Harley Davidson 2004 Touring Models. Service Manual — page 44

HOME

Holding the fuel valve to prevent rotation, turn the hex

jam nut in a counterclockwise direction until snug.

f2052x4x

Tighten the hex jam nut to 15-20 ft-lbs (20.3-27.1 Nm).

Fuel Tank

Side

CAUTION

Do not allow dirt or fluids to get into the vacuum tube

that connects the fuel valve to the intake manifold. Con-

taminants can block the vacuum signal which could

O-Ring

cause the fuel valve to malfunction.

Connect elbow of intake manifold vacuum tube to fitting

on inboard side of the fuel valve.

Figure 4-16. Fuel Tank Adapter

Slide new clamp onto free end of carburetor fuel inlet

hose. Install hose onto fuel outlet fitting at front of fuel

valve. Crimp clamp using HOSE CLAMP PLIERS (HD-

FUEL TANK ADAPTER

97087-65B).

Turn the handle of the fuel valve to OFF and fill the fuel

If leakage or damage is observed at the fuel tank adapter,

tank. Carefully inspect for leaks at fitting.

replace O-ring and/or adapter as follows:

10.

Turn the valve handle to ON and start engine. No priming

Remove fuel valve assembly. See REMOVAL in this sec-

or special procedures are required to start fuel flow.

tion.

Carefully inspect for leaks at fitting.

Slide a 7/8 inch socket over hex on adapter, and looking

11.

Stop engine and return the valve to the OFF position.

down at top of fuel tank, rotate in a clockwise direction to

remove. See Figure 4-16.

Remove O-ring from adapter. Discard O-ring.

Apply a very thin film of clean H-D 20W50 engine oil to

new O-ring. Install O-ring into groove of adapter.

Hand thread adapter into fuel tank bore. Looking down at

top of fuel tank, rotate adapter in a counterclockwise

direction until snug.

Slide a 7/8 inch socket over hex and tighten to 22-26 ft-

lbs (30-35 Nm).

Install fuel valve assembly. See INSTALLATION in this

section.

4-20

2004 Touring: Fuel

HOME

FUEL TANK (CARBURETED)

4.7

COMPLETE REMOVAL

f1924x8x

NOTE

For fuel injected models, see Section 9.4 FUEL TANK (FUEL

INJECTED) for removal and installation instructions.

FLHT/C

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

Fuel Tank

1WARNING

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

cle, disconnect the negative battery cable before pro-

ceeding. Inadequate safety precautions could result in

death or serious injury.

Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.

Fuel Vapor

Fuel Tank Harness

Vent Tube

Connector [13]

(To Vapor Valve)

Not Present on FLHR/C/S

1WARNING

Figure 4-17. Fuel Level Sender Connector (FLHT/C)

Gasoline is extremely flammable and highly explosive.

When servicing the fuel system, do not smoke or allow

open flame or sparks in the vicinity. Inadequate safety

precautions could result in death or serious injury.

1WARNING

Drain the fuel tank. See Section 4.6 VACUUM OPER-

A small amount of gasoline may drain from the cross-

ATED FUEL VALVE (CARBURETED), DRAINING FUEL

over hose when disconnected from the fuel tank. Thor-

TANK, steps 1-8.

oughly wipe up any spilled fuel immediately and dis-

Carefully cut anchored cable strap securing main har-

pose of rags in a suitable manner. Gasoline is extremely

ness bundles, fuel level sender conduit, and fuel vapor

flammable and highly explosive. Inadequate safety pre-

cautions could result in death or serious injury.

vent tube to left side of frame backbone.

Disconnect fuel tank harness connector [13], 3-place

11. Using a side cutters, cut clamp from one end of cross-

Multilock, in front of battery. See Figure 4-17.

over hose beneath fuel tank. Drain free end of hose into

a suitable container.

Open fuel door on console. Remove two Allen head

screws inboard of rubber bumpers. These screws secure

12. Remove fuel tank from motorcycle.

console to clip nuts on the canopy bracket.

Remove Allen head screw to detach flange at rear of

console from clip nut on fuel tank weldment.

FLHR/S

Lay a clean shop cloth on forward part of rear fender.

Remove filler cap from neck of fuel tank. Remove con-

Remove seat. See Section 2.24 SEAT, REMOVAL.

sole and lay upside down on shop cloth. Reinstall filler

cap.

1WARNING

Gently pry fuel vapor vent tube from fitting on filler neck

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

of fuel tank. Exercise caution to avoid pulling fitting from

cle, disconnect the negative battery cable before pro-

filler neck.

ceeding. Inadequate safety precautions could result in

10.

Remove two fuel tank front mounting bolts (with flat

death or serious injury.

washers) from left and right side of frame. Remove bolt

(with flat washer) to free rear of fuel tank from frame

Unthread bolt and remove battery negative cable (black)

backbone.

from battery negative (-) terminal.

2004 Touring: Fuel

4-21

HOME

CLEANING AND INSPECTION

1WARNING

Gasoline is extremely flammable and highly explosive.

Inspect the fuel tank for leaks and other damage.

When servicing the fuel system, do not smoke or allow

Replace damaged tanks that cannot be successfully

open flame or sparks in the vicinity. Inadequate safety

repaired.

precautions could result in death or serious injury.

If sludge, rust or varnish deposits are evident, clean fuel

3. Drain the fuel tank. See Section 4.6 VACUUM OPER-

tank as follows:

ATED FUEL VALVE (CARBURETED), DRAINING FUEL

TANK, steps 1-8.

1WARNING

4. Remove two fuel tank front mounting bolts (with flat

Even with the fuel tank completely drained, a small

washers) from left and right side of frame. Remove bolt

amount of gasoline may leak from the bore when the fuel

(with flat washer) to free rear of fuel tank from frame

valve is loosened or removed. Thoroughly wipe up any

backbone. On FLHRS models, removal of rear bolt also

spilled fuel immediately and dispose of rags in a suitable

releases instrument console bracket.

manner. Gasoline is extremely flammable and highly

5. Carefully cut anchored cable strap securing main har-

explosive. Inadequate safety precautions could result in

ness bundle, instrument console conduit, and fuel vapor

death or serious injury.

vent tube to left side of frame backbone.

a. Remove the fuel valve assembly and plug fuel tank

6. Remove acorn nut from instrument console. If present,

opening. See Section

4.6 VACUUM OPERATED

also remove Phillips screw and large flat washer (absent

FUEL VALVE (CARBURETED), REMOVAL.

on FLHRS models).

b. Remove canopy as follows:

7. Raise instrument console and bend back flexible clamp

FLHT/C, FLTR: See Section 8.29 FUEL LEVEL

on canopy to release main harness conduit. Depress

SENDER (CARBURETED), FLHT/C CANOPY,

button on socket side and remove fuel level sender con-

REMOVAL, steps 11-13.

nector [141], 3-place Mini-Deutsch.

FLHR: See Section 8.29 FUEL LEVEL SENDER

(CARBURETED), FLHR/S CANOPY, REMOVAL,

CAUTION

steps 10-12.

When removing instrument console, exercise caution to

avoid damaging speedometer unit. Wrap console in a

1WARNING

clean, dry shop towel to prevent damage.

An open flame or spark may cause a fuel tank explosion

Secure instrument console to top of rear fender using

if all traces of fuel are not purged from the tank. Use

bungee cords.

extreme caution when servicing fuel tanks. Inadequate

9. Remove console mounting bolt from slot at top of can-

safety precautions could result in death or serious injury.

opy.

c. Fill the tank with commercial cleaning solvent or a

10. Gently pry fuel vapor vent tube from fitting.

soap and water solution. Shake the tank to agitate

the cleaning agent.

11. At bottom left side of fuel tank, gently pull on convoluted

tubing to draw fuel gauge connector [117], 4-place Mul-

tilock, out of tunnel. Depress button on socket terminal

1WARNING

side and pull apart pin and socket halves.

To assist in loosening deposits, use only non-ferrous

metal balls (such as lead pellets) with fuel tank cleaning

1WARNING

solutions. The use of ferrous materials may cause a

spark, which can then ignite fuel vapors inside the tank.

A small amount of gasoline may drain from the crossover

The resulting flames or explosion could result in death or

hose when disconnected from the fuel tank. Thoroughly

serious injury.

wipe up any spilled fuel immediately and dis-pose of rags

in a suitable manner. Gasoline is extremely flammable

d. If necessary, non-ferrous metallic balls or pellets

and highly explosive. Inadequate safety precautions

may be added to the tank to help loosen deposits.

could result in death or serious injury.

e. Thoroughly flush the fuel tank after cleaning. Allow

12. Using a side cutters, cut clamp from one end of cross-

tank to air dry.

over hose beneath fuel tank. Drain free end of hose into

Install fuel valve assembly. See Section 4.6 VAC-

a suitable container.

UUM OPERATED FUEL VALVE (CARBURETED),

13. Remove fuel tank from motorcycle.

INSTALLATION.

4-22

2004 Touring: Fuel

HOME

Slide new clamp onto free end of carburetor fuel inlet

hose. Install hose onto fuel outlet fitting at side of fuel

Hose Cutter

valve. Crimp clamp.

Part No. HD-41185

Install the intake manifold vacuum hose onto the vacuum

fitting at the back of the fuel valve.

Start fuel tank front mounting bolts (with flat washers)

into left and right side of frame.

Hose Clamp Pliers

Part No. HD-97087-65B

Install bolt (with flat washer) to secure rear of fuel tank to

frame backbone. Tighten bolt to 15-20 ft-lbs (20-27 Nm).

Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

27 Nm).

Connect fuel vapor vent tube to fitting on filler neck of

fuel tank.

Remove filler cap. Position console on canopy. Route

Figure 4-18. Hose Cutter/Hose Clamp Pliers

cables from beneath console as shown in Figure 4-19.

Be sure that hoses and wires are not pinched by the

console during installation. Reinstall filler cap.

g. Install canopy as follows:

10.

Install Allen head screw to fasten rear flange of console

FLHT/C, FLTR: See Section 8.29 FUEL LEVEL

to clip nut on fuel tank weldment. Tighten screw to 25-30

SENDER (CARBURETED), FLHT/C CANOPY,

in-lbs (2.8-3.4 Nm).

INSTALLATION, steps 1-3.

FLHR: See Section 8.29 FUEL LEVEL SENDER

11.

Open fuel door on console. Install two Allen head screws

(CARBURETED), FLHR/S CANOPY, INSTALLA-

to secure front of console to clip nuts on canopy bracket.

TION, steps 1-3.

Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).

Inspect crossover hose for cuts, cracks, nicks or other

damage. Be sure aging has not caused the hose to

become hard and brittle. If replacing from bulk storage,

use SAE R9 or equivalent fuel hose only. Remove old

hose and cut new hose to same length using HOSE

Fuel

Tank

CUTTER (HD-41185). See Figure 4-18.

Console

INSTALLATION

Fuel Level

(AFTER COMPLETE REMOVAL)

Sender Conduit

FLHT/C

Fuel

Overflow

Fuel Vapor

Hose

CAUTION

Vent Tube

(To Vapor Valve)

Exercise caution to avoid pinching wire harness be-

tween fuel tank and vehicle frame. Wire damage may

Main

result in electrical problems.

Harness

1. Work fuel tank into position aligning front flange holes

Bundle

Anchored

Main

with those in frame.

Cable Strap

Harness

Slide new clamp onto free end of crossover hose. Run-

Bundle

f1739b9x

ning hose beneath frame backbone, install hose onto fit-

ting at bottom front of fuel tank. Crimp clamp using

Figure 4-19. Console Cable/Hose Routing -FLHT/C, FLTR

HOSE CLAMP PLIERS (HD-97087-65B). See Figure 4-

18.

(Top View)

2004 Touring: Fuel

4-23

HOME

12. Connect fuel tank harness connector [13], 3-place Mul-

tilock, in front of battery. See Figure 4-17.

13. Snap anchor of new cable strap into hole on left side of

Convoluted

frame backbone. Tighten cable strap capturing main har-

Tubing

ness bundles, fuel level sender conduit, and fuel vapor

vent tube. Cut any excess cable strap material.

NOTE

Route fuel overflow hose inboard of wire bundles on right side

of frame, but do not capture in cable straps. See Figure 4-19.

14. Insert bolt through battery negative cable (black) into

threaded hole of battery negative (-) terminal. Tighten

bolt to 60-96 in-lbs (6.8-10.9 Nm).

8870

15. Install seat. See Section 2.24 SEAT, INSTALLATION.

Figure 4-20. Fuel Gauge (FLHR/S)

16. Turn the handle of the fuel valve to OFF and fill the fuel

tank. Carefully inspect for leaks. Turn the valve handle to

ON and start engine. Repeat inspection.

11.

Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

27 Nm).

17. Stop engine and return the valve to the OFF position.

12.

Install acorn nut at top of instrument console and tighten

to 50-90 in-lbs (5.7-10.2 Nm). If present, also install Phil-

lips screw and large flat washer (absent on FLHRS mod-

FLHR/S

els). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).

13.

Connect fuel gauge to main harness. Route pin housing

CAUTION

and convoluted tubing forward and then inboard between

front of crossover hose fitting and bottom of fuel tank.

Exercise caution to avoid pinching the wiring harness

Mate pin and socket halves of fuel gauge connector

between the fuel tank and vehicle frame. Wire damage

[117], 4-place Multilock. Feed connector into tunnel of

may result in electrical problems.

fuel tank. See Figure 4-20.

Work fuel tank into position aligning front flange holes

14.

Snap anchor of new cable strap into hole on left side of

with those in frame.

frame backbone. Tighten cable strap capturing main har-

ness bundle, instrument console conduit, and fuel vapor

Slide new clamp onto free end of crossover hose. Run-

vent tube. Cut any excess cable strap material.

ning hose beneath frame backbone, install hose onto fit-

ting at bottom front of fuel tank. Crimp clamp using

NOTE

HOSE CLAMP PLIERS (HD-97087-65B).

Route fuel overflow hose inboard of wire bundles on right side

Slide new clamp onto free end of carburetor fuel inlet

of frame, but do not capture in cable straps. See Figure 4-19.

hose. Install hose onto fuel outlet fitting at side of fuel

15. Insert bolt through battery negative cable (black) into

valve. Crimp clamp.

threaded hole of battery negative (-) terminal. Tighten

Install the intake manifold vacuum hose onto the vacuum

bolt to 60-96 in-lbs (6.8-10.9 Nm).

fitting at the back of the fuel valve.

16. Install seat. See Section 2.24 SEAT, INSTALLATION.

Connect fuel vapor vent tube to fitting at top of canopy.

17. Turn the handle of the fuel valve to OFF and fill the fuel

Slide head of console mounting bolt into slot at top of

tank. Carefully inspect for leaks. Turn the valve handle to

canopy.

ON and start engine. Repeat inspection.

18. Stop engine and return the valve to the OFF position.

Moving instrument console toward installed position,

install fuel level sender connector [141], 3-place Mini-

Deutsch, at top of canopy. Bend flexible clamp to capture

main harness conduit.

PARTIAL REMOVAL

Align hole in instrument console with console mounting

bolt and place into position on fuel tank.

NOTE

Start fuel tank front mounting bolts (with flat washers)

For fuel injected models, see Section 9.4 FUEL TANK (FUEL

into left and right side of frame.

INJECTED) for removal and installation instructions.

10.

Install bolt (with flat washer) to secure rear of fuel tank to

frame backbone. On FLHRS models, capture instrument

FLHT/C

console bracket during installation. Tighten bolt to 15-20

ft-lbs (20-27 Nm).

Remove seat. See Section 2.24 SEAT, REMOVAL.

4-24

2004 Touring: Fuel

HOME

Remove two fuel tank front mounting bolts (with flat

1WARNING

washers) from left and right side of frame. Remove bolt

(with flat washer) to free rear of fuel tank from frame

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

backbone. On FLHRS models, removal of rear bolt also

cle, disconnect the negative battery cable before pro-

releases instrument console bracket.

ceeding. Inadequate safety precautions could result in

death or serious injury.

Carefully cut anchored cable strap securing main har-

ness bundle, instrument console conduit, and fuel vapor

Unthread bolt and remove battery negative cable (black)

vent tube to left side of frame backbone.

from battery negative (-) terminal.

Remove acorn nut from instrument console. If present,

Carefully cut anchored cable strap securing main har-

also remove Phillips screw and large flat washer (absent

ness bundles, fuel level sender conduit, and fuel vapor

on FLHRS models).

vent tube to left side of frame backbone.

Raise instrument console and bend back flexible clamp

Disconnect fuel tank harness connector [13], 3-place

on canopy to release main harness conduit. Depress

Multilock, in front of battery. See Figure 4-17.

button on socket side and remove fuel level sender con-

Open fuel door on console. Remove two Allen head

nector [141], 3-place Mini-Deutsch.

screws inboard of rubber bumpers. These screws secure

console to clip nuts on the canopy bracket.

CAUTION

Remove Allen head screw to detach flange at rear of

When removing instrument console, exercise caution to

console from clip nut on fuel tank weldment.

avoid damaging speedometer unit. Wrap console in a

Lay a clean shop cloth on forward part of rear fender.

clean, dry shop towel to prevent damage.

Remove filler cap from neck of fuel tank. Remove con-

sole and lay upside down on shop cloth. Reinstall filler

Secure instrument console to top of rear fender using

cap.

bungee cords.

Gently pry fuel vapor vent tube from fitting on filler neck

Remove console mounting bolt from slot at top of can-

of fuel tank. Exercise caution to avoid pulling fitting from

opy.

filler neck.

Gently pry fuel vapor vent tube from fitting.

Remove two fuel tank front mounting bolts (with flat

10. At bottom left side of fuel tank, gently pull on convoluted

washers) from left and right side of frame. Remove bolt

tubing to draw fuel gauge connector [117], 4-place Mul-

(with flat washer) to free rear of fuel tank from frame

tilock, out of tunnel. Depress button on socket terminal

backbone.

side and pull apart pin and socket halves.

10.

Raise the fuel tank approximately 2 inches. Move the

11. Raise the fuel tank approximately 2 inches. Move the

fuel tank crossover hose to the rear of the ignition coil,

so that the tank can be raised an additional 2-3 inches.

Move fuel tank straight back and rest on frame back-

bone.

11.

Obtain three 1 x 2 inch wooden blocks. Raise the front of

the fuel tank off the frame backbone by placing one

12. Obtain three 1 x 2 inch wooden blocks. Raise the front of

the fuel tank off the frame backbone by placing one

block in the recess centered at the bottom of the tank. At

the rear of the tank, place two blocks in the recess, one

block in the recess centered at the bottom of the tank. At

the rear of the tank, place two blocks in the recess, one

block on top of the other.

FLHR/S

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

INSTALLATION

(AFTER PARTIAL REMOVAL)

1WARNING

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

cle, disconnect the negative battery cable before pro-

FLHT/C

ceeding. Inadequate safety precautions could result in

Remove wooden blocks and move fuel tank toward its

death or serious injury.

installed position. Half way down, move fuel tank cross-

Unthread bolt and remove battery negative cable (black)

over hose in front of ignition coil. Work fuel tank into

from battery negative (-) terminal.

position aligning front flange holes with those in frame.

2004 Touring: Fuel

4-25

HOME

Connect fuel vapor vent tube to fitting at top of canopy.

CAUTION

Slide head of console mounting bolt into slot at top of

Exercise caution to avoid pinching the wiring harness

canopy.

between the fuel tank and vehicle frame. Wire damage

Moving instrument console toward installed position,

may result in electrical problems.

install fuel level sender connector [141], 3-place Mini-

Deutsch, at top of canopy. Bend flexible clamp to capture

Start fuel tank front mounting bolts (with flat washers)

main harness conduit.

into left and right side of frame.

Align hole in instrument console with console mounting

Install bolt (with flat washer) to secure rear of fuel tank to

bolt and place into position on fuel tank.

frame backbone. Tighten bolt to 15-20 ft-lbs (20-27 Nm).

Start fuel tank front mounting bolts (with flat washers)

Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

into left and right side of frame.

27 Nm).

Install bolt (with flat washer) to secure rear of fuel tank to

Connect fuel vapor vent tube to fitting on filler neck of

frame backbone. On FLHRS models, capture instrument

fuel tank.

console bracket during installation. Tighten bolt to 15-20

ft-lbs (20-27 Nm).

Remove filler cap. Position console on canopy. Route

cables from beneath console as shown in Figure 4-19.

Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

Be sure that hoses and wires are not pinched by the con-

27 Nm).

sole during installation. Reinstall filler cap.

Install acorn nut at top of instrument console and tighten

Install Allen head screw to fasten rear flange of console

to 50-90 in-lbs (5.7-10.2 Nm). If present, also install Phil-

to clip nut on fuel tank weldment. Tighten screw to 25-30

lips screw and large flat washer (absent on FLHRS mod-

in-lbs (2.8-3.4 Nm).

els). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).

10.

Connect fuel gauge to main harness. Route pin housing

Open fuel door on console. Install two Allen head screws

and convoluted tubing forward and then inboard between

to secure front of console to clip nuts on canopy bracket.

front of crossover hose fitting and bottom of fuel tank.

Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).

Mate pin and socket halves of fuel gauge connector

Connect fuel tank harness connector [13], 3-place Mul-

[117], 4-place Multilock. Feed connector into tunnel of

tilock, in front of battery. See Figure 4-17.

fuel tank. See Figure 4-20.

10.

Snap anchor of new cable strap into hole on left side of

11.

Snap anchor of new cable strap into hole on left side of

frame backbone. Tighten cable strap capturing main har-

ness bundles, fuel level sender conduit, and fuel vapor

ness bundle, instrument console conduit, and fuel vapor

vent tube. Cut any excess cable strap material.

NOTE

Route fuel overflow hose inboard of wire bundles on right side

of frame, but do not capture in cable straps. See Figure 4-19.

12. Insert bolt through battery negative cable (black) into

11. Insert bolt through battery negative cable (black) into

threaded hole of battery negative (-) terminal. Tighten

bolt to 60-96 in-lbs (6.8-10.9 Nm).

13. Install seat. See Section 2.24 SEAT, INSTALLATION.

12. Install seat. See Section 2.24 SEAT, INSTALLATION.

FLHR/S

Remove wooden blocks and move fuel tank toward its

installed position. Half way down, move fuel tank cross-

over hose in front of ignition coil. Work fuel tank into posi-

tion aligning front flange holes with those in frame.

CAUTION

Exercise caution to avoid pinching the wiring harness

between the fuel tank and vehicle frame. Wire damage

may result in electrical problems.

4-26

2004 Touring: Fuel

HOME

EVAPORATIVE EMISSIONS CONTROL SYSTEM

4.8

● When the engine is running, negative pressure

CALIFORNIA MODELS ONLY

(vacuum) draws the fuel vapors stored in the char-

coal canister through the purge tube to the carbure-

GENERAL

tor (or induction module) where they are burned as

part of the normal combustion process.

Harley-Davidson motorcycles sold in the state of California

● On carbureted models, fuel vapors emanating from

are equipped with an evaporative (EVAP) emissions control

the carburetor throat are drawn to the charcoal can-

system. In conformance with California Air Resource Board

ister through the clean air inlet tube connected to

(CARB) regulations, the EVAP system prevents both fuel and

the inboard side of the air cleaner backplate. Crank-

crankcase vapors from escaping into the atmosphere. See

case vapors passing from the breather tubes into

Figure 4-21.

the air filter element follow the fuel vapors to the

charcoal canister. These vapors, after passing

The EVAP system functions as follows:

through the charcoal canister, also travel through

the purge tube to the carburetor where they are

● The fuel vapor vent tube connected to a fitting on

burned.

the filler neck (top of canopy on FLHR/C/S models)

allows fuel vapors in the fuel tank to be vented

● When the engine is not running, the gravity-oper-

through the vapor valve to the charcoal canister. If

ated baffle plate at the air cleaner air inlet port

the motorcycle is tipped, the vapor valve also pre-

closes to prevent fuel and crankcase vapors from

vents the loss of gasoline through the vent tube.

escaping into the atmosphere.

Filler Neck Fitting

Vacuum

(Top of Canopy on FLHR/C/S)

Tube

Carburetor

Fuel

Tank

Clean Air

Inlet Tube

Fuel

Fuel Vapor

Valve

Vapor

Vent Tube

Valve

Purge

Tube

Air Cleaner

Fuel Vapor

Backplate

Vent Tube

Charcoal

Canister

f1706x4x

Figure 4-21. California Evaporative Emissions Control System (Carbureted Models)

2004 Touring: Fuel

4-27

HOME

1WARNING

Vent

Verify that the evaporative emissions tubes/hoses do not

Tube

contact hot exhaust or engine parts. Tubes/hoses con-

135˚

tain flammable vapors that can be ignited if damaged,

Elbow

possibly causing fire or explosion which could result in

death or serious injury.

Vapor

Valve

TROUBLESHOOTING

Arm

The EVAP system has been designed to operate with a mini-

mum of maintenance. Check that all tubes/hoses are cor-

Hole

rectly routed and properly connected. Also, verify that the

tubes/hoses are not pinched or kinked.

VAPOR VALVE

Cable Strap

Small

Slot

f2184x4x

NOTE

On 49 State models, the charcoal canister is absent and the

Figure 4-22. Vapor Valve Mounting Bracket

bottom tube of the vapor valve is vented to the atmosphere.

REMOVAL

From right side of bracket, insert end of small cable strap

Remove seat. See Section 2.24 SEAT, REMOVAL.

(P/N 10065) through hole in arm and then around body

Remove left side saddlebag. See Section 2.25 SADDLE-

of vapor valve. Mate ends of cable strap and pull tight

BAG, REMOVAL.

engaging strap in slot of arm. Cut any excess cable strap

Gently pull side cover from frame downtubes (no tools

material. See Figure 4-22.

required).

Install free end of 135˚ elbow onto neck at top of vapor

Locate vapor valve attached to frame cross member in

valve.

front of battery box (left side). See Figure 4-22.

Verify that vapor valve is completely vertical. Momen-

Cut cable strap to release vapor valve from mounting

tarily push on top of vapor valve to verify that it returns to

bracket.

the completely vertical position.

Remove 135˚ elbow from neck at top of vapor valve.

On California models, raise vapor valve slightly and pull

1WARNING

hose fitting on vent tube from bottom fitting on vapor

valve.

Verify that the vent tubes do not contact hot exhaust or

engine parts. Tubes contain flammable vapors that can

NOTE

be ignited if damaged, possibly causing fire or explosion,

On 49 State models, just pull out vapor valve with bottom vent

which could result in death or serious injury.

tube attached. Remove hose fitting on vent tube from bottom

fitting of vapor valve.

5. Recheck bottom vent tube routing to be sure that hose

fittings are not pinched or kinked, and that there is no

contact with the drive belt. For California models, see

INSTALLATION

Figure 4-24.

Hold vapor valve in its approximate position on left side

On 49 State models, verify that vent tube at bottom of

of mounting bracket (with long necked end at the top).

vapor valve is routed through opening above fuse block

On California models, install hose fitting on vent tube to

bracket (upper weldment between downtubes) to out-

bottom fitting of vapor valve.

board side. Orient vent tube so that it runs downward

NOTE

along the back of the forward frame downtube, where the

On 49 State models, attach hose fitting on vent tube to bot-

free end is then tucked into opening at front of lower

tom fitting on vapor valve. Insert vapor valve through opening

weldment (containing side cover grommet).

above fuse block bracket (upper weldment between down-

6. Align barbed studs in side cover with grommets in frame

tubes), and hold in its approximate position on left side of

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

mounting bracket.

4-28

2004 Touring: Fuel

HOME

7. Install left side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

Left Side View

8. Install seat. See Section 2.24 SEAT, INSTALLATION.

PURGE TUBE

Fuel Vapor Vent Tube

To Carburetor or Induction Module

CHARCOAL CANISTER

CARB.

TANK

REMOVAL

1. Remove rear fender. See Section 2.33 REAR FENDER,

REMOVAL.

Fuel Vapor Vent Tube

From Filler Neck of Fuel Tank

1WARNING

Via Vapor Valve

f1063b9x

Always disconnect the negative battery cable first. If the

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.

Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.

3. Unthread bolt and remove battery positive cable (red)

from battery positive (+) terminal.

4. Using a T40 TORX drive head, loosen bolt to move lip of

Top View

hold-down clamp off edge of battery. Remove battery

Clean Air Inlet Tube

from battery box.

From Air Cleaner Backplate

on Carbureted Models Only

Reaching into battery box, pry plastic retaining pin out of

hole on left side. See inset of Figure 4-23.

Reaching in between battery box and right side frame

member, pull clean air inlet tube (to air cleaner backplate

Retaining Pin

on carbureted models) from fitting on right side of char-

coal canister. On fuel injected models, pull 90˚ elbow

connector from fitting.

Figure 4-23. Charcoal Canister

Moving to rear left side of motorcycle, center a flashlight

on drive belt and direct the beam forward. Note the two

tube connections on the left side of the canister. See

Moving to rear right side of motorcycle, attach clean air

inlet tube (to air cleaner backplate on carbureted mod-

Figure 4-23. Reaching in between battery box and frame

member, pull tubes from canister.

els) to fitting on right side of canister. On fuel injected

models, install 90˚ elbow connector with the free end

8. With the handle of a rubber mallet, rap canister toward

pointing down.

left side of motorcycle until tongue at top of canister is

NOTE

free of grooves in bottom of battery box. From right side

of motorcycle, pull canister out of opening between bat-

The clean air inlet tube is absent on fuel injected models.

tery box and frame member.

Place battery in battery box, terminal side forward.

INSTALLATION

WARNING

1. With tongued side up, slide canister into cavity using

opening between battery box and right side frame mem-

Always connect the positive battery cable first. If the

ber. Start tongue into grooves on left side of battery box.

positive cable should contact ground with the negative

Push the canister toward the right side of the motorcycle

cable installed, the resulting sparks may cause a battery

until fully engaged. Snap plastic retaining pin into hole at

explosion, which could result in death or serious injury.

bottom of battery box (left side) to lock position of canis-

Insert bolt through battery positive cable

(red) into

ter. See inset of Figure 4-23.

threaded hole of battery positive (+) terminal. Tighten

2. Attach tubes to fittings on left side of canister. Install the

bolt to 60-96 in-lbs (6.8-10.9 Nm).

purge tube to the carburetor (or induction module) onto

Insert bolt through battery negative cable (black) into

the top fitting stamped “CARB.” Install the fuel vapor vent

tube from the fuel tank (via the vapor valve) to the bot-

threaded hole of battery negative (-) terminal. Tighten

bolt to 60-96 in-lbs (6.8-10.9 Nm).

tom fitting stamped “TANK.”

2004 Touring: Fuel

4-29

HOME

Clean Air Inlet Tube

From Air Cleaner Backplate

on Carbureted Models Only

Fuel Vapor Vent Tube

From Fuel Tank

Purge Tube

To Carburetor

or Induction Module

Fuel Vapor Vent Tube

From Vapor Valve

f1884x4x

Figure 4-24. Charcoal Canister Tube/Hose Routing (Left Side View)

Rotate hold-down clamp so that the lip (with rubber pad)

Fuel Vapor Vent Tube:

rests on the edge of the battery. Using a T40 TORX drive

head, tighten the clamp bolt to 15-20 ft-lbs (20-27 Nm).

From bottom fitting on left side of charcoal canister (stamped

“TANK”), vent tube is routed forward and then upward in front

Install rear fender. See Section 2.33 REAR FENDER,

of battery box to bottom fitting on vapor valve mounted to rear

INSTALLATION.

of upper frame crossmember.

Another section connected to top fitting of vapor valve follows

the inboard side of the main harness bundle, where it is cap-

Charcoal Canister Hose Routing

tured in anchored cable strap on left side of frame backbone

before passing under console pod/instrument console to fit-

ting on filler neck of fuel tank (top of canopy on FLHR/C/S

1WARNING

models).

Verify that the vent tubes do not contact hot exhaust or

engine parts. Tubes contain flammable vapors that can

be ignited if damaged, possibly causing fire or explosion,

Clean Air Inlet Tube:

which could result in death or serious injury.

From 90˚ elbow connector on right side of charcoal canister,

clean air inlet tube runs forward under frame crossmember

Purge Tube:

and then upward (inboard of starter connections) following

angle of crossmember, where it is routed over crossover pipe

From top fitting on left side of charcoal canister (stamped

and rear cylinder rocker cover into tunnel of fuel tank on right

“CARB”), purge tube is routed forward where it runs under

side of frame backbone. Tube turns right just to the rear of the

frame crossmember, and then angles upward between cross-

top engine mounting bracket, where it connects to fitting on

member and inner primary housing. Captured in clip

inboard side of air cleaner backplate.

anchored in hole at front of crossmember (rear and inboard of

cruise hole), purge tube goes over crossover pipe, runs along

NOTE

left side of rear cylinder rocker cover and into tunnel of fuel

The clean air inlet tube is absent on fuel injected models, so

tank. It then crosses to right side of motorcycle just to the rear

the fitting on the right side of the canister terminates in a 90˚

of the top engine mounting bracket, where it connects to a fit-

elbow connector (the free end pointing down).

ting on the carburetor (or induction module). See Figure 4-24.

4-30

2004 Touring: Fuel

HOME

SPECIFICATIONS

5.1

STARTER

TORQUE VALUES

Item

Specification

Item

ft/in-lbs

Thru-bolts

39-65 in-lbs

4.4-7.3 Nm

Free (no load) speed

3000 rpm (min.) @ 11.5 V

End cover mounting

50-60 in-lbs

5.6-6.8 Nm

Free (no load) current

90 amp (max.) @ 11.5V

bracket

Stall torque

8.0 ft-lbs (10.8 Nm) @ 2.4 V

End cover center screw

90-110 in-lbs

10.2-12.4 Nm

Battery cable terminal

60-96 in-lbs

6.8-10.9 Nm

bolts

SERVICE WEAR LIMITS

Starter front and rear

13-20 ft-lbs

18-27 Nm

mounting screws

Oil filler spout allen head

Item

IN.

84-108 in-lbs

9.5-12.2 Nm

socket screws

Starter jackshaft bolt

60-80 in-lbs

6.8-9.0 Nm

Brush length minimum

0.433

Solenoid terminal nut

70-90 in-lbs

7.9-10.2 Nm

Commutator diameter

1.141

minimum

2004 Touring: Starter

5-1

HOME

STARTER SYSTEM

5.2

The magnetic forces of the pull-in and hold-in windings in the

GENERAL

solenoid, pull the plunger and cause it to shift to the left, so

that the pinion gear is engaged with the clutch ring gear. At

The starter is made up of an armature, field winding assem-

the same time, the main solenoid contacts are closed and

bly, solenoid, drive assembly, idler gear, and drive housing.

battery current flows directly through the field windings to the

The starter motor torque is increased through gear reduction.

armature and to ground. Simultaneously, the pull-in winding

The gear reduction consists of the drive pinion on the arma-

is opened.

ture, an idler gear, and a clutch gear in the drive housing. The

The current continues flowing through the hold-in winding,

idler gear is supported by rollers and the clutch gear is part of

keeping the main solenoid contacts closed. At this point the

the overrunning clutch/drive assembly.

starter begins to crank the engine.

The overrunning clutch is the part which engages and drives

the clutch ring gear. It also prevents the starter from overrun-

After the engine has started, the pinion gear turns freely on

the pinion shaft through the action of the overrunning clutch

ning. The field windings are connected in series with the

armature through brushes and commutator segments.

which prevents the armature overrunning by the rotation of

the clutch ring gear.

The starter relay is a non-repairable part and must be

replaced if it malfunctions.

When the starter switch is released, the current of the hold-in

winding is fed through the main solenoid contacts and the

direction of the current in the pull-in winding is reversed. The

Operation (Figure 5-1)

solenoid plunger is returned to its original position by the

return spring, disengaging the pinion gear from the clutch

When the starter switch is pushed, the starter relay is acti-

ring gear.

vated and battery current flows into the pull-in winding and

the hold-in winding, to ground.

5-2

2004 Touring: Starter

HOME

STARTER AT MOMENT STARTER SWITCH IS CLOSED

Armature

Field winding

Brush

Idler gear

Ball

bearing

Pinion

Plunger

gear

Main

contacts

Hold-In

Overrunning

Pull-In

winding

Clutch

clutch

winding

ring gear

Battery

Start

circuit. See

wiring

diagram.

STARTER DURING CRANKING

Armature

Field winding

Brush

Idler gear

Pinion

Ball

gear

bearing

Plunger

Main

contacts

Overrunning

Hold-in

Pull-In

winding

Battery

Clutch

clutch

ring gear

Start circuit.

See wiring

diagram

Figure 5-1. Starter Operation

2004 Touring: Starter

5-3

HOME

STARTER RELAY

5.3

REMOVAL

FLHR/C/S

Brake Light

FLHR/C/S

Relay [124]

Remove left side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

Gently pull side cover from frame downtubes (no tools

required).

Depress latches on maxi-fuse holder and then slide

cover rearward to disengage tongue from groove in fuse

block cover.

Starter

Relay [123]

Pull fuse block from tabs on mounting panel. Tabs on

f2210x8x

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

NOTE

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

Check the wire tags for positive

FLTR, FLHT/C/U

One spare 10 amp and 15 amp fuse are provided.

identification of relays. Starter

relay can be positively identified

by heavy gauge Green wire.

Remove the fuse block cover. Raise lipped side slightly

to disengage slots from tabs on fuse block.

Starter

Ignition Keyswitch

Pull relay from slots in fuse block. See upper frame of

Relay [123]

Relay [126]

Figure 5-2.

FLTR, FLHT/C/U

Remove seat. See Section 2.24 SEAT, REMOVAL.

Locate the starter relay installed in cavity of frame cross-

member at rear of battery box. See lower frame of Fig-

ure 5-2.

3. Place a finger on the rubber molding to hold it in posi-

tion, and using a needle nose pliers, carefully pull on tab

to release starter relay. Since the position of the relays

may be reversed, starter relay can be positively identi-

fied by heavy gauge Green wire.

Remove harness connector from bottom of relay.

f2192x8x

INSTALLATION

Figure 5-2. Locate Starter Relay

FLHR/C/S

9. Slide maxi-fuse cover forward to engage tongue in

1. Install new relay in fuse block.

groove of fuse block cover and then insert maxi-fuse

holder into cover until latches engage.

7. Slide cover over fuse block until slots fully engage tabs

on block.

10. Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

8. Slide fuse block into position on mounting panel. Tabs on

required).

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

5-4

2004 Touring: Starter

HOME

11. Install left side saddlebag. See Section 2.25 SADDLE-

FLTR, FLHT/C/U

BAG, INSTALLATION.

Install harness connector at bottom of new relay.

Place a finger on the molding to hold it in position and

push on relay until seated in cavity of frame cross-

member.

Install seat. See Section 2.24 SEAT, INSTALLATION.

2004 Touring: Starter

5-5

HOME

STARTER

5.4

REMOVAL

f2268x8x

Frame Hole

Frame

Cruise Cable

Cross Member

Routing Only

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

1WARNING

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

cle, disconnect the negative battery cable before pro-

ceeding. Inadequate safety precautions could result in

death or serious injury.

Positive

Unthread bolt and remove battery negative cable (black)

Battery Cable

from battery negative (-) terminal.

Remove the primary chaincase cover. See Section 6.5

PRIMARY CHAINCASE, REMOVAL, steps 3-8.

Bend tab on lockplate away from head of jackshaft bolt.

Holding pinion gear to prevent rotation, remove the jack-

shaft bolt with lockplate and thrust washer.

Negative

From right side of motorcycle, remove starter front

Battery Cable

mounting screw with lockwasher. Remove rear mounting

screw with lockwasher (and battery negative cable ring

terminal). Remove Keps nut from stud of bracket tab and

remove exhaust support bracket.

Main Power

To Maxi-Fuse

Pull back rubber boot and remove flange nut from starter

post. Remove main power and battery positive cable

Figure 5-3. Battery Cable Routing (Right Side View)

ring terminals from starter post. See Figure 5-3.

Depress external latch and pull solenoid connector from

top of starter housing.

2. From right side of motorcycle, tilt starter and work into its

installed position. Starter output shaft coupling must

Locate oil filler plug/dipstick on right side of motorcycle

remain on shaft and mate to starter jackshaft. See Sec-

at top of transmission case. To remove the oil filler plug,

tion 5.6 STARTER JACKSHAFT, if necessary.

pull steadily while moving plug back and forth.

3. Install oil filler plug/dipstick at top of transmission case

10.

Remove the starter from the right side of the motorcycle,

on right side of motorcycle.

carefully sliding it through the space between the

4. Install slot of exhaust support bracket onto stud of

exhaust pipe and side cover.

bracket tab aligning other holes with those in starter

NOTE

flange. Start Keps nut on stud.

If necessary, remove allen screw and decorative chrome

5. Engaging hole in exhaust support bracket, install starter

cover to facilitate starter removal.

front mounting screw with lockwasher. Install rear

mounting screw with lockwasher (and battery negative

11. Remove the coupling from the starter motor output shaft,

cable ring terminal) in the same manner.

if necessary.

6. Alternately tighten starter front and rear mounting

12. Before disassembly, perform tests on the assembled

screws to 13-20 ft-lbs (18-27 Nm). Tighten Keps nut on

starter. See DISASSEMBLY, TESTING AND REPAIR in

stud of bracket tab.

this section.

7. Install battery positive and main power cable ring termi-

nals onto starter post. Install flange nut and tighten to

70-90 in-lbs (7.9-10.2 Nm). Pull down rubber boot over

INSTALLATION

terminal connections on starter post. See Figure 5-3.

8. Snap solenoid connector to terminal at top of starter

1. Inspect the retaining ring within the output shaft coupling

housing.

for damage or distortion. Replace as necessary. With the

NOTE

counterbore on the outboard side, install the coupling on

If removed, install allen screw to fasten decorative chrome

the starter motor output shaft, if removed.

cover to starter.

2004 Touring: Starter

5-6

HOME

1. Field wire

15. Drive assembly/overrunning clutch

2. Thru-bolt (2)

16. Idler gear

3. Field coil

17. Idler gear bearing & cage

4. End cap

18. O-ring

5. End cap screw (2)

19. Spring

6. Brush spring (4)

20. Shaft

7. Brushes

21. Return spring

8. Brush holder

22. Ball

9. Armature

23. O-ring (2)

10. Armature bearings

11. Drive housing mounting screw (2)

12. Lockwasher (2)

13. Drive housing

14. Solenoid housing

f1107axx

Figure 5-4. Starter

NOTE

11. Holding pinion gear to prevent rotation, tighten jackshaft

bolt to 60-80 in-lbs (6.8-9.0 Nm). Bend tab on lockplate

If removed, install allen screw to fasten decorative chrome

against flat of bolt head to secure.

cover to starter.

12. Install the primary chaincase cover. See Section 6.5

9. Slide lockplate and new thrust washer onto jackshaft

PRIMARY CHAINCASE, INSTALLATION, steps 20-31.

bolt, if removed. Insert bolt into jackshaft bore.

13. Insert bolt through battery negative cable (black) into

10. Insert key on lockplate through slot in thrust washer and

threaded hole of battery negative (-) terminal. Tighten

into keyway on jackshaft. Thread the jackshaft bolt into

bolt to 60-96 in-lbs (6.8-10.9 Nm).

the starter shaft making sure that the lockplate key

remains in the keyway.

14. Install seat. See Section 2.24 SEAT, INSTALLATION.

2004 Touring: Starter

5-7

HOME

See Figures 5-7 and 5-8. Remove the end cap screws

DISASSEMBLY, TESTING AND

and cap.

REPAIR

1. See Figures 5-4 and 5-5. Disconnect field wire (1).

3500

3497

Figure 5-7. Remove End Cap Screws and O-Rings

Figure 5-5. Remove Thru-Bolts

3501

2. See Figures

5-4 and

5-6. Remove thru-bolts

(2).

Remove field coil (3) and end cap (4).

3498

Figure 5-8. Remove End Cap

See Figures 5-4 and 5-9. Disengage brush springs (6)

and pull field coil brushes (7) out of brush holders (8).

3502

Figure 5-6. Remove Field Coil and Cap

Figure 5-9. Remove Brush Holder

5-8

2004 Touring: Starter

HOME

Commutator

Starting groove in mica

Undercutting mica with piece

with 3 cornered file

of hacksaw blade

Mica

Segments

Wrong way

Right way

Mica must not be left

Mica must be cut away

with a thin edge next to

clean between segments.

segments.

Figure 5-10. Undercutting the Mica Separators

Check the brush length. Brushes less than 0.433 inch

(11 mm) long should be replaced.

CAUTION

Do not use sandpaper or emery cloth on commutator.

NOTE

The abrasive grit may remain on commutator segments

●

Replace brushes in sets of four only.

and could cause excessive brush wear.

●

Field coil and brush holder brushes are attached to field

10. See Figure 5-11. Check for SHORTED ARMATURE with

coil and brush holder. To replace brushes, replace field

a growler. Place armature on growler. Hold a thin steel

coil and brush holder.

strip (hacksaw blade) against armature core and slowly

turn armature. A shorted armature will cause the steel

See Figure 5-4. Remove armature (9).

strip to vibrate and be attracted to the core. Shorted

armatures should be replaced.

Place armature in lathe or truing stand and check runout

of commutator. Commutators with more than 0.015 in.

(0.38 mm) of runout should be replaced or machined on

2231

a lathe. Commutators should be replaced when diame-

ter is less than 1.141 in. (29.98 mm).

Check depth of mica on commutator. If undercut is less

than 0.008 in. (0.20 mm), use an undercutting machine

to undercut the mica to 1/32 in. (0.79 mm) deep. The

slots should then be cleaned to remove any dirt or cop-

per dust.

See Figure 5-10. If an undercutting machine is not avail-

able, undercutting can be done satisfactorily using a thin

hacksaw blade. After undercutting, lightly sand the

armature with crocus cloth to remove any burrs.

Figure 5-11. Shorted Armature Test Using Growler

2004 Touring: Starter

5-9

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