Harley Davidson 2004 Touring Models. Service Manual — page 62
HOME
CLUTCH MASTER CYLINDER/RESERVOIR
2.10
GENERAL
REMOVAL
1.
Remove acorn nut, washer and rear view mirror with
The clutch is hydraulically actuated. Squeezing the clutch
tapered spacer. Support turn sign bullet housing and
hand lever causes the clutch master cylinder to apply pres-
bracket.
sure via the clutch fluid in the clutch line to the secondary
2.
Remove electrical controls.
clutch actuator mounted in the clutch release cover. The sec-
ondary clutch actuator piston extends and contacts the clutch
release bearing which disengages the clutch.
CAUTION
To prevent dirt and other contaminants from entering the
A bleeder valve at the secondary clutch actuator is used to
master cylinder reservoir, thoroughly clean the cover
bleed air from the clutch line. D.O.T. 5 SILICONE BRAKE
before removal.
FLUID is used in the clutch system.
3.
See Figure 2-18. Loosen, but do not remove, screws
Check the clutch fluid level in the clutch fluid reservoir on left
with flat washers that detach handlebar clamp from
clutch master cylinder/reservoir.
handlebar. If the sight glass is dark, the fluid level in the res-
ervoir is above the sight glass prism and the reservoir is full.
4.
Loosen both screws on cover to relieve pressure in mas-
If the sight glass appears clear, the fluid level is below the
ter cylinder reservoir.
sight glass prism and the fluid level should be checked.
Clutch fluid should be level with the internal shelf marked
1WARNING
FILL LEVEL with the motorcycle upright and the gasket sur-
Be sure NO clutch fluid gets on tires, wheels, or brakes
face level.
when draining clutch fluid. Traction will be adversely
affected which could result in loss of control of the
motorcycle and death or serious injury.
CAUTION
NOTE
D.O.T. 5 SILICONE BRAKE FLUID is used for the hydrau-
Place a large cup under the banjo fitting. Hydraulic fluid will
lic clutch and is referred to as clutch fluid in this manual.
begin draining from the reservoir as the banjo bolt is
Do not use other types of fluid as they are not compati-
removed.
ble.
CAUTION
CAUTION
Damaged banjo bolt surfaces will leak when reassembled.
Clutch fluid volume increases with clutch wear. Do not
Prevent damage to seating surfaces by carefully remov-
ing clutch line components.
overfill clutch reservoir.
5.
Slowly loosen banjo bolt and allow clutch fluid from res-
ervoir to drain into cup.
IMPORTANT NOTE
Dispose of clutch fluid in accordance with local regula-
tions.
6.
Remove banjo bolt and two steel/rubber washers to dis-
connect fitting of hydraulic clutch fluid line from clutch
reservoir and master cylinder. Discard steel/rubber
washers.
NOTE
To prevent the rest of the clutch fluid from draining from the
clutch line and secondary clutch actuator, support the banjo
fitting and clutch fluid line upright. Plug the banjo bolt hole
with a finger to transfer the assembly to a workbench without
spilling clutch fluid.
7.
Remove handlebar clamp screws and take clamp and
clutch master cylinder/reservoir assembly to a work-
bench.
2-18
2004 FLHTCSE: Chassis
HOME
v0035x2x
DISASSEMBLY
2
1
CAUTION
To prevent dirt and other contaminants from entering the
master cylinder reservoir, thoroughly clean the cover
10
9
before removal.
3
8
1. Drain additional clutch fluid from master cylinder/reser-
7
voir.
4
2. Remove screws securing master cylinder cover.
Remove cover and gasket. Turn housing upside down to
remove remaining clutch fluid from reservoir.
5
1WARNING
6
Always wear proper eye protection when removing
1.
Cover
retaining rings. Use the correct retaining ring pliers. Ver-
2.
Clutch hand lever
ify that the tips of the pliers are not damaged or exces-
3.
Cover hold down screws
sively worn. Slippage could propel the ring with force
4.
Banjo fitting
which could cause death or serious injury.
5.
Clutch fluid line
6.
Banjo bolt
3. Remove retaining ring from pivot pin groove.
7.
Steel/rubber washers
8.
Handlebar clamp
NOTE
9.
Washer
10.
Clamp screw
To take the piston spring load off the pin and remove the pivot
pin, gently force the clutch lever toward the piston (as if oper-
Figure 2-18. Clutch Master Cylinder/Reservoir
ating the clutch).
4. Remove pivot pin through top of housing. Remove and
save pivot pin and clutch lever.
5. See Figure 2-19. Using a toothpick or small screwdriver,
gently pry outer edge of piston boot out of piston bore.
6. Remove piston and spring.
1WARNING
Always use denatured alcohol or D.O.T. 5 SILICONE
BRAKE FLUID to clean clutch system components. Do
not use mineral base solvents (such as gasoline or paint
thinner) or deterioration of rubber parts may occur after
assembly. Deterioration of components may result in pre-
mature brake failure and death or serious injury. Wipe the
housing with a lint free cloth. With a clean air supply,
blow out drilled passages and bore in the master cylinder
housing.
NOTE
Do not use a wire or sharp instrument to clean drilled oil pas-
sages.
7. Inspect cylinder housing bore for scoring, pitting or cor-
rosion. Also check outlet port for damage. Replace
housing if necessary.
8. Inspect the cover, sight glass, and gasket for cuts, tears
or general deterioration.
2004 FLHTCSE: Chassis
2-19
HOME
ASSEMBLY
9370
1
To rebuild clutch master cylinder, use the components found
in the SERVICE PARTS KIT No. 46244-01.
2
1. See Figure 2-19. Lightly lubricate inside of primary cup
and fit over lip on spring end of piston so the closed end
(small ID) contacts evenly with the shoulder in primary
cup grove.
7
2. Lightly lubricate inside of secondary cup (steep taper
8
from center to outside diameter) and fit over the lip on
outboard end of piston so that flared end is open toward
the shoulder of the secondary cup groove.
3. Install boot, large sealing ID first, on piston until seal on
smaller ID fits snugly into thin groove in piston.
3
NOTE
5
6
See Figure 2-20. The flared ends of the primary cup and the
secondary cup face the spring end of the piston.
3
4. Using lubricant in SERVICE PARTS KIT
(Part No.
46244-01) thoroughly coat outside diameters of primary
and secondary cups. Coat master cylinder piston bore.
5. With tapered end out, install spring into opening on
inboard side of piston assembly.
4
6. Align and install piston assembly into bore. Firmly press
on flat end of piston, compressing spring, until the entire
assembly slides into cylinder bore.
NOTE
When fitting the piston sealing boot, be careful not to tear,
perforate or damage the piston sealing boot.
7.
Compress piston until it is even with the end of bore.
Using a small dull bladed screwdriver or similar tool,
gently work around sealing edges of boot until entire cir-
cumference of boot is seated in cylinder bore groove.
8.
If cover gasket and/or sight glass replacement is neces-
sary. Proceed as follows:
a. From inboard side, push sight glass toward top of
cover until free.
b. Pull rubber gasket from cover.
c. Fit nipple of new gasket into hole of cover aligning
gasket and cover thru holes.
d. From bottom of gasket, push flat end of sight glass
through nipple until top of glass is flush with top of
gasket. Verify that glass is square in bore. If lubrica-
tion is necessary, use clean D.O.T. 5 SILICONE
BRAKE FLUID.
1.
Boot
2.
Piston
3.
Shoulder
4.
Spring
5.
Primary cup
6.
Groove - primary cup
7.
Secondary cup
8.
Groove - secondary cup
Figure 2-19. Clutch Master Cylinder Components
2-20
2004 FLHTCSE: Chassis
HOME
9. Install cover with gasket on master cylinder reservoir.
INSTALLATION
Install two screws to fasten the cover to reservoir, but do
not tighten.
1. See Figure
2-18. Attach master cylinder/reservoir to
handlebars with handlebar clamp. Orient lever to rider
1WARNING
position and tighten two clamp screws.
Always wear proper eye protection when installing retain-
ing rings. Use the correct retaining ring pliers. Verify that
2. Attach banjo fitting of clutch fluid line to master cylinder
the tips of the pliers are not damaged or excessively
with new steel/rubber washers. Install electrical controls.
worn. Slippage could propel the ring with force which
3. Loosen bleeder valve on clutch release cover. See 7.4
could cause death or serious injury.
CLUTCH RELEASE COVER.
10. To install existing clutch hand lever, install clutch hand
lever, pivot pin, and a new retaining ring.
4. Fill reservoir with D.O.T. 5 SILICONE BRAKE FLUID.
11. To install a replacement clutch hand lever, use SERVICE
Allow fluid to fill clutch line until a steady flow of clutch
PARTS KIT (Part No. 46243-01). See 2.11 CLUTCH
fluid flows from bleeder valve. Finger tighten bleeder
HAND LEVER.
valve.
5. Bleed clutch line. See BLEEDING CLUTCH FLUID
9686
LINE.
1
2
6. Verify that fluid level in clutch fluid reservoir is at FILL
3
LEVEL with motorcycle upright and gasket surface level.
CAUTION
Clutch fluid volume increases with clutch wear. Do not
overfill clutch reservoir.
7. Verify pressure by squeezing clutch hand lever.
8. Tighten fasteners as follows:
1.
Boot in piston groove
2.
Secondary cup flare
a. Banjo bolt to 17-22 ft-lbs (23-31 Nm).
3.
Primary cup
b. Bleeder screw to 80-100 in-lbs (9-11 Nm).
Figure 2-20. Assembled Cups and Piston
c. Reservoir cover screws to 6-8 in-lbs (0.7-0.9 Nm).
9. Install rear view mirror and turn signals with bracket. See
8.1 TURN SIGNALS.
1WARNING
Check for proper turn signal lamp operation before
riding motorcycle. Visibility is a major concern for motor-
cyclists. Failure to have proper lamp operation could
result in death or serious injury.
10. Test ride motorcycle.
2004 FLHTCSE: Chassis
2-21
HOME
CLUTCH HAND LEVER
2.11
INSTALLATION
9477
1. See Figure 2-21. Slide bushing cups onto pins of roller
2
with cup flanges against roller.
3
NOTE
Be careful when handling the bushing cups. The bushing
cups are hard plastic and can be easily broken.
1
2. With connector bow portion of the bushing cups parallel
with groove in clutch handle, snap roller pin with the
bushing cups installed into clutch lever roller groove. If
4
bushing is positioned correctly, roller/bushing assembly
will install with a snap and will be held securely.
3. Lightly grease pivot bushing and install into clutch hand
lever pivot hole. Position bushing until it is flush with both
1.
Clutch hand lever
2.
Pivot bushing
sides of lever.
3.
Bushing cups connector bow
4.
Roller pin
NOTE
If the clutch master cylinder/reservoir is full of clutch fluid
Figure 2-21. Clutch Hand Lever
under pressure, it may be necessary to apply force to the
hydraulic piston (in the clutch hand lever mount) in order to
align the clutch hand lever and to allow the pivot pin to be
inserted.
4. Orient clutch lever in lever mounting bracket. Insert pivot
pin from top and tap into place.
5. Install new retaining ring on pivot pin.
2-22
2004 FLHTCSE: Chassis
HOME
CLUTCH FLUID LINE
2.12
REPLACEMENT
9930
1. Remove outer fairing.
1
1WARNING
2
Be sure NO clutch fluid gets on rear tire, wheel or brakes
3
when draining clutch fluid. Traction will be adversely
affected which could result in loss of control of the
motorcycle and death or serious injury.
2. See Figure 2-22. Place a suitable container under clutch
release cover.
3. Loosen the clutch master cylinder/reservoir cover.
4. Loosen flare nut and allow clutch fluid to drain.
1. Bleeder valve (cap removed)
5. Remove flare nut on outside of the clutch release cover.
2. Flare nut
3. Clutch fluid line
6. Drain clutch fluid line.
NOTE
Figure 2-22. Clutch Release Cover
Dispose of clutch fluid in accordance with local regulations.
(exhaust system removed)
7. See Figure 2-23. Remove and discard o-ring.
1WARNING
NOTE
Clutch fluid line o-ring may stick to inside of clutch release
Be sure NO clutch fluid gets on tires, wheels or brakes
cover. Use a pick to remove old o-ring and other debris.
when adding clutch fluid. Traction will be adversely
affected which could result in loss of control of the
8.
Remove banjo bolt and two steel/rubber washers to dis-
motorcycle and death or serious injury.
connect fitting of hydraulic clutch fluid line from clutch
reservoir and master cylinder. Discard washers.
9.
Carefully pull banjo bolt end of clutch fluid line out
1WARNING
through inner fairing.
Do not allow dirt or debris to enter the clutch master cyl-
10.
See Figure
2-26. Route new clutch fluid line back
inder reservoir. Dirt or debris in the reservoir can cause
through fairing retracing path of old.
improper operation of the clutch and equipment dam-
age. (00205a)
11.
Loosely install banjo bolt and tie free end away from
chrome and painted surfaces.
12.
See Figure 2-26. Loosen clamps and cut cable ties
CAUTION
around old clutch fluid line along right side frame down
Direct contact of D.O.T. 5 brake fluid with eyes can cause
tube and behind cam cover around the rear brake line in
front of the clamp.
eye irritation, swelling, and redness. Avoid eye contact.
Incase of eye contact flush with large amounts of water
13.
Remove old clutch fluid line.
and get medical attention. Swallowing large amount of
14.
Route new clutch fluid line down right side frame tube,
D.O.T 5 brake fluid can cause digestive discomfort. If
under cam cover and up to clutch release cover. See
swallowed, obtain medical attention. Use in well venti-
CLUTCH FLUID LINE ROUTING.
lated area. (00144a)
15.
See Figure 2-23. Install new o-ring on end of clutch fluid
20. Loosen bleeder valve.
line.
21. Remove clutch master cylinder/reservoir cover and fill
16.
Thread in and finger tighten flare nut fastening clutch
reservoir with D.O.T. 5 SILICONE BRAKE FLUID. Allow
fluid line to clutch release cover.
fluid to fill clutch line until a steady flow of clutch fluid
17.
Attach banjo fitting of the clutch fluid line to master cylin-
flows from bleeder screw. Finger tighten bleed screw.
der with new steel/rubber washers.
NOTE
18.
Cable wrap clutch fluid line in original places on inner
A Snap-on BASIC VACUUM BRAKE BLEEDER with a fitting
fairing bracket and behind cam cover around the rear
that mates to the bleeder valve can be used to draw the fluid
brake line in front of the clamp.
down the clutch line.
19.
Install outer fairing assembly. See FAIRING in this Ser-
vice Manual.
22. Bleed clutch fluid line. See BLEEDING CLUTCH FLUID
LINE.
2004 FLHTCSE: Chassis
2-23
HOME
2. Route clutch fluid line:
CAUTION
a. Route line through inner fairing grommet.
Clutch fluid volume increases with clutch wear. Do not
b. See Figure 2-26. Route line around top of steering
overfill clutch reservoir.
head and back out to P-clamp used for throttle
cables.
23. Verify that fluid level in clutch fluid reservoir is at FILL
c. Run clutch fluid line behind engine guard and in
LEVEL with motorcycle upright and gasket surface level.
front of right frame downtube.
24. Test pressure by squeezing clutch hand lever.
d. Run line behind foot controls bracket.
25. Tighten fasteners as follows:
e. Following inboard side of frame downtube, route
cable between bottom of cam cover and top of lower
a. Clutch fluid reservoir banjo bolt to 17-22 ft-lbs (23-
frame tube.
31 Nm).
f.
See Figure 2-26. Line is cable wrapped along rear
b. Clutch line flare nut to 80-115 in-lbs (9-13 Nm).
brake line just in front of main wire harness conduit.
c. Actuator bleeder valve to 80-100 in-lbs (9-11 Nm).
g. Route line up to clutch release cover.
d. Reservoir cover screws to 6-8 in-lbs (0.7-0.9 Nm).
3. See Figure 2-26. Install clamps to retain clutch fluid line
26. Test ride motorcycle. Incorrect pressure or fluid lever can
at two locations on right frame downtube.
cause:
4. Install outer fairing. See FAIRING.
a. Dragging clutch.
10555
b. Hard shifting.
9994
Figure 2-25. Clamp Locations on Frame Down Tube
9991
Figure 2-23. Clutch Fluid Line O-ring
CLUTCH FLUID LINE ROUTING
1. Remove outer fairing.
Figure 2-26. Cable Wrap Location around Brake Line
Figure 2-24. Clutch Fluid Line Inner Fairing Grommet
2-24
2004 FLHTCSE: Chassis
HOME
4.
Fill reservoir to FILL LEVEL and repeat the previous
BLEEDING CLUTCH FLUID LINE
step three times or more until only a steady flow of clutch
fluid escapes banjo fitting and fluid level in reservoir is at
FILL LEVEL with motorcycle in an upright position.
1WARNING
5.
Cover exhaust with towel and place a suitable pan under
Be sure NO clutch fluid gets on tires, wheels or brakes
clutch release cover to catch excess clutch fluid.
when adding clutch fluid. Traction will be adversely
affected which could result in loss of control of the
IMPORTANT NOTE
motorcycle and death or serious injury.
Dispose of clutch fluid in accordance with local regula-
tions.
CAUTION
6.
While holding reservoir cover in place:
Do not allow dirt or debris to enter the clutch master cyl-
a. Pump clutch hand lever 5 times.
inder reservoir. Dirt or debris in the reservoir can cause
improper operation of the clutch and equipment dam-
b. Hold clutch hand lever against handlebar.
age. (00205a)
c. Loosen secondary clutch actuator bleed valve.
d. Run hose from bleeder valve to suitable container.
CAUTION
Direct contact of D.O.T. 5 brake fluid with eyes can cause
e. Watch bleeder valve for air bubbles.
eye irritation, swelling, and redness. Avoid eye contact.
f.
Tighten bleeder valve.
Incase of eye contact flush with large amounts of water
and get medical attention. Swallowing large amount of
g. Release hand lever.
D.O.T 5 brake fluid can cause digestive discomfort. If
swallowed, obtain medical attention. Use in well venti-
7.
With reservoir level, fill reservoir to FILL LEVEL and
repeat the previous step three times or more until only a
lated area. (00144a)
steady flow of clutch fluid escapes bleeder valve and
NOTE
fluid level in reservoir is at FILL LEVEL with motorcycle
in an upright position.
When filling an empty clutch fluid line, a Snap-on BASIC
VACUUM BRAKE BLEEDER with a fitting that mates to the
secondary clutch actuator bleeder valve can be used to ini-
CAUTION
tially draw the fluid down the clutch line.
Clutch fluid volume actually increases with clutch wear.
1. Stand motorcycle upright and turn handlebars right lock
Do not overfill reservoir.
as required to level clutch reservoir. Remove reservoir
cover.
8.
Test pressure by squeezing clutch hand lever.
9.
Tighten fasteners as follows:
CAUTION
a. Clutch fluid reservoir banjo bolt to 17-22 ft-lbs (23-
Clutch fluid volume actually increases with clutch wear.
31 Nm).
Do not overfill reservoir.
b. Clutch line flare nut to 80-115 in-lbs (9-13 Nm).
2. If necessary, add D.O.T. 5 SILICONE BRAKE FLUID,
c. Actuator bleeder valve to 80-100 in-lbs (9-11 Nm).
(HD-99902-77) to master cylinder reservoir. Initial fluid
level should not exceed FILL LEVEL with reservoir level.
d. Reservoir cover screws to 6-8 in-lbs (0.7-0.9 Nm).
10.
Replace cap on actuator bleeder valve.
1CAUTION
11.
Test ride motorcycle. Incorrect pressure or fluid level can
Loosen banjo bolt only enough to allow air bubbles to
cause:
escape. Clutch fluid under pressure can squirt a steady
a. Dragging clutch.
stream several feet.
b. Hard shifting.
3. While holding reservoir cover in place:
a. Pump clutch hand lever 5 times.
b. Hold clutch hand lever against handlebar.
c. Hold shop towel under fitting and loosen banjo bolt.
d. Watch banjo fitting for air bubbles.
e. Retighten banjo fitting.
f.
Release hand lever.
2004 FLHTCSE: Chassis
2-25
HOME
SEAT
2.13
REMOVAL
f2149x0a
1. Remove rider and passenger backrests.
1
3
2. Remove saddlebag.
3. See Figure 2-27. Remove fastener with flat washer hold-
2
ing one side of passenger grabstrap.
4. Remove fastener holding seat to fender.
5. Slide seat backward to free tongue on bottom front of
seat from slot in frame backbone. and remove seat.
5
6
CLEANING AND INSPECTION
4
1. Passenger grabstrap
2. Seat
CAUTION
3. Fastener
Do NOT use bleach or detergents containing bleach on
4. Tongue
saddlebags, seats, or tank panels. Doing so may result
5. Bracket
in equipment damage.
6. Retention nut
● Do not use ordinary soap to clean leather. It could
Figure 2-27. Seat Components
dry or remove the oils from the leather.
INSTALLATION
● Use ONLY a good quality saddle soap to clean
leather. Be sure to rinse saddle soap off thoroughly
before treating leather.
1. See Figure 2-27. Set seat on frame and slide seat for-
ward until tongue engages slot in frame backbone.
● Never try to dry leather quickly, using artificial
means. Always let leather dry naturally at room tem-
2. Push seat forward until retention nut in fender is cen-
perature.
tered in hole of bracket. Install fastener.
NOTE
1WARNING
HARLEY-DAVIDSON LEATHER DRESSING
(Part No.
After installing the seat, pull upward on the front of the
98261-91V) has been tested and approved for materials
seat to be sure it is locked into position. If seat is loose,
used in FLHTCSE seats.
it could shift during operation, resulting in loss of con-
trol of the motorcycle and death or serious injury.
1. Inspect seat for wear or damage.
3.
Pull up on seat to verify that it is properly secured.
2. Clean underside of pillion and seat. Clean fender and
frame mounting surfaces.
4.
Install passenger grabstrap to saddlebag mounting
bracket.
5.
Install rider and passenger backrests.
2-26
2004 FLHTCSE: Chassis
HOME
RIDER BACKREST
2.14
REMOVAL
INSTALLATION
1. See Figure 2-28. Spread the seat covering at the base of
1. See Figure 2-30. Spread the seat opening to expose the
the backrest exposing the two spring loaded support
keyed backrest support bracket.
arms.
2. See Figure 2-29. Using two hands, squeeze together the
10566
spring loaded support arms.
10564
1
2
1.
Support arms
Figure 2-28. Removable Rider Backrest
2.
Spring
3. Pull upward to remove the backrest from the bracket.
Figure 2-30. Backrest Installation
10565
2. Squeeze together the two spring loaded support arms
on the backrest.
3. See Figure 2-31. Insert the support arms into the keyed
support bracket.
4. Test to assure the seat is secured into the bracket.
NOTE
The backrest is spring loaded to assist the passenger in get-
ting on and off the vehicle.
o0163xox
1
Figure 2-29. Backrest Removal - Spring Loaded Support
Arms
2
1. Seat
2. Keyed support bracket
Figure 2-31. Backrest Mounting Bracket
2004 FLHTCSE: Chassis
2-27
HOME
PASSENGER BACKREST
2.15
REMOVAL
INSTALLATION
1. Remove the saddlebags. See SADDLEBAG, REMOVAL
9993
in Touring Models Service Manual.
3
5
6
2
1
2. See Figure 2-32. Push in the spring-loaded locking latch
4
and pull the swivel latch rearward on the passenger
backrest.
3.
Lift the backrest off by lifting upward and then toward the
rear of the motorcycle.
4.
See Figure
2-33. Remove front docking point bolt,
washer and front docking bushing.
5.
Remove rear docking point bolt, washer, docking point
(4), nut and docking point bracket.
8
7
6.
Remove fender mounting bolt.
9
7.
Remove rear mounting bolt, lock washer, washer and
nut.
1.
Front docking bushing
8. Cover filler strip to protect finish and remove lower
2.
Docking points bracket
mounting bolt, washer and nut.
3.
Air suspension valve
4.
Rear docking point
9.
Remove mounting bracket and saddlebag mounting
bracket.
5.
Fender mounting bolt
6.
Rear mounting bolt
10. Repeat for opposite side.
7.
Mounting bracket
11. Inspect all parts and replace as required.Passenger
8.
Lower mounting bolt
backrest
9.
Saddlebag mounting bracket
Your motorcycle comes with a detachable passenger back-
rest.
Figure 2-33. Passenger Backrest Mounting Location
o0181xox
1.
See Figure 2-34. Install mounting bracket with fender
mounting bolt.
2.
Install upper mounting bolt, lock washer and washer.
3.
Cover filler strip to protect finish.
4.
Install lower mounting bolt and washer with saddlebag
mounting bracket.
5.
Install rear docking point, fastener, washer and nut with
1
2
the dock point bracket.
6.
Install the front docking bushing with fastener and
washer through the dock point bracket into the frame.
7.
Align saddlebag mounting hole with saddlebag.
1.
Rear latch
2.
“C” bracket guides
8.
Tighten fasteners:
a. Fender mounting bolt to 15-20 ft-lbs (12-27 Nm).
Figure 2-32. Detachable Passenger Backrest
b. Upper and lower mounting bolts to
15-20 ft-lbs
(20.3-27 Nm).
c. Front and rear docking point bolts to 15-20 ft-lbs
(20.3-27 Nm).
9.
Repeat for opposite side.
10.
Install passenger backrest by sliding bracket c-guides
onto front docking bushing and pushing down on the
rear of the bracket with latches aligned to rear docking
points until the rotate and lock into position.
11.
Check that passenger backrest is locked in place before
operating motorcycle.
2-28
2004 FLHTCSE: Chassis
HOME
z0021f
2
1
3
19
4
7
18
6
9
5
17
16
15
14
8
9
11
10
12
13
1.
Fastener
2.
Backrest mounting bracket
3.
Passenger backrest
4.
Pad
5.
Docking points bracket
6.
Nut
7.
Washer
8.
Front docking bushing
9.
Washer
10.
Docking point bolt
11.
Rear docking point
12.
Washer
13.
Docking point bolt
14.
Lower mounting bolt
15.
Washer
16.
Upper mounting bolt
17.
Lock washer
18.
Mounting bracket
19.
Spacer
Figure 2-34. Passenger Backrest Components
2004 FLHTCSE: Chassis
2-29
HOME
SADDLEBAG SUPPORTS
2.16
REMOVAL
INSTALLATION
1. Install the trim to the support bracket. Loosely fasten
support bracket to fender support bracket.
1WARNING
2. Install passenger backrest mounting bracket to support
To prevent accidental vehicle start-up, which could
bracket. Pull docking points bracket and docking points
cause death or serious injury, remove maxi-fuse before
into place.
proceeding. (00251a).
3. Loosely install fasteners into passenger backrest bracket
and rear saddlebag bracket. Be sure the washers are in
1.
Remove the saddlebags. See SADDLEBAG, REMOVAL
place behind and in front of passenger backrest bracket.
in Touring Models Service Manual.
4. Tighten fasteners:
a. Passenger backrest mounting bracket to support
2.
Remove side cover.
bracket - 15-20 ft-lbs (20.4-27 Nm).
3.
Remove Maxi-Fuse.
b. Fender support bracket to support bracket 15-20 ft-
lbs (20.4-27 Nm).
4.
See Figure
2-35. Remove filler strip fasteners and
c. Support to support bracket 15-20 ft-lbs
remove filler strip.
(20.4-27 Nm).
5. Install filler strip with washers between filler strip and
support bracket. Tighten fasteners to 15-20 ft-lbs
8879
(20.3-27 Nm).
6. Install Maxi-Fuse.
7. Install side cover.
8. Install saddlebags.
Figure 2-35. Removing Filler Strip
5.
Remove fastener holding support to support bracket.
6.
Remove fastener holding saddlebag support to fender
support bracket. See Touring Models Service Manual.
7.
Remove the three fasteners holding the passenger
backrest mounting bracket. Remove the rear saddlebag
bracket. See 2.15 PASSENGER BACKREST.
8.
Loosen but do not remove the rear docking point fas-
tener and the front docking point fastener. Fold the dock-
ing points bracket out of the way.
9.
Remove the support bracket and trim.
10. Remove fasteners holding support to muffler.
11. Remove fasteners holding support and remove support.
12. Repeat for opposite side.
2-30
2004 FLHTCSE: Chassis
HOME
f2249a2x
2
1
3
5
8
4
15
9
9
7
14
6
13
14
10
12
11
1. Rear saddlebag bracket
2. Clip nut
3. Filler strip
4. Washer
5. Support bracket
6. Locknut
7. Fastener and washer
8. Front saddlebag bracket
9. Receptacle
10. Nut
11. Fastener
12. Support
13. Fastener
14. Fastener and washer
15. Fastener and washer
Figure 2-36. Saddlebag Support Components
2004 FLHTCSE: Chassis
2-31
HOME
MUFFLER END CAP
2.17
REPLACEMENT
10553
1. See Figure 2-37. Loosen and remove three fasteners
holding muffler end cap in place. Remove end cap.
2.
Install muffler end cap, align holes. Install and tighten
fasteners.
Figure 2-37. Muffler End Cap Fastener Locations
2-32
2004 FLHTCSE: Chassis
HOME
SPECIFICATIONS
3.1
Table 3-1. General
Table 3-3. Oiling System
Number of cylinders
2
Twin gerotor, dual scavenge, crank mounted
Pump
Type
4-cycle, 45˚, air-cooled
and driven, internal oil pump, dry sump
100 ft-lbs (138 Nm)
30-38 psi (207-262 kN/m2) at
Torque
Pressure
2000 RPM and normal operating temperature
@ 3500 RPM
of 230˚ F (110˚ C)
Bore
3.875 in. (98.425 mm)
10 micron media,
Stroke
4.375 in. (111.125 mm)
Filtration
filtered between pump and engine
Piston displacement (approx.)
103 cu. in. (1690 cc)
Cooling
Thermostat controlled oil cooler
Compression ratio
9.0:1
Combustion chamber
Hemispherical
Twin cams, chain driven with
Cam system
spring loaded tensioners
Max. sustained engine speed
5800 RPM
Idle speed
1000 RPM ± 50
Weight
165 lbs (74.8 kg)
Table 3-2. Ignition System
Sequential, non waste spark,
Type
MAP-N control
Ignition timing:
20˚-30˚
1050 RPM (hot idle)
Spark plug size
12 mm
Spark plug type
Harley-Davidson 6R12
Spark plug gap
0.038-0.043 in. (0.97-1.09 mm)
Spark plug torque
12-18 ft-lbs (16.3-24.4 Nm)
2004 FLHTCSE: Engine
3-1
HOME
MANUFACTURING TOLERANCES
3.2
Table 3-4. Rocker Arms
Table 3-10. Pistons
IN.
MM
IN.
MM
Shaft fit in bushing
0.0005-0.0020
0.013-0.051
Fit in cylinder
0.0014-0.0025
0.036-0.064
(loose)
Ring end gap:
End clearance
0.003-0.013
0.08-0.033
Top compression ring
0.010-0.020
0.254-0.508
Bushing fit in rocker arm
0.002-0.004
0.051-0.102
(tight)
2nd compression ring
0.014-0.024
0.3556-0.6096
Oil control ring
0.010-0.050
0.25-1.27
Table 3-5. Rocker Arm Shaft
Ring side clearance:
Top compression ring
0.0012-0.0037
0.030-0.094
IN.
MM
2nd compression ring
0.0012-0.0037
0.030-0.094
Shaft fit in rocker arm
0.0007-0.0022
0.018-0.056
support plate (loose)
Oil control ring
0.0031-0.0091
0.079-0.231
Piston pin fit (loose)
0.0002-0.0005
0.005- 0.013
Table 3-6. Hydraulic Lifters
Table 3-11. Connecting Rods
IN.
MM
Fit in crankcase (loose)
0.0008-0.0020
0.02-0.05
IN.
MM
Piston pin fit (loose)
0.0003-0.0007
0.008-0.018
Table 3-7. Cylinder Heads
Side play between
0.005-0.015
0.13-0.38
flywheels
IN.
MM
Connecting rod to
0.0004-0.0017
0.0102-0.0432
Valve guide in head (tight)
0.0020-0.0033
0.051-0.084
crankpin (loose)
Valve seat in head (tight)
0.003-0.0045
0.076-0.114
Head gasket surface
Table 3-12. Flywheels
0.006
0.0152
(flatness)
IN.
MM
Table 3-8. Valves
Runout
0.000-0.010
0.0-0.25
(flywheels at rim)
IN.
MM
Runout
0.000-0.002
0.0-0.05
(shaft at flywheel)
Fit in guide (exhaust)
0.0015-0.0033
0.038-0.084
Fit in guide (intake)
0.0008-0.0026
0.020-0.066
End play
0.003-0.010
0.076-0.254
Seat width
0.040-0.062
1.02-1.58
Stem protrusion from
Table 3-13. Crankshaft (Roller) Bearing
1.990-2.024
50.55-51.41
cylinder head boss
IN.
MM
Roller bearing fit (loose)
0.0002-0.0015
0.005-0.038
Table 3-9. Valve Spring Assembly
Crankshaft runout
0.0-0.003
0.0-0.076
PRESSURE
DIMENSION
Bearing fit in
0.0038-0.0054
0.097-0.137
crankcase (tight)
Closed
165 lbs (75 kg).
1.820 in (46.2 mm).
Bearing inner race on
Open
416 lbs (189 kg)
1.290 in. (32.7 mm)
0.0001-0.0010
0.0025-0.0254
crankshaft (tight)
Free length
n/a
2.210 in (56.1 mm)
3-2
2004 FLHTCSE: Engine
HOME
SERVICE WEAR LIMITS
3.3
Table 3-14. Rocker Arm/Rocker Shaft
Table 3-18. Cylinders
REPLACE IF WEAR EXCEEDS
REPLACE IF WEAR EXCEEDS
IN.
MM
IN.
MM
Shaft fit in bushing (loose)
0.0035
0.089
Taper
0.002
0.051
End clearance
0.025
0.635
Out of round
0.002
0.051
Shaft fit in rocker arm
Warpage of gasket or
0.0035
0.089
0.006
0.152
support plate (loose)
O-ring surfaces: top
Warpage of gasket or
0.004
0.102
O-ring surfaces: base
Table 3-15. Hydraulic Lifters
REPLACE IF WEAR EXCEEDS
Table 3-19. Cylinder Bore
IN.
MM
REPLACE IF WEAR EXCEEDS
Fit in crankcase
0.003
0.08
IN.
MM
Roller fit
0.0015
0.038
Standard
3.877
98.48
Roller end clearance
0.015
0.38
0.005 in. oversize
3.882
98.60
0.010 in. oversize
3.887
98.73
Table 3-16. Cam Support Plate
REPLACE IF WEAR EXCEEDS
Table 3-20. Pistons
IN.
MM
REPLACE IF WEAR EXCEEDS
Cam chain
0.080-0.090
2.03-2.29
IN.
MM
tensioner shoe
1/2 thickness of shoe
Fit in cylinder (loose)
0.003
0.076
Warpage
0.010
0.25
Piston pin fit (loose)
0.0008
0.020
Crankshaft bushing fit
0.0008-0.001
0.0203-0.0254
Top compression
0.030
0.762
Ring
2nd compression
0.034
0.863
Table 3-17. Cylinder Heads
end gap
Oil control ring rails
0.050
1.27
REPLACE IF WEAR EXCEEDS
Top compression
0.0045
0.11
Ring
IN.
MM
side
2nd compression
0.0045
0.11
clearance
Oil control ring rails
0.010
0.25
Valve guide (tight)
< 0.002
< 0.051
Valve seat (tight)
< 0.002
< 0.051
Head warpage
> 0.006
> 0.152
2004 FLHTCSE: Engine
3-3
HOME
Table 3-21. Connecting Rods
REPLACE IF WEAR EXCEEDS
IN.
MM
Piston pin fit (loose)
0.001
0.025
Side play between
0.020
0.51
flywheels
Fit on crankpin (loose)
0.002
0.05
Table 3-22. Flywheels
REPLACE IF WEAR EXCEEDS
IN.
MM
Flywheel runout at rim
0.015
0.38
Shaft runout at flywheel
0.003
0.08
End play
0.010
0.254
Table 3-23. Crankshaft Sprocket
Shaft Bearing
IN.
MM
Bearing fit (loose)
0.0015
0.038
Crankshaft runout
0.003
0.076
Bearing fit in
0.0038-0.0054
0.097-0.137
crankcase (tight)
Bearing inner race on
0.0001
0.0254
crankshaft (tight)
3-4
2004 FLHTCSE: Engine
HOME
TORQUE VALUES
3.4
ITEM
TORQUE
NOTES
Rocker housing bolts
120-168 in-lbs
13.6-18.9 Nm
page 3-9
Oil vent line crankcase fitting
130-150 in-lbs
14.7-16.9 Nm
page 3-17
Oil fittings
120-168 in-lbs
13.6-19.0 Nm
page 3-17
Chrome oil vent line nuts
60-80 in-lbs
6.8-9.0 Nm
page 3-17
Oil cooler to mounting backet
80-110 in-lbs
9.1-12.4 Nm
page 3-21
Transfer passage cover
90-120 in-lbs
10.2-13.5 Nm
page 3-23
Oil filter mount
130-150 in-lbs
14.7-16.9 Nm
page 3-23
Thermostat plug
15-20 ft-lbs
20.4-27.1 Nm
page 3-23
Oil filter adapter
12-16 ft-lbs
16.3-21.7 Nm
page 3-23
Thermostat plug
15-20 ft-lbs
20.4-27.1 Nm
page 3-24
2004 FLHTCSE: Engine
3-5
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