Harley Davidson 2005 touring models. Service repair manual — page 24
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6421
6420
Hex Adjuster
Hex Adjuster
LEFT SIDE
RIGHT SIDE
Figure 8-32. Headlamp Adjustment (FLTR)
6.
Stand the motorcycle upright with both tires resting on
11. Using a deepwell 4.5 mm with 1/4 inch drive socket
the floor and with the front wheel held in straight align-
(Snap-On STMM4.5) and flexible driver
(Snap-On
ment (directly forward).
TM62B), adjust the headlamp horizontally by turning
either the left or right side adjuster. Turn both adjusters
7.
Turn the Ignition/Light Key Switch to IGNITION. Set the
equally to adjust the headlamp vertically.
Light Switch on the left handlebar to Hi(gh) beam.
NOTE
If the socket does not easily fit the adjuster, see if a deepwell
8.
Check the light beam for proper height alignment. The
3/16 inch with 1/4 inch drive socket (Snap-On STM6) pro-
center of the main beam of light should be even with the
duces better results.
horizontal line on the screen or wall.
Adjuster rotation moves the headlamp beam as follows:
9.
Check the light beam for proper lateral alignment. The
main beam of light should be directed straight ahead
Table 8-6. FLTR Hex Adjuster Rotation
(i.e., equal area of light to right and left of center).
Beam
Hex Adjuster
Rotation
10.
Locate the hex adjusters near the bottom edge of the
Movement
inner fairing. See Figure
8-32. Turning the adjusters
Left Only
CW
causes the double headlamp housing to pivot around its
To the Right
upper mount.
Right Only
CCW
Left Only
CCW
To the Left
Right Only
CW
Left and Right Equally
CW
Upward
Left and Right Equally
CCW
Downward
CW= Clockwise
CCW= Counter-Clockwise
8-30
2005 Touring: Electrical
HOME
AUXILIARY LAMPS
8.13
AUXILIARY LAMP BULB
f2329x8x
Nesting Ring
Index Tab
REMOVAL
1. Loosen auxiliary lamp door screw as required to pull
lamp door from lip of lamp housing. See Figure 8-33.
2. Pull socket terminals from spade contacts at back of
lamp.
3. Remove nesting ring and discard lamp.
Lamp
INSTALLATION
Index Tab
1. Verify that two adhesive foam strips are present on
inboard side of lamp door. Install new foam strips if dete-
riorated or missing.
Figure 8-34. Install Nesting Ring at Back of
2. Place nesting ring at back of new lamp with the concave
Auxiliary Lamp Bulb
side up.
3. Install black wire socket terminal onto spade contact on
5.
Holding nesting ring in place, rotate lamp so that index
index tab side of lamp. Install second socket terminal
tab at back engages slot in nesting ring.
onto remaining spade contact. See Figure 8-34.
4. Install lamp fitting nesting ring over edge of lamp hous-
NOTE
ing. Rotate nesting ring so that index tab engages slot at
Since there are two slots in nesting ring, be sure that lamp
bottom of lamp housing.
index tab engages slot closest to left side of motorcycle.
6.
Install lamp door over lip of lamp housing. Rotate lamp
Auxiliary
door so that screw is centered at bottom, and then
9462
Lamp
Door
tighten door screw until snug.
AUXILIARY LAMP
Door
Screw
REMOVAL
1.
Proceed as follows:
Screw
FLHT/C/U: Remove the outer fairing. See Section 2.29
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
FAIRING/WINDSHIELD, REMOVAL. Locate auxiliary
lamp connector (white 2-place Multilock) below upper
Mounting
Bracket
fork bracket. See Figure 8-35.
FLHR/C: Remove the Phillips screw at the bottom of the
Turn Signal
headlamp door (chrome ring). Remove the headlamp
Lamp
door. Remove the eight Phillips screws to free the head-
lamp housing from the headlamp nacelle. Squeeze the
two external tabs to remove the wire connector at the
back of the headlamp bulb. Remove the headlamp hous-
ing assembly from the vehicle. Locate auxiliary lamp
connector (white 2-place Multilock). See Figure 8-36.
Figure 8-33. Auxiliary Lamp and Turn Signal
2005 Touring: Electrical
8-31
HOME
5. Obtain length of strong flexible wire for use as mechan-
Auxiliary Lamp
ics wire. Feed wire through opening in socket terminal
Connector [73]
and then loop back twisting end until tightly coiled
around longer strand as shown in Figure 8-37.
NOTE
Be sure that mechanics wire is of sufficient strength to pull
terminal through conduit without breaking. Wire length must
also be long
enough so that free end is not lost in conduit
when pulled.
6. Carefully
pull wire to draw socket terminal through con-
duit.
7. Unravel mechanics wire to release socket terminal.
8. Insert flare nut socket (Snap-on® FRX181) at bottom of
turn signal mounting bracket and remove locknut from
stud. Remove the turn signal mounting bracket and
clamp block.
f2238x8x
9. Remove auxiliary lamp (with Belleville washer and swivel
block) from the auxiliary lamp bracket.
Figure 8-35. Inner Fairing (FLHT/C/U)
INSTALLATION
f2212x8x
1.
Lay old auxiliary lamp next to new auxiliary lamp and cut
Gray/Black wire to length.
2.
Strip 3/16 inch (4.8 mm) of insulation off new lamp wire
and crimp on new socket terminal.
NOTE
For instructions on crimping wire terminals, see APPENDIX
B.2 AMP MULTILOCK ELECTRICAL CONNECTORS,
CRIMPING INSTRUCTIONS.
3.
If removed, slide swivel block and Belleville washer down
Gray/Black wire onto auxiliary lamp stud. Be sure that
rounded side of swivel block and concave side of
Belleville washer face auxiliary lamp.
Auxiliary Lamp
Auxiliary Lamp
Switch Connector [109]
Connector [73]
Mechanics Wire
Figure 8-36. Headlamp Nacelle (FLHRC)
2.
Depress the button on the socket terminal side of the
connector and pull apart the pin and socket halves.
3.
Remove terminal of Gray/Black wire from socket hous-
ing.
NOTE
Socket Terminal
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
TORS, REMOVING SOCKET/PIN TERMINALS.
f1418x2x
4.
Remove two screws to release turn signal lamp from
mounting bracket. See Figure 8-33.
Figure 8-37. Fix Mechanics Wire to Socket Terminals
8-32
2005 Touring: Electrical
HOME
4. Feed Gray/Black wire of auxiliary lamp through slot at
FLHR/C: Slide slots of auxiliary lamp bracket onto upper
top of auxiliary lamp bracket and insert threaded stud
and lower fork bracket studs. Install acorn nuts on studs.
into forward slot. Slide clamp block (rounded side up),
Alternately tighten acorn nuts to 72-108 in-lbs (8.1-12.2
turn signal mounting bracket and locknut up Gray/Black
Nm) using a crosswise pattern.
wire onto auxiliary lamp stud at bottom of bracket.
All Others: Slide slots of auxiliary lamp bracket onto
5. Using flare nut socket (Snap-on® FRX181), tighten lock-
T40 TORX screws in upper and lower fork brackets.
nut to 18 ft-lbs (24.4 Nm).
Alternately tighten screws to 15-20 ft-lbs (20-27 Nm)
6. Reattach mechanics wire to socket terminal and care-
using a crosswise pattern.
fully pull end of mechanics wire to draw socket terminal
back through conduit.
7. Carefully remove mechanics wire to avoid damage to
ADJUSTMENT
terminal.
8. Install terminal of Gray/Black wire into socket housing.
NOTE
Headlamp High Beam
For instructions on properly installing wire terminals, see
1.
Adjust the headlamp high beam for proper height and
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
lateral alignment. See Section 8.11 HEADLAMP (FLHR/
TORS, INSTALLING SOCKET/PIN TERMINALS.
C/S, FLHT/C/U), HEADLAMP ADJUSTMENT, steps 1-
10.
9. Mate pin and socket halves of auxiliary lamp connector.
10. Turn Ignition/Light Key Switch to IGNITION and test for
2.
With a rider seated on the motorcycle and the front
proper operation and alignment. Adjust if necessary.
wheel pointed straight ahead, turn on the headlamp high
beam.
11. Start two screws to secure turn signal lamp to mounting
bracket. See Figure 8-33. Verify that conduit fits in slot at
3.
Mark the center of the headlamp high beam by making a
back of bracket and is not pinched. Alternately tighten
vertical line through the horizontal line already drawn on
screws to 36-60 in-lbs (4.1-6.8 Nm).
the wall. Properly adjusted, the beam should project an
12. Proceed as follows:
equal area of light to the left and right of the vertical cen-
terline. See item 1 in Figure 8-38.
FLHT/C/U: Route auxiliary lamp conduit upward in front
of chrome skirt and then rearward using relief in upper
outboard corner (in front of fairing bracket). Install the
Auxiliary Lamps
outer fairing. See Section 2.29 UPPER FAIRING/WIND-
SHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD,
4.
Turn the headlamp off and move to the front of the
INSTALLATION.
motorcycle.
FLHR/C: Install wire connector at the back of the head-
5.
Measure the distance from the headlamp horizontal cen-
lamp bulb. Align holes in headlamp housing with those in
terline down to the horizontal centerline of the left side
headlamp nacelle (headlamp door bracket at bottom).
auxiliary lamp. Now measure the distance from the
Install eight Phillips screws.
headlamp vertical centerline out to the vertical centerline
of the same lamp.
AUXILIARY LAMP BRACKET
6.
Repeat measurements performed in step 5 on right side
auxiliary lamp.
REMOVAL
7.
From the headlamp high beam centerlines, perform the
measurements taken in steps 5-6 to locate the left and
1. Remove auxiliary lamp bracket from motorcycle. Pro-
right side auxiliary lamp centerlines on the wall. See
ceed as follows:
items 2 and 3 in Figure 8-38.
FLHR/C: Remove acorn nuts from fork bracket studs.
8.
Turn on the headlamp high beam again, and with a rider
All Others: Using a T40 TORX drive head, loosen upper
seated on the motorcycle, verify that it is still aligned with
and lower fork bracket screws.
the horizontal and vertical centerlines.
2. Remove auxiliary lamp bracket from motorcycle.
9.
Turn on the headlamp low beam and then cover both the
headlamp and the right side auxiliary lamp. Adjust the
left side auxiliary lamp as necessary so that the entire
INSTALLATION
high intensity zone is both below and to the right of the
left side auxiliary lamp centerlines. See item 4 in Figure
1. Install auxiliary lamp bracket on motorcycle. Proceed as
8-38.
follows:
2005 Touring: Electrical
8-33
HOME
f2322x8x
1
2
3
4
5
1. Adjust headlamp high beam for proper height and lateral alignment.
2. Locate left side auxiliary lamp relative to high beam centerlines.
3. Locate right side auxiliary lamp relative to high beam centerlines.
4. Adjust high intensity beam below and right of left side auxiliary lamp centerlines.
5. Adjust high intensity beam below and right of right side auxiliary lamp centerlines.
Figure 8-38. Properly Aim Auxiliary Lamps
10. Leaving the headlamp covered, remove cover from right
b. Insert flare nut socket (Snap-on® FRX181) at bot-
side auxiliary lamp and place over left side auxiliary
tom of turn signal mounting bracket and tighten
lamp. Adjust the right side auxiliary lamp as necessary
locknut to 18 ft-lbs (24.4 Nm).
so that the entire high intensity zone is both below and to
the right of the right side auxiliary lamp centerlines. See
c. Start two screws to secure turn signal lamp to
item 5 in Figure 8-38.
mounting bracket. Verify that conduit fits in slot at
back of bracket and is not pinched. Alternately
11. Verify that auxiliary lamps are properly tightened. Pro-
tighten screws to 36-60 in-lbs (4.1-6.8 Nm).
ceed as follows:
a. Remove two screws to release turn signal lamp
from mounting bracket. See Figure 8-33.
8-34
2005 Touring: Electrical
HOME
TAIL LAMP ASSEMBLY
8.14
3.
Place tail lamp into position against chrome plastic
TAIL LAMP/TAIL LAMP BULB
bracket.
REMOVAL
CAUTION
1. Remove two Phillips screws from lense to release tail
Over tightening screws can crack the lense or result in
lamp assembly from chrome plastic bracket at back of
scratching of the fender paint.
rear fender. Carefully pull tail lamp assembly from
bracket. See left side of Figure 8-39.
4.
Install two Phillips screws and alternately tighten to 20-
24 in-lbs (2.3-2.7 Nm).
2. Depress button at bottom of 4-place Multilock socket to
release tail lamp assembly from pin housing. See right
5.
Turn the Ignition/Light Key Switch to IGNITION and test
side of Figure 8-39.
lamp for proper operation.
3. Rotate bulb socket 1/4 turn in a counterclockwise direc-
tion and remove from tail lamp assembly. Gently pull
CIRCUIT BOARD/TAIL LAMP
bulb from socket.
BRACKET
INSTALLATION
1. Gently push new bulb into socket. Insert socket into tail
REMOVAL
lamp assembly and rotate 1/4 turn in a clockwise direc-
tion.
1.
Remove two Phillips screws from lense to release tail
2. Orient 4-place Multilock socket so that the release but-
lamp assembly from chrome plastic bracket at back of
ton is at the bottom and insert into pin housing until it
rear fender. Carefully pull tail lamp assembly from
“clicks.” See right side of Figure 8-39.
bracket. See left side of Figure 8-39.
Tail Lamp [93]
Tail Lamp
Chrome Plastic
4-place Multilock
Assembly
Bracket
f2331x8x
Figure 8-39. Remove Tail Lamp and Depress Button to Release Socket Housing
2005 Touring: Electrical
8-35
HOME
All remaining release buttons are at the top, with the
exception of the rear fender lights harness socket, where
Right Turn
the button is on the outboard side. To release socket
Signal Lamp
Fender Tip
[19]
housings of left and right turn signal lamps, use a pick or
Lamp [45]
small screwdriver to depress top release button as
Left Turn
Fender Lights
shown in Figure 8-41.
Signal Lamp
Tail Lamp
Harness to
[18]
4. Remove large Phillips screw and pull pin housing with
[93]
Circuit Board
[94]
attached circuit board (and gasket) from chrome plastic
bracket. Two tabs at back of pin housing fit into holes in
bracket.
5. Remove chrome plastic bracket. Use both thumbs to
push bracket upward until it becomes free of fender and
then pull out of fender hole.
6. Feed Multilock sockets through openings to inboard side
of bracket. See Figure 8-40. For best results, free the
smaller sockets first.
INSTALLATION
1.
Feed Multilock sockets through openings to outboard
side of chrome plastic bracket. See Figure 8-40. For best
results, feed the larger sockets first.
2.
Fit bottom of bracket into fender hole and then push
down to align center hole in bracket with clip nut on
Opening
f2172x8x
fender flange.
3.
Place pin housing over circuit board, if removed. See
Figure 8-40. Rear Fender Lights Assembly
Figure 8-42.
4.
Snap tabs at back of pin housing into holes in plastic
bracket.
Pick
Tool
CAUTION
Over tightening screw can crack the plastic bracket or
result in scratching of the fender paint.
Pin Housing
f1497b8x
Figure 8-41. Release Left Turn Signal Lamp Socket
H-D
USA
68830-98
2.
Depress button at bottom of 4-place Multilock socket to
release tail lamp assembly from pin housing. See right
Circuit Board
f1506x8x
side of Figure 8-39.
3.
Depress buttons to remove four remaining Multilock
Figure 8-42. Place Pin Housing Over Circuit Board
sockets from pin housing. See Figure 8-40.
8-36
2005 Touring: Electrical
HOME
5. Install large Phillips screw to secure pin housing, circuit
board and plastic bracket to fender flange. Tighten screw
CAUTION
to 40-48 in-lbs (4.5-5.4 Nm).
Over tightening screws can crack the lense or result in
6. Install each socket into pin housing until it “clicks.” Install
scratching of the fender paint.
rear fender tip lamp and both left and right turn signal
lamp sockets so that the release buttons are at the top.
9.
Install two Phillips screws and alternately tighten to 20-
Install the rear fender lights harness socket with the but-
24 in-lbs (2.3-2.7 Nm).
ton on the outboard side and the tail lamp socket with
10. Turn the Ignition/Light Key Switch to IGNITION and test
the button at the bottom.
lamp for proper operation.
7. To avoid stressing wires, verify that tail lamp conduit is
positioned on the outboard side of the rear fender tip
lamp and left turn signal lamp conduit as shown in Fig-
ure 8-39.
8. Place tail lamp into position against chrome plastic
bracket.
2005 Touring: Electrical
8-37
HOME
FENDER TIP LAMPS
8.15
FRONT FENDER TIP LAMP
Front Fender
Tip Lamp [32]
REMOVAL
1.
Insert blade of small screwdriver into slot at top of fender
tip lamp lense. Rotate end of screwdriver to unsnap
lense from lamp bracket.
2.
Remove gasket from fender tip lamp bracket, if present.
3.
Holding Keps nuts at inboard
side of rear fender, remove
two Phillips screws to release fender tip lamp bracket.
4.
Depress button on socket terminal side of black 2-place
Multilock connector to release fender tip lamp assembly
from jumper harness. See Figure 8-45.
INSTALLATION
1.
Mate pin and socket halves of black 2-place Multilock
connector to attach front fender tip lamp assembly to
jumper harness. See Figure 8-45.
2.
With wires routed along bottom left side, place fender tip
lamp bracket into position aligning holes in bracket with
f2238x8x
those in fender.
Figure 8-43. Inner Fairing (FLHT/C/U)
CAUTION
Over tightening screws can crack the bracket or result in
scratching of the fender paint.
3.
Slide Phillips screws through bracket and fender holes
and install Keps nuts. Holding nuts at inboard side of
fender, tighten screws to 20-24 in-lbs (2.3 - 2.7 Nm).
4.
Place gasket into position on fender tip lamp bracket, if
present.
5.
Insert tab at bottom of lense into slot of fender tip lamp
bracket. Apply thumb pressure at top of lense until it
snaps into place.
6.
Turn the Ignition/Light Key Switch to IGNITION and test
lamp for proper operation.
FRONT FENDER TIP LAMP
JUMPER HARNESS
Front Fender
Tip Lamp [32]
Used on FLHR Only
f2212x8x
REMOVAL
Figure 8-44. Headlamp Nacelle (FLHRC)
1.
Proceed as follows:
FLHT/C/U: Reaching in below the fairing cap on the left
side of the steering head, locate the front fender tip lamp
FLHR: Remove the Phillips screw at the bottom of the
connector (black 2-place Multilock). See Figure 8-43.
headlamp door (chrome ring). Remove the headlamp
Remove the outer fairing only if necessary. See Section
door. Remove the eight Phillips screws to free the head-
2.29 UPPER FAIRING/WINDSHIELD
(FLHT/C/U),
lamp housing from the headlamp nacelle. Squeeze the
OUTER FAIRING/WINDSHIELD, REMOVAL.
8-38
2005 Touring: Electrical
HOME
two external tabs (if present) to remove the wire connec-
tor at the back of the headlamp bulb. Remove the head-
Fender Tip
lamp housing assembly from the vehicle. Locate the
Lamp Bracket
Oblong Hole
front fender tip lamp connector (black 2-place Multilock).
See Figure 8-44.
2. Depress the button on the socket terminal side of the
connector and pull apart the pin and socket halves.
3. Draw socket connector down to fender area.
4. Carefully cut cable strap to release front fender tip lamp
wires from brake line hose.
5. Remove terminals from socket housing.
NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
Tee Bolt
TORS, REMOVING SOCKET/PIN TERMINALS.
Wire Conduit
6. Place the motorcycle on a hydraulic center stand with
the front wheel raised off the ground.
Trim Strip
f1505x8x
7. Remove the front wheel. See Section
2.3 FRONT
WHEEL, REMOVAL.
Figure 8-46. Install Conduit in Trim Strip
8. From inboard side of front fender, remove two nuts to
release trim strip from left side of fender. See Figure 8-
46.
Grommet
9. Pull wires and Multilock socket terminals through grom-
met to inboard side of fender. See Figure 8-47. Reach-
ing under left side of fender, release wires from one weld
clip and four metal adhesive clips.
10. Feed wires and Multilock socket terminals through
oblong hole to outboard side of fender.
f1504a8x
Socket
Brake
Terminals
Hose
f1503b8x
Figure 8-47. Pull Fender Tip Lamp Wires and Terminals
Through Fender Grommet
Fender Tip
11. Insert blade of small screwdriver into slot at top of fender
Lamp Bracket
tip lamp lense. Rotate end of screwdriver to unsnap
2-Place
lense from lamp bracket.
Multilock
Connector
12. Remove gasket from fender tip lamp bracket, if present.
LEFT SIDE
13. Holding Keps nuts at inboard side of front fender,
remove two Phillips screws to release fender tip lamp
Figure 8-45. Fender Tip Lamp Assembly
bracket.
2005 Touring: Electrical
8-39
HOME
14. Depress button on socket terminal side of 2-place Mul-
tilock connector to release fender tip lamp assembly
f2003x8x
from jumper harness. See Figure 8-45.
2
3
INSTALLATION
4
1.
See Figure 8-48. Carefully inspect the condition and
1
security of the four metal adhesive clips in the left side
fender well. Replace the clips if broken, loose or missing.
Proceed as follows:
a. Remove remnants of old clip, as well as all residual
adhesive.
Weld
Fender
b. Using a soapy Scotch Brite® pad, thoroughly clean
Clip
Bracket
fender well in area of clip.
c. Rinse with clear water and dry with a clean white
cloth. Repeat step until clean cloth shows no evi-
Figure 8-48. Four Metal Adhesive Clips
dence of dirt.
(Left Side Front Fender Well)
d. Swab area with isopropyl alcohol.
e. Obtain new metal adhesive clip (Part No. 10187).
11. Install terminals into socket housing.
f.
Remove paper backing to expose adhesive and
firmly press clip into place.
NOTE
For instructions on properly installing wire terminals, see
2.
Mate pin and socket halves of 2-place Multilock connec-
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
tor to attach front fender tip lamp assembly to jumper
TORS, INSTALLING SOCKET/PIN TERMINALS.
harness. See Figure 8-45.
3.
With wires routed along bottom left side, place fender tip
12. Reaching under left side of fender, route wires of the
lamp bracket into position aligning holes in bracket with
jumper harness through one weld clip and four metal
those in fender.
adhesive clips. See Figure 8-48.
CAUTION
1WARNING
Over tightening screws can crack the bracket or result in
If any portion of the jumper harness crosses over the riv-
scratching of the fender paint.
eted fender bracket, contact with the tire can cause chaf-
4.
Slide Phillips screws through bracket and fender holes
ing or other damage. Damage to the wiring can lead to
and install Keps nuts. Holding nuts at inboard side of
loss of lighting while riding, which could result in death
fender, tighten screws to 20-25 in-lbs (2.3-2.8 Nm).
or serious injury.
5.
Place gasket into position on fender tip lamp bracket, if
13. Verify that no portion of the jumper harness crosses over
present.
the riveted fender bracket.
6.
Insert tab at bottom of lense into slot of fender tip lamp
bracket. Apply thumb pressure at top of lense until it
snaps into place.
1WARNING
7.
Route wire conduit inside trim strip and slide front tee
If the height of any metal clip is above the riveted fender
bolt over conduit. See Figure 8-46. Verify that second
bracket, contact with the tire can cause damage that
tee bolt is in position at rear of trim strip.
results in premature tire failure, which could result in
death or serious injury.
8.
Feed Multilock socket terminals and wires through
oblong hole to inboard side of fender.
14. Using finger pressure, bend arm of each clip down over
9.
While removing slack from wires on outboard side of
wires so that no portion of the clip is above the height of
fender, align tee bolts with fender holes. Wtih trim strip
the fender bracket.
positioned against left side of fender, reach under fender
and install nuts on tee bolts. Alternately tighten nuts to
15. Route socket housing of front fender tip lamp connector
10-15 in-lbs (1.1-1.7 Nm).
upward behind chrome skirt (FLHT/C/U) or through bot-
tom of headlamp nacelle (FLHR) to area beneath upper
10. Pull Multilock socket terminals and wires through grom-
fork bracket. Mate pin and socket halves.
met to outboard side of fender. See Figure 8-47.
8-40
2005 Touring: Electrical
HOME
NOTE
To connect front fender tip lamp with the outer fairing
installed (FLHT/C/U models), reach in below the fairing cap
on the left side of the steering head.
Screwdriver
16. Install the front wheel. See Section 2.3 FRONT WHEEL,
INSTALLATION.
17. Install new cable strap to secure front fender tip lamp
wires to brake line hose. Cut any excess cable strap
material.
18. Proceed as follows:
FLHT/C/U: Install the outer fairing, if removed. See Sec-
tion 2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U),
OUTER FAIRING/WINDSHIELD, INSTALLATION.
FLHR: Install wire connector at the back of the head-
lamp bulb. Align holes in headlamp housing with those in
headlamp nacelle. Install eight Phillips screws. Install
the headlamp door
(chrome ring) and door screw.
Tighten screw to 9-18 in-lbs (1.0-2.0 Nm).
Lense
19. Turn Ignition/Light Key Switch to IGNITION and test
f1501x8x
lamp for proper operation.
Fender Tip
Gasket
Lamp Bracket
REAR FENDER TIP LAMP
REMOVAL
1.
Remove two Phillips screws from lense to release tail
lamp assembly from chrome plastic bracket at back of
rear fender. Carefully pull tail lamp assembly from
bracket.
Rear Fender
Tail Lamp [93]
Tip Lamp [45]
TORX
Screws
f1500x8x
Figure 8-50. Remove Rear Fender Tip Lamp Lense
and Bracket
2.
Depress button at bottom of 4-place Multilock socket to
release tail lamp assembly from pin housing. See Figure
8-49.
3.
Depress button at top of 3-place Multilock socket to
release fender tip lamp assembly from pin housing.
4.
Feed
3-place Multilock socket through opening in
chrome plastic bracket to inboard side of rear fender.
Reaching under left side of rear fender, release conduit
from two cable clips anchored on T-studs.
5.
Insert blade of small screwdriver into slot at top of fender
Opening
f2172x8x
tip lamp lense. Rotate end of screwdriver to unsnap
lense from lamp bracket. See upper frame of Figure 8-
Figure 8-49.
Depress Button to Release Socket
50.
From Pin Housing
2005 Touring: Electrical
8-41
HOME
NOTE
Fender
Hole
For instructions on properly installing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
TORS, INSTALLING SOCKET/PIN TERMINALS.
4.
Feed 3-place Multilock socket and conduit through bot-
tom fender hole. See Figure 8-51.
5.
Place fender tip lamp bracket into position aligning holes
in bracket with those in fender. Slide TORX screws
through bracket and fender holes and install nuts.
6.
Place gasket into position on fender tip lamp bracket, if
present. See lower frame of Figure 8-50.
7.
Insert tab at bottom of lense into slot of fender tip lamp
Fender Tip
bracket. Apply thumb pressure at top of lense until it
Lamp Bracket
f1499x8x
snaps into place.
Figure 8-51. Feed Fender Tip Lamp Socket and Conduit
8.
Reaching under left side of rear fender, capture conduit
in two cable clips anchored on T-studs. Feed 3-place
Through Fender Hole
Multilock socket through opening on left side of chrome
plastic bracket to outboard side of rear fender.
6.
Remove gasket from fender tip lamp bracket, if present.
9.
Orient 3-place Multilock socket so that the release but-
See lower frame of Figure 8-50.
ton is at the top and insert into pin housing until it
7.
Holding nuts at inboard side of rear fender, remove two
“clicks.”
TORX screws to release fender tip lamp bracket.
10.
To install tail lamp assembly, orient 4-place Multilock
8.
Draw conduit and 3-place Multilock socket out through
socket so that the release button is at the bottom and
bottom fender hole. See Figure 8-51.
insert into pin housing until it “clicks.” To avoid stressing
9.
Remove terminals from socket housing.
wires, verify that tail lamp conduit is positioned on the
outboard side of the rear fender tip lamp and left turn
NOTE
signal lamp conduit as shown in Figure 8-49.
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
11.
Place tail lamp into position against chrome plastic
TORS, REMOVING SOCKET/PIN TERMINALS.
bracket.
INSTALLATION
CAUTION
1.
Place new fender tip lamp assembly next to discarded
Over tightening screws can crack the lense or result in
unit and cut wires to proper length.
scratching of the fender paint.
2.
Crimp new socket terminals onto fender tip lamp wires.
12. Install two Phillips screws and alternately tighten to 20-
NOTE
24 in-lbs (2.3-2.7 Nm).
For instructions on crimping wire terminals, see APPENDIX
B.2 AMP MULTILOCK ELECTRICAL CONNECTORS,
13. Turn the Ignition/Light Key Switch to IGNITION and test
CRIMPING INSTRUCTIONS.
lamp for proper operation.
3. Install terminals into socket housing.
Table 8-7. Rear Fender Tip Lamp [45]
Chamber
Wire Color
Number
Black
1
Not Used
2
Black
3
8-42
2005 Touring: Electrical
HOME
TURN SIGNAL LAMPS
8.16
BULB REPLACEMENT
Turn Signal Lamp
Connector [31]
REMOVAL
1. Proceed as follows:
FLHR/C, FLHT/C/U: Remove two Phillips screws to
release lense from lamp housing. See Figure 8-52.
FLHRS, FLTR: Insert blade of small screwdriver into slot
at bottom of lense. Gently rotate end of screwdriver to
unsnap lense from lamp housing.
2. While pushing in bulb, rotate in a counter-clockwise
direction to remove.
3. Inspect condition of electrical contacts in socket. If nec-
essary, clean with a small wire brush and electrical con-
tact cleaner.
INSTALLATION
1. Liberally apply dielectric grease to contacts in socket
and at bottom of new bulb. For correct bulb type, see
f2238x8x
Section 8.2 BULB CHART.
Figure 8-53. Inner Fairing (FLHT/C/U)
2. While pushing in new bulb, rotate in a clockwise direc-
tion to install.
3.
Proceed as follows:
FLHR/C, FLHT/C/U: Seat lense in lamp housing and
Auxiliary
9462
install two Phillips screws.
Lamp
FLHRS, FLTR: Seat lense in lamp housing and gently
apply thumb pressure to lense until it snaps into place.
Rotate lense to position slot at bottom of lamp housing.
FRONT TURN SIGNAL LAMP
Screw
FLHR/C, FLHT/C/U
Removal
Mounting
1.
Proceed as follows:
Bracket
Lense
FLHT/C/U: Remove the outer fairing. See Section 2.29
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
Turn Signal
FAIRING/WINDSHIELD, REMOVAL. Locate front turn
Lamp
signal lamp connector (6-place Multilock) on T-stud at
top of left fairing support brace. See Figure 8-53.
FLHR/C: Remove the Phillips screw at the bottom of the
headlamp door (chrome ring). Remove the headlamp
Figure 8-52. Front Turn Signal Lamp
door. Remove the eight Phillips screws to free the head-
lamp housing from the headlamp nacelle. Squeeze the
(FLHR/C, FLHT/C/U)
2005 Touring: Electrical
8-43
HOME
NOTE
Turn Signal Lamp
Be sure that mechanics wire is of sufficient strength to pull
Connector [31]
terminals through conduit without breaking. Wire lengths
must also be long enough so that free ends are not lost in
conduit when pulled.
6. Carefully pull wires to draw socket terminals through
both sections of conduit. For best results, pull one wire
at a time.
7. Unravel mechanics wire to release socket terminals.
Installation
1.
Lay old turn signal lamp next to new turn signal lamp
and cut wires to length.
2.
Strip 3/16 inch (4.8 mm) of insulation off new lamp wires
f2212x8x
and crimp on new socket terminals.
NOTE
Figure 8-54. Headlamp Nacelle (FLHRC)
For instructions on crimping wire terminals, see APPENDIX
B.2 AMP MULTILOCK ELECTRICAL CONNECTORS,
CRIMPING INSTRUCTIONS.
two external tabs (if present) to remove the wire connec-
tor at the back of the headlamp bulb. Remove the head-
3.
Reattach mechanics wire to socket terminals and care-
lamp housing assembly from the vehicle. Locate the
fully pull ends of mechanics wire to draw socket termi-
front turn signal lamp connector (black 6-place Multilock)
nals back through conduit.
anchored in hole of fork stem nut lock plate (left side).
See Figure 8-54.
4.
Carefully remove mechanics wire to avoid damage to
terminals.
2.
Depress the button on the socket terminal side of the
connector and pull apart the pin and socket halves.
5.
Install terminals into socket housing.
3.
Remove appropriate terminals from socket housing.
NOTE
For instructions on properly installing wire terminals, see
Table 8-8. Front Turn Signal Lamps [31]
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
TORS, INSTALLING SOCKET/PIN TERMINALS.
Left Side
Right Side
Wire Color
Chamber
Wire Color
Chamber
Blue (DOM)
4
Black
1
Violet/Brown
5
Violet/Brown
2
Mechanics Wire
Black
6
Blue (DOM)
3
NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
TORS, REMOVING SOCKET/PIN TERMINALS.
4.
Remove two screws to release turn signal lamp from
mounting bracket. See Figure 8-52.
Socket Terminal
5.
Obtain three equal lengths of strong flexible wire for use
as mechanics wire. Feed wire through opening in socket
f1418x2x
terminal and then loop back twisting end until tightly
coiled around longer strand as shown in Figure 8-55.
Repeat step with remaining socket terminals.
Figure 8-55. Fix Mechanics Wire to Socket Terminals
8-44
2005 Touring: Electrical
HOME
6. Start two screws to secure turn signal lamp to mounting
bracket. See Figure 8-52. Verify that conduit fits in slot at
back of bracket and is not pinched. Alternately tighten
screws to 36-60 in-lbs (4.1-6.8 Nm).
7. Mate pin and socket halves of front turn signal lamp con-
nector.
8. Proceed as follows:
FLHT/C/U: Verify that conduit is routed upward in front
of chrome skirt and then rearward using relief in upper
outboard corner (in front of fairing bracket). Install con-
nector on T-stud at top of left fairing support brace. See
Figure 8-53. Install the outer fairing. See Section 2.29
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
9408
FAIRING/WINDSHIELD, INSTALLATION.
Figure 8-56. Front Turn Signal Lamp (FLTR)
FLHR/C: Install anchor on connector into hole of fork
stem nut lock plate (left side). See Figure 8-54. Install
wire connector at the back of the headlamp bulb. Align
holes in headlamp housing with those in headlamp
NOTE
nacelle. Install eight Phillips screws. Install the head-
For instructions on properly removing wire terminals, see
lamp door (chrome ring) and door screw. Tighten screw
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
to 9-18 in-lbs (1.0-2.0 Nm).
TORS, REMOVING SOCKET/PIN TERMINALS.
9. Turn Ignition/Light Key Switch to IGNITION and test for
5.
Carefully cut cable strap to release turn signal lamp con-
proper operation.
duit from lower handlebar clamp. Draw free end of con-
duit out of headlamp nacelle.
6.
Remove two cable clips anchored in holes at bottom of
FLTR
handlebar. Free turn signal lamp conduit from cable
clips.
Removal
7.
Remove acorn nut, lock washer and turn signal lamp
bracket from stem of mirror. Remove turn signal lamp
See Section 2.30 UPPER FAIRING/WINDSHIELD (FLTR),
assembly from motorcycle.
OUTER FAIRING, REMOVAL, steps 1-5. See Figure 8-56.
Installation
Installation
1.
If removed, install stem of mirror into hole in clutch lever
bracket (left side) or master cylinder reservoir bracket
See Section 2.30 UPPER FAIRING/WINDSHIELD (FLTR),
(right side).
OUTER FAIRING, INSTALLATION, steps 2 and 6-12.
2.
Slide turn signal lamp bracket onto stem of mirror and
install lock washer and acorn nut.
NOTE
FLHRS
Index pin at bottom of clutch lever bracket engages blind hole
at top of left turn signal lamp bracket to ensure proper orien-
Removal
tation. On the right side, location of the front brake lever pivot
pin relief prevents improper installation. See Figure 8-57.
1. Remove handlebar clamp shroud/wind deflector. See
Section
2.31 WINDSHIELD/HEADLAMP NACELLE
3.
Following bottom of handlebar, feed free end of turn sig-
(FLHR/C/S), NACELLE REMOVAL (FLHRS), steps 1-7.
nal lamp conduit into top of headlamp nacelle staying
outboard of lower handlebar clamp.
2. Inside headlamp nacelle, locate the front turn signal
lamp connector (black 6-place Multilock) anchored in
4.
Reaching inside headlamp nacelle, install terminals into
hole of fork stem nut lock plate (left side). See Figure 8-
socket housing of turn signal lamp connector (black 6-
54.
place Multilock). For correct terminal locations see Table
8-8.
3. Depress the button on the socket terminal side of the
connector and pull apart the pin and socket halves.
NOTE
For instructions on properly installing wire terminals, see
4.
Remove appropriate terminals from socket housing. See
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
Table 8-8.
TORS, INSTALLING SOCKET/PIN TERMINALS.
2005 Touring: Electrical
8-45
HOME
2. Point turn signal lamp straight forward and snug set
9409
screw.
Left
3. Carefully turn the front forks to the left and right fork
Turn Signal
stops to verify that the turn signal lamp does not contact
fuel tank or any other components. Loosen set screw
and readjust lamp as required.
4. Tighten set screw to 50-60 in-lbs (5.7-6.8 Nm).
REAR TURN SIGNAL LAMP
Blind
Hole
NOTE
Although the rear turn signal lamp assembly used on FLHRS
and FLTR appears different from that found on FLHR/C and
FLHT/C/U, the instructions which follow will work for both.
Right
Turn Signal
REMOVAL
1.
Remove saddlebag on same side of vehicle. See Sec-
tion 2.25 SADDLEBAG, REMOVAL.
Pivot Pin
Relief
f2263x8x
6
9410
4
5
3
Figure 8-57. Front Turn Signal Lamps (FLHRS)
7
8
5.
Install anchor on turn signal lamp connector into hole of
fork stem nut lock plate (left side).
2
6.
Install two cable clips into holes at bottom of handlebar
9
5
after capturing handlebar switch and turn signal lamp
conduit.
4
7.
Install new cable strap to secure handlebar switch and
turn signal lamp conduit to lower handlebar clamp. Cut
any excess cable strap material.
8
3
8.
Install handlebar clamp shroud/wind deflector. See Sec-
9
tion 2.31 WINDSHIELD/HEADLAMP NACELLE (FLHR/
C/S), NACELLE INSTALLATION (FLHRS), steps 5-13.
1
9.
Adjust mirror as necessary and tighten acorn nut to 60-
96 in-lbs (6.8-10.8 Nm).
4.
Ball Stud
10.
Turn Ignition/Light Key Switch to IGNITION and test for
5.
Set Screw
proper operation.
6.
Left Bracket
1.
Right Lamp
7.
Left Lamp
2.
Right Bracket
8.
Lock Washer
Adjustment
3.
Jam Nut
9.
Acorn Nut
1.
Using a 1/4 inch allen head socket, loosen set screw in
turn signal lamp bracket. See Figure 8-58.
Figure 8-58. Front Turn Signal Lamp Brackets (FLHRS)
8-46
2005 Touring: Electrical
HOME
2.
Remove two Phillips screws from lense to release tail
lamp assembly from chrome plastic bracket at back of
Left Turn
rear fender. Carefully pull tail lamp assembly from
Signal Lamp
Right Turn
[18]
Signal Lamp
bracket.
Tail Lamp
[19]
3.
Depress button at bottom of 4-place Multilock socket to
[93]
release tail lamp assembly from pin housing. See Figure
8-59.
4.
Depress button at top of 2-place Multilock socket to
release turn signal lamp assembly from pin housing. To
release socket housing, use a pick or small screwdriver
to depress release button as shown in Figure 8-60.
5.
Feed
2-place Multilock socket through opening in
chrome plastic bracket to inboard side of rear fender.
6.
Reaching under rear fender, release conduit from cable
clip anchored on T-stud.
7.
Draw conduit and 2-place Multilock socket out through
fender hole just below chrome plastic bracket. See Fig-
ure 8-60.
8.
Draw conduit and 2-place Multilock socket through hole
on inboard side of rear turn signal lamp bracket, so that
f2172x8x
length is suspended below turn signal lamp.
Figure 8-59. Release Tail Lamp Socket
9.
Inserting a long shank ball end socket
(Snap-on®
FABL5) through same hole in bracket, remove two
socket head screws to release turn signal lamp assem-
Pick
f1497x8x
Tool
bly.
10.
Remove terminals from socket housing.
NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
TORS, REMOVING SOCKET/PIN TERMINALS.
INSTALLATION
1. Place new turn signal lamp assembly next to discarded
unit and cut wires to proper length.
2. Crimp new socket terminals onto turn signal lamp wires.
NOTE
For instructions on crimping wire terminals, see APPENDIX
Opening
B.2 AMP MULTILOCK ELECTRICAL CONNECTORS,
CRIMPING INSTRUCTIONS.
Fender Hole
3. Install terminals into socket housing.
Figure 8-60. Release Left Turn Signal Lamp Socket
Table 8-9. Rear Turn Signal Lamps [18/19]
NOTE
Chamber
Wire Color
For instructions on properly installing wire terminals, see
Number
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
Violet/Brown
1
TORS, INSTALLING SOCKET/PIN TERMINALS.
Black
2
4.
Align holes in turn signal lamp assembly with those in
rear turn signal lamp bracket and install two socket head
2005 Touring: Electrical
8-47
HOME
screws. For best results, insert a long shank ball end
REAR TURN SIGNAL LAMP
socket (Snap-on® FABL5) through hole on inboard side
of bracket, and alternately tighten screws to 30-50 in-lbs
BRACKET
(3.4-5.6 Nm).
5.
Route 2-place Multilock socket through same hole in
NOTE
bracket, and then feed socket through fender hole just
below chrome plastic bracket. See Figure 8-60.
Although the rear turn signal lamp assembly used on FLHRS
and FLTR appears different from that found on FLHR/C and
6.
Reaching under rear fender, capture conduit in cable clip
FLHT/C/U, the instructions which follow will work for both.
anchored on T-stud.
7.
Feed
2-place Multilock socket through opening in
REMOVAL
chrome plastic bracket to outboard side of rear fender.
1.
Remove circuit board and tail lamp bracket. See Section
8.
Orient 2-place Multilock socket so that the release but-
8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/TAIL
ton is at the top and insert into pin housing until it
LAMP BRACKET, REMOVAL.
“clicks.”
2.
Remove rear turn signal lamps from bracket. See REAR
9.
To install tail lamp assembly, orient 4-place Multilock
TURN SIGNAL LAMP, REMOVAL, in this section, steps
socket so that the release button is at the bottom and
6-9.
insert into pin housing until it “clicks.” To avoid stressing
3.
Remove two flange bolts to free rear turn signal lamp
wires, verify that tail lamp conduit is positioned on the
bracket from rear fender.
outboard side of the rear fender tip lamp and left turn
signal lamp conduit as shownn Figure 8-59.
10.
Place tail lamp into position against chrome plastic
INSTALLATION
bracket.
1.
Apply one drop of LOCTITE THREADLOCKER 271
CAUTION
(Red) to two flange bolts.
Over tightening screws can crack the lense or result in
2.
Install flange bolts to fasten rear turn signal lamp bracket
scratching of the fender paint.
to rear fender. Alternately tighten bolts to 84-144 in-lbs
(9.5-16.3 Nm).
11. Install two Phillips screws and alternately tighten to 20-
3.
Install rear turn signal lamps to bracket. See REAR
24 in-lbs (2.3-2.7 Nm).
TURN SIGNAL LAMP, INSTALLATION, in this section,
12. Turn the Ignition/Light Key Switch to IGNITION and test
steps 4-6.
lamp for proper operation.
4.
Install tail lamp bracket and circuit board assembly. See
13. Install saddlebag on vehicle. See Section 2.25 SADDLE-
Section 8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/
BAG, INSTALLATION.
TAIL LAMP BRACKET, INSTALLATION.
8-48
2005 Touring: Electrical
HOME
TURN SIGNAL/SECURITY MODULE
8.17
REMOVAL
NOTE
The turn signal/security module also houses the bank angle
sensor.
IMPORTANT NOTE
If equipped with the optional “Harley-Davidson Factory
Security System,” verify that the security status lamp in
speedometer face is not flashing before proceeding
(security system disarmed).
1. Remove seat. See Section 2.24 SEAT, REMOVAL.
2. Depress tab at front of spring clip and lift to release legs
from holes in frame crossmember at rear of battery box.
Spring
See Figure 8-61.
Clip
Turn Signal/Security
3. Remove module from cavity and disconnect turn signal/
Module
f2013x8x
security module connector [30], 12-place Deutsch.
Figure 8-61. Turn Signal/Security Module
INSTALLATION
3.
Install seat. See Section 2.24 SEAT, INSTALLATION.
1. Connect turn signal/security module connector [30], 12-
4.
Test all turn signal functions. Test all security system
place Deutsch, to new module. Install module in cavity
functions, if so equipped.
of frame crossmember at rear of battery box.
2. Insert legs of spring clip into holes in frame crossmem-
ber and push down until tab at front snaps in place.
2005 Touring: Electrical
8-49
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