Harley Davidson 2004 Touring Models. Service Manual — page 28

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FLUID CONVERSIONS

C.2

UNITED STATES SYSTEM

BRITISH IMPERIAL SYSTEM

Unless otherwise specified, all fluid volume measurements

Fluid volume measurements in this Service Manual do not

in this Service Manual are expressed in United States

include the British Imperial (Imp.) system equivalents. The fol-

(U.S.) units-of-measure. See below:

lowing conversions exist in the British Imperial system:

●

1 pint (U.S.) = 16 fluid ounces (U.S.)

●

1 pint (Imp.) = 20 fluid ounces (Imp.)

●

1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.)

●

1 quart (Imp.) = 2 pints (Imp.)

●

1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.)

●

1 gallon (Imp.) = 4 quarts (Imp.)

Although the same unit-of-measure terminology as the U.S.

METRIC SYSTEM

system is used in the British Imperial (Imp.) system, the

actual volume of each British Imperial unit-of-measure differs

Fluid volume measurements in this Service Manual include

from its U.S. counterpart. The U.S. fluid ounce is larger than

the metric system equivalents. In the metric system, 1 liter (L)

the British Imperial fluid ounce. However, the U.S. pint, quart,

= 1,000 milliliters (mL). Should you need to convert from U.S.

and gallon are smaller than the British Imperial pint, quart,

units-of-measure to metric units-of-measure (or vice versa),

and gallon, respectively. Should you need to convert from

refer to the following:

U.S. units to British Imperial units (or vice versa), refer to the

following:

● fluid ounces (U.S.) x 29.574 = milliliters

● pints (U.S.) x 0.473 = liters

● fluid ounces (U.S.) x 1.042 = fluid ounces (Imp.)

● quarts (U.S.) x 0.946 = liters

● pints (U.S.) x 0.833 = pints (Imp.)

● gallons (U.S.) x 3.785 = liters

● quarts (U.S.) x 0.833 = quarts (Imp.)

● milliliters x 0.0338 = fluid ounces (U.S.)

● gallons (U.S.) x 0.833 = gallons (Imp.)

● liters x 2.114 = pints (U.S.)

● fluid ounces (Imp.) x 0.960 = fluid ounces (U.S.)

● liters x 1.057 = quarts (U.S.)

● pints (Imp.) x 1.201 = pints (U.S.)

● liters x 0.264 = gallons (U.S.)

● quarts (Imp.) x 1.201 = quarts (U.S.)

● gallons (Imp.) x 1.201 = gallons (U.S.)

C-2

Appendix C

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JAPANESE MAINSHAFT/COUNTERSHAFT

D.1

NOTE

Check the eight digit number stamped on the transmission

case just above the side door. If the third digit is “9,” then the

Mainshaft

transmission was built for Japan only. If the digit is “0,” then it

Plug

was built for all countries except Japan. See the instructions

which follow if servicing a Japanese transmission. For all

other transmissions, see Section 7.6 MAINSHAFT/COUN-

TERSHAFT.

DISASSEMBLY

NOTES

● Perform all steps if completely overhauling the transmis-

9411

sion assembly.

Figure D-2. Press Out Countershaft

● Perform steps 1-11 and 17-18 if replacing only the coun-

tershaft or one or more countershaft gears.

● Perform steps 1-5 and 12-18 if replacing only the main-

shaft or one or more mainshaft gears.

1WARNING

● Perform steps 1-6, 12, and 17-18 if replacing only the

Always wear proper eye protection when removing re-

side door bearings.

taining rings. Use the correct retaining ring pliers. Verify

that the tips of the pliers are not damaged or excessively

worn. Slippage may propel the ring with enough force to

1. Position the side door assembly on a bench with the

cause eye injury.

shafts pointing straight up, the mainshaft on the left hand

side. The mainshaft is the longer of the two shafts. See

Locate retaining ring just above the mainshaft 3rd gear

Figure D-3.

(spur). Move the retaining ring up approximately 3/8 inch

2. Slide off the mainshaft 2nd gear (spur).

(9.5 mm) towards the free end of the shaft. Turn side

door assembly upside down and verify that mainshaft

NOTE

3rd gear is still partially engaged with countershaft 3rd

gear.

To facilitate reassembly, label each gear as it is removed.

See Figure D-1.

3. Obtain the TRANSMISSION SHAFT RETAINING RING

CAUTION

PLIERS, Part No. J-5586.

Failure to move the retaining ring on the mainshaft can

cause countershaft 1st gear to contact mainshaft 3rd

gear when the countershaft is pressed out. On the other

hand, if the retaining ring is moved too far, loss of

9412

engagement between mainshaft 3rd gear and counter-

shaft 3rd gear can result in hard contact between these

two gears. Any hard contact can result in gear tooth

damage.

5. With the outboard side up, rest side door on parallel

blocks under ram of arbor press. Be sure that assembly

is flat and does not rest on dowel on inboard side.

6. Center countershaft under ram. Install mainshaft plug

into hole at end of countershaft. Slowly apply pressure

until countershaft is free. See Figure D-2. Remove main-

shaft plug.

Figure D-1. Note Gear Location During Disassembly

Appendix D D-1

HOME

9413

1. Mainshaft

9. Gold Spacer

2nd Gear

10. Countershaft

Retaining Ring

11.

5th Gear

Thrust Washer

12.

2nd Gear

3rd Gear

13.

3rd Gear

Split Cage Bearing

14.

1st Gear

15.

4th Gear

16. Blue Spacer

Figure D-3. Fully Assembled Side Door

Slide blue spacer and countershaft 4th gear (helical) off

Secure countershaft in a vise with the threaded end top-

threaded end of countershaft.

side. Be sure to install a pair of aluminum or brass jaw

inserts in vise to avoid parts damage. See Figure D-4.

D-2

Appendix D

HOME

17. Set the side door on a bench with the outboard side up.

9416

Remove retaining ring from the bearing bore.

NOTE

Countershaft

1st Gear

Depending upon whether one or both shafts were removed,

replace one or both side door bearings. Always replace the

bearing if the shaft was pressed out.

18. Turn side door over so that the inboard side is up and

place on flat plate under ram of arbor press. Apply pres-

sure to outer race to press bearing from bore.

CLEANING AND INSPECTION

Aluminum

Jaws

Clean all parts in cleaning solvent and blow dry with

compressed air.

Figure D-4. Disassemble/Assemble Countershaft

Check gear teeth for damage. Replace the gears if they

are pitted, scored, rounded, cracked or chipped.

Inspect the engaging dogs on the gears. Replace the

Remove retaining ring just above the countershaft 1st

gears if the dogs are rounded, battered or chipped.

gear (spur with single row of indents on teeth). Remove

thrust washer and countershaft 1st gear. Gently pull

Inspect the side door bearings. Bearings must rotate

apart the split cage bearing and remove. Remove sec-

freely without drag. Replace the bearings if pitted,

ond thrust washer.

grooved, or if the shafts were removed.

10.

Remove retaining ring above the countershaft 3rd gear

(spur). Remove countershaft 3rd gear.

11.

Remove retaining ring just above the countershaft 2nd

9415

gear (spur). Remove thrust washer and countershaft

2nd gear. Gently pull apart the split cage bearing and

remove.

Mainshaft

1st Gear

12.

Center mainshaft under ram of arbor press. Install main-

shaft plug into hole at end of mainshaft. Slowly apply

pressure until mainshaft is free. Remove mainshaft plug.

13.

Slide gold spacer, mainshaft 4th gear (helical), split cage

bearing and thrust washer off end of mainshaft.

14.

Secure the mainshaft in a vise with the longer splined

end at the top. Be sure to install a pair of aluminum or

brass jaw inserts in vise to avoid parts damage. See Fig-

ure D-5.

15.

Remove retaining ring above the mainshaft 1st gear

(spur with double row of indents on teeth). Remove

mainshaft 1st gear.

16.

Remove retaining ring just above the mainshaft 3rd gear

Figure D-5. Disassemble/Assemble Mainshaft

(spur). Remove the thrust washer and mainshaft 3rd

gear. Gently pull apart the split cage bearing and

remove. Remove the second thrust washer. Remove the

last retaining ring, which was moved out of the groove

before the countershaft was pressed out.

Appendix D D-3

HOME

ASSEMBLY

9417

Mainshaft

Plug

NOTES

● Perform all steps if the transmission assembly was com-

pletely overhauled.

● Perform steps 1-5 and 12-24 if only the countershaft or

one or more countershaft gears were replaced.

● Perform steps 1-11 and 20-24 if only the mainshaft or

one or more mainshaft gears were replaced.

● Perform steps 1-4, 11, and 18-24 if only the side door

bearings were replaced.

1. With the outboard side up, place side door on flat plate

under ram of arbor press.

NOTE

Note the two drill points between the bearing bores on the

Figure D-6. Press In Countershaft

side door. See Figure D-7. Two drill points indicate that the

side door must be fitted with the new style 12mm wide bear-

ings. Installation of the old style 14mm wide bearings would

6. Secure the mainshaft in a vise with the longer splined

cover the retaining ring grooves.

end at the top. Be sure to install a pair of aluminum or

brass jaw inserts in vise to avoid parts damage.

2. Position new bearing over bore with the number stamp

7. Install new retaining ring approximately 3/8 inch (9.5

topside.

mm) below the bottom retaining ring groove.

3. Applying pressure to outer race, press bearing into bore

8. Slide thrust washer down mainshaft until it contacts

until firm contact is made with the counterbore.

retaining ring. Lightly coat split cage bearing with oil and

install in race just above thrust washer. Install mainshaft

1WARNING

3rd gear (spur) with the shifter dogs down. Install second

thrust washer. Install new retaining ring in groove just

Always wear proper eye protection when installing re-

above the bearing race.

taining rings. Use the correct retaining ring pliers. Verify

9. With the fork groove up, slide mainshaft 1st gear (spur

that the tips of the pliers are not damaged or excessively

with double row of indents on teeth) down mainshaft until

worn. Slippage may propel the ring with enough force to

it contacts retaining ring. Install new retaining ring in

cause eye injury.

groove above the gear. See Figure D-5.

4. With the flat side in towards the bearing (beveled side

out), install new retaining ring in bearing bore.

CAUTION

NOTE

Verify that the mainshaft 1st gear has the double row of

Depending upon the level of disassembly, replace one or

indents on teeth. Using a gear with a single row of

both side door bearings. Always replace the bearing if the

indents will result in transmission damage.

shaft was pressed out.

10. Slide thrust washer down the mainshaft until it contacts

5. Obtain the TRANSMISSION SHAFT RETAINING RING

the retaining ring. Lightly coat the split cage bearing

PLIERS, Part No. J-5586.

(double roller) with oil and install in race above the thrust

washer. Install mainshaft

4th gear

(helical) over the

bearing with the shifter dogs down. Install gold spacer.

1WARNING

11. With the inboard side up, place side door on flat plate

Always use new retaining rings when assembling the

under ram of arbor press. Holding mainshaft assembly

mainshaft and countershaft. Reusing retaining rings can

together, remove from vise and position over bearing

cause the transmission to become “locked” during

bore in side door. Install mainshaft plug into hole at end

motorcycle operation, a situation which could result in

of mainshaft. Supporting inner race of bearing, press

death or serious injury.

mainshaft into bearing bore. Remove mainshaft plug.

D-4

Appendix D

HOME

21. Return side door assembly to bench. Position with the

shafts pointing straight up, the mainshaft on the left hand

side.

Mainshaft

Countershaft

Locknut

22. Move partially installed retaining ring into groove just

above the mainshaft 3rd gear.

23. Install mainshaft 2nd gear (spur) with the fork groove

down.

The final assembly appears as shown in Figure D-3.

24. Install spacer and locknut on the threaded end of each

shaft and tighten the nuts until finger tight. See Figure D-

Two Drill

Points

NOTE

For final tightening of the locknuts and installation of the side

door, see Section

7.6

MAINSHAFT/COUNTERSHAFT,

9414

INSTALLATION.

Figure D-7. Install Mainshaft/Countershaft Locknuts

12.

Secure the countershaft in a vise with the threaded end

topside. Be sure to install a pair of aluminum or brass

jaw inserts in vise to avoid parts damage.

13.

Lightly coat split cage bearing with oil and install in race

next to the countershaft 5th gear.

14.

Install countershaft 2nd gear (spur) over the bearing with

the shifter dogs up. Install thrust washer and new retain-

ing ring.

15.

Install countershaft 3rd gear (spur) with the fork groove

down. Install new retaining ring in groove above the

gear.

16.

Slide the thrust washer down the countershaft until it

contacts the retaining ring. Lightly coat the split cage

bearing with oil and install in the race just above the

thrust washer. Install countershaft 1st gear (spur with

single row of indents on teeth) with the taper up. Install

second thrust washer and new retaining ring. See Fig-

ure D-4.

17.

Install countershaft

4th gear (helical) with the sleeve

down. Install blue spacer with the taper up.

18.

With the inboard side up, place side door on flat plate

under ram of arbor press. Support inner race of bearing.

19.

Holding countershaft assembly together, remove from

vise. Raising mainshaft 3rd gear until it contacts partially

installed retaining ring, position countershaft over bear-

ing bore. Verify that taper on blue spacer is facing

towards the bearing.

20.

Place mainshaft plug at end of countershaft. Be sure

that mainshaft and countershaft gears mesh and that

assembly is square. Press countershaft into bearing

bore. Remove mainshaft plug. See Figure D-6.

Appendix D D-5

HOME

NOTES

D-6

Appendix D

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TROUBLESHOOTING

1.1

10. Ignition timing incorrect due to faulty ignition coil, ignition

GENERAL

module or sensors (MAP, CKP and/or TSM/TSSM).

The following check list of possible operating troubles and

11. Engine lubricant too heavy (winter operation).

their probable causes will be helpful in keeping your motorcy-

NOTE

cle in good operating condition. More than one of these con-

Always disengage clutch for cold weather starts.

ditions may be causing the trouble and all should be carefully

checked.

12. Sticking or damaged valve or push rod wrong length.

13. Primary cam sprocket spline sheared or missing spacer.

1WARNING

The troubleshooting section of this manual is intended

Starts Hard

solely as a guide to diagnosing problems. Carefully read

Spark plugs in bad condition, have improper gap or are

the appropriate sections of this manual before perform-

partially fouled.

ing any work. Improper repair and/or maintenance could

result in death or serious injury.

Spark plug cables in bad condition.

Battery nearly discharged.

ENGINE

Loose wire connection at one of the battery terminals,

ignition coil or plug between ignition sensor and module.

Carburetor controls not adjusted correctly.

Starter Motor Does Not Operate or Does

Water or dirt in fuel system and carburetor.

Not Turn Engine Over

Intake air leak.

1. Ignition/Light Key Switch not in IGNITION position.

Fuel tank vent hose and vapor valve plugged, or carbu-

2. Engine Stop switch in the OFF position.

retor fuel line closed off and restricting fuel flow.

3. Discharged battery, loose or corroded connections

Enrichener valve inoperative.

(solenoid chatters).

10. Engine lubricant too heavy (winter operation).

4. TSM/TSSM BAS tripped and Ignition/Light Key Switch

NOTE

not cycled to OFF and then back to IGNITION.

Always disengage clutch for cold weather starts.

5. Starter control circuit, relay or solenoid faulty.

11. Ignition not functioning properly (possible sensor failure).

6. Electric starter shaft pinion gear not engaging or over-

running clutch slipping.

12. Faulty ignition coil.

13. Valves sticking.

Engine Turns Over But Does Not Start

Starts But Runs Irregularly or Misses

1. Fuel tank empty.

2. Fuel supply valve turned to OFF.

1. Spark plugs in bad condition or partially fouled.

3. Fouled spark plugs.

2. Spark plug cables in bad condition and leaking.

4. Engine flooded with gasoline as a result of over use of

3. Spark plug gap too close or too wide.

enrichener.

4. Faulty ignition coil, module and/or sensor.

5. Fuel valve or filter clogged.

5. Battery nearly discharged.

6. Vacuum hose to automatic fuel supply valve discon-

6. Damaged wire or loose connection at battery terminals,

nected, leaking or pinched.

ignition coil, or plug between ignition sensor and module.

7. Discharged battery, loose or broken battery terminal

7. Intermittent short circuit due to damaged wire insulation.

connections.

8. Water or dirt in fuel system, carburetor or filter.

8. Loose wire connection at coil, battery or plug between

9. Fuel tank vent system plugged or carburetor vent line

ignition sensor and module.

closed off.

Spark plug cables in bad condition and shorting, cable

10. Carburetor controls misadjusted.

connections loose, or cables connected to wrong cylin-

ders.

11. Damaged carburetor.

2004 Touring: Maintenance

1-1

HOME

12. Loose or dirty ignition module connector at crankcase.

Engine to transmission mounting bolts loose.

13. Faulty MAP and/or CKP Sensor.

Upper engine mounting bracket loose.

14. Incorrect valve timing.

Ignition timing incorrect/poorly tuned engine.

15. Weak or broken valve springs.

Internal engine problem.

16. Damaged intake or exhaust valve.

Broken frame.

9. Stabilizer links worn or loose.

A Spark Plug Fouls Repeatedly

10. Rubber mounts loose or worn.

11. Rear fork pivot shaft nuts loose.

Fuel mixture too rich or enrichener left out too long.

12. Front engine mounting bolts loose.

Incorrect spark plug for the kind of service.

Piston rings badly worn or broken.

Check Engine Lamp Illuminates During

Valve guides or seals badly worn.

Operation

Fault detected. Check for trouble codes.

Pre-Ignition or Detonation (Knocks or

Pings)

1. Fuel octane rating too low.

LUBRICATION SYSTEM

2. Faulty spark plugs.

3. Incorrect spark plug for the kind of service.

4. Excessive carbon deposit on piston head or in combus-

Oil Does Not Return To Oil Pan

tion chamber.

Oil pan empty.

5. Ignition timing advanced due to faulty sensor inputs

Oil pump not functioning.

(MAP, CKP).

3. Restricted oil lines or fittings.

Restricted oil filter.

Overheating

5. Oil pump misaligned or in poor condition.

Insufficient oil supply or oil not circulating.

O-ring damaged or missing from oil pump/crankcase

Insufficient air flow over engine.

junction (also results in poor engine performance).

Heavy carbon deposit.

Ignition timing retarded due to faulty MAP and/or CKP

Engine Uses Too Much Oil Or Smokes

Sensor.

Excessively

Leaking valve.

Oil pan overfilled.

Restricted oil return line to pan.

Valve Train Noise

Restricted breather operation.

Low oil pressure caused by oil feed pump not functioning

Restricted oil filter.

properly or oil passages obstructed.

Oil pump misaligned or in poor condition.

Faulty hydraulic lifters.

Piston rings badly worn or broken.

Bent push rod.

Valve guides or seals worn.

Incorrect push rod length.

O-ring damaged or missing from oil pump/crankcase

Rocker arm binding on shaft.

junction (also results in poor engine performance).

Valve sticking in guide.

Chain tensioner spring or shoe worn.

Engine Leaks Oil From Case, Push Rods,

Hoses, Etc.

Excessive Vibration

Loose parts.

1. Wheels and/or tires worn or damaged.

Imperfect seal at gaskets, push rod cover, washers, etc.

2. Engine/transmission/motorcycle not aligned properly.

Restricted oil return line to pan.

Restricted breather hose to air cleaner.

3. Primary chain badly worn or links tight as a result of

insufficient lubrication or misalignment.

Restricted oil filter.

1-2

2004 Touring: Maintenance

HOME

6. Oil pan overfilled.

Inlet valve and/or valve seat worn or damaged.

7. Rocker housing gasket (bottom) installed upside down.

Float misadjusted.

5. Leaky or damaged float.

Low Oil Pressure

Excessive “pumping” of hand throttle grip.

1. Oil pan underfilled.

See TROUBLESHOOTING CHART in Section 4.

2. Faulty low oil pressure switch.

3. Oil pump O-ring(s) damaged or missing.

4. Oil pressure relief valve stuck in open position.

TRANSMISSION

5. Ball or clean out plug missing from cam support plate.

Transmission Shifts Hard

High Oil Pressure

1. Clutch dragging slightly.

1. Oil pan overfilled.

Primary chaincase overfilled with lubricant.

2. Oil pressure relief valve stuck in closed position.

Corners worn off shifter clutch dogs.

4. Shifter return spring bent or broken.

Bent shifter rod.

ELECTRICAL SYSTEM

6. Shifter forks sprung.

7. Transmission lubrication too heavy (winter operation).

Alternator Does Not Charge

1. Module not grounded.

Jumps Out Of Gear

2. Engine ground wire loose or broken.

1. Shifter rod improperly adjusted.

3. Faulty regulator-rectifier module.

2. Shifter drum damaged.

4. Loose or broken wires in charging circuit.

3. Shifter engaging parts (inside transmission) badly worn

5. Faulty stator and/or rotor.

and rounded.

4. Shifter forks bent.

Alternator Charge Rate Is Below Normal

Damaged gears.

1. Weak or damaged battery.

2. Loose connections.

Clutch Slips

3. Faulty regulator-rectifier module.

Clutch controls improperly adjusted.

4. Faulty stator and/or rotor.

Insufficient clutch spring tension.

Worn friction discs.

Speedometer Operates Erratically

1. Contaminated speedometer sensor (remove sensor and

Clutch Drags Or Does Not Release

clean off metal particles).

2. Loose connections.

Clutch controls improperly adjusted.

Lubricant level too high in primary chaincase.

Primary chain badly misaligned.

CARBURETOR

Clutch discs warped.

Insufficient clutch spring tension.

Carburetor Floods

Clutch Chatters

1. Dirt or other foreign matter between valve and its seat.

2. Inlet valve sticking.

Friction discs or steel discs worn or warped.

2004 Touring: Maintenance

1-3

HOME

BRAKES

HANDLING

Brake Does Not Hold Normally

Irregularities

Master cylinder reservoir low on fluid.

Improperly loaded motorcycle. Non-standard equipment

on the front end such as heavy radio receivers, extra

Brake system contains air bubbles.

lighting equipment or luggage tends to cause unstable

Master or wheel cylinder piston worn or parts damaged.

handling.

Incorrect air suspension pressure.

Brake pads contaminated with grease or oil.

Damaged tire(s) or improper front-rear tire combination.

Brake pads badly worn- friction material 0.04 inch (1.02

mm) thick or less.

Irregular or peaked front tire tread wear.

Brake disc badly worn or warped.

Incorrect tire pressure.

Brake fades due to heat build up - brake pads dragging

Shock absorber not functioning normally.

or excessive braking.

Loose wheel axle nuts. Tighten to recommended tight-

Brake drags - insufficient brake pedal free play.

ness.

Excessive wheel hub bearing play.

Improper vehicle alignment.

10.

Steering head bearings improperly adjusted. Correct

adjustment and replace pitted or worn bearings and

races.

11.

Tire and wheel unbalanced.

12.

Rims and tires out-of-round or eccentric with hub.

13.

Rims and tires out-of-true sideways.

14.

Shock absorber improperly adjusted.

15.

Worn engine stabilizer links.

16.

Damaged rear engine isolation mounts.

17.

Swingarm pivot shaft nut improperly tightened or assem-

bled.

1-4

2004 Touring: Maintenance

HOME

SHOP PRACTICES

1.2

REPAIR NOTES

Disassembly and Assembly

Always assemble or disassemble one part at a time. Do not

General maintenance practices are given in this section. All

work on two assemblies simultaneously. Be sure to make all

special tools and torque values are noted at the point of use

necessary adjustments. Recheck your work when finished.

and all required parts or materials can be found in the appro-

Be sure that everything is done.

priate PARTS CATALOG.

Operate the motorcycle to perform any final check or adjust-

ments. If all is correct, the motorcycle is ready to go back to

Safety

the customer.

Safety is always the most important consideration when per-

forming any job. Be sure you have a complete understanding

Checking Torques on Fasteners with Lock

of the task to be performed. Use common sense. Use the

proper tools. Don’t just do the job - do the job safely.

Patches

To check the torque on a fastener that has a lock patch:

Removing Parts

Set the torque wrench for the lowest setting in the speci-

fied torque range.

Always consider the weight of a part when lifting. Use a hoist

whenever necessary. Do not lift heavy parts by hand. A hoist

Attempt to tighten fastener to set torque. If fastener does

and adjustable lifting beam or sling are needed to remove

not move and lowest setting is satisfied (torque wrench

some parts. The lengths of chains or cables from the hoist to

clicks), then the proper torque has been maintained.

the part should be equal and parallel, and should be posi-

tioned directly over the center of the part. Be sure that no

obstructions will interfere with the lifting operation. Never

leave a part suspended in mid-air.

REPAIR AND REPLACEMENT

Always use blocking or proper stands to support the part that

PROCEDURES

has been hoisted. If a part cannot be removed, verify that all

bolts and attaching hardware have been removed. Check to

see if any parts are in the way of the part being removed.

Hardware and Threaded Parts

When removing hoses, wiring or tubes, always tag each part

Install helical thread inserts when inside threads in castings

to ensure proper installation.

are stripped, damaged or not capable of withstanding speci-

fied torque.

Cleaning

Replace bolts, nuts, studs, washers, spacers and small com-

mon hardware if missing or in any way damaged. Clean up or

If you intend to reuse parts, follow good shop practice and

repair minor thread damage with a suitable tap or die.

thoroughly clean the parts before assembly. Keep all dirt out

of parts; the unit will perform better and last longer. Seals, fil-

Replace all damaged or missing lubrication fittings.

ters and covers are used in this motorcycle to keep out envi-

Use Teflon tape on pipe fitting threads.

ronmental dirt and dust. These items must be kept in good

condition to ensure satisfactory operation.

Clean and inspect all parts as they are removed. Be sure all

Wiring, Hoses and Lines

holes and passages are clean and open. After cleaning,

cover all parts with clean lint-free cloth, paper or other mate-

Replace hoses, clamps, electrical wiring, electrical switches

rial. Be sure the part is clean when it is installed.

or fuel lines if they do not meet specifications.

Always clean around lines or covers before they are

removed. Plug, tape or cap holes and openings to keep out

dirt, dust and debris.

Instruments and Gauges

Always verify cleanliness of blind holes before assembly.

Replace broken or defective instruments and gauges.

Tightening screws with dirt, water or oil in the holes can

Replace dials and glass that are so scratched or discolored

cause castings to crack or break.

that reading is difficult.

2004 Touring: Maintenance

1-5

HOME

Bearings

Seals should not be removed unless necessary. Only remove

seals if required to gain access to other parts or if seal dam-

Anti-friction bearings must be handled in a special way. To

age or wear dictates replacement.

keep out dirt and abrasives, cover the bearings as soon as

Leaking oil or grease usually means that a seal is damaged.

they are removed from the package.

Replace leaking seals to prevent overheated bearings.

Wash bearings in a non-flammable cleaning solution. Knock

Always discard seals after removal. Do not use the same

out packed lubricant inside by tapping the bearing against a

seal twice.

wooden block. Wash bearings again. Cover bearings with

clean material after setting them down to dry. Never use com-

pressed air to dry bearings.

O-Rings (Preformed Packings)

Coat bearings with clean oil. Wrap bearings in clean paper.

Always discard O-rings after removal. Replace with new O-

rings. To prevent leaks, lubricate the O-rings before installa-

Be sure that the chamfered side of the bearing always faces

tion. Apply the same type of lubricant as that being sealed.

the shoulder (when bearings installed against shoulders).

Be sure that all gasket, O-ring and seal mating surfaces are

Lubricate bearings and all metal contact surfaces before

thoroughly clean before installation.

pressing into place. Only apply pressure on the part of the

bearing that makes direct contact with the mating part.

Gears

Always use the proper tools and fixtures for removing and

Always check gears for damaged or worn teeth.

installing bearings.

Remove burrs and rough spots with a honing stone or crocus

Bearings do not usually need to be removed. Only remove

cloth before installation. Lubricate mating surfaces before

bearings if necessary.

pressing gears on shafts.

Bushings

Shafts

If a shaft does not come out easily, check that all nuts, bolts

Do not remove a bushing unless damaged, excessively worn

or retaining rings have been removed. Check to see if other

or loose in its bore. Press out bushings that must be

parts are in the way before using force.

replaced.

Shafts fitted to tapered splines should be very tight. If shafts

When pressing or driving bushings, be sure to apply pres-

are not tight, disassemble and inspect tapered splines. Dis-

sure in line with the bushing bore. Use a bearing/bushing

card parts that are worn. Be sure tapered splines are clean,

driver or a bar with a smooth, flat end. Never use a hammer

dry and free of burrs before putting them in place. Press mat-

to drive bushings.

ing parts together tightly.

Inspect the bushing and the mated part for oil holes. Be sure

Clean all rust from the machined surfaces of new parts.

all oil holes are properly aligned.

Part Replacement

Gaskets

Always replace worn or damaged parts with new parts.

Always discard gaskets after removal. Replace with new gas-

kets. Never use the same gasket twice (unless instructed

CLEANING

otherwise). Be sure that gasket holes match up with holes in

the mating part.

If a gasket must be made, be sure to cut holes that match up

Part Protection

with the mating part. Serious damage can occur if any flange

Before cleaning, protect rubber parts (such as hoses, boots

holes are blocked by the gasket. Use material that is the right

and electrical insulation) from cleaning solutions. Use a

type and thickness.

grease-proof barrier material. Remove the rubber part if it

cannot be properly protected.

Lip Type Seals

Cleaning Process

Lip seals are used to seal oil or grease and are usually

installed with the sealing lip facing the contained lubricant.

Any cleaning method may be used as long as it does not

result in parts damage. Thorough cleaning is necessary for

Seal orientation, however, may vary under different applica-

proper parts inspection. Strip rusted paint areas to bare

tions.

metal before repainting.

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2004 Touring: Maintenance

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Rust or Corrosion Removal

Bearings

Remove rust and corrosion with a wire brush, abrasive cloth,

Remove shields and seals from bearings before cleaning.

sand blasting, vapor blasting or rust remover. Use buffing

Clean bearings with permanent shields and seals in solution.

crocus cloth on highly polished parts that are rusted.

Clean open bearings by soaking them in a petroleum clean-

ing solution. Never use a solution that contains chlorine.

Let bearings stand and dry. Do not dry using compressed air.

Do not spin bearings while they are drying.

2004 Touring: Maintenance

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HOME

TOOL SAFETY

1.3

AIR TOOLS

PUNCHES/CHISELS

● Always use approved eye protection equipment when

● Never use a punch or chisel with a chipped or mush-

performing any task using air-operated tools.

roomed end; dress mushroomed chisels and punches

with a file.

● On all power tools, use only recommended accessories

with proper capacity ratings.

● Hold a chisel or a punch with a tool holder if possible.

● Do not exceed air pressure ratings of any power tools.

● When using a chisel on a small piece, clamp the piece

● Bits should be placed against work surface before air

firmly in a vise, and chip toward the stationary jaw.

hammers are operated.

● Wear approved eye protection when using these tools.

● Disconnect the air supply line to an air hammer before

● Protect bystanders with approved eye protection.

attaching a bit.

● Never point an air tool at yourself or another person.

SCREWDRIVERS

● Protect bystanders with approved eye protection.

● Don’t use a screwdriver for prying, punching, chiseling,

WRENCHES

scoring, or scraping.

● Use the right type of screwdriver for the job; match the

● Never use an extension on a wrench handle.

tip to the fastener.

● If possible, always pull on a wrench handle and adjust

your stance to prevent a fall if something lets go.

● Don’t interchange POZIDRIV®, PHILLIPS®, or REED

AND PRINCE screwdrivers.

● Never cock a wrench.

● Screwdriver handles are not intended to act as insula-

● Never use a hammer on any wrench other than a Strik-

tion; don’t use on live electrical circuits.

ing Face wrench.

● Don’t use a screwdriver with rounded edges because it

● Discard any wrench with broken or battered points.

will slip - redress with a file.

● Never use a pipe wrench to bend, raise, or lift a pipe.

RATCHETS AND HANDLES

PLIERS/CUTTERS/PRYBARS

● Periodically clean and lubricate ratchet mechanisms with

● Plastic or vinyl covered pliers handles are not intended

a light grade oil. Do not replace parts individually; ratch-

to act as insulation; don’t use on live electrical circuits.

ets should be rebuilt with the entire contents of service

● Don’t use pliers or cutters for cutting hardened wire

kit.

unless they were designed for that purpose.

● Never hammer or put a pipe extension on a ratchet or

● Always cut at right angles.

handle for added leverage.

● Don’t use any prybar as a chisel, punch, or hammer.

● Always support the ratchet head when using socket

extensions, but do not put your hand on the head or you

may interfere with the action of its reversing mechanism.

HAMMERS

● When breaking loose a fastener, apply a small amount

● Never strike one hammer against a hardened object,

of pressure as a test to be sure the ratchet’s gear wheel

such as another hammer.

is engaged with the pawl.

● Always grasp a hammer handle firmly, close to the end.

● Strike the object with the full face of the hammer.

SOCKETS

● Never work with a hammer which has a loose head.

● Never use hand sockets on power or impact wrenches.

● Discard hammer if face is chipped or mushroomed.

● Select the right size socket for the job.

● Wear approved eye protection when using striking tools.

● Protect bystanders with approved eye protection.

● Never cock any wrench or socket.

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2004 Touring: Maintenance

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● Select only impact sockets for use with air or electric

STORAGE UNITS

impact wrenches.

● Replace sockets showing cracks or wear.

● Don’t open more than one loaded drawer at a time.

Close each drawer before opening up another.

● Keep sockets clean.

● Close lids and lock drawers and doors before moving

● Always use approved eye protection when using power

storage units.

or impact sockets.

● Don’t pull on a tool cabinet; push it in front of you.

● Set the brakes on the locking casters after the cabinet

has been rolled to your work.

2004 Touring: Maintenance

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NOTES

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2004 Touring: Maintenance

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SCHEDULED MAINTENANCE TABLE

1.4

The scheduled maintenance table beginning on this page

lists the maintenance requirements for Touring models. If you

Lubricant

Part Number

are familiar with the procedures, just reference the table for

Engine Oil

See Table 1-1.

the recommended maintenance interval as well as the

Hydraulic Fork Oil, Type “E”

99884-80 (16 oz.)

required specifications. On the other hand, if more informa-

tion is needed, turn to page 14 for the start of more detailed

D.O.T. 5 Hydraulic Brake Fluid

99902-77 (12 oz.)

service procedures. For your added convenience, the adja-

Quart

99892-84

cent chart lists the part numbers of required lubricants.

Semi-Synthetic

Case of Quarts

98853-96

Transmission Lubricant

Gallon

99891-84

Case of Gallons

98852-96

Quart

99887-84

Primary Chaincase

Lubricant

Gallon

99886-84

Super Oil

Clutch and Throttle Cable Lubricant

94968-85TV

Special Purpose Grease

Steering Head Bearing Lubricant

99857-97 (cartridge)

Electrical Contact Grease

99861-90

SCHEDULED MAINTENANCE TABLE

Service

Operation

Data

Check condition and

Battery

clean connections.

Oil level

Separate HOT and

COLD checks per

procedure.

Engine Oil

Oil capacity

4 qt. (3.8 L) per

chart in procedure.

Hand tighten

Engine

1/2-3/4 turn after

Oil Filter

gasket contact.

R - Replace or change

I - Inspect (adjust, clean or replace as required)

L - Lubricate (with specified lubricant)

X - Perform

T - Tighten to proper torque

D - Disassemble (lube and inspect as required)

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2004 Touring: Maintenance

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Service

Operation

Data

Deflection

Cold: 5/8-7/8 in.

Primary Chain

(15.9-22.2 mm)

Tension

Hot: 3/8-5/8 in.

(9.5-15.9 mm)

Lubricant capacity

32 oz (946 mL)

Primary Chain

Part No.’s

Lubricant

99887-84 (qt)

99886-84 (gal)

Free play at

adjuster screw

1/2-1 turn

Clutch

Free play at hand

Adjustment

lever

1/16-1/8 in.

(1.6-3.2 mm)

Lubricant level

Dipstick at FULL

with motorcycle

level and filler plug

resting on threads.

Lubricant capacity

20-24 oz (590-710

mL) Part No.’s

Transmission

99892-84 (qt),

Lubricant

99891-84 (gal)

Transmission drain

plug torque

14-21 ft-lbs

(19-28 Nm).

Filler plug torque

25-75 in-lbs

(2.8-8.5 Nm)

Tire Condition

See Table 1-3.

and Pressure

Spoke nipple

torque

Wheel Spokes

40-50 in-lbs

(4.5-5.6 Nm)

R - Replace or change

I - Inspect (adjust, clean or replace as required)

L - Lubricate (with specified lubricant)

X - Perform

T - Tighten to proper torque

D - Disassemble (lube and inspect as required)

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2004 Touring: Maintenance

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Service

Operation

Data

Lubricate through

neck fitting with

Special

Purpose Grease,

Part No. 99857-

Steering

97 (cartridge)

Head Bearings

For swing-by

inspection or

disassembly

instructions, see

Section 2.17.

D.O.T. 5 Brake fluid

Brake Fluid

Part No.’s 99902-

Reservoir Level

77 (12 oz),

and Condition

99901-77 (gal)

Minimum brake

Brake Pad

pad thickness

Linings and Discs

0.04 in.

(1.02 mm)

On ground without

rider

5/16-3/8 in.

Drive Belt

(7.9-9.5 mm) in

bottom strand

with 10 lb. (4.5

kg) upward force

Rear Shock

See Section 2.19.

Absorbers

Air cleaner cover

screw torque

Air Cleaner

36-60 in-lbs

(4-7 Nm)

Fuel Valve, Lines

Check for leaks.

and Fittings

Hex fitting torque

Fuel Tank Filter

15-20 ft-lbs

(20-27 Nm)

Enrichener Control

See Section 4.3.

R - Replace or change

I - Inspect (adjust, clean or replace as required)

L - Lubricate (with specified lubricant)

X - Perform

T - Tighten to proper torque

D - Disassemble (inspect and repack as required)

2004 Touring: Maintenance

1-13

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Harley Davidson 2004 Touring Models. Service Manual — page 28

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