Harley Davidson 2005 touring models. Service repair manual — page 66
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MOTOR (PUMP)/RELAY: DTC 5-1, 5-2, 5-3, 5-4
A.14
GENERAL
9468
The codes will set if the motor voltage is out of parameter for
an extended period.
Table A-14. Code Description
DTC
DESCRIPTION
5-1
Motor Locks
5-2
Motor Failed OFF
5-3
Motor Failed ON
5-4
Fail Safe Relay Failed ON/Failed OFF/Sticks
Figure A-34. ABS Module
DIAGNOSTICS
HD41404-46
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the Test A.14 flow chart.
1. Obtain DARK BLUE PIN PROBES (Part No. HD-41404-
46) and patch cord from HARNESS CONNECTOR TEST
KIT (Part No. HD-41404A).
1WARNING
Figure A-35. Dark Blue Pin Probes (Part No. HD-41404-46)
Use only gray pin probes from HARNESS CONNECTOR
TEST KIT (Part No. HD-41404A) on small terminals (1-7,
10-23) of ABS Module connector [166B], and dark blue
pin probes on large terminals (8-9, 24-25). Use of the
wrong probes can damage terminals causing insufficient
or excessive current to be passed to solenoid valves
and/or pump, a condition which could cause the ABS to
malfunction, possibly resulting in death or serioius
injury.
Appendix A: Anti-Lock Brake System A-37
HOME
f2335e8x
ABS MODULE
[166A] [166B]
20 AMP FUSES
ABS SOLENOID POWER
8
R/V
R TO +BATT (TERMINAL B OF MAXI-FUSE)
9
R/V
ABS MOTOR/PUMP POWER
FUSE BLOCK [64]
FLHP/E
FLHTP
FLHP/E Fuse Block
FLHTP Fuse Block
Wire
10A
Wire
Fuse
Cavity
Color
20A
10A
20A
Fuse
Cavity
Color
BRAKE
BRAKE
4H
R/V
RELAY
15A
20A
20A
RELAY
15A
15A
3H
R/V
Solenoid
START
Solenoid
4G
R
3G
R
RELAY
15A
15A
15A
15A
15A
15A
3B
R/V
4H
R/V
Motor
Motor
3A
R
15A
15A
15A
15A
15A
15A
15A
15A
4G
R
24
BK
ABS MODULE CONNECTOR [166A]
25
BK
2
ABS MODULE CONNECTOR [166B]
1
ABS MODULE PINOUT:
8
+BATTERY-SOLENOID POWER
9
+BATTERY-MOTOR POWER
24
GROUND
25
GROUND
Figure A-36. ABS Motor/Pump Circuit
Table A-15. Wire Harness Connectors in Figure A-36.
NO.
DESCRIPTION
MODEL
TYPE
LOCATION
ABS Solenoid Power Fuse
All
20 Amp (Red)
Fuse Block (Under Left Side Cover)
[64]
ABS Motor/Pump Power Fuse
All
20 Amp (Red)
Fuse Block (Under Left Side Cover)
[166]
ABS Module
All
25-place Amp
Under Right Side Saddlebag
A-38
Appendix A: Anti-Lock Brake System
HOME
Test A.14 (Part 1 of 1)
MOTOR (PUMP)/RELAY: DTC 5-1, 5-2, 5-3, 5-4
Place hand on ABS module.
Does ABS module vibrate like
internal motor is running?
YES
NO
Replace ABS
Check for voltage between sock-
1
module.
ets 9 (+) and 25 (-) of connector
[166B]. Is battery voltage present?
2430
YES
NO
Check for continuity to ground
Check for continuity to ground
on socket 24 of connector
on socket 25 of connector
[166B]. Continuity present?
[166B]. Continuity present?
YES
NO
YES
NO
Check for blown
Locate and repair open on BK
ABS motor power
wire between socket 25 of
Replace ABS
Locate and repair open
fuse. Fuse blown?
connector [166B] and ground.
module.
on BK wire between
socket 24 of connector
2417
2430
[166B] and ground.
2417
YES
NO
Check for continuity to
Check for continuity to ground
ground on socket 9 of
on socket 9 of connector
connector [166B].
[166B] to ABS motor power
Continuity present?
fuse. Continuity present?
YES
NO
YES
NO
Locate and repair short to
Replace ABS
Replace ABS
Locate and repair open on
ground on R/V wire between
motor power
module.
R/V wire between socket 9
socket 9 of connector [166B] and
fuse.
of connector [166B] and
ABS motor power fuse. Replace
2430
ABS motor power fuse.
2474
ABS motor power fuse.
2427
2427
After repair of motorcycle, perform Final Diag-
nostic Check to confirm proper operation without
setting codes. See Section A.6 INITIAL/FINAL
DIAGNOSTIC CHECK.
Appendix A: Anti-Lock Brake System A-39
HOME
BATTERY VOLTAGE: DTC 6-1, 6-2
A.15
GENERAL
2
FLHP/E
The codes will set when battery voltage at terminal 16 is out
of parameter for an extended period.
3
1
Table A-16. Code Description
DTC
DESCRIPTION
6-1
Below Normal
f2305x8x
6-2
Above Normal
FLHTP
3
DIAGNOSTICS
2
1
Diagnostic Tips
● Low voltage generally indicates a loose wire, corroded
connections, battery and/or a charging system problem.
f2303x8x
● A high voltage condition may be caused by a faulty volt-
1.
ABS Solenoid Power
age regulator.
2.
ABS Motor/Pump Power
3.
Brakes/Pursuit
Figure A-37. Fuse Locations
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the Test A.15 flow chart.
2. Obtain HARNESS CONNECTOR TEST KIT (Part No.
HD-41404A). Use gray (small terminal) and dark blue
1.
Was battery allowed to discharge? Was battery drawn
(large terminal) pin probes and patch cord.
down by a starting problem?
a. Yes. Charge battery.
1WARNING
b. No. See charging system troubleshooting.
Use only gray pin probes from HARNESS CONNECTOR
TEST KIT (Part No. HD-41404A) on small terminals (1-7,
10-23) of ABS Module connector [166B], and dark blue
pin probes on large terminals (8-9, 24-25). Use of the
wrong probes can damage terminals causing insufficient
or excessive current to be passed to solenoid valves
and/or pump, a condition which could cause the ABS to
malfunction, possibly resulting in death or serioius
injury.
A-40
Appendix A: Anti-Lock Brake System
HOME
ABS MODULE
[166A] [166B]
20 AMP FUSES
ABS SOLENOID POWER
8
R/V
R TO +BATT (TERMINAL B OF MAXI-FUSE)
9
R/V
ABS MOTOR/PUMP POWER
FUSE BLOCK [64]
FLHP/E FLHTP
FLHP/E Fuse Block
FLHTP Fuse Block
Wire
Wire
Fuse
Cavity
Color
20A
10A
20A
10A
Fuse
Cavity
Color
BRAKE
BRAKE
4H
R/V
RELAY
20A
20A
RELAY
3H
R/V
Solenoid
START
15A
15A
15A
Solenoid
4G
R
3G
R
RELAY
15A
15A
15A
15A
15A
15A
3B
R/V
4H
R/V
Motor
Motor
3A
R
15A
15A
15A
15A
15A
15A
15A
15A
4G
R
4
3
16
O/V
2
1
1
1
2
2
3
3
[176B] [176A]
4
4
FLHP/E ONLY
5
5
24
BK
6
6
25
BK
[176B] [176A]
FLHTP ONLY
FLHTP ONLY
2
1
2
3
4
5
6
7
8
9
10
11
12
[1A]
1
[1B]
1
2
3
4
5
6
7
8
9
10
11
12
ABS MODULE PINOUT:
8
+BATTERY-SOLENOID POWER
O/V
TO BRAKES/PURSUIT
ABS MODULE CONNECTOR [166A]
FUSE
9
+BATTERY-MOTOR POWER
16
IGNITION
24
GROUND
25
GROUND
ABS MODULE CONNECTOR [166B]
f2335f8x
Figure A-38. ABS Motor/Pump Circuit
Table A-17. Wire Harness Connectors in Figure A-38.
NO.
DESCRIPTION
MODEL
TYPE
LOCATION
[1]
Main to Interconnect Harness
FLHTP
12-place Deutsch
Inner Fairing (Right Fairing Bracket)
[64]
Brakes/Pursuit Fuse
All
15 Amp (Blue)
Fuse Block (Under Left Side Cover)
[166]
ABS Module
All
25-place Amp
Under Right Side Saddlebag
Main to Interconnect Harness
FLHTP
6-place Deutsch
Inner Fairing (Right Side)
[176]
Main to Main Harness
FLHP/E
4-place Deutsch
Under Left Side Cover
Appendix A: Anti-Lock Brake System A-41
HOME
Test A.15 (Part 1 of 1)
BATTERY VOLTAGE: DTC 6-1, 6-2
Perform charging
1
system tests.
Charging system OK?
YES
NO
Check for voltage between
Repair charging
2
sockets 16 (+) and 25 (-) of
system. See Touring
connector [166B]. Is battery
Models Electrical
voltage present?
Diagnostics Manual.
YES
NO
Check for resistance to ground
Check for resistance to ground
on socket 24 of connector
on socket 25 of connector
[166B]. Resistance less than
[166B]. Resistance less than
0.5 ohms?
0.5 ohms?
YES
NO
YES
NO
Check for resistance between
Locate and repair high
Check for resistance between
Locate and repair high
socket 16 of connector [166B]
resistance on BK wire between
socket 16 of connector [166B]
resistance on BK wire between
and brakes/pursuit fuse.
socket 24 of connector [166B]
and brakes/pursuit fuse.
socket 25 of connector [166B]
Resistance less than 0.5 ohms?
and ground.
Resistance less than 0.5 ohms?
and ground.
2417
2417
YES
NO
YES
NO
Replace
Locate and repair high
Replace ABS
Locate and repair high
brakes/pursuit fuse.
resistance on O/V wire
module.
resistance on O/V wire
between socket 16 of
between socket 16 of
2472
2430
connector [166B] and
connector [166B] and
brakes/pursuit fuse.
brakes/pursuit fuse.
2462
2462
After repair of motorcycle, perform Final Diag-
nostic Check to confirm proper operation without
setting codes. See Section A.6 INITIAL/FINAL
DIAGNOSTIC CHECK.
A-42
Appendix A: Anti-Lock Brake System
HOME
TIRES: DTC 7-1
A.16
GENERAL
The code will set if tires and/or wheels are improperly
matched, or tire pressure is significantly low. See Figure A-
39.
Table A-18. Code Description
DTC
DESCRIPTION
7-1
Tire Size Difference
f2340x2x
Figure A-39. Use Only OEM Tires and Wheels
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the Test A.16 flow chart.
1. The ABS monitors the rotational speed of the wheels
through individual wheel speed sensors. Changing to dif-
ferent diameter wheels or different size tires can alter the
rotational speed. This can upset the calibration of the
ABS and have an adverse effect on its ability to detect
and prevent lockups.
Appendix A: Anti-Lock Brake System A-43
HOME
Test A.16 (Part 1 of 1)
TIRES: DTC 7-1
1
Is tire or wheel
changed from OEM
configuration?
YES
NO
Change back
Is tire inflation
to OEM
pressure low?
configuration.
YES
NO
Inflate tire.
Replace ABS
module.
2430
After repair of motorcycle, perform Final Diag-
nostic Check to confirm proper operation without
setting codes. See Section A.6 INITIAL/FINAL
DIAGNOSTIC CHECK.
A-44
Appendix A: Anti-Lock Brake System
HOME
ABS MODULE: DTC 8-1
A.17
GENERAL
9468
The code will set only if an internal failure has occurred.
Replace ABS module. See Figure A-40.
Table A-19. Code Description
DTC
DESCRIPTION
8-1
Internal Error
Figure A-40. ABS Module
Appendix A: Anti-Lock Brake System A-45
HOME
Test A.17 (Part 1 of 1)
ABS MODULE: DTC 8-1
Inspect tone ring. Is
debris present?
YES
NO
Clean tone
Is tone ring loose or
ring.
damaged?
2460
YES
NO
Replace brake
Inspect wheel speed
disc.
sensor. Is wheel
speed sensor loose?
Front 2450
Rear 2452
YES
NO
Tighten wheel
Is wheel speed
speed sensor.
sensor damaged?
2458
YES
NO
Replace
Replace ABS
wheel speed
module.
sensor.
2430
Front 2469
Rear 2470
After repair of motorcycle, perform Final Diag-
nostic Check to confirm proper operation without
setting codes. See Section A.6 INITIAL/FINAL
DIAGNOSTIC CHECK.
A-46
Appendix A: Anti-Lock Brake System
HOME
SERVICE PROCEDURES
A.18
ABS MODULE
Removal
NOTE
The ABS module is located under the right side saddlebag
and is rubber mounted to a bracket fastened to the saddlebag
support rail. The bottom foward part of the saddlebag is
recessed to accommodate the ABS module. See Figure A-
41.
1.
Remove right side saddlebag. For best results, move
saddlebag forward slightly before lifting.
9459
2.
Pull orange latch upward to release ABS module con-
nector [166], 25-place Amp. See Figure A-42.
Figure A-41. Right Side Saddlebag
3.
Pull anchor on convoluted tubing of wire harness from
hole in bracket.
9468
4.
Drain brake fluid. See DRAINING/FILLING/BLEEDING
HYDRAULIC BRAKE FLUID in this section. Be prepared
to immediately wipe up any spilled fluid with a damp
cloth. DOT 4 brake fluid can damaged finished surfaces.
5.
Remove two banjo bolts from top of ABS module to
release brake lines to front and rear calipers. Discard
steel/rubber washers. See Figure A-42.
6.
Remove two banjo bolts from inboard side of ABS mod-
ule to release brake lines from front and rear master cyl-
inders. Discard steel/rubber washers.
7.
Remove two socket screws to release bracket (with ABS
module) from weldment on saddlebag support rail.
8.
Remove three 10 mm hex head screws to release ABS
module from bracket.
Figure A-42. ABS Module
Installation
Table A-20. Brake Fittings to ABS Module
1. Inspect three rubber mounts in bracket for damage or
deterioration. If replacement is necessary, replace
Brake Line Fitting
ABS Module Port
bracket as rubber mounts are not sold separately.
From Rear Brake Master Cylinder
Rear Inboard
2. Verify that bushings are installed in ID of rubber mounts,
From Front Brake Master Cylinder
Front Inboard
and then install three 10 mm hex head screws (with flat
via Bottom Fitting of Brake Manifold
washers) to fasten bracket to ABS module. Alternately
To Rear Brake Caliper
Rear Top
tighten screws to 60-96 in-lbs (6.8-10.8 Nm).
To Front Brake Caliipers
Front Top
3. Install two socket screws to fasten bracket (with ABS
via Top Fitting of Brake Manifold
module) to weldment on saddlebag support rail. Alter-
nately tighten screws to 84-108 in-lbs (9.5-12.2 Nm).
5. Install two banjo bolts (with new steel/rubber washers) at
4. Orient brake fittings to their respective ports on the ABS
inboard side of ABS module to secure brake lines from
module. Refer to Table A-20.
front and rear master cylinders. Alternately tighten banjo
bolts to 17-22 ft-lbs (23.0-29.8 Nm).
Appendix A: Anti-Lock Brake System A-47
HOME
6.
Install two banjo bolts (with new steel/rubber washers) at
top of ABS module to secure brake lines to front and rear
9469
calipers. Alternately tighten banjo bolts to 17-22 ft-lbs
(23.0-29.8 Nm).
1WARNING
Be sure there is sufficient clearance between the shock
absorber and the brake line to the rear brake caliper. Any
contact can cause chafing of the brake line during move-
ment of the rear suspension system resulting in fluid
leaks and loss of hydraulic pressure, which could cause
death or serious injury.
7. Add brake fluid and bleed system. See DRAINING/FILL-
ING/BLEEDING HYDRAULIC BRAKE FLUID in this sec-
tion. Be prepared to immediately wipe up any spilled fluid
Figure A-43. Front Wheel Speed Sensor/Tone Ring
with a damp cloth. DOT 4 brake fluid can damaged fin-
ished surfaces.
8. With orange latch fully extended, start socket housing
onto pin housing of ABS module. Push latch downward
until socket housing locks in place.
9. Install anchor on convoluted tubing of wire harness into
3
hole in bracket.
4
10. Install right side saddlebag.
1
2
FRONT WHEEL SPEED SENSOR
CAUTION
Always remove the wheel speed sensor before removing
1
the wheel. Similarly, always install the wheel before
f2346x2x
installing the wheel speed sensor. Any contact with the
brake disc and/or tone ring during wheel removal or
installation can damage the wheel speed sensor.
1.
Cable Strap (2)
2.
Front Wheel Speed Sensor Cable
Removal
3.
Brake Hose
4.
Front Fender Tip Lamp Wires
1. Turn front wheel to right fork stop. Reaching in at rear left
side of headlamp nacelle (FLHP/E) or fairing (FLHTP),
Figure A-44. Install Cable Straps
pull external latch away from connector body and pull
apart pin and socket halves of front wheel speed sensor
connector [167], 2-place Tyco.
3.
Route wheel speed sensor cable up to lower fork bracket
2.
Carefully cut three cable straps to release front wheel
following brake hose and front fender tip lamp wires.
speed sensor cable from brake hose and front fender tip
lamp wires.
4.
Feed pin housing into left side of headlamp nacelle
3.
Remove two button head screws and pull front wheel
(FLHP/E) or fairing (FLHTP) through opening in front of
speed sensor from hole in speed sensor bracket. See
lower fork bracket.
Figure A-43.
5.
Turn front wheel to right fork stop. Reaching in at rear left
side of headlamp nacelle (FLHP/E) or fairing (FLHTP),
Installation
mate pin and socket halves of front wheel speed sensor
connector [167].
1.
Install new front wheel speed sensor in hole of speed
sensor bracket.
6.
Install three new cable staps as follows:
2.
Apply a small dab of Loctite Medium Strength Thread-
a. Install cable strap to secure sleeve (larger OD sec-
locker 243 (blue) to threads of two button head screws.
tion) of wheel speed sensor cable to bottom brake
Start screws and alternately tighten to 12-15 in-lbs (1.4-
hose crimp. See Figure A-44.
1.7 Nm).
A-48
Appendix A: Anti-Lock Brake System
HOME
b. Install second cable strap 2-1/2 inches (63.5 mm)
above the bottom brake hose crimp capturing wheel
f2314x8x
speed sensor cable, fender tip lamp wires and brake
hose.
c. Install third cable strap
1-1/2 inches
(38.1 mm)
below the top brake hose crimp capturing wheel
speed sensor cable, fender tip lamp wires and brake
hose.
d. Cut any excess cable strap material, but exercise
caution to avoid cutting or nicking the brake hose.
FRONT TONE RING
Removal
1. Remove two button head screws and pull front wheel
speed sensor from hole in speed sensor bracket. See
Figure A-43.
Rear Wheel
2. Remove front wheel. See Section 2.3 FRONT WHEEL,
Speed Sensor [168]
REMOVAL, in the 2005 Touring Models Service Manual
Figure A-45. Remove Right Side Cover
(Part No. 99483-05).
3. Using a T40 TORX drive head, remove five screws
securing brake disc to hub. Discard TORX screws. Dis-
card brake disc with tone ring.
Installation
1. Align upper hole in speed sensor bracket with upper lug
on fork leg. Slide long mounting bolt through speed sen-
Installation
sor bracket and fork leg and start into upper mounting
1. Install new brake disc with tone ring on hub. Using a T40
hole in caliper.
TORX drive head, install five new screws and alternately
2. Slide short mounting bolt through remaining hole in
tighten to 16-24 ft-lbs (22-33 Nm).
speed sensor bracket and lower lug of fork leg and start
2. Install front wheel. See Section
2.3 FRONT WHEEL,
into lower mounting hole in caliper. Tighten lower mount-
INSTALLATION, in the 2005 Touring Models Service
ing bolt to 28-38 ft-lbs (37.9-51.5 Nm).
Manual (Part No. 99483-05).
3. Tighten upper mounting bolt to 28-38 ft-lbs (37.9-51.5
3. Install front wheel speed sensor in hole of speed sensor
Nm).
bracket.
4. Install front wheel speed sensor in hole of speed sensor
4. Apply a small dab of Loctite Medium Strength Thread-
bracket.
locker 243 (blue) to threads of two button head screws.
5. Apply a small dab of Loctite Medium Strength Thread-
Start screws and alternately tighten to 12-15 in-lbs (1.4-
locker 243 (blue) to threads of two button head screws.
1.7 Nm).
Start screws and alternately tighten to 12-15 in-lbs (1.4-
1.7 Nm).
SPEED SENSOR BRACKET
REAR WHEEL SPEED SENSOR
Removal
1. Remove two button head screws and pull front wheel
CAUTION
speed sensor from hole in speed sensor bracket. See
Always remove the wheel speed sensor before removing
Figure A-43.
the wheel. Similarly, always install the wheel before
2. Remove both the upper and lower mounting bolts to
installing the wheel speed sensor. Any contact with the
release brake caliper and speed sensor bracket from
brake disc and/or tone ring during wheel removal or
lugs of left side fork leg.
installation can damage the wheel speed sensor.
Appendix A: Anti-Lock Brake System A-49
HOME
6. At right side of battery box, feed pin housing between
9461
frame downtubes to outboard side of motorcycle. Mate
pin and socket halves of wheel speed sensor connector.
See Figure A-45.
7. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools required).
8. Install right side saddlebag.
REAR TONE RING
Removal
1.
Remove two button head screws and pull rear wheel
Figure A-46. Rear Wheel Speed Sensor/Tone Ring
speed sensor from hole in rear brake caliper. See Figure
A-46.
2.
Remove rear wheel. See Section 2.4 REAR WHEEL,
Removal
REMOVAL, in the 2005 Touring Models Service Manual
(Part No. 99483-05).
1.
Remove right side saddlebag. For best results, move
saddlebag forward slightly before lifting.
3.
Using a T45 TORX drive head, remove five screws
securing brake disc to hub. Discard brake disc with tone
2.
Gently pull side cover from frame downtubes (no tools
ring.
required).
3.
Pull external latch away from connector body and pull
Installation
apart pin and socket halves of rear wheel speed sensor
connector [168], 2-place Tyco. See Figure A-45.
1.
Install new brake disc with tone ring on hub. Using a T45
4.
Reaching in below battery box, open two cable clips on
TORX drive head, install five screws and alternately
T-studs at top of rear swingarm. Free wheel speed sen-
tighten to 30-45 ft-lbs (41-61 Nm). Use new screws if
sor cable from cable clips.
they have been removed for the third time.
2.
Install rear wheel. See Section
2.4 REAR WHEEL,
NOTE
INSTALLATION, in the 2005 Touring Models Service
For best results, insert blade of small screwdriver into gap at
Manual (Part No. 99483-05).
side of clip and gently rotate end of screwdriver to pop open.
3.
Install rear wheel speed sensor in hole of rear brake cali-
5.
Release sleeve (larger OD section) of wheel speed sen-
per.
sor cable from metal clip attached to caliper bridge bolt.
4.
Apply a small dab of Loctite Medium Strength Thread-
locker 243 (blue) to threads of two button head screws.
6.
Remove two button head screws and pull rear wheel
Start screws and alternately tighten to 12-15 in-lbs (1.4-
speed sensor from hole in rear brake caliper. See Figure
1.7 Nm).
A-46.
Installation
BRAKE LINES
1.
Install new rear wheel speed sensor in hole of rear brake
caliper.
Front Master Cylinder to Brake Manifold
2.
Apply a small dab of Loctite Medium Strength Thread-
locker 243 (blue) to threads of two button head screws.
Removal
Start screws and alternately tighten to 12-15 in-lbs (1.4-
1.
Drain brake fluid. See DRAINING/FILLING/BLEEDING
1.7 Nm).
HYDRAULIC BRAKE FLUID, FRONT BRAKE SYSTEM,
3.
Route wheel speed sensor cable forward following top of
in this section.
rear swingarm.
2.
Obtain the 2005 Touring Models Service Manual (Part
4.
Capture sleeve (larger OD section) of wheel speed sen-
No. 99483-05), and proceed as follows:
sor cable in metal clip attached to caliper bridge bolt.
FLHP/E: Remove headlamp nacelle. See Section 2.31
5.
Capture wheel speed sensor cable in two cable clips on
WINDSHIELD/HEADLAMP NACELLE
(FLHR/C/S),
T-studs at top of rear swingarm. Snap cable clips closed.
NACELLE REMOVAL (FLHR/C).
A-50
Appendix A: Anti-Lock Brake System
HOME
2.
Start bottom banjo bolt
(with three new steel/rubber
9467
washers) to secure brake lines to brake manifold. Be
sure to position fitting on rear section of brake line (to
ABS module) inboard of fitting on front section (from front
master cylinder).
1
3.
Start banjo bolt
(with new steel/rubber washers) to
secure brake line to front brake master cylinder.
4.
Alternately tighten banjo bolts to 17-22 ft-lbs (23.0-29.8
3
Nm).
5.
At front of steering head, install new cable strap captur-
ing brake hoses and right handlebar switch control con-
duit. Cut any excess cable strap material. See Figure A-
2
4
47.
6.
Add brake fluid and bleed system. See DRAINING/FILL-
ING/BLEEDING HYDRAULIC BRAKE FLUID, FRONT
1.
Brake Hose from Front Master Cylinder
BRAKE SYSTEM, in this section.
2.
Brake Hose to Front Brake Calipers
3. Right Handlebar Switch Conduit
7.
Obtain the 2005 Touring Models Service Manual (Part
4. Cable Strap
No. 99483-05), and proceed as follows:
FLHP/E: Install headlamp nacelle. See Section
2.31
Figure A-47. Capture Brake Hoses and Conduit
WINDSHIELD/HEADLAMP NACELLE
(FLHR/C/S),
at Front of Steering Head (FLHTP)
NACELLE INSTALLATION (FLHR/C).
FLHTP: Install outer fairing and fairing cap. See Section
2.29 UPPER FAIRING/WINDSHIELD
(FLHT/C/U),
FLHTP: Remove outer fairing and fairing cap. See Sec-
OUTER FAIRING/WINDSHIELD, INSTALLATION, and
tion
2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U),
FAIRING CAP, INSTALLATION, respectively.
OUTER FAIRING/WINDSHIELD, REMOVAL, and FAIR-
ING CAP, REMOVAL, respectively.
Brake Manifold to Front Brake Calipers
3.
At front of steering head, carefully cut cable strap to
release brake hoses from right handlebar switch control
Removal
conduit. See Figure A-47.
1.
Drain brake fluid. See DRAINING/FILLING/BLEEDING
HYDRAULIC BRAKE FLUID, FRONT BRAKE SYSTEM,
4.
Remove bottom banjo bolt to release brake lines from
in this section.
brake manifold at right side of steering head. Discard
steel/rubber washers. See Figure A-48.
5.
Wrap outboard banjo fitting with piece of shop towel to
prevent any leakage of brake fluid, and then moving to
9458
1
front of motorcycle, pull end forward to front of steering
head.
6.
Remove banjo bolt to release brake line from front brake
master cylinder. Discard steel/rubber washers.
7.
Draw brake manifold end of brake line rearward (through
2
fairing cap opening on FLHTP models) to remove
assembly from motorcycle.
Installation
1.
Position brake line assembly at bottom of right side han-
dlebar. Feed brake manifold end forward (through fairing
cap opening on FLHTP models) at top of upper fork
bracket to front of steering head. Then route hose down-
1.
Brake Line to Front Brake Calipers
ward, between the right handlebar switch control conduit
2.
Brake Line from Front Master Cylinder
and the hose to front brake calipers, and then rearward
to the brake manifold. See Figure A-47.
Figure A-48. Brake Manifold (Steering Head)
Appendix A: Anti-Lock Brake System A-51
HOME
2.
Obtain the 2005 Touring Models Service Manual (Part
8.
On left side of motorcycle, install three new cable staps
No. 99483-05) and proceed as follows:
as follows:
FLHP/E: Remove headlamp nacelle. See Section 2.31
a. Install cable strap to secure sleeve (larger OD sec-
WINDSHIELD/HEADLAMP NACELLE
(FLHR/C/S),
tion) of wheel speed sensor cable to bottom brake
NACELLE REMOVAL (FLHR/C).
hose crimp. See Figure A-44.
FLHTP: Remove outer fairing. See Section 2.29 UPPER
b. Install second cable strap 2-1/2 inches (63.5 mm)
FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/
above the bottom brake hose crimp capturing wheel
WINDSHIELD, REMOVAL.
speed sensor cable, fender tip lamp wires and brake
hose.
3.
At front of steering head, carefully cut cable strap to
c. Install third cable strap
1-1/2 inches
(38.1 mm)
release brake hoses from right handlebar switch control
below the top brake hose crimp capturing wheel
conduit. See Figure A-47.
speed sensor cable, fender tip lamp wires and brake
4.
Remove top banjo bolt to release brake lines from brake
hose.
manifold at right side of steering head. Discard steel/rub-
d. Cut any excess cable strap material, but exercise
ber washers. See Figure A-48.
caution to avoid cutting or nicking the brake hose.
5.
Wrap outboard banjo fitting with piece of shop towel to
prevent any leakage of brake fluid, and then moving to
9.
At front of steering head, install new cable strap captur-
front of motorcycle, pull end forward to front of steering
ing brake hoses and right handlebar switch control con-
head.
duit. Cut any excess cable strap material. See Figure A-
47.
6.
On left side of motorcycle, carefully cut three cable
straps to release wheel speed sensor cable and front
10.
Add brake fluid and bleed system. See DRAINING/FILL-
fender tip lamp wires from brake hose.
ING/BLEEDING HYDRAULIC BRAKE FLUID, FRONT
BRAKE SYSTEM, in this section.
7.
Remove T40 TORX screw to release brake line bracket
from bottom of lower fork bracket.
11.
Obtain the 2005 Touring Models Service Manual (Part
No. 99483-05), and proceed as follows:
8.
Remove banjo bolts to release brake lines from front
brake calipers. Discard steel/rubber washers.
FLHP/E: Install headlamp nacelle. See Section
2.31
WINDSHIELD/HEADLAMP NACELLE
(FLHR/C/S),
9.
Draw brake manifold end of brake line downward to
NACELLE INSTALLATION (FLHR/C).
remove assembly from motorcycle.
FLHTP: Install outer fairing. See Section 2.29 UPPER
FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/
Installation
WINDSHIELD, INSTALLATION.
1.
Standing at front of motorcycle, position brake line
assembly at bottom of lower fork bracket.
Brake Manifold/Rear Master Cylinder to
2.
Feed brake manifold end of brake line upward through
opening between front left side of lower fork bracket and
ABS Module
inboard side of headlamp nacelle (FLHP/E), or chrome
NOTE
skirt (FLHTP), to front of steering head.
For ease of installation and to prevent improper routing, the
3.
Start banjo bolts
(with new steel/rubber washers) to
three brake lines running the length of the motorcycle are not
secure brake lines to front brake calipers.
sold separately. Damage to any single brake line requires
4.
Install T40 TORX screw to fasten brake line bracket to
replacement of all three.
bottom of lower fork bracket. Tighten screw to 120-180
in-lbs (13.6-20.3 Nm).
Removal
NOTE
5.
Route brake manifold end of brake line over to right side
of steering head (inboard of both the master cylinder
The sections referenced in steps 1-4 below are found in the
brake hose and the right handlebar switch control con-
2005 Touring Models Service Manual (Part No. 99483-05).
duit), and then rearward to the brake manifold. See Fig-
ure A-47.
1. Remove right side rider footboard. See Section 2.35
FOOTBOARDS/FOOTRESTS, RIDER FOOTBOARD,
6.
Start top banjo bolt (with three new steel/rubber wash-
REMOVAL, step 1.
ers) to secure brake lines to brake manifold. Be sure to
position fitting on rear section of brake line (from ABS
2. Remove rear brake pedal. See Section
2.11 REAR
module) inboard of fitting on front section (to front brake
BRAKE MASTER CYLINDER, BRAKE PEDAL/MASTER
calipers).
CYLINDER ASSEMBLY, REMOVAL, steps 2-5.
7.
Alternately tighten all banjo bolts to 17-22 ft-lbs (23.0-
3. Remove the exhaust system in two sections. See Sec-
29.8 Nm).
tion 3.7 REMOVING ENGINE FROM CHASSIS, step 9.
A-52
Appendix A: Anti-Lock Brake System
HOME
10. Remove socket terminals from spade contacts of rear
f2341x2x
brake light switch.
11. Remove T45 TORX screw to release aluminum guide
and saddlebag guard from weldment on rear frame
2
downtube. See Figure A-50.
12. Cut cable straps to free brake lines from two rubber
spacers anchored on T-studs at top of lower frame tube.
3
13. About 5-1/2 inches (139.7 mm) above top of crossbrace
between front frame downtubes, cut cable strap to free
brake lines from rubber spacer at front of right frame
downtube.
14. Remove banjo bolt to release brake line from rear brake
master cylinder. Discard steel/rubber washers.
15. Remove two banjo bolts to release brake lines from
brake manifold at right side of steering head. Discard
steel/rubber washers. See Figure A-48.
16. Carefully draw brake line fittings down and out from
3
under throttle/idle cables and main harness conduit.
1
Installation
1.
Support Rail to Guard Screw
2.
Rail to Saddlebag Support Screw (2)
1.
Orient brake lines on motorcycle as follows:
3.
Guard to Frame Screw (2)
a.
Carefully position brake lines along right side of
Figure A-49. Saddlebag Guard/Rails
motorcycle exercising caution to avoid bending or
kinking lines. Insert forward fittings of front brake
lines up and under throttle/idle cables and main har-
ness conduit to brake manifold at right side of steer-
4.
Remove right side saddlebag. See Section 2.25 SAD-
ing head.
DLEBAG, REMOVAL. For best results, move saddlebag
forward slightly before lifting.
b.
Position forward fitting of rear brake line adjacent to
rear brake master cylinder.
5.
Gently pull side cover from frame downtubes (no tools
required).
6.
Remove right side saddlebag guard and rails. See Figure
A-49. Proceed as follows:
9466
1
a. Remove support rail to guard screw.
b. Remove two rail to saddlebag support screws.
c. Standing on left side of vehicle, press down on rear
of seat and pull quick release pin from hole in sup-
port post. Raise seat toward fuel tank console.
2
Remove two flange nuts to release seat shroud.
d. Remove two guard to frame screws, and lift assem-
bly from motorcycle.
3
7.
Drain brake fluid. See DRAINING/FILLING/BLEEDING
HYDRAULIC BRAKE FLUID in this section.
8.
Remove banjo bolt from front top port of ABS module to
release brake line to front brake calipers. Discard steel/
1.
Rubber Spacer
rubber washers.
2.
Aluminum Guide
3.
T45 TORX Screw
9.
Remove two banjo bolts from inboard side of ABS mod-
ule to release brake lines from front and rear master cyl-
inders. Discard steel/rubber washers.
Figure A-50. Rear Frame Downtube
Appendix A: Anti-Lock Brake System A-53
HOME
c. Adjust lines as necessary so that they run forward of
9. Loosely install T45 TORX screw to fasten saddlebag
the front frame downtube, along the top of the lower
guard and aluminum guide to weldment on rear frame
frame tube and at the back of the rear frame down-
downtube. See Figure A-50. Place each brake line in its
tube.
designated position in slot of aluminum guide as shown
below. Insert rubber spacer between brake lines and rear
d. Position rear fittings of front and rear brake lines
frame downtube. Tighten screw to 15-20 ft-lbs (20-27
adjacent to ABS module.
Nm).
2.
Start top banjo bolt (with three new steel/rubber wash-
ers) to secure brake lines to brake manifold. Be sure to
Table A-22. Brake Lines to Guide
position fitting on rear section of brake line (from ABS
module) inboard of fitting on front section (to front brake
Brake Line
Guide Slot
calipers).
To Front Brake Caliipers
Inboard
3.
Start bottom banjo bolt
(with three new steel/rubber
via Top Fitting of Brake Manifold
washers) to secure brake lines to brake manifold. Be
From Rear Brake Master Cylinder
Middle
sure to position fitting on rear section of brake line (to
ABS module) inboard of fitting on front section (from front
From Front Brake Master Cylinder
Outboard
master cylinder).
via Bottom Fitting of Brake Manifold
4.
Start banjo bolt
(with new steel/rubber washers) to
secure brake line to rear brake master cylinder.
10.
Alternately tighten all banjo bolts to 17-22 ft-lbs (23.0-
5.
About 5-1/2 inches (139.7 mm) above above top of
29.8 Nm).
crossbrace between front frame downtubes, install new
11.
Be sure that brake lines are firmly seated in each rubber
cable strap to secure brake lines to rubber spacer held at
spacer. Tighten all cable straps and cut any excess cable
front of right frame downtube.
strap material. Carefully inspect all brake lines to verify
6.
Position brake lines into two rubber spacers anchored on
that no contact is made with the motorcycle frame or
T-studs at top of lower frame tube. Loosely install new
other mounted components.
cable straps to capture brake lines.
12.
Install right side saddlebag guard and rails as follows:
NOTE
a. Position assembly on motorcycle and start screws.
Cable strap around rear rubber spacer also captures main
See Figure A-49.
harness conduit (to voltage regulator connector and to oil
b. Tighten support rail to guard screw to 70-100 in-lbs
pressure sender and crankshaft position sensor connectors)
(8-11 Nm).
on inboard side of lower frame tube. Similarly captured by
cable strap around front rubber spacer are the main harness
c. Tighten two rail to saddlebag support screws to 15-
conduit (to oil pressure sender and crankshaft position sen-
20 ft-lbs (20-27 Nm).
sor connectors) and voltage regulator cables.
d. Tighten guard to frame top screw to 15-20 ft-lbs (20-
7.
Start banjo bolts
(with new steel/rubber washers) to
27 Nm).
secure brake lines to ABS module, as follows:
e. Install seat shroud. Start two flange nuts and alter-
nately tighten to 60-120 in-lbs (6.8-13.6 Nm). Move
Table A-21. Brake Fittings to ABS Module
seat down until support post engages hole in rear
seat bracket. While pressing down on rear of seat,
Brake Line Fitting
ABS Module Port
insert quick release pin into hole of support post.
From Rear Brake Master Cylinder
Rear Inboard
13.
Align barbed studs in side cover with grommets in frame
From Front Brake Master Cylinder
Front Inboard
downtubes and push firmly into place (no tools required).
via Bottom Fitting of Brake Manifold
To Rear Brake Caliper
Rear Top
NOTE
To Front Brake Caliipers
The sections referenced in steps 14-17 below are found in the
Front Top
via Top Fitting of Brake Manifold
2005 Touring Models Service Manual (Part No. 99483-05).
14. Install right side saddlebag. See Section 2.25 SADDLE-
8.
Install socket terminals onto spade contacts of rear brake
BAG, INSTALLATION.
light switch.
15. Install the exhaust system. See Section 3.8 INSTALLING
NOTE
ENGINE IN CHASSIS, step 46.
If installing new rear brake light switch, apply Loctite Pipe
Sealant with Teflon 565 to threads and start switch into rear
16. Install rear brake pedal. See Section 2.11 REAR BRAKE
brake line. Using flats on switch, tighten to 96-120 in-lbs
MASTER CYLINDER, BRAKE PEDAL/MASTER CYLIN-
(10.8-13.6 Nm).
DER ASSEMBLY, INSTALLATION, steps 3-7.
A-54
Appendix A: Anti-Lock Brake System
HOME
1
2
5
2
3
2
7
6
2
1
2
1
4
15
12
8
17
2
9
12
16
1
1.
Banjo Bolt (6)
13
2.
Steel/Rubber Washer (14)
3.
Brake Line - From Front Master Cylinder
4.
Brake Line - To Front Brake Calipers
1
5.
Brake Manifold
6.
Flange Screw (2)
7.
Wellnut (2)
2
8.
T40 TORX Screw
14
9.
Front Wheel Speed Sensor
10.
Button Head Screw (2)
10
13
11.
Small Cable Strap-10065 (2)
12.
Large Cable Strap-10039 (3)
13.
Mounting Bolt
14.
Speed Sensor Bracket
15.
Rubber Spacer, 2-Channel
16.
Rubber Spacer, 3-Channel (2)
11
f2339x2x
17.
Brake Lines
Figure A-51. Front ABS Components
17. Install right side rider footboard. See Section 2.35 FOOT-
ABS Module to Rear Brake Caliper
BOARDS/FOOTRESTS, RIDER FOOTBOARD, INSTAL-
Removal
LATION, step 1.
1. Remove right side saddlebag. See Section 2.25 SAD-
18. Add brake fluid and bleed system. See DRAINING/FILL-
DLEBAG, REMOVAL, in the 2005 Touring Models Ser-
ING/BLEEDING HYDRAULIC BRAKE FLUID in this sec-
vice Manual (Part No. 99483-05). For best results, move
tion.
saddlebag forward slightly before lifting.
Appendix A: Anti-Lock Brake System A-55
HOME
1.
Banjo Bolt (4)
2.
Banjo Bolt/Integral Bleed Fitting (Not Sold)
3.
Steel/Rubber Washer (10)
4.
Brake Line - To Front Brake Calipers
1
5.
Brake Line - To Rear Brake Caliper
6.
Brake Line - From Front Master Cylinder
4
7.
Brake Line - From Rear Master Cylinder
1
8.
Rear Brake Light Switch
3
9.
Rear Brake Caliper
3
8
10.
Wire Harness Anchor
11.
ABS Module
12.
Rubber Mount (3)
13.
Bushing (3)
2
1
14.
10 mm Hex Head Screw (3)
3
7
15.
Rear Wheel Speed Sensor
16.
Metal Clip
17.
Button Head Screw (2)
18.
Rear Frame Downtube
19.
Rubber Spacer, 3-Channel
6
20.
Aluminum Guide
3
21.
T45 TORX Screw
22.
Saddlebag Guard
23.
Saddlebag Support Rail
12, 13, 14
1
24.
Socket Screw (2)
5
10
3
9
11
16
17
19
15
20
23
18
21
24
22
f2337x2x
Figure A-52. Rear ABS Components
2.
Keeping end elevated to avoid leakage of brake fluid,
Installation
remove banjo bolt/integral bleed fitting to release brake
line from rear top port of ABS module. Discard steel/rub-
1.
Start banjo bolt
(with new steel/rubber washers) to
ber washers.
secure silver side of brake line to rear brake caliper.
3.
Wrapping end in a shop rag to avoid leakage of brake
2.
Start banjo bolt/integral bleed fitting (with new steel/rub-
fluid, remove banjo bolt to release brake line from rear
ber washers) to secure black side of brake line to rear
brake caliper. Discard steel/rubber washers.
top port of ABS module.
A-56
Appendix A: Anti-Lock Brake System
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