Harley Davidson 2004 Touring Models. Service Manual — page 30
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TIRE DATA
TORQUE VALUES
1WARNING
Item
ft/in-lbs
Nm
Tires, rims and air valves must be correctly matched to
Front brake disc TORX
16-24 ft-lbs
22-33 Nm
wheel rims. See your Harley-Davidson dealer for service.
screws
Mismatching tires, tubes, rims and air valves may result
Front axle nut
50-55 ft-lbs
68-75 Nm
in damage to the tire bead during mounting or may allow
Front axle holder nuts
132-180 in-lbs
14.9-20.3 Nm
the tire to slip on the rim, possibly causing tire failure,
which could result in death or serious injury.
Front brake caliper
28-38 ft-lbs
37.9-51.5 Nm
mounting bolts
1WARNING
Rear brake disc TORX
30-45 ft-lbs
41-61 Nm
screws
Using tires in ways other than those specified below may
adversely affect motorcycle stability. Instability may lead
Rear wheel sprocket bolts
55-65 ft-lbs
75-88 Nm
to loss of vehicle control, which could result in death or
Rear axle cone nut
95-105 ft-lbs
129-142 Nm
serious injury.
Wheel spokes
40-50 in-lbs
4.5-5.6 Nm
● Use tubeless tires on all Harley-Davidson cast and
Front engine mount to
15-20 ft-lbs
20-27 Nm
disc wheels.
frame bolts
● Tubeless tires fitted with the correct size inner tubes
Front engine mounting
bracket to rubber mount
15-20 ft-lbs
20-27 Nm
also may be used on all Harley-davidson laced
bolt
wheels, but protective rubber rim strips must be
installed to prevent damage to the inner tubes.
Voltage regulator locknuts
70-100 in-lbs
7.9-11.3 Nm
● Do not use inner tubes in radial tires. Do not use
Handlebar clamp to
master cylinder housing
60-80 in-lbs
6.8-9.0 Nm
radial tires on laced wheels.
TORX screws
● Always use the correct size tires and tubes. Tire
Brake caliper bleeder
sizes are molded on the tire sidewall. Tube sizes are
80-100 in-lbs
9.0-11.3 Nm
valve
printed on the tube.
Rear brake pedal shaft
15-20 ft-lbs
20-27 Nm
locknut
1WARNING
Brake pedal/master
cylinder assembly to
30-40 ft-lbs
41-54 Nm
Maximum inflation pressure must not exceed specifica-
mounting bracket hex nut
tion on tire sidewall. Exceeding inflation specifications
can adversely affect handling or result in tire failure,
Banjo bolt to master
17-22 ft-lbs
23-30 Nm
cylinder
which could result in death or serious injury.
Banjo bolt to brake caliper
17-22 ft-lbs
23-30 Nm
Fairing
lower
U-bolt
Tire Pressure (Cold)
35-40 in-lbs
4.0-4.5 Nm
retainer locknuts
Dunlop Tires
Front
Rear
Fairing lower to engine
Only
90-100 in-lbs
10.2-11.3 Nm
guard clamp TORX screw
PSI
BARS
PSI
BARS
Fairing lower cap screws
10-15 in-lbs
1.1-1.7 Nm
Solo Rider
36
2.5
36
2.5
Front brake master
Rider & One Passenger
36
2.5
40
2.8
cylinder reservoir cover
6-8 in-lbs
0.7-0.9 Nm
screws
Rear brake master
cylinder reservoir cover
6-8 in-lbs
0.7-0.9 Nm
screws
REAR WHEEL SPROCKET
Brake caliper pad pins
180-200 in-lbs
20-23 Nm
All Models 70 teeth
Brake caliper bridge bolts
28-38 ft-lbs
38-52 Nm
Continued ...
2-2
2004 Touring: Chassis
HOME
TORQUE VALUES (CONT.’D)
Item
ft/in-lbs
Nm
Item
ft/in-lbs
Nm
Fork oil drain plugs
72-96 in-lbs
8-11 Nm
Short fairing screws
6-12 in-lbs
0.7-1.4 Nm
(FLTR)
Fork pinch bolts
30-35 ft-lbs
41-48 Nm
Long fairing screws (FLTR)
10-15 in-lbs
1.1-1.7 Nm
Fork stem nut
60-80 ft-lbs
81-109 Nm
Instrument bezel TORX
Fork tube plug
22-58 ft-lbs
30-79 Nm
25-35 in-lbs
2.8-4.0 Nm
screws (FLTR)
Fork cap bolt
50-60 ft-lbs
68-81 Nm
Instrument nacelle to fork
15-20 ft-lbs
20-27 Nm
bracket TORX bolts (FLTR)
Damper rod/cartridge
132-216 in-lbs
14.9-24.4 Nm
6mm screw
Fairing bracket/steering
20-30 ft-lbs
27.1-40.7 Nm
head thru bolt (FLTR)
Damper rod locknut
13-20 ft-lbs
18-27 Nm
(cartridge type fork)
Radio bracket/inner fairing
to fairing bracket stud lock-
96-144 in-lbs
10.9-16.3 Nm
Shock bottom mounting
35-40 ft-lbs
47-54 Nm
nuts (FLTR)
bolt
Headlamp nacelle handle-
Shock top mounting bolt
33-35 ft-lbs
45-48 Nm
bar clamp shroud Phillips
10-20 in-lbs
1.1-2.3 Nm
Rear swingarm bracket
screw
34-42 ft-lbs
46-57 Nm
bolts
Headlamp nacelle trim
15-20 in-lbs
1.7-2.3 Nm
Rear swingarm pivot shaft
strip flange nut
40-45 ft-lbs
54-61 Nm
locknut
Passing lamp bracket fork
72-108 in-lbs
8.1-12.2 Nm
Handlebar switch
bracket stud acorn nuts
35-45 in-lbs
4-5 Nm
housing TORX screws
Front fender mounting
Handlebar clamp to clutch
16-20 ft-lbs
22-27 Nm
60-80 in-lbs
6.8-9.0 Nm
bolts
lever bracket screws
Rear fender TORX bolts
15-20 ft-lbs
20-27 Nm
Clutch release cover
120-144 in-lbs
13.6-16.3 Nm
socket head screws
Jiffy stand leg stop flange
43-53 ft-lbs
58-72 Nm
nut
Clutch cable fitting
36-60 in-lbs
4-7 Nm
Intake flange adapter
Transmission lubricant
96-144 in-lbs
10.9-16.3 Nm
14-21 ft-lbs
19-28 Nm
screws
drain plug
Exhaust flange adapter
Transmission filler plug/
100-120 in-lbs
11.3-13.6 Nm
25-75 in-lbs
2.8-8.5 Nm
nuts
dipstick
Exhaust pipe TORCA
Battery cable bolt
60-96 in-lbs
6.8-10.9 Nm
45-60 ft-lbs
61-81 Nm
clamps
Tour-Pak mounting bolts
96-120 in-lbs
10.8-13.5 Nm
Heat shield worm drive
20-40 in-lbs
2.3-4.5 Nm
Inner fairing screws
20-30 in-lbs
2.3-3.4 Nm
clamps
Transmission exhaust
Outer fairing screws
60-96 in-lbs
6.8-10.8 Nm
25-30 in-lbs
2.8-3.4 Nm
bracket clamp bolt
(below windshield)
Passenger footboard/
Fairing cap TORX screws
25-30 in-lbs
2.8-3.4 Nm
15-18 ft-lbs
20-24 Nm
footrest socket screws
Speedometer/tachometer
10-20 in-lbs
1.1-2.3 Nm
Rider footboard
bracket socket screws
84-108 in-lbs
9.5-12.2 Nm
pivot bolt nut
2 inch diameter gauge
10-20 in-lbs
1.1-2.3 Nm
Air valve mount hex nut
40-50 in-lbs
4.5-5.6 Nm
nuts
Handlebar upper clamp
Passing lamp bracket fork
12-16 ft-lbs
16.3-21.7 Nm
15-20 ft-lbs
20-27 Nm
screws
bracket TORX bolts
Handlebar lower clamp
Windshield wellnut
30-40 ft-lbs
40.7-54.2 Nm
6-13 in-lbs
0.7-1.5 Nm
bolts (risers)
screws (FLTR)
Ignition switch
DOM
50-70 in-lbs
5.7-7.9 Nm
Front turn signal lamp
bracket stud acorn nuts
40-50 in-lbs
4.5-5.7 Nm
nut
HDI
125-150 in-lbs
14.1-16.9 Nm
(FLTR)
Speaker box to
25-35 in-lbs
2.8-4.0 Nm
Continued ...
Tour-Pak bolts
Throttle cable J-clamp
9-18 in-lbs
1.0-2.0 Nm
screw to wellnut (FLHR/C)
2004 Touring: Chassis
2-3
HOME
NOTES
2-4
2004 Touring: Chassis
HOME
VEHICLE IDENTIFICATION NUMBER (VIN)
2.2
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
between the front and rear cylinders on the left side of the
crankcase.
Model Designation
DD - FLHT
DJ
- FLHTC
FB - FLHRI
FC - FLHTCUI
FD - FLHR
FF
- FLHTCI
Introduction Date and Special Models
FG - FLHTCUI W/SC
FH - FLHPI
1 = Regular introduction date
FK - FLHTCI Shrine
2 = Mid-year introduction date
Market Designation
FL
- FLHTCUI Shrine
3 = California model
1 = Domestic
FM - FLHTPI
4 = Anniversary model
5 = International (HDI)
FR - FLHRCI
FS - FLTRI
FT
- FLHPEI
Engine Type
FV - FLHTI
FW - FLHRI Shrine
V = Carbureted
FX - FLHRS
W = Fuel Injected
FY - FLHRSI
VIN Check Digit
Varies; can be 0 through 9, or X.
Model Year
4 = 2004
Serial Number
1
HD
1
DJ V
1
3
4
Y
500001
Assembly Plant
Y = York, PA
K = Kansas City, MO
Motorcycle Type
1 = Heavyweight (901 cc and larger engine displacement)
Manufacturer and Make
Harley-Davidson
Sample VIN as it appears on the steering head -1HD1DJV134Y500001
Sample abbreviated VIN as it appears on the engine crankcase- DJV4500001
Figure 2-1. Vehicle Identification Number (VIN)
2004 Touring: Chassis
2-5
HOME
FRONT WHEEL
2.3
2. Remove both the upper and lower mounting bolts from
GENERAL
lugs of front fork leg to release brake caliper assembly.
Maximum tire mileage and good handling qualities are
3. Lift caliper upward to remove from brake disc. Allow the
directly related to care given wheels and tires. Wheels and
caliper to hang loose.
tires should be regularly inspected for wear. If handling prob-
4. Repeat steps 1 thru 3 to release caliper on opposite side
lems occur, see Section 1.1 TROUBLESHOOTING, HAN-
DLING, for possible causes.
of wheel.
Always keep tires inflated to the recommended pressure and
NOTE
balance the wheel whenever a tire or tube is replaced.
Do not operate the front brake hand lever with the front wheel
removed or the caliper pistons may be forced out. Reseating
pistons requires disassembly of the caliper.
PRELIMINARY INSPECTION
5. Insert screwdriver or steel rod through hole in axle on
1.
Measure brake disc thickness for excessive wear. Mini-
right side of vehicle. While holding axle stationary,
mum acceptable thickness is stamped on side of disc.
remove the axle nut, lockwasher and flat washer on the
Also replace discs if warped or badly scored. Obtain
left side.
new T40 TORX screws if brake discs were removed.
6. Loosen the two axle holder nuts at bottom of right side
2.
Whenever the wheel is removed for tire replacement or
fork leg.
any other purpose, inspect the wheel bearings as fol-
lows:
7. With soft mallet, tap axle toward right side of vehicle until
a. Insert finger into wheel bearing and rotate the inner
loose. Catching external spacers on left and right side,
race in both directions. Repeat step on opposite
pull axle from hub while supporting wheel.
side of wheel.
8. Move wheel to bench area and inspect bearings. See
b. Replace the wheel bearings if there is rough rota-
PRELIMINARY INSPECTION on this page.
tion, abnormal noise or anything unusual. Always
replace wheel bearings as a set. Never replace just
one wheel bearing.
DISASSEMBLY
REMOVAL
1. If wheel bearing replacement is necessary, proceed as
follows:
1. Use shop rag or tape to protect fender area adjacent to
caliper, as incidental contact can occur during caliper
a. Obtain the WHEEL BEARING REMOVER/IN-
removal.
STALLER (HD-44060). Pick out the wheel bearing
remover tools for the front wheel. See Figure 2-3.
b. To prolong service life and ensure smooth opera-
9428
tion, sparingly apply graphite lubricant to threads of
forcing screw.
c. Install hex nut, flat washer and Nice bearing on forc-
ing screw. Insert end of forcing screw through hole
in bridge.
d. Install steel ball inside larger collet. Install collet at
end of forcing screw.
e. Insert collet into bearing ID. Feel for inside edge of
bearing using lip at end of collet and then back off
slightly.
f.
Holding forcing screw to prevent rotation, turn hex
on collet until lip makes firm contact with inside
edge of bearing. See upper frame of Figure 2-4.
Figure 2-2. Inspect Wheel Bearings
2-6
2004 Touring: Chassis
HOME
Bridge
f1769x2x
f1774x2x
Forcing
Screw
Larger Collet
1 Inch
Nice Bearing
Steel Ball
Hex
Flat
Nut
Washer
Flat Washer
Hex Nut
Nice
Forcing Screw
Bearing
Graphite Lubricant
Figure 2-3. Front Wheel Bearing Remover Tools
(Part No. HD-44060)
g. Holding forcing screw, turn hex nut until bearing is
free. See lower frame of Figure 2-4.
h. Remove spacer sleeve from wheel hub.
Collet Hex
Bridge
with Ball Bearing
i.
Repeat procedure to remove bearing on opposite
side of wheel. Discard bearings.
Hold Forcing Screw and Turn Hex on Collet to Expand.
2.
If brake disc replacement is necessary, use a T40 TORX
drive head and remove five screws securing brake disc
f1775x2x
to hub. Discard TORX screws. Repeat procedure to
remove disc on opposite side of wheel. If the wheel is to
be assembled with the same discs, mark both the wheel
and discs, so that they can be installed in their original
positions.
3.
If tire replacement is necessary, see Section 2.8 TIRES
AND TUBES.
4.
If the wheel is laced, and hub, spoke or rim replacement
is necessary, loosen all spoke nipples and disassemble
hub from rim.
CLEANING AND INSPECTION
1. Thoroughly clean all parts in solvent.
2. Inspect all parts for damage or excessive wear.
3. Always replace bearing assemblies as a complete set.
4. Inspect brake discs. Replace discs if warped or badly
scored. Measure disc thickness for excessive wear. Min-
Wheel
imum acceptable thickness is stamped on side of disc.
Bearing
Hold Forcing Screw and Turn Hex Nut to Pull Out Bearing.
ASSEMBLY
Figure 2-4. Remove Sealed Wheel Bearings
1. On laced wheels, if the hub and rim were disassembled,
assemble the hub, spokes and rim. See Section 2.6
WHEEL LACING - 16 INCH RIM.
2004 Touring: Chassis
2-7
HOME
1. Axle Nut
2. Lockwasher
13
3. Flat Washer
4. T40 Torx Screw (10)
5. Brake Disc (Left Side)
Left Side
6. External Spacer (Long)
7. Sealed Bearing (2)
8. Cast Wheel
9. Spacer Sleeve
10. Brake Disc (Right Side)
11. External Spacer (Short)
4
1
12. Axle
13. Laced Wheel
2
3
Right Side
6
5
7
4
8
9
7
12
11
10
f2042x2x
Figure 2-5. Front Wheel (Exploded View)
a. Obtain the WHEEL BEARING REMOVER/IN-
1WARNING
STALLER (HD-44060). Pick out the wheel bearing
installer tools for the front wheel. See Figure 2-6.
Do not allow brake fluid or other lubricants to contact
the brake disc. Such contact can adversely affect brak-
b. To prolong service life and ensure smooth opera-
ing ability, which could result in death or serious injury.
tion, sparingly apply graphite lubricant to threads of
threaded rod.
2. Using a T40 TORX drive head, install brake discs on hub
using new screws. Be sure to install discs in their origi-
c. Slide support plate onto threaded rod. Slide rod
nal positions. Alternately tighten screws to 16-24 ft-lbs
through hub on the valve stem side of the wheel.
(22-33 Nm).
See upper frame of Figure 2-7.
3. Install new wheel bearings as follows:
d. On opposite side of wheel, slide bearing onto
threaded rod with lettered side facing outboard.
NOTE
Always install first of two bearings on the left side (opposite
e. Install larger pilot, Nice bearing, flat washer and
the valve stem side of the wheel).
hex nut onto rod.
2-8
2004 Touring: Chassis
HOME
Larger Pilot
1 Inch
Support Plate
Nice Bearing
Support
Plate
Flat Washer
Hex Nut
Threaded Rod
Graphite Lubricant
f1771x2x
Figure 2-6. Front Wheel Bearing Installer Tools
Threaded
(Part No. HD-44060)
Rod
f.
Holding threaded rod on opposite side of wheel to
f1777x2x
prevent rotation, turn hex nut to install bearing. See
lower frame of Figure 2-7. Bearing is fully seated
when it makes firm contact with the counterbore.
Slide Threaded Rod (with Support Plate) Through Hub.
g. Disassemble and remove tool, but leave support
plate on threaded rod.
Wheel
Bearing
h. Slide threaded rod through installed wheel bearing
and hub of wheel.
Nice
i.
On the valve stem side of the wheel, slide spacer
Bearing
sleeve down threaded rod until it contacts installed
wheel bearing.
j.
Repeat steps 3(d) through 3(g) to complete installa-
tion of second wheel bearing. Bearing is fully seated
when hex nut can no longer be turned.
4.
Verify that wheel is true. See CHECKING CAST RIM
RUNOUT or TRUING LACED WHEEL, whichever
Pilot
applies.
Threaded
5.
Install rim strip on wheel rim, if applicable. Install tube
Rod
Flat
and tire, if applicable. Verify that wheel is balanced.
Hex
Washer
f1773x2x
Nut
Hold Threaded Rod and Turn Hex Nut to Push In Bearing.
INSTALLATION
Figure 2-7. Install Sealed Wheel Bearings
1. Place wheel into position between forks with the valve
stem on the right side of the vehicle.
5. Install flat washer, lockwasher and axle nut.
2. Coat the axle with ANTI-SIEZE LUBRICANT.
6. Insert screwdriver or steel rod through hole in axle on
3. Supporting wheel, insert threaded end of axle through
right side of vehicle. While holding axle stationary,
right fork leg. Push axle through fork, short external
tighten axle nut to 50-55 ft-lbs (68-75 Nm).
spacer and wheel hub until it begins to emerge from left
side.
7. Insert 7/16 inch drill bit into hole in axle. See Figure 2-8.
4.
With the three notches on the bearing side, push axle
8. Pull fork leg so that it just contacts drill bit, and then
through long external spacer and left fork leg until axle
tighten axle holder nuts to 132-180 in-lbs (14.9-20.3
shoulder contacts external spacer on right fork side.
Nm).
2004 Touring: Chassis
2-9
HOME
f1783x2x
1WARNING
After installation of calipers and BEFORE moving motor-
Fork Leg
cycle, pump front brake hand lever until pistons push
Right Side
pads against the brake discs. If fluid pressure is not
pumped up, the brake will not be available the first time it
is used, a situation that could result in death or serious
injury.
11.
Depress front brake hand lever several times to set
Short
Spacer
brake pads to proper operating position within caliper.
Axle
Drill Bit
Axle Holder
Nuts
Figure 2-8. Align Front Wheel
9.
Remove drill bit from axle hole.
10.
Install brake caliper as follows:
a. Use shop rag or tape to protect fender area adja-
cent to caliper, as incidental contact can occur dur-
ing caliper installation.
b. With the bleeder valve topside, position caliper so
that brake disc is situated between friction pads. Pry
inner and outer brake pads back for additional clear-
ance, if necessary.
c. Align upper mounting hole in caliper with upper
mounting lug on fork leg. Loosely install long caliper
mounting bolt into upper lug of fork leg.
d. Install short caliper mounting bolt into lower lug of
fork leg. Tighten lower mounting bolt to 28-38 ft-lbs
(37.9-51.5 Nm).
e. Tighten upper caliper mounting bolt to 28-38 ft-lbs
(37.9-51.5 Nm).
f.
Repeat step 10 to install caliper on opposite side of
wheel.
2-10
2004 Touring: Chassis
HOME
REAR WHEEL
2.4
c. Loosen TORCA clamp between rear header pipe
GENERAL
and muffer.
Maximum tire mileage and good handling qualities are
d. Remove two bolts (with lockwashers) to detach muf-
directly related to care given wheels and tires. Wheels and
fler from the lower saddlebag support rail.
tires should be regularly inspected for wear. If handling prob-
e. Remove bungee cord to release muffler from lower
lems occur, see Section 1.1 TROUBLESHOOTING, HAN-
saddlebag support rail.
DLING, for possible causes.
Always keep tires inflated to the recommended pressure and
3.
Standing on right side of vehicle, remove E-clip from
balance the wheel whenever a tire or tube is replaced.
groove at end of axle.
4.
Remove cone nut and adjuster cam from axle.
PRELIMINARY INSPECTION
5.
Using a soft mallet, gently tap end of axle towards left
side to loosen. Catching external spacers on right and
1. Measure brake disc thickness for excessive wear. Mini-
left side of hub, pull axle free of wheel and rear
mum acceptable thickness is stamped on side of disc.
swingarm.
Also replace disc if warped or badly scored.
6.
Pull wheel to release brake disc from caliper. Pry inner
2. Whenever the wheel is removed for tire replacement or
and outer brake pads back for additional clearance, if
any other purpose, inspect the wheel bearings as fol-
necessary. Use a putty knife with a wide thin blade to
lows:
avoid scoring or scratching the brake disc.
a. Insert finger into wheel bearing and rotate the inner
7.
Remove caliper from anchor weldment on rear swing-
race. Repeat step on opposite side of wheel.
arm, and carefully hang over lower saddlebag support
b. Replace the wheel bearings if there is rough rota-
rail.
tion, abnormal noise or anything unusual. Always
8.
Move wheel forward and slip belt off sprocket.
replace wheel bearings as a set. Never replace just
one wheel bearing.
9.
Move wheel to bench area and inspect bearings. See
PRELIMINARY INSPECTION on this page.
NOTE
REMOVAL
Do not operate the rear brake pedal with the rear wheel
1. Remove saddlebags. See Section 2.25 SADDLEBAG,
removed or the caliper pistons may be forced out. Reseating
REMOVAL.
pistons requires disassembly of the caliper.
2. Remove both mufflers as follows:
Left Side
DISASSEMBLY
a. Open worm drive clamps to remove heat shield
from crossover pipe.
1.
If wheel bearing replacement is necessary, proceed as
b. Using a bungee cord, tie the muffler to the lower
follows:
saddlebag support rail.
a. Remove five bolts (with flat washers) securing belt
c. Loosen TORCA clamp between crossover pipe and
sprocket to hub.
muffer.
d. Remove two bolts (with lockwashers) to detach muf-
b. Obtain the WHEEL BEARING REMOVER/IN-
fler from the lower saddlebag support rail.
STALLER (HD-44060). Pick out the wheel bearing
remover tools for the rear wheel. See Figure 2-9.
e. Remove bungee cord to release muffler from lower
saddlebag support rail.
NOTE
The smaller 3/4 inch collet (and pilot) is only used to replace
Right Side
the rear wheel bearings on 2000-01 Touring models.
a. Open worm drive clamps to remove heat shield
from rear header pipe.
c. To prolong service life and ensure smooth opera-
tion, sparingly apply graphite lubricant to threads of
b. Using a bungee cord, tie the muffler to the lower
forcing screw.
saddlebag support rail.
2004 Touring: Chassis
2-11
HOME
Bridge
f1769x2x
f1774x2x
Forcing
Screw
Larger Collet
1 Inch
Nice Bearing
Steel Ball
Hex
Flat
Nut
Washer
Flat Washer
Hex Nut
Nice
Forcing Screw
Bearing
Graphite Lubricant
Figure 2-9. Rear Wheel Bearing Remover Tools
(Part No. HD-44060)
d. Install nut, flat washer and Nice bearing on forcing
screw. Insert end of forcing screw through hole in
bridge.
Collet Hex
Bridge
with Ball Bearing
e. Install steel ball inside larger collet. Install collet at
end of forcing screw.
Hold Forcing Screw and Turn Hex on Collet to Expand.
f.
Insert collet into bearing ID. Feel for inside edge of
bearing using lip at end of collet and then back off
f1775x2x
slightly.
g. Holding forcing screw to prevent rotation, turn hex
on collet until lip makes firm contact with inside
edge of bearing. See upper frame of Figure 2-10.
h. Holding forcing screw, turn hex nut until bearing is
free. See lower frame of Figure 2-10.
i.
Remove spacer sleeve from wheel hub.
j.
Repeat procedure to remove bearing on opposite
side of wheel. Discard bearings.
2.
If brake disc replacement is necessary, use a T45 TORX
drive head and remove five screws securing brake disc
to hub. If the wheel is to be assembled with the same
disc, mark both the wheel and disc, so that it can be
installed in its original position.
3.
Remove tire, if necessary. Remove tube from the rim, if
applicable. See Section 2.8 TIRES AND TUBES.
Wheel
4.
If it is necessary to remove the hub from a laced wheel,
Bearing
loosen all spoke nipples and remove the rim and spokes.
Hold Forcing Screw and Turn Hex Nut to Pull Out Bearing.
CLEANING AND INSPECTION
Figure 2-10. Remove Sealed Wheel Bearings
1.
Thoroughly clean all parts in solvent.
2.
Inspect all parts for damage or excessive wear.
3. Always replace bearings as a complete set.
2-12
2004 Touring: Chassis
HOME
1. Axle
2. External Spacer (Large)
3. Bolt (5)
15
4. Flat Washer (5)
5.
Belt Sprocket
6.
Sealed Bearing (2)
Left Side
7.
Spacer Sleeve
8.
Cast Wheel
9.
Brake Disc
10. T45 TORX Screw (5)
11. External Spacer (Small)
1
12. Adjuster Cam
3
13. Cone Nut
14. E-Clip
4
15. Laced Wheel
2
7
Right Side
6
5
6
8
11
13
9
12
f2044x2x
14
10
Figure 2-11. Rear Wheel (Exploded View)
4. Inspect brake disc. Replace disc if warped or badly
2. Verify that wheel is true. See Section 2.5 CHECKING
scored. Measure disc thickness for excessive wear. Min-
RIM RUNOUT or Section 2.7 TRUING LACED WHEEL,
imum acceptable thickness is stamped on side of disc.
whichever applies.
5. Check the belt sprocket for wear, tooth damage, cracks
or pitting. Replace if necessary.
1WARNING
6. On laced wheels, replace spokes, rim or hub if dam-
Do not allow brake fluid or other lubricants to contact
aged.
the brake disc. Such contact can adversely affect brak-
ing ability, which could result in death or serious injury.
ASSEMBLY
3. Using a T45 TORX drive head, install five screws (and
locknuts on laced wheels) to secure brake disc to hub.
1. On laced wheels, if the hub and rim were disassembled,
Always install brake disc in its original position. Use new
assemble the hub, spokes and rim. See Section 2.6
screws after three use cycles. Alternately tighten screws
WHEEL LACING - 16 INCH RIM.
to 30-45 ft-lbs (41-61 Nm).
2004 Touring: Chassis
2-13
HOME
Larger Pilot
1 Inch
Support Plate
Nice Bearing
Support
Plate
Flat Washer
Hex Nut
Threaded Rod
Graphite Lubricant
f1771x2x
Figure 2-12. Rear Wheel Bearing Installer Tools
Threaded
(Part No. HD-44060)
Rod
4.
Install new wheel bearings as follows:
f1777x2x
NOTE
Always install first of two bearings on the right side (the valve
Slide Threaded Rod (with Support Plate) Through Hub.
stem side of the wheel).
a.
Obtain the WHEEL BEARING REMOVER/IN-
Wheel
STALLER (HD-44060). Pick out the wheel bearing
Bearing
installer tools for the rear wheel. See Figure 2-12.
b.
To prolong service life and ensure smooth opera-
Nice
tion, sparingly apply graphite lubricant to threads of
Bearing
threaded rod.
c.
Slide support plate onto threaded rod. Slide rod
through hub on the sprocket side of the wheel. See
upper frame of Figure 2-13.
d.
On the valve stem side of the wheel, slide bearing
onto threaded rod with lettered side facing out-
board.
Pilot
e.
Install larger pilot, Nice bearing, flat washer and
Threaded
hex nut onto rod.
Rod
Flat
Hex
f.
Holding threaded rod on opposite side of wheel to
Washer
f1773x2x
Nut
prevent rotation, turn hex nut to install bearing. See
lower frame of Figure 2-13. Bearing is fully seated
Hold Threaded Rod and Turn Hex Nut to Push In Bearing.
when it makes firm contact with the counterbore.
g.
Disassemble and remove tool, but leave support
Figure 2-13. Install Sealed Wheel Bearings
plate on threaded rod.
h.
Slide threaded rod through installed wheel bearing
6. Apply two drops of Loctite High Strength Threadlocker
and hub of wheel.
271 (red) to threads of five belt sprocket bolts. Always
i.
On the other side of the wheel, slide spacer sleeve
use new bolts after three use cycles. Install bolts with
down threaded rod until it contacts installed wheel
flat washers to secure sprocket to hub. Alternately
bearing.
tighten bolts to 55-65 ft-lbs (75-88 Nm).
j.
Repeat steps 4(d) through 4(g) to complete installa-
tion of second wheel bearing. Bearing is fully seated
INSTALLATION
when hex nut can no longer be turned.
5.
Install rim strip on wheel rim, if applicable. Install tube
1. Place wheel in rear swingarm. Slide wheel far enough
and tire, if applicable. Verify that wheel is balanced.
forward to slip belt over sprocket and then slide the
wheel back.
2-14
2004 Touring: Chassis
HOME
lbs. (4.5 kg) of force at the midpoint of the bottom belt
CAUTION
strand. Belt deflection should be as follows:
Do not bend or fold belt backward or into loops smaller
Table 2-1. Belt Deflection in the Air
than 5 inches (127 mm) in diameter. Sharp bending can
weaken the belt and cause premature failure.
Orientation
Inches
Millimeters
2.
Seat caliper on anchor weldment of rear swingarm. Posi-
Motorcycle Upright
3/16 - 1/4
4.8
- 6.4
tion wheel in swingarm, so that brake disc is centered
With Rear Wheel in the Air
between brake pads.
NOTE
See Section 6.4 SECONDARY DRIVE BELT AND SPROCKETS
3.
Coat the axle with ANTI-SIEZE LUBRICANT.
for belt deflection specification with motorcycle on jiffy stand.
4.
With the larger OD on the outboard side, hold external
spacer between rear swingarm and belt sprocket. Slide
10.
If belt is too tight, move to step
11 to increase belt
axle through left side of rear swingarm, external spacer,
deflection. If belt is too loose, reduce belt deflection as
and belt sprocket into wheel hub.
described below:
5.
When axle emerges from hub on brake disc side of
a. Rotate weld nut on left side of axle in a clockwise
wheel, push axle through short external spacer, caliper
direction.
bracket and right side of rear swingarm.
b. Check belt deflection. Apply 10 lbs. (4.5 kg) of force
6.
Rotate axle so that the flat on the threaded end is top-
at the midpoint of the bottom belt strand. Belt
side. With the thumb down and the cam forward, install
deflection should be within the range specified in
adjuster cam on end of axle.
Table 2-1.
7.
Apply a thin film of ANTI-SIEZE LUBRICANT to the
c. If belt is still too loose, repeat steps 10(a) through
inboard side of the cone nut avoiding contact with
10(b). If belt is now too tight, move to step 11.
threads. Install cone nut on axle, but finger tighten only.
8.
Verify that adjuster cam just contacts weld nub on both
11.
If belt is too tight, increase belt deflection as follows:
sides of rear swingarm. If necessary, push wheel for-
ward slightly to achieve the desired result. Snug the
a. Rotate weld nut on left side of axle in a counter-
cone nut to 15-20 ft-lbs (20-27 Nm). See Figure 2-14.
clockwise direction.
9.
Check deflection at the loosest spot in the belt. Use
b. Push wheel forward slightly so that adjuster cam
BELT TENSION GAUGE (HD-35381A), or install narrow
just contacts weld nub on both sides of rear swing-
saddle (HD-35381-3) on existing gauge, and apply 10
arm. See Figure 2-14.
LEFT SIDE
RIGHT SIDE
Increase
Reduce
Belt
Belt
Deflection
Deflection
Cone
Nut
Weld
Nub
Weld
Weld
Nut
E-Clip
Nub
Adjuster
8398
8407
Cam
Figure 2-14. Move Rear Wheel Forward Until Adjuster Cams Just Contact Weld Nubs
2004 Touring: Chassis
2-15
HOME
c. Check belt deflection. Apply 10 lbs. (4.5 kg) of force
at the midpoint of the bottom belt strand. Belt
CAUTION
deflection should be within the range specified in
Verify that the heat shields do not contact the vehicle
Table 2-1.
frame or any mounted components. Contact will cancel
d. If belt is still too tight, repeat steps 11(a) through
the effect of the rubber isolation mounts and transmit
11(c). If belt is now too loose, move to step 10.
vibration to the rider via the vehicle frame.
g.
Remove bungee cord from muffler.
12. Holding weld nut on left side of axle, tighten cone nut on
right side to 95-105 ft-lbs (128.8-142.4 Nm).
Right Side
NOTE
a.
Slide new TORCA clamp onto free end of rear
If the axle moves during tightening of the cone nut, then the
the belt deflection procedure must be restarted.
header pipe.
b.
Using a bungee cord, tie muffler to lower saddlebag
13. Recheck belt deflection to verify that it is still within spec-
support rail. Install muffler on rear header pipe.
ification.
Place TORCA clamp into position between rear
If the belt deflection is not within specification, loosen
header pipe and muffler.
cone nut and then snug to 15-20 ft-lbs (20-27 Nm)
c.
Tighten the two bolts (with lockwashers) to fasten
before returning to step 10.
the muffler to the lower saddlebag support rail.
14. With the flat side out, install new E-clip in groove on right
side of axle.
CAUTION
15. Install both mufflers as follows:
Verify that the exhaust pipes do not contact the vehicle
NOTE
frame or any mounted components. Contact will cancel
the effect of the rubber isolation mounts and transmit
TORCA muffler clamps have eliminated the need for silicone
vibration to the rider via the vehicle frame.
or graphite tape during assembly. To ensure sealing integrity
of muffler clamps and prevent the possibility of leakage, Har-
d.
Verify that exhaust pipes are in alignment and do
ley-Davidson recommends that TORCA clamp assemblies be
not contact the vehicle frame or mounted compo-
discarded and replaced each time they are removed.
nents.
e. Tighten the TORCA clamp to 45-60 ft-lbs (61-81
Nm).
Left Side
f.
Open worm drive clamps and install heat shield on
a. Slide new TORCA clamp onto free end of crossover
rear header pipe. Position clamp so that screw is on
pipe.
the outboard side in the most accessible position.
b. Using a bungee cord, tie muffler to lower saddlebag
support rail. Install muffler on crossover pipe. Place
CAUTION
TORCA clamp into position between crossover and
muffler.
Verify that the heat shields do not contact the vehicle
frame or any mounted components. Contact will cancel
c. Tighten the two bolts (with lockwashers) to fasten
the effect of the rubber isolation mounts and transmit
the muffler to the lower saddlebag support rail.
vibration to the rider via the vehicle frame.
g. Remove bungee cord from muffler.
CAUTION
Verify that the exhaust pipes do not contact the vehicle
frame or any mounted components. Contact will cancel
1WARNING
the effect of the rubber isolation mounts and transmit
After installation of caliper and BEFORE moving motor-
vibration to the rider via the vehicle frame.
cycle, pump rear brake pedal until pistons push pads
d. Verify that exhaust pipes are in alignment and do
against the brake disc. If fluid pressure is not pumped
not contact the vehicle frame or mounted compo-
up, the rear brake will not be available the first time it is
nents.
used, a situation that could result in death or serious
injury.
e. Tighten the TORCA clamp to 45-60 ft-lbs (61-81
Nm).
16. Depress rear brake pedal several times to set brake
pads to proper operating position within caliper.
f.
Open worm drive clamps and install heat shield on
crossover pipe. Position clamp so that screw is on
17. Install saddlebags. See Section
2.25 SADDLEBAG,
the outboard side in the most accessible position.
INSTALLATION.
2-16
2004 Touring: Chassis
HOME
CHECKING RIM RUNOUT
2.5
INSPECTION
f1379x2x
Check wheels for lateral and radial runout before installing a
new tire or tube.
1. Install truing arbor in wheel hub and place wheel in
WHEEL TRUING STAND, Part No. HD-99500-80.
2. See Figure 2-15. To check rim lateral runout, place a
gauge rod or dial indicator near the rim bead. If lateral
runout exceeds 0.040 inch (1.02 mm), replace the wheel
if cast. Retrue the wheel if laced.
3. See Figure 2-16. Check the rim radial runout as shown.
If radial runout exceeds 0.030 inch (0.76 mm), replace
the wheel if cast. Retrue the wheel if laced.
Radial
NOTE
Runout
Rim lateral and radial runout is adjustable on laced wheels.
See Section 2.7 TRUING LACED WHEEL.
Gauge
f1378x2x
Figure 2-16. Checking Rim Radial Runout
4.
If working with a laced wheel, proceed to Section 2.7
TRUING LACED WHEEL to check the wheel offset
dimension.
Lateral
Runout
Gauge
Figure 2-15. Checking Rim Lateral Runout
2004 Touring: Chassis
2-17
HOME
WHEEL LACING - 16 INCH RIM
2.6
GENERAL
WHEEL LACING
The 16 inch wheel uses only one type of spoke, rather than
1.
If front wheel, place the hub on a table with the wider
the separate inner and outer spokes (with differing head
flange side up. If rear wheel, place hub so that brake
angles) seen in the old style.
disc side is up. Insert a spoke in each hole of the lower
row as shown below. Angle the spokes in a clockwise
Exercise caution to avoid mixing old and new parts. The head
direction .
angle of the spoke is closer to 90 degrees, which makes it
very difficult to differentiate from the outer spoke of the old
style.
f1150d2x
The nipple fitting of the spoke uses a TORX style fastener
(instead of the straight slotted) and requires a special T-30
I.P. (TORX Plus) driver (HD-42135) for removal and installa-
tion. See A of Figure 2-17. Use of a standard T-30 TORX bit
will result in nipple damage.
The 16 inch hub can be easily identified by its aluminum
construction. The 16 inch rim can be quickly identified by the
shape of the flat around the valve stem. The flat is tombstone
shaped on the rim (square shaped on the old style rim). See
B and C of Figure 2-17.
Figure 2-18.
A
2.
Place the rim on the table with the valve stem side up.
Using any lower row spoke, place the first spoke into the
rim hole to the left of the valve stem hole on the upper
f1150a2x
half of the rim centerline.
Narrow Flange
Belt Sprocket Side
B
First
Wide Flange
Lower Row Spoke
Valve Stem Hole
f1150b2x
Valve Stem Flat
C Tombstone Shaped
f1150c2x
f1150e2x
Figure 2-17. Parts Identification
Figure 2-19.
2-18
2004 Touring: Chassis
HOME
3. Install the rest of the lower row spokes in every fourth
5.
Install the nine remaining upper row spokes into every
hole.
fourth hole remaining above the rim centerline.
f1150f2x
f1150h2x
Figure 2-20.
Figure 2-22.
4. Place the first upper row spoke into the hub as shown
6.
Turn the wheel over. Place any lower row spoke into the
below. Angle the spoke counterclockwise crossing four
hub. Angle the spoke clockwise and place into rim hole
lower row spokes. The spoke must enter the hole to the
angled to accept it.
left of the valve stem hole.
First
First
Upper Row Spoke
Lower Row Spoke
1
4
2
3
f1150g2x
f1150i2x
Figure 2-21.
Figure 2-23.
2004 Touring: Chassis
2-19
HOME
7.
Angled clockwise, place the nine remaining lower row
9. Install the nine remaining upper row spokes into hub and
spokes into hub and rim.
rim.
f1150j2x
f1150l2x
Figure 2-24.
Figure 2-26.
8.
Insert any upper row spoke into the hub and angle spoke
counterclockwise. Place spoke into appropriate rim hole
CAUTION
crossing four lower row spokes.
The hub is made of aluminum alloy and should not be
clamped in a vise or gripped with pliers, or the hub mate-
rial may be damaged.
First
Upper Row Spoke
10. Verify that wheel is true. See Section
2.7 TRUING
LACED WHEEL for truing procedure and spoke torque
specification.
SPOKE TIGHTNESS
At the 1000 mile (1600 km) service interval, the 5000 mile
(8000 km) service interval, and then every
15,000 mile
4
(24,000 km) service interval thereafter, inspect spoke tight-
1
ness, if applicable. Proceed as follows:
3
1.
Raise wheel off the ground.
2
CAUTION
If nipples require more than one full turn to tighten
spoke, remove tire to check that spoke protrusion has
f1150k2x
not damaged tube.
2.
Lightly tap each spoke with a spoke wrench. Loose
Figure 2-25.
spokes will sound dull and must be tightened. Tighten
spokes to 40-50 in-lbs (4.5-5.6 Nm). If more than a few
spokes are loose, true the entire wheel following the pro-
cedure on the next page.
2-20
2004 Touring: Chassis
HOME
TRUING LACED WHEEL
2.7
PROCEDURE
f1379x2x
1. Divide the wheel spokes into ten groups of four and
mark the center of each group with a piece of tape. The
groups should be directly across from one another and
approximately 90ο apart. Tighten the spokes in these
four groups finger tight, leaving all others loose.
2. See Figure 2-28. Install truing arbor in wheel hub and
place wheel in WHEEL TRUING STAND, Part No. HD-
99500-80. Tighten arbor nuts so hub will turn on its bear-
ings.
3. Lay a straightedge across the hub brake disc flange
(valve stem side of dual disc front wheel) and one of the
marked spoke groups. Measure the distance from the
straightedge to the edge of the rim as shown in Figure 2-
Radial
27. Be sure to subtract the thickness of the straightedge.
Runout
The offset dimension must be as follows:
● Front Wheel: 1.555- 1.575 inches (39.5- 40.0 mm).
Gauge
● Rear Wheel: 1.472- 1.492 inches (37.4- 37.9 mm).
If the dimension is not correct, tighten the four spokes
accordingly. Use the special T-30 I.P. (TORX Plus) driver
(HD-42135). For example, If the measurement on the right
Figure 2-28. Truing Rim Radially
rim edge side is less than it should be, loosen the two spokes
attached to the hub right side and tighten the two spokes
attached to the hub left side. Turn all four spokes an equal
CAUTION
number of turns until offset dimension is correct.
Always loosen the appropriate spokes before tightening
the other two. Reversing this procedure will cause the
rim to become out-of-round.
4.
Repeat Step 3 for all four groups on the wheel.
5.
See Figure 2-28. After rim has been trued sideways it
must be checked and trued radially. Adjust truing stand
gauge to the rim's tire bead seat as shown. The rim
should be trued within 1/32 inch (0.79 mm).
6.
Spin the rim slowly. If the rim contacts the gauge on or
near a marked group of spokes, loosen the spokes in the
marked group on the opposite side of the rim. Now
tighten the spokes in the group where the rim makes
contact. Loosen and tighten spokes an equal number of
turns.
7.
If the rim contacts the gauge between two marked
f1155b2x
groups, loosen the spokes in both opposite groups and
tighten the spoke groups on the side of the rim that
Figure 2-27.
Checking Laced Hub Offset Dimension
makes contact.
2004 Touring: Chassis
2-21
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