Harley Davidson 2005 touring models. Service repair manual — page 25
HOME
NOTES
8-50
2005 Touring: Electrical
HOME
IGNITION/LIGHT KEY SWITCH AND FORK LOCK
8.18
1WARNING
Knob
DO NOT modify the ignition/light key switch wiring to
disable the automatic-on headlamp feature. High visibil-
ity is an important safety consideration for motorcycle
riders. Ensure that the headlamp is on at all times. Fail-
ure to do so could result in death or serious injury.
FLHT/C/U, FLTR (DOMESTIC)
Nut
REMOVAL
Collar
Tab
1. Remove the outer fairing. See Section 2.29 UPPER
Down and Forward
FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/
WINDSHIELD, REMOVAL.
2. To remove the ignition switch knob, insert the Ignition
Switch key and turn to the UNLOCK position. Leaving
Spacer
Socket
the key installed, rotate the knob to ACCESS. Depress-
Screw
ing 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
Flat
remove knob. See Figure 8-62.
Washer
f1240x2x
Switch
Housing
4-Place
Button
TOP VIEW
Packard
Connector
f2115x8x
Figure 8-63. Ignition Switch Assembly (Domestic)
3.
Using a 7/8 inch wrench on flats, loosen switch nut and
remove from threaded post of ignition switch housing.
Button
Remove collar and spacer. See Figure 8-63.
4.
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.
5.
Remove the switch position plate by pulling tabs from
f1476x8x
BOTTOM VIEW
slots in fairing cap. If necessary, raise the fairing cap
slightly to facilitate removal.
Figure 8-62. Ignition Switch Knob Release Button
2005 Touring: Electrical
8-51
HOME
6.
With the forks turned fully to the left, disconnect the Fair-
ing cap switch connector
[105],
12-place Multilock
Ignition Switch
(black), from behind right side of fairing cap. Depress the
Connector [33]
button on the plug side of the connector to pull apart the
pin and socket halves.
7.
Remove the fairing cap from the motorcycle. See Figure
8-64.
8.
Locate the Ignition switch connector [33], 4-place Pack-
ard, at bottom of radio. Slide
connector off anchor and
separate pin and socket halves. See Figure 8-65.
9.
Remove the socket screws (with flat washers) and lift the
switch housing from the upper fork bracket bore. Route
the Ignition switch connector to rear of inner fairing and
remove switch housing from the vehicle.
INSTALLATION
1.
Slide base of ignition switch into bore of upper fork
f2238x8x
bracket. Install screws (with flat washers) and tighten to
36-60 in-lbs (4.1-6.8 Nm).
Figure 8-65. Ignition Switch Connector Location
(FLHT/C/U)
2.
Route the Ignition switch connector [33], 4-place Pack-
ard, to front of inner fairing. Mate pin and socket halves
of connector and install onto anchor at bottom of radio.
See Figure 8-65.
6.
Install switch position plate fitting tabs in slots of fairing
cap. Plate snaps in place when properly installed. Exer-
3.
Verify that the rubber grommets are installed on each
cise care to avoid breaking tabs. Replace plate if tabs
side of the fairing cap. Barbs on cap fit into holes in
are broken.
grommets.
4.
Connect the Fairing cap switch connector [105], 12-
7.
Using a T27 TORX drive head, start two fairing cap
place Multilock (black), on the right side of fairing cap.
screws (with flat washers). Verify that grommets in fair-
ing cap fully capture handlebar along with throttle and
5.
With the forks turned fully to the left, install fairing cap
clutch cables.
over ignition switch housing.
8.
Slide spacer over threaded post of ignition switch hous-
ing until it contacts switch position plate. Slide collar over
post with the tab side down (and forward). Install nut,
f1305b2x
and using a 7/8 inch wrench on flats, tighten to 50-70 in-
lbs (5.7-7.9 Nm).
9.
With the red arrow pointing toward the ACCESS posi-
tion, install the ignition switch knob. Turn key clockwise
to UNLOCK position and then turn knob to OFF.
10.
Using a T27 TORX drive head, tighten two fairing cap
screws to 25-30 in-lbs (2.8-3.4 Nm).
11.
Verify operation of both the ignition switch and fork lock
assemblies.
12.
Install the outer fairing. See Section 2.29 UPPER FAIR-
ING/WINDSHIELD
(FLHT/C/U), OUTER FAIRING/
Fairing Cap
WINDSHIELD, INSTALLATION.
Switch Connector [105]
12-Place Multilock
Figure 8-64. Fairing Cap Assembly (FLHT/C/U)
8-52
2005 Touring: Electrical
HOME
FLHT/C/U, FLTR
(INTERNATIONAL)
REMOVAL
1. Remove the ignition switch knob as follows:
a. Insert the ignition switch key and turn to the
UNLOCK position. Leave the key installed in the
ignition switch knob.
b. Turn the front forks to the left fork stop and rotate
Figure 8-67. Ignition Switch Alignment Tool
the knob to FORK LOCK.
(Part No. HD-45962)
c. Depressing the release button at bottom (left side)
with a small screwdriver, push key down and turn 60
degrees in a counter-clockwise direction. See Fig-
ure 8-66.
d. Lift and remove knob. Be aware that spring will drop
out of bore at underside of knob when removed.
f2080x8x
f2086x8x
Figure 8-68. Bottom Alignment Tool in Threaded Post
and Rotate to Desired Position
NOTE
Button
TOP VIEW
After removal of the knob, the IGNITION SWITCH ALIGN-
MENT TOOL (HD-45962) may be used to move the switch to
other positions as required. Insert tool until bottom of handle
contacts top of threaded post, and then rotate handle in a
clockwise direction to the selected position. See Figure 8-68.
2. Turn the front forks to the right fork stop, and using a 7/8
Button
inch open end/box wrench on flats, remove nut from
threaded post of ignition switch housing.
3.
Pull collar and spacer from threaded post.
4. Remove the switch position plate by pulling tabs from
slots in fairing cap
(FLHT/C/U) or instrument nacelle
(FLTR).
5. FLTR: Remove the instrument nacelle. See Section 2.30
UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT
NACELLE, REMOVAL.
BOTTOM VIEW
FLHT/C/U: Remove the fairing cap. See Section 2.29
f2097x8x
UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING
Figure 8-66. Ignition Switch Knob Release Button
CAP, REMOVAL.
2005 Touring: Electrical
8-53
HOME
8. Disconnect the ignition switch jumper harness connector
[33], 3-place Packard, at front of ignition switch housing.
Proceed as follows:
a. Obtain the IGNITION SWITCH CONNECTOR
REMOVER (HD-45961). See Figure 8-69.
b. Gently insert end of tool into slot in ignition switch
housing until it stops.
c. Grasping jumper harness conduit and tool, pull both
at the same time to release socket housing from
ignition switch housing. See Figure 8-70.
Figure 8-69. Ignition Switch Connector Remover
NOTE
(Part No. HD-45961)
For instructions on properly removing and installing jumper
harness terminals, see APPENDIX B.4 AUTOFUSE ELEC-
TRICAL CONNECTOR.
f2090x8x
INSTALLATION
1.
Install Ignition switch jumper harness connector [33], 3-
place Packard, at front of new ignition switch housing.
2.
Slide base of ignition switch housing into bore of upper
fork bracket.
CAUTION
Verify that the threads in the upper fork bracket are clean
and in good condition. Dirty and/or damaged threads
may cause the heads of the break-away screws to snap
off before the switch housing is properly tightened.
Figure 8-70. Pull Jumper Harness Conduit and Tool
to Release Socket Housing
CAUTION
Exercise care to avoid losing heads of break-away
screws in vehicle. Vibration may cause captured heads
1WARNING
to scratch finished surfaces, chafe wires or cause other
Always wear proper eye protection when drilling. Flying
damage.
debris may result in eye injury.
3.
Install new break-away screws at base of ignition switch
housing. Turn screws in a clockwise direction until heads
6. Remove the two break-away screws at the base of the
snap off.
ignition switch housing. Proceed as follows:
4. FLTR: Install the instrument nacelle. See Section 2.30
a. Use a center punch to make a pilot hole at the top of
UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT
each break-away screw.
NACELLE, INSTALLATION.
FLHT/C/U: Install the fairing cap. See Section
2.29
b. Install a 1/8 inch left handed bit in drill and set the
UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING
drill to Reverse. Positioning the bit in the pilot hole,
CAP, INSTALLATION.
spin out the break-away screws.
5.
Install switch position plate fitting tabs in slots of fairing
NOTE
cap (FLHT/C/U) or instrument nacelle
(FLTR). Plate
If the above method fails, use a 3/16 inch bit with long shank
snaps in place when properly installed. Exercise care to
to carefully drill off heads of break-away screws. Use a pliers
avoid breaking tabs. Replace plate if tabs are broken.
to unthread the shafts from the upper fork bracket.
6.
Install spacer over threaded post of ignition switch hous-
ing until it contacts switch position plate. Orient spacer
7. Remove ignition switch housing from upper fork bracket
so that the widest side is forward and the inside tabs fit
bore.
in slots of post. See Figure 8-71.
8-54
2005 Touring: Electrical
HOME
12.
Knob was removed in ACCESS or switch may have
been moved out of the FORK LOCK position. Proceed
1.
Knob
1
as follows:
2.
Spring
3.
Nut
a. Insert alignment tool until bottom of handle contacts
4.
Collar
top of threaded post, and holding front forks at the
5.
Spacer
left fork stop, rotate handle of tool in a counter-
6.
Break-Away Screw
clockwise direction until fork locks. See Figure 8-68.
7.
Flat Washer
8.
Switch Housing
b. Remove tool and repeat step 10.
c. If knob does not install properly, move to step 13.
2
13.
Detent and switch position lugs are misaligned. This can
occur when the alignment tool (or ignition switch knob) is
3
rotated before it is properly bottomed in the ignition
switch housing. Proceed as follows:
a.
Reinstall knob inserting shaft into threaded post and
4
gently rotate knob until it drops into the partially
installed position. Take note of the position of the
knob, that is, whether it is pointing toward the rear,
5
or to ACCESS, IGNITION or OFF.
6
b.
Remove knob and insert alignment tool so that the
bottom of the handle is approximately 1/2-3/4 inch
(12.7-19.1 mm) from the top of the threaded post,
and then hold. See Figure 8-72.
7
c.
Rotate alignment tool in a counter-clockwise
direction the number of positions needed to get to
8
f2116x8x
FORK LOCK. For example, if the knob dropped into
the partially installed position at IGNITION in step
Figure 8-71. Ignition Switch Assembly (International)
13(a), rotate the alignment tool two positions in a
counter-clockwise direction. Or if the knob was
pointing toward the rear when it dropped, rotate the
7.
Slide collar over threaded post until it contacts spacer.
alignment tool four positions in a counter-clockwise
Orient collar so that the outside tab is forward and the
direction or one position in a clockwise direction.
inside tabs fit in slots of post.
Repeat step 10.
8.
Thread nut onto post with the lipped side down and the
smaller OD topside. Turn the front forks to the right fork
stop, and using a 7/8 inch Open End Crow Foot on flats,
tighten nut to 125-150 in-lbs (14.1-16.9 Nm).
9.
Install spring into bore at underside of knob.
10.
With the knob pointing toward the FORK LOCK position,
insert shaft into threaded post. Holding the knob down,
turn key clockwise to UNLOCK. An audible “click” should
be heard when knob and switch are properly engaged.
Release knob and then rotate through all four switch
positions to verify proper operation.
If knob will not install properly, move to step 11.
11.
Proceed as follows:
a. Verify that button at bottom of knob is depressed
f2087x8x
and key is turned 60 degrees beyond the UNLOCK
position. See Figure 8-66.
Figure 8-72. Rotate Alignment Tool Without Bottoming
b. Repeat step 10.
c. If knob does not install properly, move to step 12.
2005 Touring: Electrical
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HOME
6. Raise instrument console and bend back flexible clamp
Ignition/Light
on canopy to release main harness conduit. Depress
Key Switch Connector [33]
button on socket side and remove fuel level sender/fuel
pump connector [141], 3-place Mini-Deutsch.
7. Lay a clean shop towel on forward part of rear fender.
Lift the instrument console from fuel tank and lay upside
down on shop towel.
8. Pull external latches outward to disconnect ignition/light
key switch connector [33], 3-place Packard. See Figure
8-73.
9. Remove four screws to release switch from console.
Installation
1.
Align holes in new switch with those in console. See Fig-
ure 8-73.
2.
Start four screws and alternately tighten to 20-30 in-lbs
(2.3-3.4 Nm) in a crosswise pattern.
3.
Connect ignition/light key switch connector [33], 3-place
Packard.
Screw
f2095x8x
4.
Slide head of console mounting bolt into slot at top of
canopy.
Figure 8-73. Instrument Console (FLHR/C)
5.
Moving instrument console toward installed position,
install fuel level sender/fuel pump connector [141], 3-
place Mini-Deutsch, at top of canopy. Bend flexible
FLHR/C/S
clamp to capture main harness conduit.
6.
Align hole in instrument console with console mounting
bolt and place into position on fuel tank.
IGNITION/LIGHT KEY SWITCH
7.
Install acorn nut at top of instrument console and tighten
to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
Removal
Phillips screw and large flat washer (absent on FLHRS
models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).
1. Remove seat. See Section 2.24 SEAT, REMOVAL.
8.
On FLHRS models only, install bolt (with flat washer) to
secure rear of fuel tank and instrument console bracket
to frame backbone. Tighten bolt to 15-20 ft-lbs (20-27
1WARNING
Nm).
To protect against shock and accidental start-up of vehi-
9.
Snap anchor of new cable strap into hole on left side of
cle, disconnect the negative battery cable before pro-
frame backbone. Tighten cable strap capturing main har-
ceeding. Inadequate safety precautions could result in
ness bundle, instrument console conduit, and fuel vapor
death or serious injury.
vent tube. Cut any excess cable strap material.
10.
Insert bolt through battery negative cable (black) into
2. Unthread bolt and remove battery negative cable (black)
threaded hole of battery negative (-) terminal. Tighten
from battery negative (-) terminal.
bolt to 60-96 in-lbs (6.8-10.9 Nm).
3. Carefully cut anchored cable strap securing main har-
11.
Install seat. See Section 2.24 SEAT, INSTALLATION.
ness bundle, instrument console conduit, and fuel vapor
vent tube to left side of frame backbone.
4. Remove acorn nut from instrument console. If present,
FORK LOCK
also remove Phillips screw and large flat washer (absent
Removal
on FLHRS models).
1. Remove the handlebar clamp shroud. See Section 2.31
5. On FLHRS models only, remove bolt (with flat washer) to
WINDSHIELD/HEADLAMP NACELLE
(FLHR/C/S),
free rear of fuel tank from frame backbone. Removal of
NACELLE REMOVAL
(FLHR/C), steps
1-11, or
rear bolt also releases instrument console bracket.
NACELLE REMOVAL (FLHRS), steps 1-7.
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2005 Touring: Electrical
HOME
3. Install the handlebar clamp shroud. See Section 2.31
WINDSHIELD/HEADLAMP NACELLE
(FLHR/C/S),
NACELLE INSTALLATION (FLHR/C), steps 3-15, or
f2101x8x
NACELLE INSTALLATION (FLHRS), steps 5-13.
Figure 8-74. Fork Lock (FLHR/C/S)
2. Start acorn nuts on both the left and right side fork studs
to keep halves of headlamp nacelle on motorcycle.
3. Remove two allen head socket screws (with flat wash-
ers) and pull fork lock assembly from upper fork bracket
bore. See Figure 8-74.
NOTE
On HDI models, use a center punch to make a pilot hole at
the top of each break-away screw. Install a 1/8 inch left
handed bit in drill and set the drill to reverse. Positioning the
bit in the pilot hole, spin out the break-away screws.
Installation
1. Install new fork lock assembly into bore of upper fork
bracket. See Figure 8-74.
2. Install two allen head socket screws (with flat washers)
and alternately tighten to 36-60 in-lbs (4.1-6.8 Nm).
NOTE
On HDI models, install new break-away screws and turn in a
clockwise direction until heads snap off. Verify that threads in
upper fork bracket are clean and in good condition or heads
may break off before fork lock assembly is properly tightened.
Avoid losing heads of screws in vehicle as vibration may
cause captured heads to scratch finished surfaces, chafe
wires or cause other damage.
2005 Touring: Electrical
8-57
HOME
FAIRING CAP SWITCHES (FLHTC/U)
8.19
REMOVAL
f1240x2x
1. Partially disassemble domestic ignition switch as follows:
NOTE
For partial disassembly of HDI ignition switch, see Section
8.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK,
FLHT/C/U, FLTR (INTERNATIONAL), REMOVAL, steps 1-4.
a. See Figure
8-75. To remove the ignition switch
knob, insert the Ignition Switch key and turn to the
UNLOCK position. Leaving the key installed, rotate
Button
the knob to ACCESS. Depressing the release but-
TOP VIEW
ton 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.
BOTTOM VIEW
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.
Button
c. Gently remove the switch position plate by pulling
tabs from slots in fairing cap. If necessary, raise the
fairing cap slightly to facilitate removal.
2.
Using a T27 TORX drive head, remove the two screws
f1476x8x
(with flat washers) that secure fairing cap to left and right
sides of inner fairing.
Figure 8-75. Ignition Switch Knob Release Button
3.
With the forks turned fully to the left, disconnect the fair-
ing cap switch connector
[105],
12-place Multilock
(black), from behind right side of fairing cap. Depress the
10. Remove the appropriate terminals from the socket hous-
button on the socket terminal side of the connector and
ing.
pull apart the pin and socket halves.
NOTE
4.
Remove the fairing cap from the motorcycle. See Figure
8-76.
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
5.
Bend back the flexible clamp to release switch wires
TORS, REMOVING SOCKET/PIN TERMINALS.
from the inboard side of the fairing cap. Carefully cut
cable straps to free wires from bundles.
6.
Using a T25 TORX drive head, remove two screws to
release switch bracket.
INSTALLATION
7.
Gently pry two latches on bracket outward to release
tabs on switch. Remove switch from bracket. See Figure
1.
Feeding wires through bracket, place new switch into
8-77.
position. Engage tabs on switch in slots of latches and
then gently bend tabs upward to lock position of switch
8.
If replacing Cruise or Speaker Switch, cut Black/Green
in bracket.
wire lead halfway between Cruise and Speaker Switch
terminals.
2.
Install terminals into socket housing.
9.
Follow the wires of the faulty switch to the socket hous-
NOTE
ing, or reference Figure 8-78 and Table 8-10 for the
applicable chamber numbers. For wire location pur-
For instructions on properly installing wire terminals, see
poses, numbers are stamped into the secondary locks of
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
both the pin and socket housings.
TORS, INSTALLING SOCKET/PIN TERMINALS.
8-58
2005 Touring: Electrical
HOME
Accessory
Switch
f1305b2x
Cruise
Bracket
Switch
Grommet
Switch
Speaker
Switch
Auxiliary
Lamp Switch
Cable
Strap
Grommet
Flexible
Clamp
Socket Housing
Cable
12-place Multilock
Switch Bracket
Strap
Fairing Cap Switch Connector [105]
TORX Screws
Figure 8-76. Fairing Cap (Inboard Side) - Ultra Model Shown
3. If Cruise or Speaker Switch was replaced, butt splice
Black/Green wire lead between Cruise and Speaker
Latch
Switch terminals.
NOTE
Tab
For detailed butt splicing information, see APPENDIX B.5
SEALED BUTT SPLICE CONNECTORS.
4. Using a T25 TORX drive head, install two screws to
secure switch bracket to fairing cap.
5. Install new cable straps to capture wire bundles and
then secure switch wires to the fairing cap using the flex-
Switch
ible clamp. Route the wires as shown in Figure 8-76.
Bracket
6. Verify that the rubber grommets are installed on each
side of the fairing cap. Barbs on cap fit into holes in
grommets.
7. Connect the fairing cap switch connector [105], 12-place
Cable
Multilock (black), on the right side of fairing cap.
Strap
8. With the forks turned fully to the left, install fairing cap
over ignition switch housing. Verify that grommets in fair-
ing cap fully capture handlebar along with throttle and
clutch cables.
9. Start two fairing cap screws (with flat washers). Using a
f1304b2x
T27 TORX drive head, alternately tighten screws to 25-
30 in-lbs (2.8-3.4 Nm).
Figure 8-77. Bend Latches Outward to Release Tabs
2005 Touring: Electrical
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HOME
10. Assemble domestic ignition switch as follows:
NOTE
For assembly of HDI ignition switch, see Section 8.18 IGNI-
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-
ing cap. Plate snaps in place when properly
installed. Exercise care to avoid breaking tabs.
- AMP
6
7
8
9
10
11
12
Replace plate if tabs are broken.
b.
Slide spacer over threaded post of ignition switch
Secondary Locks Open
f1287b2x
housing until it contacts switch position plate.
c.
Slide collar over post with the tab side down (and
Figure 8-78. Numbers Stamped on Secondary Locks
forward).
(Socket Housing Shown)
d.
Install nut, and using a 7/8 inch wrench on flats,
Table 8-10. Fairing Cap Switches [105]
tighten to 50-70 in-lbs (5.7-7.9 Nm).
e.
With the red arrow pointing toward the ACCESS
Chamber
Switch
Wire Color
Number
position, install the ignition switch knob. Turn key
clockwise to UNLOCK position and then turn knob
Orange/Red
1
to OFF.
Accessory
Orange
2
Black
3
Orange/Violet
4
Cruise
Red/Green
5
Ultra Only
To
Black/Green
12
Speaker
(Double Lugged)
Switch
Yellow
6
Auxiliary
Gray/Black
7
Lamp
Black
8
Orange/Blue
9
Speaker
Violet/Orange
10
Ultra Only
Brown/Orange
11
Black/Green
To Cruise Switch
8-60
2005 Touring: Electrical
HOME
INSTRUMENT NACELLE SWITCHES (FLTR)
8.20
NOTE
REMOVAL
For partial disassembly of HDI ignition switch, see Section
8.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK,
1. Using a T25 TORX drive head, remove screw on left and
FLHT/C/U, FLTR (INTERNATIONAL), REMOVAL, steps 1-4.
right side of instrument bezel.
a. To remove the ignition switch knob, insert the Igni-
2. Use thumbs to push tab at rear of bezel from slot in front
tion Switch key and turn to the UNLOCK position.
of ignition switch. Gently raise free side of bezel until
Leaving the key installed, rotate the knob to
tabs at front of instrument nacelle become disengaged
ACCESS. Depressing the release button at bottom
from slot at front of bezel (concealed behind decorative
(left side) with a small screwdriver, push key down
adhesive strip).
and turn an additional 60 degrees in a counter-
clockwise direction. Lift and remove knob. See
3. Raising bezel slightly, remove anchor on ambient tem-
upper frame of Figure 8-80.
perature sensor from hole in bottom inboard ear of
b. Using a 7/8 inch wrench on flats, loosen switch nut
speedometer bracket.
and remove from threaded post of ignition switch
housing. Remove collar and spacer. See lower
4. See Figure 8-79. Disconnect instruments and indicator
frame of Figure 8-80.
lamps from interconnect harness as follows:
c. Remove the switch position plate from threaded
● Speedometer connector [39], 12-place Packard.
post of ignition switch housing.
● Tachometer connector [108], 12-place Packard.
7.
Follow instructions based on location of defective switch.
● Indicator lamps connector [21], 10-place Multilock.
LEFT SIDE SWITCH
5. Remove bezel from motorcycle.
a. See Figure 8-79. Disconnect left side switch from
6. Partially disassemble domestic ignition switch as follows:
instrument nacelle switch harness as follows:
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 8-79. Instrument Nacelle (Bezel Removed)
2005 Touring: Electrical
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HOME
RIGHT SIDE SWITCHES
TOP VIEW
BOTTOM VIEW
a.
See Figure 8-79. Disconnect left side switch from
instrument nacelle switch harness as follows:
●
Speaker Switch connector [105], 4-place Multilock.
b.
See Figure 8-79. Disconnect instrument nacelle
switches from interconnect harness as follows:
●
Instrument nacelle switch connector [105], 12-place
Multilock.
Button
c.
Pull throttle cable clip from hole on right side of
Button
instrument nacelle.
f1240x2x
f1476x8x
d.
Using a T40 TORX drive head, remove two bolts
(with flat washers) to release right side of instru-
f1297b2x
ment nacelle from upper and lower fork brackets.
Move right side of nacelle to bench area leaving left
side on motorcycle. See Figure 8-83.
e.
Gently bend back molded retainer to release switch
bracket assembly from instrument nacelle.
Knob
f.
Carefully pry two latches on bracket outward to
release tabs on switch. Remove switch from
Nut
bracket. See Figure 8-81.
g.
Remove the appropriate terminals from the socket
and pin housings. Follow the wires of the faulty
Tab
Collar
switch or reference Table 8-11 for the applicable
Down and Forward
chamber numbers. For wire location purposes,
numbers are stamped into the secondary locks. See
Figure 8-82.
Spacer
Figure 8-80. Ignition Switch Knob (Domestic)
Latch
Tab
● Speaker Switch connector [105], 4-place Multilock.
b. Pull clutch cable clip from hole on left side of instru-
ment nacelle.
c. Using a T40 TORX drive head, remove two bolts
Switch
(with flat washers) to release left side of instrument
Bracket
nacelle from upper and lower fork brackets.
d. Unthread rubber boot from odometer reset switch,
and while carefully removing left side instrument
nacelle from motorcycle, pull odometer reset switch
from hole. Move left side of nacelle to bench area
leaving right side on motorcycle. See Figure 8-83.
e. Gently bend back molded retainer to release switch
bracket assembly from instrument nacelle.
f.
Carefully pry two latches on bracket outward to
f2215x8x
release tabs on switch. Remove switch from
bracket. See Figure 8-81.
Figure 8-81. Bend Latches Outward to Release Tabs
8-62
2005 Touring: Electrical
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Table 8-11. Right Side
b. Snap switch bracket into molded retainer in instru-
ment nacelle.
Instrument Nacelle Switches
c. While carefully placing left side of instrument
Chamber Number
nacelle on motorcycle, slide odometer reset switch
through hole and install rubber boot.
Switch
Wire Color
12-Place
4-Place
Multilock
Multilock
d. See Figure 8-79. Connect left side switch to instru-
Socket
Pin
ment nacelle switch harness as follows:
● Speaker Switch connector [105], 4-place Multilock.
Orange/Red
1
e. Using a T40 TORX drive head, install two bolts (with
Accessory
Orange
2
flat washers) to fasten left side instrument nacelle to
Black
3
upper and lower fork brackets. Alternately tighten
bolts to 15-20 ft-lbs (20-27 Nm).
Orange/Violet
4
f.
Capture clutch cable in cable clip. Insert cable clip
Red/Green
5
into hole in left side of instrument nacelle.
Cruise
Black/Green
g. Move to RIGHT SIDE SWITCHES, step 2.
12
4
(Double Lugged)
RIGHT SIDE SWITCHES
a. Place new switch into position in bracket. Engaging
tabs on switch in slots of latches, gently bend tabs
upward to lock position of switch in bracket. See
Figure 8-81.
b. Push terminals through two lengths of conduit to
wire end of socket or pin housing. For best results,
push one wire through conduit at a time.
– AMP
c. Install terminals into socket or pin housing. See
6
7
8
9
10
11
12
Table 8-11 and Figure 8-82.
Secondary Locks Open
NOTE
f1287b2x
For instructions on properly installing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
Figure 8-82. Numbers Stamped on Secondary Locks
TORS, INSTALLING SOCKET/PIN TERMINALS.
(Socket Housing Shown)
d. Snap switch bracket into molded retainer in instru-
ment nacelle.
NOTE
e. Install right side of instrument nacelle on motorcy-
For instructions on properly removing wire terminals, see
cle.
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
f.
See Figure 8-79. Connect left side switch to instru-
TORS, REMOVING SOCKET/PIN TERMINALS.
ment nacelle switch harness as follows:
h. Carefully pull wires to draw terminals through con-
● Speaker Switch connector [105], 4-place Multilock.
duit to backside of switch. For best results, pull one
wire at a time.
g. See Figure
8-79. Connect instrument nacelle
switches to interconnect harness as follows:
● Instrument nacelle switch connector [105], 12-place
Multilock.
INSTALLATION
h. Using a T40 TORX drive head, install two bolts (with
flat washers) to fasten right side instrument nacelle
1. Follow instructions based on location of defective switch.
to upper and lower fork brackets. Tighten bolts to
15-20 ft-lbs (20-27 Nm).
LEFT SIDE SWITCH
i.
Capture throttle cables in cable clip. Insert cable clip
a. Place new switch into position in bracket. Engaging
into hole in right side of instrument nacelle.
tabs on switch in slots of latches, gently bend tabs
upward to lock position of switch in bracket.
2.
Assemble domestic ignition switch as follows:
2005 Touring: Electrical
8-63
HOME
f2214x8x
CONNECTOR
DESCRIPTION
NUMBER
[A, C] = Pin
[B, D] = Socket
LEFT SIDE
[105A, 105B]
Interconnect to Nacelle Switch Harness
[105]
[105C, 105D]
Nacelle Switch Harness to Speaker Switch
Clutch
Cable Clip
RIGHT SIDE
Speaker
Switch [105D]
4-Place Multilock
Throttle
Cable Clip
Instrument Nacelle
Switches [105B]
12-Place Multilock
Speaker
Switch [105C]
4-Place Multilock
f2213x8x
Figure 8-83. Instrument Nacelle Halves
NOTE
c. With the red arrow pointing toward the ACCESS
position, install the ignition switch knob. Turn key
For assembly of HDI ignition switch, see Section 8.18 IGNI-
clockwise to UNLOCK position and then turn knob
TION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U,
to OFF.
FLTR (INTERNATIONAL), INSTALLATION, steps 5-10.
3. See Figure 8-79. Looking into the instrument nacelle,
a. Install the switch position plate over threaded post
connect instruments and indicator lamps to interconnect
of ignition switch housing. Tabs on plate fit in holes
harness as follows:
at top of instrument nacelle.
● Speedometer connector [39], 12-place Packard.
b. Slide spacer over threaded post of ignition switch
● Tachometer connector [108], 12-place Packard.
housing until it contacts switch position plate. Slide
collar over post with the tab side down (and for-
● Indicator lamps connector [21], 10-place Multilock.
ward). Install nut, and using a 7/8 inch wrench on
flats, tighten to
50-70 in-lbs
(5.7-7.9 Nm). See
4.
Install anchor on ambient temperature sensor into hole
lower frame of Figure 8-80.
in bottom inboard ear of speedometer bracket.
8-64
2005 Touring: Electrical
HOME
5. Verify that left and right sides of instrument nacelle are
NOTE
properly mated. Pins on left side of nacelle must fully
engage holes on right.
If tabs do not properly engage slot at front of bezel, then a
loose fit will result. Remove decorative adhesive strip by gen-
tly prying up outer edges, and using a flat bladed screwdriver,
6. Insert tab at rear of bezel into slot of instrument nacelle
(just in front of ignition switch). Holding left and right
carefully raise tabs so that they engage lip in slot. If dam-
aged, install new decorative adhesive strip.
sides of nacelle together, place bezel over instrument
nacelle flange. When properly mated, tabs at front of
instrument nacelle engage lip in slot at front of bezel
7.
Using a T25 TORX drive head, install screw on each
(behind decorative adhesive strip).
side of bezel. Tighten screws to 25-35 in-lbs (2.8-4.0
Nm).
2005 Touring: Electrical
8-65
HOME
HANDLEBAR SWITCHES
8.21
NOTE
GENERAL
Use the eyelet of an ordinary cable strap if the cardboard
insert is not available.
The basic switch configuration is the “Road King.” The Road
King switches have no specialized functions. Other switches,
1.
Place the cardboard insert between the brake lever and
referred to as the Road King Classic, Classic and Ultra, have
lever bracket. See Figure 8-84.
additional functions, such as cruise control, sound system
2.
Using a T27 TORX drive head, remove the two screws
controls, etc., which cause them to differ from the Road King
with flat washers securing the handlebar clamp to the
switches. To accommodate these added functions, special
master cylinder housing. Remove the brake lever/master
lower switch housings are provided.
cylinder assembly and clamp from the handlebar.
NOTE
3.
Using a T25 TORX drive head, remove the upper and
Regardless of model or option, all vehicles use the same
lower switch housing screws.
upper switch housings. The vehicles and their switch configu-
4.
Remove the friction shoe from the end of the tension
rations are as follows:
adjuster screw (non cruise equipped models only).
Table 8-12. Handlebar Switches
NOTE
The friction shoe is a loose fit and may fall out or become dis-
Road King
lodged if the lower switch housing is turned upside down or
FLHR
FLHRI
FLHRS
FLHRSI
shaken.
Road King Classic
5.
Remove the brass ferrules from the notches on the
inboard side of the throttle control grip. Remove the fer-
FLHRCI
rules from the cable end fittings.
Classic
6.
Remove the throttle control grip from the end of the han-
dlebar.
FLHT
FLHTI
FLHTC
FLHTCI
7.
Pull the crimped inserts at the end of the throttle and idle
Ultra
control cable housings from the lower switch housing.
For best results, use a rocking motion while pulling.
FLTRI
FLHTCUI
Place a drop of light oil on the retaining rings, if neces-
NOTE: See Figures 8-92 thru 8-95 for illustrations.
sary. Remove the cables from the switch housing.
8.
Cut two cable straps to release wire harness conduit
NOTE
from handlebar.
To replace or repair individual switches in either the right or
left handlebar switch assemblies, see SWITCH REPAIR/
REPLACEMENT in this section.
7959
REMOVAL
NOTE
While there are four different switch configurations for Touring
models (Road King, Road King Classic, Classic and Ultra),
the removal procedures are the same. To simplify these
instructions, only the Road King switch configuration is repre-
sented in the photographs and illustrations which follow.
RIGHT HANDLEBAR CONTROLS
CAUTION
5/32 Inch
(4.0 mm)
Do not remove the switch housing assembly without first
Cardboard
placing the 5/32 inch (4.0 mm) cardboard insert between
Insert
the brake lever and lever bracket. Removal without the
insert may result in damage to the rubber boot and
Figure 8-84. Install Cardboard Insert
plunger of the Front Stoplight Switch.
8-66
2005 Touring: Electrical
HOME
LEFT HANDLEBAR CONTROLS
7958
1. Using a T27 TORX drive head, remove the two screws
Upper
with flat washers securing the handlebar clamp to the
Switch Housing
clutch lever bracket. Remove the clutch hand lever
Cable
assembly and clamp from the handlebar.
End
Fittings
2. Using a T25 TORX drive head, remove the upper and
lower switch housing screws.
3. Cut two cable straps to release wire harness conduit
from handlebar.
4. Remove hand grip from handlebar, if damaged. See
Section
2.23 HANDLEBARS, LEFT HAND GRIP,
REMOVAL.
INSTALLATION
Figure 8-86. Route Cable to Upper Switch Housing
NOTE
While there are four different switch configurations for Touring
Note the different diameter inserts crimped into the end
models (Road King, Road King Classic, Classic and Ultra),
of the throttle and idle control cable housings. See Fig-
the installation procedures are the same. To simplify these
ure 8-85.
instructions, only the Road King switch configuration is repre-
Push the larger diameter insert (silver) on the throttle
sented in the photographs and illustrations which follow.
cable housing into the larger hole in front of the tension
adjuster screw.
RIGHT HANDLEBAR CONTROLS
Push the smaller diameter insert (gold) on the idle cable
housing into the smaller hole at the rear of the tension
1. With the concave side facing upward, install the friction
adjuster screw.
shoe so that the pin hole is over the point of the adjuster
screw (non cruise equipped models only).
NOTE
NOTE
To aid assembly, place a drop of light oil on the retaining
The friction shoe is a loose fit and may fall out or become dis-
rings of the crimped inserts. Always replace the retaining
lodged if the switch housing is turned upside down or
rings if damaged or distorted.
shaken.
3.
Route the cable to the upper switch housing as shown in
2. Push the throttle and idle control cables into the lower
Figure 8-86.
switch housing until they snap in place. Proceed as fol-
lows:
4.
Slide the throttle control grip over the end of the right
handlebar until it bottoms against the closed end. Rotate
the grip so that the ferrule notches are at the top. To pre-
vent binding, pull the grip back about 1/8 inch (3.2 mm).
7961
5.
Position the lower switch housing beneath the throttle
Lower
control grip. Install the brass ferrules onto the cables so
Switch
that the end fittings seat in the ferrule recess. Seat the
Housing
ferrules in their respective notches on the throttle control
grip. Verify that the cables are captured in the grooves
molded into the grip. See Figure 8-87.
6.
Position the upper switch housing over the handlebar
and lower switch housing.
Throttle
Cable Insert
7.
Verify that the wire harness conduit runs in the depres-
(Silver)
sion at the bottom of the handlebar. Be sure that the
Idle
upper switch housing harness will not be pinched under
Cable Insert
the handlebar when the switch housing screws are tight-
(Gold)
ened.
8.
Start the upper and lower switch housing screws, but do
Figure 8-85. Install Throttle/Idle Control Cables
not tighten.
in Lower Switch Housing
2005 Touring: Electrical
8-67
HOME
f1474x2x
Idle
CAUTION
Throttle
Cable
Cable
See Figure 8-88. Do not remove the 5/32 inch (4.0 mm)
cardboard insert (or cable strap eyelet) wedged between
the brake lever and lever bracket. Removal will result in
damage to the rubber boot and plunger of the Front
Throttle
Stoplight Switch during installation of the master cylin-
Grip
der assembly.
9.
Position the brake lever/master cylinder assembly
inboard of the switch housing assembly engaging the
tab on the lower switch housing in the groove at the top
of the brake lever bracket. See Figure 8-89.
10. Align the holes in the handlebar clamp with those in the
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.
11. 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.
Groove
Notch
Ferrule
12. Remove the cardboard insert between the brake lever
and lever bracket.
Figure 8-87. Install Throttle/Idle Control Cables on
Throttle Control Grip
The completed assembly appears as shown in Figure 8-
92.
f1225x2x
13. Secure wire harness conduit to handlebar using two
new cable straps. Position first cable strap approxi-
mately 4-5 inches (102-127 mm) from handlebar clamp.
Cut any excess cable strap material.
14. Test the switches for proper operation.
Groove
f1785x8x
Brake
Lever
Bracket
Tab
Groove
5/32 Inch
(4.0 mm)
Cardboard
Insert
Switch
Housing
Assembly
Figure 8-88. Leave Cardboard Insert in Place
Figure 8-89. Fit Brake Lever/Master Cylinder to
Right Handlebar Switch Housings
8-68
2005 Touring: Electrical
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7964
7966
Tab
Groove
Switch
Grip
Clutch
Housing
Sleeve
Lever
Assembly
Ribs
Bracket
Figure 8-91. Fit Clutch Lever Bracket to
Left Handlebar Switch Housings
Grooves
7.
Using a T25 TORX drive head, tighten the lower and
upper switch housing screws to 35-45 in-lbs (4-5 Nm).
Figure 8-90. Install Left Handlebar Switch Housings
NOTE
Always tighten the lower switch housing screw first so that
any gap between the upper and lower housings is at the front
LEFT HANDLEBAR CONTROLS
of the switch.
1.
Install new hand grip, if removed,. See Section 2.23
The completed assembly appears as shown in Figure 8-
HANDLEBARS, LEFT HAND GRIP, INSTALLATION.
92.
2.
Install upper and lower switch housings on handlebar.
8.
Secure wire harness conduit to handlebar using two
Be sure that ribs on outboard side of switch housings fit
new cable straps. Position first cable strap approxi-
in grooves molded into grip. See Figure 8-90.
mately 4-5 inches (102-127 mm) from handlebar clamp.
Cut any excess cable strap material.
3.
Verify that the wire harness conduit runs in the groove at
9.
Test the switches for proper operation.
the bottom of the handlebar. Be sure that the upper
switch housing harness will not be pinched under the
handlebar when the switch housing screws are tight-
ened.
4.
Start the upper and lower switch housing screws, but do
not tighten.
5.
Position the clutch hand lever assembly inboard of the
switch housing assembly engaging the tab on the lower
switch housing in the groove at the bottom of the clutch
lever bracket. See Figure 8-91.
6.
Align the holes in the handlebar clamp with those in the
clutch lever bracket 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.
2005 Touring: Electrical
8-69
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