Harley Davidson 2004 Touring Models. Service Manual — page 55
HOME
4.
From mid section of inner fairing (area between left and
right fairing brackets), feed conduit (with orange tape)
9421
terminating in left side speaker, fuel gauge, cigarette
lighter and front turn signal connectors behind left fairing
bracket to area of left support brace.
5.
Install connectors onto spade contacts as follows:
Left side:
● Left speaker
● Fuel gauge and lamp
● Cigarette lighter; connect the orange/white wire
socket terminal to the socket spade contact, the
black wire socket terminal to the shell contact.
Anchor
6.
From mid section of inner fairing (area between left and
right fairing brackets), also feed conduit terminating in
left handlebar switch controls connector [24] behind left
Figure 8-160. Anchor Convoluted Tubing of
fairing bracket to area of left support brace.
Headlamp Connector
7.
Push harness ground socket terminal onto spade con-
tact fastened to top of upper fork bracket (left side).
9423
8.
From mid section of inner fairing, feed conduit (with
orange tape) terminating in right side speaker and volt-
meter gauge connectors behind right fairing bracket to
area of right support brace.
Anchor
9.
Install connectors onto spade contacts as follows:
Right side:
● Right speaker
Oval Shaped
Hole
● Voltmeter gauge and lamp
10.
From mid section of inner fairing, also feed conduit ter-
minating in main to interconnect harness connectors [2]
and [156] behind right fairing bracket to area of right sup-
port brace.
Figure 8-161. Anchor Conduit of Fairing Cap
11.
Mate pin and socket halves of the following connectors
Switch Connector
and fix positions using retaining devices, if present:
a. Main to interconnect harness connector
[2],
12-
9422
place Deutsch (gray); T-stud on right fairing support
brace (outboard side).
b. Main to interconnect harness connector [156], 6-
place Deutsch (gray); T-stud on right fairing support
brace (inboard side).
c. Radio connector [27], 23-place Amp (black); back of
radio (right side).
d. Indicator lamps
[21];
10-place Multilock
(black);
above radio (between speedometer and tachometer
Cable
gauges).
Strap
e. Speedometer connector
[39];
12-place Packard
(black); back of speedometer. Slide odometer reset
switch through hole in inner fairing and install rubber
Figure 8-162. Cable Strap Convoluted Tubing, Conduit
boot.
and Connector to Fairing Bracket
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2004 Touring: Electrical
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f.
Tachometer connector
[108];
12-place Packard
13.
On opposite side of inner fairing, install anchor on con-
(gray); back of tachometer.
duit of fairing cap switch connector into hole in lower
wing of right side radio support bracket. See Figure 8-
g.
Ambient temperature sensor connector
[107], if
161.
present; 3-place Multilock (black); anchor in hole on
outboard side of left fairing bracket.
14.
Using oval shaped hole in right fairing bracket, install
new cable strap capturing convoluted tubing of intercon-
h.
Left handlebar switch controls connector [24], 12-
nect harness, conduit of main to interconnect harness
place Deutsch (gray); T-stud on top of left fairing
connectors [15] and [156], and housing of main to inter-
support brace (inboard side).
connect harness connector [1]. See Figure 8-161 and
i.
Front turn signal connector [31], 6-place Multilock
Figure 8-162.
(black); T-stud on top of left fairing support brace
15.
Install the windshield and outer fairing. See Section 2.29
(outboard side).
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
j.
Main to interconnect harness connector [1],
12-
FAIRING/WINDSHIELD, INSTALLATION.
place Deutsch (black); T-stud at front of right fairing
16.
Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
bracket.
MAXI-FUSE, INSTALLATION.
k.
Main to interconnect harness connector [15],
4-
place Packard (black); anchor in hole at bottom of
radio (right side).
l.
Fairing cap switch connector [105], 12-place Mul-
tilock (black); top of upper fork bracket (right side).
m.
Right handlebar switch controls connector [22], 12-
place Deutsch (black); T-stud on fork stem nut lock
plate (left side).
n.
Audio to interconnect harness connector
[6], if
present; 3-place Deutsch (black); back of radio.
o.
Passing lamps connector
[73],
2-place Multilock
(white); below upper fork bracket (left side).
p.
Front fender tip lamp connector [32], 2-place Mul-
tilock (black); below upper fork bracket (left side).
12.
Install anchor on convoluted tubing of headlamp connec-
tor into hole in left fairing bracket. See Figure 8-160.
2004 Touring: Electrical
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HOME
5. See Figure 8-163. Disconnect main harness from inter-
INTERCONNECT HARNESS (FLTR)
connect harness as follows:
● Main to interconnect harness connector [1], 12-
REMOVAL
place Deutsch (black); below radio (right side).
● Main to interconnect harness connector [2], 12-
1.
Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
place Deutsch (gray); below radio (right side).
MAXI-FUSE, REMOVAL.
● Main to interconnect harness connector [15], 4-
2. Place protective material on top of front fender to protect
place Packard (black); below radio (right side).
paint from scratches or other damage.
● Main to interconnect harness connector [156], 6-
3.
Remove the outer fairing and windshield. See Section
place Deutsch (gray); below radio (right side).
2.30 UPPER FAIRING/WINDSHIELD (FLTR), OUTER
FAIRING, REMOVAL.
6. See Figure 8-163. Disconnect handlebar switch controls
4.
Carefully cut two cable straps and allow wire bundles
from interconnect harness. Disconnect radio and radio
and conduit to hang naturally. See Figure 8-165.
ground. Proceed as follows:
Main to Interconnect
Harness [1]
Left Handlebar
Radio [27]
Switch Controls [24]
Right Handlebar
Switch Controls [22]
Main to Interconnect
Harness [156]
Radio
Ground
Main to Interconnect
Harness [2]
Right Turn
Left Turn
Signal [31R]
Signal [31L]
Main to Interconnect
Harness [15]
f2269x8x
Figure 8-163. Inner Fairing Connections (FLTR)
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2004 Touring: Electrical
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Instrument Nacelle
Indicator
f2219x8x
Switches [105]
Lamps [21]
Tachometer
Gauge [108]
Speedometer
Gauge [39]
Speaker
Ambient
Switch [105]
Temperature
Sensor [107]
Figure 8-164. Instrument Nacelle (Bezel Removed)
● Left handlebar switch controls connector [24], 12-
to front of inner fairing. Allow the interconnect harness to
place Deutsch (gray); T-stud on left side of radio
hang along the left side of the front fender.
bracket.
10. Remove connectors from spade contacts as follows:
● Right handlebar switch controls connector [22], 12-
place Deutsch (black); T-stud on left side of radio
Left side:
bracket.
● Left speaker
NOTE
● Fuel gauge and lamp
Push on each handlebar connector to disengage small end
of slot on attachment clip from T-stud on radio bracket. Lift
● Ambient temperature gauge and lamp
connector off T-stud.
● Cigarette lighter
● Radio connector [27], 23-place Amp (black); back of
radio (right side).
Right side:
● Radio ground; single spade and socket terminal;
● Right speaker
below radio (left side).
● Voltmeter gauge and lamp
7. Remove left side of instrument nacelle. See Section 2.30
● Oil pressure gauge and lamp
UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT
NACELLE, REMOVAL, steps 1-6.
11. Free conduit of front turn signal lamp connectors [31L]
8. See Figure
8-164. Disconnect instrument nacelle
and [31R], 3-place Multilocks, from flexible clips on sides
switches and ambient temperature sensor from intercon-
of inner fairing.
nect harness as follows:
12. Remove interconnect harness from motorcycle. Remove
● Instrument nacelle switch connector [105], 12-place
radio antenna cable connector [51] at back of radio (left
Multilock.
side) to facilitate removal.
● Ambient temperature sensor connector [107], 3-
place Multilock.
9. See Figure 8-164. Draw branches of interconnect har-
INSTALLATION
ness (terminating in odometer reset switch and speed-
ometer, tachometer, indicator lamps, instrument nacelle
1.
Center convoluted tubing of interconnect harness above
switch and ambient temperature sensor connectors)
and inboard of hooks on radio bracket. See Figure 8-
from instrument nacelle through tunnel of fairing bracket
165. To verify proper orientation, be sure that long length
2004 Touring: Electrical
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4.
See Figure 8-164. Connect instrument nacelle switches
9427
and ambient temperature sensor to interconnect har-
ness as follows:
● Instrument nacelle switch connector [105], 12-place
Multilock.
● Ambient temperature sensor connector [107], 3-
place Multilock.
5. See Figure 8-163. Connect handlebar switch controls to
interconnect harness. Connect radio and radio ground.
Proceed as follows:
● Left handlebar switch controls connector [24], 12-
place Deutsch (gray); T-stud on left side of radio
bracket.
1
2
● Right handlebar switch controls connector [22], 12-
place Deutsch (black); T-stud on left side of radio
Figure 8-165. Cable Strap Convoluted Tubing
bracket.
and Conduit
NOTE
Place large end of slot on attachment clip over T-stud on
of conduit terminating in socket terminals of cigarette
radio bracket and push on each handlebar connector to
lighter is on left side of motorcycle. Install radio antenna
engage small end of slot.
cable connector
[51] at back of radio
(left side), if
removed.
● Radio connector [27], 23-place Amp (black); back of
radio (right side).
2.
Install connectors onto spade contacts as follows:
● Radio ground; single spade and socket terminal;
Left side:
below radio (left side).
● Left speaker
● Fuel gauge and lamp
6. See Figure 8-163. Connect main harness to intercon-
nect harness as follows:
● Ambient temperature gauge and lamp
● Cigarette lighter; connect the orange/white wire
● Main to interconnect harness connector [1], 12-
socket terminal to the socket spade contact, the
place Deutsch (black); below radio (right side).
black wire socket terminal to the shell contact.
● Main to interconnect harness connector [2], 12-
place Deutsch (gray); below radio (right side).
Right side:
●
Main to interconnect harness connector [15],
4-
● Right speaker
place Packard (black); below radio (right side).
● Voltmeter gauge and lamp
● Main to interconnect harness connector [156], 6-
● Oil pressure gauge and lamp
place Deutsch (gray); below radio (right side).
Left side:
7. Orient connectors as shown in Figure 8-163. Install two
● Left speaker
new cable straps outboard of fairing bracket hooks to
● Fuel gauge and lamp
hold wire bundles together. Cut any excess cable strap
material. See Figure 8-165.
Right side:
● Right speaker
CAUTION
● Voltmeter gauge and lamp
To avoid chafing wires of interconnect harness and pos-
3.
Find branch of interconnect harness terminating in
sible damage to slots of outer fairing during installation,
odometer reset switch and speedometer, tachometer,
verify that trim strips are installed on hooks of radio
indicator lamps, instrument nacelle switch and ambient
bracket.
temperature sensor connectors. Feed connectors and
8.
Capture conduit of front turn signal lamp connectors
conduit from front of inner fairing through tunnel of fair-
ing bracket and then out through opening at top of fairing
[31L] and [31R], 3-place Multilocks, in flexible clips on
sides of inner fairing.
bracket to instrument nacelle.
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2004 Touring: Electrical
HOME
9. Install the outer fairing and windshield. See Section 2.30
11. Install bezel. See BEZEL, INSTALLATION, in this sec-
UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIR-
tion.
ING, INSTALLATION.
12. Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
10. Install left side of instrument nacelle. See Section 2.30
MAXI-FUSE, INSTALLATION.
UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT
NACELLE, INSTALLATION, steps 5-7 and 9-10.
2004 Touring: Electrical
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RADIO ANTENNA CABLE
(FLHTC/U)
Cable
Clip
Grommet
REMOVAL
1.
Remove fuel tank. For carbureted models, see Section
4.7 FUEL TANK
(CARBURETED), COMPLETE
REMOVAL, FLHT/C. For fuel injected models, see Sec-
tion 9.4 FUEL TANK (FUEL INJECTED), COMPLETE
REMOVAL, FLHT/C/U/I, FLTRI.
Cavity
2.
Remove left side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
Tour-Pak Lights
3.
Gently pull side cover from frame downtubes (no tools
Connector [12]
required).
4.
Remove the outer fairing and windshield. See Section
Radio Antenna
2.29 UPPER FAIRING/WINDSHIELD
(FLHT/C/U),
Cable
OUTER FAIRING/WINDSHIELD, REMOVAL.
f1466a2x
5.
Remove radio antenna cable connector [51] at back of
radio (left side). See Figure 8-166. Carefully cut cable
Figure 8-167. Disconnect Tour-Pak Lights Connector
where it exits branch of main harness conduit.
6.
Remove screw, ground wire ring terminal and P-clamp to
release main harness (and audio harness on FLHTCU)
Tour-Pak
Hole
Radio Antenna
from right side of steering head.
Cable Connector
7.
Carefully cut cable straps securing main harness to
frame backbone, left frame tube and luggage rack rail.
See Figure 8-169.
8.
Open Tour-Pak and proceed as follows:
FLHTC: Remove rubber mat.
Radio Antenna
Cable [51]
Grommet
Cable
Clip
f1465a2x
Figure 8-168. Feed Main Harness Thru Tour-Pak Hole
FLHTCU:
Open map pocket and remove acorn nuts
(with flat washers). Remove map pocket and molded
liner from Tour-Pak.
9. Depress external latch and remove bulb socket from left
side of Tour-Pak.
10. Rotate knurled ring in a counterclockwise direction to
separate pin and socket halves of radio antenna cable
f2238x8x
connector. Release cable from two clips at bottom of
Tour-Pak.
Figure 8-166. Remove Outer Fairing (FLHTC/U)
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2004 Touring: Electrical
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11. Depress button and separate pin and socket halves of
Tour-Pak lights connector [12], 3-place Multilock, inside
A = Anchored
Tour-Pak. See Figure 8-167.
Frame
12. Pull grommet into Tour-Pak and remove from main har-
Backbone
ness conduit.
1
13. Pull Tour-Pak lights and radio antenna cable connectors
through hole at front of Tour-Pak. See Figure 8-168.
2 A
14. Carefully cut radio antenna cable where it exits main
harness conduit.
3 A
INSTALLATION
1. Place new radio antenna cable on motorcycle following
original routing. Note that the cable follows the branches
4 A
of the main harness (and audio harness on FLHTCU)
routed to the rear left side of the motorcycle.
NOTE
Specifically, from the front of the inner fairing, the radio
5 A
antenna cable is routed under the fairing cap where it passes
through a P-clamp on the right side of the steering head. The
Saddlebag
6
Guard
cable then runs along the right side of the frame backbone,
where it crosses to the left side at the main harness anchor in
the center of the frame backbone. From this point, the cable
follows the left side of the frame backbone, runs along the
7
inboard side of the upper frame tube and then continues
down the luggage rack rail where it passes through the hole
f2225x8x
at the front of the Tour-Pak.
1
Captures main harness, cruise roll-off switch conduit,
2.
Feed Tour-Pak lights and radio antenna cable connec-
audio harness (FLHTCUI only) and frame backbone.
tors and conduit through hole at front of Tour-Pak. Cap-
2
Captures main harness and audio harness
(FLHTCUI
ture conduit in grommet. Install grommet in hole with the
only). ANCHORED.
larger OD facing inside.
3
4
Captures main harness and audio harness
(FLHTCUI
only). ANCHORED.
3.
Mate pin and socket halves of Tour-Pak lights connector
5
Captures main harness, audio harness (FLHTCUI only),
[12], 3-place Multilock, and tuck into cavity inside Tour-
fuel vapor vent tube and console pod or instrument
Pak. See Figure 8-167.
console conduit. ANCHORED.
6
Captures main harness, audio harness (FLHTCUI only),
4.
Rotate knurled ring in a clockwise direction to mate pin
console pod or instrument console conduit and upper
frame tube.
and socket halves of radio antenna cable connector.
Capture cable in two clips at bottom of Tour-Pak.
7
Captures main harness, audio harness (FLHTCUI only),
console pod conduit (FLHTCUI only) and upper frame
tube.
5.
Install bulb socket on left side of Tour-Pak.
6.
Proceed as follows:
Figure 8-169. Install Cable Straps
FLHTC: Install rubber mat in Tour-Pak. Close Tour-Pak.
FLHTCU: Install molded liner in Tour-Pak. Install map
pocket and secure using acorn nuts (with flat washers).
9.
At front of top engine stabilizer bracket, install new 14
Close Tour-Pak.
inch cable strap capturing frame backbone, radio
antenna cable, main harness and audio harness (if
7.
At front of inner fairing, connect radio antenna cable
present). Tighten cable strap, but leave loose enough so
connector [51] to back of radio. See Figure 8-166.
that one finger can be inserted between strap and frame
backbone. Do not overtighten. Cut any excess cable
8.
On right side of motorcycle, capture radio antenna cable,
strap material.
main harness and audio harness (if present) in P-clamp.
Install ground wire ring terminal on screw and fasten P-
10.
Install remaining cables straps as shown in Figure 8-
clamp to right side of steering head.
169.
2004 Touring: Electrical
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11. Install the outer fairing and windshield. See Section 2.30
13. Install left side saddlebag. See Section 2.25 SADDLE-
UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIR-
BAG, INSTALLATION.
ING, INSTALLATION.
14. Install fuel tank. For carbureted models, see Section 4.7
FUEL TANK (CARBURETED), INSTALLATION (AFTER
12. Align barbed studs in left side cover with grommets in
COMPLETE REMOVAL), FLHT/C. For fuel injected
frame downtubes and push firmly into place (no tools
models, see Section
9.4 FUEL TANK
(FUEL
required).
INJECTED), INSTALLATION
(AFTER COMPLETE
REMOVAL), FLHT/C/U/I, FLTRI.
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2004 Touring: Electrical
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RADIO ANTENNA CABLE (FLTR)
1
9425
REMOVAL
1.
Remove fuel tank. See Section 9.4 FUEL TANK (FUEL
INJECTED), COMPLETE REMOVAL, FLHT/C/U/I,
FLTRI.
2.
Remove left side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
3.
Gently pull side cover from frame downtubes (no tools
required).
4.
Remove the outer fairing and windshield. See Section
2.30 UPPER FAIRING/WINDSHIELD (FLTR), OUTER
2
FAIRING, REMOVAL.
5.
Remove radio antenna cable connector [51] at back of
Figure 8-171. Capture Radio Antenna Cable
radio (left side). See Figure 8-170. Carefully cut cable
where it exits branch of main harness conduit.
9.
Carefully cut cable strap to release radio antenna cable
6.
Remove screw, ground wire ring terminal and P-clamp to
release main harness bundle from right side of steering
from shoulder of upper frame tube (just in front of air
valve mounting bracket). Cut cable strap to release radio
head.
antenna cable from slotted hole in rear fender support.
7.
Carefully cut cable straps securing main harness to
See Figure 8-171.
frame backbone and left frame tube. See Figure 8-172.
10.
At bottom of radio antenna bracket, rotate knurled ring to
separate pin and socket halves of radio antenna cable
8.
On left side of motorcycle, remove bolt (with flat washer)
connector [51].
to remove passenger seat strap and saddlebag front
mounting bracket. Remove Phillips screw and chrome
11.
Draw radio antenna cable forward to area of fuse block
frame tube cover.
bracket. Carefully cut cable where it exits branch of main
harness conduit.
Radio Antenna
INSTALLATION
Cable [51]
1.
Place new radio antenna cable on motorcycle following
original routing. Note that the cable follows the branches
of the main harness routed to the rear left side of the
motorcycle.
NOTE
Specifically, from the front of the inner fairing, the radio
antenna cable is routed through an opening on the right side
of the fairing bracket where it then passes through a P-clamp
on the right side of the steering head. The cable runs rear-
ward along the right side of the frame backbone, where it
crosses to the left side at the main harness anchor in the
center of the frame backbone. From this point, the cable fol-
lows the left side of the frame backbone, runs along the
inboard side of the upper frame tube and then down to the
radio antenna bracket.
2.
Feed radio antenna cable and connector rearward fol-
lowing inboard side of upper frame tube. With the 3-
f2230x2x
place Multilock connector (unused) positioned about as
far rearward as the rear shock air valve, install new
Figure 8-170. Remove Outer Fairing
(FLTR)
cable strap to secure radio antenna cable to shoulder of
2004 Touring: Electrical
8-139
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upper frame tube (just in front of air valve mounting
bracket). Using slotted hole, install new cable strap to
A = Anchored
secure radio antenna cable to rear fender support. See
Figure 8-171.
Frame
Backbone
3.
At bottom of radio antenna bracket, rotate knurled ring to
1
mate pin and socket halves of radio antenna cable con-
nector [51].
4.
Install chrome frame tube cover on frame tube. Install
2 A
Phillips screw. Install bolt
(with flat washer) to fasten
saddlebag front mounting bracket and passenger seat
strap to chrome frame tube cover.
5.
At front of inner fairing, connect radio antenna cable
3 A
connector [51] at back of radio (left side). See Figure 8-
170.
6.
On right side of motorcycle, capture radio antenna cable
4 A
and main harness in P-clamp. Install ground wire ring
terminal on screw and fasten P-clamp to right side of
steering head.
7.
At front of top engine stabilizer bracket, install new 14
inch cable strap capturing frame backbone, radio
5 A
antenna cable and main harness. Tighten cable strap,
but leave loose enough so that one finger can be
Saddlebag
inserted between strap and frame backbone. Do not
6
Guard
overtighten. Cut any excess cable strap material.
8.
Install remaining cables straps as shown in Figure 8-
7
169.
9.
Install the outer fairing and windshield. See Section 2.30
f2225x8x
UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIR-
ING, INSTALLATION.
1
Captures main
harness, cruise roll-off switch conduit,
10.
Align barbed studs in left side cover with grommets in
audio harness (FLHTCUI only) and frame backbone.
frame downtubes and push firmly into place (no tools
2
Captures main harness and audio harness
(FLHTCUI
only). ANCHORED.
required).
3
4
Captures main harness and audio harness
(FLHTCUI
11.
Install left side saddlebag. See Section 2.25 SADDLE-
only). ANCHORED.
BAG, INSTALLATION.
5
Captures main harness, audio harness (FLHTCUI only),
fuel vapor vent tube and console pod or instrument
12.
Install fuel tank. See Section 9.4 FUEL TANK (FUEL
console conduit. ANCHORED.
6
Captures main harness, audio harness (FLHTCUI only),
INJECTED), INSTALLATION
(AFTER COMPLETE
console pod or instrument console conduit and upper
REMOVAL), FLHT/C/U/I, FLTRI.
frame tube.
7
Captures main harness, audio harness (FLHTCUI only),
console pod conduit (FLHTCUI only) and upper frame
tube.
Figure 8-172. Install Cable Straps
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2004 Touring: Electrical
HOME
AUDIO HARNESS (FLHTCU)
Console Pod
Connector [53]
REMOVAL
1.
Remove fuel tank. For carbureted models, see Section
4.7 FUEL TANK
(CARBURETED), COMPLETE
REMOVAL, FLHT/C. For fuel injected models, see Sec-
tion 9.4 FUEL TANK (FUEL INJECTED), COMPLETE
REMOVAL, FLHT/C/U/I, FLTRI.
2.
Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
3.
Gently pull side cover from frame downtubes (no tools
required).
4.
Repeat steps 2 and 3 on left side of motorcycle.
5.
Remove the outer fairing and windshield. See Section
2.29 UPPER FAIRING/WINDSHIELD
(FLHT/C/U),
OUTER FAIRING/WINDSHIELD, REMOVAL.
f2192x8x
6.
See Figure 8-173. Disconnect pin and socket halves of
Figure 8-174. Disconnect Console Pod Connector
the following connectors:
a. CB antenna cable connector [50], back of radio
(right side).
7.
Remove screw, ground wire ring terminal and P-clamp to
release main harness and audio harness from right side
b. Audio to interconnect harness connector
[6],
3-
of steering head.
place Deutsch (black); back of radio (right side).
8.
Carefully pull audio harness rearward under right side of
c. Radio connector [28], 23-place Amp (gray); back of
fairing cap allowing conduit and connectors to hang over
radio (left side).
top of engine guard.
9.
Carefully cut cable straps securing audio harness to
Audio to
frame backbone, left and right frame tubes, and luggage
Interconnect Harness [6]
rack rails. See Figure 8-176. Carefully cut cable straps
securing audio harness to main harness, if present.
CB Antenna
Radio [28]
10.
Release console pod connector [53],
12-place Mini-
Cable [50]
Deutsch, from attachment clip anchored in hole at rear
of battery box. See Figure
8-174. Depress external
latches and use a rocking motion to separate pin and
socket halves.
11.
Remove trim ring and gently pull on wire harness to
draw rear right speaker/passenger controls connector
[41], 6-place
Mini-Deutsch, out of speaker box. Depress
external latch
and use a rocking motion to separate pin
and socket halves.
12.
Open Tour-Pak. Open map pocket and remove acorn
nuts. Remove map pocket and molded liner from Tour-
Pak.
13.
Separate pin and socket halves of CB antenna cable
connector [50]. Release cable from clip at bottom of
Tour-Pak. See Figure 8-175.
f2238x8x
14.
Pull right side grommet into Tour-Pak and remove from
CB antenna cable. Feed CB antenna cable through hole
Figure 8-173. Audio Harness Connectors
at front of Tour-Pak.
2004 Touring: Electrical
8-141
HOME
a. CB antenna cable connector [50], back of radio
(right side).
Grommet
b. Audio to interconnect harness connector
[6],
3-
place Deutsch (black); back of radio (right side).
Cable
Clip
c. Radio connector [28], 23-place Amp (gray); back of
radio (left side).
3.
On right side of motorcycle, capture audio harness and
main harness in P-clamp. Install ground wire ring termi-
nal on screw and fasten P-clamp to right side of steering
head.
4.
Mate pin and socket halves of console pod connector
[53],
12-place Mini-Deutsch. Install connector onto
attachment clip anchored in hole at rear of battery box.
See Figure 8-174.
5.
Mate pin and socket housings of rear right speaker/pas-
CB Antenna
senger controls connector [41], 6-place Mini-Deutsch.
Cable Connector
Feed connector back up into speaker box pressing trim
f1467b2x
ring into hole.
Figure 8-175. Disconnect CB Antenna Cable Connector
6.
Pass CB antenna cable connector [50] through hole at
front of Tour-Pak. Capture cable in grommet. Install
grommet in hole with the larger OD facing inside. See
15. Moving to opposite side of motorcycle, remove trim ring
Figure 8-175.
and gently pull on wire harness to draw rear left speaker/
passenger controls connector [42], 6-place Mini-Deut-
7.
Mate pin and socket halves of CB antenna cable con-
sch, out of speaker box. Depress external latch and use
nector. Capture antenna cable in clip at bottom of Tour-
a rocking motion to separate pin and socket halves.
Pak.
16. Release rear headset receptacle from bracket at bottom
8.
Moving to opposite side of motorcycle, mate pin and
of left side speaker box. Release spring from hole in
socket housings of rear left speaker/passenger controls
receptacle wire jacket.
connector [42], 6-place Mini-Deutsch. Feed connector
back up into speaker box pressing trim ring into hole.
17. Remove audio harness from motorcycle.
9.
Attach spring to rear headset receptacle using hole in
wire jacket. Capture headset receptacle in bracket at
INSTALLATION
bottom of left side speaker box.
1.
Place new audio harness on motorcycle following origi-
10.
At front of top engine stabilizer bracket, install new 14
nal routing. Note that the audio harness follows the
inch cable strap capturing frame backbone, audio har-
branches of the main harness as it is routed to the rear
ness and main harness. Tighten cable strap, but leave
left and right sides of the motorcycle.
loose enough so that one finger can be inserted
between strap and frame backbone. Do not over-
NOTE
tighten. Cut any excess cable strap material.
Specifically, from the front of the inner fairing, the audio har-
11.
Install remaining cables straps as shown in Figure 8-
ness is routed under the fairing cap where it passes through
176.
a P-clamp on the right side of the steering head. The harness
then runs along the right side of the frame backbone, where
12.
Install the outer fairing and windshield. See Section 2.29
a branch crosses to the left side at the main harness anchor
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
in the center of the frame backbone. From this point, each
FAIRING/WINDSHIELD, INSTALLATION.
branch follows its respective side of the frame backbone, run-
ning along the inboard side of the upper frame tubes and
13.
Align barbed studs in right side cover with grommets in
then down the luggage rack rails.
frame downtubes and push firmly into place (no tools
required).
2.
See Figure 8-173. Standing at front of motorcycle, mate
pin and socket halves of the following wire harness con-
14.
Install right side saddlebag. See Section 2.25 SADDLE-
nectors:
BAG, INSTALLATION.
8-142
2004 Touring: Electrical
HOME
15. Repeat steps 13 and 14 on left side of motorcycle.
A = Anchored
16. Install fuel tank. For carbureted models, see Section 4.7
FUEL TANK (CARBURETED), INSTALLATION (AFTER
Frame
Backbone
COMPLETE REMOVAL), FLHT/C. For fuel injected
1
models, see Section
9.4 FUEL TANK
(FUEL
INJECTED), INSTALLATION
(AFTER COMPLETE
REMOVAL), FLHT/C/U/I, FLTRI.
2 A
8 A
3 A
9 A
4 A
10 A
5 A
Saddlebag
11
6
Guard
12
7
f2225x8x
1
Captures main harness, cruise roll-off switch conduit,
audio harness (FLHTCUI only) and frame backbone.
2
Captures main harness and audio harness
(FLHTCUI
only). ANCHORED.
3
4
5 Captures main harness, audio harness (FLHTCUI only),
EFI/ignition harness, and conduit to fuel tank harness (all
models except FLHR/C/S). ANCHORED.
6
7
Captures audio harness (FLHTCUI only) and upper frame
tube.
8
9
Captures main harness and audio harness
(FLHTCUI
only). ANCHORED.
10
Captures main harness, audio harness (FLHTCUI only),
fuel vapor vent tube and console pod or instrument
console conduit. ANCHORED.
11
Captures main harness, audio harness (FLHTCUI only),
console pod or instrument console conduit and upper
frame tube.
12
Captures main harness, audio harness (FLHTCUI only),
console pod conduit (FLHTCUI only) and upper frame
tube.
Figure 8-176. Install Cable Straps
2004 Touring: Electrical
8-143
HOME
CB ANTENNA CABLE (FLHTCU)
Grommet
REMOVAL
Cable
Clip
1.
Remove fuel tank. For carbureted models, see Section
4.7 FUEL TANK
(CARBURETED), COMPLETE
REMOVAL, FLHT/C. For fuel injected models, see Sec-
tion 9.4 FUEL TANK (FUEL INJECTED), COMPLETE
REMOVAL, FLHT/C/U/I, FLTRI.
2.
Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
3.
Gently pull side cover from frame downtubes (no tools
required).
4.
Remove the outer fairing and windshield. See Section
2.29 UPPER FAIRING/WINDSHIELD
(FLHT/C/U),
OUTER FAIRING/WINDSHIELD, REMOVAL.
CB Antenna
5.
Locate CB antenna cable connector [50] at back of radio
Cable Connector
f1467b2x
(right side). Rotate knurled ring in a counterclockwise
direction to disconnect. See Figure 8-177. Carefully cut
cable where it exits audio harness conduit.
Figure 8-178. CB Antenna Cable Connector
(Tour-Pak)
6.
Remove screw, ground wire ring terminal and P-clamp to
release main harness and audio harness from right side
of steering head.
8.
Open Tour-Pak. Open map pocket and remove acorn
7.
Carefully cut cable straps securing audio harness to
nuts
(with flat washers). Remove map pocket and
frame backbone, right frame tube and luggage rack rail.
molded liner from Tour-Pak.
See Figure 8-180. Carefully cut cable straps securing
9.
Separate pin and socket halves of CB antenna cable
audio harness to main harness, if present.
connector [50]. Release cable from clip at bottom of
Tour-Pak. See Figure 8-178.
10. Pull right side grommet into Tour-Pak and remove from
CB Antenna
Cable [50]
CB antenna cable. Feed CB antenna cable through hole
at front of Tour-Pak.
11. Carefully cut CB antenna cable where it exits branch of
audio harness conduit.
INSTALLATION
1.
Place new CB antenna cable on motorcycle following
original routing. Note that the cable follows the branches
of the main harness and audio harness routed to the
rear right side of the motorcycle.
NOTE
Specifically, from the front of the inner fairing, the CB
antenna cable is routed under the fairing cap where it passes
through a P-clamp on the right side of the steering head.
f2238x8x
From this point, the cable follows the right side of the frame
backbone, runs along the inboard side of the upper frame
Figure 8-177. CB Antenna Cable Connector
tube and then continues down the luggage rack rail where it
(Inner Fairing)
passes through the hole at the front of the Tour-Pak.
8-144
2004 Touring: Electrical
HOME
2.
Pass CB antenna cable connector [50] through hole at
front of Tour-Pak. Capture cable in grommet. Install
A = Anchored
grommet in hole with the larger OD facing inside. See
Figure 8-178.
Frame
Backbone
3.
Mate pin and socket halves of CB antenna cable con-
1
nector. Capture antenna cable in clip at bottom of Tour-
Pak.
2 A
4.
Install two new cable straps to secure CB antenna cable
to rear right speaker/passenger controls conduit and lug-
gage rack rail. See Figure 8-179.
5.
Install molded liner in Tour-Pak. Install map pocket and
3 A
secure using acorn nuts (with flat washers). Close Tour-
Pak.
6.
At front of inner fairing, rotate knurled ring to connect CB
4 A
antenna cable connector [50] to back of radio. See Fig-
ure 8-177.
7.
On right side of motorcycle, capture CB antenna cable,
audio harness and main harness in P-clamp. Install
ground wire ring terminal on screw and fasten P-clamp
5 A
to right side of steering head.
Saddlebag
6
Guard
8.
At front of top engine stabilizer bracket, install new 14
inch cable strap capturing frame backbone, CB antenna
cable, audio harness and main harness. Tighten cable
strap, but leave loose enough so that one finger can be
inserted between strap and frame backbone. Do not
7
overtighten. Cut any excess cable strap material.
f2225x8x
9.
Install remaining cables straps as shown in Figure 8-
180.
1
Captures main harness, cruise roll-off switch conduit,
audio harness (FLHTCUI only) and frame backbone.
10.
Install the outer fairing and windshield. See Section 2.29
2
Captures main harness and audio harness
(FLHTCUI
only). ANCHORED.
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
3
4
5 Captures main harness, audio harness (FLHTCUI only),
FAIRING/WINDSHIELD, INSTALLATION.
EFI/ignition harness, and conduit to fuel tank harness (all
models except FLHR/C/S). ANCHORED.
6
7
Captures audio harness (FLHTCUI only) and upper frame
tube.
9426
Figure 8-180. Install Cable Straps
11. Align barbed studs in right side cover with grommets in
frame downtubes and push firmly into place (no tools
1
required).
12. Install right side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
2
13. Install fuel tank. For carbureted models, see Section 4.7
FUEL TANK (CARBURETED), INSTALLATION (AFTER
COMPLETE REMOVAL), FLHT/C. For fuel injected
models, see Section
9.4 FUEL TANK
(FUEL
INJECTED), INSTALLATION
(AFTER COMPLETE
REMOVAL), FLHT/C/U/I, FLTRI.
Figure 8-179. Secure CB Antenna Cable
2004 Touring: Electrical
8-145
HOME
IGNITION HARNESS
f1847x8x
(CARBURETED)
REMOVAL
1.
Remove fuel tank. See Section 4.7 FUEL TANK (CAR-
BURETED), COMPLETE REMOVAL, FLHT/C or
1
FLHR/S.
2.
Unthread bolt and remove battery positive cable (red)
from battery positive
(+) terminal.
(Battery negative
cable already removed under FUEL TANK, COMPLETE
REMOVAL.)
3.
Using a T40 TORX drive head, loosen bolt to move lip of
hold-down clamp off edge of battery. Remove battery
from battery box.
2
4.
Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
5.
Gently pull side cover from frame downtubes (no tools
1.
Vehicle Speed Sensor [65]
required).
2.
P&A Security Siren [142]
6.
Carefully cut cable straps to free ignition harness from
Figure 8-182. Electrical Bracket (Inboard Side)
right side of frame backbone, upper frame tube and
other wire harness bundles. See Figure 8-185.
7.
Remove ignition coil connector [83] and manifold abso-
8.
Remove ignition control module connector [10]. Depress
lute pressure sensor connector [80]. Pull external latch
external latches and use a rocking motion to separate
outward and use rocking motion to separate pin and
pin and socket halves. See Figure 8-181.
socket halves. Draw conduit and connectors to right side
of motorcycle as they are disconnected.
9.
Gently pull on data link connector [91] to disengage from
arms on electrical bracket.
10.
Pull main harness connector [8] from slot in electrical
Main Harness [8]
bracket. Depress external latches and use a rocking
Data Link [91]
motion to separate pin and socket halves.
11.
Remove two flange nuts to release electrical bracket
from studs on side of battery box.
12.
On inboard side of electrical bracket, disconnect vehicle
speed sensor connector [65]. Depress button on socket
housing and pull apart pin and socket halves. See Fig-
ure 8-182.
CAUTION
Damage to wires can result in electrical problems. Be
sure that rubber boot is present on threaded end of bat-
tery box TORX screw. Replace rubber boot if absent or
damaged. See Figure 8-183.
13. Note that ignition harness conduit runs forward of the
Ignition Control
front battery box TORX screw. Pull conduit to the rear of
Module [10]
f2191x8x
the screw, and then draw connectors and conduit down
right side of frame backbone into battery box.
Figure 8-181. Electrical Bracket (Under Right Side Cover)
8-146
2004 Touring: Electrical
HOME
8321
Vehicle Speed
Ignition
Control Module
Sensor [65B]
[10B]
Rubber
Boot
Main Harness
[8A]
Figure 8-183. Remove Ignition Harness From Vehicle
14. Pull connectors and conduit out through opening at side
of battery box to remove ignition harness from motorcy-
cle.
Data Link
[91A]
INSTALLATION
1. Locate end of ignition harness terminating in two con-
nectors. See Figure 8-184.
2. Standing on right side of motorcycle, carefully feed con-
nectors and conduit through opening into battery box.
Pull up on harness and tuck conduit into space in front of
the battery box TORX screw.
CAUTION
Damage to wires can result in electrical problems. Be
sure that rubber boot is present on threaded end of bat-
tery box TORX screw. Replace rubber boot if absent or
damaged. See Figure 8-183.
3. Draw connectors and conduit up along right side of
frame backbone just below the main harness bundle.
4. Loosely install new cable straps to secure ignition har-
ness to right side of frame backbone, upper frame tube
and other wire harness bundles. See Figure 8-185.
Manifold Absolute
5. Feed ignition coil connector over the top engine stabi-
Pressure
lizer link to left side of motorcycle. Install ignition coil
Sensor [80B]
connector [83] onto left side of ignition coil.
6. Install manifold absolute pressure sensor connector [80].
7.
Returning to electrical bracket, mate pin and socket
Ignition
halves of vehicle speed sensor connector [65]. Route
Coil [83B]
siren and vehicle speed sensor connectors and conduit
on inboard side of electrical bracket as shown in Figure
f2226x8x
8-182.
Figure 8-184. Ignition Wire Harness Connectors
2004 Touring: Electrical
8-147
HOME
8.
Slide electrical bracket onto studs at side of battery box.
Be sure that conduit is properly routed on inboard side of
A = Anchored
electrical bracket or wires may be pinched during instal-
lation. Install flange nuts and tighten to
36-48 in-lbs
Frame
(4.1-5.4 Nm).
Backbone
9.
Install ignition control module connector [10].
10. Mate pin and socket halves of main harness connector
1 A
[8]. Install connector into slot of electrical bracket. See
Figure 8-181.
11. Verify that protective plug is installed in data link connec-
tor [91]. With the plug side down and in contact with tab,
2 A
position connector between arms on electrical bracket.
12. Tighten cable straps securing ignition harness to right
side of frame backbone, upper frame tube and other wire
harness bundles. Cut any excess cable strap material.
3 A
13. 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.
4 A
1WARNING
Saddlebag
Guard
Always connect the positive battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion producing personal injury and/or property
damage.
f2225x8x
14. Insert bolt through battery positive cable
(red) into
threaded hole of battery positive (+) terminal. Tighten
1
Captures ignition harness only. ANCHORED.
bolt to 60-96 in-lbs (6.8-10.9 Nm).
2
3
4 Captures main harness, audio harness (FLHTCUI only),
ignition harness and conduit to fuel tank harness (all
15. Install fuel tank. See Section 4.7 FUEL TANK (CARBU-
models except FLHR/C/S). ANCHORED.
RETED), INSTALLATION
(AFTER COMPLETE
REMOVAL), FLHT/C or FLHR/S.
Figure 8-185. Remove/Install Cable Straps
16. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place
(no tools
required).
17. Install right side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
18. Start motorcycle and verify proper operation without set-
ting trouble codes.
8-148
2004 Touring: Electrical
HOME
EFI HARNESS (FUEL INJECTED)
f2183x8x
REMOVAL
1. Remove fuel tank. See Section 9.4 FUEL TANK (FUEL
INJECTED), COMPLETE REMOVAL, FLHT/C/U/I,
FLTRI, or FLHR/C/S/I.
1
2. Remove air cleaner and backplate. See Section 4.5 AIR
CLEANER, REMOVAL.
3. Unthread bolt and remove battery positive cable (red)
from battery positive
(+) terminal.
(Battery negative
cable already removed under FUEL TANK, COMPLETE
REMOVAL.)
4. Using a T40 TORX drive head, loosen bolt to move lip of
hold-down clamp off edge of battery. Remove battery
from battery box.
2
5. Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
6. Gently pull side cover from frame downtubes (no tools
1. Vehicle Speed Sensor [65]
required).
2. P&A Security Siren [142]
NOTE
Figure 8-187. Electrical Bracket (Inboard Side)
Draw all EFI wire harness connectors to right side of motor-
cycle as they are disconnected.
8.
Remove idle air control connector [87] and manifold
7.
Carefully cut five cable straps to free EFI wire harness
absolute pressure sensor connector [80]. Pull external
from right side of frame backbone, upper frame tube and
latch(es) outward and use rocking motion to separate
other wire harness bundles. See Figure 8-190.
pin and socket halves. See Figure 8-186.
9.
Depress wire form to remove front fuel injector connec-
tor [84] and rear fuel injector connector [85].
[87A]
[84A]
Front
10.
Remove throttle position sensor connector
[88] and
intake air temperature sensor connector [89].
11.
Moving to left side of motorcycle, remove ignition coil
connector [83] from left side of ignition coil.
12.
Pull back boot to reveal engine temperature sensor con-
nector [90] at back of front cylinder. Pull external latch
outward and remove connector. Cut cable strap to
release conduit from horn bracket.
13.
Returning to right side of motorcycle, depress external
latch and remove ECM connector [78].
14.
Gently pull on data link connector [91] to disengage from
[85A]
[89A]
[88A]
arms on electrical bracket.
[80A]
15.
Locate painted white dot on inboard side of fuse block
[80A] Manifold Absolute Pressure Sensor
[119]. Pressing on dot, gently tug on conduit to release
[84A] Front Fuel Injector
tabs on fuse block from slots in bracket.
[85A] Rear Fuel Injector
16.
Pull main harness connector [8] from slot in electrical
[87A] Idle Air Control
bracket. Depress external latches and use a rocking
[88A] Throttle Position Sensor
motion to separate pin and socket halves.
[89A] Intake Air Temperature Sensor
f2162x9x
17.
Remove two flange nuts to release electrical bracket
from studs on side of battery box.
Figure 8-186. Induction Module Assembly (Top View)
2004 Touring: Electrical
8-149
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