2 HOME

SPECIFICATIONS 2.1

FUEL TANK FUEL TANK OIL TANK TRANSMISSION PRIMARY

MODEL TOTAL RESERVE W/FILTER (APPROX.) CHAINCASE

gal. liter gal. liter qt. liter oz. liter oz. liter
FLHTP
5.0 18.92 - - 4.0 3.79 24 0.71 32 0.95
FLHP

OVERALL OVERALL ROAD OVERALL SADDLE

WHEEL BASE
MODEL LENGTH WIDTH CLEARANCE HEIGHT HEIGHT (Laden)

in. mm in. mm in. mm in. mm in. mm in. mm

FLHTP 63.5 1612.9 93.70 2379.9 39.0 990.6 5.1 129.5 61.0 1549.4 27.3 693.4
FLHP 63.5 1612.9 93.70 2379.9 34.5 876.3 5.1 129.5 55.1 1399.5 27.3 693.4

DRY WEIGHT GVWR GAWR FRONT GAWR REAR

MODEL
lb. kg lb. kg lb. kg lb. kg
FLHTP 758.0 343.8 1200 544.3 500 226.8 770 349.3
FLHP 723.0 327.9 1200 544.3 500 226.8 770 349.3

NOTE NOTE
Gross vehicle weight rating (GVWR) (maximum allowable See Section 2.3 TIRES for important information regarding
loaded vehicle weight) and corresponding gross axle weight tire data and tire inflation.
rating (GAWR) are printed on a label fixed to the bottom of
the right front frame downtube.

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VEHICLE IDENTIFICATION NUMBER 2.2

GENERAL between the front and rear cylinders on the left side of the
crankcase.
A 17-digit serial number, or Vehicle Identification Number NOTE
(VIN), is stamped on the right side of the frame backbone at Always give the complete VIN when ordering parts or making
the rear of the steering head (and under the main harness an inquiry about your motorcycle.
conduit). A label bearing the VIN code is also affixed to the
left side of the steering head. An abbreviated VIN is stamped

Market Designation
1 = Domestic Manufacturer and Make Engine Type
5 = International (HDI) Harley-Davidson Model Designation V - Carbureted
FH - FLHPI W - Fuel Injected
FM - FLHTPI
Motorcycle Type FT - FLHPEI
1 - Heavyweight Introduction Date/Special Models
1 = Regular introduction date
2 = Mid-year introduction date
3 = California model
4 = Anniversary model
Vin Check Digit
Varies; can be 0 thru 9, or X.
Model Year Assembly Plant
4 - 2004 Y - York, PA
K - Kansas City, MO

Serial Number

1 HD 1 FM W 1 3 4 Y 110000

Sample VIN as it appears on the steering head - 1HD1FMW134Y110000

Sample abbreviated VIN as it appears on the engine - FMW4110000

Figure 2-1. Vehicle Identification Number (VIN)

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TIRES 2.3

GENERAL NOTE
Use the tires recommended for civilian/pleasure vehicles of
The rear tire on FL police motorcycles is fit for solo riding the same year and model family.
only. If converted to a two-up bike, that is, configured for pas-
senger use (with luggage), then the rear tire needs to be 11
1WARNING
WARNING
changed to one with a higher weight rating. Since it has long
been Harley-Davidson policy not to mix different types of tires The Dunlop front and rear tires on Harley-Davidson
on the same vehicle, we strongly recommend that both front motorcycles are not interchangeable. DO NOT put a front
and rear tires be replaced. In order to alert the customer to tire at the rear of the vehicle or a rear tire at the front.
this safety issue, the following warning appears on a label fit- Improper placement of tires can adversely affect motor-
ted to the rear fender approximately 1/4 inch (6.4 mm) behind cycle stability and handling, which may lead to loss of
the domestic seat mounting hole. vehicle control resulting in death or serious injury.
(00026a)
11
1WARNING
WARNING Tire size, manufacturer’s description and inflation pressure
are listed below.
This vehicle has tires with weight ratings for one person
operation. If this vehicle is modified to carry two people,
the tires must be changed. See your local Harley-David-
son dealer for the proper replacement tires. Failure to fol-
low this warning could cause tire failure which could
result in death or serious injury. (00096a)

Table 2-1. Tire Data

TIRE
TIRE MANUFACTURER’S
MODEL SIZE PRESSURE
LOCATION DESIGNATION
(Cold)

Dunlop 36 psi
Front MT90B1672H
D402F PT (248 kPa)
FLHTP/FLHP
Dunlop 36 psi
Rear MT90B1671H
D402 PT (248 kPa)

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SEAT 2.4

OPERATION
5872
Quick Release
Pin
CAUTION

Maximum seat air pressure is 100 psi (689 kPa). Normal

air pressure is between 30-45 psi (207-310 kPa). Minimum
air pressure is determined by rider weight. Do not oper-
ate with pressure so low that system bottoms out on
bumpy roads. (00167a)

NOTE Support
Post
Rear Seat
To set minimum air pressure, have rider sit on seat and Bracket
bounce to simulate riding conditions. Visually check for any
contact between air spring and frame components. Add air as
necessary. Figure 2-2. Seat Latch

1. Standing on left side of vehicle, press down on rear of

3. While pressing down on rear of seat, insert quick release
seat and pull quick release pin from hole in support post. pin into hole of support post.
See Figure 2-2. Raise seat toward fuel tank console.
NOTE
2. To lock seat in place, move seat down until support post
engages hole in rear seat bracket. The seat does not adjust forward or backward.

11
10
9
8
1. Air spring hose 13
2. Air spring
3. Screw (2) @ 36-60 in-lbs (4.1-6.8 Nm) 6 7 14 12
4. Trim panel
5. Seat faring 16 15
19
6. Screw
7. Rivnut (4) 17
8. Screw 5 18
9. Bushing
10. Seat support bracket 20
11. Nut @ 48-84 in-lbs (5.4-9.5 Nm)
12. Seat
13. Seat mount bracket (2) 4 21
14. Washer
15. Screw @ 60-120 in-lbs (6.8-13.6 Nm)
16. Screw (4) @ 15-20 ft-lbs (20.3-27.1 Nm)
17. Rubber bumper
3
18. Flange locknut (2) @ 96-144 in-lbs (10.9-16.3 Nm) 22
19. Quick release pin
20. Flange nut (2) @ 60-120 in-lbs (6.8-13.6 Nm)
21. Washer (2)
2
23
22. Rear seat bracket
23. Set screw (2)
24. Nut (2) @ 50-70 in-lbs (5.7-7.9 Nm) 1 24
25. Quick release fitting
p0047c2x
25
Figure 2-3. Air Seat Support

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AIR SEAT RESERVOIR f1842x2x Air Pressure

Air
Reservoir Gauge

Removal
1. Remove luggage rack. See Section 2.6 LUGGAGE
RACK, REMOVAL, steps 1-5.
2. Alternately loosen screws on each side of motorcycle to
release ends of luggage rack from frame tube weld-
ments. Continue loosening screws until luggage rack can
be raised high enough to remove air reservoir. Air Valve

3. Remove two Phillips screws (with lockwashers) from lug-

gage rack to release top of air reservoir bracket.
4. Remove two Phillips screws from license plate bracket to
free rear of air reservoir bracket. Be sure to hold reser-
voir as the last screw is removed or damage to fender
paint may occur when assembly is released.
5. Raise luggage rack and remove air reservoir from motor- Figure 2-4. Air Seat Reservoir Air Valve
cycle.
6. Remove tee fittings from reservoir, if necessary. 3. Slide Phillips screws through two holes in license plate
bracket and two holes in luggage rack engaging weld
nuts in air reservoir bracket. Alternately tighten screws
until snug.
Installation
4. Alternately tighten screws on each side of motorcycle to
1. Install tee fittings to air reservoir, if removed. secure ends of luggage rack to frame tube weldments.
2. Position air reservoir beneath luggage rack exercising 5. Install luggage rack. See Section 2.6 LUGGAGE RACK,
caution to avoid scratching fender paint. INSTALLATION, steps 1-4 and 6-13.

6 8
3

7
2
4
1. Air seat reservoir and
bracket
2. Lockwasher (2) 9
3. Screw (2)
4. Air pressure gauge
5. Air tube
6. Compression fitting
7. Air valve
8. Protective cap
1 10
9. Tee fitting (2)
p0048b2x
10. Screw (2)

Figure 2-5. Air Seat Reservoir

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FOOTBOARDS 2.5

GENERAL 4. At footboard rear bracket, slide upper hex bolt through

frame weldment, jiffy stand bracket and footboard
bracket thru hole. Install lockwasher and locknut. Slide
FLHTP and FLHP models are equipped with adjustable foot- lower hex bolt (with lockwasher) through frame weldment
boards. and jiffy stand bracket into threaded hole of footboard
bracket. Alternately tighten two hex bolts to 15-20 ft-lbs
(20.3-27.1 Nm).
NOTE
ADJUSTMENT
Perform a visual check to verify that both footboards are at
the same height.

Right Side
1. Loosen two allen head socket screws (with lockwashers
and flat washers) to release right side footboard brackets
from frame weldment. For best results, approach from
left side of vehicle using a 3/8 inch ball allen with exten-
sion.

2. Move the footboard to one of two positions. Alternately

tighten allen head socket screws to 30-35 ft-lbs (40.7-
47.5 Nm).

11
1WARNING
WARNING

Rear brake will not operate properly if brake pedal can-

not be fully depressed. After adjusting right footboard,
check for minimum clearance of 2.25 inches (57 mm)
between bottom of brake pedal and top of footboard.
Failure to allow for proper clearance can lead to loss of
braking performance, which could result in death or seri-
ous injury.

Left Side
1. Loosen the allen head socket screw (with lockwasher
and flat washer) to release the footboard forward bracket
from frame weldment. For best results, approach from
opposite side of vehicle using a 3/8 inch ball allen.

2. To free footboard rear bracket from frame weldment and

jiffy stand bracket, remove lower hex bolt (with lock-
washer) and upper hex bolt (with lockwasher and lock-
nut).

3. Move the footboard to one of two positions. Alternately

tighten allen head socket screw to 30-35 ft-lbs (40.7-47.5
Nm).

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LUGGAGE RACK 2.6

REMOVAL 6046

1. Remove both saddlebags.

2. On the right side of the motorcycle, locate the air seat

reservoir air valve under the luggage rack, and on the left
side, the rear shock air valve just below the chrome
frame cover. See Figure 2-6.

11
1WARNING
WARNING

Exercise caution when bleeding air from the air valves.

Moisture combined with lubricant (either from shock
assembly or drip oiler in the air compressor lines) may
be ejected onto the rear wheel, tire and/or brake compo-
nents and adversely affect traction and/or braking effi-
ciency, which could result in death or serious injury.

f1842x2x

Air Seat
Reservoir Figure 2-7. Remove Luggage Rack
Air Valve

3. Remove protective cap from each air valve and depress

pin to bleed air from both reservoir and shocks. To purge
rear air suspension lines of any oil, add 3-5 psi (20.7-
34.5 kPa) before releasing air. Depress collar on each
compression fitting and pull out air tube.
4. Remove bolt (with flat washer) to remove saddlebag front
mounting bracket from chrome frame cover. Remove
Phillips screw and then remove frame cover. Repeat step
on opposite side of motorcycle.
5. Remove two bolts to free license plate bracket from bot-
tom support tube.
6. Remove screws (with spacers) on each side of motorcy-
cle to release ends of luggage rack from frame tube
Rear Shock weldments.
Air Valve
7. Remove pole lamp. See Section 8.5 POLE LAMP.
8. Slide luggage rack toward rear of motorcycle to clear
front bushings, and then rotate rack upward to clear
frame tubes. See Figure 2-7.

f2018x2x INSTALLATION

Figure 2-6. Air Valves 1. Place luggage rack into position inboard of frame tubes.

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2. Install screws (with spacers) on each side of motorcycle
to secure ends of luggage rack to frame tube weldments. Table 2-2. Rear Air Suspension Pressures
3. Install two bolts to fasten license plate bracket to bottom Recommended
Shock Loading
support tube. Pressures

4. Position chrome frame cover on frame tube and install

PSI kPa
0-35 0-241
Phillips screw. Install bolt (with flat washer) to install sad-
dlebag front mounting bracket, but do not tighten. Repeat Solo rider up to 150 lbs. (68 kg) 0 0
step on opposite side of motorcycle.
Solo rider 150-200 lbs. (68-91 kg) 0-10 0-69
5. Install pole lamp. See Section 8.5 POLE LAMP. Solo rider 200-250 lbs. (91-113 kg) 5-15 35-103
6. Depress collar on compression fitting of air seat reser- Maximum GVWR (see Section 2.1
20-35 138-241
voir, and insert air tube until it bottoms. Gently tug on SPECIFICATIONS)
tube to verify that it is locked in place.

11
1WARNING
WARNING
CAUTION
Use this table as a starting point in determining suit-
Maximum seat air pressure is 100 psi (689 kPa). Normal able rear air suspension pressures. Do not exceed
air pressure is between 30-45 psi (207-310 kPa). Minimum maximum GVWR when loading vehicle and do not
air pressure is determined by rider weight. Do not oper- pressurize system in excess of 35 psi (241 kPa).
ate with pressure so low that system bottoms out on Excessive load weight and/or air suspension pres-
bumpy roads. (00167a) sure can adversely affect handling and lead to loss
of vehicle control, which could result in death or seri-
7. Fill air reservoir to desired pressure. Install protective ous injury.
cap on air valve. See upper frame of Figure 2-6.

NOTE
To set minimum air pressure, have rider sit on seat and 11. Observe air pressure gauge while filling. If leakage
bounce to simulate riding conditions. Visually check for any occurs, remove tubes and inspect ends for burrs or dam-
contact between air spring and frame components. Add air as age. If either condition is found, snip off end of tube and
necessary. insert back into fitting.

8. Observe air pressure gauge. If leakage occurs, then 12. When air pressure remains constant, install protective
remove tube and inspect end for burrs or damage. If cap on air valve.
either condition is found, snip off end of tube and insert
13. Install saddlebags. Using an open end/box wrench,
back into fitting.
tighten saddlebag front mounting bracket bolts.
9. Depress collar on compression fitting of each shock and
insert air tube until it bottoms. Gently tug on tube to verify
that it is locked in place.

10. Fill shocks to desired pressure. See Table 2-2.

CAUTION

All air components fill rapidly. Use a small hand or foot

operated air pump to avoid possible damage to shocks
or air suspension components.

NOTE
An AIR SUSPENSION PUMP AND GAUGE (Part No. HD-
34633) is available at your Harley-Davidson dealer.

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INSTRUMENT MOUNTING BRACKET: FLHP 2.7

GENERAL 8
7
The Instrument Mounting Bracket relocates the tachometer to
allow for the addition of a radio and speaker.
9
NOTE
6
The two rear holes in the handlebar clamp shroud allow the
rider to adjust the handlebars without having to remove the
shroud. To keep out moisture and debris, be sure to install 10
plastic plugs back into holes after handlebar adjustment.

INSTALLATION
11
1. Remove windshield. See Section 2.31 WINDSHIELD/ 5
HEADLAMP NACELLE (FLHR/C/S), REMOVAL, in the
2004 Touring Models Service Manual (Part No. 99483-
04).

2. Remove Phillips screw at the bottom of the headlamp

door (chrome ring). Remove the headlamp door.
4
3. Remove the eight Phillips screws to free the headlamp
housing from the headlamp nacelle.

4. Squeeze the two external tabs (if present) to remove the

wire connector at the back of the headlamp bulb. 3
Remove headlamp housing assembly from the vehicle.

5. Reaching inside the headlamp nacelle, remove flange

nut to release the chrome strip at the top of the nacelle. 2
See Figure 2-8.

6. Carefully pry off the fork lock plate at the rear of the han-
dlebar clamp shroud. Remove two Phillips screws 1
f1458d2x
beneath the lock plate.

7. Loosen the Phillips screw from tab at the front of the han- 1. Headlamp Nacelle 7. Tachometer Bracket
dlebar clamp shroud (but do not remove). 2. Nut 8. Acorn Nut (2)
3. Flat Washer 9. Fork Lock Plate
8. Remove two acorn nuts from the left side fork studs. 4. Flange Nut 10. Handlebar Clamp Shroud
Remove acorn nuts from the right side fork studs. 5. Chrome Strip 11. Stud Plate
6. Phillips Screw (2)
9. Cover front fender with suitable material to protect fender
paint. Remove the passing lamp bracket from the left and
Figure 2-8. Headlamp Nacelle Assembly
right side fork studs and carefully set on front fender.

10. Remove grommets (and clutch cable clamp) from the left
and right side fork studs. 13. Remove two acorn nuts and flat washers to release
tachometer bracket from the handlebar clamp shroud.
11. Reaching inside the headlamp nacelle, disconnect
tachometer connector [108], 3-place Deutsch. 14. A peel and stick foam tape on the stud plate holds it in
place on the inboard side of the handlebar clamp shroud,
12. Remove the handlebar clamp shroud from the vehicle, Place the instrument mounting bracket over the studs
while gently pulling the tachometer conduit and connec- and secure using hardware provided by manufacturer.
tor out of the headlamp nacelle. See Figure 2-9. See upper frame of Figure 2-11.

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5531

f1458e2x

Figure 2-9. Handlebar Clamp Shroud

Install instrument mounting bracket on stud plate.

1 p0044x5x

5532

3 6

Install instrument mounting bracket front bolt.

5530
5
4

1. Acorn Nut
2. Instrument Mounting 4. Stud Plate
Bracket 5. Screw
3. Handlebar Clamp Shroud 6. Nut

Figure 2-10. Instrument Mounting Bracket Assembly

15. Secure slotted tab of instrument mounting bracket to Install tachometer bracket.
front of handlebar clamp shroud using nut and bolt pro-
vided by manufacturer. See middle frame of Figure 2-11. Figure 2-11. Install Instrument Mounting Bracket

16. Place tachometer bracket over studs on instrument

mounting bracket and install two acorn nuts with flat
washers. See lower frame of Figure 2-11. 18. Raising handlebar clamp shroud slightly, feed tachome-
ter connector and conduit into the headlamp nacelle.
17. Part the halves of the headlamp nacelle slightly. With the
Install shroud over mating flange while routing tachome-
flat washer on the handlebar clamp shroud facing the
ter conduit through opening for left side handlebar.
inside surface of the nacelle, slide the Phillips screw
Reaching inside headlamp nacelle, mate pin and socket
down the gap until the shroud is in position at top of
halves of tachometer connector.
nacelle. See Figure 2-9.

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19. With the halves of the nacelle mated, tighten the Phillips 25. Install wire connector at the back of headlamp bulb.
screw in the tab of the handlebar clamp shroud to 10-20
in-lbs (1.1-2.3 Nm). If necessary, temporarily install a 26. Align holes in headlamp housing with those in headlamp
small cable strap into holes at the bottom of the nacelle nacelle (headlamp door bracket at bottom). Install the
(headlamp housing flange) to hold the halves together. eight Phillips screws.
20. Install two Phillips screws to fasten handlebar clamp 27. Fit the square-shaped portion of the headlamp door
shroud to the fork lock mechanism. Install fork lock plate. spring into the slot at the top of the headlamp housing
21. Inserting weld stud on chrome strip into hole at the top of and then snap the headlamp door (chrome ring) into
the headlamp nacelle, reach inside the nacelle to install place. Install Phillips screw at the bottom of the head-
flange nut. Tighten flange nut to 15-20 in-lbs (1.7-2.3 lamp door.
Nm).
28. Install windshield. See Section 2.31 WINDSHIELD/
22. Install grommets on the left and right side fork studs. HEADLAMP NACELLE (FLHR/C/S), INSTALLATION, in
23. Slide passing lamp bracket onto the left and right side the 2004 Touring Models Service Manual (Part No.
fork studs. Verify that four grommets are positioned on 99483-04).
the inboard side of the passing lamp brackets.
24. Install acorn nuts on the fork studs and tighten to 72-108
in-lbs (8.1-12.2 Nm). Be sure to capture the clutch cable
clamp on the upper left stud before installing the acorn
nut.

2004 FLT Police: Chassis 2-11

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NOTES

2-12 2004 FLT Police: Chassis