Harley Davidson 2004 Touring Models. Service Manual — page 54
HOME
6. Mate pin and socket halves of Console Pod Connector
f2007x9x
[53],
12-place Mini-Deutsch. Install connector onto
attachment clip anchored in hole of frame crossmember
Console
(at rear of battery box).
Fuel
Pod
Tank
7. 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).
8. Install seat. See Section 2.24 SEAT, INSTALLATION.
Fuel Pump,
9. Align barbed studs in side cover with grommets in frame
Fuel Level
downtubes and push firmly into place
(no tools
Sender Conduit
required).
10. Install left side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
Fuel
Main
Overflow
Harness
Fuel Vapor
Hose
FRONT HEADSET RECEPTACLE
Bundle
Vent Tube
(To Vapor Valve)
REMOVAL
1.
Remove console pod. See CONSOLE POD ASSEM-
Main
BLY, REMOVAL, in this section.
Anchored
Console
Cable Strap
Harness
2.
Remove terminals 6 through 12 from pin housing of 12-
Bundle
Pod Conduit
place Mini-Deutsch connector.
NOTE
For instructions on properly removing wire terminals, see
Figure 8-140. Console Pod Cable/Hose Routing
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
(Top View)
REMOVING/INSTALLING PINS.
3.
Raise headset receptacle cap. Place pin punch in either
1WARNING
notch of lock ring and rotate in a counterclockwise direc-
tion until loose. See Figure 8-141.
Exercise caution to avoid pinching or kinking the fuel
4.
Remove lock ring and cap from headset receptacle.
overflow hose when console is installed. A blocked hose
5.
Remove headset receptacle from pod.
can cause excess gasoline to remain above the filler
neck insert, while fuel expansion can cause an overfilled
tank to overflow through the filler cap vent. Gasoline is
INSTALLATION
extremely flammable and highly explosive. Inadequate
safety precautions could result in death or serious
1.
From inside pod, insert threaded end of headset recep-
injury.
tacle through side hole.
2. Remove filler cap. Place console over filler neck onto
canopy. Route cables from beneath console as shown in
Figure 8-140. Be sure that hoses and wires are not
pinched by the console during installation. Reinstall filler
cap.
Lock Ring
3. Install Allen head screw to fasten rear flange of console
to clip nut on fuel tank weldment. Tighten screw to 25-30
in-lbs (2.8-3.4 Nm).
4. Open fuel door on console. Install two Allen head screws
to secure front of console to clip nuts on canopy bracket.
Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).
5. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main har-
ness, audio harness, console pod conduit, fuel level
sender/fuel pump conduit, and fuel vapor vent tube. See
f2020x8x
Figure 8-140. Install new cable strap to secure console
pod conduit and audio harness to left frame tube at front
Figure 8-141. Remove Lock Ring from Receptacle
of saddlebag rail. Cut any excess cable strap material.
Using Pin Punch
8-110
2004 Touring: Electrical
HOME
2. Place receptacle cap over end of headset receptacle so
that it seats in recess of pod.
Speaker
3. Open cap, and with the notches on the outboard side,
Box
thread lock ring onto headset receptacle.
Switch
4. Place pin punch in either notch of lock ring and rotate in
Bracket
a clockwise direction until tight.
5. Install terminals 6 through 12 into pin housing of 12-
place Mini-Deutsch connector.
TORX
Table 8-16. Front Headset Receptacle
Screw
Chamber
Wire Color
Number
Blue/Yellow
6
Yellow/Black
7
Yellow/White
8
f1492b8x
Yellow/Red
9
Figure 8-142. Remove Passenger Switch Assembly
Black
10
(Right Side Speaker Box Shown)
Red
11
Black (Thick Insulation)
12
4.
Remove speaker from speaker box and carefully pull
socket terminals from speaker spade contacts.
NOTE
5.
Remove trim ring and gently pull on wire harness to
For instructions on properly installing wire terminals, see
draw 6-place Mini-Deutsch connector out of speaker
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
box.
REMOVING/INSTALLING PINS.
6.
Depress external latch on socket housing side and use a
rocking motion to separate pin and socket halves of
6. Install console pod. See CONSOLE POD ASSEMBLY,
Mini-Deutsch connector.
INSTALLATION, in this section.
7.
Draw socket half of Mini-Deutsch connector back into
7. Test operation of headset receptacle.
speaker box and pull out through speaker hole.
8.
Using a T25 TORX drive head, remove two screws to
release switch bracket from inside of speaker box.
REAR HEADSET RECEPTACLE
Remove bracket using slot to free switch wires. See Fig-
ure 8-142.
See Section 8.32 WIRING HARNESSES AND CABLES,
9.
Pull switch housing assembly, wire harness conduit,
AUDIO HARNESS (FLHTCU).
speaker terminals and Mini-Deutsch socket from
speaker box using switch housing hole on outboard side.
10.
Carefully pull keycap from switch shaft. Remove switch
from switch housing.
REAR PASSENGER SWITCHES
11.
Remove terminals 1 through 4 from socket housing.
NOTE
REMOVAL
For
instructions on properly removing wire terminals, see
NOTE
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
REMOVING/INSTALLING SOCKETS.
Right and left side replacement passenger switch assem-
blies are interchangeable.
12. Pulling one wire at a time, remove four wires from con-
duit.
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
2. Open Tour-Pak.
INSTALLATION
3. Using a T10 TORX drive head, remove four screws and
1.
Pushing one wire at a time, feed four wires of new switch
pull speaker grille from speaker box.
through conduit.
2004 Touring: Electrical
8-111
HOME
f1494b8x
Passenger
Switch
Slot faces toward the front
on right side switch assembly,
toward the rear on left side.
Slot
Cavity
Switch
f1491x8x
Housing
DISASSEMBLED
Figure 8-144. Properly Orient Switch Bracket
Speaker
Box
Switch
Bracket
Pink/White
Keycap
Wire
Rib
Slot
Forward
ASSEMBLED
f1495x8x
Figure 8-143. Install Switch in Housing
Rib
Bottom
2.
Install terminals 1 through 4 into socket housing.
Table 8-17. Rear Passenger Switches
Chamber
Wire Color
Number
Pink/White
1
Gray/White
2
f1492x8x
Violet/Black
3
* Orange/Black
4
Figure 8-145. Install Passenger Switch Assembly
* Mates to O/BK on [41A], BN/W on [42A].
(Right Side Speaker Box Shown)
8-112
2004 Touring: Electrical
HOME
NOTE
REAR SPEAKERS
For instructions on properly installing wire terminals, see
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
REMOVING/INSTALLING SOCKETS.
REMOVAL
3.
With the Pink/White wire at the bottom, place switch in
1.
Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
cavity of switch housing. Bottom of the assembly is
MAXI-FUSE, REMOVAL.
determined by location of rib on switch housing. See Fig-
2.
Open Tour-Pak.
ure 8-143.
3.
Using a T10 TORX drive head, remove four screws from
4.
Note lettering for proper orientation and gently push key-
speaker grille. Remove speaker grille from speaker box.
cap onto switch shaft. When orienting keycap, remember
that bottom of assembly is determined by location of
4.
Remove speaker from speaker box. Carefully pull two
switch housing rib.
socket terminals from speaker spade contacts.
5.
Feed Mini-Deutsch socket connector, speaker terminals
and conduit through switch housing hole on outboard
INSTALLATION
side of speaker box until switch housing backplate con-
tacts speaker box. Pull harness out through speaker
1.
Install two socket terminals onto speaker spade con-
hole.
tacts. Different size spade contacts prevent improper
assembly.
6.
Reaching into speaker box, align holes in bracket with
2.
With spade contacts at bottom, install speaker in
holes in switch housing. Using a T25 TORX drive head,
speaker box.
install two bracket screws. See Figure 8-145.
3. Align holes in speaker with those in speaker box. Align
NOTE
holes in grille with those in speaker.
To align bracket and switch housing holes, slot in bracket
4.
Install four screws. Aternately tighten screws using a
must face toward the front on right side assembly and toward
T10 TORX drive head.
the rear on left side. See Figure 8-144. Switch also must be
square in cavity of switch housing or bracket will not fit.
5.
Close Tour-Pak.
6. Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
7.
Feed Mini-Deutsch socket through speaker hole into
MAXI-FUSE, INSTALLATION.
speaker box and pull out through harness hole on
inboard side.
7.
Test speaker for proper operation.
8.
Mate pin and socket halves of Mini-Deutsch connector.
Feed connector back up into speaker box pressing trim
ring into hole.
CB LOADING COIL
9.
Install socket terminals onto speaker spade contacts. On
right side of vehicle, install socket terminal of the solid
Green wire onto contact next to the red dot. On left side,
REMOVAL
install socket terminal of the solid Brown wire onto con-
tact next to the red dot.
1.
Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
10.
Align holes in speaker grille with those in speaker and
2.
Open Tour-Pak. Open map pocket and remove acorn
slide four TORX screws through grille and speaker
holes.
nuts. Remove map pocket and molded liner from Tour-
Pak.
11.
With spade contacts at bottom rear corner, position
3.
Disconnect 1-place CB antenna cable connector on right
speaker/grille assembly against speaker box. Thread
side of Tour-Pak. Release cable from rear clip at bottom
four screws into speaker box and tighten using a T10
of Tour-Pak.
TORX drive head.
4.
Remove Keps nut, ring terminal and flat washer from
12.
Close Tour-Pak.
loading coil stud.
13.
Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
5.
Holding Phillips screw, remove flange nut at bottom of
MAXI-FUSE, INSTALLATION.
Tour-Pak to release loading coil bracket. Remove load-
ing coil from vehicle (with Phillips screw, external tooth
14.
Test switch for proper operation.
lockwasher and flange nut).
2004 Touring: Electrical
8-113
HOME
INSTALLATION
AUDIO HARNESS
1. Place new loading coil into position aligning hole in
For removal and installation instructions, see Section 8.32
bracket with hole in Tour-Pak. Holding flange nut under
WIRING HARNESSES AND CABLES, AUDIO HARNESS
Tour-Pak, install Phillips screw with external tooth lock-
(FLHTCU).
washer.
2.
Mate pin and socket halves of 1-place CB antenna cable
RADIO ANTENNA CABLE
connector. Capture antenna cable in rear clip at bottom
of Tour-Pak.
For removal and installation, see Section 8.32 WIRING HAR-
3.
Install flat washer, ring terminal and Keps nut onto load-
NESSES AND CABLES, RADIO ANTENNA CABLE
ing coil stud. Tighten hex nut.
(FLHTC/U).
4.
Install molded liner in Tour-Pak. Install map pocket and
secure using acorn nuts. Close Tour-Pak.
CB ANTENNA CABLE
5.
Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
For removal and installation, see Section 8.32 WIRING HAR-
MAXI-FUSE, INSTALLATION.
NESSES AND CABLES, CB ANTENNA CABLE (FLHTCU).
6.
Check SWR and adjust if necessary. Follow the SWR
Adjustment procedure in Section 6 of the 2004 ELEC-
TRICAL DIAGNOSTIC MANUAL (Part No. 99497-04).
Remove SWR meter, plug in antenna connector and
tighten antenna connector stud.
8-114
2004 Touring: Electrical
HOME
WIRING HARNESSES AND CABLES
8.32
6. Repeat steps 4-5 to remove right side saddlebag and
MAIN HARNESS
side cover.
NOTE
REMOVAL- ALL MODELS (PART I)
Depending upon model, continue procedure at REMOVAL-
FLHR/C/S
(PART II), REMOVAL- FLTR
(PART II), or
1. Remove fuel tank. For carbureted models, see Section
REMOVAL- FLHT/C/U (PART II).
4.7 FUEL TANK
(CARBURETED), COMPLETE
REMOVAL, FLHT/C or FLHR/S. For fuel injected mod-
els, see Section 9.4 FUEL TANK (FUEL INJECTED),
COMPLETE REMOVAL, FLHT/C/U/I, FLTRI or FLHR/C/
REMOVAL- FLHR/C/S (PART II)
S/I.
1. Remove the Phillips screw at the bottom of the head-
lamp door (chrome ring). Remove the headlamp door.
2. Unthread bolt and remove battery positive cable (red)
from battery positive
(+) terminal.
(Battery negative
2. Remove the eight Phillips screws to free the headlamp
cable already removed under FUEL TANK, COMPLETE
housing from the headlamp nacelle.
REMOVAL.)
3. Squeeze the two external tabs to remove the wire con-
nector at the back of the headlamp bulb. Remove the
3. Using a T-40 TORX drive head, loosen bolt to move lip of
headlamp housing assembly from the motorcycle.
hold-down clamp off edge of battery. Remove battery
from battery box.
4. See Figure
8-146. Reaching inside the headlamp
nacelle, disconnect main harness as follows:
4. Remove left side saddlebag. See Section 2.25 SAD-
● Front fender tip lamp connector [32], 2-place Mul-
DLEBAG, REMOVAL.
tilock (black); used on FLHR only.
5. Gently pull left side cover from frame downtubes (no
● Passing lamps connector [73], 2-place Multilock
tools required).
(white); used on FLHR/C only.
f2212x8x
Cruise Set/Resume
Front Turn
Switch [159]
Signals [31]
Used on FLHRC Only
Left Handlebar
Controls [24]
Cruise On/Off
Switch [158]
Used on FLHRC Only
Right Handlebar
Controls [22]
Accessory
Switch [67]
Front Fender
Tip Lamp [32]
Passing Lamps
Used on FLHR Only
Switch [109]
Used on FLHR/C Only
Headlamp [38]
Passing Lamps [73]
Used on FLHR/C Only
Figure 8-146. Headlamp Nacelle Connectors (FLHR/C/S)
2004 Touring: Electrical
8-115
HOME
f2095x8x
Odometer
Ignition/Light
Reset Switch
Flexible
Clip
Key Switch Connector [33]
Flexible
Clip
Speedometer
Connector [39]
Plastic
Indicator Lights
Flexible
Clip
Connector [21]
Clip
Figure 8-147. Instrument Console Assembly (FLHR/C)
● Passing lamps switch connector
[109],
4-place
8. Unthread rubber boot from odometer reset switch and
Amp; used on FLHR/C only.
pull switch from hole in instrument console.
● Accessory switch connector [67], 4-place Amp.
9. Bend back flexible clamps on inboard side of instrument
● Right handlebar switch controls connector [22], 6-
console as necessary to release main harness conduit.
place Deutsch (black); T-stud on fork stem nut lock
Set instrument console aside.
plate (left side).
10. Moving rearward, carefully cut eleven cable straps
● Cruise set/resume switch connector [159], 2-place
securing main harness to frame backbone and right and
Deutsch (black); used on FLHRC only.
left frame tubes. See Figure 8-148.
● Front turn signal lamps connector [31], 6-place Mul-
tilock; anchor in hole of fork stem nut lock plate (left
NOTE
side).
● Left handlebar switch controls connector [24], 6-
Continue procedure at REMOVAL- ALL MODELS (PART III).
place Deutsch (gray); T-stud on fork stem nut lock
plate (left side).
● Cruise on/off switch connector [158], 2-place Deut-
REMOVAL- FLTR (PART II)
sch (gray); used on FLHRC only.
5.
Carefully pull main harness rearward under right side of
1. Remove the inner fairing. See Section 2.30 UPPER
headlamp nacelle allowing conduit and connectors to
FAIRING/WINDSHIELD
(FLTR), INNER FAIRING,
hang over top of engine guard.
REMOVAL, steps 1-18.
6.
Remove screw and P-clamp to release main harness
2. Remove screw, two main harness ground ring terminals
from right side of steering head.
and P-clamp to release main harness bundle from right
side of steering head.
7.
See Figure 8-147. Moving to inboard side of instrument
console, disconnect main harness as follows:
3. Moving rearward, carefully cut eleven cable straps
securing main harness to frame backbone and right and
● Ignition/Light Key Switch connector [33],
3-place
left frame tubes. See Figure 8-148.
Packard.
● Indicator lights connector [21], 8-place Mini-Deut-
NOTE
sch.
● Speedometer connector [39], 12-place Packard.
Continue procedure at REMOVAL- ALL MODELS (PART III).
8-116
2004 Touring: Electrical
HOME
2.
See Figure 8-149. Disconnect main harness from inter-
connect harness as follows:
● Main to interconnect harness connector [1], 12-
Frame
place Deutsch (black); T-stud at front of right fairing
Backbone
1
bracket.
● Main to interconnect harness connector [2], 12-
place Deutsch (gray); T-stud on right fairing support
2 A
3 A
brace.
● Main to interconnect harness connector [15], 4-
place Packard (black); anchor in hole at bottom of
radio (right side).
9 A
4 A
● Main to interconnect harness connector [156], 6-
place Deutsch (gray); T-stud on right fairing support
brace.
3.
See Figure 8-149. Disconnect ignition switch from main
10 A
5 A
harness. Disconnect radio antenna cable. Proceed as
follows:
● Ignition switch connector
[33],
4-place Packard
(black); anchor in hole at bottom of radio (center).
● Radio antenna cable connector [51]; back of radio
11 A
6 A
(left side).
Saddlebag
7
4.
Remove screw to release main harness ground ring ter-
12
Guard
minal and brake line P-clamp from front of upper fork
bracket.
13
5.
Carefully pull main harness rearward under right side of
8
fairing cap allowing conduit and connectors to hang over
f2225x8x
top of engine guard.
6.
Remove screw, main harness ground ring terminal and
P-clamp to release main harness (and audio harness on
1
Captures main harness, cruise roll-off switch conduit,
FLHTCU models) from right side of steering head.
audio harness (FLHTCUI only) and frame backbone.
2
Captures ignition/EFI harness only. ANCHORED.
7.
Moving rearward, carefully cut eleven cable straps
3
Captures main harness and audio harness
(FLHTCUI
securing main harness to frame backbone and right and
only). ANCHORED.
left frame tubes. See Figure 8-148. Carefully cut any
4
5
6 Captures main harness, audio harness (FLHTCUI only),
cable straps securing main harness to audio harness.
EFI/ignition harness, and conduit to fuel tank harness (all
models except FLHR/C/S). ANCHORED.
NOTE
7
8
Captures audio harness (FLHTCUI only) and upper frame
tube.
Continue procedure at REMOVAL- ALL MODELS (PART III).
9
10
Captures main harness and audio harness
(FLHTCUI
only). ANCHORED.
11
Captures main harness, audio harness (FLHTCUI only),
fuel vapor vent tube and console pod or instrument
REMOVAL- ALL MODELS (PART III)
console conduit. ANCHORED.
12
Captures main harness, audio harness (FLHTCUI only),
1. If cruise equipped, locate the cruise control roll-off
console pod or instrument console conduit and upper
frame tube.
switch plumbed into the idle cable on right side of the
13
Captures main harness, audio harness (FLHTCUI only),
steering head. Push rubber boot on switch forward and
console pod conduit (FLHTCUI only) and upper frame
remove socket terminals from spade contacts.
tube.
2. Moving to left side of motorcycle, remove acorn nut to
release horn bracket from rubber mount stud. Pull elbow
Figure 8-148. Cable Strap Locations
terminals from spade contacts on horn and release con-
duit from J-clamp.
3. Remove flange nut (10 mm) from left side ground stud
on upper frame crossmember. Remove two main har-
REMOVAL- FLHT/C/U (PART II)
ness ground ring terminals. Repeat step to remove two
1. Remove the outer fairing and windshield. See Section
main harness ground ring terminals from right side
2.29 UPPER FAIRING/WINDSHIELD
(FLHT/C/U),
ground stud.See Figure 8-150.
OUTER FAIRING/WINDSHIELD, REMOVAL.
2004 Touring: Electrical
8-117
HOME
Main to Interconnect
f2238x8x
Harness [15]
Main to Interconnect
Main to Interconnect
Harness [156]
Harness [2]
Main to Interconnect
Harness [1]
Radio Antenna
Cable [51]
Ignition
Switch [33]
Figure 8-149. Inner Fairing - Main Harness Connectors (FLHTC/U)
4.
Depress latches on maxi-fuse holder and then slide
9. Disconnect the rear fender lights connector [7], 8-place
cover rearward to disengage tongue from groove in fuse
Multilock, anchored at front of rear fender. Detach pin
block cover.
housing from anchor.
5.
Moving to right side of motorcycle, pull back boot at top
10. Release ignition keyswitch and starter relays by pulling
of starter housing and remove flange nut and main
anchors on rubber molding from holes in frame weld-
power cable ring terminal from post. Release cable from
ment at rear of battery box. Remove relays and molding
clip anchored to T-stud at front of battery tray. Draw main
from connectors. Push connectors down into space
power cable to left side of motorcycle.
below frame weldment.
6.
Carefully cut anchored cable strap to release fuse block
11. Locate the turn signal/security module inside hole of
conduit from fuse block bracket. Pull fuse block from
frame weldment on opposite side. Depress tab at front of
tabs on bracket.
spring clip and lift to release legs from holes in weld-
7.
Remove the fuse block cover. Raise lipped side slightly
ment. Remove module and disconnect 12-place Deut-
to disengage slots from tabs on fuse block.
sch connector [30]. Push connector down into space
below frame weldment.
8.
If cruise equipped, lift the locking latch and remove
cruise module connector [17]. From inside battery box,
12. Pull rear fender lights, ignition keyswitch and starter
remove three flange bolts. Carefully pull cruise module
relays, and turn signal/security module conduit and con-
away from side of battery box exercising caution to avoid
nectors out through opening above rear of fuse block
losing grommets.
bracket and allow to hang on left side of motorcycle.
8-118
2004 Touring: Electrical
HOME
13. Depending upon model, proceed as follows:
FLHTCU: Open map pocket and remove acorn nuts
with flat washers. Remove map pocket and molded
FLHR/C/S: Move to step 14.
liner from Tour-Pak.
FLTR:
b. Depress external latch and remove bulb socket from
a. On left side of motorcycle, remove bolt (with flat
left side of Tour-Pak.
washer) to remove passenger seat strap and sad-
c. Rotate knurled ring in a counterclockwise direction
dlebag front mounting bracket. Remove Phillips
to separate pin and socket halves of radio antenna
screw and chrome frame tube cover.
cable connector [51]. Release cable from two clips
b. Carefully cut cable strap to release radio antenna
at bottom of Tour-Pak.
cable from shoulder of upper frame tube (just in
d. On FLHTCU models, depress button and separate
front of air valve mounting bracket). Cut cable strap
pin and socket halves of Tour-Pak lights connector
to release radio antenna cable from slotted hole in
[12], 3-place Multilock, inside Tour-Pak.
rear fender support.
e. Pull grommet into Tour-Pak and remove from main
c. At bottom of radio antenna bracket, rotate knurled
harness conduit.
ring to separate pin and socket halves of radio
antenna cable connector [51].
f.
Pull Tour-Pak lights and radio antenna cable con-
nectors through hole at front of Tour-Pak. Cut cable
d. Draw radio antenna cable forward to area of fuse
strap to release conduit from luggage rack rail.
block bracket and allow to hang with other main har-
ness branches.
g. Draw Tour-Pak lights and radio antenna cable con-
nectors forward to area of fuse block bracket and
FLHTC/U:
allow to hang with other main harness branches.
a. Open Tour-Pak and proceed as follows:
Remove flange nuts to release passenger hand rail,
FLHTC: Remove rubber mat.
if necessary.
f2250x8x
Main Harness
Ground Ring
Terminals (2)
Main Harness
Ground Ring
Terminals (2)
Chassis
Ground Cable
Fuel Tank Harness
Accessory
Connector [13]
Connector [4]
Not Present on FLHR/C/S
Battery
Positive Cable
B+ Connector [160]
Battery
Negative Cable
Figure 8-150. Electrical Connectors - Upper Frame Cross Member (Under Seat)
2004 Touring: Electrical
8-119
HOME
f2276x8x
Battery
Anchored Cable Strap
Box
See Figure 8-150.
Captures Main Harness Conduit,
Neutral Switch Conduit and
Vehicle Speed Sensor Cable
6
Cable Strap
Captures Main Harness Conduit,
Voltage Regulator Cables and
Cable Strap
Lower Frame Tube
Captures Main Harness Conduit
and Frame Downtube
5
3
2
4
1
Cable Strap
Cable Strap Anchor
Cable Strap Anchor
Captures Rear Brake Light Switch Wires
Captures Main Harness Conduit
Captures Main Harness Conduit,
and Lower Frame Tube
and Rear Brake Line
Voltage Regulator Cables and
Rear Brake Line
Figure 8-151. Cable Straps (Right Side View)
14.
Cut anchored cable strap to release accessory connec-
19.
Cut cable strap to free voltage regulator cables and main
tor [4] and B+ connector [160] from left side of frame
harness conduit (leading to oil pressure sender and
crossmember (in front of battery box). See Figure 8-150.
crankshaft position sensor connectors) from inboard
side of rear brake pedal weldment. See Figure 8-151.
15.
Cut cable strap to release vapor valve from mounting
bracket. Move vapor valve out of the way to facilitate har-
20.
Cut cable straps from two anchors installed on T-studs at
ness removal.
top of lower frame tube.
16.
Alternately feed branches of main harness hanging on
21.
Locate voltage regulator connector [77], 1-place Deut-
left side of motorcycle into battery box through opening
sch, just below the transmission exhaust bracket.
above front of fuse block bracket. For best results, feed
Depress external latch to separate pin and socket hous-
one length of conduit through at a time drawing the fuse
ings.
block through the opening last. Pulling branches out of
battery box, allow conduit and connectors to hang on left
22.
Depress external latch and pull solenoid connector from
side of frame backbone.
top of starter housing.
17.
Moving to front right side of motorcycle, locate crank-
23.
Remove two elbow connectors from neutral switch
shaft position sensor connector [79], 2-place Mini-Deut-
posts.
sch, fixed to bracket at bottom of voltage regulator. Push
connector toward right side of motorcycle to disengage
24.
Pull two socket terminals from spade contacts on rear
small end of slot on attachment clip from T-stud on
brake light switch. Cut cable strap to free rear brake light
bracket. Lift connector off T-stud. Depress button on
switch wires from lower frame tube.
socket terminal side and pull apart pin and socket
25.
Cut cable strap at rear of rear brake light switch bracket
halves.
to release main harness conduit from frame downtube.
18.
Locate oil pressure sender at the front right side of the
26.
Cut anchored cable strap in hole of frame downtube
crankcase. On FLHR/C/S models, pull elbow from post
(inboard of rear swingarm bracket) to release vehicle
of oil pressure switch. On FLHT/C/U and FLTR models,
speed sensor cable, main harness and neutral switch
pull external latch outward and use rocking motion to
conduit.
remove Packard connector from oil pressure sender.
8-120
2004 Touring: Electrical
HOME
27.
Pull ignition/EFI harness connector [8] from slot in elec-
trical bracket. Depress external latches and separate pin
and socket halves.
28.
Remove two flange nuts to release electrical bracket
from studs on side of battery box. Release security siren
connector and conduit from inboard side of electrical
bracket.
29.
Pull ignition/EFI harness connector [8] and security siren
connector [142] and conduit into battery box through
opening at rear of frame crossmember.
30.
Draw neutral switch wires out from under starter hous-
ing. For best results, move electrical bracket out of the
way and reach in under right side of battery box.
31.
Carefully pull rear brake light switch, starter solenoid,
8319
and neutral switch conduit and connectors rearward and
then feed up into battery box through same opening at
Figure 8-152. Feed Harness Into Battery Box (Right Side)
rear of frame crossmember. See Figure 8-152.
32.
Note that main harness runs forward of the front battery
8321
box TORX screw. Pull harness to the rear of the screw,
and then draw conduit and connectors out of battery box
and allow to hang on right side of frame backbone. See
lower frame of Figure 8-153.
CAUTION
Damage to wires can result in electrical problems. Be
sure that rubber boot is present on threaded end of bat-
Rubber
tery box TORX screw. Replace rubber boot if absent or
Boot
damaged. See upper frame of Figure 8-153.
33. Remove main harness from motorcycle.
INSTALLATION- ALL MODELS (PART I)
Figure 8-153. Battery Box TORX Screw (Right Side)
NOTE
NOTE
Disregard references to radio antenna cable and starter relay
If reusing the main harness, thread new cable strap through
connectors when working on FLHR/C/S models. The connec-
eye in anchor and loosely capture main harness bundle. If
tors are not part of the main harness on these motorcyles.
installing a new harness, remove and discard old anchor and
plug anchor attached to new harness into hole in center of
1. Position main harness on motorcycle as follows:
frame backbone.
a. Lay main harness on frame backbone so that front
Left Side
branches hang over top of right engine guard. On
FLHR/C/S models, front branches terminate in
c. Locate left side branch terminating in rear fender
headlamp and handlebar switch control connectors
lights, ignition keyswitch and starter relays, turn sig-
(see Figure 8-146). On FLTR and FLHT/C/U mod-
nal/security module, fuse block, cruise module (if
els, front branches terminate in the ignition switch,
equipped) and radio antenna cable connectors.
radio antenna cable and interconnect harness con-
Feed connectors and conduit into battery box pull-
nectors (see Figure 8-149).
ing branches out through opening above front of
fuse block bracket. Continue drawing harness out
b. Adjust harness so that left and right side branches
through opening until two main harness ground ring
split from main branch at location of anchor at cen-
terminals are adjacent to left side ground stud on
ter of frame backbone.
frame crossmember.
2004 Touring: Electrical
8-121
HOME
d. Feed rear fender lights, ignition keyswitch and
8.
Slide cover over fuse block until slots fully engage tabs
starter relays, and turn signal/security module con-
on block. Slide fuse block into position on mounting
duit and connectors through opening above rear of
bracket. Tabs on bracket fit into slots on each side of
fuse block bracket to area in front of rear fender.
fuse block cover. Install new anchored cable strap in
hole at rear of fuse block bracket. Tighten cable strap to
NOTE
capture fuse block conduit.
On FLTR and FLHT/C/U models, leave longer conduit of
radio antenna cable hanging outboard of fuse block bracket.
9.
Route main power cable on maxi-fuse holder through
opening above front of fuse block bracket and then for-
Right Side
ward passing under frame crossmember toward right
side of motorcycle. Pull back boot at top of starter hous-
e. Feed right side connectors and conduit into battery
ing and install ring terminal on post. Install flange nut
box pulling voltage regulator, oil pressure sender
and tighten to 70-90 in-lbs (7.9-10.2 Nm). Capture cable
and crankshaft position sensor connectors and con-
in clip anchored to T-stud at front of battery tray.
duit out through opening at rear of frame cross-
member. Feed connectors and conduit forward and
10.
Returning to left side of motorcycle, slide maxi-fuse
then downward following front of frame downtube.
cover forward to engage tongue in groove of fuse block
Continue drawing harness out through opening in
cover and then insert maxi-fuse holder into cover until
side of battery box until two main harness ground
latches engage.
ring terminals are adjacent to right side ground stud
on frame crossmember.
11.
Install new anchored cable strap in lower hole on left
side of frame crossmember (in front of battery box).
2.
Returning to left side of motorcycle, route horn conduit in
Tighten cable strap to capture conduit of both accessory
front of the top stabilizer link and then under the top
connector [4] and B+ connector [160] approximately one
engine mounting bracket to back of horn. Install elbow
inch from connector housings. See Figure 8-150.
terminals onto horn spade contacts. Capture conduit in
J-clamp. Slide horn bracket onto rubber mount stud and
12.
Hold vapor valve in position on left side of mounting
install acorn nut with flat washer. Tighten acorn nut to
bracket. From right side of bracket, insert end of small
80-100 in-lbs (9.0-11.3 Nm).
cable strap through hole in arm and then around body of
3.
Slide two main harness ground ring terminals onto left
vapor valve. Mate ends of cable strap and pull tight
side ground stud on upper frame crossmember and
engaging strap in slot of arm. Cut any excess cable strap
install flange nut (10 mm). Install chassis ground ring ter-
material.
minal onto right side ground stud and then two main har-
ness ground ring terminals and flange nut (10 mm).
13.
Depending upon model, proceed as follows:
Tighten flange nuts to 50-90 in-lbs (5.7-10.2 Nm). See
Figure 8-150.
FLHR/C/S: Move to step 14.
4.
Mate pin and socket halves of rear fender lights connec-
tor [7], 8-place Multilock, and attach to anchor at front of
FLTR:
rear fender.
a. Feed radio antenna cable and connector rearward
5.
At front of rear fender, feed ignition keyswitch and starter
following inboard side of upper frame tube. With the
relay connectors up through rectangular shaped hole in
3-place Multilock connector
(unused) positioned
frame weldment. Fit relay connectors into rubber mold-
about as far rearward as the rear shock air valve,
ing and install anchors on molding into holes in frame
install new cable strap to secure radio antenna
weldment. Install relays in connectors.
cable to shoulder of upper frame tube (just in front
6.
Feed turn signal/security module connector
[30] up
of air valve mounting bracket). Using slotted hole,
install new cable strap to secure radio antenna
through hole on opposite side of frame weldment and
cable to rear fender support. See Figure 8-154.
connect to module. Install module into hole in frame
weldment. Insert legs of spring clip into holes in weld-
ment and push down until tab at front snaps in place.
b. At bottom of radio antenna bracket, rotate knurled
ring to mate pin and socket halves of radio antenna
7.
If cruise equipped, install grommets into holes on left
cable connector [51].
side of battery box with the larger OD on the outboard
side. Align threaded holes on inboard side of cruise
c. Install chrome frame tube cover on frame tube.
module with holes in grommets and install flange bolts
Install Phillips screw. Install bolt (with flat washer) to
from inside battery box. Alternately tighten flange bolts
fasten saddlebag front mounting bracket and pas-
to 60-96 in-lbs (6.8-10.9 Nm). Install cruise module con-
senger seat strap to chrome frame tube cover.
nector [17] and engage locking latch.
8-122
2004 Touring: Electrical
HOME
16.
Snap solenoid connector to terminal at top of starter
1
9425
housing.
17.
Install new anchored cable strap in hole of frame down-
tube (inboard of rear swingarm bracket) capturing vehi-
cle speed sensor cable, main harness and neutral switch
conduit. See Figure 8-151.
18.
Install new cable strap at rear of rear brake light switch
bracket capturing main harness conduit and frame
downtube. Cut any excess cable strap material.
19.
Install two socket terminals onto spade contacts of rear
brake light switch. Install new cable strap to secure rear
brake light switch wires to lower frame tube.
20.
Route branch of the main harness (terminating in the
voltage regulator, oil pressure sender and crankshaft
2
position sensor connectors) forward to front of motorcy-
cle following inboard side of lower frame tube.
21.
Mate pin and socket housings of voltage regulator con-
Figure 8-154. Capture Radio Antenna Cable (FLTR)
nector [77], 1-place Deutsch, just below the transmission
exhaust bracket.
22.
Position main harness conduit over two anchors
FLHTC/U:
installed on T-studs at top of lower frame tube. Thread
a. Feed Tour-Pak lights and radio antenna cable con-
new cable straps through eyelets in anchors to capture
nectors and conduit through hole at front of Tour-
conduit. Cut any excess cable strap material.
Pak. Capture cable and conduit in grommet. Install
grommet in hole with the larger OD facing inside.
NOTE
b. Mate pin and socket halves of Tour-Pak lights con-
In addition to the main harness conduit, rear cable strap
nector [12], 3-place Multilock, and tuck into cavity
anchor also captures rear brake line, while front anchor cap-
inside Tour-Pak.
tures rear brake line and voltage regulator cables.
c. Rotate knurled ring in a clockwise direction to mate
23.
Route main harness conduit inboard of rear brake pedal
pin and socket halves of radio antenna cable con-
weldment. Capturing main harness conduit and lower
nector [51]. Capture cable in two clips at bottom of
frame tube, install new cable strap through opening in
Tour-Pak.
rear brake pedal weldment. See Figure 8-151. Cut any
excess cable strap material.
d. Install bulb socket on left side of Tour-Pak.
e. Loosely install new cable strap to secure main har-
NOTE
ness conduit to luggage rack rail.
Cable strap also captures voltage regulator cables.
f.
Proceed as follows:
24.
Route oil pressure sender and crankshaft position sen-
FLHTC: Install rubber mat in Tour-Pak. Close Tour-
sor connectors upward at rear of lower frame crossmem-
Pak.
ber.
FLHTCU: Install molded liner in Tour-Pak. Install
25.
Mate pin and socket halves of crankshaft position sensor
map pocket and secure using acorn nuts (with flat
connector [79]. Place large end of slot on attachment
washers). Close Tour-Pak.
clip over T-stud on bracket at bottom of voltage regulator.
Push connector toward left side of motorcycle to engage
14.
Returning to right side of motorcycle, feed voltage regu-
small end of slot.
lator, oil pressure sender and crankshaft position sensor
connectors and conduit downward between rear swing-
26.
Install the oil pressure sender connector at the front right
arm and oil filler spout until free ends hang below lower
side of the crankcase. On FLHR/C/S models, install
frame tube.
elbow connector on post terminal. On FLHT/C/U and
FLTR models, install 4-place Packard connector.
15.
Route neutral switch wires under starter housing to
transmission top cover. For best results, move electrical
27.
Returning to area of electrical bracket, feed ignition/EFI
bracket out of the way and reach in under right side of
harness connector [8] and security siren connector [142]
battery box. Install two elbow connectors onto posts of
and conduit through opening to outboard side of battery
neutral switch.
box.
2004 Touring: Electrical
8-123
HOME
28. Route siren connector and conduit on inboard side of
5.
See Figure 8-146. Connect main harness as follows:
electrical bracket and install bracket on studs at side of
● Front fender tip lamp connector [32], 2-place Mul-
battery box. Install flange nuts on studs and tighten to
tilock (black); used on FLHR only.
36-48 in-lbs (4.1-5.4 Nm).
● Passing lamps connector [73], 2-place Multilock
29. Mate pin and socket halves of ignition/EFI harness con-
(white); used on FLHR/C only.
nector [8]. Install connector into slot of electrical bracket.
● Passing lamps switch connector
[109],
4-place
30. Pull up on main harness and tuck conduit into space in
Amp; used on FLHR/C only.
front of the battery box TORX screw (along with ignition/
● Accessory switch connector [67], 4-place Amp.
EFI harness). See lower frame of Figure 8-153.
● Right handlebar switch controls connector [22], 6-
place Deutsch (black); T-stud on fork stem nut lock
CAUTION
plate (left side).
● Cruise set/resume switch connector [159], 2-place
Damage to wires can result in electrical problems. Be
sure that rubber boot is present on threaded end of bat-
Deutsch (black); used on FLHRC only.
tery box TORX screw. Replace rubber boot if absent or
● Front turn signal lamps connector [31], 6-place Mul-
damaged. See upper frame of Figure 8-153.
tilock; anchor in hole of fork stem nut lock plate (left
side).
31. At front of top engine stabilizer bracket, install new 14
● Left handlebar switch controls connector [24], 6-
inch cable strap capturing frame backbone and main
place Deutsch (gray); T-stud on fork stem nut lock
harness bundle. Tighten cable strap, but leave loose
plate (left side).
enough so that one finger can be inserted between strap
and frame backbone. Do not overtighten. Cut any
● Cruise on/off switch connector [158], 2-place Deut-
excess cable strap material.
sch (gray); used on FLHRC only.
32. If cruise equipped, install cruise roll-off switch as follows:
6.
Install the wire connector at the back of headlamp bulb.
a. Separate the cruise roll-off switch wires up to the
7.
Align holes in headlamp housing with those in headlamp
point where they enter the main harness conduit.
nacelle (headlamp door bracket at bottom). Install the
b. Orient the idle cable so that the spade contacts are
eight Phillips screws.
at the top.
8.
Fit the square-shaped portion of the headlamp door
c. Slide the insulators onto the switch spade contacts
spring into the slot at the top of the headlamp housing
(polarity is not a factor). For maximum insertion, be
and then snap the headlamp door (chrome ring) into
sure that the external step on the insulators face
place. Install Phillips screw at the bottom of the head-
each other.
lamp door and tighten to 9-18 in-lbs (1.0-2.0 Nm).
d. Fit the rubber boot over the cruise control roll-off
9.
See Figure 8-147. Moving to inboard side of instrument
switch. An oval cut in the boot accommodates the
console, connect main harness as follows:
switch spade terminal connections.
● Ignition/light key switch connector
[33],
3-place
NOTE
Packard.
● Indicator lights connector [21], 8-place Mini-Deut-
Depending upon model, continue procedure at INSTALLA-
TION- FLHR/C/S (PART II), INSTALLATION- FLTR (PART
sch.
II), or INSTALLATION- FLHT/C/U (PART II).
● Speedometer connector [39], 12-place Packard.
10.
Slide odometer reset switch through hole in instrument
console and install rubber boot.
INSTALLATION- FLHR/C/S (PART II)
11.
Bend flexible clamps on inboard side of instrument con-
1.
Install remaining cables straps as shown in Figure 8-
sole as necessary to capture main harness conduit.
148.
NOTE
2.
Carefully feed main harness conduit and connectors for-
ward under right side of instrument nacelle (keeping out-
Continue procedure at INSTALLATION- ALL MODELS
board of the front brake line).
(PART III).
3.
Install P-clamp on main harness bundle. Install screw to
fasten P-clamp to right side of steering head.
4.
Moving to front of motorcycle, reach inside headlamp
INSTALLATION- FLTR (PART II)
nacelle and install screw to fasten harness ground ring
terminal and brake line P-clamp to front of upper fork
1.
Install remaining cables straps as shown in Figure 8-
bracket.
148.
8-124
2004 Touring: Electrical
HOME
2. Install P-clamp on main harness bundle. Install two main
INSTALLATION- ALL MODELS (PART III)
harness ground ring terminals onto screw and fasten P-
clamp to right side of steering head.
1.
Place battery in battery box, terminal side forward.
Rotate hold-down clamp so that lip (with rubber pad)
3. Install the inner fairing. See Section 2.30 UPPER FAIR-
rests on edge of battery and tighten clamp bolt.
ING/WINDSHIELD (FLTR), INNER FAIRING, INSTAL-
LATION, steps 3-20.
1WARNING
NOTE
Continue procedure at INSTALLATION- ALL MODELS
Always connect the positive battery cable first. If the
(PART III).
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.
INSTALLATION- FLHT/C/U (PART II)
2.
Insert bolt through battery positive cable
(red) into
threaded hole of battery positive (+) terminal. Tighten
1.
Install remaining cables straps as shown in Figure 8-
bolt to 60-96 in-lbs (6.8-10.9 Nm).
148.
3.
Insert bolt through battery negative cable (black) into
2.
Install P-clamp on main harness (and audio harness on
threaded hole of battery negative (-) terminal. Tighten
FLHTCU models). Install main harness ground ring ter-
bolt to 60-96 in-lbs (6.8-10.9 Nm).
minal onto screw and fasten P-clamp to right side of
steering head.
4.
Align barbed studs in left side cover with grommets in
frame downtubes and push firmly into place (no tools
3.
Moving to right engine guard, carefully feed main har-
ness conduit and connectors forward under right side of
required).
fairing cap to front of inner fairing.
5.
Install left side saddlebag. See Section 2.25 SADDLE-
4.
Install screw to fasten harness ground ring terminal and
BAG, INSTALLATION.
brake line P-clamp to front of upper fork bracket.
6.
Repeat steps 4-5 to install right side saddlebag and side
5.
See Figure 8-149. Standing at front of motorcycle, mate
cover.
pin and socket halves of the following connectors and fix
positions using retaining devices:
7.
Install fuel tank. For carbureted models, see Section 4.7
FUEL TANK (CARBURETED), INSTALLATION (AFTER
● Main to interconnect harness connector [1], 12-
COMPLETE REMOVAL), FLHT/C or FLHR/S. For fuel
place Deutsch (black); T-stud at front of right fairing
injected models, see Section 9.4 FUEL TANK (FUEL
bracket.
INJECTED), INSTALLATION
(AFTER COMPLETE
● Main to interconnect harness connector [2], 12-
REMOVAL), FLHT/C/U/I, FLTRI or FLHR/C/S/I.
place Deutsch (gray); T-stud on right fairing support
brace.
● Main to interconnect harness connector [15], 4-
place Packard (black); anchor in hole at bottom of
radio (right side).
FRAME GROUND STUD
● Main to interconnect harness connector [156], 6-
REPLACEMENT
place Deutsch (gray); T-stud on right fairing support
brace.
1.
Remove seat. See Section 2.24 SEAT, REMOVAL.
6.
See Figure 8-149. Connect ignition switch to main har-
2.
Locate threaded hole between ground studs. See Figure
ness. Connect radio antenna cable. Proceed as follows:
8-155. Thoroughly scrape away all paint from around
● Ignition switch connector
[33],
4-place Packard
threaded hole.
(black); anchor in hole at bottom of radio (center).
● Radio antenna cable connector [51]; back of radio
3.
Moving to front of frame crossmember, thoroughly
(left side).
scrape away all paint on face of threaded boss.
7.
Install the outer fairing and windshield. See Section 2.29
4.
Obtain five parts shown in Figure 8-156.
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
5.
Start hex screw into threaded boss and tighten to 90-120
FAIRING/WINDSHIELD, INSTALLATION.
in-lbs (10.2-13.6 Nm).
NOTE
6.
At rear of frame crossmember, install flat washer and
Continue procedure at INSTALLATION- ALL MODELS
lockwasher onto threaded end of hex screw. Install hex
(PART III).
nut and tighten to 90-120 in-lbs (10.2-13.6 Nm).
2004 Touring: Electrical
8-125
HOME
7.
If replacing left side ground stud, slide two main harness
Threaded Hole
ground ring terminals onto hex screw. If replacing right
side ground stud, install chassis ground ring terminal
before the two main harness grounds.
8.
Install jam nut onto hex screw and tighten to 50-90 in-
lbs (5.7-10.2 Nm).
9.
Install seat. See Section 2.24 SEAT, INSTALLATION.
f2250x8x
Figure 8-155. Remove Seat
Harness Ground
Ring Terminals
Frame
3
Crossmember
1
5
4
2
Boss
1.
Hex Screw, 2551W
2.
Flat Washer, 6703
4.
Hex Nut, 7688
3.
Lock Washer, 7036
5.
Jam Nut, 7689W
Figure 8-156. Install New Frame Ground Stud
8-126
2004 Touring: Electrical
HOME
INTERCONNECT HARNESS
f2254x8x
(FLHTCU)
REMOVAL
NOTE
When referencing inner fairing locations, the term “fairing
bracket” refers to either the left or right vertical support, while
the term “support brace” refers to either the left or right hori-
zontal support. References to left and right always refers to
left and right side of motorcycle.
1.
Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
2.
Remove the outer fairing and windshield. See Section
2.29 UPPER FAIRING/WINDSHIELD
(FLHT/C/U),
OUTER FAIRING/WINDSHIELD, REMOVAL.
3.
Release anchors on convoluted tubing of interconnect
Figure 8-157. Anchor Interconnect Harness in Lower
harness from lower outboard ears of speedometer and
Ears of Speedometer/Tachometer Brackets
tachometer brackets. See Figure 8-157. For best results,
squeeze anchor with needle nose pliers before pulling
from hole in ear.
g.
Ambient temperature sensor connector
[107], if
4.
Remove anchor on convoluted tubing of headlamp con-
present; 3-place Multilock (black); anchor in hole on
nector from hole in left fairing bracket. See Figure 8-160.
outboard side of left fairing bracket.
5.
On opposite side of inner fairing, remove anchor on con-
duit of fairing cap switch connector from hole in lower
h.
Left handlebar switch controls connector [24], 12-
wing of right side radio support bracket. See Figure 8-
place Deutsch (gray); T-stud on top of left fairing
161.
support brace (inboard side).
6.
Cut cable strap to release convoluted tubing of intercon-
i.
Front turn signal connector [31], 6-place Multilock
nect harness, conduit of main to interconnect harness
(black); T-stud on top of left fairing support brace
connectors [2] and [156], and housing of main to inter-
(outboard side).
connect harness connector [1] from right fairing bracket.
See Figure 8-162.
j.
Main to interconnect harness connector [1],
12-
7.
Remove connectors from their retaining devices, if
place Deutsch (black); T-stud at front of right fairing
present, and disconnect pin and socket halves. See Fig-
bracket.
ure 8-158.
k.
Main to interconnect harness connector [15],
4-
a. Main to interconnect harness connector
[2],
12-
place Packard (black); anchor in hole at bottom of
place Deutsch (gray); T-stud on right fairing support
radio (right side).
brace (outboard side).
b. Main to interconnect harness connector [156], 6-
l.
Fairing cap switch connector [105], 12-place Mul-
place Deutsch (gray); T-stud on right fairing support
tilock (black); top of upper fork bracket (right side).
brace (inboard side).
m.
Right handlebar switch controls connector [22], 12-
c. Radio connector [27], 23-place Amp (black); back of
radio (right side).
place Deutsch (black); T-stud on fork stem nut lock
plate (left side).
d. Indicator lamps
[21];
10-place Multilock
(black);
above radio (between speedometer and tachometer
n.
Audio to interconnect harness connector
[6], if
gauges).
present; 3-place Deutsch (black); back of radio.
e. Speedometer connector
[39];
12-place Packard
(black); back of speedometer. Unthread rubber boot
o.
Passing lamps connector
[73],
2-place Multilock
from odometer reset switch and pull switch from
(white); below upper fork bracket (left side).
hole in inner fairing.
p.
Front fender tip lamp connector [32], 2-place Mul-
f.
Tachometer connector
[108];
12-place Packard
tilock (black); below upper fork bracket (left side).
(gray); back of tachometer.
2004 Touring: Electrical
8-127
HOME
Left Handlebar
Main to Interconnect
Switch Controls [24]
Harness [15]
Indicator
Lamps [21]
Main to Interconnect
Harness [156]
Tachometer
Gauge [108]
Ambient
Speedometer
Temperature
Gauge [39]
Sensor [107]
Main to Interconnect
Harness [2]
Front Turn
Signals [31]
Radio [27]
Main to Interconnect
Audio to Interconnect
Harness [1]
Harness [6]
Front
Fairing Cap
Fender Tip [32]
Switches [105]
Passing
Lamp [73]
Right Handlebar
Switch Controls [22]
f2238x8x
Figure 8-158. Inner Fairing - Interconnect Harness Connectors (FLHTC/U)
8.
See Figure 8-159. Remove connectors from
spade con-
9. Feed
conduit (with orange tape) terminating in left side
tacts as follows:
speaker, fuel gauge, cigarette lighter and front turn sig-
nal connectors to mid section of inner fairing
(area
Left side:
between left and right fairing brackets). Also feed conduit
● Left speaker
terminating in left handlebar switch controls connector
● Fuel gauge and lamp
[24] to mid section.
● Cigarette lighter
8-128
2004 Touring: Electrical
HOME
f2238x8x
Right
Left
Speaker
Voltmeter Gauge
Fuel Gauge
Speaker
and Lamp
and Lamp
Cigarette
Oil Pressure
Ambient
Lighter
Gauge and Lamp
Temperature
Gauge and Lamp
Figure 8-159. Inner Fairing - Interconnect Harness Connectors (FLHTC/U)
10. Pull harness ground socket terminal from spade contact
INSTALLATION
fastened to top of upper fork bracket (left side).
NOTE
11. See Figure 8-159. Remove connectors from spade con-
When referencing inner fairing locations, the term “fairing
tacts as follows:
bracket” refers to either the left or right vertical support, while
Right side:
the term “support brace” refers to either the left or right hori-
● Right speaker
zontal support. References to left and right always refers to
left and right side of motorcycle.
● Voltmeter gauge and lamp
1.
Center interconnect harness on top of radio. To verify
12. Feed conduit (with orange tape) terminating in right side
proper orientation, be sure that convoluted tubing (with
speaker and voltmeter gauge connectors to mid section
anchor) of headlamp connector is on left side of motor-
of inner fairing (area between left and right fairing brack-
cycle, while conduit (with anchor) of fairing cap switch
ets). Also feed conduit terminating in main to intercon-
connector is on the right.
nect harness connectors [2] and [156] to mid section.
2.
Install anchors on convoluted tubing of interconnect har-
13. If present, remove connectors from spade contacts as
ness into lower outboard ears of speedometer and
follows:
tachometer brackets. See Figure 8-157.
● Oil pressure gauge and lamp
3.
If present, install connectors onto spade contacts as fol-
lows:
● Ambient temperature gauge and lamp
● Oil pressure gauge and lamp
14. Remove interconnect harness from motorcycle.
● Ambient temperature gauge and lamp
2004 Touring: Electrical
8-129
Большое спасибо!
Ваше мнение очень важно для нас.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст