Harley Davidson 2011 Touring Models. Service Manual — page 40
6.3
TRANSMISSION
POWER FLOW
See
. The 6-speed transmission consists of two
parallel shafts supporting six gears each. The longer, or
mainshaft (7), also supports the clutch and serves as the input
shaft. The shorter shaft is called the countershaft (8).
Each gear on the mainshaft is in constant mesh with a corres-
ponding gear on the countershaft. Each of these six pairs of
gears makes up a different speed in the transmission.
The transmission gears are divided into two types, gears that
rotate with the shaft, and freewheeling gears that ride on
bearings and spin freely on the shaft. A gear that rotates with
the shaft always meshes with a freewheeling gear. Also, three
dog rings are able to slide sideways on the shaft. These dog
rings are used to change transmission speeds. The dogs, or
projections, on the sides of the dog rings, engage dogs on
adjacent freewheeling gears, transmitting power through the
transmission.
Gear shifting is accomplished by three forks which fit into
grooves machined into the dog rings that slide on the guide
hubs. The position of the shifter forks is controlled by a drum-
shaped shifter cam located in the transmission side door.
Neutral
Power is introduced to the transmission through the clutch. In
neutral, with the clutch engaged, the mainshaft 1st, 2nd, 3rd
and 4th gears are rotating, but no power is transferred to the
countershaft since countershaft 1st, 2nd, 3rd and 4th gears
are freewheeling gears.
1st Gear
When the transmission is shifted into first gear, the dog ring
between countershaft 1st and 2nd, which rotates with the
countershaft, engages countershaft 1st, which has been spin-
ning freely on the countershaft driven by mainshaft 1st.
Now countershaft 1st is no longer freewheeling, but locked to
the countershaft causing the countershaft and countershaft
6th to turn. Countershaft 6th transmits the power to the main
drive gear and the sprocket as shown (1).
2nd Gear
Second gear is engaged when the dog ring between counter-
shaft 1st and 2nd is shifted out of countershaft 1st and engages
countershaft 2nd. This locks countershaft 2nd to the counter-
shaft to complete the power flow as shown (2).
3rd Gear
Two shifter forks are used to make the shift from second to
third. One fork moves the dog ring between countershaft 1st
and 2nd to its neutral position, while another fork engages the
dog ring between countershaft 3rd and 4th with countershaft
3rd. This locks countershaft 3rd to the countershaft to complete
the power flow as shown (3).
4th Gear
Fourth gear is engaged when the dog ring between counter-
shaft 3rd and 4th is shifted out of countershaft 3rd and engages
countershaft 4th. This locks countershaft 4th to the countershaft
to complete the power flow as shown (4).
5th Gear
Two shifter forks are used to make the shift from fourth to fifth.
One fork moves the dog ring between countershaft 3rd and
4th to its neutral position, while another fork engages the dog
ring between mainshaft 5th and 6th with mainshaft 5th. This
locks mainshaft 5th to the mainshaft to complete the power
flow as shown (5).
6th Gear
The shift from fifth to sixth gear occurs when the dog ring
between mainshaft 5th and 6th is shifted out of mainshaft 5th,
and is shifted directly into the main drive gear (6th gear). The
main drive gear is locked to the mainshaft resulting in a direct
one-to-one drive ratio from the clutch to the sprocket as shown
(6).
2011 Touring Service: Transmission 6-3
7.28
CIGARETTE LIGHTER: FAIRING MODELS
TROUBLESHOOTING
NOTE
The lighter socket is not intended to be used as a power port
for electrical devices. Damage to the lighter socket may occur.
1.
Ignition/light key switch must be ON or in ACCESSORY
position for lighter operation.
2.
If lighter does not work, substitute a known good lighter
element.
3.
If lighter is still inoperative, check for 12 vdc at center
socket contact and ground at outer shell contact.
4.
Refer to applicable wiring diagram in
if 12 vdc or ground are not present. Use voltage
checks to isolate problem.
REMOVAL
1.
Remove outer fairing. See
WINDSHIELD: FORK MOUNTED FAIRING MODELS
or
2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS
.
2.
Disconnect socket terminals from spade contacts on
cigarette lighter.
3.
Remove lighter from socket. Holding socket, unscrew outer
shell. Remove socket and outer shell from inner fairing.
INSTALLATION
1.
Slide socket of cigarette lighter through bore in fairing.
Thread outer shell onto socket until tight. Install cigarette
lighter in socket.
2.
Connect orange wire terminal to center socket spade
contact, the black wire terminal to outer shell contact.
3.
Install outer fairing. See
WINDSHIELD: FORK MOUNTED FAIRING MODELS
or
2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS
.
2011 Touring Service: Electrical 7-69
7.29
GAUGES AND INSTRUMENTS: FAIRING
MODELS
2 INCH DIAMETER GAUGES: FUEL LEVEL,
AMBIENT AIR TEMPERATURE,
VOLTMETER, OIL PRESSURE
Removal
1.
Remove outer fairing. See
WINDSHIELD: FORK MOUNTED FAIRING MODELS
or
2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS
.
2.
Pull 2-place and 3-place socket housings to release
interconnect harness from lamp and gauge, respectively.
NOTE
See
. To replace lamp, pull pin housing from gauge
and then pull lamp from slot of pin housing. Install new lamp
in slot and insert pin housing back into gauge.
3.
Remove hex nuts from studs. Remove mounting bracket.
4.
Remove gauge from inner fairing.
Installation
1.
Install gauge in inner fairing.
2.
See
. Slide mounting bracket over studs. Verify
that tabs on top and bottom of bracket engage slots in
inner fairing.
3.
Loosely install hex nuts on studs. Verify that gauge is
properly aligned and then tighten nuts to 10-20
in-lbs
(1.1-
2.3 Nm).
4.
Install 3-place and 2-place socket housings to connect
interconnect harness to gauge and lamp, respectively.
5.
Install outer fairing. See
WINDSHIELD: FORK MOUNTED FAIRING MODELS
or
2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS
.
1
3
6
4
2
5
sm02866
1. Pin housing
2. Hex nut
3. Stud
4. Mounting bracket
5. Tab
6. Gauge
Figure 7-91. 2 Inch Diameter Gauges
TACHOMETER
Removal
1.
Proceed as follows:
a.
Fork mounted fairing models:
Remove outer fairing.
See
2.34 UPPER FAIRING AND WINDSHIELD:
b.
Frame mounted fairing models:
Remove bezel.
See
2.39 INSTRUMENT BEZEL: FRAME MOUNTED
.
2.
Remove tachometer connector [108].
3.
Remove two screws to free tachometer bracket from back
of tachometer gauge.
4.
Push tachometer gauge toward rear of motorcycle to
remove.
Installation
1.
Insert tachometer gauge into inner fairing or bezel bore
(depending on model).
2.
Align holes in tachometer bracket with those at back of
tachometer gauge and start two screws.
3.
Rotate tachometer gauge until tabs at top and bottom of
bracket engage slots in inner fairing or bezel.
4.
Verify that gauge is properly aligned and tighten two
screws to 10-20
in-lbs
(1.1-2.3 Nm).
5.
Install tachometer connector [108].
7-70 2011 Touring Service: Electrical
6.
Proceed as follows:
a.
Fork mounted fairing models:
Install outer fairing.
See
2.34 UPPER FAIRING AND WINDSHIELD:
.
b.
Frame mounted fairing models:
Install bezel. See
2.39 INSTRUMENT BEZEL: FRAME MOUNTED
FAIRING MODELS
.
SPEEDOMETER
Removal
1.
Proceed as follows:
a.
Fork mounted fairing models:
Remove outer fairing.
See
2.34 UPPER FAIRING AND WINDSHIELD:
.
b.
Frame mounted fairing models:
Remove bezel.
See
2.39 INSTRUMENT BEZEL: FRAME MOUNTED
.
2.
Remove speedometer connector [39].
3.
Remove two screws to free speedometer bracket from
back of speedometer gauge. On fork mounted fairing
models, leave anchor on interconnect harness installed
in lower ear of speedometer bracket, if present.
4.
Push speedometer gauge toward rear of motorcycle to
remove.
Installation
1.
Insert speedometer gauge into opening.
2.
Align holes in speedometer bracket with those at back of
speedometer gauge and start two screws.
sm03707
Figure 7-92. Anchor Interconnect Harness in Ear of
Speedometer Bracket
3.
Rotate speedometer gauge until tabs at top and bottom
of bracket engage slots in inner fairing or bezel (depending
on model).
4.
Verify that gauge is properly aligned and tighten two
screws to 10-20
in-lbs
(1.1-2.3 Nm).
5.
Install speedometer connector [39].
6.
Proceed as follows:
a.
Fork mounted fairing models:
Verify that anchor
on interconnect harness is installed in lower ear of
speedometer bracket. Install outer fairing. See
2.34 UPPER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS
.
b.
Frame mounted fairing models:
Install bezel. See
2.39 INSTRUMENT BEZEL: FRAME MOUNTED
FAIRING MODELS
.
2011 Touring Service: Electrical 7-71
7.30
INDICATOR LAMPS: FAIRING MODELS
INDICATOR LAMPS
Removal
NOTE
All models are equipped with Light Emitting Diodes (LEDs) in
lieu of indicator lamps. The indicator lamp assembly is not
serviceable. If one LED is bad, the indicator lamp assembly
must be replaced.
1.
Proceed as follows:
a.
Fork mounted fairing models:
Remove outer fairing.
See
2.34 UPPER FAIRING AND WINDSHIELD:
.
b.
Frame mounted fairing models:
Remove bezel.
See
2.39 INSTRUMENT BEZEL: FRAME MOUNTED
.
2.
Disconnect indicator lamp connector [21].
3.
On fork mounted fairing models, remove tachometer gauge
to access indicator lamp assembly. See
AND INSTRUMENTS: FAIRING MODELS
.
4.
See
. Release each paddle on lens from pair
of index tabs on indicator lamp assembly. Remove lens if
damaged.
N
2
1
5
6
3
4
sm02867
1. Indicator lamp connector [21]
2. Indicator lamp assembly
3. Lens
4. Paddles
5. Index tabs
6. Orientation stamp
Figure 7-93. Indicator Lamp Assembly
Installation
1.
Place lens in inner opening, if removed. Note position of
oil icon on frame mounted fairing models to be sure that
lens is right side up. On fork mounted fairing models, slot
at bottom of lens engages index tab in inner fairing to
prevent improper orientation.
2.
With the word "TOP" facing upward, engage each paddle
on lens with pair of index tabs on indicator lamp assembly.
3.
Connect indicator lamp connector [21].
4.
On fork mounted fairing models, install tachometer gauge.
See
7.29 GAUGES AND INSTRUMENTS: FAIRING
5.
Proceed as follows:
a.
Fork mounted fairing models:
Install outer fairing.
See
2.34 UPPER FAIRING AND WINDSHIELD:
b.
Frame mounted fairing models:
Install bezel. See
2.39 INSTRUMENT BEZEL: FRAME MOUNTED
FAIRING MODELS
.
7-72 2011 Touring Service: Electrical
7.31
GAUGES AND INSTRUMENTS: ROAD KING
MODELS
FUEL GAUGE
Removal
1.
Remove main fuse. See
2.
Draw fuel gauge connector [117], 4-place Multilock, out
of tunnel on left side of fuel tank and disconnect.
NOTE
For instructions to remove wire terminals see
3.
Remove terminals from connector housing.
4.
Remove convoluted tubing from wires.
5.
Remove the gauge from the top left side of the fuel tank.
Do not twist during removal. Pull upward just far enough
to free the gauge from the fuel tank.
6.
Remove fuel gauge from motorcycle while feeding wires
and pin terminals up through tube.
7.
If reusing gauge, inspect rubber seal for tears, cuts or
general deterioration. Replace seal if necessary. Install
new
seal so that flat side contacts edge of gauge.
Installation
1.
Place
new
fuel gauge assembly next to discarded unit
and cut wires to proper length.
NOTE
For instructions on crimping wire terminals, see
070 MULTILOCK UNSEALED CONNECTOR
2.
Crimp
new
pin terminals onto fuel gauge wires.
3.
Feed wires down into tube while lowering cap into position.
When pin terminals exit hole at bottom of fuel tank, gently
pull wires while installing the fuel gauge on the fuel tank.
Do not twist the gauge during installation. Hold the gauge
firmly and press downward until it snaps in place.
4.
Install convoluted tubing on wires.
NOTE
For instructions on properly installing wire terminals, see
A.19 TYCO 070 MULTILOCK UNSEALED CONNECTOR
5.
See
. Install terminals into connector housing.
6.
Route pin housing and convoluted tubing forward and then
inboard between front of crossover hose fitting and bottom
of fuel tank. Connect fuel gauge connector and feed into
tunnel of fuel tank.
7.
Install main fuse. See
sm02975
Figure 7-94. Fuel Gauge (FLHR/C)
Table 7-18. FLHR/C Fuel Gauge [17]
CHAMBER NUMBER
WIRE COLOR
1
Orange
2
Yellow/White
3
-
4
Black
SPEEDOMETER
Removal
1.
Remove main fuse. See
.
2.
Remove seat. See
3.
Remove fasteners to release console from fuel tank.
4.
Lay a clean shop towel on forward part of rear fender and
lay console upside down on shop towel.
5.
See
. Remove speedometer connector (9). If
necessary, bend back flexible metal clips (1) to free con-
nector conduit.
6.
Gently pry three latches (7) upward to release lock ring
(8) from back of speedometer.
7.
Remove speedometer from top side of console.
8.
Remove rubber gasket from speedometer bore.
2011 Touring Service: Electrical 7-73
7
8
9
3
1
4
1
2
6
5
1
10
sm02977
6.
1.
Odometer reset switch
Metal clip (3)
2.
7.
Plastic clip
Latch (1 of 3)
8.
3.
Lock ring
Ignition/light key switch connector [33]
4.
9.
Indicator lights connector [21]
Speedometer connector [39]
10.
5.
Speedometer
Indicator lights assembly
Figure 7-95. Instrument Console Assembly (FLHR/C)
Installation
1.
Lubricate groove in rubber gasket with isopropyl alcohol
or glass cleaner. Place the gasket into position around the
console speedometer bore.
2.
Install speedometer into rubber gasket. Lubricate gasket
with isopropyl alcohol or glass cleaner, if necessary. The
speedometer should fit snugly against the gasket without
movement.
3.
See
. Place lock ring over back of speedometer
aligning two slots with console bosses. Press latches (7)
down until they lock into position.
4.
Connect speedometer connector (9).
5.
If released, bend flexible metal clips (1) to capture con-
nector conduit.
6.
Exercising caution to avoid pinching wire harness and vent
tube, position console on fuel tank.
7.
Install front and rear fasteners to secure console to fuel
tank.
8.
Tighten fasteners to 36-60
in-lbs
(4.1-6.8 Nm).
9.
Install seat. See
10. Install main fuse. See
7-74 2011 Touring Service: Electrical
7.32
INDICATOR LAMPS: ROAD KING MODELS
INDICATOR LAMPS
Removal
NOTE
All models are equipped with Light Emitting Diodes (LEDs) in
lieu of indicator lamps. The indicator lamp assembly is not
serviceable. If one LED is bad, the indicator lamp assembly
must be replaced.
1.
Remove main fuse. See
2.
Remove seat. See
.
3.
Remove fasteners to release console from fuel tank.
4.
Lay a clean shop towel on forward part of rear fender and
lay console upside down on shop towel.
5.
See
. Disconnect indicator lamp connector (2).
If necessary, bend flexible metal clip (1) to free connector
conduit.
6.
Remove indicator lamp assembly from console as follows:
a.
Insert the blade of a large screwdriver under rear
corner of indicator lamp assembly.
b.
Squeeze front and rear paddles (3) on same side of
assembly while rotating screwdriver.
c.
When one side of assembly becomes free, repeat
procedure on opposite side to release unit from con-
sole.
Installation
1.
Install indicator lamp assembly into console as follows:
a.
Place assembly into position in console engaging four
paddles in slots of indicator lamp assembly.
b.
While pushing down on assembly, push up on lens
on outboard side of console until assembly fits snugly.
3
2
1
sm02978
1. Metal clip
2. Indicator lamp connector [21]
3. Paddles
Figure 7-96. Release Paddles to Free Indicator Lamp
Assembly (FLHR/C)
2.
Connect indicator lamp connector. If released, bend flex-
ible metal clip to capture connector conduit.
3.
Exercising caution to avoid pinching wire harness and vent
tube, position console on fuel tank.
4.
Install front and rear fasteners to secure console to fuel
tank.
5.
Tighten fasteners to 36-60
in-lbs
(4.1-6.8 Nm).
6.
Install seat. See
7.
Install main fuse. See
2011 Touring Service: Electrical 7-75
7.33
ADVANCED AUDIO SYSTEM
RADIO
Removal
1.
Remove main fuse. See
2.
Remove outer fairing. See
WINDSHIELD: FORK MOUNTED FAIRING MODELS
or
2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS
.
3.
Non-Ultra Models:
a.
See
. Disconnect radio connector (1).
b.
Disconnect radio antenna cable connector (2).
4.
Ultra Models:
a.
See
. Disconnect radio connector (1).
b.
Disconnect radio antenna cable connector (2).
c.
Disconnect radio connector (3).
d.
Disconnect CB antenna cable connector (4).
e.
Disconnect CB module connector (5).
f.
Remove screw to release flange of CB module from
radio. Remove CB module.
5.
See
. Remove four screws to release radio
from radio support brackets.
6.
Pull radio forward to remove from opening in inner fairing.
4
3
2
5
1
sm02964
1. Radio [27]
2. Radio antenna cable [51]
3. Radio [28]
4. CB antenna cable [50]
5. CB module [184]
Figure 7-97. Radio/CB Connections
sm02965
Figure 7-98. Release Radio from Fairing Brackets
Installation
1.
Position radio between radio support brackets and push
into opening in inner fairing.
7-76 2011 Touring Service: Electrical
2.
Starting at the rear, install four screws and tighten to 35-45
in-lbs
(4.0-5.1 Nm).
3.
Non-Ultra Models:
a.
See
. Connect radio connector (1).
b.
Connect radio antenna cable connector (2).
4.
Ultra Models:
a.
See
. Fit CB module into rubber grommets
at top left side of radio.
b.
Fasten flange of CB module to radio and tighten screw
to 35-45
in-lbs
(4.0-5.1 Nm).
c.
Connect radio connector (3).
d.
Connect CB antenna cable connector (4).
e.
Connect CB module connector (5).
f.
Connect radio connector (1).
g.
Connect radio antenna cable connector (2).
5.
Install outer fairing. See
WINDSHIELD: FORK MOUNTED FAIRING MODELS
or
2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS
.
6.
Install main fuse. See
FRONT FAIRING SPEAKERS
Removal
1.
Remove outer fairing. See
WINDSHIELD: FORK MOUNTED FAIRING MODELS
or
2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS
.
2.
Carefully pull socket terminals from speaker spade con-
tacts.
3.
Remove three screws to release speaker adapter
assembly from inner fairing.
4.
Carefully pull speaker from adapter.
Installation
1.
With the speaker spade contacts at the top of the adapter,
the top being the side with the widest edge, snap speaker
into adapter using finger pressure.
2.
If speaker grille is loose, apply 3M-847 adhesive (Part No.
99618-60) to outer edge of adapter ring. Install grille on
adhesive.
3.
With the widest edge of adapter at the top, align holes in
speaker adapter assembly with those in inner fairing.
4.
Start two long screws to secure top of speaker adapter
assembly to inner fairing. Capturing fairing support brace,
install short screw in lower outboard hole (positioning flat
washer between adapter and support brace). The screw
hole on the lower inboard side is not used.
5.
Tighten lower speaker screw to 22-28
in-lbs
(2.5-3.2 Nm).
Tighten two upper speaker screws to 35-50
in-lbs
(4.0-
5.7 Nm).
6.
Install socket terminals onto speaker spade contacts. Dif-
ferent size spade contacts prevent improper assembly.
7.
Install outer fairing. See
WINDSHIELD: FORK MOUNTED FAIRING MODELS
or
2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS
.
FRONT HEADSET RECEPTACLE
NOTE
The following instructions may also be used for replacement
of the fuel tank console on which the front headset receptacle
is mounted.
Removal
1.
Remove seat. See
2.
Remove left side saddlebag. See
3.
Remove left side cover.
4.
Carefully cut two cable straps securing headset receptacle
conduit and audio harness to inboard side of left upper
frame tube (front and rear of saddlebag rail).
5.
Release console connector [53], 12-place Deutsch, from
attachment clip anchored in hole of frame crossmember
(at rear of battery). Disconnect pin and socket halves.
6.
Remove socket screw to release front of console from fuel
tank weldment.
7.
Remove hex screw to release rear console bracket from
clip nut on rear fuel tank bracket.
8.
Lay a clean shop towel on forward part of rear fender.
9.
Press button to open fuel door on console. Remove filler
cap. Remove console bending back flexible metal clips
as necessary to release wire harness and front headset
receptacle conduit.
10. Lay console upside down on shop towel. Install filler cap.
11. See
. Raise headset receptacle cap. Place pin
punch in either notch of lock ring and rotate in a counter-
clockwise direction until loose.
12. Remove lock ring and cap from headset receptacle.
13. Remove headset receptacle from console.
Installation
1.
Insert threaded end of headset receptacle through hole in
console.
2.
Slide receptacle cap over threaded end of headset
receptacle.
3.
Open cap, and with the notches on the outboard side,
thread lock ring onto headset receptacle.
4.
See
. Place pin punch in either notch of lock
ring and rotate in a clockwise direction until tight.
5.
Remove filler cap, if installed. Position console on fuel
tank bending flexible metal clips as necessary to capture
wire harness and front headset receptacle conduit. Install
filler cap.
2011 Touring Service: Electrical 7-77
6.
Start socket screw to fasten front of console to fuel tank
weldment.
7.
Start hex screw to fasten rear console bracket to clip nut
on rear fuel tank bracket.
8.
Alternately tighten socket/hex screws to 36-60
in-lbs
(4.1-
6.8 Nm).
9.
Connect console connector [53], 12-place Deutsch. Install
connector onto attachment clip anchored in hole of frame
crossmember (at rear of battery).
10. Install two
new
cable straps to secure headset receptacle
conduit and audio harness to inboard side of left upper
frame tube (front and rear of saddlebag rail).
11. Install left side cover.
12. Install left side saddlebag. See
13. Install seat. See
.
14. Test operation of headset receptacle.
sm02969
Figure 7-99. Remove Lock Ring from Receptacle
REAR HEADSET RECEPTACLE
Replace audio harness. See
.
REAR PASSENGER SWITCHES
Removal
NOTE
Right and left side replacement passenger switch assemblies
are interchangeable.
1.
Remove main fuse. See
2.
Open Tour-Pak.
3.
Remove four screws and pull speaker grille from speaker
box.
4.
Remove speaker from speaker box and carefully pull
socket terminals from speaker spade contacts.
5.
Remove trim ring and gently pull on wire harness to draw
rear speaker/passenger controls connector, 6-place
Deutsch, out of speaker box.
6.
Disconnect pin and socket halves of connector.
7.
Draw socket housing back into speaker box and pull out
through speaker hole.
8.
See
. Remove two screws to release switch
bracket from inside of speaker box. Remove bracket using
slot to free switch wires.
9.
Pull switch housing assembly, wire harness, speaker ter-
minals and socket housing from speaker box using switch
housing hole on outboard side.
10. Carefully pull keycap from switch shaft. Remove switch
from switch housing.
11. Remove terminals 1 through 4 from socket housing.
NOTE
For instructions on properly removing wire terminals, see
A.12 DEUTSCH DT SEALED CONNECTORS
12. Pulling one wire at a time, draw four switch wires from
conduit.
2
1
sm02970
1. T25 TORX screw (2)
2. Switch bracket
Figure 7-100. Remove Passenger Switch Assembly
Installation
1.
Inserting one wire at a time, push four switch wires through
conduit.
2.
Install terminals into socket housing. Refer to
Table 7-19. Rear Passenger Switches [41/42]
CHAMBER NUMBER
WIRE COLOR
1
Pink/White
2
Gray/White
3
Violet/Black
4
*Orange/Black
* Mates to O/BK on [41A], BN/W on [42A].
7-78 2011 Touring Service: Electrical
NOTE
For instructions on properly installing wire terminals, see
A.12 DEUTSCH DT SEALED CONNECTORS
.
3.
See
. With the Pink/White wire at the bottom,
place switch in cavity of switch housing. Bottom of
assembly is determined by location of rib on switch
housing.
4.
Note lettering for proper orientation and gently push
keycap onto switch shaft. When orienting keycap,
remember that bottom of assembly is determined by loca-
tion of switch housing rib.
5.
Feed socket housing, speaker terminals and wire harness
through switch housing hole on outboard side of speaker
box until switch housing backplate contacts speaker box.
Pull wire harness out through speaker hole.
NOTE
See
. To align bracket and switch housing holes,
slot in bracket must face toward the front on right side switch
assembly and toward the rear on left side switch assembly.
Switch also must be square in cavity of switch housing or
bracket will not fit.
6.
Reaching into speaker box, align holes in bracket with
holes in switch housing. Install two screws.
7.
Feed socket housing through speaker hole into speaker
box and pull out through harness hole on inboard side.
8.
Mate pin and socket halves of connector. Feed connector
back up into speaker box pressing trim ring into hole.
9.
Install socket terminals onto speaker spade contacts. Dif-
ferent size spade contacts prevent improper assembly.
10. Align holes in speaker grille with those in speaker and
slide four screws through grille and speaker holes.
11. With spade contacts at bottom rear corner, position
speaker/grille assembly against speaker box. Start screws
into speaker box and alternately tighten in a crosswise
pattern.
12. Close Tour-Pak.
13. Install main fuse. See
14. Test switch for proper operation.
1
2
3
4
5
6
sm02971
1. Passenger switch
2. Switch housing
3. Cavity
4. Pink/white wire
5. Rib
6. Keycap
Figure 7-101. Install Switch in Housing
2011 Touring Service: Electrical 7-79
1
2
sm02974
1. Slot faces front (right side), rear (left side)
2. Rib at bottom
Figure 7-102. Install Passenger Switch Assembly
REAR SPEAKERS
Removal
1.
Remove main fuse. See
2.
Open Tour-Pak.
3.
Remove four screws from speaker grille. Remove speaker
grille from speaker box.
4.
Remove speaker from speaker box. Carefully pull two
socket terminals from speaker spade contacts.
Installation
1.
Install two socket terminals onto speaker spade contacts.
Different size spade contacts prevent improper assembly.
2.
With spade contacts at bottom, install speaker in speaker
box.
3.
Align holes in speaker with those in speaker box. Align
holes in grille with those in speaker.
4.
Install four screws and alternately tighten in a crosswise
pattern.
5.
Close Tour-Pak.
6.
Install main fuse. See
7.
Test speaker for proper operation.
CB MODULE
Removal
1.
Remove main fuse. See
.
2.
Remove outer fairing. See
WINDSHIELD: FORK MOUNTED FAIRING MODELS
3.
See
. Disconnect the following:
a.
CB antenna cable connector [50].
b.
CB module connector [184], 12-place Deutsch (black).
4.
Remove screw to release flange of CB module from radio.
Remove CB module.
Installation
1.
Fit metal cones on CB module into rubber grommets at
top of radio. Use the position above radio connector [28],
35-place Amp, as the other location has been reserved
for certain P&A accessories.
2.
Install screw to fasten flange of CB module to radio.
Tighten screw to 35-45
in-lbs
(4.0-5.1 Nm).
3.
See
. Connect the following:
a.
CB antenna cable connector [50].
b.
CB module connector [184], 12-place Deutsch (black).
4.
Install outer fairing. See
WINDSHIELD: FORK MOUNTED FAIRING MODELS
5.
Install main fuse. See
7-80 2011 Touring Service: Electrical
7.34
WIRE TROUGH
REMOVAL
1.
Remove main fuse. See
2.
Remove fuel tank. See
.
3.
Remove T-MAP sensor connector [80].
4.
Remove front [84] and rear [85] fuel injector connectors.
5.
Remove TCA connector [211]. Cut anchored cable strap
to release connector conduit from front side of induction
module.
6.
Models with 103 engine:
Disconnect ACR connectors
and release connector housings from induction module
support.
7.
Disconnect elbow terminals from spade contacts on horn
and release harness conduit from J-clamp.
8.
Pull back boot and disconnect ET sensor connector [90].
9.
Draw connectors removed in previous steps to right side
of motorcycle.
10. See
. On ABS equipped motorcycles, release
brake lines (2, 3) from wire trough.
11. Cut two cable straps (4) to release breakout harnesses
from right side of wire trough.
12. Release catches on cover and remove cover (1).
13. See
. Using a paint pen, draw a line on each
wire bundle on both sides of each cable strap.
NOTE
Note that there are a total of ten cable straps. Eight cable straps
fix the position of the harness(es) inside the wire trough, while
two more fix the position of the breakouts on the right side.
2
1
3
4
sm06020a
1. Wire trough cover
2. Front master cylinder-to-ABS module line
3. ABS module-to-front caliper line
4. Breakout harness cable straps
Figure 7-103. Wire Trough and Brake Lines
sm05143
Figure 7-104. Mark Location of Cable Straps
1
2
sm05146
1. Reusable (tail removed)
2. Not reusable (eyelet removed)
Figure 7-105. Cut Cable Straps
NOTE
See
. When removing cable ties, cut off the tail of
the cable strap and not the eyelet. The cable strap can then
be reused to gather wires when removing harness from wire
trough.
14. Cutting as close to the eyelet as possible, cut eight cable
straps inside the wire trough. Remove each cable strap
from slots in wire trough and remove the tail remnant from
the eyelet. Install the cable strap back on the harness near
2011 Touring Service: Electrical 7-81
the painted lines to gather the bunch of wires. Be sure to
capture each wire of the harness.
15. Pull breakout harnesses out through slot in breakout
compartment. If ABS equipped, move harnesses outboard
of brake lines.
16.
FLHR/C, FLHTK:
Remove fuel gauge harness from slot
in front of wire trough.
17. Pry anchor pins at rear of wire trough from holes in frame
backbone.
18. Raise wire harnesses and remove wire trough from right
side of motorcycle.
INSTALLATION
1.
Thread eight
new
cable straps through slots inside wire
trough.
2.
Raise wire harnesses and slide wire trough into position
on frame backbone from right side of motorcycle.
3.
FLHR/C, FLHTK:
Route the fuel gauge harness through
slot in front-left of wire trough.
4.
See
. Install rear fuel injector, rear ACR (if
equipped) and T-MAP sensor breakout harnesses in the
rear of the breakout compartment and install a
new
cable
tie but do not tighten cable tie.
5.
Install front fuel injector, horn/ET sensor, front ACR (if
equipped) and TCA breakout harnesses in the front of the
breakout compartment and install a
new
cable tie but do
not tighten cable tie.
6.
Pull breakout harnesses inboard of brake lines on ABS
equipped vehicles.
7.
Adjust harness wires inside wire trough, so they are posi-
tioned within the eight cable straps. Engage each cable
strap but do not tighten.
8.
Remove the cable straps used to gather the wire bunches.
9.
Route main harness and audio harness (if equipped)
through front-left channel of wire trough.
10. Route main harness through front-right channel of wire
trough.
11. Push anchor pins at rear of wire trough into holes in frame
backbone.
12. Make final adjustments to harnesses so that the painted
lines are aligned with the cable straps. Tighten cable straps
and cut excess cable strap material.
13. Pull on each harness exiting the breakout compartment
until painted lines are aligned with cable straps. Tighten
cable straps and cut excess cable strap material.
14. Secure cover to wire trough starting at the rear and
working forward. Verify that all latches are fully engaged.
15.
ABS equipped motorcycles:
Secure brake line as shown
in
16. Install T-MAP sensor connector, rear fuel injector con-
nector, front fuel injector connector, ET sensor connector,
and elbow terminals onto horn spade contacts. Capture
horn harness conduit in J-clamp.
17. Install TCA connector. Install
new
anchored cable strap
in hole at front right side of induction module and secure
harness. Cut excess cable strap material.
18.
Models with 103 engine:
Connect ACR connectors and
secure to induction module support.
19. Install fuel tank. See
20. Install main fuse. See
1
2
4
3
5
6
7
sm06070a
1. Rear fuel injector
2. Rear ACR (if equipped)
3. T-MAP sensor
4. Horn/ET sensor
5. Front ACR (if equipped)
6. TCA
7. Front fuel injector
Figure 7-106. Breakout Harnesses
7-82 2011 Touring Service: Electrical
7.35
MAIN WIRING HARNESS
REMOVAL: ALL MODELS (PART 1)
1.
Remove fuel tank. See
.
2.
Remove battery. See
3.
Remove saddlebags. See
.
4.
Remove left and right side covers.
NOTE
Depending upon model, continue procedure at
WIRING HARNESS, Removal: Road King Models (Part 2)
,
7.35 MAIN WIRING HARNESS, Removal: Fork Mounted
Fairing Models (Part 2)
or
Removal: Frame Mounted Fairing Models (Part 2)
.
REMOVAL: ROAD KING MODELS (PART 2)
1.
Remove headlamp assembly. See
.
2.
See
. Reaching inside headlamp nacelle,
disconnect connectors and remove from their retaining
devices, if present:
a.
Auxiliary lamps [73], 2-place Multilock (white).
b.
Auxiliary lamps switch [109], 4-place Amp.
c.
Right handlebar switches [22], 6-place Molex (black).
d.
Cruise set/resume switch [159], 3-place Molex (black);
used on FLHRC only.
e.
Twist grip sensor jumper harness [204], 6-place Molex
(black).
3.
Remove rivet and P-clamp to release main harness conduit
from right side of steering head.
4.
Carefully pull main harness rearward under right side of
headlamp nacelle allowing conduit and connectors to hang
over top of engine guard.
5.
Reaching inside headlamp nacelle, disconnect connectors
and remove from their retaining devices, if present:
a.
Front fender tip lamp jumper harness [32], 2-place
Multilock (black); used on FLHR only.
b.
Accessory switch [67], 4-place Amp.
c.
Front turn signal lamps [31], 6-place Multilock.
d.
Left handlebar switches [24], 8-place Molex (gray).
e.
Cruise on/off switch [158], 3-place Molex (gray); used
on FLHRC only.
f.
Front wheel speed sensor [167], 2-place Amp (Tyco);
used on ABS equipped motorcycles only.
6.
Remove rivet and P-clamp to release main harness conduit
from left side of steering head.
7.
Carefully pull main harness rearward under left side of
headlamp nacelle allowing conduit and connectors to hang
over top of engine guard.
NOTE
Continue procedure at
.
2011 Touring Service: Electrical 7-83
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