Harley Davidson 2005 touring models. Service repair manual — page 22
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9443
9446
Figure 7-34. Main Drive Gear Bearing Installation
Figure 7-36. Main Drive Gear Installation
(Right Side)
(Right Side)
9445
9447
Figure 7-35. Main Drive Gear Bearing Installation
Figure 7-37. Main Drive Gear Installation
(Left Side)
(Left Side)
3.
On left side of transmission case, slide new bearing over
INSTALLATION
end of bolt with the lettered side out.
4.
With the side stamped “S” facing the transmission case,
NOTE
slide driver over end of bolt until it contacts bearing.
A light interference fit should allow the main drive gear bear-
5.
Install Nice bearing, flat washer and hex nut on bolt. See
ing to be hand pressed into the transmission case. Move to
Figure 7-35.
step 7 if the bearing installs easily by hand. If the bearing is
difficult to install, start at step 1 below.
6.
Holding head of bolt on right side of transmission case,
turn hex nut on left side in a clockwise direction until
1. If removed, fasten cross plate to right side of transmis-
bearing bottoms in the bore. Remove tool.
sion case using second most rearward set of holes in
the side door flange (with the stamp “this side out” facing
1WARNING
outboard and the script right side up). Alternately tighten
screws until snug.
Always wear proper eye protection when installing
retaining rings. Use the correct retaining ring pliers. Ver-
2. Slide 12 inch bolt through center hole in cross plate until
ify that the tips of the pliers are not damaged or exces-
threaded end exits left side of transmission case. See
sively worn. Slippage may propel the ring with enough
Figure 7-34.
force to cause eye injury.
7-26
2005 Touring: Transmission
HOME
a. With the lip garter spring side out (toward the trans-
9448
mission case), place a new large oil seal on lip of
tool.
b. Lightly apply Loctite RETAINING COMPOUND No.
609 to OD of oil seal.
c. Slide tool over the main drive gear so that it is posi-
tioned squarely over the bearing bore.
d. Hand press the oil seal into the bore. If necessary,
use a rubber mallet to lightly tap the tool.
15. Carefully slide new quad seal down main drive gear until
it contacts shoulder.
16. Apply a small amount of clean transmission lubricant to
Figure 7-38. Install Retaining Ring With Gap Facing Rear
OD of spacer. With the bevel on the ID toward the trans-
mission case, slide spacer down main drive gear until it
contacts shoulder (quad seal seats in bevel of spacer).
FINAL INSTRUCTIONS
1.
Verify that the two locating dowels are in place on the
right side of the transmission case. Hang a new gasket
on the dowels.
Figure 7-39. Main Drive Gear Large Oil Seal Installer
2.
Squirt a liberal amount of clean transmission lubricant
(Part No. HD-41496)
into the main drive gear to prelube needle bearings.
Install the assembled side door in the transmission case.
See Figure 7-27.
7.
With the beveled side out and the ring gap facing the
3.
Install the four 5/16 inch screws (with flat washers) to
rear, install new retaining ring in groove of bearing bore.
fasten transmission exhaust bracket and bottom of side
Verify that the ring is fully seated in the groove. See Fig-
door to the transmission case. Install the two 1/4 inch
ure 7-38.
screws to fasten the top of the side door to the transmis-
8.
From inside transmission case, carefully position main
sion case. Alternately tighten six screws until snug.
drive gear in bearing bore.
9.
Install backing plate onto 8 inch bolt. From inside trans-
L = 5/16 Inch S = 1/4 Inch
mission case, slide 8 inch bolt through main drive gear
until threaded end exits left side of transmission case.
Pull on end of bolt until backing plate is positioned flat
against inboard side of main drive gear. See Figure 7-
36.
4
2
10.
On left side of transmission case, slide installer cup over
S
S
end of bolt with the open side over the main drive gear.
11.
Sparingly apply graphite lubricant to threads of bolt.
12.
Install Nice bearing, flat washer and hex nut on bolt. See
Figure 7-37.
13.
Holding head of bolt inside transmission case, turn hex
3
L
nut on left side in a clockwise direction until shoulder on
1
main drive gear makes contact with bearing. Remove
L
6
5
tool.
L
L
7969
14.
Obtain the MAIN DRIVE GEAR LARGE OIL SEAL
INSTALLER (HD-41496). See Figure 7-39. Proceed as
follows:
Figure 7-40. Side Door Screw Size and Torque Sequence
2005 Touring: Transmission
7-27
HOME
2
4
7
6
1
3
Figure 7-42. Final Drive Sprocket Locking Tool
5
(Part No. HD-41184)
Lubricate
8
f1172a6x
Contact Surfaces
Transmission
Sprocket
1. Main Drive Gear
5. Transmission Sprocket
2. Large Oil Seal
6. Sprocket Nut
3. Quad Seal
7. Lockplate
4. Spacer
8. Socket Screw (2)
Figure 7-41. Install Transmission Sprocket Components
4.
Resetting the torque wrench as necessary, tighten the
four 5/16 inch screws to 13-16 ft-lbs (18-22 Nm) and the
two 1/4 inch screws to 84-108 in-lbs (9-12 Nm) in the
sequence shown in Figure 7-40.
5.
Install the transmission sprocket. Install the belt on the
sprocket as the sprocket is installed on the main drive
gear.
6.
Install the sprocket nut. The following procedure is based
Sprocket
on whether a new or used nut is being used.
Locking Tool
f1855x7x
Pivot Shaft
f1856x7x
CAUTION
Exercise caution to avoid getting oil on the threads of
the sprocket nut or the integrity of the lock patch may be
compromised.
New sprocket nut: smear a small quantity of clean
engine oil on the inside face of the sprocket nut and the
outside face of the sprocket. Limit the application to
where the surfaces of the two parts contact each other.
See Figure 7-41. Install the sprocket nut until finger tight.
NOTE
The transmission sprocket nut has left handed threads. Turn
the nut counterclockwise to install on the main drive gear.
Used sprocket nut: apply Loctite High Strength Thread-
Sprocket
locker 262 (red) to the threads of the sprocket nut. Also
Thumbscrew
Nut
smear a small quantity of Loctite or clean engine oil on
the inside face of the sprocket nut and the outside face
of the sprocket. Limit the application to where the sur-
Figure 7-43. Install Final Drive Sprocket Locking Tool
faces of the two parts contact each other. See Figure 7-
41. Install the sprocket nut until finger tight.
7.
Obtain FINAL DRIVE SPROCKET LOCKING TOOL
a. Insert handle of tool below pivot shaft inboard of
(HD-41184) to lock transmission sprocket. See Figure 7-
bottom frame tube and attach to sprocket. See
42. Proceed as follows:
upper frame of Figure 7-43.
7-28
2005 Touring: Transmission
HOME
a. Install pilot on threaded end of mainshaft. See
upper frame of Figure 7-45.
Wrench
b. Slide sleeve of locknut wrench over pilot and onto
sprocket nut.
c. Tighten sprocket nut to 60 ft-lbs (81 Nm). See lower
frame of Figure 7-45. As the nut is tightened the
Pilot
handle of the sprocket locking tool rises to contact
the pivot shaft, thereby preventing sprocket/main-
shaft rotation.
Figure 7-44. Mainshaft Locknut Wrench/Pilot
(Part No. HD-94660-37B )
9.
Scribe a straight line on the transmission sprocket nut
continuing the line over onto the transmission sprocket
as shown in Figure
7-46. Tighten the transmission
sprocket nut an additional 35° to 40°.
10.
Install lockplate over nut so that two diagonally opposite
holes align with two tapped holes in sprocket. To find the
best fit, lockplate can be rotated to a number of positions
and can be placed with either side facing sprocket.
11.
If holes in lockplate do not align with those in sprocket,
tighten sprocket nut as necessary (up to the 45° maxi-
mum) until sprocket and lockplate holes are in align-
ment. See Figure 7-46.
CAUTION
Sprocket
Pilot
f1857x7x
Nut
Maximum allowable tightening of sprocket nut is 45° of
counterclockwise rotation after a torque of 60 ft-lbs (81
f1858x7x
Mainshaft
Nm). Do not loosen sprocket nut to align holes or nut will
Locknut
be under tightened.
Wrench
12. Insert two socket head screws through lockplate into
sprocket holes. Tighten screws to 84-108 in-lbs (9.5-
12.2 Nm).
f1977x6x
Sprocket Nut
Torque
Wrench
45°
Figure 7-45. Install Mainshaft Locknut Pilot/Wrench
35°
and Torque Sprocket Nut
Scribe Line
Transmission
b. Snug thumbscrew to lock position of tool on
on Nut and Sprocket
Sprocket
sprocket. See lower frame of Figure 7-43.
8. Obtain MAINSHAFT LOCKNUT WRENCH/PILOT (HD-
Figure 7-46. Tighten/Secure Sprocket Nut
94660-37B). See Figure 7-44. Proceed as follows:
2005 Touring: Transmission
7-29
HOME
14. If the main drive gear small oil seal was not installed with
the needle bearings (or if a faulty seal is discovered with
Seal Protector
the main drive gear installed in the transmission case),
Sleeve
an alternative method is provided. Proceed as follows:
NOTE
If a serviceable small oil seal is already installed, proceed to
step 15.
Driver
a. Obtain the MAIN DRIVE GEAR SMALL OIL SEAL
INSTALLER (HD-41405). See Figure 7-47.
b. Verify that the lip garter spring is in place on the lip
of the oil seal.
Figure 7-47. Main Drive Gear Small Oil Seal Installer
(Part No. HD-41405 )
c. Place the seal protector sleeve over the end of the
mainshaft.
d. Lightly lubricate the protector sleeve and ID of oil
f1853x7x
seal with clean transmission lubricant.
Small
Oil Seal
e. Squarely seat the oil seal on the seal protector
sleeve with the lip garter spring facing the transmis-
sion case. See upper frame of Figure 7-48.
f.
Lightly apply Loctite RETAINING COMPOUND No.
609 to OD of oil seal.
g. Using the driver, hand press oil seal into the main
drive gear. See lower frame of Figure 7-48. A rubber
mallet may be used to lightly tap the driver, if neces-
sary.
Seal Protector
15.
Install the bearing inner race on the transmission main-
Sleeve
shaft. See Section 6.5 PRIMARY CHAINCASE, MAIN-
SHAFT BEARING INNER RACE, INSTALLATION.
16.
Install shifter cam and fork assemblies. See Section 7.4
f1854x7x
SHIFTER CAM ASSEMBLY/SHIFTER FORKS,
ASSEMBLY.
Driver
17.
Install the starter. See Section 5.4 STARTER, INSTAL-
LATION, steps 1-3 and 5-8.
18.
Install the primary chaincase and starter jackshaft
assembly. Install the clutch assembly, primary chain, and
compensating sprocket components. Install the primary
chaincase cover. See Section 6.5 PRIMARY CHAIN-
CASE, INSTALLATION.
19.
Install the exhaust system. See Section 3.8 INSTALL-
ING ENGINE IN CHASSIS, steps 46-52.
Figure 7-48. Install Small Oil Seal Using
Countershaft Needle Bearing
Seal Protector Sleeve and Driver
Replacement
1.
Find a suitable bearing driver 1-1/4 inch (31.75 mm) in
NOTE
diameter.
The socket head screws have a thread locking compound
2.
From the outside of the transmission case place the nee-
that allows them to be reused up to three times. The fourth
dle bearing open end first next to the bearing bore. Hold
time the screws are removed, replace with new screws (H-D
the driver squarely against the closed end of the bearing
Part No. 3594).
and tap the bearing into place. The bearing is properly
positioned when it is driven inward flush with the outside
13. Adjust the belt tension and complete installation of rear
surface of the case or to a maximum depth of 0.030 inch
wheel. See Section
6.4 SECONDARY DRIVE BELT
(0.76 mm).
AND SPROCKETS, ADJUSTMENT, steps 6-10.
3.
Lubricate the bearing with transmission lubricant.
7-30
2005 Touring: Transmission
HOME
TRANSMISSION CASE/OIL PAN
7.8
GENERAL
REMOVAL
The transmission case and oil pan can be removed as an
assembly if the transmission case must be replaced.
Transmission Case and Oil Pan
If necessary, the oil pan can be removed without removing
1.
See Figure 7-49. Remove both the engine oil and trans-
the transmission case. Once the rear wheel is removed, the
mission lubricant drain plugs from the oil pan. Drain the
oil pan can be slid out from the rear.
fluids into suitable containers.
2.
Remove the mainshaft and countershaft assemblies.
See Section
7.6 MAINSHAFT/COUNTERSHAFT,
REMOVAL.
f2267x7x
13
14
12
1.
Screw
9
2.
Screw
3.
Oil hose cover
4.
Oil hose (2)
5.
Hose clamp (6)
11
15
6.
Straight fitting (3)
10
7.
Crankcase
breather hose
8.
Screw (4)
16
9.
Oil filler cap/dipstick
10.
Oil filler spout
6
17
11.
Filler spout gasket
8
12.
Transmission
5
housing
7
13.
Dowel pin
4
14.
Bolt (4)
5
15.
Washer (4)
2
6
16.
Ring dowel
17.
Baffle spring
18.
Serpentine baffle
18
5
19.
Oil pan gasket
20.
Oil pan
19
21.
O-ring (2)
22.
Magnetic plug (2)
23.
Pipe plug
1
3
24.
Screw (12)
20
24
21
Transmission
Drain Plug
21
23
Engine Oil
22
22
Drain Plug
Figure 7-49. Transmission Case and Oil Pan
2005 Touring: Transmission
7-31
HOME
7. Using a side cutters, cut and remove clamps on trans-
7968
mission side of oil supply and return hoses. Pull hoses
Centering
from fittings on transmission housing.
Screw
8. Cut and remove clamp on transmission side of crank-
case breather hose. Pull hose from fitting on oil filler
spout.
9. Remove four bolts (with flat washers) to free front of
Washer
transmission from rear of crankcase. Loosen and
remove bolts in a crosswise pattern. Move transmission
Retaining
rearward until two ring dowels in lower flange are free of
Ring
crankcase.
NOTE
If the main drive gear was not removed from the transmission
Splined
Shifter Shaft
case, then it may be removed at this time. See Section 7.7
MAIN DRIVE GEAR/BEARING, REMOVAL.
Figure 7-50. Shifter Pawl Centering Screw
10. Remove the transmission case from the right side of the
motorcycle.
NOTE
Shifter
If removal is difficult, remove the twelve socket head screws
Lever Spring
to separate the oil pan from the transmission case. For best
Shifter
Pawl
results, use a long 3/16 inch ball hex socket driver. Holes in
the lower frame crossmember allow access to bolts which
would not otherwise be accessible.
Slot
Oil Pan Only
Splined
Centering
Shifter Shaft
NOTE
Spring
Perform the following procedure if only the oil pan must be
removed.
7967
1. See Figure 7-52. Remove both the engine oil and trans-
mission lubricant drain plugs from the oil pan. Drain the
Figure 7-51. Shifter Pawl Assembly
fluids into suitable containers.
3.
Remove rear wheel and rear swingarm. See Section
2.20 REAR SWINGARM, REMOVAL.
f1677x3x
9
NOTE
11
The main drive gear and bearing may be removed with the
3
transmission case in the frame. See Section
7.7 MAIN
LEFT
7
DRIVE GEAR/BEARING, REMOVAL.
2
SIDE
6
4. Remove the socket screw from the shifter lever. Remove
the lever from the splined end of the shifter shaft. Mark
splines on shaft and lever as they are removed to assist
5
8
in assembly. See Figure 7-50.
5. Using a T50 TORX drive head, turn the centering screw
out until it clears the centering spring slot of the shifter
RIGHT
1
pawl assembly. Remove the retaining ring and flat
SIDE
4
washer from the splined end of the shifter shaft. See Fig-
12
ure 7-51. Push on end of shaft to free shifter pawl
10
Transmission
Engine Oil
assembly from transmission case.
Drain Plug
Drain Plug
6. Remove two allen head socket screws to release oil
hose cover. See Figure 7-49.
Figure 7-52. Oil Pan Torque Sequence
7-32
2005 Touring: Transmission
HOME
2. Install lifting strap around frame backbone, and using
2.
Place gasket on oil pan and allow sealer to dry until
overhead jack, support motorcycle from the top.
tacky.
3. Remove rear wheel. See Section 2.4 REAR WHEEL,
3.
It is normal for the baffle springs to hold the oil pan away
REMOVAL.
from transmission housing. Use a long screwdriver to
4. With a long 3/16 inch ball hex socket driver (Snap-On
compress the springs as the pan enters the housing.
stock number FABL6 or equal), remove the twelve
Exercise caution to avoid cocking or distorting the
springs.
socket head screws from the bottom of the oil pan.
4.
Position oil pan under transmission and install the twelve
NOTE
oil pan screws, but only tighten about two turns after ini-
Holes in the frame crossmember allow access to bolts which
tial thread engagement.
would not otherwise be accessible.
CAUTION
CAUTION
Inspect the oil pan gasket to ensure that gasket is prop-
Remove the engine oil dipstick before attempting to
erly positioned. If gasket was moved out of position,
slide the oil pan rearward. Contact with the oil pan will
remove screws and repeat step 3 to ensure that gasket is
result in damage to the dipstick.
properly positioned.
5. Slide oil pan rearward and remove from underside of
5.
Tighten the oil pan screws to 84-132 in-lbs (9.5-14.9
transmission.
Nm) following the numerical sequence shown in Figure
7-52.
CLEANING AND INSPECTION
6.
Install rear wheel. See Section
2.4 REAR WHEEL,
INSTALLATION.
1. Clean all parts in solvent except the transmission case
7.
Remove lifting strap to release frame backbone from
and needle bearings. Blow dry with compressed air.
overhead jack.
CAUTION
Transmission Case and Oil Pan
The transmission case and needle bearings must not be
cleaned. Normal cleaning methods will wash dirt or other
NOTE
contaminants into the bearing case (behind the needles)
and lead to bearing failure.
If the main drive gear was assembled prior to mounting of the
transmission, place belt on transmission sprocket as trans-
2. Inspect the shifter pawl and centering spring for wear.
mission is placed in position.
Replace lever assembly if pawl ends are damaged.
Replace centering spring if elongated.
1.
From right side of motorcycle, place the transmission
3. Inspect the shifter lever spring. Replace the spring if it
case (with oil pan) in the frame. Move transmission for-
fails to hold the pawl on the cam pins.
ward until two ring dowels in lower flange fully engage
4. Thoroughly clean the oil pan with solvent, if removed.
holes in crankcase. Support the engine and transmis-
5. Inspect the hoses for nicks, cuts or general deterioration.
sion, so that they do not sag at their mating surfaces.
Replace as necessary. Used compressed air to verify
2.
Install the transmission-to-engine mounting bolts as fol-
that hoses and fittings are unobstructed.
lows:
a. Using a crosswise pattern, hand tighten four bolts
INSTALLATION
(with flat washers) to secure transmission housing
to rear of crankcase.
b. Alternately tighten the four bolts to 15 ft-lbs (20.3
Oil Pan Only
Nm) in the same crosswise pattern.
NOTE
NOTE
The following procedure describes installation of the oil pan
For best results, use Open End Crowfoot (Snap-On FC018)
with the transmission case mounted in the motorcycle frame.
on upper left and upper right transmission housing to
Follow the applicable steps to install the oil pan with the
crankcase bolts.
transmission case removed from the motorcycle frame.
1. Apply a thin coat of HYLOMAR® gasket sealer to gasket
c. Repeating the pattern again, final tighten the four
surface of oil pan.
bolts to 30-35 ft-lbs (40.7-47.5 Nm).
2005 Touring: Transmission
7-33
HOME
10. Install the primary chaincase and starter jackshaft
f1894x7x
assembly. Install clutch assembly, primary chain, and
compensating sprocket components. Install the primary
chaincase cover. See Section 6.5 PRIMARY CHAIN-
CASE, INSTALLATION.
11. Install rear swingarm and rear wheel. Adjust belt ten-
sion. See Section 2.20 REAR SWINGARM, INSTALLA-
TION.
12. Install engine oil drain plug and tighten to 14-21 ft-lbs
(19-28 Nm).
13. Add engine oil. See Section 3.3 GENERAL INFORMA-
TION, CHANGING ENGINE OIL AND FILTER, steps 9-
12.
Figure 7-53. Shifter Pawl Assembly
3.
Slide new clamps onto free ends of oil supply and return
hoses. See Figure 7-49. Install hoses onto transmission
fittings. Crimp clamps using the Hose Clamp Pliers (HD-
41137).
4.
Slide new clamp onto free end of crankcase breather
hose. Install hose onto fitting of oil filler spout. Crimp
clamp using HOSE CLAMP PLIERS (HD-97087-65B).
5.
Install two allen head socket screws (with captive wash-
ers) to secure oil hose cover to transmission and engine
housings. Longer screw goes to engine housing. Alter-
nately tighten screws to 84-108 in-lbs (10-12 Nm).
6.
Slide splined end of shifter shaft through sleeved bore
until it protrudes from left side of case. Install flat washer
and retaining ring on splined end of shaft. Hold the
shifter pawl assembly inside the transmission case so
that the centering spring slot is aligned with the center-
ing screw. Using a T50 TORX drive head, tighten center-
ing screw until snug. See Figure 7-53.
7.
Install the shifter lever onto the splined end of the shifter
shaft taking note to align marks placed on splines during
disassembly. Install socket head screw and tighten to
18-22 ft-lbs (24-30 Nm). Make sure screw registers in
slot of shifter lever.
8.
Install the mainshaft and countershaft assemblies. See
Section
7.6 MAINSHAFT/COUNTERSHAFT, INSTAL-
LATION.
9.
Install belt on transmission sprocket.
7-34
2005 Touring: Transmission
Table Of Contents
SUBJECT
PAGE NO.
8.1 Specifications
8-1
8.2 Bulb Chart
8-3
8.3 System Fuses
8-5
8.4 Ignition Control Module (Carbureted)
8-7
8.5 Sensors (Carbureted)
8-8
8.6 Ignition Coil
8-9
8.7 Spark Plugs/Spark Plug Cables
8-10
8.8 Alternator/Stator
8-12
8.9 Voltage Regulator
8-17
8.10 Battery
8-20
8.11 Headlamp (FLHR/C/S, FLHT/C/U)
8-25
8.12 Headlamp (FLTR)
8-28
8.13 Auxiliary Lamps
8-31
8.14 Tail Lamp Assembly
8-35
8.15 Fender Tip Lamps
8-38
8.16 Turn Signal Lamps
8-43
8.17 Turn Signal/Security Module
8-49
8.18 Ignition/Light Key Switch And Fork Lock
8-51
8.19 Fairing Cap Switches (FLHTC/U)
8-58
8.20 Instrument Nacelle Switches (FLTR)
8-61
8.21 Handlebar Switches
8-66
8.22 Stoplight Switches
8-83
8.23 Neutral Switch
8-84
8.24 Oil Pressure Switch/Sender
8-85
8.25 Horn
8-86
8.26 Cigarette Lighter (FLHTCU, FLTR)
8-87
8.27 Gauges/Instruments (FLHT/C/U, FLTR)
8-88
8.28 Gauges/Instruments (FLHR/C/S)
8-92
8.29 Fuel Level Sender (Carbureted)
8-96
8.30 Cruise Control (FLHRC, FLTR, FLHTCU)
8-101
8.31 Premium Sound System (FLHTC/U, FLTR)
8-109
8.32 Wiring Harnesses And Cables
8-117
ELECTRICAL
8
NOTE
See the 2005 ELECTRICAL DIAGNOSTIC MANUAL
(Part No. 99497-05) for all SYSTEM DIAGNOSIS and
ELECTRICAL TROUBLESHOOTING information.
HOME
SPECIFICATIONS
8.1
IGNITION TIMING
System Fuse Block (Under Left Side Cover)
8
ALL FL Models
FLHR/C/S
RANGE
TDC - 50˚ BTDC
9
10
START
TDC
5
11
ALTERNATOR SYSTEM
Output Voltage @ 3600 rpm 14.3-14.7
4
38 Amp:
12
FLHR, FLHRI, FLHRCI, FLHRS, FLHRSI, FLHT, FLHTI,
FLHTC
f2210x8x
3
1
2
45 Amp:
FLHTCI, FLHTCUI, FLTRI
8
7
FLTR, FLHT/C/U
9
6
10
BATTERY
5
Voltage 12V
11
Amperes - 28 AH @ 20 Hour Rate
4
FUSES
Rating
f2204x8x
2
3
Circuit
Color
1
(Amperes)
1.
Headlamp
7.
Radio Power
System Fuses
2.
Ignition
8.
Accessory
Maxi-Fuse
40
Orange
3.
Lighting
9.
Battery
4.
Instruments
10.
Brake Light Relay
Headlamp
15
Blue
5.
Brakes/Cruise
11.
P&A
6.
Radio Memory
12.
Starter Relay
Ignition
15
Blue
Lighting
15
Blue
EFI Fuse Block (Under Right Side Cover)
Instruments
15
Blue
Brakes/Cruise
15
Blue
EFI System
Relay
Spare
Radio Memory
15
Blue
Radio Power
10
Red
Fuel Pump
Accessory
15
Blue
Battery
15
Blue
P & A
15
Blue
ECM Power
f2223x9x
EFI Fuses
Fuel Pump
15
Blue
Figure 8-1. Fuse Locations
ECM Power
15
Blue
2005 Touring: Electrical
8-1
HOME
SPARK PLUG
Item
ft/in-lbs
Nm
Part No.
No.
Size
Gap
Fork lock to upper fork
36-60 in-lbs
4.1-6.8 Nm
bracket (FLHR/C/S)
0.038-0.043 in.
32317-86A
6R12
12 mm
0.97-1.09 mm
Ignition switch screws
20-30 in-lbs
2.3-3.4 Nm
(FLHR/C/S)
NOTE
Instrument bezel TORX
25-35 in-lbs
2.8-4.0 Nm
screws
Be sure spark plugs are gapped to specification before instal-
lation.
Handlebar clamp to
master cylinder housing
60-80 in-lbs
6.8-9.0 Nm
screws
Lower and upper handle-
TORQUE VALUES
bar switch housing TORX
35-45 in-lbs
4-5 Nm
screws
Handlebar clamp to
clutch lever bracket TORX
60-80 in-lbs
6.8-9.0 Nm
Item
ft/in-lbs
Nm
screws
Ignition module socket
50-60 in-lbs
5.7-6.8 Nm
Neutral switch
120-180 in-lbs
13.6-20.3 Nm
head screws
Horn stud flange nut
MAP sensor TORX screw
25-35 in-lbs
2.8-4.0 Nm
80-100 in-lbs
9.0-11.3 Nm
(10mm)
Ignition coil bracket
84-144 in-lbs
9.5-16.3 Nm
Horn bracket acorn nut to
socket screws
80-100 in-lbs
9.0-11.3 Nm
rubber mount stud
Spark plug
12-18 ft-lbs
16-24 Nm
2 inch diameter gauge
10-20 in-lbs
1.1-2.3 Nm
Stator to crankcase TORX
nuts
55-75 in-lbs
6.2-8.5 Nm
screws
Tachometer bracket
10-20 in-lbs
1.1-2.3 Nm
Battery cable bolt
60-96 in-lbs
6.8-10.9 Nm
socket screws
Voltage regulator locknuts
70-100 in-lbs
7.9-11.3 Nm
Speedometer speed
84-108 in-lbs
9-12 Nm
sensor screw
Battery hold-down clamp
15-20 ft-lbs
20-27 Nm
TORX bolt
Speedometer bracket
10-20 in-lbs
1.1-2.3 Nm
socket screws
Headlamp door screw
9-18 in-lbs
1.0-2.0 Nm
Console mounting bolt
Auxiliary lamp bracket to
50-90 in-lbs
5.7-10.2 Nm
15-20 ft-lbs
20-27 Nm
acorn nut (FLHR/C/S)
fork bracket TORX bolts
Console pod Phillips
Auxiliary lamp bracket to
6-11 in-lbs
0.7-1.2 Nm
screws
fork bracket stud acorn
72-108 in-lbs
8.1-12.2 Nm
nuts
Fuel tank canopy TORX
18-24 in-lbs
2.0-2.7 Nm
screws
Tail lamp lense screws
20-24 in-lbs
2.3-2.7 Nm
Cruise module locknuts
60-96 in-lbs
6.8-10.9 Nm
Tail lamp circuit board/
40-48 in-lbs
4.5-5.4 Nm
plastic bracket
Radio to support bracket
35-45 in-lbs
4.0-5.1 Nm
socket screws
Rear fender tip lamp nuts
20-25 in-lbs
2.3-2.8 Nm
Upper fairing speaker
Front fender tip lamp nuts
20-25 in-lbs
2.3 - 2.8 Nm
22-28 in-lbs
2.5-3.2 Nm
lower TORX screw
Front fender trim strip tee
10-15 in-lbs
1.1-1.7 Nm
Upper fairing speaker
bolt nuts
35-50 in-lbs
4.0-5.7 Nm
upper TORX screws
Ignition switch to upper
36-60 in-lbs
4.1-6.8 Nm
Throttle cable J-clamp
fork bracket
screw to wellnut
9-18 in-lbs
1.0-2.0 Nm
Fairing cap TORX screws
25-30 in-lbs
2.8-3.4 Nm
(FLHR/C/S)
Ignition
switch button
Ground post flange nuts
50-90 in-lbs
5.7-10.2 Nm
18-23 in-lbs
2.0-2.6 Nm
head screws
Voltage regulator ring
Ignition switch
DOM
50-70 in-lbs
5.7-7.9 Nm
terminal to transmission
84-108 in-lbs
9.5-12.2 Nm
nut
exhaust bracket screw
HDI
125-150 in-lbs
14.1-16.9 Nm
Vehicle speed sensor
Continued ...
84-132 in-lbs
9.5-14.9 Nm
screw
Rear stoplight switch
96-120 in-lbs
10.9-13.6 Nm
8-2
2005 Touring: Electrical
HOME
BULB CHART
8.2
Lamp Description,
Number of
Current Draw
Harley-Davidson
Wattage
All Lamps 12V
Bulbs
(Amperage)
Part No.
HEADLAMP
FLHT/C/U, FLHR/C/S
1
4.58/5
55/60
68329-03
FLTR
2
4.58/5
55/60
68329-03
POSITION LAMP (HDI)
1
0.32
3.9
53438-92
AUXILIARY LAMPS
(DOM)
2
2.10
27
68351-05
(HDI)
2
2.92
35
68847-98A
TAIL AND STOP LAMP
1
Tail Lamp
0.59
6
68167-88
Stop Lamp
2.10
24
68167-88
Tail Lamp (HDI)
0.59
6
68167-88
Stop Lamp(HDI)
2.10
24
68167-88
License Plate (HDI)
1
0.37
5.2
53436-97
TURN SIGNAL LAMP
Front/Running
2
2.25/.59
27/7
68168-89
Front (HDI)
2
1.75
21
68163-84
Rear
2
2.25
27
68572-64B
Rear (HDI)
2
1.75
21
68163-84
TOUR-PAK
Side Marker Lamps *
4
0.3
3.7
53439-79
Tail/Brake Lamps (Ultra)
2
0.59
7
68168-89A
FENDER TIP LAMPS *
2
0.3
3.7
53439-79
INSTRUMENT PANEL LAMPS
FLHT/C/U, FLTR
High Beam
1
0.15
2.1
68024-94
Oil Pressure
1
0.15
2.1
68024-94
Neutral
1
0.15
2.1
68024-94
Turn Signal
2
0.15
2.1
68024-94
GAUGE LAMPS
FLHT/C/U, FLTR
Speedometer **
Tachometer **
Voltmeter
1
0.24
3.4
67445-00
Oil Pressure Gauge
1
0.24
3.4
67445-00
Air Temperature Gauge
1
0.24
3.4
67445-00
Fuel Gauge
1
0.24
3.4
67445-00
Engine **
INSTRUMENT PANEL/
GAUGE LAMPS
FLHR/C/S
High Beam **
Oil Pressure **
Neutral **
Turn Signal **
Fuel Gauge **
Speedometer **
Odometer **
Engine **
* Not Applicable to HDI
** LED Illuminated. LEDs are not repairable. Assembly must be replaced if LED fails.
2005 Touring: Electrical
8-3
HOME
NOTES
8-4
2005 Touring: Electrical
HOME
SYSTEM FUSES
8.3
MAXI-FUSE
REMOVAL
1. Remove left side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
2. Gently pull side cover from frame downtubes (no tools
required).
3. Depress latches on maxi-fuse holder and then slide
cover rearward to disengage tongue from groove in fuse
block cover. See Figure 8-2.
Maxi-Fuse
4. Pull maxi-fuse from maxi-fuse holder. See Figure 8-3.
f2207x8x
Figure 8-3. Remove Maxi-Fuse
INSTALLATION
MAXI-FUSE HOLDER
1. Insert maxi-fuse into maxi-fuse holder. See Figure 8-3.
2. Slide cover forward to engage tongue in groove of fuse
block cover and then insert maxi-fuse holder into cover
REMOVAL
until latches engage. See Figure 8-2.
1. Remove maxi-fuse. See MAXI-FUSE, REMOVAL, in this
3. Align barbed studs in side cover with grommets in frame
section.
downtubes and push firmly into place
(no tools
required).
2. Remove socket terminals from maxi-fuse holder. See
Section B.3 PACKARD ELECTRICAL CONNECTORS,
4. Install left side saddlebag. See Section 2.25 SADDLE-
800 METRI-PACK SERIES.
BAG, INSTALLATION.
INSTALLATION
3.
Install socket terminals into maxi-fuse holder. See
Section B.3 PACKARD ELECTRICAL CONNECTORS,
800 METRI-PACK SERIES.
4.
Install maxi-fuse. See MAXI-FUSE, INSTALLATION, in
this section.
SYSTEM FUSES/RELAYS
REMOVAL
Fuse
Maxi-Fuse
1.
Remove maxi-fuse. See MAXI-FUSE, REMOVAL, in this
Block
Cover
section.
f2206x8x
2.
Pull fuse block from tabs on mounting bracket. Tabs on
Figure 8-2. Remove Left Side Cover
bracket fit into slots on each side of fuse block cover.
2005 Touring: Electrical
8-5
HOME
INSTALLATION
Spare Fuse
Holder
1. Install system fuse/relay in fuse block. See lower frame
Fuse Block
of Figure 8-4.
Cover
NOTE
For FLHR/C/S configuration, see upper frame of Figure 8-1 in
Section 8.1 SPECIFICATIONS.
2. Slide cover over fuse block until slots fully engage tabs
on block. See upper frame of Figure 8-4.
3. Slide fuse block into position on mounting bracket. Tabs
on bracket fit into slots on each side of fuse block cover.
4. Install maxi-fuse. See MAXI-FUSE, INSTALLATION, in
this section.
f2209x8x
f2203x8x
8
7
FUSE BLOCK
9
6
10
REMOVAL
5
1. Remove system fuses and relay(s). See SYSTEM
11
FUSES/RELAYS, REMOVAL, in this section.
5. Remove socket terminals from fuse block. See Section
B.3 PACKARD ELECTRICAL CONNECTORS,
280
4
METRI-PACK SERIES.
INSTALLATION
1
2
3
1. Install socket terminals into fuse block. See Section B.3
PACKARD ELECTRICAL CONNECTORS, 280 METRI-
1.
Headlamp
7.
Radio Power
PACK SERIES.
2.
Ignition
8.
Accessory
2. Install system fuses and relay(s). See SYSTEM FUSES/
3.
Lighting
9.
Battery
RELAYS, INSTALLATION, in this section.
4.
Instruments
10.
Brake Light Relay
5.
Brakes/Cruise
11.
P&A
6.
Radio Memory
EFI FUSES
Figure 8-4. Fuse Block (FLTR, FLHTC/U)
See Section 9.2 ELECTRICAL BRACKET ASSEMBLY, EFI
FUSES.
NOTE
The fuse block cover also serves as the spare fuse holder.
One spare 10 amp and 15 amp fuse are provided.
3. Remove the fuse block cover. Raise lipped side slightly
to disengage slots from tabs on fuse block. See upper
frame of Figure 8-4.
4. Remove system fuse/relay from fuse block. Replace
fuse if the element is burned or broken. Automotive type
ATO fuses are used. See lower frame of Figure 8-4.
NOTE
For FLHR/C/S configuration, see upper frame of Figure 8-1 in
Section 8.1 SPECIFICATIONS.
8-6
2005 Touring: Electrical
HOME
IGNITION CONTROL MODULE (CARBURETED)
8.4
REMOVAL
f2191x8x
1. Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
2. Gently pull side cover from frame downtubes (no tools
required).
3. Depress external latches and use a rocking motion to to
remove electrical connector. See Figure 8-5.
4. Remove two socket screws to detach ignition control
module from electrical bracket.
INSTALLATION
1. Align holes in ignition control module with those in elec-
Ignition Control Module
trical bracket. Install two socket screws and tighten to
Connector [10]
50-60 in-lbs (5.7-6.8 Nm).
2. Align tabs on socket housing with grooves on pin hous-
Figure 8-5. Electrical Bracket (Under Right Side Cover)
ing and push connector halves together until latches
click.
3. Align barbed studs in side cover with grommets in frame
4. Install right side saddlebag. See Section 2.25 SADDLE-
downtubes and push firmly into place
(no tools re-
BAG, INSTALLATION.
quired).
2005 Touring: Electrical
8-7
HOME
SENSORS (CARBURETED)
8.5
MANIFOLD ABSOLUTE
PRESSURE SENSOR
MAP Sensor
T20 TORX
Removal
Screw
1. Partially remove fuel tank. See Section 4.7 FUEL TANK
(CARBURETED), PARTIAL REMOVAL, FLHT/C, or
FLHR/S.
2. Pull external latch outward and use rocking motion to
remove electrical connector.
3. Remove T20 TORX screw to release retaining clip from
intake manifold. See Figure 8-6.
4. Carefully pull pressure port (enveloped in rubber seal)
Retaining
from hole in intake manifold.
Clip
5. If reusing sensor, inspect condition of rubber seal.
Figure 8-6. Intake Manifold
Replace the seal if it is cut, torn or shows signs of deteri-
oration.
3.
Install T20 TORX screw and tighten to 25-35 in-lbs (2.8-
4.0 Nm). See Figure 8-6.
Installation
4.
Align latch on socket housing with locking tab on pin
housing and push connector halves together until latch
1. Install rubber seal on pressure port, if removed.
clicks.
2. With port side down, slide end of retaining clip in slot at
5.
Install fuel tank. See Section 4.7 FUEL TANK (CARBU-
side of sensor. Aligning hole in retaining clip with
RETED), INSTALLATION (AFTER PARTIAL REMOVAL),
threaded hole in intake manifold, carefully press pres-
FLHT/C, or FLHR/S.
sure port into bore,
CRANKSHAFT POSITION SENSOR
See Section
9.3 SENSORS, CRANKSHAFT POSITION
SENSOR.
8-8
2005 Touring: Electrical
HOME
IGNITION COIL
8.6
6. Install fuel tank. For carbureted models, see Section 4.7
REMOVAL
FUEL TANK (CARBURETED), INSTALLATION (AFTER
PARTIAL REMOVAL), FLHT/C or FLHR/S. For fuel
1. Partially remove fuel tank. For carbureted models, see
injected models, see Section 9.4 FUEL TANK (FUEL
Section
4.7 FUEL TANK (CARBURETED), PARTIAL
INJECTED), INSTALLATION
(AFTER PARTIAL
REMOVAL, FLHT/C or FLHR/S. For fuel injected mod-
REMOVAL), FLHT/C/U/I, FLTRI or FLHR/C/S/I.
els, see Section 9.4 FUEL TANK (FUEL INJECTED),
PARTIAL REMOVAL, FLHT/C/U/I, FLTRI or FLHR/C/S/I.
2.
Unplug spark plug cables from ignition coil towers.
8316
3.
Pull external latch outward and use rocking motion to
remove electrical connector from left side of ignition coil.
4.
Pull sides of ignition coil bracket outward to remove from
bosses of front fuel tank mount. See Figure 8-7.
5.
Remove two socket screws to free ignition coil from
bracket.
INSTALLATION
1. Align holes in new ignition coil with holes in bracket.
Properly positioned, connector pin housing should be
positioned at cut in bracket. Install two socket screws
and tighten to 84-144 in-lbs (9.5-16.3 Nm). See Figure
8-8.
Figure 8-7. Remove Ignition Coil Bracket From Vehicle
2. With the coil towers facing rear of vehicle, hold ignition
coil and bracket at bottom of frame backbone. Pull sides
f1925x8x
of bracket outward and install on bosses of front fuel
tank mount. See Figure 8-7.
3. Install electrical connector on left side of ignition coil.
Align latch on socket housing with locking tab on pin
housing and push connector halves together until latch
clicks.
4. Install spark plug cable to front cylinder onto left side coil
tower. Verify that spark plug cable is captured in double-
sided cable clip at bottom left side of frame backbone.
Install new cable clip on T-stud if damaged or missing.
See Figure 8-10.
Front
5. Install spark plug cable to rear cylinder onto right side
coil tower. Verify that spark plug cable is captured in two
single-sided cable clips at bottom left side of frame back-
Rear
bone. Install new cable clips on T-studs if damaged or
missing. See Figure 8-10.
Figure 8-8. Install Bracket to Ignition Coil
2005 Touring: Electrical
8-9
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