Harley Davidson 2005 touring models. Service repair manual — page 27
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8.
Locate vehicle speed sensor mounted next to the starter
10. Install right side saddlebag. See Section 2.25 SADDLE-
on the right side of the transmission case. Remove
BAG, INSTALLATION.
screw and pull sensor from transmission case. See Fig-
11. Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
ure 8-114.
MAXI-FUSE, INSTALLATION.
9.
Draw sensor and cable forward to remove from motorcy-
cle.
SPEEDOMETER
INSTALLATION
REMOVAL
1.
Inspect vehicle speed sensor O-ring for cuts, tears or
general deterioration. Replace as necessary.
1.
Proceed as follows:
2.
Insert sensor into transmission case. Install screw and
FLHT/C/U: Remove the outer fairing. See Section 2.29
tighten to 84-132 in-lbs (9.5-14.9 Nm).
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
FAIRING/WINDSHIELD, REMOVAL.
3.
Feed cable rearward under and inboard of the chrome
starter cover. Running cable up the frame downtube,
FLTR: Remove instrument bezel. See Section
2.30
capture cable in new cable strap anchored in hole of
UPPER FAIRING/WINDSHIELD
(FLTR), BEZEL,
frame downtube.
REMOVAL, steps 1-2. Raising bezel slightly, remove
anchor on ambient temperature sensor from bottom
NOTE
inboard ear of speedometer bracket.
Anchored cable strap also captures the main harness and
2.
Bend back the external latches slightly and remove
neutral switch conduit.
speedometer connector [39], 12-place Packard, at back
of speedometer.
4.
Draw cable rearward between frame downtube and side
of battery box to area of electrical bracket.
3.
Remove two allen head socket screws to free speedom-
eter bracket from back of speedometer gauge. On FLHT/
5.
Referencing the following table, install terminals into pin
C/U models, leave anchors on interconnect harness
housing of 3-place Deutsch.
installed in outboard ears of speedometer bracket.
4.
Push speedometer gauge toward rear of motorcycle to
Table 8-13. Vehicle Speed Sensor [65]
remove from inner fairing
(FLHT/C/U) or bezel bore
(FLTR).
Wire Color
Chamber Number
Red
A
White
B
INSTALLATION
Black
C
1.
Insert speedometer gauge into inner fairing (FLHT/C/U)
or bezel bore (FLTR).
NOTE
2.
Align holes in speedometer bracket with those at back of
For instructions on properly installing wire terminals, see
speedometer gauge and start two allen head socket
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
screws.
REMOVING/INSTALLING PINS.
3.
Rotate speedometer gauge until tabs at top and bottom
6.
Mate pin and socket halves of vehicle speed sensor con-
of bracket engage slots in inner fairing (FLHT/C/U) or
nector. Route connector and cable on inboard side of
bezel (FLTR).
electrical bracket as shown in Figure 8-113. Be sure that
NOTE
cable is properly routed or wires may be pinched during
installation of bracket.
On FLHT/C/U models, both the speedometer and tachome-
ter brackets are oriented with the ears on the outboard side.
7.
Slide electrical bracket onto studs at side of battery box.
On FLTR models, the brackets are oriented with the ears
inboard.
8.
Install flange nuts on studs and tighten to 36-48 in-lbs
(4.1-5.4 Nm).
4.
Verify that gauge is properly aligned and tighten two
allen head socket screws to 10-20 in-lbs (1.1-2.3 Nm).
9.
Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place
(no tools
5.
Install speedometer connector [39], 12-place Packard, at
required).
back of speedometer.
8-90
2005 Touring: Electrical
HOME
4.
Release four paddles to free indicator bulb housing from
f2254x8x
lense assembly. See Figure
8-116. Remove lense
assembly from inner fairing (FLHT/C/U) or bezel (FLTR),
if damaged.
5.
To replace indicator lamp bulbs, carefully remove rubber
boot from bulb housing. Remove bulb from socket in
boot.
INSTALLATION
1.
Install new bulb in socket. Install boot in bulb housing.
2.
Place lense assembly in inner fairing (FLHT/C/U) or
bezel (FLTR), if removed. Note position of oil icon to be
sure that lense is right side up.
3.
Engage all four paddles on lense assembly with tabs on
indicator bulb housing. Be sure that flange on bulb hous-
Figure 8-115. Anchor Interconnect Harness in Lower
ing faces upward.
Ears of Speedometer/Tachometer Brackets
4.
Mate pin and socket halves of indicator lamps connector
[21], 10-place Multilock.
6. Proceed as follows:
5.
On FLHT/C/U models, install tachometer gauge. See
FLHT/C/U: Verify that anchors on interconnect harness
GAUGES-
4 INCH DIAMETER, TACHOMETER,
INSTALLATION, in this section.
are installed in lower outboard ears of both the speed-
ometer and tachometer brackets. See Figure 8-115.
6.
Proceed as follows:
Install outer fairing. See Section 2.29 UPPER FAIRING/
WINDSHIELD
(FLHT/C/U), OUTER FAIRING/WIND-
FLHT/C/U: Install outer fairing. See Section
2.29
SHIELD, INSTALLATION.
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
FAIRING/WINDSHIELD, INSTALLATION.
FLTR: Install anchor on ambient temperature sensor into
bottom inboard ear of speedometer bracket. Install
FLTR: Install instrument bezel. See Section
2.30
instrument bezel. See Section 2.30 UPPER FAIRING/
UPPER FAIRING/WINDSHIELD
(FLTR), BEZEL,
WINDSHIELD (FLTR), BEZEL, INSTALLATION, steps
INSTALLATION, steps 1-2.
3-5.
Indicator Lamp
Connector [21]
INDICATOR LAMPS
10-Place Multilock
REMOVAL
Bulb
1. Proceed as follows:
Housing
FLHT/C/U: Remove the outer fairing. See Section 2.29
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
FAIRING/WINDSHIELD, REMOVAL.
FLTR: Remove instrument bezel. See Section
2.30
UPPER FAIRING/WINDSHIELD
(FLTR), BEZEL,
Rubber
REMOVAL, steps 1-2.
Boot
2. Disconnect indicator lamps connector
[21],
10-place
Multilock. Depress button on plug side of connector and
Paddle
pull apart pin and socket halves.
Lense
f2262x8x
3. On FLHT/C/U models, remove tachometer gauge to
access indicator lamp assembly. See GAUGES- 4 INCH
DIAMETER, TACHOMETER, REMOVAL, in this section.
Figure 8-116. Indicator Lamp Assembly
2005 Touring: Electrical
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GAUGES/INSTRUMENTS (FLHR/C/S)
8.28
FUEL GAUGE
REMOVAL
1.
Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
2.
At bottom left side of fuel tank, gently pull on convoluted
tubing to draw fuel gauge connector [117], 4-place Mul-
tilock, out of tunnel. Depress button on socket terminal
side and pull apart pin and socket halves.
3.
Remove terminals from pin housing.
NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
TORS, REMOVING SOCKET/PIN TERMINALS.
4.
Remove convoluted tubing from wires.
5.
Remove the gauge cap on the top left side of the fuel
f2155x8x
tank. Do not twist the cap during removal. Hold the cap
firmly and pull upward just far enough to free the cap
from the fuel tank.
6.
To remove fuel gauge from vehicle, feed wires and pin
Convoluted
terminals up into drain tube of fuel tank while carefully
Tubing
raising cap.
7.
If reusing gauge, inspect rubber seal for tears, cuts or
general deterioration. Replace seal if necessary. Install
new seal so that flat side contacts edge of gauge.
INSTALLATION
8870
1.
Place new fuel gauge assembly next to discarded unit
and cut wires to proper length.
Figure 8-117. Fuel Gauge (FLHR/C/S)
2.
Crimp new pin terminals onto fuel gauge wires.
NOTE
5. Install terminals into pin housing of 4-place Multilock.
For instructions on crimping wire terminals, see APPENDIX
B.2 AMP MULTILOCK ELECTRICAL CONNECTORS,
Table 8-14. Fuel Gauge [117]
CRIMPING INSTRUCTIONS.
Wire Color
Chamber
3. While carefully lowering cap, feed wires down into drain
Number
tube until pin terminals exit hole at bottom of fuel tank.
Fuel Injected
Carbureted
Gently pull wires (to remove slack) while installing the
Orange
Orange
1
fuel gauge cap on the fuel tank. Do not twist the cap dur-
ing installation. Hold the cap firmly and press downward
Yellow/White
-
2
until it snaps in place.
-
-
3
4. Install convoluted tubing on wires.
Black
Black
4
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2005 Touring: Electrical
HOME
NOTE
1WARNING
For instructions on properly installing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
To protect against shock and accidental start-up of vehi-
TORS, INSTALLING SOCKET/PIN TERMINALS.
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
6. Route pin housing and convoluted tubing forward and
death or serious injury.
then inboard between front of crossover hose fitting and
bottom of fuel tank. Mate pin and socket halves of fuel
2.
Unthread bolt and remove battery negative cable (black)
gauge connector [117], 4-place Multilock. Feed connec-
from battery negative (-) terminal.
tor into tunnel of fuel tank. See lower frame of Figure 8-
3.
Carefully cut anchored cable strap securing main har-
117.
ness bundle, instrument console conduit, and fuel vapor
vent tube to left side of frame backbone.
7. Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
MAXI-FUSE, INSTALLATION.
4.
Remove acorn nut from instrument console. If present,
also remove Phillips screw and large flat washer (absent
on FLHRS models).
5.
On FLHRS models only, remove bolt (with flat washer) to
free rear of fuel tank from frame backbone. Removal of
VEHICLE SPEED SENSOR
rear bolt also releases instrument console bracket.
6.
Lay a clean shop towel on forward part of rear fender.
See Section
8.27 GAUGES/INSTRUMENTS (FLHT/C/U,
7.
Raise instrument console and bend back flexible clamp
FLTR), VEHICLE SPEED SENSOR.
on canopy to release main harness conduit. Depress
button on socket side and remove fuel level sender/fuel
pump connector [141], 3-place Mini-Deutsch.
8.
Lay instrument console upside down on shop towel.
SPEEDOMETER
9.
If necessary, bend back the flexible metal clips to free
the main harness conduit from the bottom of the con-
sole.
REMOVAL
10. Bend back the external latches slightly and remove
speedometer connector [39], 12-place Packard, at back
1. Remove seat. See Section 2.24 SEAT, REMOVAL.
of speedometer.
f2095x8x
Ignition/Light
Latch
Reset
Switch
Indicator Lights
Key Switch Connector [33]
(1 of 3)
Assembly
Flexible
Flexible
Clip
Clip
Lock
Ring
Speedometer
Connector [39]
Plastic
Speedometer
Indicator Lights
Clip
Flexible
Connector [21]
Clip
Figure 8-118. Instrument Console Assembly (FLHR/C)
2005 Touring: Electrical
8-93
HOME
11. See Figure 8-118. Gently pry the three latches upward
INDICATOR LIGHTS
to release the lock ring from the back of the speedome-
ter.
NOTE
12. Turn the console over and remove the speedometer
from the top side.
All FLHR/C/S models are equipped with Light Emitting
Diodes (LED’s) in lieu of indicator lamps. The indicator light
13. Remove gasket from console speedometer bore.
assembly is not serviceable. If one LED is bad, the indicator
light assembly must be replaced.
INSTALLATION
REMOVAL
1.
Lubricate the groove in the rubber speedometer gasket
with isopropyl alcohol or glass cleaner. Place the gasket
1.
Remove seat. See Section 2.24 SEAT, REMOVAL.
into position around the console speedometer bore.
2.
From the top side of the console, feed the speedometer
1WARNING
into the gasket. Lubricate the gasket with isopropyl alco-
hol or glass cleaner, if necessary. The speedometer
To protect against shock and accidental start-up of vehi-
should fit snugly against the gasket without movement.
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
3.
Turn the console over. Place the lock ring over the back
death or serious injury.
of the speedometer aligning the two slots with the con-
sole bosses. Press the latches down until they lock into
2.
Unthread bolt and remove battery negative cable (black)
position.
from battery negative (-) terminal.
4.
Install speedometer connector [39], 12-place Packard, at
3.
Carefully cut anchored cable strap securing main har-
back of speedometer.
ness bundle, instrument console conduit, and fuel vapor
vent tube to left side of frame backbone.
5.
If released, position the speedometer harness so that it
runs the length of the console on the left side. Bend the
4.
Remove acorn nut from instrument console. If present,
flexible metal clip to capture the harness conduit. See
also remove Phillips screw and large flat washer (absent
Figure 8-118.
on FLHRS models).
6.
Slide head of console mounting bolt into slot at top of
5.
On FLHRS models only, remove bolt (with flat washer) to
canopy, if removed.
free rear of fuel tank from frame backbone. Removal of
rear bolt also releases instrument console bracket.
7.
Moving instrument console toward installed position,
install fuel level sender connector [141], 3-place Mini-
6.
Lay a clean shop towel on forward part of rear fender.
Deutsch, at top of canopy. Bend flexible clamp to capture
main harness conduit.
7.
Raise instrument console and bend back flexible clamp
on canopy to release main harness conduit. Depress
8.
Align hole in instrument console with console mounting
button on socket side and remove fuel level sender/fuel
bolt and place into position on fuel tank.
pump connector [141], 3-place Mini-Deutsch.
9.
Install acorn nut at top of instrument console and tighten
8.
Lay instrument console upside down on shop towel.
to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
Phillips screw and large flat washer (absent on FLHRS
9.
Disconnect the indicator lights connector [21], 8-place
models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).
Mini-Deutsch, at back of console. Depress the external
latches and use a rocking motion to separate pin and
10.
On FLHRS models only, install bolt (with flat washer) to
socket halves.
secure rear of fuel tank and instrument console bracket
to frame backbone. Tighten bolt to 15-20 ft-lbs (20-27
10.
Remove indicator lights assembly from console as fol-
Nm).
lows:
11.
Snap anchor of new cable strap into hole on left side of
a. Insert the blade of a large screwdriver under rear
frame backbone. Tighten cable strap capturing main har-
corner of indicator lights assembly.
ness bundle, instrument console conduit, and fuel vapor
b. Using thumb and index finger, squeeze front and
vent tube. Cut any excess cable strap material.
rear paddles on same side of assembly while rotat-
12.
Insert bolt through battery negative cable (black) into
ing screwdriver. See Figure 8-119.
threaded hole of battery negative (-) terminal. Tighten
c. When one side of assembly becomes free, repeat
bolt to 60-96 in-lbs (6.8-10.9 Nm).
procedure on opposite side to release unit from
13.
Install seat. See Section 2.24 SEAT, INSTALLATION.
console.
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2005 Touring: Electrical
HOME
6.
Install acorn nut at top of instrument console and tighten
f2095x8x
Paddles
to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
Phillips screw and large flat washer (absent on FLHRS
models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).
7.
On FLHRS models only, install bolt (with flat washer) to
secure rear of fuel tank and instrument console bracket
to frame backbone. Tighten bolt to 15-20 ft-lbs (20-27
Nm).
8.
Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main har-
ness bundle, instrument console conduit, and fuel vapor
vent tube. Cut any excess cable strap material.
9.
Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
10. Install seat. See Section 2.24 SEAT, INSTALLATION.
IGNITION SWITCH
Figure 8-119. Release Paddles to Free
Indicator Lights Assembly (FLHR/C)
NOTE
See Section
8.18 IGNITION/LIGHT
KEY
SWITCH
AND
INSTALLATION
FORK LOCK, FLHR/C/S.
1. Install indicator lights assembly into console as follows:
a. Place assembly into position in console engaging
four paddles in slots of indicator light assembly.
b. While pushing down on assembly with thumbs,
push up on lense on outboard side of console until
assembly fits snugly.
2. Connect the indicator lights connector [21], 8-place Mini-
Deutsch, at back of console. Align tabs on socket hous-
ing with grooves on pin housing, and push connector
halves together until the latches “click.”
3. Slide head of console mounting bolt into slot at top of
canopy, if removed.
4. Moving instrument console toward installed position,
install fuel level sender connector [141], 3-place Mini-
Deutsch, at top of canopy. Bend flexible clamp to capture
main harness conduit.
5. Align hole in instrument console with console mounting
bolt and place into position on fuel tank.
2005 Touring: Electrical
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FUEL LEVEL SENDER (CARBURETED)
8.29
13. Remove and discard canopy gasket. Verify that sealing
FLHT/C CANOPY
devices from screws are not lodged in canopy holes.
Remove and discard devices if present.
NOTE
14. Replace fuel level sender. See FUEL LEVEL SENDER
For replacement of the fuel level sender on fuel injected mod-
in this section.
els, see Section 9.4 FUEL TANK (FUEL INJECTED), FUEL
LEVEL SENDER.
INSTALLATION
1.
Obtain new canopy gasket. With the locator bump on the
REMOVAL
gasket OD toward the front, position gasket at bottom of
canopy. Start four nubs on gasket into holes in canopy.
1.
Remove seat. See Section 2.24 SEAT, REMOVAL.
Moving to top of canopy, alternately grasp each nub and
pull through hole.
1WARNING
To protect against shock and accidental start-up of vehi-
CAUTION
cle, disconnect the negative battery cable before pro-
Exercise care to avoid bending float rod of fuel level
ceeding. Inadequate safety precautions could result in
sender during installation. A bent float rod will result in
death or serious injury.
erroneous gauge readings.
2.
Unthread bolt and remove battery negative cable (black)
2.
Holding assembly so that canopy is at a 45˚ angle to top
from battery negative (-) terminal.
of fuel tank, insert assembly into left side lobe of fuel
3.
Drain the fuel tank. See Section 4.6 VACUUM OPER-
tank.
ATED FUEL VALVE (CARBURETED), DRAINING FUEL
TANK, steps 1-8.
4.
Carefully cut anchored cable strap securing main har-
Sealing
ness bundle, fuel level sender conduit, and fuel vapor
Device
vent tube to left side of frame backbone.
5.
Open fuel door on console. Remove two Allen head
screws inboard of rubber bumpers. These screws secure
console to clip nuts on the canopy bracket.
6.
Remove Allen head screw to detach flange at rear of
f1963x9x
console from clip nut on fuel tank weldment.
7.
Lay a clean shop towel on forward part of rear fender.
Figure 8-120. Canopy Sealing Screws
8.
Remove filler cap from neck of fuel tank. Remove con-
sole and lay upside down on shop towel. Reinstall filler
1
cap.
7
9
9.
Gently pry fuel vapor vent tube from fitting on filler neck
of fuel tank. Exercise caution to avoid pulling fitting from
3
6
filler neck.
10.
Depress button on socket side and remove fuel level
5
4
sender connector [141], 3-place Mini-Deutsch, at top of
canopy.
11.
Using a T20 TORX bit, remove ten screws around the
outer edge of the canopy. Discard screws.
10
8
12.
Remove canopy with attached fuel level sender from fuel
tank. Tilt canopy toward the right until it is at a 45˚ angle
f2011x9x
2
to top of fuel tank and then carefully pull assembly from
left side lobe of fuel tank.
Figure 8-121. Canopy Torque Sequence (FLHR)
8-96
2005 Touring: Electrical
HOME
1WARNING
Always use new screws when installing the canopy.
Fuel
Reusing old screws may compromise sealing integrity
Tank
resulting in gas leaks. Gas leakage can cause fire or
Console
explosion which could result in death or serious injury.
NOTE
Check canopy screws for proper sealing devices. Screws
Fuel Level
must have a bonded seal on underside of head. Replace
Sender
screws if seal is missing or damaged. See Figure 8-120.
Conduit
3.
While pushing down on the canopy, align holes in can-
opy with those in fuel tank. Hand start ten new T20
Fuel
TORX screws in perimeter of canopy. Tighten screws to
Overflow
18-24 in-lbs (2.0-2.7 Nm) using the pattern shown in
Fuel Vapor
Hose
Figure 8-121.
Vent Tube
(To Vapor Valve)
4.
Connect fuel vapor vent tube to fitting on filler neck of
fuel tank.
Main
5.
Install fuel level sender connector [141], 3-place Mini-
Harness
Bundle
Deutsch, at top of canopy.
Anchored
Main
6.
Remove filler cap. Position console on canopy. Route
Cable Strap
Harness
cables from beneath console as shown in Figure 8-122.
Bundle
f1739b9x
Be sure that hoses and wires are not pinched by the
console during installation. Reinstall filler cap.
Figure 8-122. Console Cable/Hose Routing
7.
Install Allen head screw to fasten rear flange of console
- FLHT/C, FLTR (Top View)
to clip nut on fuel tank weldment. Tighten screw to 25-30
in-lbs (2.8-3.4 Nm).
8.
Open fuel door on console. Install two Allen head screws
REMOVAL
to secure front of console to clip nuts on canopy bracket.
Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).
1.
Remove seat. See Section 2.24 SEAT, REMOVAL.
9.
Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main har-
1WARNING
ness bundles, fuel level sender conduit, and fuel vapor
vent tube. See Figure 8-122. Cut excess cable strap
To protect against shock and accidental start-up of vehi-
material.
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
10.
Insert bolt through battery negative cable (black) into
death or serious injury.
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
2.
Unthread bolt and remove battery negative cable (black)
11.
Install seat. See Section 2.24 SEAT, INSTALLATION.
from battery negative (-) terminal.
12.
Turn the handle of the fuel valve to OFF and fill the fuel
3.
Drain the fuel tank. See Section 4.6 VACUUM OPER-
tank. Carefully inspect for leaks. Turn the valve handle to
ATED FUEL VALVE (CARBURETED), DRAINING FUEL
ON and start engine. Repeat inspection.
TANK, steps 1-8.
13.
Stop engine and return the valve to the OFF position.
4.
Carefully cut anchored cable strap securing main har-
ness bundle, instrument console conduit, and fuel vapor
vent tube to left side of frame backbone.
FLHR/S CANOPY
5.
Remove acorn nut from instrument console. If present,
also remove Phillips screw and large flat washer (absent
on FLHRS models).
NOTE
For replacement of the fuel level sender on fuel injected mod-
6.
On FLHRS models only, remove bolt (with flat washer) to
els, see Section 9.4 FUEL TANK (FUEL INJECTED), FUEL
free rear of fuel tank from frame backbone. Removal of
LEVEL SENDER.
rear bolt also releases instrument console bracket.
2005 Touring: Electrical
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HOME
7.
Raise instrument console and bend back flexible clamp
NOTE
on canopy to release main harness conduit. Depress
Check canopy screws for proper sealing devices. Screws
button on socket side and remove fuel level sender con-
must have a bonded seal on underside of head. Replace
nector [141], 3-place Mini-Deutsch.
screws if seal is missing or damaged. See Figure 8-120.
3.
While pushing down on the canopy, align holes in can-
CAUTION
opy with those in fuel tank. Hand start ten new T20
TORX screws in perimeter of canopy. Tighten screws to
When removing instrument console, exercise caution to
18-24 in-lbs (2.0-2.7 Nm) using the pattern shown in
avoid damaging speedometer unit. Wrap console in a
Figure 8-121.
clean, dry shop towel to prevent damage.
4.
Connect fuel vapor vent tube to fitting at top of canopy.
8.
Secure instrument console to top of rear fender using
5.
Slide head of console mounting bolt into slot at top of
bungee cords.
canopy, if removed.
9.
Remove console mounting bolt from slot at top of can-
6.
Moving instrument console toward installed position,
opy.
install fuel level sender connector [141], 3-place Mini-
10. Gently pry fuel vapor vent tube from fitting at top of can-
Deutsch, at top of canopy. Bend flexible clamp to capture
opy.
main harness conduit.
11. Using a T20 TORX bit, remove ten screws around the
7.
Align hole in instrument console with console mounting
outer edge of the canopy. Discard screws.
bolt and place into position on fuel tank.
12. Remove canopy with attached fuel level sender from fuel
8.
Install acorn nut at top of instrument console and tighten
tank. Tilt canopy toward the right until it is at a 45˚ angle
to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
to top of fuel tank and then carefully pull assembly from
Phillips screw and large flat washer (absent on FLHRS
left side lobe of fuel tank.
models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).
9.
On FLHRS models only, install bolt (with flat washer) to
13. Remove and discard canopy gasket. Verify that sealing
secure rear of fuel tank and instrument console bracket
devices from screws are not lodged in canopy holes.
Remove and discard devices if present.
to frame backbone. Tighten bolt to 15-20 ft-lbs (20-27
Nm).
14. Replace fuel level sender. See FUEL LEVEL SENDER
10.
Snap anchor of new cable strap into hole on left side of
on this page.
frame backbone. Tighten cable strap capturing main har-
ness bundle, instrument console conduit, and fuel vapor
vent tube. Cut any excess cable strap material.
INSTALLATION
11.
Insert bolt through battery negative cable (black) into
1.
Obtain new canopy gasket. With the locator bump on the
threaded hole of battery negative (-) terminal. Tighten
gasket OD toward the front, position gasket at bottom of
bolt to 60-96 in-lbs (6.8-10.9 Nm).
canopy. Start four nubs on gasket into holes in canopy.
Moving to top of canopy, alternately grasp each nub and
12.
Install seat. See Section 2.24 SEAT, INSTALLATION.
pull through hole.
13.
Turn the handle of the fuel valve to OFF and fill the fuel
tank. Carefully inspect for leaks. Turn the valve handle to
ON and start engine. Repeat inspection.
CAUTION
14.
Stop engine and return the valve to the OFF position.
Exercise care to avoid bending float rod of fuel level
sender during installation. Be sure to position float rod
to the right of the fuel gauge drain tube or it will be bent
during installation of the canopy. A bent float rod will
FUEL LEVEL SENDER
result in erroneous gauge readings.
2.
Holding assembly so that canopy is at a 45˚ angle to top
REMOVAL
of fuel tank, insert assembly into left side lobe of fuel
tank keeping the float rod positioned to the right of the
fuel gauge drain tube.
CAUTION
Do not replace the special teflon coated fuel level sender
1WARNING
wiring with ordinary bulk wire. Ordinary insulation mate-
rials may deteriorate when in contact with gasoline.
Always use new screws when installing the canopy.
Reusing old screws may compromise sealing integrity
NOTE
resulting in gas leaks. Gas leakage can cause fire or
Damaged fuel level sender wiring requires replacement of
explosion which could result in death or serious injury.
the fuel level sender unit.
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2005 Touring: Electrical
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1. See FLHT/C CANOPY, REMOVAL, or FLHR/S CAN-
OPY, REMOVAL, in this section.
f2060x8x
2. Cut cable strap to release wiring from support arm.
3. Unwind spiral tubing from fuel level sender wiring.
4. At bottom of canopy, remove socket terminal from spade
Push
contact on connector clip.
Pull
1CAUTION
Always wear proper eye protection when drilling. Flying
debris may result in eye injury.
CAUTION
Exercise care to avoid bending support arm during
removal of the fuel level sender. Support area around
rivet head when drilling or tapping. A bent support arm
will result in erroneous gauge readings.
To disengage tabs from windows, simultaneously
5.
Drill off head of fuel level sender rivet using a 1/4 inch
pull on one safety pin while pushing on the other.
drill bit. Exercise caution to avoid enlarging hole in sup-
port arm when drilling. Use a punch to tap rivet shaft
through hole in support arm if necessary. Blow away all
Pull terminals from wire block and cut.
metal shavings and debris using compressed air.
6.
Remove socket terminals from 3-place Mini-Deutsch
connector on canopy. Proceed as follows:
a. At underside of canopy, take note of the rectangular
opening or window on each side of the connector
body. Now take note of the tab inside each window.
b. Obtain two safety pins. On each side of connector
body, insert a safety pin between body and wire
block until end of each pin appears in window. To
disengage tabs from windows, gently pull on one
safety pin while pushing on the other. See upper
frame of Figure 8-123. With tabs released, gently
tug on wires to release wire block from connector
body.
f2059x8x
c. Pull the wire socket terminals out of the wire block.
See lower frame of Figure 8-123. Cut off the socket
Figure 8-123. Remove Wire Block and Cut Terminals
terminals and back the wires out of the wire block.
d. Insert wire block back into connector body until tabs
lock in windows. One corner of wire block and con-
nector body is square to prevent improper installa-
tion.
3.
Insert socket terminals into wire block. Take note of the
table below for wire locations.
INSTALLATION
Table 8-15. Fuel Level Sender [141]
1. Position new fuel level sender on inboard side of support
Chamber
Wire Color
Function
arm fitting finger at end of support arm into bottom hole
in fuel level sender flange.
1
-
-
2. Align top hole in fuel level sender flange with hole in sup-
2
Yellow
Sender Output
port arm and install new rivet. Insert rivet through the
support arm first, so that deformed end is on the fuel
3
Black
Ground
level sender side.
2005 Touring: Electrical
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HOME
NOTE
INSTALLATION
A series of dots are molded into the wire end of the block to
indicate wire location, one dot indicating chamber 1, two dots
1.
Apply a very thin film of clean H-D 20W50 engine oil to
chamber 2, three dots chamber 3. (Wire location numbers
new O-ring. Install O-ring in groove of connector body.
are also stamped below the terminals inside the Mini-Deutch
2.
Fit connector body into hole at top of canopy. At under-
pin housing.)
side of canopy, install connector clip engaging slots in
connector body.
4. Gently tug on wires to verify that they will not back out of
wire block.
3.
Insert wire block back into connector body until tabs lock
in windows. One corner of wire block and connector
5. Install socket terminal onto spade contact on connector
clip.
body is square to prevent improper installation.
6. Wind spiral tubing around fuel level sender wiring.
4.
Install socket terminal onto spade contact on connector
clip.
7. Insert new cable strap into hole in support arm. Tighten
cable strap capturing fuel level sender wiring. Cut any
5.
See FLHT/C CANOPY, INSTALLATION, or FLHR/S
excess cable strap material.
CANOPY, INSTALLATION, in this section.
8. See FLHT/C CANOPY, INSTALLATION, or FLHR/S
CANOPY, INSTALLATION, in this section.
CANOPY CONNECTOR/O-RING
REMOVAL
1.
See FLHT/C CANOPY, REMOVAL, or FLHR/S CAN-
OPY, REMOVAL, in this section.
2. At bottom of canopy, remove socket terminal from spade
contact on connector clip.
3. Remove wire block from connector body as described
under FUEL LEVEL SENDER, REMOVAL, steps 6(a)-
6(b), on the previous page.
4.
Slide connector clip from slots on connector body.
Remove connector body from canopy.
5.
Remove O-ring from groove on connector body.
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2005 Touring: Electrical
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CRUISE CONTROL (FLHRC, FLTR, FLHTCU)
8.30
GENERAL
f1368a8x
The Cruise Control system provides automatic vehicle speed
control. The electronics and stepper motor are contained in a
control module mounted under the left side cover. The step-
per motor actuates the cruise control cable through a gear
train and ribbon reel.
SYSTEM OPERATION
Set/Resume
To engage and disengage the cruise control system, proceed
Switch
as follows:
1.
While riding in fourth or fifth gear, turn the Cruise ON/
OFF Switch to the ON position. See Figure 8-124. The
switch is located on the fairing cap of FLHTCU models,
the instrument nacelle of FLTR models, and the left han-
dlebar lower switch housing on FLHRC models. The
Cruise Enabled/Engaged lamp in the tachometer face
Figure 8-125. Right Handlebar Switch Assembly
(speedometer on FLHRC models) turns red to indicate
(FLTR, FLHTCU)
that the system is activated. See Figure 8-126. A red
lamp in the switch on both FLHTCU and FLTR models
f2160x8x
Tachometer
also indicates this condition to the rider.
2.
Power (12 vdc) is supplied to the cruise control module
through a 15 amp fuse located in the fuse block mounted
under the left side cover.
60
40
3.
With the motorcycle traveling at the desired “cruise”
50
70
30
50
speed (30 mph/48 km/h to 85 mph/137 km/h), momen-
40
80
tarily push the Cruise SET/RESUME switch to SET. See
30
90
20
60
MPH
RPM x100
Figure 8-125.
20
100
10
70
10
110
0
120
0
80
Ignition/Light
Key Switch
TI
-D
-D
Cruise ON/OFF
Switch
Cruise Enabled/Engaged Lamp
Figure 8-126. Instrument Panel (FLHTCU)
The cruise control module “reads” the vehicle speed
sensor (VSS) output to establish the desired vehicle
speed. The module then sends a signal to the stepper
motor which drives the ribbon reel to take up the slack in
the cruise cable. The Cruise Enabled/Engaged lamp in
the tachometer face (speedometer on FLHRC models)
turns from red to green to indicate that the cruising
speed is locked in. See Figure 8-126.
f2031x8x
4.
The cruise control module monitors both the engine
RPM and the VSS output speed signal. The module sig-
Figure 8-124. Fairing Cap (FLHTCU)
nals the stepper motor to open or close the throttle to
keep the speedometer output speed signal constant.
The engine RPM is monitored to detect engine
2005 Touring: Electrical
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ENGAGE SEQUENCE
DISENGAGE SEQUENCE
CRUISE SWITCH ON
FRONT/REAR BRAKE
SET/RESUME
SWITCH TO SET
IDLE CABLE ROLL-OFF
READS VSS
(DISENGAGE) SWITCH
OUTPUT SPEED SIGNAL
CRUISE
CRUISE SWITCH OFF
STEPPER MOTOR
MODULE
GEAR TRAIN
& RIBBON REEL
CRUISE ENGAGED
HANDLEBAR
LAMP
ENGINE STOP
SWITCH OFF
THROTTLE
ACTUATION
ENGINE RPM
MONITORED*
CLUTCH DISENGAGE
(ENGINE RPM)
*Tachometer receives signal from ignition coil on
carbureted models, and from ECM on EFI models.
Figure 8-127. Cruise System Diagram
overspeed, a condition which automatically causes
f.
Handlebar mounted Cruise SET/RESUME switch is
cruise disengagement.
pushed to SET and held in that position until vehicle
speed drops below 30 mph (48 km/h).
5.
The cruise control automatically disengages (stepper
motor drives cruise cable to the full-out position) when-
NOTE
ever the cruise control module receives one of the fol-
If the vehicle speed is above 30 mph (48 km/h) when the
lowing inputs:
Cruise SET/RESUME Switch is released, then the cruise
system automatically re-engages.
a. Front or rear brake is applied.
b. Throttle is “rolled back” or closed, thereby actuating
idle cable roll-off (disengage) switch.
CABLE ADJUSTMENT
c. Motorcycle clutch is disengaged (module senses
too great an increase in RPM).
NOTE
d. Cruise ON/OFF Switch placed in the OFF position.
Always adjust the cables in the sequence presented below,
The switch is located on the fairing cap of FLHTCU
that is, throttle and then idle cable. The cruise cable only
models, the instrument nacelle of FLTR models, and
requires adjustment if the cruise module or cruise cable are
the left handlebar lower switch housing on FLHRC
removed or replaced, and then it must be adjusted last using
models. The green Cruise Enabled/Engaged lamp
the CABLE LASH INITIALIZATION routine on the next page.
in the tachometer face (speedometer on FLHRC
models) is extinguished to indicate that the system
is deactivated. The red lamp in the fairing cap switch
THROTTLE CABLE
of FLHTCU models and the instrument nacelle
1.
With handlebar in straight ahead position, idle cable
switch of FLTR models is also extinguished.
adjusted to full slack and throttle control grip turned to
e. Handlebar mounted Engine Stop Switch placed in
wide open throttle
(WOT), adjust pull open cable to
the OFF position. (This removes tachometer input
obtain full throttle opening at carburetor/induction mod-
signal which results in module disengagement.)
ule.
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2005 Touring: Electrical
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2. Twist throttle grip to full closed position. Check that idle
CABLE LASH INITIALIZATION
stop-screw is touching idle stop with handlebar in
straight ahead position, and while turning handlebar
With the elimination of the mechanical cruise cable adjuster,
the tolerance stack-ups are intended to result in a cable that
from “lock-to-lock”.
is too long. The extra cable length is then taken up upon exe-
NOTE
cution of the Cable Lash Initialization routine. During the rou-
If idle stop-screw is not touching idle stop, adjust (loosen)
tine, the system calculates the number of “motor steps” the
pull-open cable just enough so that contact is made through
cable is pulled before the throttle plates are moved (a maxi-
full lock-to-lock handlebar movement. Also check that cruise
mum of 200 motor steps equivalent to 1.2 inches or 31 mm).
cable has slack and is not opening throttle. Loosen cruise
This information is then stored in permanent memory.
cable if required.
NOTE
3. Rotate throttle grip to WOT and release. Throttle must
Perform the initialization routine whenever the cruise module,
return to idle position freely. If it does not, check for
cruise cable or throttle body are removed or replaced. For
incorrect cable routing, damaged cables or binding in the
best results, be sure the engine is at normal operating tem-
throttle grip.
perature and throttle and idle cables are correctly adjusted
and operational.
To set the correct cable lash, proceed as follows:
IDLE CABLE
a. Push the Cruise Switch on the right handlebar to
1.
Remove left side saddlebag. See Section 2.25 SAD-
RESUME and hold.
DLEBAG, REMOVAL.
b. Turn the Cruise ON/OFF switch to ON.
2.
Gently pull side cover from frame downtubes (no tools
c. Turn the Ignition/Light Key Switch to IGNITION.
required).
d. Start the engine. The green Cruise Enabled/
3.
Lift the locking latch and remove the cruise module con-
Engaged lamp in the tachometer face (speedometer
nector [17]. With idle cable still adjusted to full slack posi-
on FLHRC models) will illuminate. Wait 3 seconds
tion, connect ohmmeter to violet/yellow and orange/
for the lamp to go off.
violet leads on connector [17A].
e. Release the Cruise Switch from the RESUME posi-
4.
Ohmmeter must indicate infinity (switch contacts open).
tion.
If ohmmeter indicates continuity, the roll-off switch may
f.
Push the Cruise Switch to RESUME and hold.
be shorted and entire cable must be replaced.
Cruise will pull in cable until change in RPM is
5.
With handlebar in straight ahead position, adjust idle
detected. The number of motor steps required to rev
cable until approximately 0.06 inch (1.5 mm) of freeplay
the engine is stored in memory.
exists at the outside diameter (OD) of the throttle grip.
g. After engine revs and Cruise Enabled/Engaged
6.
With light force, rotate the throttle grip toward the closed
lamp is extinguished, release the Cruise Switch
position. The ohmmeter must indicate continuity. If it
from the RESUME position.
does not, decrease freeplay at throttle grip by adjusting
h. Turn the Ignition/Light Key Switch to OFF.
the idle cable to obtain continuity while maintaining
some freeplay at the throttle grip.
7.
While holding the throttle grip (with light force) in the
THROTTLE/IDLE CABLES
closed position, turn handlebar from “lock-to-lock”. Ohm-
meter must indicate continuity throughout handlebar
NOTE
movement.
While the same throttle cable is used on all Touring models,
8.
With handlebar in straight ahead position, rotate throttle
the idle cable of “cruise” models is provided with a cruise roll-
grip to WOT and release. Throttle must return to idle
off (disengage) switch.
position freely.
9.
Repeat step 8 with handlebar at full left and right posi-
REMOVAL
tions. If throttle does not return to idle position freely,
1. See Section 2.21 THROTTLE CABLES (NON-CRUISE),
loosen idle cable slightly and repeat steps 6-9.
REMOVAL, THROTTLE SIDE.
10.
Install cruise module connector [17] and engage locking
2. Remove the air cleaner and backplate. See Section 4.5
latch.
AIR CLEANER, REMOVAL.
11.
Align barbed studs in side cover with grommets in frame
3. Raise fuel tank to access cables in area of frame back-
downtubes and push firmly into place
(no tools
bone. For carbureted models, see Section 4.7 FUEL
required).
TANK (CARBURETED), PARTIAL REMOVAL, FLHT/C,
or FLHR/S. For fuel injected models, see Section 9.4
12.
Install left side saddlebag. See Section 2.25 SADDLE-
FUEL TANK (FUEL INJECTED), PARTIAL REMOVAL,
BAG, INSTALLATION.
FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
2005 Touring: Electrical
8-103
HOME
Main
Harness
Female Spade
Terminal
Insulator
Cruise Control
Roll-Off Switch
External
(Under Boot)
Step
Switch Spade
Contact
Idle Cable
Throttle Cable
f2037x8x
Figure 8-128. Throttle/Idle Cable Configuration (Right Side View)
4.
Locate the cruise control roll-off switch plumbed into the
2.
Route the throttle and idle cables as follows:
idle cable on the right side of the vehicle. See Figure 8-
FLHTCU: Route the cables downward following the
128. Push rubber boot on switch forward to access
brake line to the inner fairing. Pass the cables through
spade type wire terminals.
the inner fairing grommet and then loop them toward the
5.
Remove both female spade type terminals from spade
rear along the right side of the steering head.
contacts on cruise control roll-off switch.
FLHRC: Route the cables downward following the right
6. Carbureted: Using a needle nose pliers, carefully pull
handlebar to the handlebar clamp shroud. Pass the
idle cable barrel from upper inboard hole in throttle
cables through the opening in the shroud and then loop
wheel. Pull throttle cable barrel from remaining hole.
them toward the rear along the right side of the steering
Release idle and throttle cables from guides in throttle
head. Capture cables in J-clamp and then start screw
cable bracket.
(with flat washer) to fasten J-clamp to wellnut in right
Induction Module: Using a needle nose pliers, carefully
side of steering head. Tighten screw to 9-18 in-lbs (1.0-
pull idle cable barrel from upper hole in throttle wheel.
2.0 Nm).
Pull throttle cable barrel from lower hole. Using slots,
3.
Route the throttle and idle cables rearward along the
release idle and throttle cables from guides in throttle
right side of the frame backbone. After passing through
cable bracket.
J-clamp riveted to frame backbone, route cables down-
7. Free cables from J-clamp riveted to right side of frame
ward to carburetor/induction module.
backbone.
4.
Use a pliers to straighten spade contacts of cruise roll-
8. If present, remove screw (with flat washer) to release J-
off switch if bowed or bent back. The contacts must be
clamp from wellnut in right side of steering head.
parallel and line up perpendicular to the idle cable.
Remove J-clamp from cables.
5.
Separate the cruise roll-off switch wires up to the point
where they enter the wire harness conduit. Now route
INSTALLATION
the leads straight down.
1. See Section 2.21 THROTTLE CABLES (NON-CRUISE),
6.
Orient the idle cable so that the spade contacts are at
INSTALLATION, THROTTLE SIDE.
the top.
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2005 Touring: Electrical
HOME
7. Slide the insulators onto the switch spade contacts
cables as necessary to keep barrel ends from dislodg-
(polarity is not a factor). For maximum insertion, be sure
ing. Verify operation by turning throttle grip and observ-
that the external step on the insulators face each other.
ing cable action.
See Figure 8-128.
12. Install fuel tank. For carbureted models, see Section 4.7
8. Fit the rubber boot over the cruise control roll-off switch.
FUEL TANK (CARBURETED), INSTALLATION (AFTER
An oval cut in the boot accommodates the switch spade
PARTIAL REMOVAL), FLHT/C, or FLHR/S. For fuel
terminal connections.
injected models, see Section 9.4 FUEL TANK (FUEL
INJECTED), INSTALLATION
(AFTER PARTIAL
9. Position the throttle cable below the idle cable.
REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
10. Carbureted: Install sleeve on throttle cable housing into
shorter cable guide in throttle cable bracket. Drawing
13. Install backplate and air cleaner assembly. See Section
throttle cable downward, fit barrel end into lower out-
4.5 AIR CLEANER, INSTALLATION.
board hole in throttle wheel. Install sleeve and spring on
14. Adjust the throttle and idle cables. Be sure to use the
idle cable housing into longer cable guide inserting bar-
cable adjustment procedure for Ultra models. See
rel end into upper inboard hole in throttle wheel.
CABLE ADJUSTMENT, in this section.
Induction Module: Install sleeve on throttle cable hous-
ing into shorter cable guide at top of throttle cable
bracket. Drawing throttle cable downward, fit barrel end
CRUISE CABLE
into lower hole in throttle wheel. Install sleeve and spring
on idle cable housing into longer cable guide at bottom
of throttle cable bracket inserting barrel end into upper
REMOVAL
hole in throttle wheel.
11. Verify that cables are fully seated in channel of throttle
1.
Remove the air cleaner and backplate. See Section 4.5
wheel, and using cable adjusters at handlebar, tighten
AIR CLEANER, REMOVAL.
f2206x8x
Cruise Cable
Cruise Module
Connector
Cruise Module
Connector [17]
Spare Fuse
Holder
Maxi-Fuse
Fuse Block
Holder
Figure 8-129. Cruise Control Module (Under Left Side Cover)
2005 Touring: Electrical
8-105
HOME
7. Pull the cable out of the connector and remove the cable
end bead from the ribbon end eyelet. See Figure 8-131.
f1965x8x
8. Pull anchored cable clip from hole in frame crossmem-
ber. See Figure 8-132.
9. Carefully pull cruise cable from beneath fuel tank draw-
ing it out through hole in frame crossmember.
INSTALLATION
Wheel Pin
1.
Draw the cruise cable forward along the left side of the
frame backbone, and then route the cable toward the
right side of the vehicle in front of the top engine stabi-
End Fitting
lizer bracket.
2.
Slide groove in cruise cable end fitting over cap of wheel
pin. Push on end fitting until it snaps in place. See Figure
8-130.
Figure 8-130. Remove End Fitting From Wheel Pin
3.
Using slot, slip cruise cable housing into cable guide in
throttle cable bracket. At bottom of bracket, install new
2.
Remove E-clip from sleeve at end of cruise cable hous-
E-clip on sleeve at end of cruise cable housing.
ing. Discard E-clip. Using slot, remove cruise cable
housing from cable guide in throttle cable bracket.
4.
Feed cruise cable and connector through hole in frame
crossmember. See Figure 8-132.
3.
Push the plastic end fitting on the cruise cable to the out-
board side to release from wheel pin. See Figure 8-130.
CAUTION
4.
Remove left side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
Be sure that the ribbon is not twisted. A twisted ribbon
may adversely affect performance or even prevent cruise
5.
Gently pull side cover from frame downtubes (no tools
operation.
required).
6.
Rotate cruise cable connector in a counterclockwise
5.
With the hole in the ribbon end eyelet and the flat on the
direction to detach from cruise module. See Figure 8-
cable connector housing facing outboard, fit cable end
129.
bead into ribbon end eyelet. See Figure 8-131.
Flat
Ribbon
Cruise
Module
Ribbon End
Eyelet
Cruise Cable
Connector
Cable End
Bead
f1549x8x
Figure 8-131. Remove Cable End Bead From Ribbon End Eyelet
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2005 Touring: Electrical
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f1548x8x
1WARNING
Cruise
Always disconnect the negative battery cable first. If the
Cable
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion which could result in death or serious injury.
4.
Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
Cable Clip
5.
Unthread bolt and remove battery positive cable (red)
from battery positive (+) terminal.
Hole
6.
Using a T40 TORX drive head, loosen bolt to move lip of
hold-down clamp off edge of battery. Remove battery
from battery box.
7.
Lift the locking latch and remove the cruise module con-
nector [17]. See Figure 8-129.
Figure 8-132. Cruise Cable Routing (Left Side)
8.
Rotate cruise cable connector in a counterclockwise
direction to detach from cruise module.
6.
Verify that bead, eyelet and ribbon are lined up correctly.
9.
From inside battery box, remove three flange bolts.
If necessary, remove plastic end fitting from wheel pin
Carefully pull cruise module away from side of battery
and gently pull on end fitting to remove cable slack.
box exercising caution to avoid losing grommets.
Reinstall end fitting, if removed.
7.
Insert cruise cable connector into cruise module and
rotate in a clockwise direction until tabs on connector
INSTALLATION
fully engage grooves or detentes in cruise module hous-
ing.
1.
Install grommets into holes on left side of battery box
with the larger OD on the outboard side. See Figure 8-
8.
Capture cruise cable in cable clip and anchor in hole of
133.
frame crossmember. See Figure 8-132.
9.
Adjust the throttle and idle cables. See CABLE ADJUST-
2.
Align threaded holes on inboard side of cruise module
with holes in grommets and install flange bolts from
MENT, in this section.
inside battery box.
10.
Install backplate and air cleaner assembly. See Section
4.5 AIR CLEANER, INSTALLATION.
3.
Alternately tighten flange bolts to 60-96 in-lbs (6.8-10.9
Nm). Install cruise module connector [17] and engage
11.
Align barbed studs in side cover with grommets in frame
locking latch.
downtubes and push firmly into place
(no tools
required).
12.
Install left side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
f2004x8x
Mounting
13.
Perform the CABLE LASH INITIALIZATION routine des-
Holes
cribed in this section.
CRUISE CONTROL MODULE
REMOVAL
1.
Remove the air cleaner and backplate. See Section 4.5
AIR CLEANER, REMOVAL.
2.
Push the plastic end fitting on the cruise cable to the out-
board side to release from wheel pin. See Figure 8-130.
3.
Remove seat. See Section 2.24 SEAT, REMOVAL.
Figure 8-133. Battery Box (Right Side View)
2005 Touring: Electrical
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CRUISE CONTROL SWITCHES
CAUTION
Be sure that the ribbon is not twisted. A twisted ribbon
may adversely affect performance or even prevent cruise
FAIRING CAP
operation.
See Figure 8-134. For instructions on replacement of the
CRUISE ON/OFF SWITCH, see Section 8.19 FAIRING
4.
With the hole in the ribbon end eyelet and the flat on the
CAP SWITCHES (FLHTC/U), Section 8.20 INSTRU-
cable connector housing facing outboard, fit cable end
MENT NACELLE SWITCHES (FLTR), or Section 8.21
bead into ribbon end eyelet. See Figure 8-131.
HANDLEBAR SWITCHES (FLHRC).
5.
Verify that bead, eyelet and ribbon are lined up correctly.
If necessary, remove plastic end fitting from wheel pin
Cruise ON/OFF
and gently pull on end fitting to remove cable slack.
Switch
6.
Insert cruise cable connector into cruise module and
rotate in a clockwise direction until tabs on
connector
fully engage grooves or detentes in cruise module hous-
ing.
7.
Install the cruise module connector [17] until locking
latch engages. See Figure 8-129.
8. Place battery in battery box, terminal side forward.
Rotate hold-down clamp so that lip (with rubber pad)
rests on edge of battery and tighten clamp bolt.
1WARNING
f2031x8x
Always connect the positive battery cable first. If the
positive cable should contact ground with the negative
Figure 8-134. Fairing Cap (FLHTCU)
cable installed, the resulting sparks may cause a battery
explosion which could result in death or serious injury.
HANDLEBAR
9. Insert bolt through battery positive cable
(red) into
See Figure 8-135. For instructions on replacement of the
threaded hole of battery positive (+) terminal. Tighten
handlebar mounted CRUISE SET/RESUME switch, see
bolt to 60-96 in-lbs (6.8-10.9 Nm).
Section
8.21 HANDLEBAR SWITCHES, SWITCH
REPAIR/REPLACEMENT.
10. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
f1368a8x
11. Install seat. See Section 2.24 SEAT, INSTALLATION.
12. Slide groove in cruise cable end fitting over cap of wheel
pin. Push on end fitting until it snaps in place. See Figure
8-130.
13. Install backplate and air cleaner assembly. See Section
4.5 AIR CLEANER, INSTALLATION.
14. Perform the CABLE LASH INITIALIZATION routine des-
Set/Resume
cribed in this section.
Switch
Figure 8-135. Right Handlebar Switch Assembly
(FLTR, FLHTCU)
8-108
2005 Touring: Electrical
HOME
PREMIUM SOUND SYSTEM (FLHTC/U, FLTR)
8.31
RADIO (FLHTC/U)
Radio [28]
f2238x8x
CB Antenna
Gray
Cable [50]
Ultra Only
REMOVAL
Ultra Only
1. Remove seat. See Section 2.24 SEAT, REMOVAL.
Radio Antenna
Radio [27]
Cable [51]
Black
1WARNING
To protect against shock and accidental start-up of vehi-
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury.
CAUTION
To prevent possible damage to the sound system,
always verify that the Ignition/Light Key Switch is in the
OFF position before disconnecting the battery negative
cable from the battery terminal.
2. Verify that the Ignition/Light Key Switch is in the OFF
1
2
3
position. Unthread bolt and remove battery negative
cable (black) from battery negative (-) terminal.
3. Remove the outer fairing. See Section 2.29 UPPER
1.
Main to Interconnect [1]
FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/
2.
Main to Interconnect [15]
WINDSHIELD, REMOVAL.
3.
Ignition/Light Key Switch [33]
Figure 8-137. Radio Connections - FLHTCU
NOTE
To separate pin and socket halves of Radio connectors [27]
and [28], use thumbnail to pull down external latch before
b. Radio antenna cable connector [51].
pulling socket from pin side. See Figure 8-136.
c. Radio connector [28], 23-place Amp (gray). Ultra
4. See Figure 8-137. Separate pin and socket halves of the
models only.
following connectors:
d. CB antenna cable connector [50]. Rotate knurled
a. Radio connector [27], 23-place Amp (black).
nut counterclockwise until free. Ultra models only.
f1555x8x
f1559x8x
Figure 8-136. Pull Down Latch to Free Radio Connector
Figure 8-138. Release Carrier from Fairing Brackets
2005 Touring: Electrical
8-109
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