Harley Davidson 2005 touring models. Service repair manual — page 63
HOME
10. See Figure
8-15. Push the three harness wires up
Socket Head
through the mounting bracket stem and into the lamp
Screw
Recessed
bucket following the route used to remove the original
Area
power wire.
11. Obtain three socket terminals and one 3-place socket
housing from kit.
12. Install sockets on wires. See Section B.2 AMP MUL-
TILOCK ELECTRICAL CONNECTORS in the 2005 Tour-
ing Models Service Manual (Part No. 99483-05).
Turn Signal
13. Taking note of the numbers stamped on the socket hous-
Assembly
ing, install the terminals into their respective chambers.
Table 8-3. Terminal Location
i03979
TERMINAL WIRE COLOR
CHAMBER
Red
1
Figure 8-16. Install Turn Signal to Mounting Bracket
Black
2
White
3
i03980
NOTE
The red Par-36 Strobe is typically installed on the left side of
the motorcycle, while the blue strobe is installed on the right.
Strobe
Harnesses
14.
Obtain the red Par-36 strobe lamp from kit and mate the
harness connector with the left side strobe connector.
15.
Position the strobe within the lamp bucket and reinstall
the chrome ring using Phillips screw. Tighten securely.
Power Supply
16.
See Figure 8-16. Make sure conduit rests in the recess
Control Harness
of the clamp area as shown. Install the left turn signal
assembly to the mounting bracket using two socket head
screws. Tighten screws securely.
Figure 8-17. Connect Strobes to Power Supply Outlets
17.
Using the blue Par-36 strobe, perform steps 3-16 on the
right side of the motorcycle.
18.
Route the left and right strobe harnesses under the fuel
21. Obtain the power supply control harness and Instruction
tank then toward the rear of the motorcycle following the
Sheet J02192 from kit. Install harness following instruc-
same paths as the conduit for the left and right turn sig-
tions. Connect control harness to power supply.
nal lamps. Continue along the frame tubes and then back
into the opening in the Tour-Pak.
22. Install fuel tank. See Section 9.4 FUEL TANK (FUEL
INJECTED) in the 2005 Touring Models Service Manual
19.
Obtain three cable straps from kit and secure the strobe
(Part No. 99483-05).
harness to the frame (or turn signal lamp conduit) at suit-
able locations. Repeat step for the other harness.
1
WARNING
20.
See Figure 8-17. Connect the strobe harness connectors
Connect positive (+) battery cable first. If positive (+)
to the power supply as shown.
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explo-
NOTE
sion, which could result in death or serious injury.
(00068a)
Depending on which of the four outlets are chosen, the flash
pattern can be set so lamps flash alternately or simulta-
23. Install battery cables, positive cable first.
neously. You may want to experiment with the various outlets
until the desired flash pattern is obtained.
24. Close Tour-Pak and test strobe lights for proper opera-
tion.
2005 FLT Police: Electrical
8-11
HOME
POLE LAMP
8.5
GENERAL
6105
Harley-Davidson police model motorcycles are shipped from
the factory with the brackets necessary to mount a police pole
lamp.
INSTALLATION
1.
Rotate knurled rings to remove from pole lamp.
Knurled Ring
(Bevel Up)
Lower
2.
Cut all but approximately 14 inches (356 mm) of wire off
Bracket
pole lamp.
3.
Crimp terminals on wires and install in pin side of 2-place
Deutsch connector. See Section B.1 DEUTSCH ELEC-
TRICAL CONNECTORS, in the 2005 Touring Models
Service Manual (Part No. 99483-05).
Knurled Ring
(Bevel Down)
NOTE
The black wire must go to the black and the green/red wire
must go to the red. The lamp will not work if wires are not
matched correctly.
4.
Slide pole through grommet in luggage rack. Spray glass
Figure 8-18. Install Pole Lamp
cleaner on pole to lubricate surfaces, if necessary.
5.
Install knurled ring at bottom of pole with the beveled
6106
side up. See Figure 8-18.
6.
Insert pole through lower bracket and install second
Connector
knurled ring with the beveled side down.
7.
Alternately tighten knurled rings to lock position of pole.
8.
Mate pin and socket halves of 2-place Deutsch connec-
tor. Secure connector and conduit to saddlebag guard
and saddlebag support bracket using new cable straps.
See Figure 8-19.
Cable
Strap
Figure 8-19. Install Cable Straps
8-12
2005 FLT Police: Electrical
HOME
SIREN AND PUBLIC ADDRESS SYSTEM
8.6
GENERAL
TROUBLESHOOTING
The siren and public address (PA) system consists of: ampli-
If siren and/or PA system are inoperative, refer to the trouble-
fier, speaker, microphone, microphone jack, siren, horn/siren
shooting chart below.
switches and connecting wiring.
The Whelen 100 watt siren amplifier, WS-320, (Part No.
91156- 93) uses a waterproof connector.
Table 8-4. Troubleshooting
PROBLEM
CAUSE
SOLUTION
Siren and PA not
Connector not properly installed.
Be sure connector is properly oriented and screw is tight.
operational.
Apply wheel bearing grease to connector pins and sockets
to reduce corrosion.
Siren and PA not
Faulty amplifier or speaker.
Substitute a known good amplifier and check system func-
operational.
tion. If system is still inoperative, substitute a known good
speaker and check for system operation.
NOTE
If neither an amplifier nor speaker is available, see Section
8.8 SPEAKER, TROUBLESHOOTING in this manual. If
speaker checks “good”, continue at Section 8.7 VOLTAGE
CHECKS, RESISTANCE AND CONTINUITY CHECKS.
Siren functions, PA
PA gain control not properly
See Section 8.10 SIREN AMPLIFIER, GAIN ADJUST-
not operational.
adjusted.
MENT.
Inoperative microphone.
Substitute a known good microphone. If known good micro-
phone is not available, see Section 8.11 MICROPHONE
AND JACK.
Microphone jack or connecting
leads do not provide good electri-
See Section 8.11 MICROPHONE AND JACK.
cal connection.
Wrong microphone.
Some Whelen microphones are electrically different and
cannot be interchanged.
NOTE
Microphones used with WS-320 amplifiers should be
marked 010245648-00.
2005 FLT Police: Electrical
8-13
HOME
VOLTAGE CHECKS
8.7
ALL MODELS
Table 8-5. Voltage Checks at
Motorcycle Siren Harness
See Figure 8-20, Table 8-5, and the appropriate wiring dia-
gram in Section 8.1 WIRING DIAGRAMS. Measure the volt-
VOLTAGE MEASURED AT
Switch
ages at the motorcycle siren harness connector (pins 1C, 2F,
PINS
Switch
Position
and 1F) as listed in Table 8-5. The Ignition/Light Key Switch
1C
2F
1F
must at IGNITION while checking voltages. Connect common
or negative lead of voltmeter to a good ground. If voltages
Do Not
Do Not
Ignition
ON
12 Vdc
specified in Table 8-4 are not present, refer to applicable wir-
Measure
Measure
ing diagram to diagnose the problem.
Siren
OFF
Do Not
0 Vdc
12 Vdc
Measure
Siren/Horn
ON
Siren
ON
Do Not
12 Vdc
0 Vdc
p0011a8x
Siren/Horn
OFF
Measure
Siren/Horn
ON
Do Not
12 Vdc
12 Vdc
Measure
Siren
ON
To Motorcycle Harness
Pin
Description
1A
Ground (-) to motorcycle
3A
Speaker (+)
12 Vdc supply to amplifier.
1C
Present when ignition is on.
3C
Speaker (-)
Air horn enabled - 12 Vdc is present when
1D
connected to horn circuit and button is
pushed. See Section 8.12 AIR HORN.
2D
Push-to-talk (mic)
1E
Mic (-)
Yelp, 12 Vdc is present when siren/horn
1F
switch is ON.
Wail, 12 Vdc is present when siren switch
2F
is ON.
3F
Mic (+)
Figure 8-20. Pin Connector
8-14
2005 FLT Police: Electrical
HOME
RESISTANCE AND CONTINUITY
CAUTION
CHECKS
Do not connect ohmmeter probes to a “live” circuit or
ohmmeter will be damaged.
See Figure 8-20 and Table 8-6 below. Perform checks with
both battery cables removed.
If ohmmeter readings in Table 8-6 are not obtained, refer to
Section 8.1 WIRING DIAGRAMS and diagnose the problem
using the appropriate schematic.
Table 8-6. Resistance/Continuity Checks (Battery Cables Disconnected)
OHMMETER PROBE
OHMETER
COMPONENT AND WIRE BEING CHECKED
LOCATION (PINS)
3A & 3C
6-10 Ohms
Speaker coil voice and leads from pin connector to speaker.
3F & 1E
Infinity
Verifies microphone circuit is not shorted.
Verifies PTT switch is functioning and two microphone leads from
connector have continuity.
Press and hold PTT switch
0-1 Ohms
with probes on pins 2D & 1E.
For microphone jack connections, see Figure 8-28. To check third
lead, place one probe on pin 3F and the other probe on tip terminal of
microphone jack.
Common probe to ground,
0-1 Ohms
Checks amplifier to motorcycle ground.
other probe to pin 1A.
2005 FLT Police: Electrical
8-15
HOME
SPEAKER
8.8
TROUBLESHOOTING
Connector
If speaker is inoperative, check voice coil impedance as fol-
Bolt
lows:
1. Disconnect speaker leads and measure impedance by
connecting ohmmeter leads to speaker leads.
2. Measured resistance must be 6-10 ohms.
3. Replace speaker if resistance is not within specification.
NOTE
A binding voice coil or torn speaker cone could also cause
speaker to be inoperative. To check for these conditions, con-
nect speaker to shop stereo. If speaker works, it’s functional.
Screw
4579p
REMOVAL
Figure 8-21. Speaker (Rear View)
1. Cut two cable straps to release 2-place Deutsch connec-
tor and cable from top rail of right side engine guard. Dis-
4578p
connect pin and socket halves. See Figure 8-21.
2. Reaching into speaker horn, remove flange locknuts, flat
washers and rubber washers from top and side bolts.
Pull bolts from speaker horn and mounting bracket.
Remove flat washers and rubber washers between horn
and mounting bracket.
3. Remove bolt to release back of speaker from mounting
bracket.
Drain
INSTALLATION
Hole
1. Position speaker in mounting bracket aligning holes in
speaker with those in bracket.
2. Loosely install bolt to fasten mounting bracket to back of
speaker. See Figure 8-21.
Figure 8-22. Speaker (Bottom View)
3. Position rubber washers and flat washers between holes
in horn and mounting bracket, rubber washers against
horn.
6.
Mate pin and socket halves of 2-place Deutsch connec-
NOTE
tor. Install two new cable straps to secure connector and
Be sure the speaker voice coil drain hole is facing down to
cable to top rail of right side engine guard.
provide good drainage. Hole is located 180° from “Made in
USA” logo. See Figure 8-22.
CAUTION
4. Slide bolts through mounting bracket, flat washers, rub-
Use of a high pressure washer on or near speaker can
ber washers and horn. Reaching into speaker horn,
result in damage.
install rubber washers, flat washers and flange locknuts
on bolts.
NOTE
5. Alternately tighten all fasteners. Rubber washers should
If speaker center cone is removed to make installation easier,
deform slightly when flange locknuts are properly tight-
apply 2-3 drops of Loctite 242 (blue) on center cone screw
ened.
and then tighten until snug.
8-16
2005 FLT Police: Electrical
HOME
HANDLEBAR SWITCHES
8.9
6. While holding down the ramp, pull both switches from the
HORN/SIREN YELP SWITCH
housing.
7. Cut the wires from the old switches as follows:
NOTE
● Yellow/Black wire: 1-1/4 inches (32 mm)
Consult the 2005 Touring Models Service Manual (Part No.
99483-05) for assembly/disassembly instructions and general
● Orange/White wires: 1-7/8 inches (48 mm)
repair procedures.
● Brown/Black wire: 1-1/2 inches (38 mm)
NOTE
Removal
Replacement Horn/Siren Yelp Switch wires are cut to length
1. See Section 8.21 HANDLEBAR SWITCHES, LEFT SIDE
and partially stripped (Yellow/Black wire: 3-3/4 inches (95
HANDLEBAR SWITCHES, DISASSEMBLY, in the 2005
mm); Orange/White wires: 3-1/2 inches (89 mm); Brown/
Touring Models Service Manual (Part No. 99483-05).
Black wire: 3-3/8 inches (86 mm).
2. From inside the switch housing, carefully cut cable strap
8.
See GENERAL REPAIR PROCEDURES, in the 2005
to free conduit from the turn signal switch bracket.
Touring Models Service Manual (Part No. 99483-05).
3. Remove the Phillips screw (with lockwasher) to release
NOTE
the turn signal switch bracket. Remove the switch
If the ramp and spring mechanism becomes loose, install as
assembly from the housing.
follows: Using the blade of a small screwdriver, compress
4. Remove the two T8 TORX screws and the Phillips screw
spring and place in wider portion of channel at bottom of
(with lockwasher) to release the lower bracket. Carefully
ramp. Verify that spring is evenly compressed and is not
lift out the bracket so as not to disturb the spring-loaded
cocked or skewed. Push spring so that it bottoms in channel.
ramp on the inboard side of the housing.
With tab side of ramp facing inboard and hook end on switch
5. Carefully remove the keycap disengaging slot from hook
side of casting, install ramp so that narrow channels engage
on ramp.
pins cast into housing.
f1237a2x
Right Handlebar Switch Housings
Upper Switch Housing:
● Engine Start Switch
● Engine Stop Switch: Off/Run
Lower Switch Housing:
● Turn-Right Signal Switch
● Front Stoplight Switch
● Pole and Pursuit Lamp Switch:
Off/Aux(iliary)/Purs(uit)
Left Handlebar Switch Housings
Upper Switch Housing:
● Siren Switch: On/Off
● Light Switch: Hi(gh) and Lo(w) Beam
Lower Switch Housing:
● Turn-Left Signal Switch
● Horn/Siren Yelp Switch
● Clutch/Starter Interlock Switch
f1236a2x
Figure 8-23. Police Handlebar Switch Assemblies
2005 FLT Police: Electrical
8-17
HOME
Installation
from end of conduit. Cut any excess cable strap material.
If necessary, bend angular arm of bracket downward to
1.
Install the switches in the housing with contacts facing
firmly secure Clutch Interlock Switch in installed position.
tabs on ramp. For best results, install one switch at a
14. See Section 8.21 HANDLEBAR SWITCHES, LEFT SIDE
time. Ribs cast in lower housing hold switches in posi-
HANDLEBAR SWITCHES, ASSEMBLY, in the 2005
tion.
Touring Models Service Manual (Part No. 99483-05).
The Horn switch with the Yellow/Black lead (pivot point
towards rider) is installed at the bottom, while the Siren
Yelp switch with the Brown/Black lead
(pivot point
towards the front) is at the top. Route switch wires in
CLUTCH INTERLOCK SWITCH
channel on the outboard side of the ribbed area.
2.
Install the keycap engaging slot with hook on ramp.
NOTE
3.
Install lower bracket sliding pin through keycap and
All Police models have a Clutch Interlock Switch that prevents
engaging hole in lower casting.
the motorcycle from starting (even in Neutral) if the clutch
4.
Slide T8 TORX screws through holes in lower bracket
lever is not pulled in.
and switches and thread into lower casting until snug.
Removal
5.
Install Phillips screw (with lockwasher), to secure lower
bracket to threaded boss in housing. Verify operation of
1.
See Section 8.21 HANDLEBAR SWITCHES, LEFT SIDE
Horn and Siren Yelp switches to ensure that both are
HANDLEBAR SWITCHES, DISASSEMBLY, in the 2005
spring returned.
Touring Models Service Manual (Part No. 99483-05).
6.
Install Clutch Interlock Switch in bore of lower switch
2.
From inside the switch housing, carefully cut cable strap
housing, if loose.
to free conduit from the turn signal switch bracket.
7.
Insert tapered end of new 7 inch cable strap into round
3.
Remove the Phillips screw (with lockwasher) to release
hole in turn signal switch bracket and then feed back
the turn signal switch bracket. Remove the switch
through using the adjacent hole. Reserve the oblong
assembly from the housing.
hole for the bracket screw.
4.
Remove the Clutch Interlock Switch from the housing.
NOTE
Be sure that all splices are positioned above the turn signal
5.
Cut wires 1/4 inch (6 mm) from old switch. Discard switch
switch bracket.
assembly.
8.
Place the turn signal switch assembly into the housing
NOTE
aligning the oblong hole in the bracket with the lower
Replacement Clutch Interlock Switch wires are cut to length
bracket weld nut. Be sure that bracket is fully seated.
(looking at backside, left side switch wire is 2-1/4 inches (57
Tabs on each side are captured in slots cast into switch
mm), right side is 2-3/4 inches (70 mm) and partially stripped.
housing.
9.
Install Phillips screw (with lockwasher) to secure bracket
6.
See GENERAL REPAIR PROCEDURES, in the 2005
Touring Models Service Manual (Part No. 99483-05).
inside housing.
CAUTION
Installation
If routed incorrectly, wires may be pinched by casting or
1.
Install Clutch Interlock Switch in bore of lower switch
handlebar resulting in switch failure.
housing.
10. Loop switch wires so that spliced lengths are positioned
2.
Insert tapered end of new 7 inch cable strap into round
directly over bracket screw.
hole in turn signal switch bracket and then feed back
11. Capturing conduit about
1/4 inch
(6 mm) from end,
through using the adjacent hole. Reserve the oblong
securely tighten cable strap to draw conduit to bracket.
hole for the bracket screw.
Remove any excess cable strap material.
NOTE
12. On opposite side, install second 7 inch cable strap cap-
Be sure that all splices are positioned above the turn signal
turing conduit and wire splices. Securely tighten cable
switch bracket.
strap to draw splices to conduit. Remove any excess
cable strap material.
3.
Place the turn signal switch assembly into the housing
13. Route wire bundle to upper switch housing below and
aligning the oblong hole in the bracket with the lower
then forward of the main wire harness positioning conduit
bracket weld nut. Be sure that bracket is fully seated.
in channel next to angular arm of bracket. Secure bundle
Tabs on each side are captured in slots cast into switch
to arm placing new cable strap 1/4 inch (6 mm)
housing.
8-18
2005 FLT Police: Electrical
HOME
PURSUIT/AUXILIARY SWITCH
Clutch Interlock
Switch
Removal
1. See Section
8.21 HANDLEBAR SWITCHES, RIGHT
SIDE HANDLEBAR SWITCHES, DISASSEMBLY, in the
2005 Touring Models Service Manual (Part No. 99483-
05).
2. From inside the switch housing, carefully cut cable strap
to free conduit from the turn signal switch bracket.
3. Remove the Phillips screw (with lockwasher) to release
the turn signal switch bracket. Remove the switch
assembly from the housing.
4. Remove the two T8 TORX screws and the Phillips screw
(with lockwasher) to release the lower bracket. Remove
the bracket from the housing.
5. Pull both switches from the housing.
6. Cut the wires from the old switches as follows:
● Gray/Black wire: 1-1/2 inches (38 mm)
● Orange/Violet wires: 1-7/8 inches (48 mm)
p0040a8x
● Green/Red wire: 1-1/4 inches (32 mm)
Figure 8-24. Lower Switch Housing
NOTE
Replacement Pursuit/Auxiliary Switch wires are cut to length
and partially stripped (Gray/Black wire: 2 inches (51 mm);
4.
Install Phillips screw (with lockwasher) to secure bracket
Orange/Violet wires: 1-7/8 inches (48 mm); Green/Red wire:
inside housing.
1-3/4 inches (45 mm).
7. See GENERAL REPAIR PROCEDURES, in the 2005
CAUTION
Touring Models Service Manual (Part No. 99483-05).
If routed incorrectly, wires may be pinched by casting or
8. Move keycap to the OFF position. Install the switches in
handlebar resulting in switch failure.
the housing with contacts facing the recessed area on
the ramp. Ribs cast in lower housing hold switches in
5. Loop switch wires so that spliced lengths are positioned
position.
directly over bracket screw.
The Auxiliary switch with the Gray/Black lead is installed
6. Capturing conduit about
1/4 inch
(6 mm) from end,
at the bottom, while the Pursuit switch with the Green/
securely tighten cable strap to draw conduit to bracket.
Red lead is at the top. Route switch wires into corner
Remove any excess cable strap material.
space outside of the ribbed area.
NOTE
7. On opposite side, install second 7 inch cable strap cap-
turing conduit and wire splices. Securely tighten cable
If the keycap and ramp mechanism requires replacement,
strap to draw splices to conduit. Remove any excess
install as follows: Slide ramp upward to remove from keycap
cable strap material.
shaft. Remove keycap from switch housing. Install spring into
hole on inboard side of new keycap. Position ball on end of
8. Route wire bundle to upper switch housing below and
spring. Use a small amount of grease to hold ball in place.
then forward of the main wire harness positioning conduit
Install keycap so that ball engages detente in switch housing.
in channel next to angular arm of bracket. Secure bundle
Slide ramp over keycap shaft so that tongues on ramp
to arm placing new cable strap 1/4 inch (6 mm) from end
engage grooves in keycap shaft.
of conduit. Cut any excess cable strap material. If neces-
sary, bend angular arm of bracket downward to firmly
secure Clutch Interlock Switch in installed position.
Installation
9. See Section 8.21 HANDLEBAR SWITCHES, LEFT SIDE
1.
Install lower bracket with the weld nut side down.
HANDLEBAR SWITCHES, ASSEMBLY, in the 2005
2.
Slide the T8 TORX screws through holes in lower bracket
Touring Models Service Manual (Part No. 99483-05).
and switches and thread into lower casting until snug.
2005 FLT Police: Electrical
8-19
HOME
3.
Install Phillips screw (with lockwasher), to secure lower
bracket to threaded boss in housing. Work Auxiliary and
Pursuit switches to ensure smooth operation.
7 Inch
Cable Strap
4.
See Figure 8-25. Insert tapered end of new 7 inch cable
Bracket
strap into round hole in turn signal switch bracket and
then feed back through using the adjacent hole. Reserve
the oblong hole for the bracket screw.
NOTE
Be sure that all splices are positioned above the turn signal
switch bracket.
5. Place the turn signal switch assembly into the housing
aligning the oblong hole in the bracket with the lower
bracket weld nut. Be sure that bracket is fully seated.
Tabs on each side are captured in slots cast into switch
housing.
Right Turn
6. Install Phillips screw (with lockwasher) to secure turn sig-
Signal Switch
nal switch bracket inside housing.
f1294x2x
CAUTION
If routed incorrectly, wires may be pinched by casting or
Figure 8-25. Insert Cable Strap in Switch Bracket
handlebar resulting in switch failure.
7.
Loop switch wires so that spliced lengths are positioned
10.
Route wire bundle to upper switch housing in channel
directly over bracket screw.
next to angular arm of bracket. Secure bundle to arm
8.
Capturing conduit about
1/4 inch
(6 mm) from end,
placing new cable strap 1/4 inch (6 mm) from end of con-
securely tighten cable strap to draw conduit to bracket.
duit. Cut any excess cable strap material. If necessary,
Remove any excess cable strap material.
bend angular arm of bracket downward to firmly secure
Front Stoplight Switch in installed position.
9.
On opposite side, install second 7 inch cable strap cap-
turing conduit and wire splices. Securely tighten cable
11.
See Section 8.21 HANDLEBAR SWITCHES, RIGHT
strap to draw splices to conduit. Remove any excess
SIDE HANDLEBAR SWITCHES, ASSEMBLY, in the
cable strap material.
2005 Touring Models Service Manual (Part No. 99483-
05).
8-20
2005 FLT Police: Electrical
HOME
SIREN AMPLIFIER
8.10
AMPLIFIER
4577p
Part No. /Description
91156-93
Whelen 100 Watt (WS-320) Siren Amplifier
REMOVAL
See Figure 8-26. The Whelen amplifiers are mounted to the
mounting bracket in front of the left saddlebag with screws
and washers.
1.
Pull back rubber boot.
2.
Loosen connector screw and disconnect connector.
3.
Remove mounting screws.
INSTALLATION
1. Position amplifier as shown in Figure 8-26.
2. Install mounting screws and tighten to 6 ft-lbs (8 Nm).
Figure 8-26. Whelen Amplifier Mounting
3. Plug in the connector and tighten connector screw.
4. Install rubber boot.
GAIN ADJUSTMENT
NOTE
The Public Address (PA) amplifier gain is set at the manufac-
turer and normally does not require adjustment. If it has feed-
back, low volume or distortion, adjust the gain as follows:
1. Remove access screw to expose the internal adjusting
screw. See Figure 8-27.
2. Press Push-To-Talk switch on microphone, speak into
microphone in normal manner and while speaking, care-
fully turn internal adjusting screw, with a proper size
screwdriver, to obtain maximum distortion free output.
Adjustment Screw
(Under Access Hole Screw)
3. Replace access screw.
4575p
Figure 8-27. PA Gain Adjustment Screw
2005 FLT Police: Electrical
8-21
HOME
MICROPHONE AND JACK
8.11
FLHP: Remove headlamp assembly. See Section 8.11
MICROPHONE
HEADLAMP
(FLHR/C/S), HEADLAMP ASSEMBLY,
REMOVAL, in the 2005 Touring Models Service Manual
(Part No. 99483-05).
Troubleshooting
2. Remove nut and washer to release microphone jack.
1.
To verify that Push-To-Talk (PTT) switch is functioning
3. Unsolder leads from jack terminals.
properly, connect probes of ohmmeter to tip and ring of
microphone plug. See Figure 8-28.
2.
With PTT switch off (not depressed) there must be no
INSTALLATION
continuity.
3.
Depress PTT switch. Ohmmeter must read 0-1 ohm.
1.
Solder leads to jack terminals as shown in Figure 8-28.
Replace microphone if there is no continuity.
2.
Install microphone jack and secure with washer and nut.
3. FLHTP: Install outer fairing. See Section 2.29 UPPER
FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/
REMOVAL
WINDSHIELD, INSTALLATION, in the 2005 Touring
Models Service Manual (Part No. 99483-05).
1. FLHTP: Remove outer fairing. See Section 2.29 UPPER
FLHP: Install headlamp assembly. See Section 8.11
FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/
HEADLAMP
(FLHR/C/S), HEADLAMP ASSEMBLY,
WINDSHIELD, REMOVAL, in the 2005 Touring Models
INSTALLATION, in the 2005 Touring Models Service
Service Manual (Part No. 99483-05).
Manual (Part No. 99483-05).
4
5
p0013a8x
R
W
To Pin Connector
3
BE
2
Microphone Jack
1
6
Microphone Plug
1.
Sleeve
2.
Ring
3.
Tip
Microphone Jack
Microphone Plug
4.
Ring
5.
Sleeve
6.
Tip
Figure 8-28. Microphone and Jack Connections
8-22
2005 FLT Police: Electrical
HOME
AIR HORN
8.12
ENABLING AIR HORN
Left Handlebar Controls [24]
(Gray)
1. FLHTP: Remove outer fairing. See Section 2.29 UPPER
FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/
WINDSHIELD, REMOVAL, in the 2005 Touring Models
Service Manual (Part No. 99483-05).
FLHP: Remove headlamp assembly. See Section 8.11
HEADLAMP
(FLHR/C/S), HEADLAMP ASSEMBLY,
REMOVAL, in the 2005 Touring Models Service Manual
(Part No. 99483-05).
2. Locate the gray 12-place Deutsch connector for the left
side handlebar switch controls [24]. See Figure 8-29 for
FLHTP models, Figure 8-30 for FLHP models.
3. Remove the secondary lock from the socket half of the
connector and proceed as follows:
a. Pull seal pin from cavity 11.
b. Remove Y/BK wire from cavity 6.
c. Install Y/BK wire in cavity 11. See Figure 8-31.
p0128x8x
d. Push seal pin into cavity 6.
Figure 8-30. Headlamp Nacelle (FLHP)
NOTE
For instructions on properly removing and installing wire ter-
minals, see APPENDIX B.1, DEUTSCH ELECTRICAL CON-
MOVE Y/BK WIRE TO CAVITY
NECTORS, REMOVING/INSTALLING SOCKETS, in the
11 IF USING WHELEN SIREN
AMPLIFIER & AIR HORN
2005 Touring Models Service Manual (Part No. 99483-05).
FUNCTION IS DESIRED
[24B]
(GRAY)
4. Place a rag in the speaker cone to reduce volume. Turn
O/W
1
Y
2
the Ignition/Light Key Switch to IGNITION and test oper-
BE
3
ation of air horn.
W
4
FROM
W/V
5
MAIN
Y/BK
6
HARNESS
BK/R
7
[24A]
BK/R
8
PK/BK
9
Left Handlebar Controls [24]
TN/BK
10
(Gray)
Y/BK
11
12
CLUTCH
LOCKOUT SWITCH
SIREN OFF/RUN
SWITCH
HEADLAMP HI/LO
SWITCH
LEFT
DIRECTIONAL
SWITCH
HORN/SIREN
SWITCH
p0042c8x
Figure 8-31. Enabling the Air Horn (All Models)
5. FLHTP: Install outer fairing. See Section 2.29 UPPER
FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/
WINDSHIELD, INSTALLATION, in the 2005 Touring
p0058x8x
Models Service Manual (Part No. 99483-05).
FLHP: Install headlamp assembly. See Section 8.11
Figure 8-29. Inner Fairing (FLHTP)
HEADLAMP
(FLHR/C/S), HEADLAMP ASSEMBLY,
INSTALLATION, in the 2005 Touring Models Service
Manual (Part No. 99483-05).
2005 FLT Police: Electrical
8-23
HOME
TOUR-PAK
8.13
GENERAL
i03730
Phillips Screws
The Tour-Pak Kit (White- Part No. 53238-01; Black- Part No.
with Washers
53239-01) is designed for installation on both FLHP and
FLHTP model motorcycles and is available from your Harley-
Davidson Dealer.
1WARNING
The rider's safety depends upon the correct installation
of this kit. If the procedure is not within your capabilities
or you do not have the correct tools, have a Harley-
Davidson dealer perform the installation. Improper instal-
lation of this kit could result in death or serious injury.
Luggage
Hex Head
(00308a)
Rack Spacer
Screws
Figure 8-32. Remove Radio Tray and Hardware
INSTALLATION
1.
See Figure 8-32. Remove the five hex head cap screws
i03731
Strobe Head
and two smaller Phillips screws (with washers) securing
Connectors
existing radio tray to mounting rail. Leave the two rectan-
Nut
gular license plate spacers and set aside three remain-
ing spacers. Discard screws and washers, but save nuts
for installation later. Discard radio tray.
Nut
2.
See Figure 8-33. Carefully remove Tour-Pak assembly
and hardware from shipping container. Open Tour-Pak.
Remove the three nuts securing the power supply
mounting plate to the bottom of the Tour-Pak. Save for
reinstallation.
3.
Note connector locations for reinstallation and discon-
nect the strobe head connectors from the power supply.
Nut
4.
See Figure 8-34. Set power supply aside temporarily.
Raise and position (lean) the mounting plate up against
Figure 8-33. Remove Plate Securing Power Supply
the front side of Tour-Pak to provide access to the Tour-
Pak permanent mounting holes. If necessary, use a
cable strap to hold plate in place. Temporarily set Tour-
i03732
Pak assembly aside.
Power Supply
Mounting Plate
Leaning Toward
Front of Tour-Pak
Figure 8-34. Provide Room For Mounting Tour-Pak
8-24
2005 FLT Police: Electrical
HOME
5. See Figure 8-35. Remove the quick release seat pin clip
from the seat pin and pivot the seat forward as far as
i03733
Seat Pin
possible. It may be necessary to tie or brace seat in the
full forward position.
6. Remove the two nuts and washers securing the trim
panel assembly to the fender and remove panel. Save
hardware and panel for reinstallation.
1WARNING
Cut Cable
Straps
To prevent accidental vehicle start-up, which could
Securing
cause death or serious injury, disconnect negative (-)
Pole Lamp
Harness
Trim Panel
battery cable before proceeding. (00048a)
Nuts
1WARNING
Disconnect negative (-) battery cable first. If positive (+)
Figure 8-35. Remove Trim Panel
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explo-
sion, which could result in death or serious injury.
i03734
(00049a)
7.
Disconnect battery cables, negative battery cable first.
8.
Cut the two cable straps securing the pole lamp harness
Tour-Pak Mounting
to the support rail. Discard cable straps. Route pole lamp
Bolts (with Washers)
harness away from Tour-Pak mounting area.
9.
See upper frame of Figure 8-36. Return to the Tour-Pak.
Using parts from kit, pre-install four long hex head bolts
with washers from inside bottom of Tour-Pak at four per-
manent mounting holes.
Luggage
License Plate
10.
Raise the Tour-Pak up and position onto rack with four
Rack Spacer
Bracket Spacer
mounting bolts aligned with four holes in support rail (two
on each side).
See lower frame of Figure 8-36. Make sure the two
license plate bracket spacers remain in position and
bolts can pass through them. Obtain the two rectangular
luggage rack spacers and four nuts saved from step 2.
Washers
Obtain four new washers from kit and loosely install
and Nuts
washers and nuts to secure Tour-Pak to support rail.
i03735
11.
Obtain rear mounting block (with1 hole), hex head bolt
Figure 8-36. Install Tour-Pak Mounting Hardware
and two flat washers from kit. Also obtain rectangular
spacer and nut saved from step 1.
12.
See Figure 8-37. Install washer to bolt and position bolt
i03736
Mounting
above hole at rear center Tour-Pak above rear block
Block
mounting position.
13.
Orient rear mounting block (with hole running vertical)
and position between recessed area of Tour-Pak (near
center) and rail support. Install bolt through Tour-Pak,
rear block and rail, then loosely Install spacer followed by
washer and nut.
Spacer
Washer
and Nut
Figure 8-37. Install Tour-Pak Mounting Block
2005 FLT Police: Electrical
8-25
HOME
14. Obtain the remaining mounting block (with 2 holes), two
long Phillips and two flat washers from kit.
Front
15. See Figure 8-38. Install flat washers to Phillips screws
Air Tank
Mounting
and position screws above two holes near front center of
Mounting
Block
Tour-Pak above front mounting block position.
Bracket
16. Position block (with holes running vertical) between Tour-
Pak and air tank mounting bracket. Install screws
through Tour-Pak and mounting block and thread into air
tank mounting bracket. Tighten screws to 22 in-lbs (2.5
Nm).
17. Return to mounting hardware installed in Steps
9
through 15 and alternately tighten to 60-84 in-lbs (6.8-
9.5 Nm).
i03737
18. See Figure 8-39. Reposition power supply onto mounting
plate and reinstall the three nuts removed in step 3 to
provide access for mounting Tour-Pak. Obtain two more
Figure 8-38. Install Tour-Pak Front Mounting Block
nuts from kit and install to remaining mounting plate
studs. Tighten nuts to 80 in-lbs (9.0 Nm).
i03738
Nut
19. Reconnect the strobe head (male to female) connectors
disconnected in step 4.
NOTE
Nut
When performing the next few steps, install battery mounting
bracket, battery strap and battery only. Do NOT connect bat-
Nut
tery terminals at this time.
20. See Figure 8-40. Loosely assemble battery mounting
bracket with bolt, washers and nut obtained from kit.
21. Orient and position battery behind mounting bracket as
shown. Loosely install battery strap using two bolts, four
Strobe
washers and two nuts from kit.
Connectors
22. Make sure battery is centered and mounting bracket is
Nut
positioned properly. While pushing mounting bracket for-
ward, tighten bracket hardware to 120-144 in-lbs (13.6-
Figure 8-39. Install Power Supply Mounting Plate and
16.3 Nm). Return to battery strap hardware and tighten
Reconnect Strobe Heads
to 120-144 in-lbs (13.6-16.3 Nm).
Battery
i03739
Battery
Strap
Mounting
Bracket
Nut
Nut
Washer
Washer
Figure 8-40. Install Battery Mounting Bracket and Battery
8-26
2005 FLT Police: Electrical
HOME
23. See Figure 8-41. Locate positive and negative battery
cables in Tour-Pak. Make sure cables are not touching
each other or anything metal in the Tour-Pak.
Negative
24. See Figure 8-42. Route control harness (from Tour-Pak)
Cable
Positive
along left upper frame tube to PNA accessory connector
Cable
in space immediately in front of motorcycle battery.
25. Connect control harness to PNA accessory connector.
26. Locate the two-pin connector originally routed to pole
lamp and connect to the two-pin connecter coming from
Tour-Pak.
NOTE
Prior to installing positive battery terminal to battery post,
locate insulated end of positive battery cable (directly after
maxi-fuse) and bend a 90 degree radius into the cable as
i03739
shown. This will keep the terminal from kinking when install-
ing terminal to battery post.
Figure 8-41. Positive and Negative
Tour-Pak Battery Cables
1WARNING
Connect positive (+) battery cable first. If positive (+)
2-Pin
cable should contact ground with negative (-) cable con-
Connector
PNA
nected, the resulting sparks can cause a battery explo-
Accessory
sion, which could result in death or serious injury.
Connector
(00068a)
27. See Figure 8-43. Route the positive battery cable with
Maxi-fuse as shown and loosely install positive battery
terminal over existing terminal to battery positive post.
Tuck the Maxi-Fuse along with the pole lamp harness
down into the space between the battery and the left
upper frame tube as shown. Tighten terminal to 30 in-lbs
(3.4 Nm).
28. Route the negative battery cable around the front of the
Control
battery and install terminal over existing terminal to neg-
Harness
i03741
ative battery post. Tighten terminal to 30 in-lbs (3.4 Nm).
Figure 8-42. Install Tour-Pak Harness and
2-Pin Connectors
i03742
Maxi-Fuse
Positive Cable
Radius to Prevent
Terminal Kinking
Pole Lamp
Harness
Connector
Figure 8-43. Install Tour-Pak Battery Cables
to Motorcycle
2005 FLT Police: Electrical
8-27
HOME
29. See Figure 8-44. Install cable strap to secure Tour-Pak
Harness to mounting rail.
i03743
30. See Figure 8-45. Reinstall trim panel to fender using nuts
and washers saved from step 7.
31. Reinstall trim panel cover to protect battery and wiring.
32. Pivot seat downward and lower until it engages seat pin
completely. Install quick release seat pin clip to fully
secure seat.
1WARNING
Cable
Tour-Pak
After installing seat, pull upward on front of seat to be
Strap
Harness
sure it is in locked position. While riding, a loose seat can
shift causing loss of control, which could result in death
or serious injury. (00070a)
Figure 8-44. Secure Tour-Pak Harness to Mounting Rail
1WARNING
Connect positive (+) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
Trim Panel
nected, the resulting sparks can cause a battery explo-
sion, which could result in death or serious injury.
(00068a)
33. See Figure 8-46. Return to Tour-Pak and locate positive
and negative battery cables. Route positive battery ter-
minal to battery and install terminal to battery post.
Tighten terminal to 30 in-lbs (3.4 Nm).
34. Route negative battery terminal to negative battery post
and install terminal. Tighten terminal to 30 in-lbs (3.4
Nm).
35. Close Tour-Pak and test strobe lights for proper opera-
i03744
tion.
Figure 8-45. Reinstall Trim Panel
Positive Post
Negative Post
and Terminal
and Terminal
i03740
Figure 8-46. Install Tour-Pak Battery Terminals
8-28
2005 FLT Police: Electrical
HOME
ELECTRICAL CONNECTOR LOCATIONS
8.14
Table 8-7. FLHTP Wire Harness Connectors
No.
Description
Type
Location
[1]
Main to Interconnect Harness
12-Place Deutsch (Black)
Inner Fairing - Right Fairing Bracket
[2]
Main to Interconnect Harness
12-Place Deutsch (Gray)
Inner Fairing - Right Fairing Support Brace
[4]
Accessory
4-Place Deutsch
Upper Frame Cross Member (Under Seat)
[5]
Maxi-Fuse
2-Place Packard
Under Left Side Cover
[7]
Rear Fender Lights Harness
8-Place Multilock
Top of Rear Fender (Under Seat)
[8]
EFI Harness
12-Place Deutsch (Gray)
Under Right Side Cover
[13]
Fuel Tank Harness
3-Place Multilock
Behind Fuel Tank (Under Seat)
[15]
Main to Interconnect Harness
4-Place Packard
Inner Fairing - Front of Right Fairing Bracket
[18]
Left Rear Turn Signal
2-Place Multilock
Circuit Board Under Tail Lamp Assembly
[19]
Right Rear Turn Signal
2-Place Multilock
Circuit Board Under Tail Lamp Assembly
[21]
Indicator Lamps
10-Place Multilock
Inner Fairing - Above Storage Box
[22]
Right Handlebar Controls
12-Place Deutsch (Black)
Inner Fairing - Fork Stem Nut Lock Plate (Left Side)
[24]
Left Handlebar Controls- Air Horn Option
12-Place Deutsch (Gray)
Inner Fairing - Left Fairing Support Brace
[30]
Turn Signal Module
12-Place Deutsch
Cavity in Crossmember at Rear of Battery Box (Under Seat)
[31]
Front Turn Signal/Pursuit Lamps
6-Place Multilock
Inner Fairing - Outboard of Left Fairing Bracket
[32]
Front Fender Tip Lamp (DOM)
2-Place Multilock (Black)
Inner Fairing - Below Upper Fork Bracket (Left Side)
[33]
Ignition/Light Key Switch
4-Place Packard
Inner Fairing - Front of Right Fairing Bracket
[38]
Headlamp
Headlamp Connector
Inner Fairing
[39]
Speedometer
12-Place Packard (Black)
Inner Fairing (Back of Speedometer)
[45]
Rear Fender Tip Lamp (DOM)
3-Place Multilock
Circuit Board Under Tail Lamp Assembly
[46]
Stator
2-Place Packard
Bottom of Voltage Regulator
[57]
Siren/PA Speaker
2-Place Deutsch
Top Rail of Engine Guard (Right Side)
[59]
Rear Pole Lamp
2-Place Deutsch
Under Luggage Rack (Left Side)
[64]
Fuse Block
Packard
Under Left Side Cover
[65]
Vehicle Speed Sensor
3-Place Deutsch
Under Right Side Cover (Behind Electrical Bracket)
[69]
Pursuit Flasher
Relay Connector
Inner Fairing - Front of Speedometer
[70]
Siren Amplifier Harness
12-Place Deutsch
Inner Fairing - Left Fairing Support Brace
[72]
Siren Amplifier
18-Place Packard
Top Rail of Saddlebag Guard (Left Side)
[73]
Pursuit Lamps
2-Place Multilock (White)
Inner Fairing - Below Upper Fork Bracket (Left Side)
[77]
Voltage Regulator
1-Place Deutsch
Right Lower Frame Tube (Below Transmission Bracket)
[78]
Electronic Control Module (ECM)
36-Place Packard
Under Right Side Cover
[79]
Crankshaft Position (CKP) Sensor
2-Place Mini-Deutsch
Bottom of Voltage Regulator
[80]
Manifold Absolute Pressure (MAP) Sensor
3-Place Packard
Top of Intake Manifold/Induction Module
[83]
Ignition Coil
4-Place Packard
Below Fuel Tank (Left Side)
[84]
Front Injector
2-Place Packard
Below Fuel Tank (Left Side)
[85]
Rear Injector
2-Place Packard
Below Fuel Tank (Left Side)
[87]
Idle Air Control (IAC)
4-Place Packard
Below Fuel Tank (Right Side)
[88]
Throttle Position Sensor (TP Sensor)
3-Place Packard
Below Fuel Tank (Right Side)
[89]
Intake Air Temperature Sensor (IAT Sensor)
2-Place Packard
Below Fuel Tank (Right Side)
[90]
Engine Temperature Sensor (ET Sensor)
2-Place Packard
Back of Front Cylinder (Left Side)
Continued ...
2005 FLT Police: Electrical
8-29
HOME
[108]
[156]
[70]
[24]
[21]
[2]
[39]
[69]
[1]
[31]
[15]
[176]
[167]
[32]
[22]
p0058x8x
[33]
[73]
Figure 8-47. Inner Fairing (FLHTP)
Table 8-7. FLHTP Wire Harness Connectors (Continued)
No.
Description
Type
Location
[91]
Data Link
4-Place Deutsch
Under Right Side Cover
[93]
Tail Lamp
4-Place Multilock
Circuit Board Under Tail Lamp Assembly
[94]
Rear Fender Lights Harness to Circuit Board
6-Place Multilock
Circuit Board Under Tail Lamp Assembly
[105]
Fairing Cap Switches
12-Place Multilock
Inner Fairing - Above Upper Fork Bracket (Right Side)
[107]
Ambient Air Temperature Sensor
3-Place Multilock
Inner Fairing - Left Fairing Bracket (Outboard Side)
[108]
Tachometer
12-Place Packard (Gray)
Inner Fairing (Back of Tachometer)
[110]
Voltmeter Lamp
Spade Connector
Inner Fairing
[111]
Voltmeter
Spade Connector
Inner Fairing
[116]
Fuel Gauge Lamp
Spade Connector
Inner Fairing
[117]
Fuel Gauge
Spade Connector
Inner Fairing
[119]
EFI Fuses
Fuse Terminals
Fuse Block (Under Right Side Cover)
[121]
Rear Brake Light Switch
Spade Terminals
Beneath Transmission (Right Side)
[122]
Horn
Spade Terminals
Between Cylinders (Left Side)
[123]
Starter Relay
Relay Connector
Rear of Battery Box (Under Seat) - Left Side
[124]
Brake Light Relay
Relay Connector
Fuse Block (Under Left Side Cover)
[126]
Ignition Keyswitch Relay
Relay Connector
Rear of Battery Box (Under Seat) - Left Side
[128]
Starter Solenoid
Spade Terminals
Top of Starter
[129]
Harness Grounds
Ring Terminals
Upper Frame Cross Member (Under Seat)
Continued ...
8-30
2005 FLT Police: Electrical
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