Harley Davidson FXD DYNA 2019. Service repair Manual and Wiring Diagrams — page 18
340
CHAPTER EIGHT
69
71
70
72
6. Separate the field coil (B, Figure 70) from the
solenoid housing (C).
73
7. Remove the end cap screws, washers and O-rings
(A, Figure 71). Then remove the end cap (B).
8. Pull the brush holder (A, Figure 72) away from
the commutator and remove the armature (B) from
the field coil assembly.
9. Remove the two field coil brushes from the
brush holder (Figure 73).
10. Clean all grease, dirt and carbon from the arma-
ture, field coil assembly and end covers.
CAUTION
Be extremely careful when selecting a
74
solvent to clean the electrical compo-
nents. Do not immerse any of the wire
windings in solvent, because the insu-
lation may be damaged. Wipe the
windings with a cloth lightly moist-
ened with solvent, then allow the solu-
tion to dry thoroughly.
11. To service the drive housing assembly, refer to
Drive Housing Disassembly/Inspection/Assembly
in this chapter.
ELECTRICAL SYSTEM
341
75
79
12. To service the solenoid housing, refer to Sole-
76
noid Housing Disassembly/Inspection/Assembly in
this chapter.
Inspection
8
1. Measure the length of each brush with a vernier
caliper (Figure 74). If the length is less than the
minimum specified in Table 4, replace all of the
brushes as a set. See Figure 75 for the field coil and
Figure 76 for the brush holder.
NOTE
77
The field coil brushes (Figure 75) are
soldered in position. To replace, un-
solder the brushes by heating their
joints with a soldering gun, then pull
them out with a pair of pliers. Position
the new brushes and solder in place
with rosin core solder—do not use
acid core solder.
2. Inspect the commutator (A, Figure 77). The
mica should be below the surface of the copper
commutator segments (Figure 78). If the commuta-
tor bars are worn to the same level as the mica insu-
lation, have the commutator serviced by a
78
dealership or electrical repair shop.
3. Inspect the commutator copper segments for dis-
coloration. If the commutator segments are rough,
Good
discolored or worn, have the commutator serviced
by a dealership or electrical repair shop.
4. Measure the outer diameter of the commutator
with a vernier caliper (Figure 79). Replace the ar-
Worn
mature if worn to the service limit listed in Table
4.
5. Use an ohmmeter to perform the following:
342
CHAPTER EIGHT
80
82
Ohmmeter
Starter terminal
Field frame
81
83
Ohmmeter
Field frame
a. Check for continuity between the commuta-
tor bars (Figure 80); there must be continuity
84
between pairs of bars.
b. Check for continuity between any commuta-
Insulated
tor bar and the shaft (Figure 81). There must
brush
be no continuity.
holders
c. If the unit fails either of these tests, replace
the armature.
6. Use an ohmmeter to perform the following:
a. Check for continuity between the starter cable
terminal and each field frame brush (Figure
82); there must be continuity.
b. Check for continuity between the field frame
housing and each field frame brush (Figure
83); there must be no continuity.
c. If the unit fails either of these tests, replace
the field frame assembly.
Test leads
7. Use an ohmmeter and check for continuity be-
Brush holder plate
tween the brush holder plate and each brush holder
(Figure 84); there must be no continuity. If the unit
fails this test, replace the brush holder plate.
8. Service the armature bearings as follows:
a. Check the bearings (B, Figure 77) on the arma-
ture shaft. Replace worn or damaged bearings.
ELECTRICAL SYSTEM
343
85
89
NOTE
86
The armature shaft bearings have dif-
ferent part numbers. Identify the old
bearings before removing them.
b. Check the bearing bores in the end cover and
solenoid housing. Replace the cover or hous-
ing if the area is worn or cracked.
8
Assembly
Refer to Figure 66.
1. If serviced, assemble the drive housing as de-
scribed in this chapter.
87
2. If serviced, assemble the solenoid housing as de-
scribed in this chapter.
3. Lubricate the armature bearings (B, Figure 77)
with high-temperature grease.
4. Install two new O-rings onto the field coil shoul-
ders (Figure 85).
5. Install the two field coil brushes into the brush
plate holders (Figure 86).
6. Install the armature partially through the field
coil as shown in Figure 72. Then pull the brushes
back and push the armature forward so that when
released, all of the brushes contact the commutator
as shown in Figure 87 and Figure 88.
7. Install the end cap (Figure 89) and the two
88
screws, washers and O-rings. Tighten the screws se-
curely.
8. Align the field coil (A, Figure 90) with the sole-
noid housing (B) and assemble both housings. Hold
the assembly together while installing the drive
housing in Step 9.
9. Align the drive housing (Figure 91) with the
field coil and solenoid housing assembly and install
it. Install the two drive housing screws and
lockwashers (Figure 68) and tighten securely.
344
CHAPTER EIGHT
90
91
10. Install the two through bolts, washers and
O-rings (Figure 67) and tighten securely.
92
11. Reconnect the C terminal field wire (C, Figure
90) at the solenoid housing.
Drive Housing
Disassembly/Inspection/Assembly
The drive housing was removed during starter
disassembly.
1. Remove the return spring (A, Figure 92), ball,
clutch shaft (B), and drive spring (Figure 93) from
the drive assembly.
2. Remove the idler gear (Figure 94) from the
93
drive housing.
3. Remove the idler gear bearing and cage assem-
bly (A, Figure 95). There are five individual bear-
ing rollers (Figure 96).
4. Remove the drive assembly (B, Figure 95).
5. Replace the drive housing O-ring (Figure 97) if
worn or damaged. Lubricate the O-ring with high
temperature grease.
6. Inspect the idler gear bearing and cage assembly
(Figure 96) for worn or damaged parts.
CAUTION
The drive assembly (Figure 98) is a
sealed unit. Do not clean or soak it in
94
any type of solvent.
7. Inspect the drive assembly and its bearings (Fig-
ure 98) for worn or damaged parts. If the bearings
are worn or damaged, replace the drive assembly
and bearings as a set.
8. Assemble the drive housing by reversing these
steps, while noting the following.
9. Lubricate the following components with high
temperature grease:
ELECTRICAL SYSTEM
345
95
99
STARTER SOLENOID
96
8
97
1. Solenoid housing
5. Clip
2. Plunger
6. Lockwasher
3. Gasket
7. Bolt
4. Cover
a. Idler gear bearing and cage assembly (Figure
96).
b. Drive housing O-ring and shaft (Figure 97).
c. Drive assembly (Figure 98).
d. Clutch shaft, drive spring, return spring, and
98
ball.
10. Install the idler gear bearing and cage assembly
so that the open side of the cage (A, Figure 95)
faces toward the solenoid housing.
Solenoid Housing
Disassembly/Inspection/Assembly
1. Remove the solenoid housing (Figure 99) as de-
scribed during starter disassembly.
346
CHAPTER EIGHT
2. Remove the screws, washers and clip securing
the end cover to the solenoid housing. Then remove
100
the end cover (Figure 100) and gasket.
3. Remove the plunger assembly (Figure 101).
4. Inspect the plunger (Figure 102) for scoring,
deep wear marks or other damage.
5. Inspect the solenoid housing (Figure 103) for
wear, cracks or other damage.
6. The solenoid housing is a separate assembly
and cannot be serviced. If any part is defective,
the solenoid housing must be replaced as an as-
sembly.
7. Assemble the solenoid housing by reversing
these steps. Lubricate the solenoid plunger with
101
high temperature grease.
LIGHTING SYSTEM
The lighting system consists of a headlight, tail-
light/brake light combination and turn signals.
Always use the correct wattage bulb. The use of
a larger wattage bulb will give a dim light and a
smaller wattage bulb will burn out prematurely.
Table 5 lists replacement bulbs.
Headlight Bulb Replacement
102
Refer to Figure 104.
CAUTION
All models are equipped with a
quartz-halogen bulb. Do not touch
the bulb glass. Traces of oil on the
bulb will drastically reduce the life
of the bulb. Clean all traces of oil
from the bulb glass with a cloth
moistened in alcohol or lacquer
thinner.
WARNING
103
If the headlight has just burned out or
been turned off it will be hot. To avoid
burned fingers, do not touch the bulb.
Allow the bulb to cool prior to re-
moval.
1. Loosen the pinch screw (A, Figure 105) and re-
move the trim bezel (B).
2. Pull straight out and disconnect the electrical
connector from the bulb (Figure 106) and remove
the headlight assembly.
ELECTRICAL SYSTEM
347
104
HEADLIGHT
1.
Plug (all models except
FXDWG)
2.
Nut (all models except
FXDWG)
3.
Lockwasher (all
models except
FXDWG)
4.
Washer (all models
except FXDWG)
5.
Bracket (all models
except FXDWG)
6.
Trim (all models except
FXDWG)
7.
Bolt
8.
Housing (all models
except FXDWG)
9.
Housing (FXDWG
models)
10.
Washer (FXDWG
8
models)
11.
Mounting block
(FXDWG models)
12.
Washer (FXDWG
models)
13.
Lockwasher (FXDWG
models)
14.
Nut (FXDWG models)
15.
Mounting bracket
(FXDWG models)
16.
Mounting ring
17.
Rubber cover
18.
Bulb
19.
Lens
20.
Trim bezel
21.
Nut
22.
Connector
105
106
348
CHAPTER EIGHT
3. Remove the rubber cover (Figure 107) from the
back of the headlight lens. Check the rubber boot
107
for tears or deterioration; replace if necessary.
4. Unhook the light bulb retaining clip (Figure
108) and pivot it out of the way.
5. Remove the blown bulb (Figure 109).
6. Align the tangs on the new bulb with the
notches in the headlight lens and install the bulb.
7. Securely hook the retaining clip onto the bulb
(Figure 108).
8. Position the rubber cover so that the TOP mark
on the boot is positioned at the top of the headlight
lens. Install the rubber cover
(Figure 107) and
make sure it is correctly seated against the bulb and
108
the headlight lens.
9. Correctly align the electrical plug terminals with
the bulb
(Figure
106) and connect it. Push it
straight on until it bottoms on the bulb and the rub-
ber cover.
10. Check headlight operation.
11. Insert the lens into the headlight housing and
seat it correctly.
12. Install the trim bezel onto the headlight lens
and housing.
13. Securely tighten the pinch screw.
14. Check headlight adjustment as described in this
chapter.
109
Headlight Adjustment
1. Park the motorcycle on a level surface approxi-
mately 25 ft. (7.6 m) from the wall (Figure 110).
2. Check tire inflation pressure, and adjust if neces-
sary as described in Chapter Three.
3. Draw a horizontal line on the wall that is 35 in.
(0.9 m) above the floor.
4. Have a rider sit on the seat.
5. Aim the headlight at the wall and turn on the
headlight. Switch the headlight to the high beam.
a. Remove the plug (Figure 111) from the top of
The front wheel must be pointing straight ahead.
the headlight housing.
6. Check the headlight beam alignment. The broad,
b. Loosen the headlight clamp nut (Figure 112).
flat pattern of light (main beam of light) must be
c. Tilt the headlight assembly up or down to ad-
centered on the horizontal line (equal area of light
just the beam vertically.
above and below line).
d. Turn the assembly to the left or right sides to
7. Now check the headlight beam lateral align-
adjust the beam horizontally.
ment. With the headlight beam pointed straight
e. When the beam is properly adjusted, tighten
ahead (centered), there must be an equal area of
the headlight adjust nut securely.
light to the left and right of center.
f. Push the plug into the headlight housing.
8A. On models except FXDWG, if the beam is incor-
8B. On FXDWG models, if the beam is incorrect as
rect as described in Step 6 or Step 7, adjust as follows.
described in Step 6 or Step 7, adjust as follows.
ELECTRICAL SYSTEM
349
110
HEADLIGHT ADJUSTMENT
35 in.
(0.9 m)
25 ft.
(7.6 m)
8
a. Loosen the vertical adjust bolt at the base of
111
the headlight unit.
b. Tilt the headlight assembly up or down to adjust
the beam vertically. Tighten the bolt securely.
c. Loosen the horizontal adjust bolt at the base
of the steering stem lower bracket.
d. Turn the assembly left or right to adjust the
beam horizontally. Tighten the bolt securely.
Taillight/Brake Light Replacement
Refer to Figure 113.
1. Remove the screws securing the lens (Figure
114).
112
2. Pull the lens off the base and disconnect the elec-
trical connector (Figure 115).
3. Pull the bulb/socket assembly (Figure 116) out
from the backside of the lens.
4. Rotate the bulb and remove it from the socket as-
sembly (Figure 117).
5. Install a new bulb, then install the socket assem-
bly into the lens.
6. Connect the electrical connector (Figure 115)
and install the lens onto the base.
350
CHAPTER EIGHT
113
TAILLIGHT/BRAKE LIGHT
114
115
1. Screw
2. Lens
3. Bulb
4. Socket/harness
5. Screw
6. Circuit board/cover
assembly
7. Base
8. Cage nut
7. Install the screws and tighten securely. Do not
overtighten the screws as the lens may crack.
116
8. To replace the base, perform the following:
a. From underneath the rear fender, disconnect
the wiring harness from the backside of the
base.
b. Remove the screw securing the printed circuit
board and base
(Figure
118) to the rear
fender.
c. Remove the base.
Turn Signal Light Replacement
117
1A. On 1999-2000 models, remove the screws se-
curing the lens and remove the lens.
1B. On 2001-on models, carefully pry the lens (Fig-
ure 119) from the base.
2. Push in on the bulb, rotate it and remove it.
3. Install a new bulb and lens.
4. On 1999-2000 models, install the screws and
tighten securely. Do not overtighten the screws as
the lens may crack.
ELECTRICAL SYSTEM
351
118
119
120
Switch
Red/Black
Red
Red/Gray
Position
Off
•
8
Acc.
•
•
Ignition
•
•
•
SWITCHES
1. Check the battery as described under Battery in
this chapter; if necessary, charge or replace the battery.
Testing
2. Disconnect the negative battery cable (see this
chapter) before checking the continuity of any
Test switches for continuity by using an ohmme-
switch.
ter (see Chapter One) or a self-powered test light at
3. Detach all connectors located between the
the switch connector plug and operating the switch
switch and the electrical circuit.
in each of its operating positions. Compare these re-
sults with the switch operating diagrams included in
CAUTION
the wiring diagrams at the end of the manual. For
Do not attempt to start the engine with
example, Figure 120 shows a continuity diagram
the battery disconnected.
for the ignition switch. It shows which terminals
should show continuity when the switch is in a
4. When separating two connectors, pull on the
given position.
connector housings and not the wires.
When the ignition switch is in the IGNITION posi-
5. After locating a defective circuit, check the con-
tion, there should be continuity between the
nectors to make sure they are clean and properly
red/black, the red and red/gray terminals. The line on
connected. Check all wires going into a connector
the continuity diagram indicates this. An ohmmeter
housing to make sure each wire is positioned prop-
connected between these three terminals should indi-
erly and that the wire end is not loose.
cate little or no resistance, or a test light should light.
6. To reconnect connectors properly, push them to-
When the starter switch is OFF, there should be no
gether until they click or snap into place.
continuity between the same terminals.
If the switch or button does not perform properly,
When testing the switches, note the following:
replace it.
352
CHAPTER EIGHT
121
122
123
LEFT SIDE HANDLEBAR SWITCH
Upper housing without splices
Upper housing with splices
1. Horn switch
1. Horn switch
2. Headlight high/low
2. Headlight high/low
beam switch
beam switch
3. Conduit
3. Conduit or splices
4. Phillips screw and
4. Splices
washer
5. Cable strap
5. Bracket
ELECTRICAL SYSTEM
353
124
RIGHT SIDE HANDLEBAR SWITCH
8
Upper housing without splices
Upper housing with splices
1. Start switch
1. Start switch
2. Stop switch
2. Stop switch
3. Conduit
3. Conduit or splices
4. Phillips screw and
4. Splices
washer
5. Cable strap
5. Bracket
Left handlebar switch description
Handlebar Switch Replacement
The left side handlebar switch housing (Figure
1. Remove the screws securing the left side switch
121) is equipped with the following switches:
housing (Figure 121) to the handlebar. Then care-
1. Headlight HI-LO beam.
fully separate the switch housing to access the de-
2. Horn.
fective switch (Figure 123).
3. Left side turn signal.
2. Remove the screws securing the right side
4. Siren on/off (FXDP models).
switch housing (Figure 122) to the handlebar. Then
5. Clutch lockout (FXDP models).
carefully separate the switch housing to see the de-
fective switch (Figure 124).
Right handlebar switch description
NOTE
To service the front brake light switch,
The right side handlebar switch housing (Figure
refer to Front Brake Light Switch
122) is equipped with the following switches:
Replacement in this chapter.
1. Engine stop/run.
2. Starter.
3A. On models without splices, remove the screw
3. Right side turn signal.
and bracket.
4. Front brake light.
3B. On models with splices, remove the cable strap.
5. Pursuit (FXDP models).
4. Pull the switch(es) out of the housing.
354
CHAPTER EIGHT
5. Cut the switch wire(s) from the defective
switch(s).
125
6. Slip a piece of heat shrink tubing over each wire
cut in Step 2.
7. Solder the wire end(s) to the new switch. Then
shrink the tubing over the wire(s).
8. Install the switch by reversing these steps, plus
the following:
a. When clamping the switch housing onto the
handlebar, check the wiring harness routing
position to make sure it is not pinched be-
tween the housing and handlebar.
b. To install the right side switch housing, refer
9. To install the right side switch housing, refer to
to Throttle and Idle Cable Replacement in
Throttle and Idle Cable Replacement in Chapter
Chapter Seven.
Seven.
WARNING
WARNING
Do not ride the motorcycle until the
Do not ride the motorcycle until the
throttle cables are properly adjusted.
throttle cables are properly adjusted.
Also, the cables must not catch or
Likewise, the cables must not catch or
pull when the handlebars are turned.
pull when the handlebars are turned.
Improper cable routing and adjust-
Improper cable routing and adjust-
ment can cause the throttle to stick
ment can cause the throttle to stick
open. This could cause loss of con-
open. This could cause loss of control.
trol. Recheck all work before riding
Recheck the work before riding the
the motorcycle.
motorcycle.
Front Brake Light Switch Replacement
Ignition/Light Switch
The front brake light switch (Figure 125) is
Removal/Installation
mounted in the right side switch lower housing.
1. Separate the right side switch housing as de-
FXDWG and FXDP models
scribed under Handlebar Switch Replacement in
1. Disconnect the negative battery cable as de-
this chapter.
scribed in this chapter.
2. If still in place, remove the wedge between the
2. Turn the ignition switch OFF and remove the ig-
switch and the switch housing.
nition key.
3. While depressing the switch plunger, slowly ro-
3A. On FXDWG models (Figure 126), remove the
tate the switch upward, rocking it slightly, and re-
acorn nut from the instrument panel on the fuel
move it from the switch housing.
tank.
4. Cut the switch wires from the defective switch.
3B. On FXDP models (Figure 127), remove the
5. Slip a piece of heat shrink tubing over each wire
four screws and washers from the center console on
cut in Step 4.
the fuel tank.
6. Solder the wire ends to the new switch. Then
4. Lift the instrument panel, or center console, up
shrink the tubing over the wires.
and then turn it over. Place a heavy cloth under the
7. Install the switch by reversing these steps, plus
instrument panel to avoid scratching the fuel tank.
the following.
8. When clamping the switch housing onto the han-
NOTE
dlebar, check the wiring harness routing position to
Before disconnecting the wires in Step
make sure it is not pinched between the housing and
5, confirm the wire color connections
handlebar.
at the ignition switch with the wiring
ELECTRICAL SYSTEM
355
126
INSTRUMENTS (FXDWG)
1. Speedometer
2. Gasket
3. Trim plate
4. Indicator light bezel
5. Acorn nut
6. Console
7. Boot
8. Reset switch
9. Set screw
10. Clip
11. Trim piece
12. Ignition switch and key
13. Cage nut
14. Clamp
15. Cable strap
16. Screw
17. Indicator light panel
8
127
IGNITION SWITCH (FXDP)
1. Screw
2. Ignition switch and key
3. Trim plate
4. Screw
5. Washer
6. Center console
7. Gasket
8. Pop rivet
9. Bracket
10. Nut clip
11. Mounting bracket
356
CHAPTER EIGHT
diagram for the model being worked
on.
128
5. Disconnect the ignition switch wires from the ig-
nition switch.
6. Remove the ignition switch mounting screws.
Then remove the ignition switch.
7. Reverse these steps to install the new ignition
switch.
8. Check the switch in each of its operating posi-
tions.
129
All models
except FXDWG and FXDP
1. Remove the seat as described in Chapter Thir-
teen.
2. Disconnect the negative battery cable as de-
scribed in this chapter.
3. Turn the ignition switch OFF and remove the ig-
nition key.
4. Loosen and remove the outer chrome nut secur-
ing the ignition switch to the mounting plate (Fig-
Oil Pressure Switch
ure 128).
5. Push the ignition switch through the cover (to-
Operation
ward inside) and remove it from the mounting plate
The oil pressure switch is located on the front
(Figure 129).
right side of the crankcase.
6. Remove the ignition switch harness cover and
A pressure-actuated diaphragm-type oil pressure
cut the switch wires 3 in. (76.2 mm) from the
switch is used. When the oil pressure is low or when
switch.
oil is not circulating through a running engine, spring
7. To reconnect the new ignition switch:
tension inside the switch holds the switch contacts
a. Slide the replacement conduit onto the wire
closed. This completes the signal light circuit and
harness.
causes the oil pressure indicator lamp to light.
The oil pressure signal light should turn on when
b. Match the ignition switch and wire harness
any of the following occurs:
color codes, and then install new butt connec-
1. The ignition switch is turned on prior to starting
tors to the wire harness and ignition switch
the engine.
wires. Seal the butt splice connectors as
2. The engine idle is below 1000 rpm.
shown in Figure 130.
3. The engine is operating with low oil pressure.
8. Install the ignition switch into the hole in the
4. Oil is not circulating through the running engine.
switch cover so that the TOP mark stamped on the
switch body faces up (toward the switch position
decal).
Testing/replacement
9. Tighten the ignition switch locknut securely.
NOTE
10. Check the switch operation in each of its oper-
The oil pressure signal light may not
ating positions.
come on when the ignition switch is
ELECTRICAL SYSTEM
357
turned off and then back on immedi-
130
SEALED BUTT
ately. This is due to the oil pressure
CONNECTOR INSTALLATION
retained in the oil filter housing.
The following steps test the electrical part of the
STEP 1
oil pressure switch. If the oil pressure switch, indi-
Metal insert
cator lamp and related wiring are in good condition,
inspect the lubrication system as described in Chap-
ter Two.
1. Remove the rubber boot and disconnect the elec-
STEP 2
Insert stripped wire
trical connector from the switch (Figure 131).
ends into connector
2. Turn the ignition switch ON.
3. Ground the switch wire to the engine.
4. The oil pressure indicator lamp on the instru-
ment panel must light.
5. If the signal indicator lamp does not light, check
Crimp wire ends
STEP 3
for a defective indicator lamp and inspect all wiring
between the switch and the indicator lamp.
Heat and allow
connector to cool
6A. If the oil pressure warning light operates prop-
erly, attach the electrical connector to the pressure
8
switch. Make sure the connection is tight and free
from oil. Slide the rubber boot back into position.
Melted sealant
6B. If the warning light remains ON when the en-
gine is running, shut the engine off. Check the en-
gine lubrication system as described in Chapter
Two.
7. To replace the switch, perform the following:
131
a. Unscrew it from the engine.
b. Apply Loctite pipe sealant with Teflon to the
switch threads prior to installation.
c. Install the switch and tighten to the specifica-
tion in Table 6.
d. Test the new switch as described in Steps 1-4.
Neutral Indicator Switch Replacement
The neutral indicator switch is located on the
transmission top cover. The neutral indicator light
on the instrument panel must light when the igni-
132
tion is turned ON and the transmission is in
NEUTRAL.
1. Disconnect the electrical connector from the
neutral indicator switch (Figure 132).
2. Turn the ignition switch on.
3. Ground the neutral indicator switch wire to the
transmission.
4. If the neutral indicator lamp lights, the neutral
switch is defective. Replace the neutral indicator
switch and retest.
358
CHAPTER EIGHT
5. If the neutral indicator lamp does not light, check
for a defective indicator lamp, faulty wiring or a
133
loose or corroded connection.
NOTE
The electrical connector can be at-
tached to either stud on the switch.
6A. If the neutral switch operates correctly, attach
the electrical connector to the neutral switch. Make
sure the connection is tight and free from oil.
6B. If the neutral switch is defective, replace the
neutral indicator switch.
7. To replace the old switch, perform the following:
a. Shift the transmission into NEUTRAL.
134
b. Unscrew and remove the old switch and
O-ring from the transmission top cover.
c. Apply clean transmission oil to the new
O-ring seal.
d. Install the new switch and tighten to the spec-
ification in Table 6.
Rear Brake Light Switch
Testing/Replacement
A hydraulic, normally-open rear brake light
c. If the switch fails either of these tests, replace
switch is used on all models. The rear brake light is
the switch.
attached to the rear brake caliper brake hose (Fig-
5.
Place a drip pan under the switch, as some
ure 133). When the rear brake pedal is applied, hy-
brake fluid will drain out when the switch is re-
draulic pressure closes the switch contacts,
moved.
providing a ground path so the rear brake lamp co-
mes on. If the rear brake lamp does not come on,
6. Loosen and remove the switch from the fitting
perform the following.
on the rear brake line.
7. Thread the new switch into the fitting and
NOTE
tighten securely.
Removal of the exhaust system is not
8. Reconnect the switch electrical connectors.
necessary, but it does provide addi-
9. Bleed the rear brake as described in Chapter
tional work room for this test and re-
placement if necessary.
Twelve.
10. Check the rear brake light with the ignition
1. If necessary, remove the exhaust system as de-
switch turned ON and the rear brake applied.
scribed in Chapter Seven.
2. Turn the ignition switch OFF.
HORN
3. Disconnect the electrical connector from the
switch (Figure 134).
The horn is mounted on the frame boss on the left
4. Connect an ohmmeter between the switch termi-
side of the frame.
nals and check the following:
a. Apply the rear brake pedal. There must be
continuity.
Testing
b. Release the rear brake pedal. There must be
no continuity.
1. Remove the seat.
ELECTRICAL SYSTEM
359
a. Make sure the electrical connectors and horn
135
spade terminals are free of corrosion.
b. Connect the black wire connector to the top
(silver) horn terminal.
c. Connect the yellow/black wire connector to
the bottom (gold) horn terminal.
d. Check that the horn operates correctly.
ELECTRIC PANEL
The electric panel assembly mounts on the left
side of the motorcycle. The panel assembly houses
the circuit breaker, fuses, ignition module, starter
2. Disconnect the negative battery cable as de-
relay, turn signal canceller, security module (mod-
scribed in this chapter.
els so equipped) and the main wiring harness con-
3. Disconnect the electrical connectors from the
nector.
backside of the horn.
Refer to Figure 136 (1999-2000 models) and
4. Connect a 12-volt battery to the horn as fol-
Figure 137 (2001-on models).
lows:
1. Disconnect the negative battery cable as de-
a. Connect the negative lead to the top (silver)
scribed in this chapter.
8
horn terminal.
2. Carefully pull out and remove the electric panel
b. Connect the positive lead to the bottom (gold)
cover (Figure 138).
horn terminal.
3. Remove the nuts securing the outer panel (Fig-
5. If the horn is good, it will sound. If not, replace
ure 139) and remove the outer panel.
the horn.
4. Install the outer panel (Figure 139) and tighten
6. Reconnect the electrical connectors to the horn
the nuts.
as follows:
5. Correctly position the electrical panel cover with
the this side down label facing down (Figure 140).
a. Connect the black wire connector to the top
6. Carefully push the electric panel cover (Figure
(silver) horn terminal.
138) back into position. Push it on until it bottoms.
b. Connect the yellow/black wire connector to
the bottom (gold) horn terminal.
7. Connect the negative battery cable as described
TURN SIGNAL MODULE
in this chapter.
(1999-2000 MODELS)
The turn signal module (TSM) is an electronic
Replacement
microprocessor that controls the turn signals and the
four-way hazard flasher. The turn signal module re-
1. Remove the seat as described in Chapter Thir-
ceives its information from the speedometer and
teen.
turn signal switches.
2. Disconnect the negative battery cable as de-
The turn signal module is located in the electrical
scribed in this chapter.
panel on the left side of the frame.
3. Remove the long acorn nut (A, Figure 135) se-
If the following tests do not solve or confirm the
curing the horn assembly bracket to the frame post.
problem with the TSM, have a Harley-Davidson deal-
4. Move the horn assembly (B, Figure 135) to the
ership test the unit by using the Speedometer Tester
frame and engine and disconnect the electrical con-
along with the specific diagnostic code retrieval.
nectors from the horn terminals.
5. Remove the screw and nut securing the horn to
Operation
the mounting bracket and remove the horn.
6. Install the horn by reversing these removal steps.
For example, when the rider signals for left turn,
Note the following:
the following occurs. Refer to Figure 141.
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