Harley Davidson 2004 Touring Models. Service Manual — page 49
HOME
SPARK PLUGS/SPARK PLUG CABLES
8.7
SPARK PLUGS
Inspect spark plugs at 5000 miles (8,000 km) and replace at
10,000 miles (16,000 km).
The number 6R12 plug is supplied as original equipment and
is the only plug that should be used. The resistor plug
reduces radio interference created by the ignition system and
will not adversely affect performance or fuel economy.
REMOVAL
1.
Remove spark plug cables. See SPARK PLUG CABLES
on the next page.
2. Remove spark plug using a 5/8 inch spark plug socket.
INSPECTION
See Figure 8-9. Examine plugs as soon as they have been
removed. The deposits on the plug base are an indication of
the plug efficiency and are a guide to the general condition of
rings, valves, carburetor and ignition system.
a. A wet black and shiny deposit on plug base, elec-
Figure 8-9. Types of Plug Base Deposits
trodes and ceramic insulator tip indicate an oil
fouled plug. The condition may be caused by worn
rings and pistons, loose valves or seals, weak bat-
2.
Use a thin file to flatten spark plug electrodes. A spark
tery or faulty ignition.
plug with sharp edges on its electrodes requires 25%-
40% less firing voltage than one with rounded edges.
b. A dry fluffy or sooty black deposit indicates a too
rich carburetor air-fuel mixture or long periods of
3.
Adjust spark plug gap. See ADJUSTMENT below.
engine idling. Excessive use of the enrichener may
also cause this condition.
ADJUSTMENT
c. An overheated plug can be identified by a light
brown, glassy deposit. This condition may be
Use only a wire-type gauge. Bend the outside electrode so
accompanied by cracks in the insulator or by ero-
only a slight drag on the gauge is felt when passing it
sion of the electrodes. This condition is caused by
between electrodes. Never make adjustments by bending the
too lean an air-fuel mixture, a hot running engine,
center electrode. Set gap on all plugs at 0.038-0.043 in.
valves not seating or improper ignition timing. The
(0.97-1.09 mm).
glassy deposit on the spark plug is a conductor
when hot and may cause high speed misfiring. A
INSTALLATION
plug with eroded electrodes, heavy deposits or a
cracked insulator should be replaced.
1.
Before installing spark plugs, check condition of threads
d. A plug with white, yellow or light tan to rusty brown
in cylinder head and on plug. If necessary soften depos-
powdery deposit indicates balanced combustion.
its with penetrating oil and clean out with a thread
The deposits may be cleaned off at regular intervals
chaser.
if desired.
2.
Apply a very light coating of ANTISEIZE LUBRICANT to
spark plug threads. Install spark plug. Tighten spark plug
CLEANING
to 12-18 ft-lbs (16-24 Nm).
1.
Degrease firing end of spark plug using ELECTRICAL
If a torque wrench is not available, finger-tighten spark
CONTACT CLEANER. Dry spark plug with compressed
plug and then using a spark plug wrench, tighten plug an
air.
additional 1/4-turn.
8-10
2004 Touring: Electrical
HOME
3. Connect spark plug cables to spark plugs. Make sure
INSPECTION
boots/caps are secured properly.
1.
Check cables for cracks or loose terminals.
4. Check engine idle speed, and adjust if necessary.
2.
Check spark plug cable resistance with an ohmmeter.
Resistance must be as follows:
SPARK PLUG CABLES
Table 8-1. Spark Plug Cable Resistance
Resistor-type high-tension cables have a carbon-impreg-
Position
Cable Length
Resistance (Ohms)
nated fabric core (instead of solid wire) for radio noise sup-
pression and improved reliability of electronic components.
Front /Rear
20 Inches (508 mm)
5,000 - 11,666
Use the exact replacement cable for best results.
3.
Replace cables that are worn or damaged, or that do not
REMOVAL
meet resistance specifications.
4.
Check cable boots/caps for cracks or tears. Also check
for loose fit on ignition coil and spark plugs. Replace
1WARNING
boots/caps if defects are noted.
Never disconnect a spark plug cable with the engine run-
ning. Doing so will result in an electric shock from the
INSTALLATION
ignition system that could result in death or serious
injury.
1. Connect spark plug cables to spark plugs.
2. Install spark plug cable to front cylinder onto left side coil
CAUTION
tower. Verify that spark plug cable is captured in double-
sided cable clip at bottom left side of frame backbone.
When disconnecting a spark plug cable from the spark
Install new cable clip on T-stud if damaged or missing.
plug terminal, always grasp and pull on the rubber boot
See Figure 8-10.
at the end of the cable assembly (as close to the spark
3. Install spark plug cable to rear cylinder onto right side
plug terminal as possible). Pulling on the cable portion
coil tower. Verify that spark plug cable is captured in two
will damage the carbon core.
single-sided cable clips at bottom left side of frame back-
1. Disconnect spark plug cables from ignition coil and
bone. Install new cable clips on T-studs if damaged or
spark plug terminals.
missing. See Figure 8-10.
8497
Figure 8-10. Spark Plug Cable Clips (Left Side View)
2004 Touring: Electrical
8-11
HOME
ALTERNATOR/STATOR
8.8
REMOVAL
Rotor
f2120x8x
1.
Remove seat. See Section 2.24 SEAT, REMOVAL.
1WARNING
To protect against shock and accidental start-up of vehi-
Engine
cle, disconnect the negative battery cable before pro-
Sprocket Shaft
ceeding. Inadequate safety precautions could result in
death or serious injury.
2. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
3. Remove the primary chaincase cover. Remove the
clutch, primary chain, compensating sprocket and shaft
1. Clean Sprocket Shaft Threads.
extension as a single assembly. See Section 6.5 PRI-
MARY CHAINCASE, REMOVAL, steps 3-15.
4. Remove the alternator rotor spacer, if present.
1CAUTION
Shaft Protector
The high-output rotor is used on fuel injected vehicles,
Sleeve
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.
5. Remove the rotor as follows:
2. Install Shaft Protector Sleeve.
High Output Rotor - 45 Amp
a. Verify that threads of engine sprocket shaft are
clean, especially of old Loctite material. Thread the
Thumbscrew
Shaft Protector Sleeve onto the shaft. See Figure 8-
11.
b. Turn thumbscrews of Rotor Remover/Installer into
threaded holes in rotor face.
Forcing Screw
c. Rotate handle of forcing screw in a clockwise direc-
tion to remove rotor from shaft.
Low Output Rotor - 38 Amp
CAUTION
Thumbscrew
Do not strike or drop rotor. Damage to magnet adhesive
may result in rotor failure.
Handle
a. Fabricate wire hooks or use the ends of two allen
wrenches to carefully pull rotor at holes in rotor
3. Install Rotor Remover/Installer.
face.
Rotate Handle in a Clockwise Direction.
b. Pull rotor from stator. Magnets in rotor cause some
resistance during removal.
Figure 8-11. Remove Rotor from Engine Sprocket Shaft
8-12
2004 Touring: Electrical
HOME
12. Using a T27 TORX drive head, remove four screws to
free stator from crankcase. Discard screws.
13. Using point of awl, carefully lift capped rib on grommet
away from crankcase and then insert into bore between
grommet and casting. See Figure 8-14. Tilt awl slightly
squirting isopropyl alcohol or glass cleaner into opening.
Repeat this step at one or two other locations around
grommet.
14. While pushing on capped rib from outside of crankcase,
draw grommet through bore by pulling on cable stop with
needle nose pliers. Rock grommet back and forth to
facilitate removal, if necessary. Exercise caution to avoid
damaging ribs on grommet if stator is to be reused.
15. Draw stator cables and socket terminals through crank-
case bore. For best results, feed one cable and socket
terminal through at a time.
Stator
Connector [46]
f2256x8x
CLEANING AND INSPECTION
Figure 8-12. Voltage Regulator (Left Side View)
6.
Locate stator connector [46], 2-place Packard, fixed to
1.
Check inside of rotor and remove any metal fragments
bracket at bottom of voltage regulator. Cut small cable
captured by magnets.
strap and slide connector toward left side of motorcycle
2.
Clean the rotor using a petroleum solvent. Clean the sta-
to release groove from tongue on bracket. Raise the
tor and grommet by wiping it with a clean cloth.
external latch and separate pin and socket halves. See
Figure 8-12.
7.
Remove locknut from left side leg of voltage regulator.
f1912x8x
Loosen right side locknut. Raise voltage regulator as
necessary to free left side leg from stud on lower frame
crossmember.
8.
Remove P-clip from stud. Remove P-clip from cable con-
Cavity
duit.
Terminal A
9.
Draw cable conduit and connector to rear of front engine
stabilizer link and then up to area in front of primary
chaincase.
10.
Depress tangs inside socket housing and back out sock-
ets through wire end of connector. Proceed as follows:
a. Looking into the socket housing, take note of the
cavity on each side of the terminal. See upper frame
of Figure 8-13.
f1911x8x
b. Gently insert pick (Snap-On TT600-3) into the cavity
about 1/4 inch (6.4 mm) or until it stops, and pivot
the side of the pick toward the terminal body.
Repeat step on other cavity. See lower frame of Fig-
ure 8-13.
Pick
c. Gently tug on cable to pull terminal from chamber. If
terminal is still locked, one or both tangs are not
fully depressed. Repeat steps 10(b) and 10(c) as
necessary.
d. Repeat procedure to release second terminal.
11.
Remove conduit from cables. For best results, pull one
cable and socket terminal through conduit at a time.
Figure 8-13. Remove Socket Terminals
2004 Touring: Electrical
8-13
HOME
NOTE
Capped
f1634x8x
Stator
Rib
The Shaft Protector Sleeve not only protects the threads from
the splines of the rotor, but acts as a guide to ensure that the
rotor is properly centered.
b. Center ball on forcing screw in recess at end of
engine sprocket shaft. Rotate the handle of the tool
in a counterclockwise direction to ease rotor into
position over stator.
c. Loosen thumbscrews and remove Rotor Remover/
Installer. Remove Shaft Protector Sleeve.
d. Install the shaft extension on the engine sprocket
shaft. (No alternator rotor spacer is provided.)
Low Output Rotor - 38 Amp
Awl
a. Slide rotor over stator with the concave side
Opening
inboard.
Figure 8-14. Remove Grommet From Crankcase
1CAUTION
When installing rotor, keep fingers away from edge that
mates with crankcase. Since rotor is magnetized, as it
INSTALLATION
nears the crankcase it may be pulled in with consider-
able force, resulting in pinched fingers or other hand
1. From inside crankcase, feed socket terminals and stator
injury.
cables through hole in crankcase. For best results, feed
one cable and socket terminal through at a time.
b. See inset of Figure
8-16. Install the
0.020 inch
(0.508 mm) thick alternator rotor spacer and the
2. Thorougly lubricate grommet with isopropyl alcohol or
shaft extension on the engine sprocket shaft.
glass cleaner. Ribs of grommet must be clean and free
7.
Install conduit onto cables. For best results, feed one
of dirt and oily residue.
socket terminal and cable through conduit at a time.
3. Carefully grasp cable stop behind grommet with a nee-
8.
Install sockets into stator/voltage regulator connector as
dle nose pliers. Push grommet into crankcase bore while
follows:
carefully pulling on outside cable. Installation is com-
plete when cable stop contacts casting and capped rib of
a. Using a fingernail or a thin flat blade, like that on an
grommet exits crankcase bore.
X-Acto knife, carefully bend the tangs outward away
from each terminal body. See Figure 8-15.
4. If necessary, carefully run awl around edge of capped rib
so that it rests flat against seating surface on crankcase.
b. Feed each socket into wire end of stator/voltage
regulator connector until it “clicks” in place.
CAUTION
Do not reuse T27 TORX screws. The threads of the
screws contain a locking compound in pellet form. When
the screw is started, the pellet breaks releasing the com-
pound.
5.
Using a T27 TORX drive head, install four new screws to
X-Acto Knife
fasten stator to crankcase. Alternately tighten screws to
55-75 in-lbs (6.2-8.5 Nm).
Tang
6. Install the rotor as follows:
High Output Rotor - 45 Amp
f1913x8x
a. Install the Shaft Protector Sleeve and Rotor
Remover/Installer, if removed. See Figure 8-11.
Figure 8-15. Bend Tangs Outward
8-14
2004 Touring: Electrical
HOME
f2119x8x
Rotor
Voltage
Flange
Regulator
Locknut
P-Clamp
Anchored
Cable Strap
Alternator Rotor Spacer
Brake Pedal
0.020 Inch (0.508 mm) Thick
38 AMP
Weldment
P-Clamp
f2221x8x
Stator
Connector [46]
Secondary
Lock
Cable Strap
Pin
Stator Connector
Housing
Socket
Cable Straps
Housing
and Anchors
Lower Frame Tube
Cable Stop
Voltage Regulator
Connector [77]
Grommet
Rotor
Ring Terminal
Stator
T27 TORX
38 Amp:
Screw
FLHR, FLHRI, FLHRCI, FLHRS, FLHRSI, FLHT, FLHTC
NO
45 Amp:
Alternator Rotor Spacer
FLHTI, FLHTCI, FLHTCUI, FLTRI
Figure 8-16. Stator/Voltage Regulator Assemblies - 45 AMP
c. Verify that sockets will not back out of chambers. A
10. Install P-clip on cable conduit approximately five inches
slight tug on each cable will confirm that it is locked.
(127 mm) from socket housing. Slide P-clip over left side
stud on lower frame crossmember. Properly oriented, P-
9. Feed connector and cable conduit under front engine
clip is positioned at front of stud with the open side up
stabilizer link and then forward along outboard side of
and angled so that it is inline with the lower rail of the
voltage regulator leg. See Figure 8-12.
engine guard.
2004 Touring: Electrical
8-15
HOME
11. Raise voltage regulator as necessary to install left side
14. Install the clutch, primary chain, compensating sprocket
leg onto stud. Install locknut and tighten to 70-100 in-lbs
and shaft extension as a single assembly. Install the pri-
(7.9-11.3 Nm).
mary chaincase cover. See Section
6.5 PRIMARY
CHAINCASE, INSTALLATION, steps 9-33.
12. Tighten right side locknut to
70-100 in-lbs (7.9-11.3
Nm).
15. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
13. Mate pin and socket halves of stator connector [46], 2-
bolt to 60-96 in-lbs (6.8-10.9 Nm).
place Packard. At bottom of voltage regulator, slide con-
nector toward right side of motorcycle until groove fully
16. Install seat. See Section 2.24 SEAT, INSTALLATION.
engages tongue on bracket. Install new cable strap cap-
turing bracket, connector and cable loop at rear of con-
nector. See Figure 8-12.
8-16
2004 Touring: Electrical
HOME
VOLTAGE REGULATOR
8.9
REMOVAL
Left
Right
1.
Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
Side
Side
MAXI-FUSE, REMOVAL.
2.
Moving to right side of motorcycle, remove socket head
Anchored
screw (with captive washer) to release ring terminal from
P-Clip
weld nut at front of transmission exhaust bracket.
3.
Locate voltage regulator connector [77], 1-place Deut-
sch, just below the transmission exhaust bracket.
Depress external latch to separate pin and socket hous-
ings.
4.
Cut cable strap to free voltage regulator cables from
front anchor installed on T-stud at top of lower frame
tube.
5.
Cut cable strap to free voltage regulator cables from
inboard side of rear brake pedal weldment.
Stator
Connector [46]
6.
Draw voltage regulator cables forward allowing ring ter-
minal and Deutsch socket housing to hang at rear of
lower frame crossmember.
7.
Locate stator connector [46], 2-place Packard, fixed to
bracket at bottom of voltage regulator. Cut small cable
strap and slide connector toward left side of motorcycle
to release groove from tongue on bracket. Raise the
Voltage Regulator
external latch and separate pin and socket halves. See
Connector [77]
Figure 8-17.
f2256x8x
Ring Terminal
f2220x8x
Figure 8-18. Voltage Regulator (Rear View)
8.
Locate crankshaft position sensor connector
[79],
2-
place Mini-Deutsch, also fixed to bracket at bottom of
voltage regulator. Push connector toward right side of
motorcycle to disengage small end of slot on attachment
clip from T-stud on bracket. Lift connector off T-stud.
Stator
Connector [46]
9.
Remove locknuts from studs on lower frame crossmem-
Crankshaft
ber. Lift voltage regulator off studs to remove from
Position Sensor
motorcycle. Note that right side P-clip is anchored to leg
Connector [79]
of voltage regulator. See Figure 8-18.
Figure 8-17. Voltage Regulator (Left Side View)
2004 Touring: Electrical
8-17
HOME
Crankshaft Position Sensor Connector
[79] and Cable Strap Not Shown
Stator
Connector [46]
Front Cable Strap
Anchor
Rear Brake Pedal
Weldment
f2281x8x
Figure 8-19. Voltage Regulator Cable Routing (Right Side View)
NOTE
INSTALLATION
For instructions on removing and installing wire terminals in
stator connector
[46],
2-place Packard, see Section
8.8
1.
If removed, slide P-clip over left side stud on lower frame
ALTERNATOR/STATOR, REMOVAL and INSTALLATION,
crossmember. Properly oriented, P-clip is positioned at
steps 10 and 8, respectively. To remove and install cable in
front of stud with the open side up and angled so that it
voltage regulator connector [77], 1-place Deutsch, see Sec-
is inline with the lower rail of the engine guard.
tion B.1 DEUTSCH ELECTRICAL CONNECTORS, 1-PLACE
CABLE CONNECTOR.
2. Slide voltage regulator over studs feeding two cables
downward at rear of lower frame crossmember. Allow
ring terminal and Deutsch socket housing to hang
beneath motorcycle.
8-18
2004 Touring: Electrical
HOME
3. Install locknuts on studs and tighten to 70-100 in-lbs
8.
Mate pin and socket housings of voltage regulator con-
(7.9-11.3 Nm).
nector [77], 1-place Deutsch, just below the transmission
exhaust bracket.
4. Locate crankshaft position sensor connector
[79],
2-
place Mini-Deutsch, at rear of voltage regulator. Place
9.
Install socket head screw (with captive washer) to fasten
large end of slot on attachment clip over T-stud on
ring terminal to weld nut at front of transmission exhaust
bracket at bottom of voltage regulator. Push connector
bracket. Tighten screw to 20-35 in-lbs (2.3-4.0 Nm).
toward left side of motorcycle to engage small end of
slot.
10.
Install maxi-fuse. See Section
8.3
SYSTEM FUSES,
5. Mate pin and socket halves of stator connector [46], 2-
MAXI-FUSE, INSTALLATION.
place Packard. At bottom of voltage regulator, slide con-
nector toward right side of motorcycle until groove fully
11.
Load test charging system.
engages tongue on bracket. Install new cable strap cap-
turing bracket, connector and cable loop at rear of con-
nector.
6. Route voltage regulator cables rearward following
inboard side of lower frame tube. Capturing voltage reg-
ulator cables and lower frame tube, install new cable
strap through opening in rear brake pedal weldment.
See Figure 8-19. Cut any excess cable strap material.
NOTE
Cable strap also captures branch of main harness leading to
oil pressure sender and crankshaft position sensor connec-
tors.
7. Position voltage regulator cables over front anchor
installed on T-stud at top of lower frame tube. Thread
new cable strap through eyelets in anchor to capture
cables. Cut any excess cable strap material.
NOTE
Cable strap anchor also captures rear brake line and branch
of main harness leading to oil pressure sender and crank-
shaft position sensor connectors.
2004 Touring: Electrical
8-19
HOME
BATTERY
8.10
GENERAL
Warning
Label
All batteries are permanently sealed, maintenance-free,
valve-regulated, lead/calcium and sulfuric acid batteries. The
batteries are shipped pre-charged and ready to be put into
service. Do not attempt to open these batteries for any rea-
son.
1WARNING
All batteries contain electrolyte. Electrolyte is a sulfuric
acid solution that is highly corrosive and can cause
severe chemical burns. Avoid contact with skin, eyes,
and clothing. Avoid spillage. Always wear protective face
shield, rubberized gloves and protective clothing when
working with batteries. A warning label is attached to the
top of the battery. See Figure 8-20. Never remove warn-
ing label from battery. Failure to read and understand all
f1730x8x
precautions contained in warning label before perform-
ing any service on batteries could result in death or seri-
ous injury. See Figure 8-21.
Figure 8-20. Maintenance-Free Battery
Table 8-2. Antidote
VOLTMETER TEST
External -
Flush with water
Internal -
Drink large quantities of milk or
See Table 8-3. The voltmeter test provides a general indica-
water, followed by milk of magne-
tor of battery condition. Check the voltage of the battery to
sia, vegetable oil or beaten eggs.
verify that it is in a 100% fully charged condition. If the open
Call doctor immediately.
circuit (disconnected) voltage reading is below 12.6V, charge
the battery and then recheck the voltage after the battery has
Eyes -
Flush with water, get immediate
set for one to two hours. If the voltage reading is 12.8V or
medical attention.
above, perform the LOAD TEST described in this section.
Contents
Wear
Contents
Keep
Read
Keep Away
are Corrosive. Safety Glasses. are Explosive.
Flames Away.
Instructions.
From Children.
f2180x3x
Figure 8-21. Battery Warning Label
8-20
2004 Touring: Electrical
HOME
Table 8-3. Voltmeter Test
BATTERY CHARGING
Voltage (OCV)
State of Charge
SAFETY PRECAUTIONS
12.8
100%
Never charge a battery without first reviewing the instructions
12.6
75%
for the charger being used. In addition to the manufacturer’s
12.3
50%
instructions, follow these general safety precautions:
12.0
25%
● Always wear proper eye, face and hand protection.
11.8
0%
● Always charge batteries in a well-ventilated area.
● Turn the charger “OFF” before connecting the leads
to the battery to avoid dangerous sparks.
DISCONNECTION AND REMOVAL
● Never try to charge a visibly damaged or frozen bat-
tery.
1. Remove seat. See Section 2.24 SEAT, REMOVAL.
● Connect the charger leads to the battery; red posi-
tive (+) lead to the positive (+) terminal and black
1WARNING
negative (-) lead to the negative (-) terminal. If the
battery is still in the vehicle, connect the negative
Always disconnect the negative battery cable first. If the
lead to the chassis ground. Be sure that the ignition
positive cable should contact ground with the negative
and all electrical accessories are turned off.
cable installed, the resulting sparks may cause a battery
explosion which could result in death or serious injury.
● Make sure that the charger leads to the battery are
not broken, frayed or loose.
2. Unthread bolt and remove battery negative cable (black)
● If the battery becomes hot, or if violent gassing or
from battery negative (-) terminal.
spewing of electrolyte occurs, reduce the charging
3. Unthread bolt and remove battery positive cable (red)
rate or turn off the charger temporarily.
from battery positive (+) terminal.
● Always turn the charger “OFF” before removing
charger leads from the battery to avoid dangerous
4. Using a T-40 TORX drive head, loosen bolt to move lip of
sparks.
hold-down clamp off edge of battery. Remove battery
from battery box.
CHARGING BATTERY
CLEANING AND INSPECTION
Charge the battery if any of the following conditions exist:
● Vehicle lights appear dim.
1. Battery top must be clean and dry. Dirt and electrolyte
● Electric starter sounds weak.
on top of the battery can cause battery to self-discharge.
● Battery has not been used for an extended period of
Clean battery top with a solution of baking soda (sodium
time.
bicarbonate) and water (5 teaspoons baking soda per
quart or liter of water). When the solution stops bubbling,
1WARNING
rinse off the battery with clean water.
Always charge the battery in a well ventilated area.
2. Clean cable connectors and battery terminals using a
Explosive hydrogen gas escapes from the battery during
wire brush or sandpaper. Remove any oxidation.
charging. Keep open flames, electrical sparks and smok-
ing materials away from the battery at all times. Failure
3. Inspect the battery screws, clamps and cables for break-
to do so could result in death or serious injury.
age, loose connections and corrosion. Clean clamps.
4. Check the battery posts for melting or damage caused
CAUTION
by overtightening.
If the battery releases an excessive amount of gas dur-
ing charging, decrease the charging rate. If the battery
5. Inspect the battery for discoloration, raised top or a
warped or distorted case, which might indicate that the
gets hotter than 110˚F. (43˚C) during charging, discon-
tinue charging and allow the battery to cool. Overheating
battery has been frozen, overheated or overcharged.
may result in plate distortion, internal shorting, dryout or
6. Inspect the battery case for cracks or leaks.
other damage.
2004 Touring: Electrical
8-21
HOME
Table 8-4. Battery Charging Rates/Estimated Times
State of Charge
Battery
3
6
10
20
Amp-Hour
Amp Charger
Amp Charger
Amp Charger
Amp Charger
Voltage Reading
% of Charge
12.8 V
100%
-
-
-
-
12.6 V
75%
2.5 hours
1.25 hours
45 minutes
25 minutes
TOURING
12.3 V
50%
5 hours
2.5 hours
1.5 hours
50 minutes
28
12.0 V
25%
7.5 hours
3.75 hours
2.25 hours
70 minutes
11.8 V
0%
10 hours
5 hours
3 hours
1.5 hours
The figures listed above assume that the battery is charging at room temperature. If warmer than room temperature, use a slightly shorter
charging time. If colder, use a slightly longer charging time.
The use of constant current chargers to charge sealed maintenance-free batteries is not recommended. Any overcharge will cause dry-
out and premature battery failure. If a constant current charger is the only type available, do not exceed the charge times listed above and
do not continue charging the battery if it gets hot. When charging, never exceed 15 volts for more than 30 minutes.
1.
Perform a voltmeter test to determine the state of
NOTE
charge. See VOLTMETER TEST in this section. If bat-
If the battery is still in the vehicle, connect the negative lead
tery needs to be charged, proceed to step 2.
to the chassis ground. Be sure that the ignition and all electri-
cal accessories are turned off.
CAUTION
5.
Step away from the battery and turn on the charger. See
the charging instructions in Table 8-4.
Always remove the battery from the motorcycle before
charging. Accidental electrolyte leakage will damage
motorcycle parts.
1WARNING
Always unplug or turn OFF the battery charger before
2.
Remove the battery from the motorcycle. See DISCON-
NECTION AND REMOVAL in this section. Place the bat-
disconnecting the charger clamps from the battery. Dis-
connecting clamps with the charger ON could cause a
tery on a level surface.
spark resulting in a battery explosion. A battery explo-
sion may rupture the battery case causing a discharge
1WARNING
or spray of sulfuric acid which could result in death or
serious injury.
Always unplug or turn OFF the battery charger before
connecting the charger clamps to the battery. Connect-
6.
After the battery is fully charged, disconnect the black
ing clamps with the charger ON could cause a spark
battery charger lead to the negative (-) terminal of the
resulting in a battery explosion. A battery explosion may
battery.
rupture the battery case causing a discharge or spray of
7.
Disconnect the red battery charger lead to the positive
sulfuric acid which could result in death or serious
(+) terminal of the battery.
injury.
8.
Mark the charging date on the battery.
9.
Perform a load test to determine the condition of the bat-
CAUTION
tery. See LOAD TEST on this page.
Do not reverse the charger connections described in the
following steps or the charging system of the motorcycle
could be damaged.
LOAD TEST
3.
Connect the red battery charger lead to the positive (+)
terminal of the battery.
The load test measures battery performance under full cur-
4.
Connect the black battery charger lead to the negative
rent load and is the best indicator of battery condition. To
(-) terminal of the battery.
load test the battery, proceed as follows:
8-22
2004 Touring: Electrical
HOME
CAUTION
CAUTION
Load testing a discharged battery can result in perma-
To avoid load tester and/or battery damage, do not leave
nent battery damage.
the load tester switch turned ON for more than 20 sec-
onds.
1. Always fully charge the battery before testing or test
readings will be incorrect. See CHARGING BATTERY, in
4.
Referencing Table 8-4, load battery at 50% of CCA rat-
ing using the load tester. Voltage reading after 15 sec-
this section. Load testing a discharged battery can also
result in permanent battery damage.
onds should be 9.6V or more at 70°F. (21°C).
2. After charging, allow battery to stand for at least one
Table 8-5. Battery Load Test
hour before testing.
COLD CRANKING
100%
50%
AMPERAGE (CCA)
1WARNING
TOURING
300
150
Always turn the battery load tester OFF before connect-
ing the tester cables to the battery terminals. Connecting
tester cables with the load tester ON could cause a spark
1WARNING
resulting in a battery explosion. A battery explosion may
rupture the battery case causing a discharge or spray of
Always turn the battery load tester OFF before discon-
sulfuric acid which could result in death or serious
necting the tester cables from the battery terminals. Dis-
injury.
connecting tester cables with the load tester ON could
cause a spark resulting in a battery explosion. A battery
3.
Connect tester leads to battery posts and place induc-
explosion may rupture the battery case causing a dis-
tion pickup over negative (black) cable. See Figure 8-22.
charge or spray of sulfuric acid which could result in
death or serious injury.
5.
Install the battery on the motorcycle. See INSTALLA-
Load
TION AND CONNECTION below.
Tester
BATTERY CABLE ROUTING
1WARNING
Hole on left side of frame crossmember is used for
cruise cable routing only. Use of the hole for battery
cable routing can result in contact with hot exhaust pipe
causing melting or burning of the cable insulation, dam-
age that can lead to driveability problems or fire hazard,
conditions which could result in death or serious injury.
Induction
Pickup
Route all battery cables through opening between tray of bat-
tery box and bottom of frame cross member. Cables should
be positioned as shown in Figure 8-23.
INSTALLATION AND CONNECTION
1.
Place the fully charged battery into the battery box, ter-
minal side forward.
CAUTION
f1731x8x
Connect the cables to the correct battery terminals or
Figure 8-22. Load Test Battery
damage to the motorcycle electrical system will occur.
2004 Touring: Electrical
8-23
HOME
1WARNING
f1732x8x
Effect of Temperature on
Always connect the positive battery cable first. If the
Battery Self-Discharge Rate
positive cable should contact ground with the negative
100 %
cable installed, the resulting sparks may cause a battery
C
explosion which could result in death or serious injury.
A
P
at 77°F
75 %
A
C
at 105°F
I
T
CAUTION
Y
50 %
MONTHS OF STAND
Overtightening bolts can damage battery terminals.
0
3
6
9
12
15
1. Insert bolt through battery positive cable
(red) into
threaded hole of battery positive (+) terminal. Tighten
Figure 8-24. Battery Self-Discharge Rate
bolt to 60-96 in-lbs (6.8-10.9 Nm).
2. Insert bolt through battery negative cable (black) into
STORAGE
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
3. Apply a light coat of petroleum jelly or corrosion retar-
1WARNING
dant material to both battery terminals.
Store the battery out of the reach of children. Inadequate
4. Rotate the hold-down clamp so that the lip (with rubber
safety precautions could result in death or serious
pad) rests on the edge of the battery. Using a T-40 TORX
injury.
drive head, tighten the clamp bolt to 15-20 ft-lbs (20-27
Nm).
CAUTION
5. Install seat. See Section 2.24 SEAT, INSTALLATION.
The electrolyte in a discharged battery will freeze if
exposed to freezing temperatures. Freezing may crack
the battery case and buckle battery plates.
f2268x8x
Frame Hole
Frame
Cruise Cable
Cross Member
If the motorcycle will not be operated for several months,
Routing Only
such as during the winter season, remove the battery from
the motorcycle and fully charge. See CHARGING BATTERY
in this section.
Self-discharge is a normal condition and occurs continuously
at a rate that depends on the ambient temperature and the
battery’s state of charge. Batteries discharge at a faster rate
at higher ambient temperatures. To reduce the self-discharge
Positive
rate, store battery in a cool (not freezing), dry place. See Fig-
Battery Cable
ure 8-24.
Charge the battery every month if stored at temperatures
below 60˚ F. (16˚ C). Charge the battery more frequently if
stored in a warm area above 60˚ F. (16˚ C).
NOTE
Negative
The GLOBAL BATTERY CHARGER (Part No. 99863-01)
Battery Cable
may be used to maintain battery charge for extended periods
of time without risk of overcharging or boiling.
When returning a battery to service after storage, refer to the
Main Power
instructions under CHARGING BATTERY in this section.
To Maxi-Fuse
Figure 8-23. Battery Cable Routing (Right Side View)
8-24
2004 Touring: Electrical
HOME
HEADLAMP (FLHR/C/S, FLHT/C/U)
8.11
HEADLAMP ASSEMBLY
f1268x2x
REMOVAL
Wider
Wire Form
Ear
Loop
1. Remove the Phillips screw at the bottom of the head-
lamp door (chrome ring). Remove the headlamp door.
2. Proceed as follows:
Hinge
FLHT/C/U: Remove the four TORX screws to free the
Slots
headlamp housing from the fairing.
FLHR/C/S: Remove the eight Phillips screws to free the
headlamp housing from the headlamp nacelle.
Backplate
3. Squeeze the two external tabs (if present) to remove the
wire connector at the back of the headlamp bulb.
Wire Form
Bulb
Remove the headlamp housing assembly from the vehi-
Loop
Socket
Lense
cle.
INSTALLATION
Figure 8-26. Headlamp Lense/Bulb Assembly
1.
Install the wire connector at the back of headlamp bulb.
(Rear View)
2.
Proceed as follows:
FLHT/C/U: Align holes in headlamp housing with those
HEADLAMP BULB REPLACEMENT
in fairing (headlamp door bracket at bottom). Install the
four TORX screws.
The headlamp is a replaceable bulb (and not a sealed
FLHR/C/S: Align holes in headlamp housing with those
beam). Made of quartz glass filled with Halogen gas, the bulb
in headlamp nacelle (headlamp door bracket at bottom).
is very delicate and must be handled with care.
Install the eight Phillips screws.
NOTE
3.
Fit the square-shaped portion of the headlamp door
When replacement is required, use only the specified bulb
spring into the slot at the top of the headlamp housing
available from your Harley-Davidson dealer. Improper watt-
and then snap the headlamp door (chrome ring) into
age or bulb may cause charging system problems.
place. Install Phillips screw at the bottom of the head-
lamp door and tighten to 9-18 in-lbs (1.0-2.0 Nm).
1.
Remove the Phillips screw at the bottom of the head-
lamp door (chrome ring). Remove the headlamp door.
2.
Remove the three Phillips screws to free the retaining
5372
ring from the headlamp housing. See Figure 8-25. Care-
fully remove the lense and bulb assembly.
3.
Squeeze the two external tabs (if present) to remove the
wire connector at the back of the headlamp bulb.
Remove the lense and bulb assembly from the vehicle.
4.
Remove the rubber boot at the back of the lense.
Retaining
5.
Push down on loops of wire form to free ends from slots
Ring Screws
on lense insert. See Figure 8-26. Use hinge to swing
wire form out of the way.
1WARNING
The bulb contains Halogen gas under pressure. Wear
adequate eye protection and handle the bulb carefully.
Figure 8-25. Remove Retaining Ring Screws
Inadequate safety precautions could result in death or
(FLHT/C/U Model Shown)
serious injury.
2004 Touring: Electrical
8-25
HOME
f1285b2x
A
A
25 ft.
(7.62m)
Figure 8-27. Check Headlamp Alignment
6.
Remove and discard bulb.
5374
Headlamp
Door
CAUTION
Never touch the quartz bulb with your fingers. Finger-
prints will etch the glass and cause premature bulb fail-
ure. Always wrap the bulb in paper or a clean dry cloth
during handling.
7.
Install new bulb in lense. Rotate bulb as necessary so
Slot
that backplate makes full contact with lense insert.
NOTE
Wider ear on backplate should point toward the top of the
lense. The top can be determined by the position of the head-
lamp door bracket, which is at the bottom (on the opposite
side).
5372
8.
Use hinge to place wire form over socket at back of bulb.
Press down on loops so ends of wire form engage slots
on lense insert.
Vertical
Adjuster Screw
9.
Install rubber boot at back of lense tucking outer edge
into headlamp housing.
Horizontal
10. Install the wire connector at the back of headlamp bulb.
Adjuster Screw
11. Fit lense and bulb assembly into headlamp housing.
Align holes in retaining ring with those in headlamp
housing. Install the three Phillips screws.
12. Fit the square-shaped portion of the headlamp door
spring into the slot at the top of the headlamp housing
(Headlamp Door Removed for Illustration Purposes)
and then snap the headlamp door (chrome ring) into
place. Install Phillips screw at the bottom of the head-
lamp door and tighten to 9-18 in-lbs (1.0-2.0 Nm).
Figure 8-28. Adjust Headlamp Alignment
(FLHT/C/U Model Shown)
HEADLAMP ADJUSTMENT
Check headlamp beam for proper height and lateral align-
ment.
8-26
2004 Touring: Electrical
HOME
NOTE
1WARNING
The headlamp adjustment can be performed without remov-
DO NOT modify the ignition/light key switch wiring to
ing the headlamp door (chrome ring).
disable the automatic-on headlamp feature. High visibil-
ity is an important safety consideration for motorcycle
10.
If the headlamp alignment requires adjustment, use slots
riders. Ensure that the headlamp is on at all times. Fail-
in headlamp door to insert Phillips screw driver between
ure to do so could result in death or serious injury.
headlamp housing and rubber gasket. Turn the vertical
adjuster screw as necessary to adjust the headlamp ver-
1.
Verify correct front and rear tire inflation pressure.
tically. Turn the horizontal adjuster screw to adjust the
headlamp horizontally. See Figure 8-28.
2.
Place the motorcycle on a level floor or pavement in an
area with minimum light.
3.
See Figure 8-27. Point the front of the motorcycle toward
a screen or wall which is 25 feet (7.62 m) from where
patch of front tire contacts floor (i.e. - directly below front
axle).
4.
Draw a horizontal line on screen or wall that is exactly
the same height above the floor as the headlamp center.
5.
Have a person whose weight is roughly the same as that
of the principal rider sit on the motorcycle seat. The
weight of the rider will compress the vehicle suspension
slightly.
6.
Stand the motorcycle upright with both tires resting on
the floor and with the front wheel held in straight align-
ment (directly forward).
7.
Turn the Ignition/Light Key Switch to IGNITION. Set the
Light Switch on the left handlebar to Hi(gh) beam.
8.
Check the light beam for proper height alignment. The
center of the main beam of light should be even with the
horizontal line on the screen or wall.
9.
Check the light beam for proper lateral alignment. The
main beam of light should be directed straight ahead
(i.e., equal area of light to right and left of center).
2004 Touring: Electrical
8-27
HOME
HEADLAMP (FLTR)
8.12
HEADLAMP ASSEMBLY
Plastic
Bulb
Retainer
Housing
REMOVAL
1.
Remove the outer fairing. See Section 2.30 UPPER
FAIRING/WINDSHIELD
(FLTR), OUTER FAIRING,
REMOVAL.
2.
Move outer fairing assembly to bench area.
3.
Squeeze two external tabs to disconnect headlamp har-
ness connectors from bulb contacts.
CAUTION
Wrap electrical tape around blade of screwdriver to pre-
vent damage to tabs of transparent lense cover.
4.
From inboard side of outer fairing, release top of trans-
f1546x8x
parent lense cover from slots in fairing by gently
depressing two tabs with blade of screwdriver. Depress
Figure 8-30. Remove Retainer to Release Bulb
two bottom tabs and remove lense cover from fairing.
5.
Depress mounting clips on three hex adjuster studs and
INSTALLATION
pull headlamp assembly out front of outer fairing. See
Figure 8-29.
1.
Align hex adjuster studs with plastic bosses on inboard
side of outer fairing. Push headlamp assembly into posi-
tion until mounting clips engage bosses.
2.
Carefully snap bottom tabs of transparent lense cover
Plastic
Hex Adjuster
into bottom slots of outer fairing. Carefully snap upper
Boss
Stud
tabs of lense cover into upper slots of fairing.
3.
Install headlamp harness connectors onto bulb contacts.
4.
Install the outer fairing. See Section 2.30 UPPER FAIR-
ING/WINDSHIELD (FLTR), OUTER FAIRING, INSTAL-
LATION.
HEADLAMP BULB REPLACEMENT
The headlamp is a replaceable bulb (and not a sealed
beam). Made of quartz glass filled with Halogen gas, the bulb
is very delicate and must be handled with care.
NOTE
When replacement is required, use only the specified bulb
available from your Harley-Davidson dealer. Improper watt-
age or bulb may cause charging system problems.
REMOVAL
Mounting
1.
Remove the outer fairing. See Section 2.30 UPPER
Clip
f1544x8x
FAIRING/WINDSHIELD
(FLTR), OUTER FAIRING,
REMOVAL.
Figure 8-29. Depress Mounting Clips
2.
Move outer fairing assembly to bench area.
8-28
2004 Touring: Electrical
HOME
INSTALLATION
f1545x8x
CAUTION
Never touch the quartz bulb with your fingers. Finger-
Wider
prints will etch the glass and cause premature bulb fail-
Ear
ure. Always wrap the bulb in paper or a clean dry cloth
during handling.
1.
Install new bulb in bulb housing. Orient bulb so that
wider ear on backplate is topside and then push bottom
of backplate so that tabs on outboard side fit snugly in
slot of bulb housing. See Figure 8-31.
2.
Place plastic retainer over bulb housing flange and
rotate in a clockwise direction until tight. See Figure 8-
Slot
30.
3.
Install rubber boot over retainer until flush with base of
Tabs
bulb socket.
4.
Connect headlamp harness connector to bulb contacts.
Figure 8-31. Install New Bulb in Bulb Housing
5.
Install the outer fairing. See Section 2.30 UPPER FAIR-
ING/WINDSHIELD (FLTR), OUTER FAIRING, INSTAL-
3. Squeeze two external tabs to disconnect headlamp har-
LATION.
ness connector from bulb contacts.
4. Remove rubber boot at back of bulb housing.
HEADLAMP ADJUSTMENT
5. Rotate plastic retainer in a counter-clockwise direction to
remove from bulb housing flange. See Figure 8-30.
Check headlamp beam for proper height and lateral align-
ment.
1WARNING
1
WARNING
The bulb contains Halogen gas under pressure. Wear
adequate eye protection and handle the bulb carefully.
DO NOT modify the ignition/light key switch wiring to
Inadequate safety precautions could result in death or
disable the automatic-on headlamp feature. High visibil-
serious injury.
ity is an important safety consideration for motorcycle
riders. Ensure that the headlamp is on at all times. Fail-
6.
Remove and discard bulb.
ure to do so could result in death or serious injury.
6421
6420
Hex Adjuster
Hex Adjuster
LEFT SIDE
RIGHT SIDE
Figure 8-32. Headlamp Adjustment (FLTR)
2004 Touring: Electrical
8-29
Большое спасибо!
Ваше мнение очень важно для нас.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст