Harley Davidson 2005 touring models. Service repair manual — page 36

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    2005 FLHTC, FLHTCU and FLTR
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    DOMESTIC and INTERNATIONAL Models,
    DOMESTIC and INTERNATIONAL Models,
    Radio, CB/Intercom and Rear Speakers
    Radio, CB/Intercom and Rear Speakers
    B-56
    Appendix B
    HOME
    OPTIONAL SECURITY SIREN
    FENDER TIP
    HEADLAMP
    PASSING LP
    PASSING
    HDI
    ODOMETER
    LAMP
    SWITCH
    LAMPS
    POS.
    RESET
    [38B]
    TO IGNITION/EFI
    [32B]
    [109B]
    [73B]
    LAMP
    IGNITION SWITCH LEGEND
    POWER
    SWITCH
    TO FUEL
    SIGNAL
    A
    BN/GY
    HARNESS
    [8A]
    (BK)
    1
    2
    3
    4
    1
    2
    [29B]
    R/GY
    R/BK
    R
    [154]
    SPEEDOMETER
    FUEL GAUGE
    SENDER
    POSITION
    GROUND
    B
    LGN/BN
    1
    2
    ACCESS.
    IGN.
    BATT.
    C
    BK
    [73A]
    [141A]
    ACCESSORY
    1 2 3 4 5 6 7 8 9101112
    [109A]
    123 4
    (WE)
    LOCK
    1
    2
    3
    4
    5
    6
    7
    8
    9101112
    3
    2
    1
    [142A]
    [142B]
    [32A]
    [117B]
    IGNITION
    [141B]
    [8B]
    THROTTLE
    (GY)
    POWER
    [39B]
    ROLL-OFF
    RELAY
    IGNITION SWITCH
    (BK)
    SWITCH
    [75A]
    [75C]
    [33A]
    [75B]
    [75D]
    [126A]
    O/V
    V/Y
    [33B]
    [64B]
    [126B]
    ON/OFF
    A
    R/GN
    SET/COAST
    B
    BE/BK
    R/Y
    3F
    5
    RESUME/ACCEL
    C
    W/BE
    O/V
    4E
    3
    THROTTLE ROLL-OFF
    D
    V/Y
    BRAKE
    GROUND
    E
    BK
    BK
    4F
    1
    RELAY
    IGNITION
    F
    O/V
    R/BE
    3E
    2
    BRAKE SIGNAL
    G
    R/BE
    ENGINE SPEED
    H
    BE/O
    SET LAMP
    J
    GN/R
    1B
    INSTRUMENTS - 15a
    1A
    SPEED SIGNAL
    K
    W/GN
    O
    R/BK
    1D
    LIGHTS - 15A
    1C
    [17A]
    [17B]
    BE
    CRUISE CONTROL STANDARD
    1H
    HEADLAMP - 15A1G
    MAXI-FUSE
    ON RK CLASSIC ONLY
    BE
    40 A
    1F
    IGNITION - 15A
    1E
    RH CRUISE
    GY
    R/BK
    4D
    P&A IGN - 2A MAX
    4C
    CONNECTION
    2
    BK
    BK
    BE/BK
    R/BK
    (BLK)
    1
    W/BE
    LH
    RH
    2B
    CRUISE/BRAKE - 15A
    [159B]
    2A
    [5B]
    [159A]
    GND
    FRAME GROUND
    GND
    O/V
    STUD
    STUD
    2D
    ACCESSORIES - 15A
    B A
    2C
    O/W
    LH CRUISE
    BK
    BK
    P&A- 15A
    2F
    2E
    CONNECTION
    O/R
    R/GY
    BATTERY - 15A
    3C
    (GY)
    3D
    2
    BN/GY
    R
    [158B]
    1
    R/GN
    [158A]
    R/GY
    2J
    5
    GN
    3H
    3
    START
    [24A]
    TN/GN
    3J
    1
    RELAY
    1
    O/W
    BK/R
    2H
    2
    TO LEFT HAND
    2
    Y
    CONTROLS
    3
    BE
    B+
    REGULATOR
    MAIN POWER
    HAND
    4
    W
    CONNECTOR
    [77A]
    AT STARTER
    5
    W/V
    (GRAY)
    [160B]
    6
    Y/BK
    [24B]
    SEE CHARGING SYSTEM FOR
    FURTHER CONNECTIONS
    [22A]
    1
    O/W
    STARTER
    TO RIGHT HAND
    2
    R/BE
    CRANK POSITION
    SOLENOID
    3
    GY
    SENSOR
    CONTROLS
    [128B]
    4
    W/BK
    (BLACK)
    5
    W/BN
    [22B]
    6
    BK/R
    TURN SIGNAL/SECURITY
    MODULE
    2
    2
    (GY)
    BK
    BK
    R
    1
    1
    R
    [30A]
    [30B]
    [79B]
    [79A]
    TSM/TSSM
    BATTERY
    1
    BN/GY
    IGNITION
    2
    GY
    [131]
    VSS / SERIAL DATA LINK
    3
    LGN/V
    SECURITY INDICATOR
    4
    BN/V
    (BK)
    LEFT TURN FEED
    5
    V
    [4A]
    RIGHT TURN FEED
    6
    BN
    REAR
    RIGHT TURN SWITCH INPUT
    7
    W/BN
    123
    4
    STOPLIGHT
    LEFT TURN SWITCH INPUT
    8
    W/V
    SWITCH
    NEUTRAL
    START RELAY CONTROL
    9
    TN/GN
    [121]
    SWITCH
    IGNITION ENABLE SIGNAL
    10
    ALARM SIGNAL
    11
    LGN/BN
    GROUND
    12
    BK
    GN/Y
    [67A]
    [120B]
    (BK)
    HORN
    1234
    [31A]
    (BK)
    ACCESSORY
    P &A
    [21A]
    [7A]
    1
    BK
    ACCESSORY
    SWITCH
    1
    2
    3
    4
    5
    6
    7
    8
    TO FRONT
    2
    BN
    8
    7
    6
    5
    4
    3
    2
    1
    CONNECTOR
    3
    BE
    TURN
    OIL
    15A MAX
    4
    BE
    TO INDICATOR
    [122]
    PRESSURE
    TO REAR LIGHTS
    SIGNALS
    5
    V
    SWITCH
    LAMPS
    [7B]
    f2227r8x
    [31B]
    6
    BK
    [120A]
    (BK)
    2005 FLHR, FLHRC and FLHRS, DOMESTIC and INTERNATIONAL Models,
    Main Harness
    B-57
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    2005 FLHR, FLHRC and FLHRS,
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    Main Harness
    B-58
    Appendix B
    HOME
    MAP
    DATA
    IGNITION
    SENSOR
    C B A
    LINK
    COIL
    +5V DC
    CARBURETED
    (GY)
    1234
    CB A
    R/W
    A
    A
    R
    IGNITION
    W/GN
    B
    B
    W
    COIL
    VEHICLES
    [91A]
    [83B]
    [80A]
    [83A]
    BK
    C
    C
    BK
    (CARB)
    OUTPUT
    [65B]
    SENSOR
    GROUND
    C B A
    (BK)
    [65A]
    IGNITION CONTROL MODULE
    VEHICLE
    [80B]
    SPEED SENSOR
    (BLK)
    [BLK]
    [10A]
    [10B]
    BK
    12
    RUN/STOP SIGNAL
    1
    ABCD
    [83A]
    1
    W/BK
    LGN/V
    11
    BATTERY
    2
    10
    2
    BN/GY
    FRONT SPARK
    IGNITION
    +5V SENSOR PWR
    3
    R/W
    9
    FROM
    REAR SPARK PLUG
    COIL
    3
    PLUG
    SENSOR GROUND
    4
    BK/W
    BK
    8
    4
    MAIN
    (EFI)
    MODULE GROUND
    5
    BK
    R
    7
    5
    HARNESS
    COIL FRONT
    6
    BE/O
    GY
    6
    6
    [8B]
    COIL REAR
    7
    Y/BE
    W/GN
    5
    7
    CRANK SENSOR (+)
    8
    8
    R
    4
    9
    BK
    BE/O
    3
    CRANK SENSOR (-)
    9
    10
    W/GN
    W/BK
    2
    VEHICLE SPD SIG
    10
    11
    V/W
    BN/GY
    1
    MAP SIGNAL
    11
    +5V DC
    12
    12
    LGN/V
    DATALINK
    [8A]
    R/W
    A
    A
    R
    W/GN
    B
    B
    W
    (GY)
    BK
    C
    C
    BK
    OUTPUT
    [65B]
    SENSOR
    (BK)
    [65A]
    GROUND
    CARBURETED OVERLAY: 32435-04
    VEHICLE
    EFI OVERLAY: 70233-04
    SPEED SENSOR
    REAR
    FRONT
    INTAKE
    ENGINE
    INJECTOR
    INJECTOR
    AIR
    IDLE AIR
    TEMP.
    TEMP.
    CONTROL ACTUATOR
    SENSOR
    SENSOR
    THROTTLE
    MAP
    BK
    12
    POSITION
    LGN/V
    11
    FUEL INJECTED
    SENSOR
    SENSOR
    O/GY
    10
    R
    9
    FROM
    VEHICLES
    DATA
    IGNITION
    BK
    8
    R
    MAIN
    LINK
    COIL
    7
    (GY)
    GY
    6
    HARNESS
    1
    2
    3
    4
    AB
    AB
    ABCD
    W/GN
    5
    [8B]
    [91A]
    4
    ELECTRONIC
    DCB A
    PK
    3
    (GY)
    [83B]
    AB
    AB
    CB A
    CBA
    [87B]
    CONTROL
    [90B]
    [89B]
    W/BK
    2
    MODULE
    [85B]
    1
    [84B]
    [88B]
    [80B]
    [78A]
    [78B]
    [8A]
    ALDL & FLASH PIN
    LGN/R
    CHECK ENG LP
    TACH OUTPUT
    PK
    SYSTEM RELAY
    GN/O
    SERIAL DATA LINK
    LGN/V
    ENGINE TEMPERATURE
    PK/Y
    INTAKE AIR TEMPERATURE
    LGN/Y
    OXYGEN SENSOR A
    ANALOG INPUT
    POWER GROUND
    BK
    COIL REAR
    Y/BE
    [119B]
    CRANK POS. SENSOR (-)
    BK+
    SWITCH POWER
    W/BK
    FUEL PUMP 15A
    5V SENSOR POWER
    R/W
    G
    H
    DIGITAL GROUND
    O/GY
    Y/GN
    FREQUENCY INPUT
    IDLE AIR CNTL MOTOR
    BK/O
    ECM POWER 15A
    IDLE AIR CNTL MOTOR
    BK/PK
    A
    B
    INJECTOR REAR
    GN/GY
    BE/GY
    R
    OUTPUT (unused)
    INJECTOR FRONT
    W/Y
    SYSTEM RELAY
    (BK)
    OUTPUT (UNUSED)
    OXYGEN SENSOR B
    Y/GN
    K
    5
    THROTTLE POS SNSR INPUT
    GY/V
    T
    4
    MAP SENSOR INPUT
    V/W
    BE/GY
    E
    3
    5V SENSOR GROUND
    BK/W
    GN/O
    S
    2
    ION SENSE
    GY/BE
    W/BK
    U
    1
    POWER GROUND
    BK
    COIL FRONT
    BE/O
    CRANK POS. SNSR (+)
    R
    CONSTANT POWER
    BE/GY
    SWITCH INPUT (unused)
    VEHICLE SPEED INPUT
    W/GN
    DIGITAL POWER
    IDLE AIR CNTL MOTOR
    BE/GN
    IDLE AIR CNTL MOTOR
    BN/R
    f2227x8x
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    Ignition Harness (Carbureted), Electronic Fuel Injection (EFI) Harness
    B-59
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    2005 FLHR, FLHRC and FLHRS,
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    DOMESTIC and INTERNATIONAL Models,
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    Ignition Harness (Carbureted),
    Electronic Fuel Injection (EFI) Harness
    Electronic Fuel Injection (EFI) Harness
    B-60
    Appendix B
    HOME
    VOLTAGE
    STATOR
    REGULATOR
    [46A]
    [46B]
    BATTERY
    +
    BK
    A
    DC AC
    A
    BK
    -
    MAXIFUSE
    BK
    B
    B
    BK
    40 A
    STARTER
    MAXIFUSE
    40 A
    [128]
    B A
    CHARGING CIRCUIT
    R
    B A
    RIGHT
    LEFT
    GROUND
    [77B]
    [77A]
    STUDS
    [64]
    BK
    R
    3D
    BATTERY
    15A
    3C
    BN/GY
    R
    IGNITION
    1F
    IGN:
    15A
    1E
    SWITCH (REAR VIEW)
    GY
    R/BK
    BK
    BK
    [33A]
    A
    B I
    [33B]
    BATTERY
    STARTER
    POWERTRAIN
    GROUND
    R/GY
    2J
    5
    GN
    3H
    3
    TN/GN
    3J
    1
    IGNITION SWITCH LEGEND
    2H
    POSITION
    A RED/
    I RED/
    B RED
    BK/R
    2
    GREY
    BLACK
    ACCESSORY
    START
    OFF
    HAND CONTROLS,
    RELAY
    IGNITION
    RIGHT
    RIGHT DIR SWITCH
    MAIN FUSE BLOCK COVER
    ENGINE OFF/RUN SWITCH
    START SWITCH
    STOPLIGHT SWITCH
    10A
    15A
    P&A
    IGN
    BRAKE
    [22B]
    [22A]
    15A
    RELAY
    1
    1
    BATTERY
    2
    2
    START
    GY
    3
    3
    GY
    RELAY
    4
    4
    SPARE FUSES
    P&A
    ACCESS.
    CRUISE/BRK
    5
    5
    BK/R
    6
    6
    BK/R
    HEADLAMPS IGN
    LIGHTS
    INSTRUMENTS
    TURN SIGNAL/SECURITY
    MODULE
    [30A]
    [30B]
    TS/TSSM
    BATTERY
    1
    BN/GY
    IGNITION
    2
    GY
    VSS / SERIAL DATA LINK
    3
    BRAKE
    SECURITY INDICATOR
    4
    RELAY
    LEFT TURN FEED
    5
    START
    15A
    RIGHT TURN FEED
    6
    RELAY
    RIGHT TURN SWITCH INPUT
    7
    15A
    15A
    15A
    LEFT TURN SWITCH INPUT
    8
    START RELAY CONTROL
    9
    TN/GN
    IGNITION ENABLE SIGNAL
    10
    15A
    15A
    15A
    15A
    ALARM SIGNAL
    11
    GROUND
    12
    Wire Color Code Key
    64
    BK
    HANDLEBAR
    GROUND
    BK - Black
    GN - Green
    LT.GN - Light Green
    PIN CONNECTOR
    P/N 70142-93
    TRIPLE
    (A side)
    CLAMP
    MAIN FUSE BLOCK
    BN - Brown
    BE - Blue
    PK - Pink
    P/N 70101-94
    GROUNDS
    FRAME
    BK
    R - Red
    V - Violet
    TN - Tan
    SOCKET CONNECTOR
    GROUND
    O - Orange
    GY - Gray
    Wire color-XX/XX-Stripe color
    (B side)
    Y - Yellow
    W - White
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    2005 FLHR, FLHRC and FLHRS, DOMESTIC and INTERNATIONAL Models,
    Starting and Charging
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    2005 FLHR, FLHRC and FLHRS,
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    DOMESTIC and INTERNATIONAL Models,
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    Starting and Charging
    Starting and Charging
    B-62
    Appendix B
    HOME
    FROM MAIN
    FROM MAIN
    f2227q8b
    FROM MAIN
    HARNESS
    HARNESS [31A]
    HARNESS [73A]
    1
    2
    3
    45
    6
    CHASSIS GROUNDS
    2
    1
    2
    1
    [31B]
    [ 73B ]
    HANDLEBAR
    TRIPLE CLAMP
    HAND CONTROLS
    [32B]
    BK
    (WE)
    GROUND
    GROUNDS
    RIGHT
    (BK)
    RIGHT
    P/N 70142-93
    FRAME
    BK
    AUXILIARY
    LH CRUISE CONTROLS
    RH CRUISE CONTROLS
    GROUND
    P/N 70101-94
    LAMP
    RIGHT DIR SWITCH
    ENGINE OFF/RUN SWITCH
    START SWITCH
    STOPLIGHT SWITCH
    GY/BK
    POWER
    R
    S
    O
    O
    [22B]
    E
    E
    RESUME
    N
    F
    W/BE
    1
    RH CRUISE
    S
    T
    F
    SET
    BE/BK
    2
    CONNECTOR
    O/W
    1
    GND
    R/BE
    2
    [159B]
    RIGHT
    BK
    GY
    3
    FROM MAIN
    TURN
    (BK)
    W/BK
    4
    DIRECTIONAL
    BN
    HARNESS
    W/BN
    5
    AND DOM
    BE
    [22A]
    BK/R
    6
    (BK)
    RUNNING LAMP
    RUNNING
    LH CRUISE
    R/GN
    1
    2
    CONNECTOR
    [24B]
    DOM ONLY
    [158B]
    O/W
    1
    FRONT FENDER
    (GY)
    FROM MAIN
    y
    2
    TIP LAMP
    O/W
    3
    FROM MAIN
    HARNESS
    BE
    (DOMESTIC ONLY)
    SPEEDOMETER
    W
    4
    HARNESS
    BK
    [21A]
    W/V
    5
    [24A]
    Y/BK
    6
    1
    2
    3
    4
    5
    6
    7
    8
    (GY)
    POSITION LAMP
    O/W
    REAR LIGHTING HARNESS
    HORN SWITCH
    (HDI ONLY)
    [21B]
    BK
    (BK)
    LIGHTS HI/LOW SWITCH
    HIGH
    LEFT DIR SWITCH
    BEAM
    FROM MAIN
    INDICATOR
    HARNESS [7A]
    W
    LAMPS
    Y
    8 7 6 5 4 3
    2
    1
    HAND CONTROLS
    HEADLAMP
    BK
    -
    11
    LEFT
    RIGHT
    [7B]
    TURN
    RT
    3
    LOW
    BEAM
    +
    10
    OIL
    PRESSURE
    GND
    OP
    9
    BK
    LEFT
    TURN
    +
    10
    DIRECTIONAL
    V
    NEUTRAL
    AND DOM
    BE
    N
    8
    [94B]
    RUNNING LAMP
    -
    11
    RUNNING
    [39A]
    HIGH
    1
    DOM ONLY
    BEAM
    2
    HB
    4
    3
    -
    11
    4
    RIGHT REAR
    1
    2
    3
    4
    5
    6
    7
    8
    9
    10
    11 12
    LEFT
    5
    DIRECTIONAL
    TURN
    6
    LAMP
    GY/BK
    LT
    5
    V/BN
    LEFT
    BK
    AUXILIARY
    FROM MAIN
    FUEL GAUGE
    LAMP
    HARNESS
    BRAKE LIGHT
    [94B]
    G
    6543
    2
    1
    BK
    S I
    R/Y
    [19B]
    O/W
    [19A]
    BE
    V/BN
    1
    1
    2
    2
    [94A]
    BK
    TAIL
    HDI ONLY
    FROM MAIN HARNESS
    EFI ONLY
    CARBURETED ONLY
    [18B]
    [67A] AND [66A]
    [18A]
    TAIL
    [66B]
    V/BN
    1
    1
    DOM ONLY
    TAILLAMP
    [117A]
    BK
    2
    2
    AND/OR
    1234
    Y
    [67B]
    1
    2
    34
    4
    4
    REAR VIEW OF
    BK
    BK
    1
    1
    3
    3
    TOGGLE SWITCH
    TO MAIN
    2
    2
    2
    2
    WITH KEYWAY DOWN
    BK
    3
    3
    1
    1
    FENDERTIP LAMP (DOM)
    HARNESS
    FUEL
    PUMP
    [93B]
    LICENSE PLATE LAMP (HDI)
    ON
    [45B]
    [45A]
    [93A]
    NORMALLY CLOSED
    BK
    COMMON
    BK
    BK
    NORMALLY OPEN
    FULL:39.5/27.5 OHMS
    BK
    V/BN
    FULL: 39.5/27.5 OHMS
    1/2: 118.0/97.0 OHMS
    KEYWAY DOWN
    1/2: 118.0/97.0 OHMS
    EMPTY: 260.0/240.0 OHMS
    BK
    OFF
    1
    2
    3
    [141A]
    EMPTY: 260.0/240.0 OHMS
    3
    2
    1
    [141A]
    ACCESSORY/AUX LAMP SWITCH
    LEFT REAR
    FUEL PUMP ASSEMBLY IN TANK
    FUEL LEVEL SENDER IN TANK
    DIRECTIONAL
    LAMP
    2005 FLHR, FLHRC and FLHRS, DOMESTIC and INTERNATIONAL Models,
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    B-63
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    2005 FLHR, FLHRC and FLHRS,
    2005 FLHR, FLHRC and FLHRS,
    DOMESTIC and INTERNATIONAL Models,
    DOMESTIC and INTERNATIONAL Models,
    Handlebar Controls, Speedometer, Indicator Lamps,
    Handlebar Controls, Speedometer, Indicator Lamps,
    Tail Lamp, Auxiliary Lamps, Directional Lamps,
    Tail Lamp, Auxiliary Lamps, Directional Lamps,
    Fender Tip Lamps and Aux Lamp/Accessory Switches
    Fender Tip Lamps and Aux Lamp/Accessory Switches
    B-64
    Appendix B
    HOME
    O/W
    BE
    R/Y
    BK
    LBE/W
    SIDECAR
    LGN/BK
    SIDECAR
    6 5 4 3
    2
    1
    [94B]
    LEFT SPEAKER
    LBE/BK
    RIGHT SPEAKER
    [SC205]
    LGN/W
    [SC206]
    6 5 4 3
    2
    1
    [94A]
    [41D]
    [150B]
    PK/W
    1
    TAIL
    TO
    1
    1
    2
    3 4
    GY/W
    2
    LAMP
    MOTORCYCLE
    2
    PAINT
    PAINT
    V/BK
    3
    O/BK
    AUDIO
    DOT
    1
    2
    3 4
    DOT
    4
    GN
    5
    HARNESS
    [150A]
    LGN/BN
    6
    1
    [41C]
    2
    PK/W
    1
    4
    4
    BK
    GY/W
    2
    TO
    1
    1
    3
    3
    R/Y
    V/BK
    3
    RIGHT SPEAKER
    2
    2
    2
    2
    O/W
    O/BK
    3
    3
    4
    POD CONNECTOR
    1
    1
    GN
    5
    LGN/BN
    6
    [32B]
    [32A]
    SIDECAR FRONT
    [93A]
    [93B]
    FENDER TIP LAMP
    [53D]
    BK
    O/V
    1
    W/R
    2
    BK
    SIDECAR AUDIO
    W/V
    3
    HARNESS
    V/GY
    4
    P/N 88403-98
    BK
    5
    TO
    [149]
    BE/Y
    6
    MOTORCYCLE
    NOTE: RIGHT REAR
    Y/BK
    7
    AUDIO
    DIRECTIONAL LAMP
    1
    LBE/BK
    Y/W
    8
    HARNESS
    BULB MUST BE
    2
    W/BN
    Y/R
    9
    REMOVED FROM
    3
    BN
    BK
    10
    MOTORCYCLE WHEN
    4
    LGN/BN
    R
    11
    SIDECAR IS
    5
    GN
    BK
    12
    INSTALLED
    6
    7
    LGN/W
    [53C]
    8
    LGN/BK
    9
    LBE/W
    O/V
    1
    SIDECAR
    10
    W/R
    2
    DIRECTIONAL
    SIDE CAR
    11
    W/V
    3
    BN
    LAMP
    AMPLIFIER
    12
    V/GY
    4
    TO
    BK
    2
    2
    BK
    13
    BK
    5
    BN
    1
    1
    14
    BE/Y
    6
    CONSOLE
    15
    PK/W
    Y/BK
    7
    CONNECTOR
    [SC18A]
    [SC18B]
    16
    O/BK
    Y/W
    8
    17
    BN/W
    Y/R
    9
    18
    BK
    10
    19
    R
    11
    [SC7A]
    20
    BK
    BK
    12
    21
    O/V
    BN
    1
    O/W
    2
    TO MOTORCYCLE
    22
    V/BK
    V
    3
    REAR LIGHTING
    23
    GY/W
    [42D]
    BK
    4
    HARNESS
    BK
    5
    PK/W
    1
    CONNECTOR
    R/Y
    6
    GY/W
    2
    TO
    [7B]
    BE
    7
    V/BK
    3
    MOTORCYCLE
    BK
    8
    BN/W
    4
    AUDIO
    BN
    5
    HARNESS
    W/BN
    6
    [SC7B]
    BN
    1
    [42C]
    O/W
    2
    V
    3
    TO MOTORCYCLE
    PK/W
    1
    BK
    4
    MAIN HARNESS
    GY/W
    2
    TO
    BK
    5
    CONNECTOR
    V/BK
    3
    LEFT SPEAKER
    R/Y
    6
    BN/W
    4
    POD CONNECTOR
    [7A]
    BE
    7
    BN
    5
    BK
    8
    W/BN
    6
    SIDECAR HARNESS
    [76C]
    P/N 70221-99
    GRAY TWISTED PAIR - R
    1
    GY/BK
    2
    GY/Y
    3
    TO
    GRAY TWISTED PAIR - BK
    4
    MOTORCYCLE
    GY/O
    5
    AUDIO
    6
    HARNESS
    7
    GRAY TWISTED PAIR - SHIELD
    TAB
    SIDE CAR
    [76F]
    DIN HARNESS
    [76D]
    88401-98
    1
    GRAY TWISTED PAIR - R
    GRAY TWISTED PAIR - R
    1
    2
    GY/BK
    GY/BK
    2
    TO
    3
    GY/Y
    GY/Y
    3
    TO
    SIDECAR
    4
    GRAY TWISTED PAIR - BK
    GRAY TWISTED PAIR - BK
    4
    PASSENGER
    HEADSET
    5
    GY/O
    GY/O
    5
    HEADSET
    6
    6
    7
    7
    SIDECAR[84].
    TAB
    GRAY TWISTED PAIR - SHIELD
    GRAY TWISTED PAIR - SHIELD
    TAB
    2005 TLE, TLE-U SIDECARS, DOMESTIC AND INTERNATIONAL Models,
    Chassis and Audio Harness
    B-65
    HOME
    2005 TLE, TLE-U SIDECARS,
    2005 TLE, TLE-U SIDECARS,
    DOMESTIC and INTERNATIONAL Models,
    DOMESTIC and INTERNATIONAL Models,
    Chassis and Audio Harness
    Chassis and Audio Harness
    B-66
    Appendix B
    HOME
    METRIC CONVERSIONS
    C.1
    Table C-1. Metric Conversions
    MILLIMETERS to INCHES
    INCHES to MILLIMETERS
    (mm x 0.03937 = inches)
    (inches x 25.40 = mm)
    mm
    in.
    mm
    in.
    mm
    in.
    mm
    in.
    in.
    mm
    in.
    mm
    in.
    mm
    in.
    mm
    .1
    .0039
    25
    .9842
    58
    2.283
    91
    3.582
    .001
    .025
    .6
    15.240
    1 15/16
    49.21
    3 5/16
    84.14
    .2
    .0078
    26
    1.024
    59
    2.323
    92
    3.622
    .002
    .051
    5/8
    15.875
    2
    50.80
    3 3/8
    85.72
    .3
    .0118
    27
    1.063
    60
    2.362
    93
    3.661
    .003
    .076
    11/16
    17.462
    2 1/16
    52.39
    3.4
    86.36
    .4
    .0157
    28
    1.102
    61
    2.401
    94
    3.701
    .004
    .102
    .7
    17.780
    2.1
    53.34
    3 7/16
    87.31
    .5
    .0197
    29
    1.142
    62
    2.441
    95
    3.740
    .005
    .127
    3/4
    19.050
    2 1/8
    53.97
    3 1/2
    88.90
    .6
    .0236
    30
    1.181
    63
    2.480
    96
    3.779
    .006
    .152
    .8
    20.320
    2 3/16
    55.56
    3 9/16
    90.49
    .7
    .0275
    31
    1.220
    64
    2.519
    97
    3.819
    .007
    .178
    13/16
    20.638
    2.2
    55.88
    3.6
    91.44
    .8
    .0315
    32
    1.260
    65
    2.559
    98
    3.858
    .008
    .203
    7/8
    22.225
    2 1/4
    57.15
    3 5/8
    92.07
    .9
    .0354
    33
    1.299
    66
    2.598
    99
    3.897
    .009
    .229
    .9
    22.860
    2.3
    58.42
    3 11/16
    93.66
    1
    .0394
    34
    1.338
    67
    2.638
    100
    3.937
    .010
    .254
    15/16
    23.812
    2 5/16
    58.74
    3.7
    93.98
    2
    .0787
    35
    1.378
    68
    2.677
    101
    3.976
    1/64
    .397
    1
    25.40
    2 3/8
    60.32
    3 3/4
    95.25
    3
    .1181
    36
    1.417
    69
    2.716
    102
    4.016
    .020
    .508
    1 1/16
    26.99
    2.4
    60.96
    3.8
    96.52
    4
    .1575
    37
    1.456
    70
    2.756
    103
    4.055
    .030
    .762
    1.1
    27.94
    2 7/16
    61.91
    3 13/16
    96.84
    5
    .1968
    38
    1.496
    71
    2.795
    104
    4.094
    1/32
    .794
    1 1/8
    28.57
    2 1/2
    63.50
    3 7/8
    98.42
    6
    .2362
    39
    1.535
    72
    2.834
    105
    4.134
    .040
    1.016
    1 3/16
    30.16
    2 9/16
    65.09
    3.9
    99.06
    7
    .2756
    40
    1.575
    73
    2.874
    106
    4.173
    .050
    1.270
    1.2
    30.48
    2.6
    66.04
    3 15/16
    100.01
    8
    .3149
    41
    1.614
    74
    2.913
    107
    4.212
    .060
    1.524
    1 1/4
    31.75
    2 5/8
    66.67
    4
    101.6
    9
    .3543
    42
    1.653
    75
    2.953
    108
    4.252
    1/16
    1.588
    1.3
    33.02
    2 11/16
    68.26
    4 1/16
    102.19
    10
    .3937
    43
    1.693
    76
    2.992
    109
    4.291
    .070
    1.778
    1 5/16
    33.34
    2.7
    68.58
    4.1
    104.14
    11
    .4331
    44
    1.732
    77
    3.031
    110
    4.331
    .080
    2.032
    1 3/8
    34.92
    2 3/4
    69.85
    4 1/8
    104.77
    12
    .4724
    45
    1.772
    78
    3.071
    111
    4.370
    .090
    2.286
    1.4
    35.56
    2.8
    71.12
    4 3/16
    106.36
    13
    .5118
    46
    1.811
    79
    3.110
    112
    4.409
    .1
    2.540
    1 7/16
    36.51
    2 13/16
    71.44
    4.2
    106.68
    14
    .5512
    47
    1.850
    80
    3.149
    113
    4.449
    1/8
    3.175
    1 1/2
    38.10
    2 7/8
    73.02
    4 1/4
    107.95
    15
    .5905
    48
    1.890
    81
    3.189
    114
    4.488
    3/16
    4.762
    1 9/16
    39.69
    2.9
    73.66
    4.3
    109.22
    16
    .6299
    49
    1.929
    82
    3.228
    115
    4.527
    .2
    5.080
    1.6
    40.64
    2 15/16
    74.61
    4 5/16
    109.54
    17
    .6693
    50
    1.968
    83
    3.268
    116
    4.567
    1/4
    6.350
    1 5/8
    41.27
    3
    76.20
    4 3/8
    111.12
    18
    .7086
    51
    2.008
    84
    3.307
    117
    4.606
    .3
    7.620
    1 11/16
    42.86
    3 1/16
    77.79
    4.4
    111.76
    19
    .7480
    52
    2.047
    85
    3.346
    118
    4.645
    5/16
    7.938
    1.7
    43.18
    3.1
    78.74
    4 7/16
    112.71
    20
    .7874
    53
    2.086
    86
    3.386
    119
    4.685
    3/8
    9.525
    1 3/4
    44.45
    3 1/8
    79.37
    4 1/2
    114.30
    21
    .8268
    54
    2.126
    87
    3.425
    120
    4.724
    .4
    10.160
    1.8
    45.72
    3 3/16
    80.96
    4 9/16
    115.89
    22
    .8661
    55
    2.165
    88
    3.464
    121
    4.764
    7/16
    11.112
    1 13/16
    46.04
    3.2
    81.28
    4.6
    116.84
    23
    .9055
    56
    2.205
    89
    3.504
    122
    4.803
    1/2
    12.700
    1 7/8
    47.62
    3 1/4
    82.55
    4 5/8
    117.47
    24
    .9449
    57
    2.244
    90
    3.543
    123
    4.842
    9/16
    14.288
    1.9
    48.26
    3.3
    83.82
    4 11/16
    119.06
    Appendix C C-1
    HOME
    FLUID CONVERSIONS
    C.2
    UNITED STATES SYSTEM
    BRITISH IMPERIAL SYSTEM
    Unless otherwise specified, all fluid volume measurements
    Fluid volume measurements in this Service Manual do not
    in this Service Manual are expressed in United States
    include the British Imperial (Imp.) system equivalents. The fol-
    (U.S.) units-of-measure. See below:
    lowing conversions exist in the British Imperial system:
    ●
    1 pint (U.S.) = 16 fluid ounces (U.S.)
    ●
    1 pint (Imp.) = 20 fluid ounces (Imp.)
    ●
    1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.)
    ●
    1 quart (Imp.) = 2 pints (Imp.)
    ●
    1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.)
    ●
    1 gallon (Imp.) = 4 quarts (Imp.)
    Although the same unit-of-measure terminology as the U.S.
    METRIC SYSTEM
    system is used in the British Imperial (Imp.) system, the
    actual volume of each British Imperial unit-of-measure differs
    Fluid volume measurements in this Service Manual include
    from its U.S. counterpart. The U.S. fluid ounce is larger than
    the metric system equivalents. In the metric system, 1 liter (L)
    the British Imperial fluid ounce. However, the U.S. pint, quart,
    = 1,000 milliliters (mL). Should you need to convert from U.S.
    and gallon are smaller than the British Imperial pint, quart,
    units-of-measure to metric units-of-measure (or vice versa),
    and gallon, respectively. Should you need to convert from
    refer to the following:
    U.S. units to British Imperial units (or vice versa), refer to the
    following:
    ● fluid ounces (U.S.) x 29.574 = milliliters
    ● pints (U.S.) x 0.473 = liters
    ● fluid ounces (U.S.) x 1.042 = fluid ounces (Imp.)
    ● quarts (U.S.) x 0.946 = liters
    ● pints (U.S.) x 0.833 = pints (Imp.)
    ● gallons (U.S.) x 3.785 = liters
    ● quarts (U.S.) x 0.833 = quarts (Imp.)
    ● milliliters x 0.0338 = fluid ounces (U.S.)
    ● gallons (U.S.) x 0.833 = gallons (Imp.)
    ● liters x 2.114 = pints (U.S.)
    ● fluid ounces (Imp.) x 0.960 = fluid ounces (U.S.)
    ● liters x 1.057 = quarts (U.S.)
    ● pints (Imp.) x 1.201 = pints (U.S.)
    ● liters x 0.264 = gallons (U.S.)
    ● quarts (Imp.) x 1.201 = quarts (U.S.)
    ● gallons (Imp.) x 1.201 = gallons (U.S.)
    C-2
    Appendix C
    HOME
    JAPANESE MAINSHAFT/COUNTERSHAFT
    D.1
    NOTE
    Check the eight digit number stamped on the transmission
    case just above the side door. If the third digit is “9,” then the
    Mainshaft
    transmission was built for Japan only. If the digit is “0,” then it
    Plug
    was built for all countries except Japan. See the instructions
    which follow if servicing a Japanese transmission. For all
    other transmissions, see Section 7.6 MAINSHAFT/COUN-
    TERSHAFT.
    DISASSEMBLY
    NOTES
    ● Perform all steps if completely overhauling the transmis-
    9411
    sion assembly.
    Figure D-2. Press Out Countershaft
    ● Perform steps 1-11 and 17-18 if replacing only the coun-
    tershaft or one or more countershaft gears.
    ● Perform steps 1-5 and 12-18 if replacing only the main-
    shaft or one or more mainshaft gears.
    1WARNING
    ● Perform steps 1-6, 12, and 17-18 if replacing only the
    Always wear proper eye protection when removing re-
    side door bearings.
    taining rings. Use the correct retaining ring pliers. Verify
    that the tips of the pliers are not damaged or excessively
    worn. Slippage may propel the ring with enough force to
    1. Position the side door assembly on a bench with the
    cause eye injury.
    shafts pointing straight up, the mainshaft on the left hand
    side. The mainshaft is the longer of the two shafts. See
    4.
    Locate retaining ring just above the mainshaft 3rd gear
    Figure D-3.
    (spur). Move the retaining ring up approximately 3/8 inch
    2. Slide off the mainshaft 2nd gear (spur).
    (9.5 mm) towards the free end of the shaft. Turn side
    door assembly upside down and verify that mainshaft
    NOTE
    3rd gear is still partially engaged with countershaft 3rd
    gear.
    To facilitate reassembly, label each gear as it is removed.
    See Figure D-1.
    3. Obtain the TRANSMISSION SHAFT RETAINING RING
    CAUTION
    PLIERS, Part No. J-5586.
    Failure to move the retaining ring on the mainshaft can
    cause countershaft 1st gear to contact mainshaft 3rd
    gear when the countershaft is pressed out. On the other
    hand, if the retaining ring is moved too far, loss of
    9412
    engagement between mainshaft 3rd gear and counter-
    shaft 3rd gear can result in hard contact between these
    two gears. Any hard contact can result in gear tooth
    damage.
    5. With the outboard side up, rest side door on parallel
    blocks under ram of arbor press. Be sure that assembly
    is flat and does not rest on dowel on inboard side.
    6. Center countershaft under ram. Install mainshaft plug
    into hole at end of countershaft. Slowly apply pressure
    until countershaft is free. See Figure D-2. Remove main-
    shaft plug.
    Figure D-1. Note Gear Location During Disassembly
    Appendix D D-1
    HOME
    9413
    1
    10
    11
    6
    12
    3
    2
    4
    4
    3
    13
    5
    6
    3
    4
    4
    3
    7
    6
    14
    3
    4
    4
    3
    8
    6
    15
    9
    16
    1. Mainshaft
    9. Gold Spacer
    2.
    2nd Gear
    10. Countershaft
    3.
    Retaining Ring
    11.
    5th Gear
    4.
    Thrust Washer
    12.
    2nd Gear
    5.
    3rd Gear
    13.
    3rd Gear
    6.
    Split Cage Bearing
    14.
    1st Gear
    7.
    1st Gear
    15.
    4th Gear
    8.
    4th Gear
    16. Blue Spacer
    Figure D-3. Fully Assembled Side Door
    7.
    Slide blue spacer and countershaft 4th gear (helical) off
    8.
    Secure countershaft in a vise with the threaded end top-
    threaded end of countershaft.
    side. Be sure to install a pair of aluminum or brass jaw
    inserts in vise to avoid parts damage. See Figure D-4.
    D-2
    Appendix D
    HOME
    17. Set the side door on a bench with the outboard side up.
    9416
    Remove retaining ring from the bearing bore.
    NOTE
    Countershaft
    1st Gear
    Depending upon whether one or both shafts were removed,
    replace one or both side door bearings. Always replace the
    bearing if the shaft was pressed out.
    18. Turn side door over so that the inboard side is up and
    place on flat plate under ram of arbor press. Apply pres-
    sure to outer race to press bearing from bore.
    CLEANING AND INSPECTION
    Aluminum
    Jaws
    1.
    Clean all parts in cleaning solvent and blow dry with
    compressed air.
    Figure D-4. Disassemble/Assemble Countershaft
    2.
    Check gear teeth for damage. Replace the gears if they
    are pitted, scored, rounded, cracked or chipped.
    3.
    Inspect the engaging dogs on the gears. Replace the
    9.
    Remove retaining ring just above the countershaft 1st
    gears if the dogs are rounded, battered or chipped.
    gear (spur with single row of indents on teeth). Remove
    thrust washer and countershaft 1st gear. Gently pull
    4.
    Inspect the side door bearings. Bearings must rotate
    apart the split cage bearing and remove. Remove sec-
    freely without drag. Replace the bearings if pitted,
    ond thrust washer.
    grooved, or if the shafts were removed.
    10.
    Remove retaining ring above the countershaft 3rd gear
    (spur). Remove countershaft 3rd gear.
    11.
    Remove retaining ring just above the countershaft 2nd
    9415
    gear (spur). Remove thrust washer and countershaft
    2nd gear. Gently pull apart the split cage bearing and
    remove.
    Mainshaft
    1st Gear
    12.
    Center mainshaft under ram of arbor press. Install main-
    shaft plug into hole at end of mainshaft. Slowly apply
    pressure until mainshaft is free. Remove mainshaft plug.
    13.
    Slide gold spacer, mainshaft 4th gear (helical), split cage
    bearing and thrust washer off end of mainshaft.
    14.
    Secure the mainshaft in a vise with the longer splined
    end at the top. Be sure to install a pair of aluminum or
    brass jaw inserts in vise to avoid parts damage. See Fig-
    ure D-5.
    15.
    Remove retaining ring above the mainshaft 1st gear
    (spur with double row of indents on teeth). Remove
    mainshaft 1st gear.
    16.
    Remove retaining ring just above the mainshaft 3rd gear
    Figure D-5. Disassemble/Assemble Mainshaft
    (spur). Remove the thrust washer and mainshaft 3rd
    gear. Gently pull apart the split cage bearing and
    remove. Remove the second thrust washer. Remove the
    last retaining ring, which was moved out of the groove
    before the countershaft was pressed out.
    Appendix D D-3
    HOME
    ASSEMBLY
    9417
    Mainshaft
    Plug
    NOTES
    ● Perform all steps if the transmission assembly was com-
    pletely overhauled.
    ● Perform steps 1-5 and 12-24 if only the countershaft or
    one or more countershaft gears were replaced.
    ● Perform steps 1-11 and 20-24 if only the mainshaft or
    one or more mainshaft gears were replaced.
    ● Perform steps 1-4, 11, and 18-24 if only the side door
    bearings were replaced.
    1. With the outboard side up, place side door on flat plate
    under ram of arbor press.
    NOTE
    Note the two drill points between the bearing bores on the
    Figure D-6. Press In Countershaft
    side door. See Figure D-7. Two drill points indicate that the
    side door must be fitted with the new style 12mm wide bear-
    ings. Installation of the old style 14mm wide bearings would
    6. Secure the mainshaft in a vise with the longer splined
    cover the retaining ring grooves.
    end at the top. Be sure to install a pair of aluminum or
    brass jaw inserts in vise to avoid parts damage.
    2. Position new bearing over bore with the number stamp
    7. Install new retaining ring approximately 3/8 inch (9.5
    topside.
    mm) below the bottom retaining ring groove.
    3. Applying pressure to outer race, press bearing into bore
    8. Slide thrust washer down mainshaft until it contacts
    until firm contact is made with the counterbore.
    retaining ring. Lightly coat split cage bearing with oil and
    install in race just above thrust washer. Install mainshaft
    1WARNING
    3rd gear (spur) with the shifter dogs down. Install second
    thrust washer. Install new retaining ring in groove just
    Always wear proper eye protection when installing re-
    above the bearing race.
    taining rings. Use the correct retaining ring pliers. Verify
    9. With the fork groove up, slide mainshaft 1st gear (spur
    that the tips of the pliers are not damaged or excessively
    with double row of indents on teeth) down mainshaft until
    worn. Slippage may propel the ring with enough force to
    it contacts retaining ring. Install new retaining ring in
    cause eye injury.
    groove above the gear. See Figure D-5.
    4. With the flat side in towards the bearing (beveled side
    out), install new retaining ring in bearing bore.
    CAUTION
    NOTE
    Verify that the mainshaft 1st gear has the double row of
    Depending upon the level of disassembly, replace one or
    indents on teeth. Using a gear with a single row of
    both side door bearings. Always replace the bearing if the
    indents will result in transmission damage.
    shaft was pressed out.
    10. Slide thrust washer down the mainshaft until it contacts
    5. Obtain the TRANSMISSION SHAFT RETAINING RING
    the retaining ring. Lightly coat the split cage bearing
    PLIERS, Part No. J-5586.
    (double roller) with oil and install in race above the thrust
    washer. Install mainshaft
    4th gear
    (helical) over the
    bearing with the shifter dogs down. Install gold spacer.
    1WARNING
    11. With the inboard side up, place side door on flat plate
    Always use new retaining rings when assembling the
    under ram of arbor press. Holding mainshaft assembly
    mainshaft and countershaft. Reusing retaining rings can
    together, remove from vise and position over bearing
    cause the transmission to become “locked” during
    bore in side door. Install mainshaft plug into hole at end
    motorcycle operation, a situation which could result in
    of mainshaft. Supporting inner race of bearing, press
    death or serious injury.
    mainshaft into bearing bore. Remove mainshaft plug.
    D-4
    Appendix D
    HOME
    21. Return side door assembly to bench. Position with the
    shafts pointing straight up, the mainshaft on the left hand
    side.
    Mainshaft
    Countershaft
    Locknut
    Locknut
    22. Move partially installed retaining ring into groove just
    above the mainshaft 3rd gear.
    23. Install mainshaft 2nd gear (spur) with the fork groove
    down.
    The final assembly appears as shown in Figure D-3.
    24. Install spacer and locknut on the threaded end of each
    shaft and tighten the nuts until finger tight. See Figure D-
    Two Drill
    7.
    Points
    NOTE
    For final tightening of the locknuts and installation of the side
    door, see Section
    7.6
    MAINSHAFT/COUNTERSHAFT,
    9414
    INSTALLATION.
    Figure D-7. Install Mainshaft/Countershaft Locknuts
    12.
    Secure the countershaft in a vise with the threaded end
    topside. Be sure to install a pair of aluminum or brass
    jaw inserts in vise to avoid parts damage.
    13.
    Lightly coat split cage bearing with oil and install in race
    next to the countershaft 5th gear.
    14.
    Install countershaft 2nd gear (spur) over the bearing with
    the shifter dogs up. Install thrust washer and new retain-
    ing ring.
    15.
    Install countershaft 3rd gear (spur) with the fork groove
    down. Install new retaining ring in groove above the
    gear.
    16.
    Slide the thrust washer down the countershaft until it
    contacts the retaining ring. Lightly coat the split cage
    bearing with oil and install in the race just above the
    thrust washer. Install countershaft 1st gear (spur with
    single row of indents on teeth) with the taper up. Install
    second thrust washer and new retaining ring. See Fig-
    ure D-4.
    17.
    Install countershaft
    4th gear (helical) with the sleeve
    down. Install blue spacer with the taper up.
    18.
    With the inboard side up, place side door on flat plate
    under ram of arbor press. Support inner race of bearing.
    19.
    Holding countershaft assembly together, remove from
    vise. Raising mainshaft 3rd gear until it contacts partially
    installed retaining ring, position countershaft over bear-
    ing bore. Verify that taper on blue spacer is facing
    towards the bearing.
    20.
    Place mainshaft plug at end of countershaft. Be sure
    that mainshaft and countershaft gears mesh and that
    assembly is square. Press countershaft into bearing
    bore. Remove mainshaft plug. See Figure D-6.
    Appendix D D-5
    HOME
    NOTES
    D-6
    Appendix D
    STARTING/CHARGING
    1
    Table Of Contents
    SUBJECT
    PAGE NO.
    1.1 Starter Troubleshooting
    1-1
    1.2 Starting System Diagnosis
    1-3
    1.3 Starter Activation Circuits
    1-7
    1.4 Diagnostics/Troubleshooting
    1-8
    1.5 Starter System Testing
    1-9
    1.6 Testing Assembled Starter
    1-11
    1.7 Charging System
    1-13
    1.8 Battery Load Test
    1-19

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    Матвей Александрович29.05.2024 04:09
    Политика конфиденциальности