Harley Davidson 2005 touring models. Service repair manual — page 9
HOME
4.
Position two spacers between bottom of luggage rack
and tabs of license plate bracket. Slide 2-1/4 inch bolts
f1467b2x
Grommet
(with flat washers) through two center holes in Tour-Pak
and luggage rack, and then through spacers and tabs of
license plate bracket. If necessary, loosen two hex bolts
Cable
at back of license plate bracket to align holes in tabs with
Clip
bolts. Install flat washers and nylon cap locknuts on bolts
and tighten until snug. See inset of Figure 2-143.
5.
In a crosswise pattern, alternately tighten five bolts to
96-120 in-lbs (10.8-13.5 Nm). Be sure that concavity on
each spacer is inline with the rail and has not rotated out
of position.
6.
On right side of vehicle, mate pin and socket halves of 6-
place Mini-Deutsch connector. Feed connector back up
into right side speaker box pressing trim ring into hole.
7.
Pass CB antenna cable through hole in Tour-Pak. Cap-
Tour-Pak
ture cable in grommet. Install grommet in hole with the
Mounting Bolt
CB Antenna
larger OD facing inside.
Cable Connector
8.
Mate pin and socket halves of 1-place CB antenna cable
connector. Capture cable in two clips at bottom of Tour-
Figure 2-144. Disconnect CB Antenna Cable Connector
Pak. See Figure 2-144.
9.
Moving to left side of vehicle, mate pin and socket halves
of 6-place Mini-Deutsch connector. Feed connector back
12. Holding nylon cap locknuts at bottom of Tour-Pak,
up into left side speaker box pressing trim ring into hole.
remove five bolts (with flat washers) to release Tour-Pak
from luggage rack. Luggage rack spacers will become
10.
Capture rear headset receptacle in bracket at bottom of
free as nuts are removed. Be sure to have a firm grasp
left side speaker box.
on the Tour-Pak as the last bolt is removed. See Figure
11.
Feed socket connectors and main harness conduit
2-143.
through hole in Tour-pak. Capture conduit in grommet.
Install grommet in hole with the larger OD facing inside.
12.
Mate pin and socket halves of Tour-pak lights connector
INSTALLATION
[12], 3-place Multilock, and tuck into cavity inside Tour-
Pak. See Figure 2-141.
1.
Place Tour-Pak on luggage rack and open lid.
13.
Rotate knurled lock ring in a clockwise direction to mate
2.
Align rear center hole in Tour-Pak with same hole in lug-
pin and socket halves of Radio antenna cable connector.
gage rack. Slide 2 inch bolt (with flat washer) through
Capture cable in two clips at bottom of Tour-Pak.
ring terminal of radio antenna ground, and then through
Tour-Pak and luggage rack holes. At bottom of luggage
14.
Install bulb socket on left side of Tour-pak.
rack, install spacer (concave side up) and nylon cap
15.
Install molded liner in Tour-Pak. Install map pocket and
locknut on bolt. With concavity on spacer inline with the
secure using acorn nuts (with flat washers). Close Tour-
rail, hold nut and tighten bolt until snug.
Pak.
CAUTION
Always install the mounting bolts from inside the Tour-
Pak. If the bolts are installed upside down, then the ends
of the bolts can tear the molded liner and scratch
objects, such as helmets, stored inside the Tour-Pak.
3.
Install remaining
2 inch bolts (with flat washers and
nylon cap locknuts) in two front Tour-Pak and luggage
rack holes (one each side) in the manner described
under step 2 above.
2-116
2005 Touring: Chassis
HOME
TOUR-PAK LIGHTS/BACKREST/SPEAKER BOX
2.27
GENERAL
Mounting
Tour-Pak
All domestic model Tour-Paks are equipped with side marker
Bracket
lights. Ultra models also have a wrap-around rear light
assembly that contains two 2-filament lamps. One filament is
a supplemental brake light and the other a supplemental tail
lamp.
SIDE MARKER LIGHTS
FLHTC/U
Bulb
BULB/LENSE REPLACEMENT
Lense
Eyelet
Stepped
1.
Open Tour-Pak.
Rib
Screwdriver
2.
On Ultra models, open map pocket and remove acorn
nuts
(with flat washers). Remove map pocket and
f1810x2x
molded liner from Tour-Pak.
3.
Remove three T15 TORX screws to release lens at side
Figure 2-145. Remove Eyelets to Release
of Tour-Pak.
Mounting Bracket From Lense
4.
Using the blade of an X-Acto knife or small screwdriver,
gently pry up three eyelets on inboard side of mounting
bracket. See Figure 2-145. Remove eyelets and then
3.
Close Tour-Pak. Turn Tour-Pak over and remove remain-
remove mounting bracket from lense. Discard eyelets if
ing six flange nuts at bottom.
damaged.
4.
Place Tour-Pak topside up and open lid. Reach inside
5.
Remove bulb from socket and discard. Install new bulb
Tour-Pak and remove metal plate pulling threaded studs
in socket.
from holes at bottom.
6.
Align holes in mounting bracket with those in lense.
5.
Locate 2-place Multilock connector in channel at bottom
Push three eyelets through mounting bracket holes into
of Tour-Pak. Remove masking tape if necessary. See
bosses of lense. Use new eyelets if damaged.
Figure 2-146.
7.
Place lense assembly into position at side of Tour-Pak,
but exercise caution to avoid pinching or kinking wires.
6.
Depress button on socket side of Multilock connector
Note that center rib on inboard side of lense has a
and separate pin and socket halves.
stepped area for routing of the top wire. See Figure 2-
7.
Remove three T15 TORX screws to release lens at side
145.
of Tour-Pak.
8.
From inside Tour-Pak, install three T15 TORX screws.
8.
Compress grommet at side of Tour-Pak and push
9.
On Ultra models, install molded liner in Tour-Pak. Install
through hole to outboard side. Feed conduit and socket
map pocket and secure using acorn nuts (with flat wash-
through hole to release side marker light assembly.
ers).
10.
Close Tour-Pak.
INSTALLATION
REMOVAL
1.
Feed socket and conduit of new side marker light
assembly through hole at side of Tour-Pak.
1. Remove Tour-Pak. See Section 2.26 TOUR-PAK, RE-
2.
Compress grommet on conduit and install in hole.
MOVAL, either FLHTC or FLHTCU. Move Tour-Pak to
bench area.
3.
Place lense assembly into position at side of Tour-Pak,
2. Open Tour-Pak. Holding Phillips screw inside Tour-Pak
but exercise caution to avoid pinching or kinking wires.
(rear right corner), remove flange nut at bottom to
Note that center rib on inboard side of lense has a
release loading coil bracket. Remove Phillips screw with
stepped area for routing of the top wire. See Figure 2-
external tooth lockwasher.
145.
2005 Touring: Chassis
2-117
HOME
Tour-Pak Lights
f1753x2x
Connector [12]
3-place Multilock
Left Side
Right Side
Side Marker Light
Masking
Side Marker Light
Connector
Tape
Connector
2-place Multilock
2-place Multilock
Figure 2-146. Side Marker Light Connectors and Conduit
4.
From inside Tour-Pak, install three T15 TORX screws.
WRAP-AROUND LIGHT ASSEMBLY
5.
Mate pin and socket halves of 2-place Multilock connec-
FLHTCU
tor. Be sure that connector and conduit are positioned in
channel at bottom of Tour-Pak.
BULB REPLACEMENT
CAUTION
1.
Open Tour-Pak.
2.
Open map pocket and remove acorn nuts (with flat
If conduit and connector are not completely captured in
washers). Remove map pocket and molded liner from
channel at bottom of Tour-Pak, installation of metal plate
Tour-Pak.
can pinch wires or damage connector.
3.
Depress external latch and rotate bulb socket to release
6.
Place masking tape over channel to secure position of
from lens.
connector and conduit. See Figure 2-146.
4.
Remove bulb from socket and discard.
7.
With the square cut positioned at the front left corner,
5.
Install new bulb in socket.
install metal plate at bottom of Tour-Pak so that threaded
6.
Rotate bulb socket to install in lens.
studs exit holes at bottom.
7.
Install molded liner in Tour-Pak. Install map pocket and
8.
Place loading coil into position aligning hole in bracket
secure using acorn nuts (with flat washers).
with hole in rear right corner of metal plate. Slide Phillips
8.
Close Tour-Pak.
screw (with external tooth lockwasher) through holes. At
bottom of Tour-Pak, install flange nut on Phillips screw.
9.
Close lid and turn Tour-Pak over. Install six flange nuts
REMOVAL
on threaded studs of metal plate.
1.
Open Tour-Pak. Open map pocket and remove acorn
10. Install Tour-Pak on vehicle. See Section 2.26 TOUR-
nuts
(with flat washers). Remove map pocket and
PAK, INSTALLATION, either FLHTC or FLHTCU.
molded liner from Tour-Pak.
2-118
2005 Touring: Chassis
HOME
INSTALLATION
f2286x2x
Tour-Pak
1.
Install light bar, metal clips and flange nuts to secure
light bar to Tour-Pak. Inside Tour-Pak, use RTV silicone
sealer (Part No. 99710-88) to seal perimeter of light bar.
See Figure 2-147.
2.
Install radio antenna mast into lamp housing. Thread
connector stud into mast. Turn
1/2 in.-20 UNF nut
(installed on connector during removal) in a clockwise
direction to tighten.
3.
Remove 1/2 in.-20 UNF nut and jam nut. Install large flat
washer, ring terminal and internal tooth lockwasher onto
connector. Reinstall jam nut and tighten.
4.
Rotate knurled lock ring in a clockwise direction to mate
pin and socket halves of Radio antenna cable connector.
Metal Clip
Capture cable in rear clip at bottom of Tour-Pak.
Bulb Housing
5.
On right side of Tour-Pak, install CB antenna mast into
Caulking
lamp housing. Install stud into mast and tighten with 2.5
mm allen head wrench.
Figure 2-147. Wrap-Around Light Assembly
6.
Place loading coil into position aligning hole in bracket
with hole in rear right corner of Tour-Pak. Slide Phillips
screw (with external tooth lockwasher) through holes. At
2.
Depress external latch and rotate housing to release
bottom of Tour-Pak, install flange nut on Phillips screw.
bulb sockets from both sides of Tour-Pak.
7.
Install flat washer, ring terminal and Keps nut onto load-
ing coil stud. Tighten Keps nut.
3.
Disconnect 1-place CB antenna cable connector on right
side of Tour-Pak. Release cable from rear clip at bottom
8.
Mate pin and socket halves of 1-place CB antenna cable
of Tour-Pak.
connector. Capture antenna cable in rear clip at bottom
of Tour-Pak.
4.
Remove Keps nut, ring terminal and flat washer from
9.
Install bulb sockets on both sides of Tour-pak.
loading coil stud.
10.
Install molded liner in Tour-Pak. Install map pocket and
5.
Holding Phillips screw, remove flange nut at bottom of
secure using acorn nuts. Close Tour-Pak.
Tour-Pak to release loading coil bracket. Remove Phil-
11.
Install SWR meter. Check SWR following procedure in
lips screw (with external tooth lockwasher) and loading
Section 6 of the ELECTRICAL DIAGNOSTIC MANUAL.
coil from vehicle.
When the antenna is adjusted, remove the SWR meter
and tighten the antenna connector at the transceiver.
6.
Using a 2.5 mm allen head wrench, remove loading coil
stud. Remove CB antenna mast from lamp housing.
PASSENGER BACKREST
7.
On left side of Tour-Pak, rotate knurled lock ring in a
counter-clockwise direction to separate pin and socket
FLHTCU
halves of Radio antenna cable connector. Release cable
from rear clip at bottom of Tour-Pak.
REMOVAL
8.
Remove jam nut from Radio antenna cable connector at
back of Tour-Pak. Remove internal tooth lockwasher,
1.
Open Tour-Pak. Open map pocket and remove acorn
ring terminal and large flat washer from connector.
nuts
(with flat washers). Remove map pocket and
molded liner from Tour-Pak.
9.
Install jam nut back onto connector. Thread a 1/2 in.-20
2.
Remove two locknuts and backplate to detach center
UNF nut onto connector until contact is made with jam
backrest from Tour-Pak cover. See Figure 2-148.
nut. Turn jam nut to in a counter-clockwise direction to
remove connector stud from radio antenna mast.
3.
Remove two locknuts and backplate to detach right side
Remove mast from lamp housing.
backrest from cover.
4.
Remove two locknuts to detach left side backrest from
10.
Remove caulking from around light bar. Remove four
cover.
flange nuts and metal clips to free light bar from Tour-
Pak. See Figure 2-147.
5.
Remove backrest.
2005 Touring: Chassis
2-119
HOME
SPEAKER BOX
5142
FLHTCU
Right Side
REMOVAL
Fasteners
Passenger
and Backplate
Backrest
1.
Remove trim ring and gently pull on wire harness to
draw 6-place Mini-Deutsch connector out of speaker
box. Depress external latch and use a rocking motion to
separate pin and socket halves.
2.
Open Tour-Pak. Open map pocket and remove acorn
Center
nuts
(with flat washers). Remove map pocket and
Fasteners
molded liner from Tour-Pak.
and Backplate
3.
Remove three bolts with flat washers to free speaker box
from Tour-Pak.
INSTALLATION
1.
Install three bolts with flat washers to secure speaker
box to Tour-Pak. Alternately tighten bolts to 25-35 in-lbs
(2.8-4.0 Nm).
Left Side
Fasteners
2.
Install molded liner in Tour-Pak. Install map pocket and
secure using acorn nuts (with flat washers). Close Tour-
Pak.
3.
Mate pin and socket halves of 6-place Mini-Deutsch con-
nector. Feed connector back up into speaker box press-
ing trim ring into hole.
Figure 2-148. Tour-Pak Cover (Underside)
INSTALLATION
1.
Position backrest against Tour-Pak cover.
2.
From inside Tour-Pak, install two locknuts with backplate
to attach center backrest to cover.
3.
Install two locknuts and backplate to attach right side
backrest to cover.
4.
Install two locknuts to attach left side backrest to cover.
5.
Install molded liner in Tour-Pak. Install map pocket and
secure using acorn nuts (with flat washers). Close Tour-
Pak.
2-120
2005 Touring: Chassis
HOME
LOWER FAIRING/ENGINE GUARD
2.28
LOWER FAIRING (FLHTCU)
9475
NOTE
By increasing the flow of air on each side of the engine, vent-
ing or completely removing the fairing lowers evacuates
heated air and provides some relief to the rider in warmer
temperatures (70˚ F. or above).
VENTING
Opening
1. Rotate arm to open fairing lower vent door. See Figure
2-149.
NOTE
If additional cooling is desired, remove the air deflectors, if
Vent Door Arm
installed. See Section 2.29 UPPER FAIRING/WINDSHIELD
(FLHT/C/U), AIR DEFLECTORS (FLHTCU), REMOVAL.
Figure 2-149. Fairing Lower (Right Side) - FLHTCU
Closing
NOTE
Close fairing lower vents in colder weather.
2.
Holding screw inside fairing lower, install new rubber
washer, clamp and locknut to attach bottom of fairing
1. Rotate arm to close fairing lower vent door.
lower to engine guard. Do not tighten locknut.
REMOVAL
3.
Verify that two clip studs are fully installed on fairing cap.
1. Unfasten snaps to release glove box door flap. Release
4.
Position fairing cap at front of engine guard and against
anchor on draw string from hole in glove box door. Set
fairing lower so that clip studs engage holes in fairing
door flap aside.
lower and glove box tray. Reaching into glove box, start
two flange nuts on clip studs.
2. Reaching into glove box, remove two flange nuts from
clip studs and remove fairing cap. If necessary, push
5.
Verify that fairing lower is square, and then alternately
ends of studs through holes in glove box tray and fairing
tighten flange nuts on clip studs to 35-40 in-lbs (4.0-4.5
lower to release fairing cap. Do not twist or rotate fairing
Nm).
cap or damage may result.
3. Hold locknut at bottom of fairing lower, and using a T40
6.
Hold locknut at bottom of fairing lower, and using a T40
TORX drive head, turn inside screw to free assembly
TORX drive head, turn inside screw to fasten assembly
from engine guard clamp. Discard rubber washer.
to engine guard clamp. Tighten screw to 90-100 in-lbs
(10.2-11.3 Nm).
4. Repeat steps 1-3 on other side of motorcycle.
7.
Repeat steps 1-6 on other side of motorcycle.
NOTE
If additional cooling is desired, remove the air deflectors, if
installed. See Section 2.29 UPPER FAIRING/WINDSHIELD
(FLHT/C/U), AIR DEFLECTORS (FLHTCU), REMOVAL.
DISASSEMBLY
1.
See REMOVAL, steps 1-3.
INSTALLATION
2.
Remove three T20 TORX screws to release glove box
NOTE
door and glove box tray from fairing lower.
Reinstall fairing lowers in colder weather.
3.
Remove two T20 TORX screws to release glove box
door from glove box tray.
1. Place fairing lower into position at front of engine guard.
2005 Touring: Chassis
2-121
HOME
4.
Remove locknut, flat washer, compression spring (rub-
Installation
ber sleeve), glove box tray and two serrated washers
1. Obtain two new serrated washers.
from pivot screw in vent door arm.
2. With the teeth up, carefully install first serrated washer at
5.
Remove pivot screw from vent door arm.
top of vent door arm. Be sure that square shaped boss
on washer engages square recess in arm.
ASSEMBLY
3. With the teeth down, carefully install second serrated
washer at bottom of glove box tray. Be sure that square
1.
Slide threaded end of pivot screw up through hole in
shaped boss on washer engages square hole in tray.
center of vent door arm.
2. With the teeth facing upward, slide serrated washer over
4. Slide threaded end of pivot screw up through hole in
center of vent door arm.
end of pivot screw. Square shaped boss at bottom of
serrated washer should engage square recess in vent
5. Reaching into glove box, install compression spring
door arm.
(rubber sleeve), flat washer and locknut on pivot screw.
3.
Slide second serrated washer over pivot screw so that
6. Tighten locknut only until flat washer is snug (does not
teeth engage those on first serrated washer.
rotate) and then tighten an additional 1-1/2 turns. Verify
4.
Slide square hole on glove box tray over end of pivot
proper vent door operation.
screw until it engages square shaped boss at top of sec-
ond serrated washer.
NOTE
5.
Install compression spring (rubber sleeve), flat washer
For best results, the 0.50 inch compression spring must be
and locknut on pivot screw. Verify that pin at front of
compressed to a height of 0.420 to 0.460 inches (10.7-11.7
glove box tray engages slot at top of vent door.
mm).
6.
Tighten locknut only until flat washer is snug (does not
rotate) and then tighten an additional 1-1/2 turns. Verify
proper vent door operation.
ENGINE GUARD
NOTE
For best results, the 0.50 inch compression spring must be
compressed to a height of 0.420 to 0.460 inches (10.7-11.7
REMOVAL
mm).
1.
Remove fairing lowers, if present. See LOWER FAIRING
7.
Align bottom two holes in glove box tray with bosses on
(FLHTCU), REMOVAL, in this section. Remove fairing
glove box door and start two T20 TORX screws. Alter-
lower clamps from engine guard.
nately tighten screws to 20-25 in-lbs (2.3-2.8 Nm).
2.
Remove T40 TORX screws (with flanged locknuts) to
8.
Fit glove box tray into top of fairing lower and align three
release ends of engine guard from frame weldments.
holes in fairing lower with holes in glove box tray and
3.
Remove hex socket screw (with flat washer) to release
bosses in glove box door. Install three T20 TORX
tab at top of engine guard from slot at base of steering
screws. Alternately tighten screws to 20-25 in-lbs (2.3-
head.
2.8 Nm).
9.
See INSTALLATION, steps 1-6.
10. Install anchor on draw string of glove box door flap into
INSTALLATION
hole in glove box door. Fasten snaps to install glove box
1.
Insert tab at top of engine guard into slot at base of
door flap.
steering head. Start hex socket screw (with flat washer)
to hang engine guard.
SERRATED WASHER REPLACEMENT
2.
Position ends of engine guard outboard of frame weld-
ments on each side of motorcycle. Install T40 TORX
Removal
screws positioning flanged locknuts on inboard side of
1.
Unfasten snaps to release glove box door flap.
frame weldments.
2.
Reaching into glove box, remove locknut, flat washer
3.
Alternately tighten three screws to 15-20 ft-lbs (20.3-
and compression spring
(rubber sleeve) from pivot
27.1 Nm).
screw in vent door arm. Remove pivot screw.
4.
Install fairing lowers, if present, but first install fairing
3.
Carefully extract first serrated washer at top of vent door
lower clamps on each side of engine guard. See
arm. Remove second washer at bottom of glove box tray.
LOWER FAIRING (FLHTCU), INSTALLATION, in this
Discard washers.
section.
2-122
2005 Touring: Chassis
HOME
UPPER FAIRING/WINDSHIELD (FLHT/C/U)
2.29
OUTER FAIRING/WINDSHIELD
T27 TORX Screws
2
REMOVAL
1
3
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
2. Remove the outer fairing as follows:
a. Standing at the front of the vehicle, use a T27 TORX
drive head to remove the three outer fairing screws
(with flat washers) just below the windshield. See
40
50
60
70
80
30
40
50
30
90
20
60
20
100
10
70
Figure 2-150.
100
MPH
110120
0
RPMx100
80
b. Moving to the inner fairing side, remove the two fair-
ing screws just above the wind deflectors on the left
and right side.
c. Turn the handlebar to the right and remove the outer
fairing screw reaching in below the left side of the
fairing cap. Turn the handlebar to the left and
remove the fairing screw below the right side of the
fairing cap.
d. Tilting the outer fairing toward the front, squeeze the
6
7
4
5
two external tabs to remove the wire connector at
f2029x2x
the back of the headlamp assembly.
e. Lift the fairing
(with headlamp assembly) off the
Figure 2-150. Outer Fairing TORX Screw Locations
motorcycle.
e. Turn the handlebar to the left and start the outer fair-
CAUTION
ing screw reaching in below the right side of the fair-
Since the outer fairing screws hold the windshield in
ing cap. Turn the handlebar to the right and start the
place, the windshield may fall to the floor if not removed.
fairing screw below the left side of the fairing cap.
f.
Alternately tighten the four fairing screws on the
3. Remove the windshield.
inner fairing side to 20-30 in-lbs (2.3-3.4 Nm).
g. Moving to the front of the vehicle, tighten the outer
fairing screws below the windshield to 25-30 in-lbs
INSTALLATION
(2.8-3.4 Nm).
2.
Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
1. Install the outer fairing as follows:
MAXI-FUSE, INSTALLATION.
a. Place the fairing (with headlamp assembly) on the
motorcycle installing the wire connector at the back
of the headlamp assembly.
FAIRING CAP
b. Place the windshield in position on the inner fairing
aligning the slots with the threaded inserts.
REMOVAL
c. Using a T27 TORX drive head, start the three outer
fairing screws
(with flat washers) just below the
1.
Partially disassemble domestic ignition switch as follows:
windshield.
NOTE
d. Moving to the inner fairing side, start the two fairing
For partial disassembly of HDI ignition switch, see Section
screws just above the wind deflectors on both the
8.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK,
left and right side.
FLHT/C/U, FLTR (INTERNATIONAL), REMOVAL, steps 1-4.
2005 Touring: Chassis
2-123
HOME
4. Remove the fairing cap from the motorcycle. See Figure
TOP VIEW
BOTTOM VIEW
2-152.
INSTALLATION
1.
Verify that the rubber grommets are installed on each
side of the fairing cap. Barbs on cap fit into holes in
grommets. See Figure 2-152.
2.
Connect the Fairing cap switch connector [105], 12-
Button
place Multilock (black), on the right side of fairing cap.
Button
3.
With the forks turned fully to the left, install fairing cap
f1240x2x
f1476x8x
over ignition switch housing.
f1297b2x
4.
Using a T27 TORX drive head, start two fairing cap
screws (with flat washers). Verify that grommets in fair-
ing cap fully capture handlebar along with throttle and
clutch cables.
5.
Assemble domestic ignition switch as follows:
Knob
NOTE
For assembly of HDI ignition switch, see Section 8.18 IGNI-
Nut
TION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U,
FLTR (INTERNATIONAL), INSTALLATION, steps 5-10.
a.
Install switch position plate fitting tabs in slots of fair-
Tab
Collar
ing cap. Plate snaps in place when properly
Down and Forward
installed. Exercise care to avoid breaking tabs.
Replace plate if tabs are broken.
b.
Slide spacer over threaded post of ignition switch
Spacer
housing until it contacts switch position plate. Slide
collar over post with the tab side down (and for-
Figure 2-151. Ignition Switch Knob (Domestic)
ward). Install nut, and using a 7/8 inch wrench on
flats, tighten to 50-70 in-lbs (5.7-7.9 Nm).
a. See upper frame of Figure 2-151. To remove the
ignition switch knob, insert the Ignition Switch key
and turn to the UNLOCK position. Leaving the key
Rubber
f1305b2x
installed, rotate the knob to ACCESS. Depressing
Grommet
the release button at bottom (left side) with a small
screwdriver, push key down and turn an additional
60 degrees in a counter-clockwise direction. Lift and
remove knob.
b. Using a 7/8 inch wrench on flats, loosen switch nut
and remove from threaded post of ignition switch
housing. Remove collar and spacer. See lower
frame of Figure 2-151.
c. Gently remove the switch position plate by pulling
tabs from slots in fairing cap.
2.
Using a T27 TORX drive head, remove the two screws
(with flat washers) that secure fairing cap to left and right
sides of inner fairing.
Fairing Cap
3.
With the forks turned fully to the left, disconnect the Fair-
Switch Connector [105]
ing cap switch connector
[105],
12-place Multilock
12-Place Multilock
(black), from behind right side of fairing cap. Depress the
button on the socket terminal side of the connector
(plug) to pull apart the pin and socket halves.
Figure 2-152. Fairing Cap Assembly (FLHT/C/U)
2-124
2005 Touring: Chassis
HOME
3.
Using a T40 TORX drive head, remove four screws to
Auxiliary Lamp
Turn Signal Lamp
release auxiliary lamp bracket from upper and lower fork
Connector [73]
Connector [31]
brackets. Remove auxiliary lamp assembly from the
motorcycle.
4.
Remove the fairing cap. See FAIRING CAP, REMOVAL,
in this section.
5.
Pull chrome skirt from inner fairing. See Figure 2-153.
6.
Slide rubber boot off clutch cable adjuster. Holding cable
adjuster with 1/2 inch wrench, loosen jam nut using 9/16
inch wrench. Back jam nut away from cable adjuster.
Move adjuster toward jam nut to introduce free play at
hand lever.
7.
Remove retaining ring from pivot pin groove at bottom of
clutch lever bracket. Remove pivot pin.
8.
Using a T27 TORX drive head, remove two screws (with
flat washers) to release handlebar clamp from clutch
lever bracket. Remove clutch hand lever from clutch
lever bracket.
9.
Remove anchor pin and clutch cable eyelet from clutch
hand lever. See Figure 2-115.
10.
Feed clutch cable and cable eyelet through inner fairing
grommet to front of motorcycle.
Chrome
f2238x8x
Skirt
CAUTION
Figure 2-153. Inner Fairing (Front View)
Do not remove the switch housing assembly without first
placing a 5/32 inch (4.0 mm) cardboard insert between
the brake lever and lever bracket. Removal without the
c. With the red arrow pointing toward the ACCESS
insert may result in damage to the rubber boot and
position, install the ignition switch knob. Turn key
plunger of the front stoplight switch.
clockwise to UNLOCK position and then turn knob
to OFF.
NOTE
6. Using a T27 TORX drive head, tighten two fairing cap
Use the eyelet of a small cable strap if the cardboard insert is
screws to 25-30 in-lbs (2.8-3.4 Nm).
not available.
INNER FAIRING
7959
REMOVAL
CAUTION
To avoid scratches or other damage, place protective
material over front fender, fuel tank and fairing lowers, if
present.
1. Remove the outer fairing. See OUTER FAIRING/WIND-
SHIELD, REMOVAL, in this section.
5/32 Inch
(4.0 mm)
2.
Locate auxiliary lamp (white 2-place Multilock) and front
Cardboard
turn signal lamp (6-place Multilock) connectors. Depress
Insert
button on socket terminal side and pull apart pin and
socket halves of both connectors. See Figure 2-153.
Figure 2-154. Install Cardboard Insert
2005 Touring: Chassis
2-125
HOME
Speedometer
[39]
Voltmeter
Fuel Gauge
Indicator Lamps
Tachometer
[21]
Speaker
[108]
Adapter
Speaker
Adapter
Ambient
Temperature
Gauge
Oil Pressure
Cigarette
Gauge
Lighter
f2238x8x
Figure 2-155. Inner Fairing Connections (FLHTC/U)
11. Place the cardboard insert between the brake lever and
15. Remove the throttle control grip from the end of the han-
lever bracket. See Figure 2-154.
dlebar.
12. Using a T25 TORX drive head, remove
the upper and
16. Remove two-sided plastic clip inboard of cable adjuster
lower switch housing screws.
boots to separate throttle and idle control cable hous-
ings. Pull the crimped inserts at the end of the cable
13. Using a T27 TORX drive head, loosen the upper screw
housings from the lower handlebar switch housing. For
securing the handlebar clamp to the master cylinder
best results, place a drop of light oil on the retaining
housing. Remove the lower clamp screw with flat
rings and use a rocking motion while pulling.
washer.
14. Remove the brass ferrules from the notches on the
17. Feed the throttle and idle control cables through the
inboard side of the throttle control grip. For best results,
inner fairing grommet to front of motorcycle.
place flat tip screwdriver in slot on outboard side and
18. See Figure 2-155. Pull socket terminals from spade con-
rotate ferrule in notch. Remove the ferrules from the
tacts on the cigarette lighter. Remove cigarette lighter
cable end fittings.
from socket. Holding socket to prevent rotation, unscrew
outer shell. Remove socket from inner fairing.
NOTE
On non cruise equipped models, remove the friction shoe
19. Pull socket terminals from speaker spade contacts.
from the end of the tension adjuster screw. The friction shoe
Using a T25 TORX drive head, remove three screws to
is a loose fit and may fall out or become dislodged if the lower
release the speaker adapter from the inner fairing.
switch housing is turned upside down or shaken.
Repeat step on opposite side of motorcycle.
2-126
2005 Touring: Chassis
HOME
23.
Pull the interconnect harness connectors from the volt-
Hex Nut
meter and fuel gauge.
Lamp
24.
Remove four socket head screws to free inner fairing
Connector
from fairing bracket. See Figure 2-158.
25.
Spread bottom of inner fairing to free from dowels in
lower fork bracket. Spread bottom of fairing bracket to
release from same dowels.
26.
Raise inner fairing and fairing bracket slightly to prevent
reengagement with dowels. On Classic and Ultra mod-
Mounting
els, remove the connectors from the oil pressure and
Bracket
ambient air temperature gauges.
Stud
Tab
27.
Raise inner fairing and fairing bracket together and then
separate by pulling fairing bracket toward the front and
inner fairing toward the rear.
Gauge
f1345x2x
28.
When inner fairing becomes free of the radio, remove
from motorcycle and move to bench area.
Figure 2-156. Voltmeter Gauge Assembly
29.
Install fairing bracket (with radio and interconnect har-
ness) back onto motorcycle aligning holes with dowels in
Indicator Lamp
lower fork bracket. Loosely install T40 TORX screws.
Connector [21]
10-Place Multilock
30.
At bench area, remove hex nuts from studs at back of
voltmeter and fuel gauges. Remove mounting brackets
from gauges and remove gauges from inner fairing. See
Figure 2-156. On Classic and Ultra models, repeat step
Bulb
to remove oil pressure and ambient air temperature
Housing
gauges.
31.
Remove clutch and throttle cable
grommets from the
inner fairing.
Rubber
Boot
Fairing Bracket
Screws
Paddle
Lense
f2262x8x
Figure 2-157. Indicator Lamp Assembly
20.
Unthread rubber boot from odometer reset switch. Pull
switch from hole in inner fairing.
21.
Bend back the external latches slightly and remove con-
nectors at back of speedometer and tachometer gauges.
See Figure 2-155. Leaving anchors on interconnect har-
ness installed in outboard ears of brackets, remove allen
head socket screws to remove brackets from gauges.
Push gauges toward rear of motorcycle to remove from
inner fairing.
Fairing Bracket
Screws
22.
Separate pin and socket halves of indicator lamps con-
nector (10-place Multilock). See Figure 2-155. Release
f2238x8x
four paddles to free indicator bulb housing from lense
assembly. See Figure 2-157. Remove lense assembly
Figure 2-158.
Remove Fairing Bracket Screws
from inner fairing.
2005 Touring: Chassis
2-127
HOME
INSTALLATION
11. With the widest edge at the top, align holes in speaker
adapter with those in inner fairing. Install two long
1.
At bench area, install clutch and throttle cable grommets
screws to fasten top of speaker adapter. Capturing fair-
in inner fairing.
ing support brace, install short screw in lower outboard
hole (positioning flat washer between adapter and sup-
2.
Install voltmeter and fuel gauges in inner fairing. Slide
port brace). Using a T25 TORX drive head, tighten the
mounting brackets over studs. Verify that tabs on top and
lower screw to 22-28 in-lbs (2.5-3.2 Nm). Tighten the
bottom of brackets engage slots in inner fairing. Loosely
two upper screws to 35-50 in-lbs (4.0-5.7 Nm).
install hex nuts on studs. Verify that gauge is properly
aligned and tighten nuts to 10-20 in-lbs (1.1-2.3 Nm).
NOTE
See Figure 2-156. On Classic and Ultra models, repeat
The screw hole on the lower inboard side of the speaker
step to install ambient air temperature and oil pressure
adapter is not used.
gauges.
12. Push the socket terminals onto the speaker spade con-
tacts. Different size spade contacts prevent improper
CAUTION
assembly.
To avoid scratches or other damage, place protective
13. Repeat steps 11-12 on opposite side of motorcycle.
material over front fender, fuel tank and fairing lowers, if
present.
14. From rear of inner fairing, slide socket of cigarette lighter
through bore in fairing. Thread outer shell onto socket
3.
Remove T40 TORX screws to free fairing bracket (with
until tight. Install cigarette lighter in socket. Connect the
radio and interconnect harness) from lower fork bracket.
orange/white wire terminal to the socket spade contact,
Raise fairing bracket and then tilt forward at about a 45
the black wire terminal to the outer shell contact.
degree angle.
15. Feed the throttle and idle control cables through the right
4.
Position inner fairing at rear of fairing bracket. Tilting
side inner fairing grommet.
inner fairing rearward at about a 45 degree angle, align
NOTE
upper and lower fork bracket thru holes with those in fair-
On non cruise equipped models, install the friction shoe with
ing bracket. Draw fairing bracket and inner fairing
the concave side up so that the pin hole is over the point of
together fitting radio into slot in inner fairing.
the adjuster screw. The friction shoe is a loose fit and may fall
5.
Align upper thru holes in fairing bracket and inner fairing
out or become dislodged if the lower switch housing is turned
with threaded holes in upper fork bracket and start T40
upside down or shaken.
TORX screws. Align lower thru holes in fairing bracket
and inner fairing with dowels in lower fork bracket and
16. Push the throttle and idle control cables into the lower
handlebar switch housing until they snap in place. Pro-
start screws. Alternately tighten four T40 TORX screws
until snug.
ceed as follows:
a. Note the different diameter inserts crimped into the
6.
Install four socket head screws to attach inner fairing to
end of the throttle and idle control cable housings.
fairing brackets. See Figure 2-158.
b. Push the larger diameter insert (silver) on the throt-
7.
Install the interconnect harness connectors onto the volt-
tle cable housing into the larger hole (front).
meter and fuel gauge. On Classic and Ultra models,
install the connectors onto the oil pressure and ambient
c. Push the smaller diameter insert (gold) on the idle
air temperature gauges.
cable housing into the smaller hole (rear).
8.
Place indicator lamp lense assembly into inner fairing.
NOTE
Slot at bottom of lense engages tab in inner fairing to
To aid assembly, place a drop of light oil on the retaining
prevent improper orientation. Engage all four paddles on
rings of the crimped inserts. Always replace the retaining
lense assembly with slots on indicator bulb housing.
rings if damaged or distorted.
Mate pin and socket halves of indicator lamps connector
17. Slide the throttle control grip over the end of the right
(10-place Multilock). See Figure 2-157.
handlebar until it bottoms against the closed end. Rotate
9.
Install speedometer and tachometer gauges in inner fair-
the grip so that the ferrule notches are at the top. To pre-
ing. Align holes in brackets with those at back of gauges
vent binding, pull the grip back about 1/8 inch (3.2 mm).
and start two allen head socket screws. Rotate gauges
18. Position the lower switch housing beneath the throttle
until tabs at top and bottom of brackets engage slots in
control grip. Install the brass ferrule onto the throttle
inner fairing. Verify that gauge is properly aligned and
cable so that the end fitting seats in the ferrule recess.
tighten allen head socket screws to 10-20 in-lbs (1.1-2.3
Be sure that ferrule is oriented so that when installed in
Nm). Install speedometer and tachometer connectors at
notch of throttle control grip, slotted end is on the out-
back of gauges.
board side. Install ferrule in notch of throttle control grip.
10.
Slide odometer reset switch through hole in inner fairing.
Verify that cable is captured in groove molded into the
Install rubber boot to secure.
grip. Repeat step to install idle control cable. See Figure
2-159.
2-128
2005 Touring: Chassis
HOME
23. Align the holes in the handlebar clamp with those in the
Ferrule
Notch
Groove
master cylinder housing and start the two screws (with
flat washers). Position for rider comfort. Beginning with
the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0
Nm) using a T27 TORX drive head.
24. Using a T25 TORX drive head, tighten the lower and
upper switch housing screws to 35-45 in-lbs (4-5 Nm).
NOTE
Always tighten the lower switch housing screw first so that
any gap between the upper and lower housings is at the front
of the switch.
25.
Remove the cardboard insert between the brake lever
and lever bracket.
26.
Install two-sided plastic clip inboard of cable adjuster
boots to hold throttle and idle control cable housings
together.
27.
Moving to other side of motorcycle, feed clutch cable
Throttle
through left side inner fairing grommet.
Grip
28.
Insert clutch cable eyelet into groove of clutch hand lever
aligning eyelet with hole without bushing. Insert anchor
pin through lever and eyelet.
Idle
29.
Insert lever into groove of clutch lever bracket fitting
Throttle
f1474x2x
Cable
sleeve at end of cable housing into bore on inboard side
Cable
of bracket.
30.
Align hole in hand lever with hole in bracket and install
Figure 2-159. Install Throttle/Idle Control Cables on
pivot pin. Install retaining ring in pivot pin groove.
Throttle Control Grip
31.
Using a T27 TORX drive head, install two screws (with
flat washers) to secure handelbar clamp to clutch lever
bracket. Starting with the top screw, tighten screws to
19. Position the upper switch housing over the handlebar
60-80 in-lbs (6.8-9.0 Nm).
and lower switch housing.
32.
Adjust the clutch. See Section 6.3 CLUTCH, ADJUST-
20. Verify that the wire harness conduit runs in the depres-
MENT.
sion at the bottom of the handlebar. Also be sure that the
33.
Install the fairing cap. See FAIRING CAP, INSTALLA-
upper switch housing harness will not be pinched
TION, in this section.
against the handlebar when the switch housing screws
are tightened.
34.
Remove two T40 TORX screws from lower fork bracket.
Install chrome skirt aligning thru holes with screws just
21. Start the upper and lower switch housing screws, but do
removed. Start T40 TORX screws back into lower fork
not tighten.
bracket.
35.
Loosen two T40 TORX screws from upper fork bracket.
CAUTION
36.
Slide slots of auxiliary lamp bracket onto upper and
lower fork bracket screws. Alternately tighten four T40
See Figure 2-154. Do not remove the 5/32 inch (4.0 mm)
TORX screws to 15-20 ft-lbs (20-27 Nm) in a crosswise
cardboard insert (or cable strap eyelet) wedged between
pattern.
the brake lever and lever bracket. Removal will result in
37.
Route auxiliary lamp conduit upward in front of chrome
damage to the rubber boot and plunger of the Front
Stoplight Switch during installation of the master cylin-
skirt and then rearward using relief in upper outboard
der assembly.
corner (in front of fairing bracket). Route conduit of other
auxiliary lamp in the same manner. Mate pin and socket
22. Position the brake lever/master cylinder assembly
halves of auxiliary lamp connector (white 2-place Mul-
inboard of the switch housing assembly engaging the
tilock) and front turn signal lamp connector (6-place Mul-
tab on the lower switch housing in the groove at the top
tilock).
of the brake lever bracket.
38.
Install the outer fairing. See OUTER FAIRING/WIND-
SHIELD, INSTALLATION, in this section.
2005 Touring: Chassis
2-129
HOME
AIR DEFLECTORS (FLHTCU)
NOTE
Air
By increasing the flow of air behind the fairing, removing the
Deflector
air deflectors evacuates heated air and provides some relief
to the rider in warmer temperatures (70˚ F. or above).
REMOVAL
1.
Remove three knurled thumbscrews to release air
deflector at side of inner fairing. See Figure 2-160.
2.
Repeat step to remove air deflector on opposite side of
motorcycle.
NOTE
Knurled
f1815x2x
Thumbscrew (3)
If additional cooling is desired, either vent or remove the fair-
ing lowers, if installed. See Section 2.28 LOWER FAIRING/
ENGINE GUARD, LOWER FAIRING (FLHTCU), VENTING
Figure 2-160. Remove/Install Air Deflectors
or REMOVAL.
INSTALLATION
NOTE
Reinstall air deflectors in colder weather.
1. Install three knurled thumbscrews to fasten air deflector
at side of inner fairing.
2. Repeat step to install air deflector on opposite side of
motorcycle. See Figure 2-160.
2-130
2005 Touring: Chassis
HOME
UPPER FAIRING/WINDSHIELD (FLTR)
2.30
WINDSHIELD ONLY
Wellnut
Flat Washer
Phillips
Plastic
Screw
REMOVAL
1. Standing at front of motorcycle, locate five Phillips
screws at base of windshield. Alternately loosen and
then remove screws (with plastic flat washers).
Windshield
2. Remove windshield from outer fairing.
3. Carefully remove wellnuts
(with rubber flat washers)
from holes in outer fairing. See Figure 2-161. Exercise
caution to avoid pushing wellnuts into fairing during
removal. Inspect wellnuts and rubber flat washers for
Flat Washer
Rubber
cuts, tears or signs of deterioration. Replace as neces-
sary.
Outer
Fairing
INSTALLATION
f2280x2x
1. Preinstall hardware on windshield as follows:
Figure 2-162. Install Windshield
a. Slide plastic flat washers onto Phillips screws.
(Decal Removed for Illustration Purposes)
b. Slide Phillips screws through holes in decal to orient
hardware in slots of windshield.
2. Moving to front of motorcycle, push wellnuts into holes in
NOTE
outer fairing. See Figure 2-162.
If installing new windshield, poke holes in decal from inboard
3. Starting with center screw, alternately tighten the five
side of windshield. Punching holes from outboard side will
Phillips screws to 6-13 in-lbs (0.7-1.5 Nm).
dislocate or tear decal on windshield.
c. Slide rubber flat washers onto wellnuts.
d. Start wellnuts onto Phillips screws.
OUTER FAIRING
Wellnuts
f1525x2x
REMOVAL
NOTE
Windshield may be left in place during outer fairing removal.
1.
Place protective material on top of front fender to protect
paint from scratches or other damage.
2.
Standing on left side of motorcycle, use a T25 TORX
drive head to remove screw at edge of fairing outboard
of the left speaker. See Figure 2-163. Remove screw
outboard of the right speaker.
3.
Loosen top left and right screws just outboard of the fuel
and volt gauges, respectively.
4.
Remove screw just below left side glove compartment.
Remove screw below right side glove compartment.
5. On inboard side of right fairing support, remove rear
acorn nut (with flat washer) from stud of front turn signal
Figure 2-161. Remove Wellnuts From Outer Fairing
lamp bracket. Remove front acorn nut with flat washer.
2005 Touring: Chassis
2-131
HOME
2
2
50
60
70
30
40
50
3040
MPH
8090
20
RPMx100
60
10
20
100110
10
70
0
120
0
80
CERTIFIEDN
N
1
1
HARLEY-DAVIDSON
Long Screw
Long Screw
3
3
f2169x2x
Figure 2-163. Remove/Install Six Outer Fairing Screws
Pull front turn signal lamp assembly from motorcycle
and allow to hang at front of engine guard. Repeat step
to remove front turn signal lamp assembly on left side.
See Figure 2-164.
Acorn Nuts
6.
Remove top left and right screws just outboard of the
fuel and volt gauges, respectively (previously loosened).
7.
Raise outer fairing slightly and then rest on protective
fender pad.
8.
Squeeze two external tabs to disconnect headlamp
jumper harness connector.
9.
To avoid possible wire damage, separate pin and socket
halves of front turn signal lamp connectors [31L] and
[31R], 3-place Multilocks, and move to bench area. See
Figure 2-165.
9424
INSTALLATION
Figure 2-164. Remove Acorn Nuts to Release
Turn Signal Lamp and Bracket
1. Place protective material on top of front fender to protect
paint from scratches or other damage.
2.
Mate pin and socket halves of front turn signal lamp con-
NOTE
nectors [31L] and [31R], 3-place Multilocks. Verify that
The front turn signal lamp assemblies are not interchange-
conduit is captured in flexible clips on inner fairing. Allow
able. Note that the letters R(ight) or L(eft) are stamped on the
front turn signal lamp assemblies to hang at front of
inboard side of the turn signal lamp bracket to help ensure
engine guard until outer fairing installation is complete.
proper assembly.
2-132
2005 Touring: Chassis
HOME
10. Alternately tighten four short fairing screws to 6-12 in-
lbs (0.7-1.4 Nm). Alternately tighten two long fairing
screws to 10-15 in-lbs (1.1-1.7 Nm). Use the torque pat-
tern shown in Figure 2-163.
11. Slide studs on front turn signal lamp bracket through
holes in fairings and fairing support. Loosely install
acorn nuts with flat washers. Alternately tighten acorn
nuts to 40-50 in-lbs (4.5-5.7 Nm).
12. Repeat step 11 to install front turn signal lamp assembly
on opposite side of motorcycle.
9408
BEZEL
Figure 2-165. Front Turn Signal Lamp
REMOVAL
1.
Using a T25 TORX drive head, remove screw on left and
3. To avoid chafing wires of interconnect harness, verify
right side of instrument bezel. See Figure 2-166.
that trim strips are installed inboard of hooks on radio
2.
Use thumbs to push tab at rear of bezel from slot in front
bracket.
of ignition switch. Gently raise free side of bezel until
4. Rest outer fairing on front fender pad and connect head-
tabs at front of instrument nacelle become disengaged
lamp jumper harness connector.
from slot at front of bezel (concealed behind decorative
adhesive strip).
CAUTION
3.
Raising bezel slightly, remove anchor on ambient tem-
perature sensor from hole
in bottom
inboard ear
of
If windshield is attached during outer fairing installation,
speedometer bracket.
exercise caution to avoid scratching or damaging inner
fairing with windshield screws and wellnuts.
5. Place outer fairing against inner fairing. Two slots in
outer fairing must engage hooks on radio bracket. Move
harness conduit and wiring as necessary to ensure full
Bezel Screws
engagement between outer and inner fairings.
T25 TORX
6. Move to side of outer fairing to verify that alignment tabs
are properly engaged. Alignment tabs on inner fairing
must be positioned outboard of those on the outer fair-
ing. Repeat step on opposite side of motorcycle.
NOTE
Although the tightening sequence described below begins on
the left side of the motorcycle, if the left side of the outer fair-
ing fits the inner fairing better than the right, then start the
50
60 70
30
40
first screw on the right side. In other words, install the first
40
80
50
30
MPH
90
20
RPMx100
60
20
100
10
70
screw on the side that does not have the best fit.
10
110
0
120
0
80
CERTIFIEDN
N
7. Using a T25 TORX drive head, install screw at edge of
fairing outboard of the left speaker. Install screw out-
board of the right speaker. Mounting bosses on inner
fairing are painted white for easier alignment of holes.
8. Install the top left and right screws just outboard of the
Bezel
fuel and volt gauges, respectively.
Instrument
9. Moving to left side of motorcycle, install the first of two
Nacelle
long screws just below the glove compartment. Install
f2167x2x
the second long screw below the right side glove com-
partment.
Figure 2-166.
Remove Instrument Bezel Screws
2005 Touring: Chassis
2-133
HOME
Instrument Nacelle
Indicator
f2219x8x
Switches [105]
Lamps [21]
Tachometer
Gauge [108]
Speedometer
Gauge [39]
Throttle
Cables
Clutch
Cable
Speaker
Ambient
Switch [105]
Temperature
Sensor [107]
Figure 2-167. Instrument Nacelle (Bezel Removed)
4.
See Figure 2-167. Disconnect instruments and indicator
NOTE
lamps from interconnect harness as follows:
If tabs do not properly engage slot at front of bezel, then a
● Speedometer connector [39], 12-place Packard.
loose fit will result. Remove decorative adhesive strip by gen-
● Tachometer connector [108], 12-place Packard.
tly prying up outer edges, and using a flat bladed screwdriver,
carefully raise tabs so that they engage lip in slot. If dam-
● Indicator lamps connector [21], 10-place Multilock.
aged, install new decorative adhesive strip.
5.
Remove bezel from motorcycle.
5.
Using a T25 TORX drive head, install screw on each
side of bezel. Tighten screws to 25-35 in-lbs (2.8-4.0
Nm). See Figure 2-166.
INSTALLATION
1.
See Figure 2-167. Looking into the instrument nacelle,
connect instruments and indicator lamps to interconnect
harness as follows:
INSTRUMENT NACELLE
● Speedometer connector [39], 12-place Packard.
● Tachometer connector [108], 12-place Packard.
REMOVAL
● Indicator lamps connector [21], 10-place Multilock.
1.
Remove bezel. See BEZEL, REMOVAL, in this section.
2.
Install anchor on ambient temperature sensor into hole
in bottom inboard ear of speedometer bracket.
2.
Partially disassemble domestic ignition switch as follows:
3.
Verify that left and right sides of instrument nacelle are
NOTE
properly mated. Pins on left side of nacelle must fully
For partial disassembly of HDI ignition switch, see Section
engage holes on right.
8.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK,
4.
Insert tab at rear of bezel into slot of instrument nacelle
FLHT/C/U, FLTR (INTERNATIONAL), REMOVAL, steps 1-4.
(just in front of ignition switch). Holding left and right
sides of nacelle together, place bezel over instrument
a. To remove the ignition switch knob, insert the Igni-
nacelle flange. When properly mated, tabs at front of
tion Switch key and turn to the UNLOCK position.
instrument nacelle engage lip in slot at front of bezel
Leaving the key installed, rotate the knob to
(behind decorative adhesive strip).
ACCESS. Depressing the release button at bottom
2-134
2005 Touring: Chassis
HOME
6.
Unthread rubber boot from odometer reset switch, and
TOP VIEW
BOTTOM VIEW
while carefully removing left side instrument nacelle from
motorcycle, pull odometer reset switch from hole. See
Figure 2-169.
7.
See Figure
2-170. Disconnect instrument nacelle
switches from interconnect harness as follows:
● Instrument nacelle switch connector [105], 12-place
Multilock.
8.
Pull throttle cable clip from hole on right side of instru-
ment nacelle.
Button
9.
Using a T40 TORX drive head, remove two bolts (with
Button
f1240x2x
f1476x8x
flat washers) to release right side of instrument nacelle
from upper and lower fork brackets.
f1297b2x
INSTALLATION
1.
Install right side of instrument nacelle on motorcycle.
2.
See Figure 2-170. Connect instrument nacelle switches
Knob
to interconnect harness as follows:
● Instrument nacelle switch connector [105], 12-place
Nut
Multilock.
3.
While carefully placing left side of instrument nacelle on
Tab
Collar
motorcycle, slide odometer reset switch through hole
Down and Forward
and install rubber boot.
4.
See Figure 2-170. Connect left side switch to instrument
nacelle switch harness as follows:
● Speaker Switch connector [105], 4-place Multilock.
Spacer
5.
Verify that left and right sides of nacelle are properly
Figure 2-168. Ignition Switch Knob (Domestic)
mated. Four pins on left side of nacelle must fully
engage holes on right.
6.
Using a T40 TORX drive head, install two bolts (with flat
(left side) with a small screwdriver, push key down
washers) to fasten left side instrument nacelle to upper
and turn an additional 60 degrees in a counter-
and lower fork brackets. Alternately tighten bolts to 15-
clockwise direction. Lift and remove knob. See
20 ft-lbs (20-27 Nm).
upper frame of Figure 2-168.
7.
Capture clutch cable in cable clip. Insert cable clip into
b. Using a 7/8 inch wrench on flats, loosen switch nut
hole in left side of instrument nacelle.
and remove from threaded post of ignition switch
8.
Using a T40 TORX drive head, install two bolts (with flat
housing. Remove collar and spacer. See lower
washers) to fasten right side instrument nacelle to upper
frame of Figure 2-168.
and lower fork brackets. Tighten bolts to 15-20 ft-lbs (20-
c. Remove the switch position plate from threaded
27 Nm).
post of ignition switch housing.
9.
Capture throttle cables in cable clip. Insert cable clip into
hole in right side of instrument nacelle.
3.
See Figure 2-167. Disconnect left side switch from
10.
Assemble domestic ignition switch as follows:
instrument nacelle switch harness as follows:
● Speaker Switch connector [105], 4-place Multilock.
NOTE
For assembly of HDI ignition switch, see Section 8.18 IGNI-
4.
Pull clutch cable clip from hole on left side of instrument
TION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U,
nacelle.
FLTR (INTERNATIONAL), INSTALLATION, steps 5-10.
5.
Using a T40 TORX drive head, remove two bolts (with
a. Install the switch position plate over threaded post
flat washers) to release left side of instrument nacelle
of ignition switch housing. Tabs on plate fit in holes
from upper and lower fork brackets.
at top of instrument nacelle.
2005 Touring: Chassis
2-135
Большое спасибо!
Ваше мнение очень важно для нас.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст