add air as

necessary.

Figure 2-2. Seat Latch

1. Standing on left side of vehicle, press down on rear of

3. While pressing down on rear of seat, insert quick release

seat and pull quick release pin from hole in support post.

pin into hole of support post.

See Figure 2-2. Raise seat toward fuel tank console.

NOTE

2. To lock seat in place, move seat down until support post

engages hole in rear seat bracket.

The seat does not adjust forward or backward.

Air spring hose

Air spring

Screw (2) @ 36-60 in-lbs (4.1-6.8 Nm)

Trim panel

Seat faring

Screw

Rivnut (4)

Screw

Bushing

10.

Seat support bracket

11.

Nut @ 48-84 in-lbs (5.4-9.5 Nm)

12.

Seat

13.

Seat mount bracket (2)

14.

Washer

15.

Screw @ 60-120 in-lbs (6.8-13.6 Nm)

16.

Screw (4) @ 15-20 ft-lbs (20.3-27.1 Nm)

17.

Rubber bumper

18.

Flange locknut (2) @ 96-144 in-lbs (10.9-16.3 Nm)

19.

Quick release pin

20.

Flange nut (2) @ 60-120 in-lbs (6.8-13.6 Nm)

21.

Washer (2)

22.

Rear seat bracket

23.

Set screw (2)

24.

Nut (2) @ 50-70 in-lbs (5.7-7.9 Nm)

25.

Quick release fitting

p0047c2x

Figure 2-3. Air Seat Support

2-4

2004 FLT Police: Chassis

HOME

AIR SEAT RESERVOIR

f1842x2x

Air Pressure

Air

Gauge

Reservoir

Removal

Remove luggage rack. See Section

2.6 LUGGAGE

RACK, REMOVAL, steps 1-5.

2. Alternately loosen screws on each side of motorcycle to

release ends of luggage rack from frame tube weld-

ments. Continue loosening screws until luggage rack can

be raised high enough to remove air reservoir.

Air Valve

3. Remove two Phillips screws (with lockwashers) from lug-

gage rack to release top of air reservoir bracket.

Remove two Phillips screws from license plate bracket to

free rear of air reservoir bracket. Be sure to hold reser-

voir as the last screw is removed or damage to fender

paint may occur when assembly is released.

Figure 2-4. Air Seat Reservoir Air Valve

Raise luggage rack and remove air reservoir from motor-

cycle.

Slide Phillips screws through two holes in license plate

6. Remove tee fittings from reservoir, if necessary.

bracket and two holes in luggage rack engaging weld

nuts in air reservoir bracket. Alternately tighten screws

until snug.

Installation

Alternately tighten screws on each side of motorcycle to

1. Install tee fittings to air reservoir, if removed.

secure ends of luggage rack to frame tube weldments.

2. Position air reservoir beneath luggage rack exercising

Install luggage rack. See Section 2.6 LUGGAGE RACK,

caution to avoid scratching fender paint.

INSTALLATION, steps 1-4 and 6-13.

1. Air seat reservoir and

bracket

2. Lockwasher (2)

3. Screw (2)

4. Air pressure gauge

5. Air tube

6. Compression fitting

7. Air valve

8. Protective cap

9. Tee fitting (2)

p0048b2x

10. Screw (2)

Figure 2-5. Air Seat Reservoir

2004 FLT Police: Chassis

2-5

HOME

FOOTBOARDS

2.5

4. At footboard rear bracket, slide upper hex bolt through

GENERAL

frame weldment, jiffy stand bracket and footboard

bracket thru hole. Install lockwasher and locknut. Slide

FLHTP and FLHP models are equipped with adjustable foot-

lower hex bolt (with lockwasher) through frame weldment

boards.

and jiffy stand bracket into threaded hole of footboard

bracket. Alternately tighten two hex bolts to 15-20 ft-lbs

(20.3-27.1 Nm).

NOTE

ADJUSTMENT

Perform a visual check to verify that both footboards are at

the same height.

Right Side

Loosen two allen head socket screws (with lockwashers

and flat washers) to release right side footboard brackets

from frame weldment. For best results, approach from

left side of vehicle using a 3/8 inch ball allen with exten-

sion.

Move the footboard to one of two positions. Alternately

tighten allen head socket screws to 30-35 ft-lbs (40.7-

47.5 Nm).

1WARNING

Rear brake will not operate properly if brake pedal can-

not be fully depressed. After adjusting right footboard,

check for minimum clearance of 2.25 inches (57 mm)

between bottom of brake pedal and top of footboard.

Failure to allow for proper clearance can lead to loss of

braking performance, which could result in death or seri-

ous injury.

Left Side

1. Loosen the allen head socket screw (with lockwasher

and flat washer) to release the footboard forward bracket

from frame weldment. For best results, approach from

opposite side of vehicle using a 3/8 inch ball allen.

2. To free footboard rear bracket from frame weldment and

jiffy stand bracket, remove lower hex bolt

(with lock-

washer) and upper hex bolt (with lockwasher and lock-

nut).

3. Move the footboard to one of two positions. Alternately

tighten allen head socket screw to 30-35 ft-lbs (40.7-47.5

Nm).

2-6

2004 FLT Police: Chassis

HOME

LUGGAGE RACK

2.6

REMOVAL

6046

1. Remove both saddlebags.

2. On the right side of the motorcycle, locate the air seat

reservoir air valve under the luggage rack, and on the left

side, the rear shock air valve just below the chrome

frame cover. See Figure 2-6.

1WARNING

Exercise caution when bleeding air from the air valves.

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.

f1842x2x

Air Seat

Reservoir

Figure 2-7. Remove Luggage Rack

Air Valve

Remove protective cap from each air valve and depress

pin to bleed air from both reservoir and shocks. To purge

rear air suspension lines of any oil, add 3-5 psi (20.7-

34.5 kPa) before releasing air. Depress collar on each

compression fitting and pull out air tube.

Remove bolt (with flat washer) to remove saddlebag front

mounting bracket from chrome frame cover. Remove

Phillips screw and then remove frame cover. Repeat step

on opposite side of motorcycle.

Remove two bolts to free license plate bracket from bot-

tom support tube.

Remove screws (with spacers) on each side of motorcy-

cle to release ends of luggage rack from frame tube

Rear Shock

weldments.

Air Valve

Remove pole lamp. See Section 8.5 POLE LAMP.

Slide luggage rack toward rear of motorcycle to clear

front bushings, and then rotate rack upward to clear

frame tubes. See Figure 2-7.

f2018x2x

INSTALLATION

1. Place luggage rack into position inboard of frame tubes.

Figure 2-6. Air Valves

2004 FLT Police: Chassis

2-7

HOME

Install screws (with spacers) on each side of motorcycle

Table 2-2. Rear Air Suspension Pressures

to secure ends of luggage rack to frame tube weldments.

Recommended

Install two bolts to fasten license plate bracket to bottom

Shock Loading

support tube.

Pressures

PSI

kPa

Position chrome frame cover on frame tube and install

0-35

0-241

Phillips screw. Install bolt (with flat washer) to install sad-

dlebag front mounting bracket, but do not tighten. Repeat

Solo rider up to 150 lbs. (68 kg)

step on opposite side of motorcycle.

Solo rider 150-200 lbs. (68-91 kg)

0-10

0-69

Install pole lamp. See Section 8.5 POLE LAMP.

Solo rider 200-250 lbs. (91-113 kg)

5-15

35-103

Depress collar on compression fitting of air seat reser-

Maximum GVWR (see Section 2.1

20-35

138-241

voir, and insert air tube until it bottoms. Gently tug on

SPECIFICATIONS)

tube to verify that it is locked in place.

1WARNING

CAUTION

Use this table as a starting point in determining suit-

Maximum seat air pressure is 100 psi (689 kPa). Normal

able rear air suspension pressures. Do not exceed

air pressure is between 30-45 psi (207-310 kPa). Minimum

maximum GVWR when loading vehicle and do not

air pressure is determined by rider weight. Do not oper-

pressurize system in excess of 35 psi (241 kPa).

ate with pressure so low that system bottoms out on

Excessive load weight and/or air suspension pres-

bumpy roads. (00167a)

sure can adversely affect handling and lead to loss

of vehicle control, which could result in death or seri-

Fill air reservoir to desired pressure. Install protective

ous injury.

cap on air valve. See upper frame of Figure 2-6.

NOTE

To set minimum air pressure, have rider sit on seat and

11.

Observe air pressure gauge while filling. If leakage

bounce to simulate riding conditions. Visually check for any

occurs, remove tubes and inspect ends for burrs or dam-

contact between air spring and frame components. Add air as

age. If either condition is found, snip off end of tube and

necessary.

insert back into fitting.

Observe air pressure gauge. If leakage occurs, then

12.

When air pressure remains constant, install protective

remove tube and inspect end for burrs or damage. If

cap on air valve.

either condition is found, snip off end of tube and insert

13.

Install saddlebags. Using an open end/box wrench,

back into fitting.

tighten saddlebag front mounting bracket bolts.

Depress collar on compression fitting of each shock and

insert air tube until it bottoms. Gently tug on tube to verify

that it is locked in place.

10. Fill shocks to desired pressure. See Table 2-2.

CAUTION

All air components fill rapidly. Use a small hand or foot

operated air pump to avoid possible damage to shocks

or air suspension components.

NOTE

An AIR SUSPENSION PUMP AND GAUGE (Part No. HD-

34633) is available at your Harley-Davidson dealer.

2-8

2004 FLT Police: Chassis

HOME

INSTRUMENT MOUNTING BRACKET: FLHP

2.7

GENERAL

The Instrument Mounting Bracket relocates the tachometer to

allow for the addition of a radio and speaker.

NOTE

The two rear holes in the handlebar clamp shroud allow the

rider to adjust the handlebars without having to remove the

shroud. To keep out moisture and debris, be sure to install

plastic plugs back into holes after handlebar adjustment.

INSTALLATION

Remove windshield. See Section 2.31 WINDSHIELD/

HEADLAMP NACELLE (FLHR/C/S), REMOVAL, in the

2004 Touring Models Service Manual (Part No. 99483-

04).

Remove Phillips screw at the bottom of the headlamp

door (chrome ring). Remove the headlamp door.

Remove the eight Phillips screws to free the headlamp

housing from the headlamp nacelle.

Squeeze the two external tabs (if present) to remove the

wire connector at the back of the headlamp bulb.

Remove headlamp housing assembly from the vehicle.

Reaching inside the headlamp nacelle, remove flange

nut to release the chrome strip at the top of the nacelle.

See Figure 2-8.

Carefully pry off the fork lock plate at the rear of the han-

dlebar clamp shroud. Remove two Phillips screws

f1458d2x

beneath the lock plate.

Headlamp Nacelle

Tachometer Bracket

Loosen the Phillips screw from tab at the front of the han-

Nut

Acorn Nut (2)

dlebar clamp shroud (but do not remove).

Flat Washer

Fork Lock Plate

Remove two acorn nuts from the left side fork studs.

Flange Nut

10.

Handlebar Clamp Shroud

Remove acorn nuts from the right side fork studs.

Chrome Strip

11.

Stud Plate

Phillips Screw (2)

Cover front fender with suitable material to protect fender

paint. Remove the passing lamp bracket from the left and

Figure 2-8. Headlamp Nacelle Assembly

right side fork studs and carefully set on front fender.

10.

Remove grommets (and clutch cable clamp) from the left

and right side fork studs.

13. Remove two acorn nuts and flat washers to release

tachometer bracket from the handlebar clamp shroud.

11.

Reaching inside the headlamp nacelle, disconnect

tachometer connector [108], 3-place Deutsch.

14. A peel and stick foam tape on the stud plate holds it in

place on the inboard side of the handlebar clamp shroud,

12.

Remove the handlebar clamp shroud from the vehicle,

Place the instrument mounting bracket over the studs

while gently pulling the tachometer conduit and connec-

and secure using hardware provided by manufacturer.

tor out of the headlamp nacelle. See Figure 2-9.

See upper frame of Figure 2-11.

2004 FLT Police: Chassis

2-9

HOME

5531

f1458e2x

Figure 2-9. Handlebar Clamp Shroud

Install instrument mounting bracket on stud plate.

p0044x5x

5532

Install instrument mounting bracket front bolt.

5530

1. Acorn Nut

2. Instrument Mounting

4. Stud Plate

Bracket

5. Screw

3. Handlebar Clamp Shroud

6. Nut

Figure 2-10. Instrument Mounting Bracket Assembly

Install tachometer bracket.

15. Secure slotted tab of instrument mounting bracket to

front of handlebar clamp shroud using nut and bolt pro-

vided by manufacturer. See middle frame of Figure 2-11.

Figure 2-11. Install Instrument Mounting Bracket

16. Place tachometer bracket over studs on instrument

mounting bracket and install two acorn nuts with flat

washers. See lower frame of Figure 2-11.

18.

Raising handlebar clamp shroud slightly, feed tachome-

ter connector and conduit into the headlamp nacelle.

17. Part the halves of the headlamp nacelle slightly. With the

Install shroud over mating flange while routing tachome-

flat washer on the handlebar clamp shroud facing the

ter conduit through opening for left side handlebar.

inside surface of the nacelle, slide the Phillips screw

Reaching inside headlamp nacelle, mate pin and socket

down the gap until the shroud is in position at top of

halves of tachometer connector.

nacelle. See Figure 2-9.

2-10

2004 FLT Police: Chassis

HOME

19. With the halves of the nacelle mated, tighten the Phillips

25. Install wire connector at the back of headlamp bulb.

screw in the tab of the handlebar clamp shroud to 10-20

in-lbs (1.1-2.3 Nm). If necessary, temporarily install a

26. Align holes in headlamp housing with those in headlamp

small cable strap into holes at the bottom of the nacelle

nacelle (headlamp door bracket at bottom). Install the

(headlamp housing flange) to hold the halves together.

eight Phillips screws.

20. Install two Phillips screws to fasten handlebar clamp

27. Fit the square-shaped portion of the headlamp door

shroud to the fork lock mechanism. Install fork lock plate.

spring into the slot at the top of the headlamp housing

21. Inserting weld stud on chrome strip into hole at the top of

and then snap the headlamp door (chrome ring) into

the headlamp nacelle, reach inside the nacelle to install

place. Install Phillips screw at the bottom of the head-

flange nut. Tighten flange nut to 15-20 in-lbs (1.7-2.3

lamp door.

Nm).

28. Install windshield. See Section

2.31 WINDSHIELD/

22. Install grommets on the left and right side fork studs.

HEADLAMP NACELLE (FLHR/C/S), INSTALLATION, in

23. Slide passing lamp bracket onto the left and right side

the

2004 Touring Models Service Manual

(Part No.

99483-04).

fork studs. Verify that four grommets are positioned on

the inboard side of the passing lamp brackets.

24. Install acorn nuts on the fork studs and tighten to 72-108

in-lbs (8.1-12.2 Nm). Be sure to capture the clutch cable

clamp on the upper left stud before installing the acorn

nut.

2004 FLT Police: Chassis

2-11

HOME

NOTES

2-12

2004 FLT Police: Chassis

HOME

BULB CHART

8.1

GENERAL

NOTE

The chart below gives the bulb requirements for FLHTP and

For Cycle Signal Lamp replacement bulbs, phone Whelen

FLHP police model motorcycles.

Engineering at (203) 526-9504.

Table 8-1. Bulb Chart FLHTP/FLHP

NUMBER OF

LAMP DESCRIPTION

CURRENT DRAW

HARLEY-DAVIDSON

BULBS

WATTAGE

(ALL LAMPS 12V)

(AMPERAGE)

PART NUMBER

(REQUIRED)

Head Lamp

Low Beam

4.58

68329-03

HIgh Beam

5.00

Tail/Stop Lamp

Tail Lamp

0.59

68167-88

Stop Lamp

2.10

Turn Signal Lamp

Front / Running

2.25 / 0.59

27/7

68168-89

Rear

2.25

68572-64B

Rear Fender Tip Lamp

Rear Fender Tip Bulb

0.33

3.7

53439-79

Pursuit Lamp

Left (Red)

68727-64A

2.5

Right (Blue)

68728-64

Rear Strobe, if provided

1WARNING

As a high voltage source, rear strobe must

N/A

67598-88

be off at least 10 minutes before servicing.

Inadequate safety precautions may result

in death or serious injury. (00097a)

Instrument Panel Lamps-FLHTP

High Beam Indicator

Oil Pressure Indicator

0.15

2.1

68024-94

Neutral Indicator

Turn Signal Indicator

Gauge Lamps-FLHTP

Speedometer**

N/A

Tachometer**

Voltmeter

0.24

3.4

67445-00

Fuel Gauge

Engine**

N/A

Pursuit

0.08

1.1

68642-96

** LED illuminated. LED’s are not repairable. Assembly must be replaced if LED fails.

2004 FLT Police: Electrical

8-1

HOME

Table 8-1. Bulb Chart FLHTP/FLHP

NUMBER OF

LAMP DESCRIPTION

CURRENT DRAW

HARLEY-DAVIDSON

BULBS

WATTAGE

(ALL LAMPS 12V)

(AMPERAGE)

PART NUMBER

(REQUIRED)

Instrument/Gauge Lamps-FLHP Indicator Module (with LED’s)

High Beam Indicator

Oil Pressure Indicator

N/A

0.05

N/A

68113-99

Neutral Indicator

Turn Signal Indicator

Fuel Gauge**

Speedometer**

Odometer**

N/A

Engine**

Pursuit**

** LED illuminated. LED’s are not repairable. Assembly must be replaced if LED fails.

8-2

2004 FLT Police: Electrical

HOME

SYSTEM FUSES/RELAYS

8.2

GENERAL

System Fuse Block (Under Left Side Cover)

Fuses are provided to protect electrical components. To

inspect or replace the fuses, carefully follow the procedures

FLHP/E

below. If an electrical fault occurs after replacement of a fuse,

see your Harley-Davidson dealer for service.

SYSTEM FUSES

Removal

1. Verify that the Ignition/Light Key Switch is turned to the

OFF position.

2. Remove left side saddlebag.

f2283x8x

3. Remove wing nut style bolt to release bottom of siren

amplifier mounting bracket from clamp on saddlebag

FLHTP

guard. Rotate bracket upward to gain complete access to

side cover area. Loosen top bolt, if necessary. See Fig-

ure 8-1.

4. Gently pull side cover from frame downtubes (no tools

required). Exercise caution to avoid scratching side cover

on amplifier mounting bracket.

5. Depress latches on maxi-fuse holder and then slide

cover rearward to disengage tongue from groove in fuse

block cover.

6. Pull fuse block from tabs on mounting bracket. Tabs on

bracket fit into slots on each side of fuse block cover.

f2204x8x

NOTE

The fuse block cover also serves as the spare fuse holder.

Headlamp

Siren

One spare 10 amp and 15 amp fuse are provided.

Ignition

Accessory

Lighting

Battery

7. Remove the fuse block cover. Raise lipped side slightly

Instruments

10.

Brake Light Relay

to disengage slots from tabs on fuse block.

Brakes/Pursuit

11.

P&A

Radio Memory

12.

Starter Relay

Figure 8-2. Fuse Locations

8243

Remove fuse from fuse block and inspect the element.

See Figure 8-2. Replace fuse if element is burned or bro-

ken. Automotive type ATO fuses are used.

NOTE

The fuse block cover also serves as the spare fuse holder.

One spare 10 amp and 15 amp fuse are provided.

Wing Nut

Style Bolt

CAUTION

Always use replacement fuses that are of the correct

type and value. Use of incorrect fuses can result in dam-

Figure 8-1. Siren Amplifier Mounting Bracket

age to the electrical system. See Table 8-2. (00222a)

2004 FLT Police: Electrical

8-3

HOME

Installation

Table 8-2. FLHTP/FLHP System Fuses

Install fuse in fuse block.

RATING

CIRCUIT

COLOR

(AMPERES)

Slide cover over fuse block until slots fully engage tabs

on block.

Maxi-Fuse

Orange

Headlamp

Blue

Slide fuse block into position on mounting bracket. Tabs

on bracket fit into slots on each side of fuse block cover.

Ignition

Blue

Slide maxi-fuse cover forward to engage tongue in

Lighting

Blue

groove of fuse block cover and then insert maxi-fuse

Instruments

Blue

holder into cover until latches engage.

Brakes/Pursuit

Blue

Align barbed studs in side cover with grommets in frame

Radio Memory

Blue

downtubes and push firmly into place (no tools required).

Siren

Red

Rotate siren amplifier mounting bracket downward.

Accessory

Blue

Install wing nut style bolt to secure bracket to clamp on

saddlebag guard. Tighten top bolt, if loosened.

Battery

Blue

P & A

Blue

Install left side saddlebag.

8-4

2004 FLT Police: Electrical

HOME

STROBE HEADLAMP

8.3

GENERAL

i04382

This Strobe Headlamp Kit is designed for installation on both

FLHP and FLHTP model motorcycles.

NOTE

The Strobe Headlamp Kit as well as replacement Strobe

Lamps (Part Number 68692-02) are available at your Harley-

Davidson Dealer.

Phillips

Screw

INSTALLATION

Chrome

1WARNING

Ring

To protect against shock and accidental start-up of vehi-

cle, disconnect the negative battery cable before pro-

Figure 8-3. Remove Headlamp Door (FLHTP)

ceeding. Inadequate safety precautions could result in

death or serious injury. (00048a)

1WARNING

Torx

Always disconnect the negative battery cable first. If the

Screws

positive cable should contact ground with the negative

cable installed, the resulting sparks may cause a battery

explosion which could result in death or serious injury.

(00049a)

Disconnect battery cables, negative cable first.

2. See Figure 8-3. Remove the Phillips screw at the bottom

of the headlamp door (chrome ring). Remove the head-

lamp door.

3. FLHTP: Remove the four Torx screws to free the head-

lamp housing from the fairing. See Figure 8-4.

FLHP: Remove the seven Phillips screws to free the

i04383

headlamp housing from the headlamp nacelle. See Fig-

ure 8-5.

Figure 8-4. Headlamp Housing Mount (FLHTP)

4. Squeeze the two external tabs (if present) to remove the

wire connector at the back of the headlamp bulb.

Remove the headlamp housing assembly from the vehi-

c. Turn the handlebar to the right and remove the outer

cle.

fairing screw (5) reaching in below the left side of the

fairing cap. Turn the handlebar to the left and

5. FLHP: Move to step 16.

remove the fairing screw (6) below the right side of

FLHTP: Proceed as follows:

the fairing cap.

a. See Figure 8-6. Standing at the front of the vehicle,

d. Remove the windshield and lift the fairing off the

use a T27 TORX drive head to remove the three

motorcycle.

outer fairing screws (1, 2 and 3) and flat washers

Install the power supply as follows:

just below the windshield.

b. Moving to the inner fairing side, use a T27 TORX

a. See Figure 8-7. Locate the metal plate on which the

drive head to remove the two fairing screws (4 and

power supply will be mounted. Remove the black

7) just above the wind deflectors on the left and right

plastic wire retainer (Christmas Tree) from the hole

side.

in the metal plate.

2004 FLT Police: Electrical

8-5

Была ли эта страница вам полезна?

Да!Нет

2 посетителя считают эту страницу полезной.

Harley Davidson 2004 Touring Models. Service Manual — page 58

Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.