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SPECIFICATIONS 2.1

Table 2-1. Dimensions Table 2-3. Capacities

ITEM IN. MM ITEM U.S. METRIC
Wheel Base 63.5 1613 Fuel Tank (gallons)
Total 5 18.9
Overall Length 91.9 2334
Reserve 0.9 Gal. 3.4 Liters
Overall Width 38.5 977.9
Oil Tank (quarts)
Road Clearance 4.21 106.9 with filter 4 Quarts 3.78 Liters
Overall Height 51.75 1314.45 Transmission 20-24 591-710 Mil-
Saddle Height* 26.7 678 (Ounces, approximate) Ounces liliters

* With 180 Lb. Rider Primary Chaincase

(Ounces, approximate) 32 Ounces 946 Mililiters
Left Right Left Right
Front Fork (Ounces) 314 314
10.6 10.6 ml ml
Table 2-2. Weight
ITEM LBS. KG
DRY WEIGHT** 776/788 352.3/357.8
GVWR 1259 572
GAWR – Front 500 227
GAWR – Rear 827 375
** As shipped from the factory

NOTE
Gross Vehicle Weight Rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding Gross Axle Weight
Ratings (GAWR) are given on a label located on the inside of
the right front frame downtube.

2004 FLHTCSE: Chassis 2-1

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TORQUE VALUES 2.2

ITEM TORQUE NOTES

Actuator bleeder valve 80-100 in-lbs 9-11 Nm page 2-24

Actuator bleeder valve 80-100 in-lbs 9-11 Nm page 2-25
Banjo bolt 17-22 ft-lbs 23-31 Nm page 2-24
Banjo bolt 17-23 ft-lbs 23-31 Nm page 2-25
Brake caliper pad pins 180-200 in-lbs 21-22 Nm page 2-6
Brake fluid reservoir cover 6-8 in-lbs 0.7-0.9 Nm page 2-6
Brake pedal to brake arm 25-29 ft-lbs 34-39 Nm page 2-9
Clutch fluid line flare nut 80-115 in-lbs 9-13 Nm page 2-24
Clutch fluid line flare nut 80-115 in-lbs 9-13 Nm page 2-25
Clutch fluid reservoir cover 6-8 in-lbs 0.7-0.9 Nm page 2-21
Clutch master cylinder banjo bolt 17-22 ft-lbs 23-31 Nm page 2-21
Clutch reservoir cover screws 6-8 in-lbs 0.7-0.9 Nm page 2-24
Clutch reservoir cover screws 6-8 in-lbs 0.7-0.9 Nm page 2-25
Fender mounting bolt 15-20 ft-lbs 20.4-27.1 Nm page 2-28
Filler strip 15-20 ft-lbs 20.4-27.1 Nm page 2-30
Footboard hinge bolts 84-108 in-lbs 9.5-12.2 Nm page 2-7
Footboard hinge bolts 84-108 in-lbs 9.5-12.2 Nm page 2-7
Front axle cover set screw 60-84 in-lbs 6.8-9.5 Nm page 2-10
Handlebar clamp screws 71-80 in-lbs 8-9 Nm page 2-21
Handlebar top clamp 12-16 ft-lbs 16.3-20.3 Nm page 2-16
Left footboard brackets 15-20 ft-lbs 20.4-27.1 Nm page 2-7
Pad pins 180-200 in-lbs 21-22 Nm page 2-6
Passenger backrest docking points 15-20 ft-lbs 20.4-27.1 Nm page 2-28
Passenger backrest mounting bracket 15-20 ft-lbs 20.4-27.1 Nm page 2-30
Passenger mounting bracket fasteners 15-20 ft-lbs 20.4-27.1 Nm page 2-28
Rear axle cone nut 95-105 ft-lbs 128.9-142.4 Nm page 2-4
Right footboard brackets 30-35 ft-lbs 41.7-47.4 Nm page 2-7
Right footboard brackets 30-35 ft-lbs 41.7-47.4 Nm page 2-7
Saddlebag support to support bracket 15-20 ft-lbs 20.4-27.1 Nm page 2-30
Secondary actuator bleeder valve 80-100 in-lbs 9-11 Nm page 2-21
Shift lever clamp bolts 90-110 in-lbs 10.2-12.4 Nm page 2-9
Shift lever peg 144-168 in-lbs 16.3-18.9 Nm page 2-9
Triple clamp cover backside fasteners 70-110 in-lbs 7.9-12.4 Nm page 2-11
Triple clamp lower Allen head fastener 120-180 in-lbs 13.5-20.3 Nm page 2-11

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VEHICLE IDENTIFICATION NUMBER (V.I.N.) 2.3

GENERAL
10528

See Figure 2-1. An abbreviated V.I.N. is stamped on the left

side crankcase at the base between the cylinders.
NOTE
Always give the full 17 digit Vehicle Identification Number
when ordering parts or making any inquiry about your motor-
cycle.
See Figure 2-2. The full 17 digit serial, or Vehicle Identifica-
tion Number (V.I.N.) is stamped on the right side of the steer-
ing head and on a label located on the left side of the
steering head.

Figure 2-1. Abbreviated V.I.N. Location

1 - Manufactured for U.S.A.

Market Designation
5 - Manufactured for International Countries

Model Designation PJ - FLHTCSE

Engine Type E - 1690 (EFI)
Varies - 1 thru 8

Model Year - 2004

Y - Manufactured in York, PA
K - Manufactured in Kansas City, MO
Sequential Number

1 HD1 PJ E 1 * 4 Y 950000
*Varies - can be 0 thru 9 or X
Sample V.I.N. as it appears on the steering head - 1HD1PJE1*4Y950000
Sample abbreviated V.I.N. as it appears on the left crankcase - PJE4950000

Figure 2-2. Vehicle Identification Number

2004 FLHTCSE: Chassis 2-3

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REAR WHEEL 2.4

REMOVAL 4. Tilt the bottom of the tire to the right.

5. Orient the axle to the lowest cam position and angle the
axle to match angle of rear wheel.
1. Block motorcycle under frame so rear wheel is off the
ground. 6. With the larger OD on the outboard side, hold external
spacer between the rear fork and belt sprocket. Slide the
2. Remove saddlebags. See SADDLEBAG in Touring Mod- axle through left side of rear swingarm, external spacer,
els Service Manual. and sprocket into the wheel hub.
3. Remove mufflers. See REAR WHEEL in Touring Models 7. When the axle emerges from the hub, straighten the
Service Manual. wheel and push axle through short external spacer, cali-
per bracket and rear fork.
4. Remove e-clip from groove on right end of rear axle.
8. Rotate flat on threaded end of axle to the top. With the
5. Remove cone nut and adjuster cam from axle. thumb down and the cam forward, install adjuster cam
on end of axle.
6. Using a soft mallet, gently tap end of axle towards left
9. Apply a thin film of LOCTITE ANTI-SEIZE to inboard
side to loosen.
side of cone nut. Install cone nut on axle, but finger
7. Pull the axle out to saddlebag support. tighten only.
10. Verify that adjuster cam just contacts weld nub on both
8. To clear the saddlebag support, rotate the axle to lowest
sides of rear fork. If necessary push wheel forward
cam position and push the bottom of the tire to the right
slightly to achieve the desired result. Snug the cone nut
to angle the assembly in the fender with the left end of
to 15-20 ft-lbs (20-27 Nm).
axle tilted down.
11. Lower motorcycle to ground.
9. Pull the axle the rest of the way out. 12. Rotate weld nut on left side of axle in a clockwise direc-
10. Pull wheel to release brake disc from caliper. Pry inner tion.
and outer brake pads back for additional clearance. If 13. Check belt deflection. See DRIVE BELT under SCHED-
necessary, use a putty knife with a wide thin blade to ULED MAINTENANCE PROCEDURES.
avoid scratching the brake disc. 14. When belt deflection is within specifications, hold weld
nut and final tighten cone nut to 95-105 ft-lbs (128.9-
NOTE
142.4 Nm).
Do not operate the rear brake pedal with the rear wheel 15. With the flat side out, install new e-clip in axle groove.
removed or the caliper pistons may be forced out. Reseating
pistons requires disassembly of the caliper. 16. Install mufflers. See REAR WHEEL in the Touring Mod-
els Service Manual.
11. Move wheel forward to slip belt off sprocket and remove
wheel from rear fork. 1WARNING
NOTE After installation of caliper and BEFORE moving motor-
cycle, pump rear brake pedal until pistons push pads
Removal of the rear wheel can be also facilitated by remov-
against the brake disc. If fluid pressure is not pumped
ing the lower shock bolts and dropping the rear fork below
up, the rear brake will not be available the first time it is
the saddlebag support brackets. This provides access to the
used, a situation that could result in death or serious
rear axle.
injury.
17. Press rear brake pedal several times to set brake pads.
INSTALLATION 18. Install saddelbags. See SADDLEBAG in the Touring
Models Service Manual.
1. Place rear wheel in rear swingarm. Slide wheel forward
and slip belt over sprocket.

CAUTION

Do not bend or fold belt backward or into loops smaller

than 5 inches in diameter. Sharp bending can weaken
the belt and cause premature failure.

2. Seat caliper on anchor weldment of rear swingarm. Posi-

tion wheel in rear fork, so that brake disc is centered
between brake pads.
3. Coat the axle with LOCTITE ANTI-SEIZE.

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REAR BRAKE PADS 2.5

GENERAL
8696
Follow service instructions for INSPECTION, BRAKE DISC 1
THICKNESS/WARPAGE, BRAKE PADS, and BRAKE LINE/
HOSE INSPECTION. See REAR BRAKE CALIPER in Tour-
ing Models Service Manual. 2

Procedures for rear brake pad replacement are similar. How-

ever, the brake pads must be rotated along the arc of the
brake disc to clear the disc rivets and spring washers during
brake pad removal and installation.

REPLACEMENT
3
1. Raise the rear wheel off the ground.

2. Remove right side saddlebag. See SADDLEBAGS, 1. Bridge bolt

REMOVAL in Touring Models Service Manual. 2. Pad pin
3. Spring washer and rivet
3. See Figure 2-3. Loosen both pad pins, but do not
remove. Figure 2-3. Rear Brake Disc and Caliper
4. Remove two Phillips screws to release cover from rear
master cylinder reservoir. o0035x0x

CAUTION
Inner brake pad Outer brake pad
As the pistons are pushed back into the caliper, fluid
level may rise more than 1/8 inch (3.2 mm) and overflow
the reservoir. Watch the fluid level as the pistons are
retracted and remove fluid from the reservoir if neces-
sary. 1 2
5. Pry the inner pad back pushing the pistons into their
bores. Use a putty knife with a wide thin blade to avoid
scoring or scratching the brake disc.

CAUTION

Do not completely pull pad pins from caliper during the

next step. Completely removing pad pins at this time will 3
1. Two tabs
make assembly difficult. 2. Single tab
3. Curved portion faces rear
6. Once the pistons have been retracted, pull the pad pins
part way out to free the inside pad. Figure 2-4. Rear Brake Pad Orientation
7. Slide the inside pad along the arc of the brake disc to
remove pads from calipers. Note the orientation of the
pad.

1WARNING
Always replace brake pads in pairs. Never replace just
one brake pad. Mismatched brake pads can lead to brake
system damage and loss of braking performance, which
could result in death or serious injury.

2004 FLHTCSE: Chassis 2-5

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8. See Figure 2-4. Orient new inner brake pad against the 20. Verify that brake fluid level is 1/8 inch (3.2 mm) below top
brake disc. Curved portion must face rear of motorcycle. of reservoir with master cylinder in a level position. Add
D.O.T. 5 SILICONE BRAKE FLUID, if necessary. Install
9. Hold brake pad against brake disc and rotate the rear
master cylinder reservoir cover. Install two Phillips
wheel to rotate the pad forward into caliper.
screws to fasten cover to reservoir and tighten to 6-8 in-
10. Install pad pins, but do not fully tighten. lbs (0.7-0.9 Nm).

11. Pump rear brake pedal to move inside pistons out until 21. Install right side saddlebag. See SADDLEBAGS,
they contact inner brake pad. INSTALLATION in Touring Models Service Manual.

12. Pry the outside pad back pushing the pistons into their 22. Test operation of brake lamp with the rear brake applied
bores. Use a putty knife with a wide thin blade to avoid and the ignition/light key switch turned to IGNITION.
scoring or scratching the brake disc.

13. Verify that inner pad is captured between brake disc and 1WARNING
pistons. After completing repairs or bleeding the system, always
14. Completely remove pad pins to free outer brake pad. test motorcycle brakes at low speed. If brakes are not
Note the orientation of the outer brake pad. operating properly or braking efficiency is poor, testing
at high speeds may result in death or serious injury.
15. Orient new outer brake pad against the brake disc.
Curved portion of pad must face rear of motorcycle. 23. Test ride motorcycle. If the brakes fell spongy, bleed the
brake lines. See BLEEDING HYDRAULIC BRAKE
16. Hold brake pad against brake disc and rotate the rear
LINES in Touring Models Service Manual.
wheel to rotate the pad forward into caliper. If the inside
pad moved during the previous step, reinstall.

17. Inspect pad pins and clean or replace as required.

18. Install two pad pins and tighten to 180-200 in-lbs (20.3-
22.6 Nm).

1WARNING
After installation of new pads and BEFORE moving
motorcycle, pump rear brake pedal until pistons push
pads against the brake disc. If fluid pressure is not
pumped up, the rear brake will not be available the first
time it is used, a situation that could result in death or
serious injury.

19. Pump rear brake pedal to move pistons out until they
contact both brake pads. Verify piston location against
pads.

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FOOTBOARDS AND CONTROLS 2.6

RIDER FOOTBOARDS 10518

NOTE
Unless the inserts or bottom assemblies are being replaced,
they do not have to be removed from footboard brackets.

Removal
1. See Figure 2-5. With footboards in up position, use a
screwdriver to work cover rubber collars out through
footboards. Remove insert assemblies.
2. See Figure 2-6. Remove right footboard pivot bolts, nuts
and remove footboard bottom assembly.
3. Remove screws, washer, lock washer and right rear foot- Figure 2-5. Footboard Cover Rubber Collars
board bracket.
4. Remove screws, lock washers, nuts and right front foot- PASSENGER FOOTBOARDS
board bracket.
5. Remove left footboard pivot bolts, nuts and remove foot-
board bottom assembly. Removal
6. Remove screws, washers, lock washers and both front 1. See Figure 2-6. Remove socket screw and lockwasher
and rear left footboard brackets. to remove footboard bracket from swingarm bracket

Installation Installation
1. See Figure 2-6. Install right front footboard bracket. Posi- 1. Insert pin on footboard bracket into hole in swingarm
tion for rider posture. Install lock washers, washers, nuts bracket.
and screws. Tighten screws to 30-35 ft-lbs (41.7-47.4 NOTE
Nm). Passenger footboards can be adjusted to one of three posi-
2. Install right rear footboard bracket. Position for rider pos- tions. To move footboards to a new position, remove plastic
ture. Install lock washer, washer and screw. Tighten plugs from holes in rear swingarm bracket as necessary.
screws to 30-35 ft-lbs (41.7-47.4 Nm). 2. Install socket screw with lockwasher. Tighten socket
NOTE screw to 15-18 ft-lbs (20-24 Nm).

The right and left footboard frame mounts allow a small vari-
ance in height and angle.

3. Install right footboard bottom assembly. Install and

tighten pivot bolts and nut to 84-108 in-lbs (9.5-13.5
Nm).
4. Install left footboard brackets. Position for rider posture.
Install washers, lock washers, and screws. Tighten
screws to 30-35 ft-lbs (41.7-47.4 Nm).
5. Install left footboard bottom assembly. Install and tighten
pivot bolts and nut to 84-108 in-lbs (9.5-13.5 Nm).
6. Moisten footboard cover rubber collars with soapy water.
7. With left footboard bottom assembly in up position, hold
new footboard cover in position.
8. From underside of footboard use a pliers to pull each
rubber collar through footboard hole.
9. Repeat for other side.

CAUTION

Avoid contacting chrome surfaces with abrasive materi-

als (stones, sand, etc.) as damage will result.

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Disassembly Assembly
NOTE 1. Install footboard bracket. See PASSENGER FOOT-
BOARD INSTALLATION, in this section.
If only replacing the rubber pad, refer to step 1 below and
then see steps 4-5 under ASSEMBLY. 2. Place spring into hole in footboard bracket. Place ball on
top of spring.
1. Tilt footboard bottom assembly upward. From bottom 3. Place footboard bottom assembly into position on
side, use a small blade screwdriver to push rubber bracket and install retaining pins from the outboard side.
beads on pad up through holes in footboard bottom Using a brass drift and rubber mallet, tap pins until cen-
assembly. Remove insert assembly. tered in lugs of bracket.
2. Using a brass drift and rubber mallet, tap two retaining 4. Moisten rubber beads on new insert assembly with
pins toward center of footboard and remove. soapy water. Place insert assembly into position on foot-
board bottom assembly. Press firmly on footboard insert
3. Remove footboard bottom assembly from footboard
in areas of rubber beads.
bracket.
4. Remove ball and spring from hole in footboard bracket.
5. Remove footboard bracket from rear swingarm bracket.
See PASSENGER FOOTBOARD, REMOVAL in this sec-
tion.

z0020d

22

6 24 11 10
5
21 12
1 2 4 23
13
3
7
14
15

2 19 15 20
14
18
8
15
14
17 16

1. Insert Assembly, passenger footboard, right-side 13. Bracket, support, footboard, left-side
(Left-side not shown) 14. Washer
2. Pivot pin 15. Lockwasher
3. Spring 16. Bracket, support, footboard, right-side
4. Ball 17. Bottom assembly, right-side
5. Socket screw 18. Insert assembly, right-side
6. Lockwasher 19. Bracket, support footboard, right rear
7. Bracket, footboard, passenger 20. Screw
8. Bottom assembly, footboard, passenger 21. Screw
9. Insert assembly, rider, left-side 22. Bracket, support footboard, left rear
10. Bottom assembly, with hinge, left-side 23. Lockwasher
11. Nut 24. Locknut
12. Pivot bolt

Figure 2-6. Footboard and Passenger Footrest Components

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SHIFT LEVER

Replacement
1. Remove and replace shift lever pegs. Tighten fasteners
to 144-168 in-lbs (16.3-18.9 Nm).
2. If necessary, loosen clamp bolts and pull shift levers off
splined shaft.
3. Position shift levers on splined shaft for rider posture and
tighten clamp bolts to 90-110 in-lbs (10.2-12.4 Nm).

REAR BRAKE PEDAL PAD

Replacement
1. Remove screws (4) and remove brake pedal from brake
arm. Disassemble.
f2287x0x

4 2
1. Metal brake pedal cover
2. Rubber tread
3. Metal backing plate
4. Screws

Figure 2-7. Rear Brake Pedal

2. See Figure 2-7. Assemble metal brake pedal cover to

rubber tread.
3. Slide metal backing plate into metal brake pedal cover/
rubber tread assembly.
4. Install pedal to brake arm with screws. Tighten screws to
22-29 in-lbs (2.5-3.3 Nm).

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FRONT AXLE COVERS 2.7

REPLACEMENT
10522

1. See Figure 2-8. Loosen but do not remove set screw

under cover. Remove cover.

2. Remove set screws from cover.

3. Liberally apply LOCTITE THREADLOCKER 262 (red)

(HD-94759-77) to threads of set screw.

4. Orient cover over axle end so that set screw is on the

bottom and will tighten down against a flat on the axle
nut.

5. Install and tighten set screw to 60-84 in-lbs (6.8-9.5

Nm). Figure 2-8. Front Axle Cover Set Screw

6. Repeat for opposite side.

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LOWER TRIPLE CLAMP COVER 2.8

REPLACEMENT
o0041x0x
1
1. See Figure 2-9. Loosen but do not remove the two fas-
2
teners on the backside of cover.
2. Remove the lower Allen fastener through the brake line 3
manifold on bottom.
3. Remove two backside fasteners and washers and
remove cover.
4. To replace cover, fit cover inside bottom of nacelle and
around triple clamp. Hold in place.
5. Install but do not tighten all three fasteners and washers.
Verify that the cover is snug against the rear surface of
triple clamp.

NOTE 4
Plastic plugs in locator holes in rear surface of triple clamp
can cause interference with the cover. Verify that the center
1. Backside fasteners
plug has been removed.
2. Washer
6. Tighten backside fasteners to 70-110 in-lbs (7.9-12.4 3. Lower triple clamp cover
Nm). 4. Lower Allen head fastener

7. Tighten lower Allen head fastener to 120-180 in-lbs

Figure 2-9. Lower Triple Clamp Cover
(Nm).
8. Verify that the brake line does not rub on cover. Adjust
line or cover as necessary.

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HANDLEBARS 2.9

REMOVAL/REPLACEMENT f1915x8x

1
1WARNING 2
To prevent accidental vehicle start-up, which could 3
cause death or serious injury, remove maxi-fuse before
proceeding. (00251a)
4
1. Remove left side cover.
2. Remove Maxi-Fuse. 7 5
3. Remove outer fairing and fairing cap. See FAIRING CAP
in Touring Models Service Manual. 6
4. Remove radio chassis. See RADIO REMOVAL in Tour- 1. Locking wedge
ing Models Service Manual. 2. Internal seal
3. Socket housing
5. See Figure 2-10. Separate handlebar switch connectors 4. Wire seal
[22] and [24] and turn signal multilock connector [31]. 5. Seal pin
6. See Figure 2-11. Remove wires from socket side hous- 6. Socket terminal
ings from socket terminal wires: 7. External latch

a. Use a screw driver to pry out the secondary locking Figure 2-11. 12-place Deutsch Socket Side Connector
wedges. See DEUTSCH ELECTRICAL CONNEC-
TORS in Touring Models Service Manual. 10. Shorten throttle and idle cable adjustors and pull idle
and throttle cable inserts and elbows from switch hous-
b. See Figure 2-13. Depress internal terminal latches
ing.
and pull socket terminals out of the wire seal.
11. Remove upper and lower fasteners holding right turn
7. Using mechanic’s wire, neatly wrap the socket terminals signal and cruise control housings to handlebars.
and wires with 1 or 2 twists to form leaders for turn sig-
nal and handlebar switch connector wires. 12. See Figure 2-14. Use a screwdriver to rotate cable fer-
rules in throttle grip notches. Remove cables from
8. String wire along the turn signal wire. String sufficient notches on inboard side of throttle grip and remove
wire to pull conduits through handlebars. throttle grip from handlebar.
9. Wrap with electrical tape from the open end of the con- 13. Remove the cables from the housing.
duit past the turn signal lamp sockets to form a leader. 14. Protect chrome and painted surfaces and tie idle and
throttle cables away from chrome and paint finishes.
f2238x8a Maintain the routing of the cables.
3 15. See Figure 2-12. Insert a 5/32 in. (4 mm) cardboard
between front brake lever and lever bracket.
16. Remove fasteners securing handlebar clamp to master
cylinder and front brake lever.

CAUTION

See Figure 2-12. Do not remove the 5/32 in. (4 mm) card-
board insert wedged between the brake lever and lever
bracket. Removal will result in damage to the rubber
boot and plunger of the front stoplight switch during
installation of the master cylinder assembly.
1
2 17. Protect chrome and painted surfaces and tie the master
cylinder, reservoir and brake line out of the way.
18. Remove upper and lower fasteners holding left turn sig-
nal and cruise control housings to handlebars.
1. Right handlebar switch connector [22]
2. Left handlebar switch connector [24] 19. Remove fasteners and washers securing the handlebar
3. Turn signal multilock connector [31] clamp to the clutch lever bracket.
20. Protect chrome and painted surfaces and tie the master
Figure 2-10. Turn Signal and Cruise Switch Connectors cylinder, reservoir and clutch fluid line out of the way.

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f1225x2x 10521

2 Figure 2-14. Throttle and Idle Cable Ferrules

26. If necessary to repair wires, unwrap the electrical tape

and wire from the socket terminals.
27. Repair and replace switches and socket wires as neces-
sary.

1. Notch for switch housing NOTE

2. 5/32 in. (4 mm) cardboard For handlebar switch repair procedures, see HANDLEBAR
SWITCHES in Touring Models Service Manual.
Figure 2-12. Cardboard Insert

21. Remove upper handlebar clamps and lift handlebars, 8689

turn signal housings, and wire harness from motorcycle.
NOTE
If handlebar rubber mounts require service. See HANDLE-
BARS in the Touring Models Service Manual.

o0031x0x

8688

Figure 2-13. Internal Deutsch Terminal Latches

22. Place handlebars and wiring on work bench.

23. Cut wire tie at handlebar.
24. See Figure 2-15. Lightly lubricate conduits and tape with
glass cleaner then pull the left and right side wiring and
conduits from the handgrip ends through the handlebar
and handlebar grommets.
25. If installing original handlebars, leave the wire leader in
each handlebar half. If installing new bars, string wire
leader through grommets on outside ends of bars and
through the center hole. Figure 2-15. Wire Leader in Handlebars

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HANDGRIPS ASSEMBLY/INSTALLATION
1. Using mechanic’s wire, neatly wrap the socket terminals
NOTE
and wires with a few twists to form leaders for turn signal
It is not necessary to remove the handlebars from the motor-
and cruise control wires and conduit.
cycle to replace the handgrips. Remove the control levers
and control housings according to the instructions in this sec- NOTES
tion and replace the hand grips. If installing the original handle bars, use the wire end left in
the handlebar half to wrap the socket terminals.
1. Replace right hand throttle grip. Slide throttle grip on in
operating position. 2. String wire along the turn signal lamp wire. String suffi-
2. Pry off end cap from left hand grip and using a sharp cient wire to pull conduits through handlebars.
blade carefully cut rubber between metal sleeve until the 3. Wrap socket wires with electrical tape.
metal sleeve can be pulled off the bars.
3. Clean left handlebar end. 1WARNING
NOTE Without protective grommets around wire entry open-
Before installing left hand grip, remove end cap to prevent ings in handlebars, wires can rub against sharp metal
trapping air. edges of opening. A short or broken connection can
cause loss of electrical control which can lead to death
1WARNING or serious injury.
4. Lubricate wire conduits with glass cleaner. With the wire
FLAMMABLE, INJURIOUS TO EYES, HARMFUL IF SWAL-
leader, pull wire bundles through grommets and handle-
LOWED, VAPOR HARMFUL. FLAMMABLE: CONTAINS
bar to the handlebars center hole.
METHYL ETHYL KETONE. Use only in well ventilated
areas. Avoid contact with eyes, mucous membranes, and 5. See Figure 2-16. and Figure 2-17. Orient wires in switch-
prolonged skin contact. KEEP OUT OF REACH OF CHIL- housings. The right hand RUN and STOP wires are
DREN. If swallowed, do not induce vomiting. Call a phy- wrapped over the front of the bars and back and into the
sician immediately. This product contains a chemical(s) handlebar through the grommet. The wires should be to
known to the State of California to cause cancer or other the outside of the clamping post inside the housing.
reproductive harm. 6. Loosely install left and right switch housings.
4. Apply a coat of HARLEY-DAVIDSON ADHESIVE (Part 7. Pull wire leaders and unwrap the tape and mechanic’s
No. 99839-95) to inside surface of new left hand grip at wire.
a point 1 in. (25.4 mm) from open end. Apply a coat of 8. Cable wrap wire conduits at exit from handlebars.
adhesive to handlebar end. 9. See Figure 2-11. Fit wire seal into back of Deutsch
5. Immediately push grip completely onto the handlebar socket housings.
end. Install grip with a twisting motion while aligning the 10. Insert wire color coded socket terminals into numbered
horizontal pattern on the left hand grip to the pattern on chambers in socket housings:
the right hand grip in the closed position.
a. Hold socket terminal 1 in. (25.4 mm) behind contact
NOTE barrel.
Do not hesitate when installing left grip or adhesive will dry
b. Gently push socket terminal through hole in wire
before installation is complete. Allow 6-8 hours at 70° F (21˚
seal into chamber until it “clicks” in place.
C) to achieve full cure of the adhesive.
c. Verify that socket will not back out of chamber. Tug
6. Install end caps. on the wire to confirm that is locked.

2-14 2004 FLHTCSE: Chassis

HOME
NOTE
An ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-
39965) can be used to install Deutsch pin and socket termi-
Table 2-4. Handlebar Deutsch Connectors
nals on wires.
Wire Color Chamber No.
f1270x2x
RH Connector (12 socket) (BLACK)
Orange/White (O/W) 1

Red/Blue (R/BE) 2

Gray (GY) 3

White/Black (W/BK) 4
1
White/Brown (W/BN) 5

Black/Red (BK/R) 6

Brown/White (BN/W) 7

Gray/White (GY/W) 8

Pink/White (PK/W) 9

Violet/Black (V/BK) 10

White/Blue (W/BE) 11
1. Run/stop switch wiring
Blue/Black (BE/BK) 12
Figure 2-16. Wiring in Upper Right Hand Control Housing LH Connector (12 socket) (GRAY)

Orange/White (O/W) 1
f1328x2x
Yellow (Y) 2

Blue/White (BE) 3

White (W) 4

White/Violet (W/V) 5
2
1 Yellow/Black (Y/BK) 6

BLANK 7

4 Brown/Black (BN/BK) 8
3
Pink/White (PK/W) 9

5 Green/Blue (GN/BE) 10

Gray/Green (GY/GN) 11

BLANK 12

13. Gently tug on wire ends to verify that all terminals are
1. Right turn signal control and wiring locked.
2. Cruise control switch
3. Mode select switch CAUTION
4. Lower bracket
5. Clamping post Improperly aligned handlebars can hit tank when turned
lock to lock. Verify turning clearance before maneuvering
Figure 2-17. Wiring in Lower Right Hand Control Housing or riding motorcycle.
14. Carry handlebars with internal wire harness and control
11. Install internal seals on lip of socket housings. housings to the motorcycle.
12. Snap tapered end of locking wedges into socket hous- 15. Set handlebars on lower clamps and loosely install
ings. upper handle bar clamps and fasteners. Position wires
NOTE so they exit under radio to front of vehicle from between
If the locking wedge does not snap into position, verify that all risers.
terminals are fully seated in the socket housing.

2004 FLHTCSE: Chassis 2-15

HOME
27. Remove cardboard insert between brake lever and
CAUTION bracket.

Never adjust handlebars using excessive force. Doing so a. Control lever clamps beginning with top fastener to
may result in damage to handlebar. 60-80 in-lbs (6.8-9.0 Nm). The gap, if any must be
at clearance flat on handlebar.
NOTE
b. Turn signal and cruise control housings beginning
If handlebars are positioned for a rider of normal size, post-
with bottom fastener to 35-45 in-lbs (4-5 Nm). Rear
pone adjustment until rider has checked their position. If cus-
gap, if any, should be tighter.
tomer requests changing handlebar position, perform the
adjustment before delivering the motorcycle. 28. Loosely assemble clutch master cylinder/reservoir and
clamp to handlebar. Alternately tighten fasteners until
16. Center handlebars laterally (sideways) in clamps. clamp is snug to bracket.
17. Snug front fasteners until upper clamp contacts lower
29. Install left turn signal and cruise control housings.
clamps.
a. Position upper switch housing so wire conduit wraps
18. Position handlebars in normal rider posture.
around front of handlebar.
19. Tighten fasteners in the following order:
b. Verify wires will not be pinched when fasteners are
a. Rear fasteners - 12-16 ft-lbs (16.3-20.3 Nm). tightened.
b. Front fasteners - 12-16 ft-lbs (16.3-20.3 Nm).
c. Position upper switch housing to wire conduit sets in
20. Push left and right harness Deutsch connectors into the clearance at bottom of handlebar and upper har-
pin side housings. ness will not be pinched when fasteners are tight-
21. Remove loosely installed control housing fasteners. ened.
22. Push throttle and idle control cable inserts into lower d. Engage lower switch housing tab with notch in
switch housing. clutch master cylinder reservoir.
NOTE 30. Install but do not tighten switch housing fasteners.
The smaller idle cable insert is gold while the larger throttle 31. Position controls for rider posture and tighten fasteners:
cable insert is silver. The inserts only fit their corresponding
a. Clutch master cylinder/reservoir clamp beginning
hold in switch housing.
with top fastener to 60-80 in-lbs (6.8 Nm). Top gap,
23. Slide throttle control grip onto handlebar until it bottoms. if any, must be at handlebar clearance.
Pull grip back about 1/8 in. (3.2 mm). b. Turn signal and cruise control housings beginning
24. Use a screwdriver to rotate barrels and fit cables through with bottom fastener to 35-45 in-lbs (4-5 Nm). Rear
notches in throttle control grip. Be sure cables ride in gap, if any, should be tighter.
grooves of throttle control grip.
32. Verify routing of wire conduits, brake line and clutch fluid
line. See FRONT BRAKE LINE in Touring Models Ser-
CAUTION vice Manual and 2.12 CLUTCH FLUID LINE in this book.
See Figure 2-12. Do not remove 5/32 in. (4 mm) card- 33. Install right rear view mirror stem through mirror spacer,
board insert wedged between brake lever and lever and the brake control lever bracket. Install lock washer
bracket. Removal will result in damage to rubber boot and acorn nut on mirror stem.
and plunger of front stoplight switch during installation 34. Install left rear view mirror stem through tapered spacer
of master cylinder assembly. and clutch master cylinder. Install lock washer and acorn
25. Assemble upper and lower control housing to handle- nut.
bars and brake lever bracket. 35. With motorcycle upright and with front fork pointed
a. Position upper switch housing so wire conduit wraps straight ahead, adjust mirrors to clearly reflect area
around outside of handlebar and sets in clearance behind motorcycle.
at bottom of handlebar.
NOTE
b. Verify that wires will not be pinched when fasteners Adjust mirrors so a small portion of riders shoulder is visible
are tightened. in each mirror. This visually establishes the distance of vehi-
c. Verify that throttle and idle control cables work cles to rear of motorcycle.
freely.
36. Tighten acorn nuts to 144 in-lbs (16.3 Nm).
d. Install switch housing fasteners.
37. Install radio according to procedure in Touring Models
26. Loosely assemble handlebar clamp to front brake control Service Manual.
lever bracket master cylinder and reservoir.
38. Install outer fairing, wind deflector and fairing cap
a. Engage tab on switch with notch at top of brake
according to procedure in touring Models Service Man-
lever bracket.
ual.
b. Alternately tighten housing and bracket fasteners
39. Install Maxi-Fuse and side cover.
until all components fit and wires route without inter-
ference. fasteners should only be snug. 40. Test clutch lever and front brake lever for pressure and
c. Verify housing and bracket clamp are tight against operation.
handgrip shoulder/edge of bar. 41. Turn throttle and idle adjusters out.

2-16 2004 FLHTCSE: Chassis

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42. Verify throttle and idle cable routing. Test for correct
operation Adjust as required. See CRUISE CONTROL in
the Touring Models Service Manual.
43. Verify brake and clutch fluid line routing.
44. Turn ignition/light key switch to IGNITION and test
switches for proper operation.
45. Apply brake lever to test stop light lamp.

2004 FLHTCSE: Chassis 2-17

HOME

CLUTCH MASTER CYLINDER/RESERVOIR 2.10

GENERAL REMOVAL

The clutch is hydraulically actuated. Squeezing the clutch 1. Remove acorn nut, washer and rear view mirror with
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
clutch actuator mounted in the clutch release cover. The sec- 2. Remove electrical controls.
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
handlebar. If the sight glass is dark, the fluid level in the res- clutch master cylinder/reservoir.
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-
overfill clutch reservoir. ing clutch line components.

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

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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

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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

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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
1WARNING handlebars with handlebar clamp. Orient lever to rider
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
could cause death or serious injury. 3. Loosen bleeder valve on clutch release cover. See 7.4
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.

1. Boot in piston groove 8. Tighten fasteners as follows:

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
sides of lever. 2. Pivot bushing
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

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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
6. Drain clutch fluid line. 3. 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.

NOTE
1WARNING
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-
11. Loosely install banjo bolt and tie free end away from age. (00205a)
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
tube and behind cam cover around the rear brake line in Direct contact of D.O.T. 5 brake fluid with eyes can cause
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
fairing bracket and behind cam cover around the rear A Snap-on BASIC VACUUM BRAKE BLEEDER with a fitting
brake line in front of the clamp. that mates to the bleeder valve can be used to draw the fluid
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
a. Clutch fluid reservoir banjo bolt to 17-22 ft-lbs (23- cable between bottom of cam cover and top of lower
31 Nm). frame tube.
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

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BLEEDING CLUTCH FLUID LINE 4. Fill reservoir to FILL LEVEL and repeat the previous
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-
inder reservoir. Dirt or debris in the reservoir can cause a. Pump clutch hand lever 5 times.
improper operation of the clutch and equipment dam- b. Hold clutch hand lever against handlebar.
age. (00205a)
c. Loosen secondary clutch actuator bleed valve.

CAUTION d. Run hose from bleeder valve to suitable container.

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
lated area. (00144a) repeat the previous step three times or more until only a
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-

ing one side of passenger grabstrap.
2

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
CAUTION 2. Seat
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.

● Use ONLY a good quality saddle soap to clean INSTALLATION

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

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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
spring loaded support arms. 10566

10564

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

1. Seat
2. Keyed support bracket

Figure 2-31. Backrest Mounting Bracket

2004 FLHTCSE: Chassis 2-27

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PASSENGER BACKREST 2.15

REMOVAL INSTALLATION
1. Remove the saddlebags. See SADDLEBAG, REMOVAL 9993
in Touring Models Service Manual. 3 5 6
1 2
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
9. Remove mounting bracket and saddlebag mounting 4. Rear docking point
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.

1 2 5. Install rear docking point, fastener, washer and nut with

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

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z0021f
2
1

19
4

7
18 6
9 5
17
16
15
14 8
11 9
12 10
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
1WARNING support bracket to fender support bracket.
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:
2. Remove side cover. a. Passenger backrest mounting bracket to support
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

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f2249a2x

1 2
3
5
8
15 4
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

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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