Harley Davidson 2005 touring models. Service repair manual — page 62
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TIRES
2.3
NOTE
GENERAL
Use the tires recommended for civilian/pleasure vehicles of
the same year and model family.
The rear tire on FL police motorcycles is fit for solo riding
only. If converted to a two-up bike, that is, configured for pas-
senger use (with luggage), then the rear tire needs to be
1WARNING
changed to one with a higher weight rating. Since it has long
been Harley-Davidson policy not to mix different types of tires
Harley-Davidson front and rear tires are not the same.
on the same vehicle, we strongly recommend that both front
Interchanging front and rear tires can cause tire failure,
and rear tires be replaced. In order to alert the customer to
which could result in death or serious injury. (00026a)
this safety issue, the following warning appears on a label fit-
ted to the rear fender approximately 1/4 inch (6.4 mm) behind
Tire size, manufacturer’s description and inflation pressure
the domestic seat mounting hole.
are listed below.
1WARNING
This vehicle has tires with weight ratings for one person
operation. If this vehicle is modified to carry two people,
the tires must be changed. See a Harley-Davidson dealer
for proper replacement tires. Using improper tires can
cause tire failure which could result in death or serious
injury. (00096a)
Table 2-3. Tire Data
TIRE
TIRE
MANUFACTURER’S
MODEL
SIZE
PRESSURE
LOCATION
DESIGNATION
(Cold)
Dunlop
36 psi
Front
MT90B1672H
D402F PT
(248 kPa)
FLHTP/FLHP
Dunlop
36 psi
Rear
MT90B1671H
D402 PT
(248 kPa)
2005 FLT Police: Chassis
2-3
HOME
SEAT
2.4
OPERATION
5872
Quick Release
Pin
CAUTION
Maximum air pressure for the seat is 100 psi (689 kPa).
Normal air pressure is 30-45 psi (207-310 kPa). Do not
operate with air pressure so low that system bottoms out
on bumpy roads. (00167a)
NOTE
To set minimum air pressure, have rider sit on seat and
bounce to simulate riding conditions. Visually check for any
Support
Post
contact between air spring and frame components. Add air as
Rear Seat
necessary.
Bracket
1. Standing on left side of vehicle, press down on rear of
seat and pull quick release pin from hole in support post.
Figure 2-2. Seat Latch
See Figure 2-2. Raise seat toward fuel tank console.
2. To lock seat in place, move seat down until support post
engages hole in rear seat bracket.
NOTE
3. While pressing down on rear of seat, insert quick release
The seat does not adjust forward or backward.
pin into hole of support post.
11
10
9
8
1.
Air spring hose
13
2.
Air spring
3.
Screw (2) @ 36-60 in-lbs (4.1-6.8 Nm)
14
12
6
7
4.
Trim panel
16
15
5.
Seat faring
19
6.
Screw
17
7.
Rivnut (4)
8.
Screw
18
5
9.
Bushing
10.
Seat support bracket
20
11.
Nut @ 48-84 in-lbs (5.4-9.5 Nm)
12.
Seat
13.
Seat mount bracket (2)
4
21
14.
Washer
15.
Screw @ 60-120 in-lbs (6.8-13.6 Nm)
16.
Screw (4) @ 15-20 ft-lbs (20.3-27.1 Nm)
17.
Rubber bumper
3
18.
Flange locknut (2) @ 96-144 in-lbs (10.9-16.3 Nm)
22
19.
Quick release pin
20.
Flange nut (2) @ 60-120 in-lbs (6.8-13.6 Nm)
2
21.
Washer (2)
23
22.
Rear seat bracket
23.
Set screw (2)
24.
Nut (2) @ 50-70 in-lbs (5.7-7.9 Nm)
1
24
25.
Quick release fitting
p0047c2x
25
Figure 2-3. Air Seat Support
2-4
2005 FLT Police: Chassis
HOME
AIR SEAT RESERVOIR
f1842x2x
Air Pressure
Air
Gauge
Reservoir
Removal
1.
Remove luggage rack. See Section
2.6 LUGGAGE
RACK, REMOVAL, steps 1-5.
2.
Alternately loosen screws on each side of motorcycle to
release ends of luggage rack from frame tube weld-
ments. Continue loosening screws until luggage rack can
be raised high enough to remove air reservoir.
Air Valve
3.
Remove two Phillips screws (with lockwashers) from lug-
gage rack to release top of air reservoir bracket.
4.
Remove two Phillips screws from license plate bracket to
free rear of air reservoir bracket. Be sure to hold reser-
voir as the last screw is removed or damage to fender
paint may occur when assembly is released.
Figure 2-4. Air Seat Reservoir Air Valve
5.
Raise luggage rack and remove air reservoir from motor-
cycle.
3.
Slide Phillips screws through two holes in license plate
6.
Remove tee fittings from reservoir, if necessary.
bracket and two holes in luggage rack engaging weld
nuts in air reservoir bracket. Alternately tighten screws
until snug.
Installation
4.
Alternately tighten screws on each side of motorcycle to
1. Install tee fittings to air reservoir, if removed.
secure ends of luggage rack to frame tube weldments.
2. Position air reservoir beneath luggage rack exercising
5.
Install luggage rack. See Section 2.6 LUGGAGE RACK,
caution to avoid scratching fender paint.
INSTALLATION, steps 1-4 and 6-13.
8
6
3
5
7
2
4
1. Air seat reservoir and
bracket
9
2. Lockwasher (2)
3. Screw (2)
4. Air pressure gauge
5. Air tube
6. Compression fitting
7. Air valve
8. Protective cap
10
1
9. Tee fitting (2)
p0048b2x
10. Screw (2)
Figure 2-5. Air Seat Reservoir
2005 FLT Police: Chassis
2-5
HOME
FOOTBOARDS
2.5
4. At footboard rear bracket, slide upper hex bolt through
GENERAL
frame weldment, jiffy stand bracket and footboard
bracket thru hole. Install lockwasher and locknut. Slide
FLHTP and FLHP models are equipped with adjustable foot-
lower hex bolt (with lockwasher) through frame weldment
boards.
and jiffy stand bracket into threaded hole of footboard
bracket. Alternately tighten two hex bolts to 15-20 ft-lbs
(20.3-27.1 Nm).
NOTE
ADJUSTMENT
Perform a visual check to verify that both footboards are at
the same height.
Right Side
1.
Loosen two allen head socket screws (with lockwashers
and flat washers) to release right side footboard brackets
from frame weldment. For best results, approach from
left side of vehicle using a 3/8 inch ball allen with exten-
sion.
2.
Move the footboard to one of two positions. Alternately
tighten allen head socket screws to 30-35 ft-lbs (40.7-
47.5 Nm).
1WARNING
Rear brake will not operate properly if brake pedal can-
not be fully depressed. After adjusting right footboard,
check for minimum clearance of 2.25 inches (57 mm)
between bottom of brake pedal and top of footboard.
Failure to allow for proper clearance can lead to loss of
braking performance, which could result in death or seri-
ous injury.
Left Side
1. Loosen the allen head socket screw (with lockwasher
and flat washer) to release the footboard forward bracket
from frame weldment. For best results, approach from
opposite side of vehicle using a 3/8 inch ball allen.
2. To free footboard rear bracket from frame weldment and
jiffy stand bracket, remove lower hex bolt
(with lock-
washer) and upper hex bolt (with lockwasher and lock-
nut).
3. Move the footboard to one of two positions. Alternately
tighten allen head socket screw to 30-35 ft-lbs (40.7-47.5
Nm).
2-6
2005 FLT Police: Chassis
HOME
LUGGAGE RACK
2.6
REMOVAL
6046
1. Remove both saddlebags.
2. On the right side of the motorcycle, locate the air seat
reservoir air valve under the luggage rack, and on the left
side, the rear shock air valve just below the chrome
frame cover. See Figure 2-6.
1WARNING
Exercise caution when bleeding air from the air valves.
Moisture combined with lubricant (either from shock
assembly or drip oiler in the air compressor lines) may
be ejected onto the rear wheel, tire and/or brake compo-
nents and adversely affect traction and/or braking effi-
ciency, which could result in death or serious injury.
f1842x2x
Air Seat
Reservoir
Figure 2-7. Remove Luggage Rack
Air Valve
3.
Remove protective cap from each air valve and depress
pin to bleed air from both reservoir and shocks. To purge
rear air suspension lines of any oil, add 3-5 psi (20.7-
34.5 kPa) before releasing air. Depress collar on each
compression fitting and pull out air tube.
4.
Remove bolt (with flat washer) to remove saddlebag front
mounting bracket from chrome frame cover. Remove
Phillips screw and then remove frame cover. Repeat step
on opposite side of motorcycle.
5.
Remove two bolts to free license plate bracket from bot-
tom support tube.
6.
Remove screws (with spacers) on each side of motorcy-
cle to release ends of luggage rack from frame tube
Rear Shock
weldments.
Air Valve
7.
Remove pole lamp. See Section 8.5 POLE LAMP.
8.
Slide luggage rack toward rear of motorcycle to clear
front bushings, and then rotate rack upward to clear
frame tubes. See Figure 2-7.
f2018x2x
INSTALLATION
1. Place luggage rack into position inboard of frame tubes.
Figure 2-6. Air Valves
2005 FLT Police: Chassis
2-7
HOME
2.
Install screws (with spacers) on each side of motorcycle
Table 2-4. Rear Air Suspension Pressures
to secure ends of luggage rack to frame tube weldments.
Recommended
3.
Install two bolts to fasten license plate bracket to bottom
Shock Loading
support tube.
Pressures
PSI
kPa
4.
Position chrome frame cover on frame tube and install
0-35
0-241
Phillips screw. Install bolt (with flat washer) to install sad-
dlebag front mounting bracket, but do not tighten. Repeat
Solo rider up to 150 lbs. (68 kg)
0
0
step on opposite side of motorcycle.
Solo rider 150-200 lbs. (68-91 kg)
0-10
0-69
5.
Install pole lamp. See Section 8.5 POLE LAMP.
Solo rider 200-250 lbs. (91-113 kg)
5-15
35-103
6.
Depress collar on compression fitting of air seat reser-
Maximum GVWR (see Section 2.1
20-35
138-241
voir, and insert air tube until it bottoms. Gently tug on
SPECIFICATIONS)
tube to verify that it is locked in place.
1WARNING
CAUTION
Use this table as a starting point in determining suit-
Maximum air pressure for the seat is 100 psi (689 kPa).
able rear air suspension pressures. Do not exceed
Normal air pressure is 30-45 psi (207-310 kPa). Do not
maximum GVWR when loading vehicle and do not
operate with air pressure so low that system bottoms out
pressurize system in excess of 35 psi (241 kPa).
on bumpy roads. (00167a)
Excessive load weight and/or air suspension pres-
sure can adversely affect handling and lead to loss
7.
Fill air reservoir to desired pressure. Install protective
of vehicle control, which could result in death or seri-
cap on air valve. See upper frame of Figure 2-6.
ous injury.
NOTE
To set minimum air pressure, have rider sit on seat and
bounce to simulate riding conditions. Visually check for any
11.
Observe air pressure gauge while filling. If leakage
contact between air spring and frame components. Add air as
occurs, remove tubes and inspect ends for burrs or dam-
necessary.
age. If either condition is found, snip off end of tube and
insert back into fitting.
8.
Observe air pressure gauge. If leakage occurs, then
remove tube and inspect end for burrs or damage. If
12.
When air pressure remains constant, install protective
either condition is found, snip off end of tube and insert
cap on air valve.
back into fitting.
13.
Install saddlebags. Using an open end/box wrench,
9.
Depress collar on compression fitting of each shock and
tighten saddlebag front mounting bracket bolts.
insert air tube until it bottoms. Gently tug on tube to verify
that it is locked in place.
10. Fill shocks to desired pressure. Refer to Table 2-4.
CAUTION
All air components fill rapidly. Use a small hand or foot
operated air pump to avoid possible damage to shocks
or air suspension components.
NOTE
An AIR SUSPENSION PUMP AND GAUGE (Part No. HD-
34633) is available at your Harley-Davidson dealer.
2-8
2005 FLT Police: Chassis
HOME
INSTRUMENT MOUNTING BRACKET: FLHP
2.7
GENERAL
8
7
The Instrument Mounting Bracket relocates the tachometer to
allow for the addition of a radio and speaker.
9
NOTE
6
The two rear holes in the handlebar clamp shroud allow the
rider to adjust the handlebars without having to remove the
10
shroud. To keep out moisture and debris, be sure to install
plastic plugs back into holes after handlebar adjustment.
INSTALLATION
11
1.
Remove windshield. See Section 2.31 WINDSHIELD/
5
HEADLAMP NACELLE (FLHR/C/S), REMOVAL, in the
2005 Touring Models Service Manual (Part No. 99483-
05).
2.
Remove Phillips screw at the bottom of the headlamp
door (chrome ring). Remove the headlamp door.
4
3.
Remove the eight Phillips screws to free the headlamp
housing from the headlamp nacelle.
4.
Squeeze the two external tabs (if present) to remove the
wire connector at the back of the headlamp bulb.
3
Remove headlamp housing assembly from the vehicle.
5.
Reaching inside the headlamp nacelle, remove flange
nut to release the chrome strip at the top of the nacelle.
2
See Figure 2-8.
6.
Carefully pry off the fork lock plate at the rear of the han-
dlebar clamp shroud. Remove two Phillips screws
1
f1458d2x
beneath the lock plate.
1.
Headlamp Nacelle
7.
Tachometer Bracket
7.
Loosen the Phillips screw from tab at the front of the han-
2.
Nut
8.
Acorn Nut (2)
dlebar clamp shroud (but do not remove).
3.
Flat Washer
9.
Fork Lock Plate
8.
Remove two acorn nuts from the left side fork studs.
4.
Flange Nut
10.
Handlebar Clamp Shroud
Remove acorn nuts from the right side fork studs.
5.
Chrome Strip
11.
Stud Plate
6.
Phillips Screw (2)
9.
Cover front fender with suitable material to protect fender
paint. Remove the passing lamp bracket from the left and
Figure 2-8. Headlamp Nacelle Assembly
right side fork studs and carefully set on front fender.
10.
Remove grommets (and clutch cable clamp) from the left
and right side fork studs.
13. Remove two acorn nuts and flat washers to release
tachometer bracket from the handlebar clamp shroud.
11.
Reaching inside the headlamp nacelle, disconnect
tachometer connector [108], 3-place Deutsch.
14. A peel and stick foam tape on the stud plate holds it in
place on the inboard side of the handlebar clamp shroud,
12.
Remove the handlebar clamp shroud from the vehicle,
Place the instrument mounting bracket over the studs
while gently pulling the tachometer conduit and connec-
and secure using hardware provided by manufacturer.
tor out of the headlamp nacelle. See Figure 2-9.
See upper frame of Figure 2-11.
2005 FLT Police: Chassis
2-9
HOME
5531
f1458e2x
Figure 2-9. Handlebar Clamp Shroud
Install instrument mounting bracket on stud plate.
1
p0044x5x
5532
2
3
6
Install instrument mounting bracket front bolt.
5530
5
4
1. Acorn Nut
2. Instrument Mounting
4. Stud Plate
Bracket
5. Screw
3. Handlebar Clamp Shroud
6. Nut
Figure 2-10. Instrument Mounting Bracket Assembly
Install tachometer bracket.
15. Secure slotted tab of instrument mounting bracket to
front of handlebar clamp shroud using nut and bolt pro-
vided by manufacturer. See middle frame of Figure 2-11.
Figure 2-11. Install Instrument Mounting Bracket
16. Place tachometer bracket over studs on instrument
mounting bracket and install two acorn nuts with flat
washers. See lower frame of Figure 2-11.
18.
Raising handlebar clamp shroud slightly, feed tachome-
ter connector and conduit into the headlamp nacelle.
17. Part the halves of the headlamp nacelle slightly. With the
Install shroud over mating flange while routing tachome-
flat washer on the handlebar clamp shroud facing the
ter conduit through opening for left side handlebar.
inside surface of the nacelle, slide the Phillips screw
Reaching inside headlamp nacelle, mate pin and socket
down the gap until the shroud is in position at top of
halves of tachometer connector.
nacelle. See Figure 2-9.
2-10
2005 FLT Police: Chassis
HOME
19. With the halves of the nacelle mated, tighten the Phillips
25. Install wire connector at the back of headlamp bulb.
screw in the tab of the handlebar clamp shroud to 10-20
in-lbs (1.1-2.3 Nm). If necessary, temporarily install a
26. Align holes in headlamp housing with those in headlamp
small cable strap into holes at the bottom of the nacelle
nacelle (headlamp door bracket at bottom). Install the
(headlamp housing flange) to hold the halves together.
eight Phillips screws.
20. Install two Phillips screws to fasten handlebar clamp
27. Fit the square-shaped portion of the headlamp door
shroud to the fork lock mechanism. Install fork lock plate.
spring into the slot at the top of the headlamp housing
21. Inserting weld stud on chrome strip into hole at the top of
and then snap the headlamp door (chrome ring) into
the headlamp nacelle, reach inside the nacelle to install
place. Install Phillips screw at the bottom of the head-
flange nut. Tighten flange nut to 15-20 in-lbs (1.7-2.3
lamp door.
Nm).
28. Install windshield. See Section
2.31 WINDSHIELD/
22. Install grommets on the left and right side fork studs.
HEADLAMP NACELLE (FLHR/C/S), INSTALLATION, in
23. Slide passing lamp bracket onto the left and right side
the
2005 Touring Models Service Manual
(Part No.
99483-05).
fork studs. Verify that four grommets are positioned on
the inboard side of the passing lamp brackets.
24. Install acorn nuts on the fork studs and tighten to 72-108
in-lbs (8.1-12.2 Nm). Be sure to capture the clutch cable
clamp on the upper left stud before installing the acorn
nut.
2005 FLT Police: Chassis
2-11
Table Of Contents
SUBJECT
PAGE NO.
8.1 Bulb Chart
8-1
8.2 System Fuses/Relays
8-3
8.3 Strobe Headlamp
8-5
8.4 Strobe Kit (PAR-36)
8-10
8.5 Pole Lamp
8-12
8.6 Siren and Public Address System
8-13
8.7 Voltage Checks
8-14
8.8 Speaker
8-16
8.9 Handlebar Switches
8-17
8.10 Siren Amplifier
8-21
8.11 Microphone and Jack
8-22
8.12 Air Horn
8-23
8.13 Tour-Pak
8-24
8.14 Electrical Connector Locations
8-29
8.15 Wiring Diagrams
8-35
NOTE
This section provides service information unique to the FLHP and FLHTP police model
motorcycles. See the 2005 Touring Models Service Manual (Part No. 99483-05) for other
information.
ELECTRICAL
8
HOME
BULB CHART
8.1
GENERAL
NOTE
The chart below gives the bulb requirements for FLHTP and
For Cycle Signal Lamp replacement bulbs, phone Whelen
FLHP police model motorcycles.
Engineering at (203) 526-9504.
Table 8-1. Bulb Chart FLHTP/FLHP
NUMBER OF
LAMP DESCRIPTION
CURRENT DRAW
HARLEY-DAVIDSON
BULBS
WATTAGE
(ALL LAMPS 12V)
(AMPERAGE)
PART NUMBER
(REQUIRED)
Head Lamp
Low Beam
4.58
55
1
68329-03
HIgh Beam
5.00
60
Tail/Stop Lamp
Tail Lamp
0.59
6
1
68167-88
Stop Lamp
2.10
24
Turn Signal Lamp
Front / Running
2
2.25 / 0.59
27/7
68168-89
Rear
2
2.25
27
68572-64B
Rear Fender Tip Lamp
Rear Fender Tip Bulb
2
0.33
3.7
53439-79
Pursuit Lamp
Left (Red)
68727-64A
1
2.5
30
Right (Blue)
68728-64
Rear Strobe, if provided
1WARNING
N/A
20
67598-88
The rear strobe is a source of high voltage
and must be off at least 10 minutes before
servicing. Inadequate safety precautions may
result in death or serious injury. (00097a)
Instrument Panel Lamps-FLHTP
High Beam Indicator
1
Oil Pressure Indicator
1
0.15
2.1
68024-94
Neutral Indicator
1
Turn Signal Indicator
2
Gauge Lamps-FLHTP
Speedometer**
N/A
N/A
N/A
N/A
Tachometer**
Voltmeter
1
0.24
3.4
67445-00
Fuel Gauge
Engine**
N/A
N/A
N/A
N/A
Pursuit
1
0.08
1.1
68642-96
** LED illuminated. LED’s are not repairable. Assembly must be replaced if LED fails.
2005 FLT Police: Electrical
8-1
HOME
Table 8-1. Bulb Chart FLHTP/FLHP
NUMBER OF
LAMP DESCRIPTION
CURRENT DRAW
HARLEY-DAVIDSON
BULBS
WATTAGE
(ALL LAMPS 12V)
(AMPERAGE)
PART NUMBER
(REQUIRED)
Instrument/Gauge Lamps-FLHP Indicator Module (with LED’s)
High Beam Indicator
Oil Pressure Indicator
N/A
0.05
N/A
68113-99
Neutral Indicator
Turn Signal Indicator
Fuel Gauge**
Speedometer**
Odometer**
N/A
N/A
N/A
N/A
Engine**
Pursuit**
** LED illuminated. LED’s are not repairable. Assembly must be replaced if LED fails.
8-2
2005 FLT Police: Electrical
HOME
SYSTEM FUSES/RELAYS
8.2
GENERAL
System Fuse Block (Under Left Side Cover)
Fuses are provided to protect electrical components. To
8
7
inspect or replace the fuses, carefully follow the procedures
FLHP/E
below. If an electrical fault occurs after replacement of a fuse,
9
13
see your Harley-Davidson dealer for service.
10
5
11
SYSTEM FUSES
14
Removal
4
12
1. Verify that the Ignition/Light Key Switch is turned to the
OFF position.
2. Remove left side saddlebag.
f2305x8x
2
3
1
3. Remove wing nut style bolt to release bottom of siren
amplifier mounting bracket from clamp on saddlebag
8
7
FLHTP
guard. Rotate bracket upward to gain complete access to
side cover area. Loosen top bolt, if necessary. See Fig-
9
6
10
ure 8-1.
4. Gently pull side cover from frame downtubes (no tools
5
11
required). Exercise caution to avoid scratching side cover
13
on amplifier mounting bracket.
5. Depress latches on maxi-fuse holder and then slide
cover rearward to disengage tongue from groove in fuse
14
4
block cover.
6. Pull fuse block from tabs on mounting bracket. Tabs on
bracket fit into slots on each side of fuse block cover.
f2303x8x
2
3
1
NOTE
The fuse block cover also serves as the spare fuse holder.
1.
Headlamp
8.
Accessory
One spare 10 amp and 15 amp fuse are provided.
2.
Ignition
9.
Battery
3.
Lighting
10.
Brake Light Relay
7. Remove the fuse block cover. Raise lipped side slightly
4.
Instruments
11.
P&A
to disengage slots from tabs on fuse block.
5.
Brakes/Pursuit
12.
Starter Relay
6.
Radio Memory
13.
ABS Motor/Pump Power
7.
Siren
14.
ABS Solenoid Power
8243
Figure 8-2. Fuse Locations
8.
Remove fuse from fuse block and inspect the element.
See Figure 8-2. Replace fuse if element is burned or bro-
ken. Automotive type ATO fuses are used.
NOTE
The fuse block cover also serves as the spare fuse holder.
One spare 10 amp and 15 amp fuse are provided.
Wing Nut
Style Bolt
CAUTION
Always use replacement fuses that are of the correct
Figure 8-1. Siren Amplifier Mounting Bracket
type and amperage rating. Use of incorrect fuses can
result in damage to electrical systems. (00222a)
2005 FLT Police: Electrical
8-3
HOME
Installation
Table 8-2. FLHTP/FLHP System Fuses
1.
Install fuse in fuse block. For correct type and amperage
RATING
CIRCUIT
COLOR
rating, refer to Table 8-2.
(AMPERES)
2.
Slide cover over fuse block until slots fully engage tabs
Maxi-Fuse
40
Orange
on block.
Headlamp
15
Blue
3.
Slide fuse block into position on mounting bracket. Tabs
Ignition
15
Blue
on bracket fit into slots on each side of fuse block cover.
Lighting
15
Blue
4.
Slide maxi-fuse cover forward to engage tongue in
Instruments
15
Blue
groove of fuse block cover and then insert maxi-fuse
holder into cover until latches engage.
Brakes/Cruise
15
Blue
5.
Align barbed studs in side cover with grommets in frame
Radio Memory
15
Blue
downtubes and push firmly into place (no tools required).
Radio Power
10
Red
6.
Rotate siren amplifier mounting bracket downward.
Accessory
15
Blue
Install wing nut style bolt to secure bracket to clamp on
Battery
15
Blue
saddlebag guard. Tighten top bolt, if loosened.
P & A
15
Blue
7.
Install left side saddlebag.
ABS Motor/Pump Power
20
Red
ABS Solenoid Power
20
Red
8-4
2005 FLT Police: Electrical
HOME
STROBE HEADLAMP
8.3
GENERAL
i04382
This Strobe Headlamp Kit is designed for installation on both
FLHP and FLHTP model motorcycles.
NOTE
The Strobe Headlamp Kit as well as replacement Strobe
Lamps (Part Number 68692-02) are available at your Harley-
Davidson Dealer.
Phillips
Screw
INSTALLATION
Chrome
Ring
1WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
Figure 8-3. Remove Headlamp Door (FLHTP)
battery cable before proceeding. (00048a)
1WARNING
Torx
Torx
Disconnect negative (-) battery cable first. If positive (+)
Screws
Screws
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.
(00049a)
1.
Disconnect battery cables, negative cable first.
2.
See Figure 8-3. Remove the Phillips screw at the bottom
of the headlamp door (chrome ring). Remove the head-
lamp door.
3.
FLHTP: Remove the four Torx screws to free the head-
lamp housing from the fairing. See Figure 8-4.
FLHP: Remove the seven Phillips screws to free the
i04383
headlamp housing from the headlamp nacelle. See Fig-
ure 8-5.
Figure 8-4. Headlamp Housing Mount (FLHTP)
4.
Squeeze the two external tabs (if present) to remove the
wire connector at the back of the headlamp bulb.
Remove the headlamp housing assembly from the vehi-
c. Turn the handlebar to the right and remove the outer
cle.
fairing screw (5) reaching in below the left side of the
fairing cap. Turn the handlebar to the left and
5.
FLHP: Move to step 16.
remove the fairing screw (6) below the right side of
FLHTP: Proceed as follows:
the fairing cap.
a. See Figure 8-6. Standing at the front of the vehicle,
d. Remove the windshield and lift the fairing off the
use a T27 TORX drive head to remove the three
motorcycle.
outer fairing screws (1, 2 and 3) and flat washers
6.
Install the power supply as follows:
just below the windshield.
a. See Figure 8-7. Locate the metal plate on which the
b. Moving to the inner fairing side, use a T27 TORX
power supply will be mounted. Remove the black
drive head to remove the two fairing screws (4 and
plastic wire retainer (Christmas Tree) from the hole
7) just above the wind deflectors on the left and right
in the metal plate.
side.
2005 FLT Police: Electrical
8-5
HOME
c. Moving to the inner fairing side, reach in under the
i04384
fairing cap and slide the screw through the holes in
the metal plate and power supply. Returning to the
front, loosely install lockwasher and locknut.
d. Carefully pull out the two strobe harnesses, the red
(power) wire and the black (ground) wire, so that it is
free of the power supply and other wiring.
7. Obtain ring terminal from kit. Strip 3/8 inch (9.5 mm)
Screws
insulation from end of black (ground) wire exiting power
supply. Using a wire crimpers, install and crimp ring ter-
minal to wire.
8. See Figure 8-9. While holding the power supply and
mounting screw in position, remove the locknut and lock-
washer loosely installed. Install black (ground) wire ring
terminal onto screw and reinstall lockwasher and locknut.
Not Used
Tighten locknut securely.
Figure 8-5. Headlamp Housing Mount (FLHP)
1
3
2
Storage Box
50
60
70
30
40
50
3040
80
90
20
60
20
100
10
70
10
0
MPH
120
110
0
RPM x100
80
TI
D
D
Metal Plate
p0058d8x
4
7
Figure 8-7. Locate Metal Mounting Plate (FLHTP)
f1755d8x
6
5
Metal Plate
Figure 8-6. Remove Outer Fairing (FLHTP)
NOTE
Locknut and
Lockwasher
When installing the power supply, note that it is not an exact
fit. It may be necessary to manipulate the power supply into
various positions to obtain the optimal alignment and posi-
tion. Also note that the hole in the metal plate is slightly larger
than the hole in the power supply mount. While the overall fit
Power Supply
may appear less than perfect, the power supply will be secure
once the hardware is fully tightened.
Strobe
b. See Figure 8-8. Obtain the power supply (with wir-
Harnesses
ing), screw, lockwasher and locknut from kit. Posi-
i04391
tion the power supply, so that the mounting hole on
the left side is aligned with the hole in the metal
Figure 8-8. Mount Strobe Power Supply (FLHTP)
plate.
8-6
2005 FLT Police: Electrical
HOME
d. Moving to the inner fairing side, use a T27 TORX
drive head to start the two fairing screws (4 and 7)
Ground Wire
just above the wind deflectors on both the left and
From Power Supply
right side.
e. Turn the handlebar to the left and reaching in below
Locknut
the fairing cap, start the right side fairing screw (6).
Turn the handlebar to the right and start the fairing
screw (5) on the left side.
f.
Alternately tighten the four fairing screws on the
inner fairing side to 20-30 in-lbs (2.7-3.4 Nm).
g. Moving to the front of the vehicle, tighten the outer
fairing screws below the windshield to 25-30 in-lbs
(2.8-3.4 Nm).
11.
Obtain the new strobe headlamp assembly from the kit.
Ring Terminal
Reaching in through the headlamp opening of the fairing,
and Lockwasher
i04392
retrieve the two headlamp strobe harnesses. Mate the
harnesses to the connectors at the back of the head-
lamp.
Figure 8-9. Install Ground Wire Ring Terminal
12.
See Figure 8-4. Align holes in new headlamp assembly
with those in fairing (headlamp door bracket at bottom).
Install the four TORX screws.
9. Route the red (power) wire upward toward the right side
13.
See Figure 8-3. Fit the square-shaped portion of the
of the plastic storage box and proceed as follows:
headlamp door spring into the slot at the top of the head-
lamp housing and then snap the headlamp door (chrome
NOTE
ring) into place. Install the Phillips screw at the bottom of
The flasher is cable strapped to the fairing on the right side of
the headlamp door.
the storage box.
1WARNING
a. Locate the flasher and remove the three-place con-
nector. Cut the gray/black wire at a point about 4-5
Connect positive (+) battery cable first. If positive (+)
inches (101.6-127.0 mm) from the connector.
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explo-
b. Strip 3/8 inch (9.5 mm) of insulation from both ends
sion, which could result in death or serious injury.
of gray/black wire. Strip 3/8 inch (9.5 mm) of insula-
(00068a)
tion from red (power) wire from power supply.
14. Install battery cables, positive cable first.
c. Obtain the sealed butt splice connector from the kit.
15. Test strobe headlamp for proper operation.
Butt splice the red (power) wire to the gray/black
wire. See Section B.5 SEALED BUTT SPLICE
CONNECTORS in the 2005 Touring Models Service
Manual (Part No. 99483-05). See Figure 8-10.
d. Connect the three-place connector to the flasher
Flasher
and carefully tuck the wiring in and around the exist-
Gray/Black
ing wiring.
Wire
e. Obtain cable strap from kit and fix location of wiring.
Be sure wiring is positioned so that it will not be
pinched or kinked when outer fairing is installed.
10.
Install outer fairing as follows:
a. Place the outer fairing on the motorcycle.
Sealed Butt
b. Place the windshield in position on the inner fairing
Splice Connector
aligning the slots with the threaded inserts.
Red (Power)
c. See Figure 8-6. Using a T27 TORX drive head, start
Wire
i04393
the three outer fairing screws (1, 2 and 3) and flat
washers just below the windshield.
Figure 8-10. Flasher and Flasher Connector
2005 FLT Police: Electrical
8-7
HOME
f.
See Figure 8-12. While holding the power supply,
Metal Plate
i04394
remove the locknut. Remove screw and lockwasher
allowing power supply to seat inside the nacelle.
Route black (ground) wire to the rear of the metal
plate. Install ring terminal and lockwasher on screw.
Slide the screw through the metal plate and power
Locknut and
supply and install locknut. Tighten locknut securely.
Lockwasher
g.
Locate the white two-place connector inside the
headlamp nacelle (pursuit switch) and carefully pull
Strobe
both connector and wiring free. Cut the gray/purple
Harnesses
wire at a point about 2-3 inches from the connector.
h.
Strip 3/8 inch of insulation from both ends of gray/
Power
purple wire. Strip
3/8 inch of insulation from red
Supply
(power) wire from power supply.
i.
Obtain the sealed butt splice connector from the kit.
Butt splice the red (power) wire to the gray/purple
Figure 8-11. Mount Strobe Power Supply (FLHP)
wire. See Section B.5 SEALED BUTT SPLICE
CONNECTORS in the 2005 Touring Models Service
Manual (Part No. 99483-05).
j.
Carefully tuck the wiring in and around the existing
16. FLHP: Install the power supply as follows:
wiring. Obtain cable strap from kit and fix location of
wiring. Be sure wiring is positioned so that it will not
NOTE
be pinched or kinked when headlamp housing is
installed.
When installing the power supply, note that it is not an exact
fit. It may be necessary to manipulate the power supply into
various positions to obtain the optimal alignment and posi-
17.
See Figure
8-13. Obtain the new strobe headlamp
tion. Also note that the hole in the metal plate is slightly larger
assembly from the kit. Reaching into the headlamp
than the hole in the power supply mount. While the overall fit
nacelle, retrieve the two headlamp strobe harnesses.
may appear less than perfect, the power supply will be secure
Mate the harnesses to the connectors at the back of the
headlamp.
once the hardware is fully tightened.
18.
Align holes in headlamp housing with those in headlamp
a. See Figure 8-11. Locate the metal plate on which
nacelle (headlamp door bracket at bottom). Install the
the power supply will be mounted. Remove the black
seven Phillips screws.
plastic wire retainer (Christmas Tree) from the hole
in the plate.
b. Obtain the power supply (with wiring), screw, lock-
washer and locknut from kit. Install lockwasher on
i04395
screw. Position the power supply, so that the upper
mounting hole is aligned with the hole in the metal
plate.
c. Moving to the rear of the handlebars, reach in under
the headlamp nacelle and slide the screw through
the holes in the metal plate and power supply.
Returning to the front of the motorcycle, loosely
install locknut.
d. Carefully pull out the two strobe harnesses, the red
Screw with
(power) wire and the black (ground) wire, so that it is
Ground Wire
free of the power supply and other wiring.
Ring Terminal
and Lockwasher
Metal Plate
e. Obtain ring terminal from kit. Strip 3/8 inch insulation
from end of black (ground) wire exiting power supply.
Using a wire crimpers, install and crimp ring terminal
to end of wire.
Figure 8-12. Install Ground Wire Ring Terminal
8-8
2005 FLT Police: Electrical
HOME
19. Fit the square-shaped portion of the headlamp door
spring into the slot at the top of the headlamp housing
and then snap the headlamp door (chrome ring) into
Strobe
place. Install the Phillips screw at the bottom of the head-
Harness
lamp door. See Figure 8-3.
Connectors
1WARNING
Connect positive (+) battery cable first. If positive (+)
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.
Headlamp
(00068a)
Assembly
20. Install battery cables, positive cable first.
21. Test strobe headlamp for proper operation.
i04396
Figure 8-13. Install Strobe Harness to Headlamp
2005 FLT Police: Electrical
8-9
HOME
STROBE KIT (PAR-36)
8.4
GENERAL
i03977
The Strobe Kit Par-36 (Part No. 69172-01) is designed for
Push Wire Down
installation on both FLHP and FLHTP model motorcycles
Through Stem
when equipped with the H-D Police Tour-Pak, 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-
Tuck Ground Wire
Back Into Bucket
Davidson dealer perform the installation. Improper instal-
lation of this kit could result in death or serious injury.
Cut Terminal
(00308a)
From Wire
Figure 8-14. Modify Existing Wiring
INSTALLATION
Black
Harness
1WARNING
Wires
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a)
White
1WARNING
Red
Disconnect negative (-) battery cable first. If positive (+)
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.
i03978
(00049a)
Figure 8-15. Route Harness Wiring into Lamp Bucket
1. Disconnect battery cables, negative battery cable first.
2. Remove fuel tank. See Section 9.4 FUEL TANK (FUEL
7. Push the wire down through the mounting bracket stem
INJECTED) in the 2005 Touring Models Service Manual
while carefully pulling it out the opposite side. Cut the
(Part No. 99483-05).
wire where it exits the conduit. Tape the end of the wire
and tuck inside conduit.
3. Remove two socket head screws to free the left turn sig-
nal assembly from the mounting bracket.
NOTE
Tuck the black (ground) wire with terminal into the lamp
4. Remove Phillips screw to release chrome ring from
bucket so it is out of the way.
bucket of passing/pursuit lamp. Carefully pull the sealed
beam unit out of the bucket.
8. Obtain one of the strobe harnesses from kit and locate
the open end (3 wires, no connector).
5. Disconnect the wire terminals from the sealed beam unit.
9. Starting inside Tour-Pak, push the open end of the har-
6. See Figure 8-14. Locate the passing/pursuit lamp power
ness through the right side straight fitting at the bottom of
wire (gray/black) and cut the terminal off.
the Tour-Pak. Route harness along frame tube, under
fuel tank and along existing turn signal lamp conduit up
to front of motorcycle.
8-10
2005 FLT Police: Electrical
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