Harley Davidson 2004 Touring Models. Service Manual — page 31
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8.
When the wheel is centered and trued, start at the valve
9. File or grind off ends of spokes protruding through nip-
stem hole and tighten the rest of the spoke nipples one
ples to prevent puncturing tube when tire is mounted.
turn at a time until they are snug. Repeat step tightening
10. Check the rim lateral and radial runout as described
each spoke nipple to 40-50 in-lbs (4.5-5.6 Nm).
under Section 2.5 CHECKING RIM RUNOUT.
1WARNING
NOTE
Do not tighten spokes too tight, or nipples may be drawn
After installation of front wheel, visually check the relation-
through rim, or hub flanges may be distorted. If spokes
ship of the front wheel to the fork fender bosses. The front
are left too loose, they will continue to loosen when
wheel should be approximately centered between the
wheel is put into service. This could adversely affect
bosses.
handling, or cause spoke breakage, possibly leading to
loss of vehicle control, which could result in death or
serious injury.
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2004 Touring: Chassis
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TIRES AND TUBES
2.8
GENERAL
1634
Tires should be inspected for punctures, cuts, breaks and
wear at least weekly.
Whenever a tube type tire is replaced, the tube should also
be replaced. Inner tubes should be patched only as an emer-
gency measure. Replace a damaged tube as soon as possi-
ble. Inner tubes must be used on all Harley-Davidson laced
wheels.
1WARNING
Excessively worn tires are more susceptible to penetra-
tions. Always remove tires from service before they
reach the tread wear indicator bars, which indicates that
1/32 inch (0.79 mm) tread pattern depth remains. Worn/
unworn tire combinations and worn tires used in wet
conditions can ad-versely affect handling and lead to
loss of vehicle control, which could result in death or
serious injury.
Figure 2-29. Starting Bead Off Rim
1WARNING
Tubeless tires may be repaired in the tread area only and
2.
Loosen both tire beads from rim flange. See Figure 2-29.
then the puncture must be 1/4 inch (6.4 mm) or smaller.
In most cases, a bead breaker machine will be required
Never repair a tire with less than 1/16 inch (1.6 mm) tread
to loosen the bead from the rim.
depth. All repairs must be made from inside the tire. Use
of faulty or defective tires can adversely affect handling
3.
Using tire tools (not sharp instruments), and RIM PRO-
and lead to loss of vehicle control, which could result in
TECTORS, Part No. HD-01289, start upper bead over
death or serious injury.
edge of rim at valve. Do not use excessive force when
starting bead over rim. Bead wires may be damaged
NOTE
ruining the tire. Repeat all around rim until first bead is
Acceptable repair methods include a patch and plug combi-
over rim. Remove the tube.
nation, chemical or hot vulcanizing patches or head-type
plugs.
NOTE
When repairing tubeless tires, use TIRE SPREADER, Part
It
is not necessary to use tools to remove tubeless tires.
No. HD-21000 to spread the tire sidewalls.
Make sure beads are well lubricated before removing from
rim.
1WARNING
4.
Push lower bead into rim well on one side and insert tire
tool underneath bead from opposite side. Pry bead over
Always check both tire sidewalls for arrows indicating
rim edge. Remove tire from rim.
proper forward tire rotation. Some tires require different
tire rotation depending on whether tire is used on front
NOTE
or rear wheel. Improper mounting can result in poor tire
It is not always necessary to completely remove tire from rim.
mileage. In wet weather, improper mounting can ad-
Removing one side allows the tube to be replaced and allows
versely affect handling and lead to loss of vehicle con-
for inspection of tire.
trol, which could result in death or serious injury.
CLEANING AND INSPECTION
REMOVAL
1. Remove wheel from motorcycle. Let the air out of the
1.
Clean the inside of tire, rim and tube. If rim is dirty or
tube or tire.
rusty, clean with a stiff wire brush.
2004 Touring: Chassis
2-23
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1635
Indicator
Ring
Figure 2-30. Snap-in Tubeless Tire Valves
2.
Inspect the tire and tube for wear.
INSTALLATION
Figure 2-31. Starting Bead on Rim
1636
1WARNING
Use the correct inner tube and tire. See TIRE DATA in
SPECIFICATIONS. Use of incorrect tires or tubes can
adversely affect handling or result in tire failure, which
could result in death or serious injury.
1WARNING
Do not interchange tire valves from one type to another.
Always replace valves with the same type as originally
furnished, either the threaded valve stem or snap-in
type. The rim configuration is designed to fit one type
only. Use of the wrong valve can lead to tire failure,
which could result in death or serious injury.
Figure 2-32. Starting Second Bead on Rim
1. On tubeless wheels, damaged or leaking valves must be
replaced. To replace a snap-in type valve proceed as fol-
lows:
1WARNING
a. See Figure 2-30. Moisten the valve with water and
insert valve stem through rim hole.
Aftermarket valve caps that are heavier than the original
equipment cap may have clearance at slow speeds, but
b. Thread plug tool on valve stem and pull valve
at high speed the valve/cap will be moved outward by
through rim until all of the indicator ring is visible.
centrifugal force. This movement could cause the valve/
cap to strike adjacent components, damage the valve
and cause rapid tire deflation. Rapid tire deflation can
1WARNING
cause loss of vehicle control, which could result in death
Only install original equipment tire valves and valve
or serious injury.
caps. A valve, or valve and cap combination, that is too
long may strike adjacent components, damage the valve
2.
On laced wheels, install a rim strip into the rim well.
and cause rapid tire deflation. Rapid tire deflation can
Make sure no spokes protrude through nipples and be
cause loss of vehicle control, which could result in death
sure to align the valve stem hole in rim strip with hole in
or serious injury.
rim.
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2004 Touring: Chassis
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3.
Thoroughly lubricate the rim flanges and both beads of
the tire with tire lubricant. Install RIM PROTECTORS,
f1386b2x
Part No. HD-01289 to prevent scarring rims.
4.
See Figure 2-31. Starting at the valve stem, start the first
bead into the rim well. Work the bead on as far as possi-
ble by hand. Use the tire tool to pry the remaining bead
over the rim flange. If tire has colored dot on sidewall, it
is a balance mark and should be located next to valve
stem hole.
5.
Inflate tube just enough to round it out. Lubricate thor-
oughly 360˚ around the tube base. Insert tube in tire with
valve stem in hole.
6.
See Figure 2-32. Starting 180˚ from valve stem, start the
Gauge
second bead onto the rim. Work the bead onto the rim
with tire tools, working toward valve in both directions.
Remove the valve core from the rim hole before prying
the remaining bead over the rim flange.
Tire Radial Runout
Make sure inner tube valve stem moves in and out freely,
then inflate the tire to recommended pressure to seat the
bead. See TIRE DATA at the beginning of this section.
Figure 2-33. Checking Tire Radial Runout
Then deflate tire to allow inner tube to smooth out.
Inflate again to recommended pressure to seat the
bead.
7.
Use the BEAD EXPANDER (Part No. HD-28700) to seat
Tire Lateral
beads on tubeless tires.
Runout
1WARNING
Do not inflate tire over 40 psi (2.8 bars) to seat beads.
Inflating tire beyond this point can cause the tire rim
assembly to burst, which could result in death or serious
injury. If the beads fail to seat, deflate and relubricate the
bead and rim. Reinflate to seat beads, but do not exceed
40 psi (2.8 bars).
Gauge
CAUTION
When mounting tire and tube on the rim, use extreme
care so the inner tube is not pinched.
f1386a2x
Figure 2-34. Checking Tire Lateral Runout
Checking Tire Radial Runout
1. Check runout by turning wheel on axle, measuring
amount of radial displacement from a fixed point near
Checking Tire Lateral Runout
the tire. See Figure 2-33.
1.
Check runout by turning wheel on axle, measuring tread
2. Tire tread runout should be no more than 0.090 inch
runout. See Figure 2-34.
(2.28 mm) If tire tread runout exceeds this specification,
remove tire from rim and check rim runout to see if rim is
2.
Tire tread runout should be no more than 0.080 inch
at fault. (See Section 2.5 CHECKING RIM RUNOUT).
(2.03 mm). If tire tread runout exceeds this specifica-
tion, remove tire from rim and check rim bead runout to
NOTE
see if rim is at fault (see Section 2.5 CHECKING RIM
Make sure bead is properly seated on rim. Deflate and reseat
RUNOUT).
tire if necessary.
NOTE
3. If rim runout is less than 1/32 inch (0.79 mm), tire is at
fault and should be replaced. If rim runout exceeds this
Make sure bead is properly seated on rim. Deflate and reseat
specification, correct by replacing cast wheel or truing
tire if necessary.
laced wheel.
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3.
If rim bead runout is less than 1/32 inch (0.79 mm), tire
NOTE
is at fault and should be replaced. If rim bead runout
If 1 oz. (28g) or more weight must be added at one location,
exceeds this specification, correct by replacing cast
split the amount so that half is applied to each side of the rim.
wheel or truing laced wheel.
2. Remove paper backing from weight and apply three
drops of Loctite® SUPERBONDER® 420 to the adhe-
Wheel Balancing
sive side of the weight. Place the weight on rim, press
firmly in place and hold for 10 seconds. Full adhesive
Wheel balancing is recommended to improve handling and
cure takes 8 hours.
reduce vibration, especially at high road speeds. Cast alumi-
num wheels require special self-adhesive weights. Gold
3. In most cases, static balancing using WHEEL TRUING
Color - 1 oz. (28g) weight, 1/2 oz. (14g) weight, Silver Color
STAND, Part No. HD-99500-80, will produce satisfactory
1/2 oz. (14g) and 1/4 oz. (7g), and Black 1/4 oz. (7g) weight.
results. However, dynamic balancing, utilizing a wheel
spinner, should be used to produce finer tolerances for
Laced wheels use balance weights which press over the
best high and low speed handling characteristics. Follow
spoke nipples. 1 oz. (28g), 3/4 oz. (21g) and 1/2 oz. (14g)
the instructions supplied with the balance machine you
weights are available.
are using. Wheels should be balanced to within 1/2 oz.
1.
Self adhesive wheel weights should be applied to the flat
(14g) at 60 mph (96 km/h). The maximum permissible
surface of the rim. Make sure that area of application is
weight to accomplish balance is 3-1/2 oz. (99g) total.
completely clean, dry and free of oil and grease.
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2004 Touring: Chassis
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VEHICLE ALIGNMENT
2.9
1WARNING
Vehicle alignment is very important to ensure proper
handling and vibration control. Follow this procedure
carefully and in the sequence given. Failure to do so may
lead to loss of vehicle control, which could result in
death or serious injury.
METHOD A
f2117x2x
NOTE
Figure 2-35. Vehicle Alignment Tool
Use this procedure to realign the powertrain to the frame
(Part No. HD-46247)
whenever major disassembly or engine replacement occurs.
For acceptable results, a careful inspection should be
f2118x2x
performed (wheel and tire runout, laced wheel offset, rubber
mount condition, etc.) to ensure that it is conducted with
serviceable components. See INSPECTION for more infor-
Alignment
mation.
Fixture
1.
Place the motorcycle on a hydraulic center stand or
place blocking under the frame to support the vehicle
and lift the rear wheel off the ground. Be sure the motor-
cycle is positioned as level as possible.
2.
Remove socket screw with lockwasher to remove left
passenger footboard from rear swingarm bracket.
Tighten both rear swingarm bracket bolts to 34-42 ft-lbs
Pilot
Alignment
(46-57 Nm). Repeat step on right side of motorcycle.
Screw
3.
Remove the decorative chrome plug from both rear
swingarm brackets. While holding the left side pivot shaft
Figure 2-36. Install Vehicle Alignment Tool (Left Side)
locknut, tighten the right side locknut to 40-45 ft-lbs (54-
61 Nm). Then hold the right side pivot shaft locknut and
tighten the left side locknut to 40-45 ft-lbs (54-61 Nm).
c. Loosen both top stabilizer link jam nuts.
4.
Verify that belt deflection is within specification and that
d. Remove the top stabilizer link eyelet to top engine
adjuster cams are tight against rear swingarm weld
mounting bracket bolt. See B of Figure 2-37.
nubs. Holding weld nut on left side of axle, tighten cone
8. Front Engine Mount:
nut on right side to 95-105 ft-lbs (128.8-142.4 Nm).
a. Remove flange locknuts from studs on lower frame
5.
Remove seat. See Section 2.24 SEAT, REMOVAL.
crossmember. Remove voltage regulator from studs
6.
Partially remove fuel tank to gain access to top engine
and allow to hang by cables at front of motorcycle.
mounting bracket and stabilizer link. See Section 4.7
b. Tighten two engine to front engine mounting bracket
FUEL TANK (CARBURETED), PARTIAL REMOVAL,
bolts to 33-38 ft-lbs (45-52 Nm). See H of Figure 2-
FLHT/C, or FLHR/S. For fuel injected models, see Sec-
37.
tion
9.4 FUEL TANK (FUEL INJECTED), PARTIAL
REMOVAL, FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
c. Tighten front stabilizer link eyelet bolt to block on
front engine mounting bracket to 18-22 ft-lbs (24-30
7.
Top Engine Mount:
Nm). See E of Figure 2-37.
a. On left side of motorcycle, tighten the two top
d. Loosen both front stabilizer link jam nuts.
engine mounting bracket to front and rear cylinder
head bolts to 35-40 ft-lbs (48-54 Nm). See A of Fig-
e. Remove front stabilizer link eyelet to frame weld-
ure 2-37.
ment bolt. See D of Figure 2-37.
b. Moving to right side of motorcycle, tighten the top
f.
Remove the center front engine mounting bracket to
stabilizer link eyelet to frame weldment bolt to 18-22
rubber mount bolt (with washers and nut). See F of
ft-lbs (24-30 Nm). See C of Figure 2-37.
Figure 2-37.
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B
C
A
LEFT SIDE
RIGHT SIDE
Top Stabilizer Link and Engine Mounting Bracket
f2181x2x
f2111x2x
Jam Nut
H
E
D
Front
Stabilizer Link
Front Engine
F
Mounting Bracket
G
f1303x2x
Front Stabilizer Link and Engine Mounting Bracket
Top
Bottom
A Top Engine Mounting Bracket to Cylinder Heads
D Eyelet to Frame Weldment
B Eyelet to Top Engine Mounting Bracket
E Eyelet to Front Engine Mounting Bracket
C Eyelet to Frame Weldment
F Front Engine Mounting Bracket to Rubber Mount
G Front Engine Mount to Frame Crossmember
H Engine to Front Engine Mounting Bracket
Figure 2-37. Engine Mounting Bracket Bolts
9.
Obtain Vehicle Alignment Tool (HD-46247). See Figure
a. Back off alignment screws and pilot so that no con-
2-35. Proceed as follows:
tact is made with pivot shaft during initial installa-
tion.
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2004 Touring: Chassis
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b. Position alignment fixture so that pilot begins to
b. If centering or relaxation of the mount is required,
engage hole in rear swingarm bracket and then
proceed as follows:
start 5/16 allen head screw (with flat washer) into
•
Loosen the two front engine mount to frame cross-
lower hole of passenger footboard mount. Leave fix-
member bolts. See G of Figure 2-37.
ture loosely installed. Repeat step on other side of
motorcycle.
•
Push on the rubber mount to center it with the thru
bolt hole in the mounting plate. It may be necessary
NOTE
to bounce or wiggle the engine to unload any
Alignment fixtures are stamped L(eft) and R(ight) for easy
binding of the rubber mount on the mounting plate.
identification. When installing alignment fixture on right side
of motorcycle, first remove hex screw to free brake hose P-
•
After the mount is centered, tighten the two front
clamp from rear swingarm bracket. The relief in right side fix-
engine mount to frame crossmember bolts to 15-20
ture accommodates hex screw boss.
ft-lbs (20-27 Nm). See G of Figure 2-37.
c. Holding alignment fixture tight against rear swing-
•
Install center front engine mounting bracket to rub-
arm bracket, use knurling to rotate pilot until it bot-
ber mount bolt (with washers and nut) and tighten to
toms in rear swingarm bracket. Without disturbing
15-20 ft-lbs (20-27 Nm). See F of Figure 2-37.
setting of pilot, tighten allen head screw to passen-
ger footboard mount to 18-22 ft-lbs (24-30 Nm).
15.
Slide voltage regulator over studs on lower frame cross-
Repeat step on other side of motorcycle.
member at front of vehicle. Install flange locknuts on
d. Hand turn alignment screw until it bottoms against
studs and tighten to 70-100 in-lbs (7.9-11.3 Nm).
end of pivot shaft. Repeat step on other side of
16.
Install fuel tank. For carbureted models, see Section 4.7
motorcycle.
FUEL TANK (CARBURETED), INSTALLATION (AFTER
e. Tighten alignment screw to 60-80 in-lbs (6.8-9.0
PARTIAL REMOVAL), FLHT/C, or FLHR/S. For fuel
Nm). Repeat step on other side of motorcycle. See
injected models, see Section 9.4 FUEL TANK (FUEL
Figure 2-36.
INJECTED), INSTALLATION
(AFTER PARTIAL
REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
10.
Adjust each stabilizer link as follows:
17.
Verify minimum clearance between the powertrain and
a. Install bolts removed under steps 7(d) and 8(e), and
the following frame mounted components:
using the center hex to maintain equal thread
a. Top Engine/Horn Mounting Bracket to Fuel Tank:
engagement at both eyelets, adjust stabilizer links
0.328 inch (8.3 mm).
so that bolts thread in without any stress or engine
movement. See B and D of Figure 2-37.
b. Rocker Covers to Fuel Tank: 0.375 inch (9.5 mm).
b. Alternately tighten bolts to 18-22 ft-lbs (24-30 Nm).
c. Carburetor Top Cover to Fuel Tank: 0.375 inch (9.5
mm).
c. Holding the stabilizer link adjuster and mounting
eyelets to prevent movement or binding, tighten jam
d. Rear Spark Plug Boot to Fuel Valve: 0.250 inch (6.4
nuts on top and front stabilizer links.
mm).
e. Top Stabilizer Link to Induction Module: 0.375 inch
11.
Remove vehicle alignment tool from rear swingarm
(9.5 mm).
brackets.
f.
Front Stabilizer Link to Voltage Regulator: 0.375
12.
Snap the chrome plugs back into the rear swingarm
inch (9.5 mm).
brackets.
g. Inner Primary Chaincase to Lower Frame Tube:
13.
Install socket screw with lockwasher to fasten passenger
0.187 inch (4.8 mm).
footboard to rear swingarm bracket. Tighten screw to 15-
18 ft-lbs
(20-24 Nm). Repeat step on other side of
h. Exhaust Crossover Pipe to Primary Housing: 0.125
motorcycle.
inch (3.2 mm).
14.
Verify that front rubber mount is centered under the front
i.
Tire to Rear Fender: 0.100 inch (2.5 mm).
mounting plate bolt hole and has not been bound by the
j.
Perform the procedure under Method B to trouble-
plate dragging across the isolator.
shoot clearance problems and to identify offending
a. If the front rubber mount is centered and free of
component(s).
binding, proceed as follows:
18.
Install seat. See Section 2.24 SEAT, INSTALLATION.
•
Tighten the two front engine mount to frame cross-
member bolts to 15-20 ft-lbs (20-27 Nm). See G of
19.
Test ride the motorcycle.
Figure 2-37.
NOTE
•
Install center front engine mounting bracket to rub-
Vehicle leads that require more than 2-lbs pull to correct
ber mount bolt (with washers and nut) and tighten to
need further diagnosis. Perform the procedure under Method
15-20 ft-lbs (20-27 Nm). See F of Figure 2-37.
B in this section.
2004 Touring: Chassis
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c. Tighten front stabilizer link eyelet to frame weldment
METHOD B
bolt to 18-22 ft-lbs (24-30 Nm). See D of Figure 2-
37.
NOTE
d. Tighten front stabilizer link eyelet bolt to block on
Use this procedure to determine the cause of vehicle mis-
front engine mounting bracket to 18-22 ft-lbs (24-30
alignment and to locate clearance problems, or as an
Nm). See E of Figure 2-37.
alternative to use of the Vehicle Alignment Tool (HD-46247)
e. Remove the center front engine mounting bracket to
described under Method A. For acceptable results, a careful
rubber mount bolt (with washers and nut). See F of
inspection should be performed (wheel and tire runout, laced
Figure 2-37.
wheel offset, rubber mount condition, etc.) to ensure that it is
conducted with serviceable components. See INSPECTION
9.
To verify alignment, install alignment bars or other suit-
for more information.
able device on both the left and right side of motorcycle.
Proceed as follows:
1.
Place the motorcycle on a hydraulic center stand or
place blocking under the frame to support the vehicle
NOTE
and lift the rear wheel off the ground. Be sure the motor-
If the front tire is wider than the rear, then the alignment bars
cycle is positioned as level as possible.
must either be shimmed out equally at the points of contact
2.
Remove socket screw with lockwasher to remove left
on the rear tire, notched at the front to clear the front tire, or
passenger footboard from rear swingarm bracket.
attached to the front tire with all measurements performed at
Tighten both rear swingarm bracket bolts to 34-42 ft-lbs
the rear. For explanatory purposes, the following procedure
(46-57 Nm). Repeat step on right side of motorcycle.
assumes the alignment bars are secured to the rear tire.
3.
Remove the decorative chrome plug from both rear
swingarm brackets. While holding the left side pivot shaft
a. Place a set of straightedges on both the left and
locknut, tighten the right side locknut to 40-45 ft-lbs (54-
right sides of the motorcycle alongside the front and
61 Nm). Then hold the right side pivot shaft locknut and
rear tires.
tighten the left side locknut to 40-45 ft-lbs (54-61 Nm).
b. Verify that both alignment bars firmly contact the
4.
Verify that belt deflection is within specification and that
rear wheel at two points. Use clamp or bungee
adjuster cams are tight against rear swingarm weld
cords to hold the bars in place. Tension should be
nubs. Holding weld nut on left side of axle, tighten cone
equal to avoid spreading or pinching the bars.
nut on right side to 95-105 ft-lbs (128.8-142.4 Nm).
c. Verify that the bars are straight by matching the
5.
Remove seat. See Section 2.24 SEAT, REMOVAL.
width measurements at both ends.
6.
Partially remove fuel tank to gain access to top engine
d. Straighten the front end and verify that the
mounting bracket and stabilizer link. See Section 4.7
measurements from the front wheel to the bar on
FUEL TANK (CARBURETED), PARTIAL REMOVAL,
one side of the motorcycle are equal at two points,
FLHT/C, or FLHR/S. For fuel injected models, see Sec-
both fore and aft.
tion
9.4 FUEL TANK (FUEL INJECTED), PARTIAL
REMOVAL, FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
e. Measure the front wheel to the bar on the other side
of the motorcycle, both fore and aft, and compare
7.
Top Engine Mount:
the results to the measurements obtained under
a. On left side of motorcycle, tighten the two top
step 9(d). Measurements from left to right should be
engine mounting bracket to front and rear cylinder
equal +/- 0.030 inch (0.76 mm).
head bolts to 35-40 ft-lbs (48-54 Nm). See A of Fig-
ure 2-37.
f.
Loosen jam nuts, and using the center hex, adjust
the front stabilizer link as required to obtain equal
b. Moving to right side of motorcycle, tighten the top
measurements at all four points (+/- 0.030 inch or
stabilizer link eyelet to frame weldment bolt to 18-22
0.76 mm). See Figure 2-38.
ft-lbs (24-30 Nm). See C of Figure 2-37.
c. Loosen both top stabilizer link jam nuts.
NOTE
d. Remove the top stabilizer link eyelet to top engine
After each adjustment, unload any binding of the front rubber
mounting bracket bolt. See B of Figure 2-37.
mount and verify that the alignment bars and front wheel are
8.
Front Engine Mount:
still correctly positioned.
a. Remove flange locknuts from studs on lower frame
g. Holding the front stabilizer link adjuster and
crossmember. Remove voltage regulator from studs
mounting eyelets to prevent movement or binding,
and allow to hang by cables at front of motorcycle.
tighten both jam nuts.
b. Tighten two engine to front engine mounting bracket
bolts to 33-38 ft-lbs (45-52 Nm). See H of Figure 2-
h. Verify that the front rubber mount is centered under
37.
the thru bolt hole in the mounting plate.
2-30
2004 Touring: Chassis
HOME
Chassis
Chassis
To Correct:
Powertrain
Powertrain
Adjust front stablizer link.
To Correct:
Adjust top stablizer link.
FLT0239
FLT0240
Figure 2-38. Horizontally Misaligned
Figure 2-39. Vertically Misaligned
i.
If the front rubber mount is centered and free of
a. Using the center hex to maintain equal thread
binding, proceed as follows:
engagement at both eyelets, adjust stabilizer link so
that bolt removed under step 7(d) threads in without
•
Tighten the two front engine mount to frame cross-
any stress or engine movement.
member bolts to 15-20 ft-lbs (20-27 Nm). See G of
Figure 2-37.
b. Tighten the stabilizer link eyelet to top engine
mounting bracket bolt to 18-22 ft-lbs (24-30 Nm).
•
Install center front engine mounting bracket to rub-
See B of Figure 2-37.
ber mount bolt (with washers and nut) and tighten to
15-20 ft-lbs (20-27 Nm). See F of Figure 2-37.
c. Holding the top stabilizer link adjuster and mounting
eyelets to prevent movement or binding, tighten
j.
If centering or relaxation of the mount is required,
both jam nuts.
proceed as follows:
•
Loosen the two front engine mount to frame cross-
12.
Lower motorcycle to floor and remove hydraulic center
member bolts. See G of Figure 2-37.
stand or blocking.
13.
After verifying that the motorcycle is level, check vertical
•
Push on the rubber mount to center it with the thru
alignment placing an inclinometer on both front and rear
bolt hole in the mounting plate. It may be necessary
brake rotors. Front and rear lean angles should be equal
to bounce or wiggle the engine to unload any
+/-
1/2 degree. See Figure 2-39. If vertical alignment
binding of the rubber mount on the mounting plate.
exceeds specification, proceed as follows:
•
After the mount is centered, tighten the two front
a. Loosen the top stabilizer link eyelet to top engine
engine mount to frame crossmember bolts to 15-20
mounting bracket bolt. See B of Figure 2-37. Verify
ft-lbs (20-27 Nm). See G of Figure 2-37.
that bolt is unloaded and threads freely in and out of
the mounting bracket hole. If necessary, loosen jam
•
Install center front engine mounting bracket to rub-
nuts and adjust stabilizer link to a achieve a free
ber mount bolt (with washers and nut) and tighten to
15-20 ft-lbs (20-27 Nm). See F of Figure 2-37.
state. Tighten bolt to 18-22 ft-lbs (24-30 Nm) and
then tighten jam nuts before rechecking vertical
10.
Slide voltage regulator over studs on lower frame cross-
alignment.
member at front of vehicle. Install flange locknuts on
b. Look for components that are worn, damaged or out
studs and tighten to 70-100 in-lbs (7.9-11.3 Nm).
of specification. See INSPECTION on the next
11.
Adjust the top stabilizer link as follows:
page.
2004 Touring: Chassis
2-31
HOME
14.
Remove the alignment bars from both the left and right
INSPECTION
side of the motorcycle.
15.
Snap the chrome plugs back into the rear swingarm
At the 10,000 mile (16,000 km) service interval, and at every
brackets.
10,000 mile (16,000 km) service interval thereafter, inspect
the engine isolators and stabilizer links. Perform inspection
16.
Install socket screw with lockwasher to fasten passenger
sooner if any sag in the powertrain is observed or abnormal
footboard to rear swingarm bracket. Tighten screw to 15-
handling characteristics/vibrations are experienced.
18 ft-lbs
(20-24 Nm). Repeat step on other side of
motorcycle.
17.
Install fuel tank. For carbureted models, see Section 4.7
Front Rubber Mount
FUEL TANK (CARBURETED), INSTALLATION (AFTER
PARTIAL REMOVAL), FLHT/C, or FLHR/S. For fuel
1.
Verify condition and torque of the mounting hardware.
injected models, see Section 9.4 FUEL TANK (FUEL
Visually inspect for wear, damage or improper installa-
INJECTED), INSTALLATION
(AFTER PARTIAL
tion. Replace hardware as necessary.
REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
2.
Examine carefully at the bottom of the motorcycle paying
18.
Verify minimum clearance between the powertrain and
special attention to the area between the large flat metal
the following frame mounted components:
washer and the bracket on the frame. There should be a
gap between the mounting plate and the cushion portion
a. Top Engine/Horn Mounting Bracket to Fuel Tank:
of the rubber mount.
0.328 inch (8.3 mm).
3.
Replace the rubber mount if there are any signs of
b. Rocker Covers to Fuel Tank: 0.375 inch (9.5 mm).
cracking or shearing.
c. Carburetor Top Cover to Fuel Tank: 0.375 inch (9.5
mm).
Rear Swingarm Mounts
d. Rear Spark Plug Boot to Fuel Valve: 0.250 inch (6.4
mm).
1.
Verify condition and torque of the mounting hardware.
Visually inspect for wear, damage or improper installa-
e. Top Stabilizer Link to Induction Module: 0.375 inch
tion. Replace hardware as necessary.
(9.5 mm).
2.
Examine rubber mount to be sure there is no twisting or
f.
Front Stabilizer Link to Voltage Regulator: 0.375
binding at the parting line.
inch (9.5 mm).
g. Inner Primary Chaincase to Lower Frame Tube:
Engine Stabilizer Links
0.187 inch (4.8 mm).
h. Exhaust Crossover Pipe to Primary Housing: 0.125
1.
Verify condition and torque of the mounting hardware.
inch (3.2 mm).
Visually inspect for wear, damage or improper installa-
tion. Replace hardware as necessary.
i.
Tire to Rear Fender: 0.100 inch (2.5 mm).
2.
Using flats machined into the stabilizer eyelet, gently
rock the link and check for separation of the molded-in
19.
Install seat. See Section 2.24 SEAT, INSTALLATION.
sleeve. Replace as necessary.
20.
Test ride the motorcycle.
Wear in the link also can be measured with a dial indica-
NOTE
tor by hand compressing and then releasing the link.
Replace any link that exceeds 0.025 inch (0.64 mm) of
Vehicle leads that require more than 2-lbs pull to correct
play or wear.
need further diagnosis. See INSPECTION on this page.
2-32
2004 Touring: Chassis
HOME
FRONT BRAKE MASTER CYLINDER
2.10
GENERAL
f1284x2x
Dual Disc
Master cylinders designed for dual disc (two caliper) opera-
tion have an 11/16 inch bore, while those that are designed
for single disc (one caliper) operation have a 9/16 inch bore.
The bore size is stamped on the master cylinder assembly
inboard of the handlebar clamp bracket. See Figure 2-40.
1WARNING
Bore Size
Do not use a 9/16 inch bore master cylinder assembly on
Stamp
dual disc (two caliper) models. Likewise, do not use an
11/16 inch bore master cylinder assembly on single disc
(one caliper) models. These master cylinder assemblies
are not interchangeable. Using the wrong assembly can
adversely affect braking efficiency or result in brake fail-
ure, which could result in death or serious injury.
Single Disc
REMOVAL/DISASSEMBLY
Figure 2-40. Verify Correct Bore Size Before Use
1. Remove banjo bolt and two steel/rubber washers to dis-
connect fitting of hydraulic brake line from master cylin-
der housing. Hold paper cup or other suitable container
under banjo bolt bore to allow reservoir to drain. Discard
1WARNING
steel/rubber washers.
Always wear proper eye protection when removing re-
taining rings. Use the correct retaining ring pliers. Verify
CAUTION
that the tips of the pliers are not damaged or excessively
worn. Slippage may propel the ring with enough force to
Do not remove the master cylinder assembly without
cause eye injury.
first placing the
5/32 inch (4.0 mm) cardboard insert
between the brake lever and lever bracket. Removal with-
5.
Remove retaining ring from pivot pin groove at bottom of
out the insert may result in damage to the rubber boot
master cylinder bracket. Discard retaining ring.
and plunger of the Front Stoplight Switch.
6.
Remove pivot pin and brake hand lever from master cyl-
inder assembly.
NOTE
7.
Carefully remove wiper with pick or similar tool.
Use the eyelet of a small cable strap if the cardboard insert is
not available.
8.
Remove piston cap.
9.
Remove piston with O-ring and primary cup.
2. Place the cardboard insert between the brake lever and
lever bracket. See Figure 2-41.
10. Remove spring.
3. Using a T27 TORX drive head, remove two screws with
CAUTION
flat washers to release handlebar clamp from the master
cylinder housing. Remove the clamp and brake lever/
To prevent dirt and other contaminants from entering the
master cylinder assembly from the handlebar. See Fig-
master cylinder reservoir, thoroughly clean the cover
ure 2-42.
before removal.
4. Remove the cardboard insert (or cable strap eyelet)
11. Remove two Phillips screws, cover and cover gasket
between the brake lever and lever bracket.
from the master cylinder reservoir.
2004 Touring: Chassis
2-33
HOME
4. Inspect the piston bore in the master cylinder housing for
7959
scoring, pitting or corrosion. Replace the housing if any
of these conditions are found.
5. Inspect the outlet port that mates with the brake line fit-
ting. As a critical sealing surface, replace the housing if
any scratches, dents or other damage is noted.
6. Inspect the cover gasket for cuts, tears or general deteri-
oration. If gasket and/or sight glass replacement is nec-
essary, proceed as follows:
a. From inboard side, push sight glass toward top of
cover until free.
b. Pull rubber gasket from cover.
5/32 Inch
(4.0 mm)
c. Fit nipple of new gasket into hole of cover aligning
Cardboard
gasket and cover thru holes.
Insert
d. From bottom of gasket, push flat end of sight glass
Figure 2-41. Install Cardboard Insert
through nipple until top of glass is flush with top of
Before Removing Master Cylinder Assembly
gasket. Verify that glass is square in bore. If some
lubrication is necessary, use a small quantity of
clean brake fluid.
CLEANING AND INSPECTION
ASSEMBLY/INSTALLATION
1WARNING
1.
Fit O-ring into groove on outboard side of piston (pin
Do not use replacement parts from single caliper repair
side). See Figure 2-42.
kits (9/16 inch bore) on dual caliper models. Likewise, do
2.
Fit primary cup over lip on inboard side of piston, so that
not use replacement parts from dual caliper repair kits
closed side (smaller OD) contacts shoulder.
(11/16 inch bore) on single caliper models. Parts are not
interchangeable. Using the wrong replacement parts can
3.
Coat piston bore of master cylinder reservoir with spe-
adversely affect braking efficiency or result in brake fail-
cial lubricant supplied in the service parts kit. Also apply
ure, which could result in death or serious injury.
the lubricant to OD of installed O-ring and primary cup.
4.
Insert metal retainer end of spring into piston bore, so
1. Always reassemble the master cylinder using new parts
that it seats against counterbore (recess) at bottom.
from the correct repair kit.
5.
Slide piston over spring.
2. Clean all parts with denatured alcohol or D.O.T.
5
BRAKE FLUID. Do not contaminate with mineral oil or
6.
Fit wiper over piston cap so that flat side of wiper con-
other solvents. Wipe dry with a clean, lint free cloth.
tacts cap shoulder.
Blow out drilled passages and bore with a clean air sup-
ply. Do not use a wire or similar instrument to clean
7.
Fit piston cap over piston pin.
drilled passages in bottom of reservoir.
8.
Press down on wiper until it contacts the counterbore.
Larger OD of wiper must be completely seated in groove
on outlet side of piston bore.
1WARNING
9.
Note that the angular shape of the master cylinder cover
Use denatured alcohol to clean brake system compo-
makes one side thicker than the other. Install the cover
nents. Do not use mineral base solvents (such as gaso-
(with gasket) on the master cylinder reservoir, so that the
line and paint thinner) or deterioration of rubber parts
thicker side is positioned above the brake line fitting.
may occur after assembly. Deterioration of components
Install two Phillips screws to fasten cover to the reser-
may result in premature brake failure, which could result
voir, but do not tighten at this time.
in death or serious injury.
10.
Align hole in brake hand lever with hole in master cylin-
3. Carefully inspect all parts for wear or damage and
der bracket. From the top of the assembly, slide pivot pin
replace as necessary.
through bracket and hand lever.
2-34
2004 Touring: Chassis
HOME
Phillips
Screw
Provided in Service Parts Kit
Phillips
Screw
9/16 Inch Bore - HD Part No. 45006-96B
Site Glass
11/16 Inch Bore - HD Part No. 45072-96B
Cover
Gasket
Flat
T27 TORX
Washer
Screw
Master Cylinder
Reservoir
Pivot
Pin
Handlebar
Clamp
Brake Line
Seating Surface
Bushing
Spring
Primary
Cup
Piston
Metal
Retainer
O-Ring
Piston
Cap
Shoulder
O-Ring
Pin
Groove
Shoulder
Flat
Retaining
Side
Ring
Brake
Hand Lever
Wiper
Lubricant
f1866x2x
Figure 2-42. Front Brake Master Cylinder Assembly
2004 Touring: Chassis
2-35
HOME
f1225x2x
CAUTION
To avoid leakage, verify that the steel/rubber washers,
banjo bolt, brake line fitting and master cylinder bore are
completely clean.
Groove
15. Position new steel/rubber washers on each side of
hydraulic brake line fitting. Insert banjo bolt through
washers and fitting. Thread bolt into master cylinder
housing and tighten to 17-22 ft-lbs (23-30 Nm).
16. Remove the master cylinder reservoir cover. Stand the
motorcycle upright so that the master cylinder is in a
level position.
5/32 Inch
NOTE
(4.0 mm)
D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID is non-toxic.
Cardboard
Insert
17. Add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID to
the master cylinder reservoir until the fluid level is 1/8
inch (3.2 mm) from the top. Do not reuse old brake fluid.
Use only D.O.T. 5 fluid from a sealed container.
Figure 2-43. Install Cardboard Insert
1WARNING
Before Installing Master Cylinder Assembly
A plugged or covered relief port can cause brake drag or
wheel lockup and may lead to loss of vehicle control,
which could result in death or serious injury.
1WARNING
18. Verify proper operation of the master cylinder relief port.
Always wear proper eye protection when installing re-
taining rings. Use the correct retaining ring pliers. Verify
Actuate the brake hand lever. A slight spurt of fluid will
that the tips of the pliers are not damaged or excessively
break the fluid surface in the reservoir compartment if all
internal components are working properly.
worn. Slippage may propel the ring with enough force to
cause eye injury.
19. Remove cap from bleeder valve on front brake caliper.
Install end of a length of clear plastic tubing over caliper
11. Install new retaining ring in pivot pin groove. Verify that
bleeder valve, while placing free end in a suitable con-
retaining ring is completely seated in groove.
tainer.
CAUTION
f1785x8x
See Figure 2-43. Do not install the master cylinder
Brake
assembly without first placing the 5/32 inch (4.0 mm)
Lever
cardboard insert between the brake lever and lever
Bracket
Tab
bracket. Installation without the insert may result in dam-
age to the rubber boot and plunger of the Front Stoplight
Groove
Switch.
12. Place the cardboard insert between the brake lever and
lever bracket. Use the eyelet of an ordinary cable strap if
the cardboard insert is not available.
13. Position the brake lever/master cylinder assembly
inboard of the switch housing assembly engaging the
tab on the lower switch housing in the groove at the top
of the brake lever bracket. See Figure 2-44.
Switch
Housing
14. Align the holes in the handlebar clamp with those in the
Assembly
master cylinder housing and start the two screws (with
flat washers). Position for rider comfort. Beginning with
Figure 2-44. Fit Brake Lever/Master Cylinder to
the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0
Right Handlebar Switch Housings
Nm) torque using a T27 TORX drive head.
2-36
2004 Touring: Chassis
HOME
20. Depress and hold the brake hand lever to build up
27. Test ride the motorcycle. If the brake feels spongy,
hydraulic pressure.
repeat the bleeding procedure.
21. Open bleeder valve about 1/2-turn. Brake fluid will flow
NOTE
from bleeder valve through tubing. Close bleeder valve
when brake hand lever has moved 1/2 to 3/4 of its full
A sight glass enables the rider to visually check the brake
range of travel. Allow brake hand lever to return slowly to
fluid level without removing the master cylinder cover. When
the reservoir is full, the sight glass is dark. As the fluid level
its released position.
drops, the glass lightens up to indicate this condition to the
22. Add brake fluid to the master cylinder reservoir until the
rider.
fluid level is about 1/8 inch (3.2 mm) from the top.
23. Repeat steps 20-22 until all air bubbles are purged.
24. Final tighten the bleeder valve to
80-100 in-lbs
(9.0-11.3 Nm). Install the bleeder valve cap.
25. Install cover (with gasket) on the master cylinder reser-
voir, so that the thicker side is positioned above the
brake line fitting. Install two Phillips screws to fasten the
cover to the reservoir. Tighten the screws to 6-8 in-lbs
(0.7-0.9 Nm).
26. With the Ignition/Light Key Switch turned to IGNITION,
actuate the front brake hand lever to verify operation of
the brake lamp.
1WARNING
After completing repairs or bleeding the system, always
test motorcycle brakes at low speed. If brakes are not
operating properly or braking efficiency is poor, testing
at high speeds could result in death or serious injury.
2004 Touring: Chassis
2-37
HOME
REAR BRAKE MASTER CYLINDER
2.11
7.
Gently pull side cover from frame downtube (no tools
REMOVAL
required).
8.
Remove bleeder valve cap on rear brake caliper. Install
PRELIMINARY INSTRUCTIONS
end of a length of clear plastic tubing over caliper
bleeder valve, while placing free end in a suitable con-
NOTE
tainer. Open bleeder valve about 1/2-turn. Pump brake
If fairing lowers are absent, proceed to step 5.
pedal to drain brake fluid. Close bleeder valve.
1. Remove two screws from fairing lower cap on right side
of vehicle.
2. Hold nut at bottom of fairing lower, and using a T40
BRAKE PEDAL/MASTER CYLINDER
TORX drive head, turn inside screw to free assembly
ASSEMBLY, REMOVAL
from engine guard clamp. Discard rubber washer.
3. Remove two locknuts to free retainer from upper rail of
1.
See PRELIMINARY INSTRUCTIONS on this page.
engine guard. From within glove box, remove U-bolt.
2.
Remove banjo bolt and two steel/rubber washers to dis-
4. Remove glove box from fairing lower. Remove fairing
connect brake line front fitting from master cylinder
lower from vehicle.
assembly. Discard washers.
5. Remove two allen head socket screws (with lock wash-
3.
Release rear brake line as needed to move front fitting
ers and flat washers) to release right side front footboard
forward far enough to access hex nut. For further
brackets from frame weldment. For best results,
instructions See REAR BRAKE LINE, REMOVAL, steps
approach from left side of vehicle using a 3/8 inch ball
3-6, in this section.
allen with extension.
6. Remove right side saddlebag. See Section 2.25 SAD-
4.
Using 1-1/8 inch wrench, remove hex nut to free brake
DLEBAG, REMOVAL.
pedal/master cylinder assembly from mounting bracket.
f2053x2x
O-Ring
Clevis Pin
Rear
Brake Pedal
Flat
Washer
Cotter Pin
Master Cylinder
Reservoir
Retaining
Ring
Figure 2-45. Rear Brake Pedal/Master Cylinder Assembly
2-38
2004 Touring: Chassis
HOME
P-Clamp
Brake Line
and Screw
Hose
Swingarm Bracket
Rear Brake
Steel/Rubber
Brake Hose
Light Switch
Washers
Crimp
Cable Clips
Locating Tab
Top of Rear Swingarm
Brake Line
Tube
Screw and
Weld Nut
Banjo
Frame Weldment
Bolt
Cable Straps and Anchors
f2275x2x
Lower Frame Tube
Figure 2-46. Rear Brake Line Assembly
5. Remove locknut with flat washer to free brake pedal/
fitting collar on cartridge body into square-shaped hole
master cylinder assembly from pedal shaft. Remove
in mounting bracket. Install flat washer and new locknut
assembly from vehicle. Remove and discard O-ring on
on pedal shaft and tighten to 15-20 ft-lbs (20-27 Nm).
each side of brake pedal shaft bore. See Figure 2-45.
5.
Apply Loctite Medium Strength Threadlocker 243 (blue)
6. Remove cotter pin and flat washer from clevis pin. Sup-
to threads of hex nut. Install hex nut on threaded end of
porting rear brake pedal/master cylinder assembly in
cartridge body and tighten to 30-40 ft-lbs (41-54 Nm).
vise, tap out clevis pin using a brass drift. Remove mas-
6.
Position new steel/rubber washers on each side of brake
ter cylinder assembly from brake pedal flange.
line fitting. Insert banjo bolt through washers and fitting.
7. For further instructions, see MASTER CYLINDER, DIS-
Thread bolt into master cylinder assembly and tighten to
ASSEMBLY, in this section.
17-22 ft-lbs (23-30 Nm).
7.
Secure rear brake line if released during master cylinder
removal. For further instructions, see REAR BRAKE
BRAKE PEDAL/MASTER CYLINDER
LINE, INSTALLATION, steps 4-7, in this section.
ASSEMBLY, INSTALLATION
8.
See FINAL INSTRUCTIONS on the next page.
1. If master cylinder was disassembled, see MASTER
CYLINDER, ASSEMBLY, in this section, for instructions.
2. Install master cylinder assembly on brake pedal flange.
REAR BRAKE LINE, REMOVAL
Supporting assembly in vise, tap in clevis pin using a
1.
See PRELIMINARY INSTRUCTIONS on the previous
brass drift. Install flat washer and cotter pin on clevis pin.
See Figure 2-45.
page.
3. Install new O-ring on each side of brake pedal shaft
2.
Remove banjo bolt and two steel/rubber washers to dis-
bore.
connect brake line front fitting from master cylinder
assembly. Discard washers. See Figure 2-46.
4. Apply a light coat of Wheel Bearing Grease (Part No.
99855-89) to the brake pedal shaft and bore. Install
3.
Cut cable straps to free rear brake line from two anchors
brake pedal/master cylinder assembly on the pedal shaft
installed on T-studs at top of lower frame tube.
2004 Touring: Chassis
2-39
HOME
4.
Remove hex screw to free brake hose P-clamp from rear
8. Position new steel/rubber washers on each side of brake
swingarm bracket (passenger footboard bracket).
line front fitting. Insert banjo bolt through washers and
fitting. Thread bolt into master cylinder assembly and
5.
Remove socket terminals from rear brake light switch
tighten to 17-22 ft-lbs (23-30 Nm).
spade contacts. Cut cable strap to free rear brake light
switch wires from lower frame tube, if necessary.
9. See FINAL INSTRUCTIONS on this page.
6.
Remove hex screw to free brake light switch bracket
from frame weldment. Push on bracket to release locat-
ing tab from slot in frame weldment.
INSTALLATION
7.
Open two cable clips on rear swingarm T-studs. Free
rear brake line hose from cable clips.
FINAL INSTRUCTIONS
NOTE
For best results, insert blade of small screwdriver into gap at
NOTE
side of clip and gently rotate end of screwdriver to pop open.
If fairing lowers are absent, proceed to step 7.
8.
Remove banjo bolt and two steel/rubber washers to dis-
1.
Place fairing lower into position on right side of vehicle.
connect brake line fitting from rear brake caliper. Discard
Place glove box into fairing lower.
washers.
2.
Holding screw inside fairing lower, install new rubber
9.
Feed rear brake line hose forward to area in front of rear
washer, clamp and locknut to attach fairing bottom to
swingarm bracket. Remove rear brake line assembly
engine guard. Do not tighten locknut.
from vehicle.
3.
From within glove box, install U-bolt so that it encircles
the upper rail of the engine guard. Loosely install
retainer and locknuts.
REAR BRAKE LINE, INSTALLATION
4.
Adjust the fairing lower so that ear at top inboard side is
approximately 1/4 inch (6.35 mm) from frame downtube.
1.
Place rear brake line into approximate position along top
Verify that fairing lower is square, and then alternately
of lower right frame tube. From area in front of rear swin-
tighten locknuts to 35-40 in-lbs (4.0-4.5 Nm).
garm bracket, feed brake line hose rearward following
top of rear swingarm.
5.
Hold locknut at bottom of fairing lower, and using a T40
TORX drive head, turn inside screw to fasten assembly
2.
Position new steel/rubber washers on each side of brake
to engine guard clamp. Tighten screw to 90-100 in-lbs
line rear fitting. Insert banjo bolt through washers and fit-
(10.2-11.3 Nm).
ting. Thread bolt into rear brake caliper and tighten to
17-22 ft-lbs (23-30 Nm).
6.
Install two screws to secure fairing lower cap to fairing
lower. Tighten screws to 10-20 in-lbs (1.1-2.3 Nm).
3.
Capture rear brake line hose in two cable clips on rear
swingarm T-studs. Snap cable clips closed.
7.
Insert two allen head socket screws (with lockwashers
and flat washers) through frame weldment into right side
4.
Index locating tab on brake light switch bracket in slot of
front footboard brackets. For best results, approach from
frame weldment. Install hex screw to secure brake light
left side of vehicle using a 3/8 inch ball allen with exten-
switch bracket to frame weldment.
sion. Alternately tighten socket screws to 30-35 ft-lbs
5.
Install socket terminals onto rear brake light switch
(41-48 Nm).
spade contacts. If removed, install new cable strap to
8.
Install length of clear plastic tubing over caliper bleeder
secure rear brake light switch wires to lower frame tube.
valve, if removed. Place free end of tube in a suitable
container.
6.
Install hex screw to secure brake hose P-clamp to rear
swingarm bracket (passenger footboard bracket).
9.
Remove the master cylinder cover, if installed. Stand the
motorcycle upright so that the master cylinder is in a
7.
Center rear brake line over two anchors installed on T-
level position.
studs at top of lower frame tube. Thread new cable
straps through eyelets in anchors to capture brake line.
NOTE
Cut any excess cable strap material.
D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID is non-toxic.
NOTE
10. Add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID to
Cable strap anchors also capture voltage regulator cables
the master cylinder reservoir until the fluid level is 1/8
(front only) and branch of main harness leading to the oil
inch (3.2 mm) from the top. Do not reuse old brake fluid.
pressure sender and crankshaft position sensor connectors.
Use only D.O.T. 5 fluid from a sealed container.
2-40
2004 Touring: Chassis
HOME
f2274x8x
1st
Cable Clip
2nd
Cable Clip
2nd
Cable Strap
1st
Anchor
Cable Strap
Anchor
Rear
Swingarm
Frame
Weldment
Cable Strap
Captures Rear Brake Light Switch Wires
and Lower Frame Tube Only
Figure 2-47. Rear Brake Line Routing (Right Side View)
18. Install the cover (with gasket) on the master cylinder res-
1WARNING
ervoir. Install two Phillips screws to fasten the cover to
the reservoir. Tighten the screws to 6-8 in-lbs (0.7-0.9
Verify proper operation of the master cylinder relief port.
Nm).
A plugged or covered relief port can cause brake drag or
19. With the Ignition/Light Key Switch turned to IGNITION,
wheel lockup and may lead to loss of vehicle control,
actuate the rear brake pedal to verify operation of the
which could result in death or serious injury.
brake lamp.
11. Actuate the rear brake pedal. A slight spurt of fluid will
break the fluid surface in the reservoir compartment if all
1WARNING
internal components are working properly.
After completing repairs or bleeding the system, always
12. Add brake fluid to the master cylinder reservoir until the
test motorcycle brakes at low speed. If brakes are not
fluid level is 1/8 inch (3.2 mm) from the top.
operating properly or braking efficiency is poor, testing
at high speeds could result in death or serious injury.
13. Depress and hold the rear brake pedal to build up
hydraulic pressure.
20. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place
(no tools
14. Open bleeder valve about 1/2-turn. Brake fluid will flow
required).
from bleeder valve through tubing. Close bleeder valve
21. Install right side saddlebag. See Section 2.25 SADDLE-
when rear brake pedal has moved 1/2 to 3/4 of its full
BAG, INSTALLATION.
range of travel. Allow rear brake pedal to return slowly to
22. Test ride the motorcycle. If the brake feels spongy,
its released position.
repeat the bleeding procedure.
15. Repeat steps 12-14 until all air bubbles are purged.
NOTE
16. Final tighten the bleeder valve to
80-100 in-lbs
A sight glass enables the rider to visually check the brake
(9.0-11.3 Nm). Install the bleeder cap.
fluid level without removing the master cylinder cover. The
sight glass is dark when the reservoir is full, but as the fluid
17. Add brake fluid to the master cylinder reservoir until the
level drops, the glass lightens to alert the rider of this condi-
fluid level is about 1/8 inch (3.2 mm) from the top.
tion.
2004 Touring: Chassis
2-41
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