Harley Davidson 2005 touring models. Service repair manual — page 34
HOME
f2012x9x
A. Insert safety pin at wire end of
C. Raise tang with blade of X-Acto
connector to depress tang.
knife.
B. Push on wire end of lead to
D. Pull on wire end of lead to draw
remove terminal.
terminal back into chamber.
A
B
C
D
Figure B-20. Extract/Install Socket Terminal at Mating End of Connector
3.
Hold the connector so that the wireform is facing down,
2.
Gently pull on the lead at the wire end of the connector
and looking into the wire end of the connector, insert the
to draw the terminal back into the chamber. Be sure that
point of a safety pin between the top of the terminal and
the tang faces opposite the wireform as it enters the
the inside chamber wall.
chamber. A “click” is heard when the terminal is properly
4.
Push safety pin completely into chamber while watching
seated. See D in Figure B-20.
terminal on mating end of connector. When terminal is
3.
Push on lead to verify that terminal is locked in place.
observed moving forward slightly, then tang is
depressed. See A in Figure B-20. Remove safety pin.
4.
Fit rubber wire seal back into wire end of connector.
NOTE
5.
Push the pin and socket halves of the connector
Repeat steps 3 and 4 as necessary until the desired result is
together until the latch “clicks.” The groove in the socket
achieved.
housing must be aligned with the tab in the pin housing.
5.
Push on wire end of the lead to extract the terminal from
the mating end of the connector. See B in Figure B-20.
6.
If necessary, crimp new terminals on wires. See Crimp-
ing Instructions at the end of this section.
Assembly
NOTE
For wire color locations, see Section B.8 WIRING DIA-
GRAMS and then refer to Figure B-21.
1. Using a thin flat blade, like that on an X-Acto knife, care-
fully bend the tang outward away from the terminal body.
Figure B-21. Fuel Injector Connector [84B/85B]
See C in Figure B-20.
B-16
Appendix B
HOME
System Fuse Block
Disassembly
1. Remove system fuses and relay(s) from fuse block. See
Section
8.3 SYSTEM FUSES, SYSTEM FUSES/
RELAYS, REMOVAL.
2. Remove secondary locks as follows:
a. Insert end of small flat blade screwdriver under lip of
locking wedge and gently pry up secondary lock.
NOTE
For best results, start with locking wedge on outboard side of
Lip of
secondary lock. See Figure B-22.
Locking Wedge
f2205x8x
3. Remove socket terminals as follows:
Figure B-22. Remove Secondary Locks From Fuse Block
a. Looking into chamber at top of fuse block, note the
tang next to each socket terminal.
b. Using a thin flat blade, like that on an X-Acto knife,
8
7
gently push tang away from terminal, and then tug
on wire to back terminal out wire end of chamber.
9
6
10
4. If necessary, crimp new terminals on wires. See Crimp-
5
ing Instructions at the end of this section.
11
Assembly
4
1.
Install socket terminals as follows:
NOTE
See Section B.8 WIRING DIAGRAMS, MAIN HARNESS, for
f2204x8x
2
3
1
wire colors and locations.
a. With the open side of the socket terminal facing the
1. Headlamp
7.
Radio Power
tang, push lead into chamber at the wire end of the
2. Ignition
8.
Accessory
fuse block. A click is heard when the terminal is
3. Lighting
9.
Battery
properly engaged.
4. Instruments
10. Brake Light Relay
b. Gently tug on the wire to verify that the terminal is
5. Brakes/Cruise
11. P&A
locked in place and will not back out of the chamber.
6. Radio Memory
2.
Install secondary locks as follows:
Figure B-23. Fuse Block (FLTR, FLHTC/U)
a. With the locking wedges positioned above the tangs
in each chamber, slide flat side of secondary lock
into slot (between rows), and push down until it bot-
Disassembly
toms. See Figure B-22.
3.
Install system fuses and relay(s) in fuse block. See Sec-
1.
Remove seat. See Section 2.6 SEAT, REMOVAL.
tion 8.3 SYSTEM FUSES, SYSTEM FUSES/RELAYS,
INSTALLATION.
WARNING
1
Always disconnect the negative battery cable first. If the
positive cable should contact ground with the negative
480 METRI-PACK SERIES
cable installed, the resulting sparks may cause a battery
explosion, which could result in death or serious injury.
General
2.
Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
Use the following instructions to service the B+ connector.
Appendix B B-17
HOME
2.
With the tang on the same side as the square shaped
f2250x8x
opening in the mating end of the connector housing,
feed terminal into wire end of connector housing until it
“clicks” in place.
3.
Verify that terminal will not back out of the chamber. A
slight tug on the cable will confirm that it is locked.
4.
Rotate the hinged secondary lock inward until latches
fully engage tabs on both sides of connector housing.
5.
Mate pin and socket halves of connector.
6.
Install new anchored cable strap in lower hole on left
side of frame crossmember (in front of battery box).
Tighten cable strap to capture conduit of both accessory
connector and B+ connector approximately one inch
from connector housings. See Figure B-25.
7.
Place battery in battery box, terminal side forward.
B+ Connector
Figure B-24. Remove Seat
3.
Unthread bolt and remove battery positive cable (red)
from battery positive (+) terminal.
4.
Using a T40 TORX drive head, loosen bolt to move lip of
hold-down clamp off edge of battery. Remove battery
from battery box.
5.
Cut anchored cable strap to release accessory connec-
f2258x8x
A
tor and B+ connector from left side of frame crossmem-
ber (in front of battery box). See Figure B-24.
6.
Using small flat blade screwdriver, depress button on pin
housing (red wire) side of the connector and pull apart
the pin and socket halves. See A of Figure B-25.
7.
Bend back the latch slightly and free one side of second-
ary lock, then repeat the step to release the other side.
Rotate the secondary lock outward on hinge to access
terminal in chamber of connector housing. See B of Fig-
ure B-25.
f2259x8x
B
8.
On the mating end of the connector, note the tang in the
square shaped opening centered next to the terminal.
Gently insert the point of a stick pin or large safety pin
into the opening between the tang and the chamber wall
until it stops. Pivot the end of the pin toward the terminal
body to depress the tang. Remove the pin and then pull
terminal out wire end of connector housing. See C of
Figure B-25.
9.
If necessary, crimp new terminals on wires. See Crimp-
ing Instructions at the end of this section.
f2260x8x
C
Assembly
1. Carefully bend the tang outward away from the terminal
Figure B-25. Remove Socket Terminal
body.
B-18
Appendix B
HOME
Assembly
1WARNING
NOTE
Always connect the positive battery cable first. If the
For wire location purposes, alpha characters are molded into
positive cable should contact ground with the negative
the secondary locks of each connector housing.
cable installed, the resulting sparks may cause a battery
explosion, which could result in death or serious injury.
1.
Using a thin flat blade, like that on an X-Acto knife, care-
8. Insert bolt through battery positive cable
(red) into
fully bend the tang outward away from the terminal body.
threaded hole of battery positive (+) terminal. Tighten
2.
With the tang facing the chamber wall, push the lead into
bolt to 60-96 in-lbs (6.8-10.9 Nm).
the chamber at the wire end of the connector. A click is
9. Insert bolt through battery negative cable (black) into
heard when the terminal is properly seated.
threaded hole of battery negative (-) terminal. Tighten
3.
Gently tug on the wire end to verify that the terminal is
bolt to 60-96 in-lbs (6.8-10.9 Nm).
locked in place and will not back out of the chamber.
10. Rotate hold-down clamp so that the lip (with rubber pad)
4.
Rotate the hinged secondary lock inward until tabs fully
rests on the edge of the battery. Using a T40 TORX drive
engage latches on both sides of connector.
head, tighten the clamp bolt to 15-20 ft-lbs (20-27 Nm).
11. Install seat. See Section 2.6 SEAT, INSTALLATION.
5.
Push the pin and socket halves of the connector
together until the latches “click.”
6.
Install connector on barbed anchor or other retaining
device, if present.
630 METRI-PACK SERIES
General
800 METRI-PACK SERIES
Use these instructions to service the following connectors:
● Main to Interconnect Harness [15]
General
● Ignition Light/Key Switch [33]
Use the following instructions to service the maxi-fuse holder.
Disassembly
1. Remove connector from barbed anchor or other retain-
Disassembly
ing device, if present.
1.
Remove maxi-fuse. See Section 8.3 SYSTEM FUSES.
2. Bend back the external latch slightly and separate pin
MAXI-FUSE, REMOVAL.
and socket halves of the connector.
2.
Remove socket terminals as follows:
3. Bend back the latch slightly and free one side of the sec-
ondary lock. Repeat the step to unlatch the other side.
a. Gently pull sides of secondary lock away from
socket housing to disengage slots from tabs on
4. Rotate the secondary lock outward on hinge to view the
socket housing. See A of Figure B-26. Free second-
terminals in the chambers of the connector housing. The
ary lock from cables and set aside.
locking tang is on the side opposite the crimp tails and
engages a rib in the chamber wall to lock the terminal in
b. Take note of the opening on one side of the socket
place.
terminal. Gently insert flat blade of pick (Snap-On
TT600-5) or small screwdriver into opening until it
5. Moving to the mating end of the connector, take note of
the small opening on the chamber wall side of each ter-
stops. Pivot the pick toward the terminal body and
minal.
hold in position. See B of Figure B-26.
6. Insert pick
(Snap-on® TT600-3) into opening until it
c. Tug on cable to pull socket from wire end of socket
stops. Pivot the end of the pick toward the terminal to
housing. A firm tug is necessary to overcome the
depress the locking tang.
resistance of the rubber seal.
7. Remove the pick and gently tug on the wire to pull the
d. Repeat steps 2(b) and 2(c) to remove remaining
terminal from the wire end of the connector. Repeat
socket terminal.
steps if the terminal is still locked in place.
8. If necessary, crimp new terminals on wires. See Crimp-
3.
If necessary, crimp new terminals on wires. See Crimp-
ing Instructions at the end of this section.
ing Instructions at the end of this section.
Appendix B B-19
HOME
d. Repeat steps
1(a) thru
1(c) to install remaining
f2245x8x
socket terminal.
e. Install secondary lock onto cables and then push
onto wire end of socket housing until slots engage
tabs on sides of socket housing.
2.
Install maxi-fuse. See Section
8.3 SYSTEM FUSES.
MAXI-FUSE, INSTALLATION.
Tab
Secondary
Lock
PACKARD MICRO 64
A
General
f2244x8x
Use the following instructions to service the speedometer
and tachometer connectors.
Disassembly
1. Bend back the external latches slightly and separate the
pin and socket halves of the connector.
NOTE
B
To differentiate between the speedometer and tachometer
connectors, note that the speedometer connector has a sec-
ond length of conduit leading to the odometer reset switch.
2.
Locate the head of the secondary lockpin on one side of
the connector housing. See Figure B-28.
3.
Insert the blade of a small screwdriver between the cen-
ter ear of the lockpin and the connector housing and
gently pry out lockpin. When partially removed, pull lock-
pin from connector housing.
4.
Obtain the Packard Micro 64 Terminal Remover (HD-
45928). See Figure B-27. Proceed as follows:
a. Locate small hole between terminals on mating end
of connector. See Figure B-28.
f2246x8x
b. Push the adjacent terminals all the way into the con-
C
nector housing and then insert tool into hole until it
bottoms. See upper frame of Figure B-29.
Figure B-26. Remove Socket Terminals
Assembly
1. Install socket terminals as follows:
a. Carefully bend tang outward away from the terminal
body. See C of Figure B-26.
b. Feed socket into wire end of socket housing until it
“clicks” in place. Verify that socket will not back out
of chamber. A slight tug on the cable will confirm
that it is locked.
Figure B-27. Packard Micro 64 Terminal Remover
c. Push rubber seal into wire end of socket housing.
(Part No. HD-45928).
B-20
Appendix B
HOME
NOTE
Small
f2202x8x
For wire location purposes, the corners of the socket housing
Hole
are stamped with the numbers 1, 6, 7 and 12, representing
1
6
Secondary
terminals 1-6 on one side, and 7-12 on the other. See Figure
Lockpin
B-28.
2.
Bottom the terminal in the chamber and then gently tug
1
2
3
4
5
6
on the wire to verify that it is locked in place.
7
8
9
10
11
12
NOTE
Once the terminal is removed it may not lock in place when
first reinstalled. Until the lock engages, move the terminal
7
12
back and forth slightly while wiggling the lead.
Figure B-28. Mating End of Connector
3.
Since the terminal remover tool releases two terminals
simultaneously, repeat step 2 on the adjacent terminal
even if it was not pulled from the connector housing.
4.
With the center ear on the head of the secondary lockpin
facing the mating end of the connector, push lockpin in
until head is flush with the connector housing.
5.
Push the pin and socket halves of the connector
together until the latches “click.”
Crimping Instructions
1.
Strip lead removing 1/8 inch (3.0 mm) of insulation.
f2196x8x
2.
Obtain the Packard Micro 64 Terminal Crimper (HD-
45929). See Figure B-30.
3.
Squeeze the handles to cycle the tool to the fully open
position.
4.
Obtain new contact (socket terminal). Verify that contact
and crimp tails are not bent or deformed.
5.
Raise locking bar and barrel holder by pushing up on
bottom tab with index finger. See Figure B-31.
6.
With the crimp tails facing upward, insert contact
through locking bar into front hole in barrel holder (20-22
gauge wire).
7.
Release locking bar to lock position of contact. When
f2197x8x
correctly positioned, the locking bar fits snugly in the
space at the front of the core crimp tails and the closed
Figure B-29. Insert Tool and Remove Terminal
side of the terminal rests on the outer nest of the crimp
tool. See Figure B-32.
c. Leaving the tool installed, gently tug on wires to pull
either one or both terminals from wire end of con-
nector. See lower frame of Figure B-29. Remove
tool.
5.
If necessary, crimp new terminals on wires. See Crimp-
ing Instructions on this page.
Assembly
1.
Insert terminal into its respective numbered chamber on
wire end of connector. No special orientation of the ter-
Figure B-30. Packard Micro 64 Terminal Crimper
minal is necessary.
(Part No. HD-45929)
Appendix B B-21
HOME
11. Inspect the quality of the core and insulation crimps. Dis-
tortion should be minimal.
PACKARD 100W
General
Use the following instructions to service the ECM connector.
f2198x8x
Figure B-31. Raise Locking Bar and Barrel Holder
Disassembly
1.
Gently depress latch on each side of the clear plastic
f2199x8x
secondary lock and remove. For best results, release
one side at a time, See Figure B-34.
2.
Carefully cut cable strap to free strain relief collar from
conduit.
3.
Using a thin blade, gently pry at seam at back of socket
housing to release three plastic pins from slots in hous-
ing. Separate and spread halves of socket housing. See
Figure B-35.
4.
Push on selected wire to free terminal from chamber.
See Figure B-36.
Locking
Barrel
5. If necessary, crimp new terminals on wires. See Crimp-
Bar
Holder
ing Instructions on the next page.
Figure B-32. Position Contact in Crimper
1
f2062x8x
2
7
3
f2201x8x
Figure B-33. Crimp Terminal Onto Wire
6
2
8.
Insert wires between crimp tails until ends make contact
with locking bar. Verify that wire is positioned so that
1
wide pair of crimp tails squeeze bare wire strands, while
5
the narrow pair folds over the insulation material.
4
1. Latch
9.
Squeeze handle of crimp tool until tightly closed. Tool
2. Rib
5.
Conduit
automatically opens when the crimping sequence is
3. Secondary Lock
6.
Cable Strap
complete. See Figure B-33.
4. Strain Relief Collar
7.
External Latch
10. Raise locking bar and barrel holder to remove contact.
Figure B-34. Remove Secondary Lock
B-22
Appendix B
HOME
Crimping Instructions
1.
Strip wire lead removing 5/32 inch (4.0 mm) of insula-
tion.
2.
Compress handles until ratchet automatically opens.
NOTE
Pins
Always perform core crimp before insulation/seal crimp.
3.
See Figure B-37. Determine the correct die or nest for
the core crimp.
4.
Position the core crimp on the appropriate nest. Be sure
the core crimp tails are facing the forming jaws.
5.
Gently apply pressure to handles of tool until crimpers
just secure the core crimp tails.
f2063x8x
6.
Insert stripped wire between crimp tails. Verify that wire
is positioned so that short pair of crimp tails squeeze
Figure B-35. Separate Halves of Socket Housing
bare wire strands, while long pair is positioned over the
insulation or seal material.
7.
Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete.
8.
See Figure B-37. Determine the correct die or nest for
the insulation/seal crimp.
Packard Terminal Crimp Dies (Nests)
Packard 270
Packard 271
Packard 115
(HD-38125-6)
(HD-38125-7)
(HD-38125-8)
f2064x8x
Figure B-36. Push Wire to Extract Terminal
Assembly
1. From inside socket housing, gently pull on wire to draw
terminal into chamber. See Figure B-36.
2. Exercising caution to avoid pinching wires, press halves
Sealed
Non-Sealed
Non-Sealed
of socket housing together until three plastic pins fully
Terminals
Terminals
Terminals
engage slots in housing. See Figure B-35.
1-5
A-E
F-G
3. Install new cable strap in groove of strain relief collar
capturing cable conduit. See Figure B-34.
Butt Splices*
4. With the two ribs on the secondary lock on the same
*See Appendix B.5 SEALED BUTT SPLICE CONNECTORS.
side as the external latch, install over terminals until
latches lock in place.
Figure B-37.
Packard Terminal
Crimp Tools
Appendix B B-23
HOME
9.
Position the insulation/seal crimp on the appropriate
nest. Be sure the insulation/seal crimp tails are facing
SEALED TERMINAL
the forming jaws.
Core Crimp
10. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete.
11. Inspect the quality of the core and insulation/seal
crimps. Distortion should be minimal. See Figure B-38.
Seal Crimp
Seal
f1006a8x
f1005a8x
Insulation
Crimp
Core Crimp
Insulation
NON-SEALED TERMINAL
Figure B-38. Inspect Core and Insulation/Seal Crimps
B-24
Appendix B
HOME
AUTOFUSE ELECTRICAL CONNECTOR
B.4
GENERAL
8821
Use these instructions to service the following connector:
● HDI Ignition Light/Key Switch Jumper Harness [33D]
DISASSEMBLY
1. Obtain terminal pick
(Snap-on® GA500A) like that
shown Figure B-39.
2.
Insert smallest pair of pins into chamber on mating end
of socket housing to depress tangs on each side of ter-
minal simultaneously.
Figure B-39. Depress Tangs and Remove Terminal
3. Gently pull on wire to remove terminal from wire end of
socket housing.
4.
If necessary, crimp new terminals on wires.
ASSEMBLY
1. Using a thin flat blade, like that on an X-Acto knife, care-
fully bend tang on each side of terminal outward away
from terminal body.
2. With the open side of the terminal facing rib on wire end
of socket housing, insert terminal into chamber until it
locks in place.
Appendix B B-25
HOME
SEALED BUTT SPLICE CONNECTORS
B.5
8. Repeat steps 5-7 on the other side of the butt splice con-
PROCEDURE
nector.
Butt splicing may be a necessary procedure for the replace-
NOTE
ment of some components. Proceed as follows:
If adjacent wires are being spliced, stagger the splices so
1.
Strip 3/8 inch (9.5 mm) of insulation off the ends of the
that the butt splice connectors are spaced at different posi-
wires.
tions along the length of the wires.
2.
Compress the handles of the Packard Crimp Tool (HD-
38125-8) until the ratchet automatically opens.
9.
Using the UltraTorch UT-100 (HD-39969), Robinair Heat
3.
Since the size of the connectors vary with the gauge of
Gun
(HD-25070) with heatshrink attachment
(HD-
the wire, reference the following table to ensure properly
41183) or other suitable radiant heating device, heat the
sealed splices are used.
crimped splice to encapsulate the butt splice connection.
Apply heat from the center of the crimp out to each end
until the meltable sealant exudes out both ends of the
Gauge
Connector
Part
connector. See Figure B-41.
Wire
Color
Number
18-20
Red
P/N 70585-93
14-16
Blue
P/N 70586-93
Red
10-12
Yellow
P/N 70587-93
4.
Determine the correct die or nest for the crimping opera-
Blue
tion. Match the color or gauge wire marked on the butt
splice connector with the corresponding crimp cavity on
the crimp tool. See Figure B-40.
5.
Gently apply pressure to the handles until the crimper
lightly secures one side of the metal insert inside the butt
splice connector. The connector must be crimped in two
Yellow
stages, one side and then the other.
6.
See Figure B-41. Feed the wire into the butt splice con-
nector until the stripped end contacts the wire stop
inside the metal insert.
7.
Squeeze the handles of the crimp tool until tightly
closed. The tool automatically opens when the crimping
se-quence is complete.
Figure B-40. Packard Crimp Tool (HD-38125-8)
Wire
Metal
Melted Sealant
Stop
Insert
Insert stripped wire
Crimp wire ends
Apply heat and allow
ends into connector
in connector
connector to cool
f1203b8x
Figure B-41. Installing Sealed Butt Splice Connectors
B-26
Appendix B
HOME
NOTE
1WARNING
It is acceptable for the splice to rest against the heat shrink
tool attachment.
Use extreme caution when operating the UltraTorch UT-
100 or any other radiant heating device. Read the manu-
10. Heat the center of the splice until the crimp indentations
facturers instructions carefully before use. Always keep
disappear and the tubing assumes a smooth cylindrical
hands away from tool tip area and heat shrink attach-
appearance.
ment. Avoid directing the heat toward any fuel system
component. Extreme heat can cause fuel ignition/explo-
sion. Avoid directing heat toward any electrical system
component other than the connectors on which heat
shrink work is being performed. Be sure to turn the “ON/
OFF” switch to the “OFF” position after use. Inadequate
safety precautions could result in death or serious
injury.
Appendix B B-27
HOME
AMP ELECTRICAL CONNECTORS
B.6
4.
Holding the socket housing while keeping the tool firmly
1-PLACE CONNECTOR
bottomed, depress the plunger. The terminal pops out
the wire end of the connector.
The 1-place Amp MATE-N-LOK connector can be found on
some Touring models.
NOTE
If the terminal is not released from the socket housing, then
the terminal was not pushed forward far enough before
SOCKET TERMINAL
placement of the tool or the tool was not bottomed in the con-
nector housing.
Removal
1. Bend back the ears on the pin housing slightly and sepa-
rate the pin and socket halves of the connector.
Installation
2. Grasp the lead on the wire end of the socket housing
1. Note the lip at the middle of the socket housing. One
and push the terminal forward toward the mating end of
side of the lip is flat while the other side is tapered. Insert
the connector until it stops. This will disengage the lock-
the wire terminal into the socket housing on the flat lip
ing tang from the groove in the connector.
side.
3. Fit the barrel of the Amp Socket Terminal Remover (HD-
2. Push the lead into the socket housing until it stops. A
39621-27) over the socket, and while rotating the tool
click is heard when the terminal is properly seated.
slightly, push until it bottoms in the housing. Allow the
plunger to “back out” of the handle. See Figure B-42.
3. Gently tug on the lead to verify that the terminal is locked
in place.
4. Push the pin and socket halves of the connector
together until the latches “click.”
A
Install Socket Terminal Remover
PIN TERMINAL
Removal
Socket
1.
Bend back the ears on the pin housing slightly and sepa-
Housing
Amp Socket
rate the pin and socket halves of the connector.
Terminal Remover
(HD-39621-27)
2.
Grasp the lead on the wire end of the pin housing and
push the terminal forward toward the mating end of the
connector until it stops. This will disengage the locking
Lip
tang from the groove in the connector.
Plunger
3.
Fit the barrel of the Amp Pin Terminal Remover (HD-
39621-28) over the pin, and while rotating the tool
slightly, push until it bottoms in the housing. Allow the
plunger to “back out” of the handle. See Figure B-43.
4.
Holding the pin housing while keeping the tool firmly bot-
tomed, depress the plunger. The terminal pops out the
B
Depress Plunger
wire end of the connector.
NOTE
If the terminal is not released from the pin housing, then the
terminal was not pushed forward far enough before place-
ment of the tool or the tool was not bottomed in the connector
f1364x8x
housing.
Figure B-42. Remove Terminal from Amp Socket Housing
B-28
Appendix B
HOME
Installation
A
Install Pin Terminal Remover
1.
Push the lead into the pin housing until it stops. A click is
heard when the terminal is properly seated.
2.
Gently tug on the lead to verify that the terminal is locked
in place.
Pin
3.
Push the pin and socket halves of the connector
Housing
together until the latches “click.”
Amp Pin
Terminal Remover
(HD-39621-28)
Plunger
B Depress Plunger
f1366x8x
Figure B-43. Remove Terminal from Amp Pin Housing
Appendix B B-29
HOME
ELECTRICAL CONNECTOR LOCATIONS
B.7
FLHT/C/U WIRE HARNESS CONNECTORS
No.
Description
Type
Location
Fig.
[1]
Main to Interconnect Harness
12 - Place Deutsch (Black)
Inner Fairing - Right Fairing Bracket
44
[2]
Main to Interconnect Harness
12 - Place Deutsch (Gray)
Inner Fairing - Right Fairing Support Brace
44
[4]
Accessory
4 - Place Deutsch
Upper Frame Cross Member (Under Seat)
49
[5]
Maxi-Fuse
2 - Place Packard
Under Left Side Cover
46
[6]
Audio to Interconnect Harness
3 - Place Deutsch (Black)
Inner Fairing - Back of Radio
44
[7]
Rear Fender Lights Harness
8 - Place Multilock
Top of Rear Fender (Under Seat)
52
[8]
Ignition Harness (EFI Harness on Fuel Injected Models)
12 - Place Deutsch (Gray)
Under Right Side Cover
48,51
[10]
Ignition Control Module ****
12 - Place Deutsch (Black)
Under Right Side Cover
51
[12]
Tour-Pak Lights
3 - Place Multilock
Inside Tour-Pak
45
[13]
Fuel Tank Harness
3 - Place Multilock
Behind Fuel Tank (Under Seat)
55
[15]
Main to Interconnect Harness
4 - Place Packard
Inner Fairing - Bottom of Radio (Right Side)
44
[17]
Cruise Control Module **
10 - Place Packard
Under Left Side Cover
46
[18]
Left Rear Turn Signal
2 - Place Multilock
Circuit Board Under Tail Lamp Assembly
53
[19]
Right Rear Turn Signal
2 - Place Multilock
Circuit Board Under Tail Lamp Assembly
53
[21]
Indicator Lamps
10 - Place Multilock
Inner Fairing - Above Radio
44
[22]
Interconnect to Right Handlebar Switch Controls
12 - Place Deutsch (Black)
Inner Fairing - Fork Stem Nut Lock Plate (Left Side)
44
[24]
Interconnect to Left Handlebar Switch Controls
12 - Place Deutsch (Gray)
Inner Fairing - Left Fairing Support Brace
44
[27]
Radio *
23 - Place Amp (Black)
Inner Fairing - Back of Radio (Right Side)
44
[28]
Radio **
23 - Place Amp (Gray)
Inner Fairing - Back of Radio (Left Side)
44
[30]
Turn Signal/Security Module
12 - Place Deutsch
Cavity in Crossmember at Rear of Battery Box (Under Seat)
50
[31]
Front Turn Signals
6 - Place Multilock
Inner Fairing - Left Fairing Support Brace
44
[32]
Front Fender Tip Lamp (DOM)
2 - Place Multilock (Black)
Inner Fairing - Below Upper Fork Bracket (Left Side)
44
[33]
Ignition/Light Key Switch
4 - Place Packard
Inner Fairing - Bottom of Radio (Center)
44
[38]
Headlamp
Headlamp Connector
Inner Fairing
-
[39]
Speedometer
12 - Place Packard (Black)
Inner Fairing (Back of Speedometer)
44
[41]
Rear Right Speaker/Passenger Controls **
6 - Place Mini-Deutsch
Inside Rear Right Speaker Box
-
[42]
Rear Left Speaker/Passenger Controls **
6 - Place Mini-Deutsch
Inside Rear Left Speaker Box
-
[45]
Rear Fender Tip Lamp (DOM)
3 - Place Multilock
Circuit Board Under Tail Lamp Assembly
53
[46]
Stator
2 - Place Packard
Bottom of Voltage Regulator
54
[50]
CB Antenna Cable **
-
Inner Fairing - Back of Radio (Right Side)
44,45
[51]
Radio Antenna Cable *
-
Inner Fairing - Back of Radio (Left Side)
44
[53]
Console Pod **
12 - Place Mini-Deutsch
Rear of Battery Box (Under Seat)
50
[64]
Fuse Block
Packard
Under Left Side Cover
46,47
[65]
Vehicle Speed Sensor
3 - Place Deutsch
Under Right Side Cover (Behind Electrical Bracket)
48
[73]
Auxiliary Lamps
2 - Place Multilock (White)
Inner Fairing - Below Upper Fork Bracket (Left Side)
44
[75]
Cruise Roll-Off Switch
Spade Contacts
Right Side of Steering Head
-
[76]
Passenger Headset
7 - Place DIN
Below Rear Left Speaker Box
-
[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
48
[79]
Crankshaft Position (CKP) Sensor
2 - Place Mini-Deutsch
Bottom of Voltage Regulator
54
[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)
-
Continued ...
B-30
Appendix B
HOME
Left Handlebar
Main to Interconnect
Switch Controls [24]
Harness [15]
Indicator
Lamps [21]
Main to Interconnect
Harness [156]
Tachometer
Gauge [108]
Ambient
Speedometer
Temperature
Gauge [39]
Sensor [107]
Main to Interconnect
Radio [28]
Harness [2]
Front Turn
Signals [31]
Radio [27]
Main to Interconnect
Harness [1]
Radio Antenna
Cable [51]
Audio to Interconnect
Harness [6]
Fairing Cap
Switches [105]
Front
Fender Tip [32]
CB Antenna
Cable [50]
Right Handlebar
Switch Controls [22]
Auxiliary
Lamp [73]
Ignition
Switch [33]
f2238x8x
Figure B-44. Inner Fairing Connectors (FLHT/C/U)
Appendix B B-31
HOME
FLHT/C/U WIRE HARNESS CONNECTORS (Continued)
No.
Description
Type
Location
Fig.
[90]
Engine Temperature Sensor (ET Sensor) ***
2 - Place Packard
Back of Front Cylinder (Left Side)
-
[91]
Data Link
4 - Place Deutsch
Under Right Side Cover
48
[93]
Tail Lamp
4 - Place Multilock
Circuit Board Under Tail Lamp Assembly
53
[94]
Rear Fender Lights Harness to Circuit Board
6 - Place Multilock
Circuit Board Under Tail Lamp Assembly
53
[105]
Fairing Cap Switches
12 - Place Multilock
Inner Fairing - Above Upper Fork Bracket (Right Side)
44
[107]
Ambient Air Temperature Sensor *
3 - Place Multilock
Inner Fairing - Left Fairing Bracket (Outboard Side)
44
[108]
Tachometer
12 - Place Packard (Gray)
Inner Fairing (Back of Tachometer)
44
[110]
Voltmeter Lamp
Spade Connector
Inner Fairing
-
[111]
Voltmeter
Spade Connector
Inner Fairing
-
[112]
Oil Pressure Gauge Lamp
Spade Connector
Inner Fairing
-
[113]
Oil Pressure Gauge
Spade Connector
Inner Fairing
-
[114]
Air Temperature Gauge Lamp
Spade Connector
Inner Fairing
-
[115]
Air Temperature Gauge
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)
48
[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
50
[124]
Brake Light Relay
Relay Connector
Fuse Block (Under Left Side Cover)
47
[126]
Ignition Keyswitch Relay
Relay Connector
Rear of Battery Box (Under Seat) - Left Side
50
[128]
Starter Solenoid
Spade Terminals
Top of Starter
-
[129]
Harness Grounds
Ring Terminals
Upper Frame Cross Member (Under Seat)
49
[131]
Neutral Switch
Post Terminals
Transmission Top Cover
-
[132]
Cigarette Lighter *
Spade Terminals
Inner Fairing
-
[135]
EFI System Relay ***
Relay Connector
Fuse Block (Under Right Side Cover)
48
[139]
Oil Pressure Sender
4 - Place Packard
Front Right Crankcase
-
[141]
Fuel Level Sender (and Fuel Pump on EFI models)
3 - Place Mini-Deutsch
Top of Canopy (Under Console)
-
[142]
Security Siren (Optional)
3 - Place Packard
Under Right Side Cover (Behind Electrical Bracket)
48
[156]
Main to Interconnect Harness
6 - Place Deutsch
Inner Fairing - Right Fairing Support Brace
44
[160]
B+
1 - Place Packard
Upper Frame Cross Member (Under Seat)
49
* Classic and Ultra
** Ultra Only
*** Fuel Injected Models
**** Carbureted Models
f1466a2x
f1467b2x
Cavity
CB Antenna
Tour-Pak Lights
Cable Connector
Connector [12]
LEFT SIDE
RIGHT SIDE
[50C/D]
Figure B-45. Tour-Pak Connectors
B-32
Appendix B
HOME
f2206x8x
Cruise Cable
Cruise Module
Connector
Cruise Module
Connector [17]
Spare Fuse
Holder
Maxi-Fuse
Fuse Block
Holder [5]
Figure B-46. Cruise Control Module (Under Left Side Cover)
f2203x8x
f1917x9x
*P&A
Main Harness to
Security Siren
Data Link
EFI Harness [8]
[142]
[91]
8
7
9
6
10
5
11
4
1
2
3
1. Headlamp
7. Radio Power*
2. Ignition
8. Accessory
3. Lighting
9. Battery
4. Instruments
10. Brake Light Relay
EFI Fuse
5. Brakes/Cruise
11. P&A
Electronic
Block
*Vehicle Speed
Control
6. Radio Memory*
Sensor [65]
Module [78]
*Absent from FLHR/C/S models.
* Under Bracket
Figure B-47. Fuse Blocks - FLTR, FLHTC/U
Figure B-48. Electrical Bracket - Fuel Injected Models
(Under Left Side Cover)
(Under Right Side Cover)
Appendix B B-33
HOME
f2302x8x
Main Harness
Ground Ring
Terminals (2)
Audio Harness
Ground Ring
Main Harness
Terminal
Ground Ring
Terminals (2)
Chassis
Ground Cable
Fuel Tank Harness
Accessory
Connector [13]
Connector [4]
Not Present on FLHR/C/S
Battery
Positive Cable
B+ Connector [160]
Battery
Negative Cable
Figure B-49. Electrical Connectors - Upper Frame Cross Member (Under Seat)
Ignition Keyswitch
f2191x8x
Starter
Relay [126]
Relay [123]
Console Pod [53]
Ignition Control Module
Connector [10]
Turn Signal/Security
Module [30]
f2192x8x
Under Crossmember
Figure B-50. Electrical Connectors/Relays (Under Seat)
Figure B-51. Ignition Control Module - Carbureted Models
(Under Right Side Cover)
B-34
Appendix B
HOME
f2013x8x
f2256x8x
Rear Fender
Lights Connector [7]
Stator
Connector [46]
Crankshaft
Position Sensor
Connector [79]
Figure B-52. Rear Fender (Under Seat)
Figure B-54. Voltage Regulator (Left Side View)
f1924x8x
Right Turn
Signal Lamp
Fender Tip
[19]
Lamp [45]
Left Turn
Fender Lights
Signal Lamp
Tail Lamp
Harness to
[18]
[93]
Circuit Board
[94]
Fuel Tank
Fuel Vapor
Fuel Tank Harness
Vent Tube
Connector [13]
To Vapor Valve
Not Present on FLHR/C/S
f2172x8x
Figure B-53. Rear Fender Lights Assembly
Figure B-55. Rear of Fuel Tank (Under Seat)
Appendix B B-35
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