Harley Davidson 2004 Touring Models. Service Manual — page 50
HOME
1.
Verify correct front and rear tire inflation pressure.
11. Using a
4.5 mm,
1/4 inch drive socket
(Snap-On
TMM4.5) and flexible driver (Snap-On TM62B), adjust
2.
Place the motorcycle on a level floor or pavement in an
the headlamp horizontally by turning either the left or
area with minimum light.
right side adjuster. Turn both adjusters equally to adjust
3.
See Figure 8-27. Point the front of the motorcycle toward
the headlamp vertically. Adjuster rotation moves the
a screen or wall which is 25 feet (7.62 m) from where
headlamp beam as follows:
patch of front tire contacts floor (i.e. - directly below front
axle).
Table 8-6. FLTR Hex Adjuster Rotation
4.
Draw a horizontal line on screen or wall that is exactly
the same height above the floor as the headlamp center.
Beam
Hex Adjuster
Rotation
Movement
5.
Have a person whose weight is roughly the same as that
of the principal rider sit on the motorcycle seat. The
Left Only
CW
To the Right
weight of the rider will compress the vehicle suspension
Right Only
CCW
slightly.
Left Only
CCW
6.
Stand the motorcycle upright with both tires resting on
To the Left
the floor and with the front wheel held in straight align-
Right Only
CW
ment (directly forward).
Left and Right Equally
CW
Upward
7.
Turn the Ignition/Light Key Switch to IGNITION. Set the
Left and Right Equally
CCW
Downward
Light Switch on the left handlebar to Hi(gh) beam.
CW= Clockwise
CCW= Counter-Clockwise
8.
Check the light beam for proper height alignment. The
center of the main beam of light should be even with the
horizontal line on the screen or wall.
9.
Check the light beam for proper lateral alignment. The
main beam of light should be directed straight ahead
(i.e., equal area of light to right and left of center).
10.
Locate the hex adjusters near the bottom edge of the
inner fairing. See Figure
8-32. Turning the adjusters
causes the double headlamp housing to pivot around its
upper mount.
8-30
2004 Touring: Electrical
HOME
PASSING LAMPS
8.13
ADJUSTMENT
Nesting Ring
f2272x8x
Index Tab
1. Using a long shank ball end socket (Snap-on® FABL5),
remove two screws to release turn signal lamp from
mounting bracket. See Figure 8-33. Use hole in passing
lamp bracket to access inboard screw.
2. Insert flare nut socket (Snap-on® FRX181) at bottom of
turn signal mounting bracket and loosen locknut on stud.
3. Move lamp and swivel block to obtain the desired posi-
tion.
NOTE
Passing lamps should shine straight ahead with the center of
the main light beam even with a horizontal line drawn on a
Lamp
wall 25 feet (7.6 m) away. The line on the wall should be at
Index Tab
the same height as the center of the passing lamps with the
rider mounted.
Figure 8-34. Install Nesting Ring at Back of
Passing Lamp Bulb
4. Using flare nut socket, tighten locknut to 18 ft-lbs (24.4
Nm).
5.
Using long shank ball end socket, start two screws to
secure turn signal lamp to mounting bracket. Verify that
conduit fits in slot at back of bracket and is not pinched
8820
as screws are tightened.
Passing
Lamp
Door
PASSING LAMP BULB
REMOVAL
Bracket
1.
Loosen passing lamp door screw as required to pull
Screw
Door
lamp door from lip of lamp housing. See Figure 8-33.
Screw
2.
Pull socket terminals from spade contacts at back of
lamp.
Mounting
3.
Remove nesting ring and discard lamp.
Bracket
INSTALLATION
1.
Place nesting ring at back of new lamp with the concave
side up. See Figure 8-34.
2.
Install socket terminals onto spade contacts at back of
Conduit
lamp.
Turn Signal
Lamp
3.
Install lamp fitting nesting ring over edge of lamp hous-
ing. Rotate nesting ring so that index tab is aligned with
slot at bottom of lamp housing.
Figure 8-33. Passing Lamp and Turn Signal
2004 Touring: Electrical
8-31
HOME
PASSING LAMP
Passing Lamp
Connector [73]
REMOVAL
1.
Proceed as follows:
FLHT/C/U: Remove the outer fairing. See Section 2.29
UPPER
FAIRING/WINDSHIELD (FLHT/C/U), OUTER
FAIRING/WINDSHIELD, REMOVAL. Locate passing
lamp connector (white 2-place Multilock) below upper
fork bracket. See Figure 8-35.
FLHR/C: Remove the Phillips screw at the bottom of the
headlamp door (chrome ring). Remove the headlamp
door. Remove the eight Phillips screws to free the head-
lamp housing from the headlamp nacelle. Squeeze the
two external tabs to remove the wire connector at the
back of the headlamp bulb. Remove the headlamp hous-
ing assembly from the vehicle. Locate passing lamp con-
f2238x8x
nector (white 2-place Multilock). See Figure 8-36.
2.
Depress the button on the socket terminal side of the
Figure 8-35. Inner Fairing (FLHT/C/U)
connector and pull apart the pin and socket halves.
3.
Remove terminal of Gray/Black wire from socket hous-
f2212x8x
ing.
NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
TORS, REMOVING SOCKET/PIN TERMINALS.
4.
Using a long shank ball end socket (Snap-on® FABL5),
remove two screws to release turn signal lamp from
mounting bracket. See Figure 8-33. Use holes in pass-
ing lamp bracket to access inboard screw.
5.
Obtain length of strong flexible wire for use as mechan-
ics wire. Feed wire through opening in socket terminal
and then loop back twisting end until tightly coiled
around longer strand as shown in Figure 8-37.
Passing Lamp
Passing Lamp
Switch Connector [109]
Connector [73]
Mechanics Wire
Figure 8-36. Headlamp Nacelle (FLHRC)
4.
Holding nesting ring in place, rotate lamp so that dot on
lense is at the bottom and index tabs at back engage
slots in nesting ring.
5.
Verify that two adhesive foam strips are present on
Socket Terminal
inboard side of lamp door. Install new foam strips if dete-
riorated or missing.
6.
Install lamp door over lip of lamp housing. Rotate lamp
f1418x2x
door so that screw is centered at bottom, and then
tighten door screw until snug.
Figure 8-37. Fix Mechanics Wire to Socket Terminals
8-32
2004 Touring: Electrical
HOME
NOTE
11. Using a long shank ball end socket (Snap-on® FABL5),
Be sure that mechanics wire is of sufficient strength to pull
start two screws to secure turn signal lamp to mounting
bracket. Verify that conduit fits in slot at back of bracket
terminal through conduit without breaking. Wire length must
also be long enough so that free end is not lost in conduit
and is not pinched as screws are tightened. Use holes in
passing lamp bracket to access inboard screw.
when pulled.
12. Proceed as follows:
6. Carefully pull wire to draw socket terminal through con-
duit.
FLHT/C/U: Route passing lamp conduit upward in front
7. Unravel mechanics wire to release socket terminal.
of chrome skirt and then rearward using relief in upper
outboard corner (in front of fairing bracket). Install the
8. Insert flare nut socket (Snap-on® FRX181) at bottom of
outer fairing. See Section 2.29 UPPER FAIRING/WIND-
turn signal mounting bracket and remove locknut from
SHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD,
stud. Remove the turn signal mounting bracket and
INSTALLATION.
clamp block.
FLHR/C: Install wire connector at the back of the head-
9. Remove passing lamp (with Belleville washer and swivel
lamp bulb. Align holes in headlamp housing with those in
block) from the passing lamp bracket.
headlamp nacelle (headlamp door bracket at bottom).
Install eight Phillips screws.
INSTALLATION
1. Lay old passing lamp next to new passing lamp and cut
PASSING LAMP BRACKET
Gray/Black wire to length.
2. Strip 3/16 inch (4.8 mm) of insulation off new lamp wire
and crimp on new socket terminal.
REMOVAL
NOTE
1.
Remove passing lamp bracket from motorcycle. Proceed
For instructions on crimping wire terminals, see APPENDIX
as follows:
B.2 AMP MULTILOCK ELECTRICAL CONNECTORS,
CRIMPING INSTRUCTIONS.
FLHR/C: Remove acorn nuts from fork bracket studs.
3. If removed, slide swivel block and Belleville washer down
All Others: Using a T40 TORX drive head, loosen upper
Gray/Black wire onto passing lamp stud. Be sure that
and lower fork bracket screws.
rounded side of swivel block and concave side of
Belleville washer face passing lamp.
2.
Remove passing lamp bracket from motorcycle.
4. Feed Gray/Black wire of passing lamp through slot at top
of passing lamp bracket and insert threaded stud into
forward slot. Slide clamp block (rounded side up), turn
INSTALLATION
signal mounting bracket and locknut up Gray/Black wire
onto passing lamp stud at bottom of bracket.
1.
Install passing lamp bracket on motorcycle. Proceed as
follows:
5. Using flare nut socket (Snap-on® FRX181), tighten lock-
nut to 18 ft-lbs (24.4 Nm).
FLHR/C: Slide slots of passing lamp bracket onto upper
and lower fork bracket studs. Install acorn nuts on studs.
6. Reattach mechanics wire to socket terminal and care-
Alternately tighten acorn nuts to 72-108 in-lbs (8.1-12.2
fully pull end of mechanics wire to draw socket terminal
Nm) using a crosswise pattern.
back through conduit.
All Others: Slide slots of passing lamp bracket onto T40
7. Carefully remove mechanics wire to avoid damage to
TORX screws in upper and lower fork brackets. Alter-
terminal.
nately tighten screws to 15-20 ft-lbs (20-27 Nm) using a
8. Install terminal of Gray/Black wire into socket housing.
crosswise pattern.
NOTE
For instructions on properly installing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
TORS, INSTALLING SOCKET/PIN TERMINALS.
9. Mate pin and socket halves of passing lamp connector.
10. Turn Ignition/Light Key Switch to IGNITION and test for
proper operation and alignment. Adjust if necessary.
2004 Touring: Electrical
8-33
HOME
TAIL LAMP ASSEMBLY
8.14
3.
Align holes in lense with those in chrome plastic bracket
TAIL LAMP
and install two Phillips screws. Tighten screws to 20-24
in-lbs (2.3-2.7 Nm).
REMOVAL
4.
Turn the Ignition/Light Key Switch to IGNITION and test
lamp for proper operation.
1.
Remove two Phillips screws from lense to release tail
lamp assembly from chrome plastic bracket at back of
rear fender. Carefully pull tail lamp assembly from
bracket. See left side of Figure 8-38.
CIRCUIT BOARD/TAIL LAMP
2.
Depress button at bottom of 4-place Multilock socket to
BRACKET
release tail lamp assembly from pin housing. See right
side of Figure 8-38.
REMOVAL
INSTALLATION
1.
Remove two Phillips screws from lense to release tail
1.
Orient 4-place Multilock socket so that the release but-
lamp assembly from chrome plastic bracket at back of
ton is at the bottom and insert into pin housing until it
rear fender. Carefully pull tail lamp assembly from
“clicks.”
bracket. See left side of Figure 8-38.
2.
Place tail lamp into position against chrome plastic
2.
Depress button at bottom of 4-place Multilock socket to
bracket tucking conduit into space below pin housing
release tail lamp assembly from pin housing. See right
screw. See right side of Figure 8-38.
side of Figure 8-38.
3.
Depress buttons to remove four remaining Multilock
CAUTION
sockets from pin housing. See Figure 8-39.
Over tightening screws can crack the lense or result in
All remaining release buttons are at the top, with the
scratching of the fender paint.
exception of the rear fender lights harness socket, where
Tail Lamp [93]
Tail Lamp
Chrome Plastic
4-place Multilock
Assembly
Bracket
Space
f2173x8x
Figure 8-38. Remove Tail Lamp and Depress Button to Release Socket
8-34
2004 Touring: Electrical
HOME
4.
Remove large Phillips screw and pull pin housing with
attached circuit board (and gasket) from chrome plastic
Right Turn
bracket. Two tabs at back of pin housing fit into holes in
Signal Lamp
Fender Tip
[19]
bracket.
Lamp [45]
Left Turn
5.
Remove chrome plastic bracket. Use both thumbs to
Fender Lights
Signal Lamp
push bracket upward until it becomes free of fender and
Tail Lamp
Harness to
[18]
[93]
Circuit Board
then pull out of fender hole.
[94]
6.
Feed Multilock sockets through openings to inboard side
of bracket. See Figure 8-39. For best results, free the
smaller sockets first.
INSTALLATION
1.
Feed Multilock sockets through openings to outboard
side of chrome plastic bracket. See Figure 8-39. For best
results, feed the larger sockets first.
2.
Fit bottom of bracket into fender hole and then push
down to align center hole in bracket with clip nut on
fender flange.
3.
Place pin housing over circuit board, if removed. See
Figure 8-41.
4.
Snap tabs at back of pin housing into holes in plastic
Opening
f2172x8x
bracket.
Figure 8-39. Rear Fender Lights Assembly
CAUTION
Over tightening screw can crack the plastic bracket or
Pick
result in scratching of the fender paint.
Tool
5.
Install large Phillips screw to secure pin housing, circuit
board and plastic bracket to fender flange. Tighten screw
to 40-48 in-lbs (4.5-5.4 Nm).
Pin Housing
f1497b8x
H-D
Figure 8-40. Release Left Turn Signal Lamp Socket
USA
68830-98
the button is on the outboard side. To release socket
Circuit Board
f1506x8x
housings of left and right turn signal lamps, use a pick or
small screwdriver to depress top release button as
shown in Figure 8-40.
Figure 8-41. Place Pin Housing Over Circuit Board
2004 Touring: Electrical
8-35
HOME
6.
Install each socket into pin housing until it “clicks.” Install
rear fender tip lamp and both left and right turn signal
CAUTION
lamp sockets so that the release buttons are at the top.
Over tightening screws can crack the lense or result in
Install the rear fender lights harness socket with the but-
scratching of the fender paint.
ton on the outboard side and the tail lamp socket with
the button at the bottom.
9.
Align holes in lense with those in chrome plastic bracket
7.
To avoid stressing wires, verify that tail lamp conduit is
and install two Phillips screws. Tighten screws to 20-24
positioned on the outboard side of the rear fender tip
in-lbs (2.3 - 2.7 Nm).
lamp and left turn signal lamp conduit as shown in Fig-
10. Turn the Ignition/Light Key Switch to IGNITION and test
ure 8-38.
lamp for proper operation.
8.
Place tail lamp into position against chrome plastic
bracket tucking conduit into space below pin housing
screw.
8-36
2004 Touring: Electrical
HOME
FENDER TIP LAMPS
8.15
FRONT FENDER TIP LAMP
Front Fender
Tip Lamp [32]
REMOVAL
1. Insert blade of small screwdriver into slot at top of fender
tip lamp lense. Rotate end of screwdriver to unsnap
lense from lamp bracket.
2. Remove gasket from fender tip lamp bracket, if present.
3. Holding Keps nuts at inboard
side of rear fender, remove
two Phillips screws to release fender tip lamp bracket.
4. Depress button on socket terminal side of black 2-place
Multilock connector to release fender tip lamp assembly
from jumper harness. See Figure 8-44.
INSTALLATION
1. Mate pin and socket halves of black 2-place Multilock
connector to attach front fender tip lamp assembly to
jumper harness. See Figure 8-44.
2. With wires routed along bottom left side, place fender tip
lamp bracket into position aligning holes in bracket with
f2238x8x
those in fender.
Figure 8-42. Inner Fairing (FLHT/C/U)
CAUTION
Over tightening screws can crack the bracket or result in
scratching of the fender paint.
3. Slide Phillips screws through bracket and fender holes
and install Keps nuts. Holding nuts at inboard side of
fender, tighten screws to 20-24 in-lbs (2.3 - 2.7 Nm).
4. Place gasket into position on fender tip lamp bracket, if
present.
5. Insert tab at bottom of lense into slot of fender tip lamp
bracket. Apply thumb pressure at top of lense until it
snaps into place.
6. Turn the Ignition/Light Key Switch to IGNITION and test
lamp for proper operation.
FRONT FENDER TIP LAMP
JUMPER HARNESS
Front Fender
Tip Lamp [32]
Used on FLHR Only
f2212x8x
REMOVAL
Figure 8-43. Headlamp Nacelle (FLHRC)
1. Proceed as follows:
FLHT/C/U: Reaching in below the fairing cap on the left
side of the steering head, locate the front fender tip lamp
FLHR: Remove the Phillips screw at the bottom of the
connector (black 2-place Multilock). See Figure 8-42.
headlamp door (chrome ring). Remove the headlamp
Remove the outer fairing only if necessary. See Section
door. Remove the eight Phillips screws to free the head-
2.29 UPPER FAIRING/WINDSHIELD
(FLHT/C/U),
lamp housing from the headlamp nacelle. Squeeze the
OUTER FAIRING/WINDSHIELD, REMOVAL.
2004 Touring: Electrical
8-37
HOME
two external tabs (if present) to remove the wire connec-
tor at the back of the headlamp bulb. Remove the head-
Fender Tip
lamp housing assembly from the vehicle. Locate the
Lamp Bracket
Oblong Hole
front fender tip lamp connector (black 2-place Multilock).
See Figure 8-43.
2.
Depress the button on the socket terminal side of the
connector and pull apart the pin and socket halves.
3.
Draw socket connector down to fender area.
4.
Carefully cut cable strap to release front fender tip lamp
wires from brake line hose.
5.
Remove terminals from socket housing.
NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
Tee Bolt
TORS, REMOVING SOCKET/PIN TERMINALS.
Wire Conduit
6.
Place the motorcycle on a hydraulic center stand with
the front wheel raised off the ground.
Trim Strip
f1505x8x
7.
Remove the front wheel. See Section
2.3 FRONT
WHEEL, REMOVAL.
Figure 8-45. Install Conduit in Trim Strip
8.
From inboard side of front fender, remove two nuts to
release trim strip from left side of fender. See Figure 8-
45.
Grommet
9.
Pull wires and Multilock socket terminals through grom-
met to inboard side of fender. See Figure 8-46. Reach-
ing under left side of fender, release wires from one weld
clip and four metal adhesive clips.
10. Feed wires and Multilock socket terminals through
oblong hole to outboard side of fender.
f1504a8x
Socket
Brake
Terminals
Hose
f1503b8x
Figure 8-46. Pull Fender Tip Lamp Wires and Terminals
Through Fender Grommet
Fender Tip
11. Insert blade of small screwdriver into slot at top of fender
Lamp Bracket
tip lamp lense. Rotate end of screwdriver to unsnap
2-Place
lense from lamp bracket.
Multilock
Connector
12. Remove gasket from fender tip lamp bracket, if present.
LEFT SIDE
13. Holding Keps nuts at inboard side of front fender,
remove two Phillips screws to release fender tip lamp
Figure 8-44. Fender Tip Lamp Assembly
bracket.
8-38
2004 Touring: Electrical
HOME
14. Depress button on socket terminal side of 2-place Mul-
tilock connector to release fender tip lamp assembly
f2003x8x
from jumper harness. See Figure 8-44.
2
3
INSTALLATION
4
1. See Figure 8-47. Carefully inspect the condition and
1
security of the four metal adhesive clips in the left side
fender well. Replace the clips if broken, loose or missing.
Proceed as follows:
a. Remove remnants of old clip, as well as all residual
adhesive.
Weld
Fender
b. Using a soapy Scotch Brite® pad, thoroughly clean
Clip
Bracket
fender well in area of clip.
c. Rinse with clear water and dry with a clean white
cloth. Repeat step until clean cloth shows no evi-
Figure 8-47. Four Metal Adhesive Clips
dence of dirt.
(Left Side Front Fender Well)
d. Swab area with isopropyl alcohol.
e. Obtain new metal adhesive clip (Part No. 10187).
11. Install terminals into socket housing.
f.
Remove paper backing to expose adhesive and
firmly press clip into place.
NOTE
For instructions on properly installing wire terminals, see
2. Mate pin and socket halves of 2-place Multilock connec-
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
tor to attach front fender tip lamp assembly to jumper
TORS, INSTALLING SOCKET/PIN TERMINALS.
harness. See Figure 8-44.
3. With wires routed along bottom left side, place fender tip
12. Reaching under left side of fender, route wires of the
lamp bracket into position aligning holes in bracket with
jumper harness through one weld clip and four metal
those in fender.
adhesive clips. See Figure 8-47.
CAUTION
1WARNING
Over tightening screws can crack the bracket or result in
If any portion of the jumper harness crosses over the riv-
scratching of the fender paint.
eted fender bracket, contact with the tire can cause chaf-
4. Slide Phillips screws through bracket and fender holes
ing or other damage. Damage to the wiring can lead to
and install Keps nuts. Holding nuts at inboard side of
loss of lighting while riding, which could result in death
fender, tighten screws to 20-25 in-lbs (2.3-2.8 Nm).
or serious injury.
5. Place gasket into position on fender tip lamp bracket, if
13. Verify that no portion of the jumper harness crosses over
present.
the riveted fender bracket.
6. Insert tab at bottom of lense into slot of fender tip lamp
bracket. Apply thumb pressure at top of lense until it
snaps into place.
1WARNING
7. Route wire conduit inside trim strip and slide front tee
If the height of any metal clip is above the riveted fender
bolt over conduit. See Figure 8-45. Verify that second
bracket, contact with the tire can cause damage that
tee bolt is in position at rear of trim strip.
results in premature tire failure, which could result in
death or serious injury.
8. Feed Multilock socket terminals and wires through
oblong hole to inboard side of fender.
14. Using finger pressure, bend arm of each clip down over
9. While removing slack from wires on outboard side of
wires so that no portion of the clip is above the height of
fender, align tee bolts with fender holes. Wtih trim strip
the fender bracket.
positioned against left side of fender, reach under fender
and install nuts on tee bolts. Alternately tighten nuts to
15. Route socket housing of front fender tip lamp connector
10-15 in-lbs (1.1-1.7 Nm).
upward behind chrome skirt (FLHT/C/U) or through bot-
tom of headlamp nacelle (FLHR) to area beneath upper
10. Pull Multilock socket terminals and wires through grom-
fork bracket. Mate pin and socket halves.
met to outboard side of fender. See Figure 8-46.
2004 Touring: Electrical
8-39
HOME
NOTE
To connect front fender tip lamp with the outer fairing
installed (FLHT/C/U models), reach in below the fairing cap
on the left side of the steering head.
Screwdriver
16. Install the front wheel. See Section 2.3 FRONT WHEEL,
INSTALLATION.
17. Install new cable strap to secure front fender tip lamp
wires to brake line hose. Cut any excess cable strap
material.
18. Proceed as follows:
FLHT/C/U: Install the outer fairing, if removed. See Sec-
tion 2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U),
OUTER FAIRING/WINDSHIELD, INSTALLATION.
FLHR: Install wire connector at the back of the head-
lamp bulb. Align holes in headlamp housing with those in
headlamp nacelle. Install eight Phillips screws. Install
the headlamp door (chrome ring) and door screw.
Lense
19. Turn Ignition/Light Key Switch to IGNITION and test
lamp for proper operation.
f1501x8x
Fender Tip
Gasket
Lamp Bracket
REAR FENDER TIP LAMP
REMOVAL
1.
Remove two Phillips screws from lense to release tail
lamp assembly from chrome plastic bracket at back of
rear fender. Carefully pull tail lamp assembly from
bracket.
Rear Fender
Tail Lamp [93]
Tip Lamp [45]
TORX
Screws
f1500x8x
Figure 8-49. Remove Rear Fender Tip Lamp Lense
and Bracket
2. Depress button at bottom of 4-place Multilock socket to
release tail lamp assembly from pin housing. See Figure
8-48.
3. Depress button at top of 3-place Multilock socket to
release fender tip lamp assembly from pin housing.
4. Feed
3-place Multilock socket through opening in
chrome plastic bracket to inboard side of rear fender.
Reaching under left side of rear fender, release conduit
from two cable clips anchored on T-studs.
5. Insert blade of small screwdriver into slot at top of fender
Opening
f2172x8x
tip lamp lense. Rotate end of screwdriver to unsnap
lense from lamp bracket. See upper frame of Figure 8-
Figure 8-48.
Depress Button to Release Socket
49.
From Pin Housing
8-40
2004 Touring: Electrical
HOME
NOTE
Fender
Hole
For instructions on properly installing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
TORS, INSTALLING SOCKET/PIN TERMINALS.
4.
Feed 3-place Multilock socket and conduit through bot-
tom fender hole. See Figure 8-50.
5.
Place fender tip lamp bracket into position aligning holes
in bracket with those in fender. Slide TORX screws
through bracket and fender holes and install nuts.
6.
Place gasket into position on fender tip lamp bracket, if
present. See lower frame of Figure 8-49.
7.
Insert tab at bottom of lense into slot of fender tip lamp
Fender Tip
bracket. Apply thumb pressure at top of lense until it
Lamp Bracket
snaps into place.
f1499x8x
8.
Reaching under left side of rear fender, capture conduit
Figure 8-50. Feed Fender Tip Lamp Socket and Conduit
in two cable clips anchored on T-studs. Feed 3-place
Through Fender Hole
Multilock socket through opening on left side of chrome
plastic bracket to outboard side of rear fender.
9.
Orient 3-place Multilock socket so that the release but-
6. Remove gasket from fender tip lamp bracket, if present.
See lower frame of Figure 8-49.
ton is at the top and insert into pin housing until it
“clicks.”
7. Holding nuts at inboard side of rear fender, remove two
TORX screws to release fender tip lamp bracket.
10.
To install tail lamp assembly, orient 4-place Multilock
8. Draw conduit and 3-place Multilock socket out through
socket so that the release button is at the bottom and
bottom fender hole. See Figure 8-50.
insert into pin housing until it “clicks.” To avoid stressing
wires, verify that tail lamp conduit is positioned on the
9. Remove terminals from socket housing.
outboard side of the rear fender tip lamp and left turn
NOTE
signal lamp conduit as shown in Figure 8-48.
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
11.
Place tail lamp into position against chrome plastic
TORS, REMOVING SOCKET/PIN TERMINALS.
bracket tucking conduit into space below pin housing
screw.
INSTALLATION
CAUTION
1. Place new fender tip lamp assembly next to discarded
unit and cut wires to proper length.
Over tightening screws can crack the lense or result in
scratching of the fender paint.
2. Crimp new socket terminals onto fender tip lamp wires.
NOTE
12. Align holes in lense with those in chrome plastic bracket
For instructions on crimping wire terminals, see APPENDIX
and install two Phillips screws. Tighten screws to 20-25
B.2 AMP MULTILOCK ELECTRICAL CONNECTORS,
in-lbs (2.3-2.8 Nm).
CRIMPING INSTRUCTIONS.
13. Turn the Ignition/Light Key Switch to IGNITION and test
3. Install terminals into socket housing.
lamp for proper operation.
Table 8-7. Rear Fender Tip Lamp [45]
Chamber
Wire Color
Number
Black
1
Not Used
2
Black
3
2004 Touring: Electrical
8-41
HOME
TURN SIGNAL LAMPS
8.16
BULB REPLACEMENT
Turn Signal Lamp
Connector [31]
REMOVAL
1.
Proceed as follows:
FLHR/C, FLHT/C/U: Remove two Phillips screws to
release lense from lamp housing. See Figure 8-51.
FLHRS, FLTR: Insert blade of small screwdriver into slot
at bottom of lense. Gently rotate end of screwdriver to
unsnap lense from lamp housing.
2.
While pushing in bulb, rotate in a counter-clockwise
direction to remove.
3.
Inspect condition of electrical contacts in socket. If nec-
essary, clean with a small wire brush and electrical con-
tact cleaner.
f2238x8x
8820
Figure 8-52. Inner Fairing (FLHT/C/U)
Passing
Lamp
INSTALLATION
1.
Liberally apply dielectric grease to contacts in socket
and at bottom of new bulb. For correct bulb type, see
Section 8.2 BULB CHART.
2.
While pushing in new bulb, rotate in a clockwise direc-
tion to install.
3.
Proceed as follows:
FLHR/C, FLHT/C/U: Seat lense in lamp housing and
install two Phillips screws.
FLHRS, FLTR: Seat lense in lamp housing and gently
apply thumb pressure to lense until it snaps into place.
Turn Signal
Rotate lense to position slot at bottom of lamp housing.
Lamp
Lense
FRONT TURN SIGNAL LAMP
FLHR/C, FLHT/C/U
Removal
1.
Proceed as follows:
Lense
Screw
FLHT/C/U: Remove the outer fairing. See Section 2.29
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
FAIRING/WINDSHIELD, REMOVAL. Locate front turn
Figure 8-51. Front Turn Signal Lamp
signal lamp connector (6-place Multilock) on T-stud at
(FLHR/C, FLHT/C/U)
top of left fairing support brace. See Figure 8-52.
8-42
2004 Touring: Electrical
HOME
5.
Obtain three equal lengths of strong flexible wire for use
Turn Signal Lamp
as mechanics wire. Feed wire through opening in socket
Connector [31]
terminal and then loop back twisting end until tightly
coiled around longer strand as shown in Figure 8-54.
Repeat step with remaining socket terminals.
NOTE
Be sure that mechanics wire is of sufficient strength to pull
terminals through conduit without breaking. Wire lengths
must also be long enough so that free ends are not lost in
conduit when pulled.
6.
Carefully pull wires to draw socket terminals through
both sections of conduit. For best results, pull one wire
at a time.
7.
Unravel mechanics wire to release socket terminals.
f2212x8x
Installation
Figure 8-53. Headlamp Nacelle (FLHRC)
1.
Lay old turn signal lamp next to new turn signal lamp
and cut wires to length.
FLHR/C: Remove the Phillips screw at the bottom of the
2.
Strip 3/16 inch (4.8 mm) of insulation off new lamp wires
headlamp door (chrome ring). Remove the headlamp
and crimp on new socket terminals.
door. Remove the eight Phillips screws to free the head-
lamp housing from the headlamp nacelle. Squeeze the
NOTE
two external tabs (if present) to remove the wire connec-
For instructions on crimping wire terminals, see APPENDIX
tor at the back of the headlamp bulb. Remove the head-
B.2 AMP MULTILOCK ELECTRICAL CONNECTORS,
lamp housing assembly from the vehicle. Locate the
CRIMPING INSTRUCTIONS.
front turn signal lamp connector (black 6-place Multilock)
anchored in hole of fork stem nut lock plate (left side).
3.
Reattach mechanics wire to socket terminals and care-
See Figure 8-53.
fully pull ends of mechanics wire to draw socket termi-
nals back through conduit.
2. Depress the button on the socket terminal side of the
connector and pull apart the pin and socket halves.
4.
Carefully remove mechanics wire to avoid damage to
terminals.
3. Remove appropriate terminals from socket housing.
Table 8-8. Front Turn Signal Lamps [31]
Left Side
Right Side
Mechanics Wire
Wire Color
Chamber
Wire Color
Chamber
Blue (DOM)
4
Black
1
Violet/Brown
5
Violet/Brown
2
Black
6
Blue (DOM)
3
NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
Socket Terminal
TORS, REMOVING SOCKET/PIN TERMINALS.
4. Using a long shank ball end socket (Snap-on® FABL5),
f1418x2x
remove two screws to release turn signal lamps from
mounting brackets. Use holes in passing lamp bracket to
access inboard screws.
Figure 8-54. Fix Mechanics Wire to Socket Terminals
2004 Touring: Electrical
8-43
HOME
5.
Install terminals into socket housing.
NOTE
For instructions on properly installing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
TORS, INSTALLING SOCKET/PIN TERMINALS.
6. Using a long shank ball end socket (Snap-on® FABL5),
start two screws to secure turn signal lamp to mounting
bracket. Verify that conduit fits in slot at back of bracket
and is not pinched as screws are tightened. Use hole in
passing lamp bracket to access inboard screw.
7. Mate pin and socket halves of front turn signal lamp con-
nector.
9408
8. Proceed as follows:
FLHT/C/U: Verify that conduit is routed upward in front
Figure 8-55. Front Turn Signal Lamp (FLTR)
of chrome skirt and then rearward using relief in upper
outboard corner (in front of fairing bracket). Install con-
nector on T-stud at top of left fairing support brace. See
3.
Depress the button on the socket terminal side of the
Figure 8-52. Install the outer fairing. See Section 2.29
connector and pull apart the pin and socket halves.
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
FAIRING/WINDSHIELD, INSTALLATION.
4.
Remove appropriate terminals from socket housing. See
Table 8-8.
FLHR/C: Install anchor on connector into hole of fork
stem nut lock plate (left side). See Figure 8-53. Install
NOTE
wire connector at the back of the headlamp bulb. Align
For instructions on properly removing wire terminals, see
holes in headlamp housing with those in headlamp
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
nacelle. Install eight Phillips screws. Install the head-
TORS, REMOVING SOCKET/PIN TERMINALS.
lamp door (chrome ring) and door screw.
9.
Turn Ignition/Light Key Switch to IGNITION and test for
5.
Carefully cut cable strap to release turn signal lamp con-
proper operation.
duit from lower handlebar clamp. Draw free end of con-
duit out of headlamp nacelle.
6. Remove two cable clips anchored in holes at bottom of
FLTR
handlebar. Free turn signal lamp conduit from cable
clips.
Removal
7. Remove acorn nut, lock washer and turn signal lamp
See Section 2.30 UPPER FAIRING/WINDSHIELD (FLTR),
bracket from stem of mirror. Remove turn signal lamp
OUTER FAIRING, REMOVAL, steps 1-5. See Figure 8-55.
assembly from motorcycle.
Installation
Installation
See Section 2.30 UPPER FAIRING/WINDSHIELD (FLTR),
1.
If removed, install stem of mirror into hole in clutch lever
OUTER FAIRING, INSTALLATION, steps 2 and 6-12.
bracket (left side) or master cylinder reservoir bracket
(right side).
2.
Slide turn signal lamp bracket onto stem of mirror and
FLHRS
install lock washer and acorn nut.
Removal
NOTE
Index pin at bottom of clutch lever bracket engages blind hole
1.
Remove handlebar clamp shroud/wind deflector. See
at top of left turn signal lamp bracket to ensure proper orien-
Section
2.31 WINDSHIELD/HEADLAMP NACELLE
tation. On the right side, location of the front brake lever pivot
(FLHR/C/S), NACELLE REMOVAL (FLHRS), steps 1-7.
pin relief prevents improper installation. See Figure 8-56.
2.
Inside headlamp nacelle, locate the front turn signal
lamp connector (black 6-place Multilock) anchored in
3.
Following bottom of handlebar, feed free end of turn sig-
hole of fork stem nut lock plate (left side). See Figure 8-
nal lamp conduit into top of headlamp nacelle staying
53.
outboard of lower handlebar clamp.
8-44
2004 Touring: Electrical
HOME
9.
Adjust mirror as necessary and tighten acorn nut to 60-
9409
96 in-lbs (6.8-10.8 Nm).
Left
Turn Signal
10. Turn Ignition/Light Key Switch to IGNITION and test for
proper operation.
Adjustment
1.
Using a 1/4 inch allen head socket, loosen set screw in
turn signal lamp bracket. See Figure 8-57.
Blind
Hole
2.
Point turn signal lamp straight forward and snug set
screw.
3.
Carefully turn the front forks to the left and right fork
stops to verify that the turn signal lamp does not contact
Right
fuel tank or any other components. Loosen set screw
Turn Signal
and readjust lamp as required.
4.
Tighten set screw to 50-60 in-lbs (5.7-6.8 Nm).
Pivot Pin
Relief
f2263x8x
6
4
9410
5
3
Figure 8-56. Front Turn Signal Lamps (FLHRS)
7
8
4.
Reaching inside headlamp nacelle, install terminals into
2
socket housing of turn signal lamp connector (black 6-
9
place Multilock). For correct terminal locations see Table
5
8-8.
4
NOTE
For instructions on properly installing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
8
TORS, INSTALLING SOCKET/PIN TERMINALS.
3
9
5. Install anchor on turn signal lamp connector into hole of
fork stem nut lock plate (left side).
1
6. Install two cable clips into holes at bottom of handlebar
after capturing handlebar switch and turn signal lamp
4.
Ball Stud
conduit.
5.
Set Screw
6.
Left Bracket
7. Install new cable strap to secure handlebar switch and
1.
Right Lamp
7.
Left Lamp
turn signal lamp conduit to lower handlebar clamp. Cut
2.
Right Bracket
8.
Lock Washer
any excess cable strap material.
3.
Jam Nut
9.
Acorn Nut
8. Install handlebar clamp shroud/wind deflector. See Sec-
tion 2.31 WINDSHIELD/HEADLAMP NACELLE (FLHR/
Figure 8-57. Front Turn Signal Lamp Brackets (FLHRS)
C/S), NACELLE INSTALLATION (FLHRS), steps 5-13.
2004 Touring: Electrical
8-45
HOME
REAR TURN SIGNAL LAMP
Left Turn
Signal Lamp
Right Turn
[18]
Signal Lamp
NOTE
Tail Lamp
[19]
[93]
Although the rear turn signal lamp assembly used on FLHRS
and FLTR appears different from that found on FLHR/C and
FLHT/C/U, the instructions which follow will work for both.
REMOVAL
1.
Remove saddlebag on same side of vehicle. See Sec-
tion 2.25 SADDLEBAG, REMOVAL.
2.
Remove two Phillips screws from lense to release tail
lamp assembly from chrome plastic bracket at back of
rear fender. Carefully pull tail lamp assembly from
bracket.
3.
Depress button at bottom of 4-place Multilock socket to
release tail lamp assembly from pin housing. See Figure
8-58.
f2172x8x
4.
Depress button at top of 2-place Multilock socket to
release turn signal lamp assembly from pin housing. To
Figure 8-58. Release Tail Lamp Socket
release socket housing, use a pick or small screwdriver
to depress release button as shown in Figure 8-59.
Pick
f1497x8x
Tool
5.
Feed
2-place Multilock socket through opening in
chrome plastic bracket to inboard side of rear fender.
6.
Reaching under rear fender, release conduit from cable
clip anchored on T-stud.
7.
Draw conduit and 2-place Multilock socket out through
fender hole just below chrome plastic bracket. See Fig-
ure 8-59.
8.
Draw conduit and 2-place Multilock socket through hole
on inboard side of rear turn signal lamp bracket, so that
length is suspended below turn signal lamp.
9.
Inserting a long shank ball end socket
(Snap-on®
FABL5) through same hole in bracket, remove two
socket head screws to release turn signal lamp assem-
bly.
10.
Remove terminals from socket housing.
Opening
NOTE
Fender Hole
For
instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
TORS, REMOVING SOCKET/PIN TERMINALS.
Figure 8-59. Release Left Turn Signal Lamp Socket
2.
Crimp new socket terminals onto turn signal lamp wires.
INSTALLATION
NOTE
For instructions on crimping wire terminals, see APPENDIX
1.
Place new turn signal lamp assembly next to discarded
B.2 AMP MULTILOCK ELECTRICAL CONNECTORS,
unit and cut wires to proper length.
CRIMPING INSTRUCTIONS.
8-46
2004 Touring: Electrical
HOME
3. Install terminals into socket housing.
REAR TURN SIGNAL LAMP
BRACKET
Table 8-9. Rear Turn Signal Lamps [18/19]
Chamber
Wire Color
Number
NOTE
Violet/Brown
1
Although the rear turn signal lamp assembly used on FLHRS
and FLTR appears different from that found on FLHR/C and
Black
2
FLHT/C/U, the instructions which follow will work for both.
NOTE
REMOVAL
For instructions on properly installing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
1.
Remove circuit board and tail lamp bracket. See Section
TORS, INSTALLING SOCKET/PIN TERMINALS.
8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/TAIL
LAMP BRACKET, REMOVAL.
4.
Align holes in turn signal lamp assembly with those in
rear turn signal lamp bracket and install two socket head
2.
Remove rear turn signal lamps from bracket. See REAR
TURN SIGNAL LAMP, REMOVAL, in this section, steps
screws. For best results, insert a long shank ball end
6-9.
socket (Snap-on® FABL5) through hole on inboard side
of bracket, and alternately tighten screws to 30-50 in-lbs
3.
Remove two flange bolts to free rear turn signal lamp
(3.4-5.6 Nm).
bracket from rear fender.
5.
Route 2-place Multilock socket through same hole in
bracket, and then feed socket through fender hole just
below chrome plastic bracket. See Figure 8-59.
INSTALLATION
6.
Reaching under rear fender, capture conduit in cable clip
anchored on T-stud.
1.
Apply one drop of LOCTITE THREADLOCKER 271
7.
Feed
2-place Multilock socket through opening in
(Red) to two flange bolts.
chrome plastic bracket to outboard side of rear fender.
2.
Install flange bolts to fasten rear turn signal lamp bracket
8.
Orient 2-place Multilock socket so that the release but-
to rear fender. Alternately tighten bolts to 84-144 in-lbs
ton is at the top and insert into pin housing until it
(9.5-16.3 Nm).
“clicks.”
3.
Install rear turn signal lamps to bracket. See REAR
9.
To install tail lamp assembly, orient 4-place Multilock
TURN SIGNAL LAMP, INSTALLATION, in this section,
socket so that the release button is at the bottom and
steps 4-6.
insert into pin housing until it “clicks.” To avoid stressing
wires, verify that tail lamp conduit is positioned on the
4.
Install tail lamp bracket and circuit board assembly. See
outboard side of the rear fender tip lamp and left turn
Section 8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/
signal lamp conduit as shownn Figure 8-58.
TAIL LAMP BRACKET, INSTALLATION.
10.
Place tail lamp into position against chrome plastic
bracket tucking conduit into space below pin housing
screw.
CAUTION
Over tightening screws can crack the lense or result in
scratching of the fender paint.
11. Align holes in lense with those in chrome plastic bracket
and install two Phillips screws. Tighten screws to 20-24
in-lbs (2.3 - 2.7 Nm).
12. Turn the Ignition/Light Key Switch to IGNITION and test
lamp for proper operation.
13. Install saddlebag on vehicle. See Section 2.25 SADDLE-
BAG, INSTALLATION.
2004 Touring: Electrical
8-47
HOME
TURN SIGNAL/SECURITY MODULE
8.17
REMOVAL
NOTE
The turn signal/security module also houses the bank angle
sensor.
IMPORTANT NOTE
If equipped with the optional “Harley-Davidson Factory
Security System,” verify that the security status lamp in
speedometer face is not flashing before proceeding
(security system disarmed).
1. Remove seat. See Section 2.24 SEAT, REMOVAL.
2. Depress tab at front of spring clip and lift to release legs
from holes in frame crossmember at rear of battery box.
Spring
See Figure 8-60.
Clip
Turn Signal/Security
3. Remove module from cavity and disconnect turn signal/
Module
f2013x8x
security module connector [30], 12-place Deutsch.
Figure 8-60. Turn Signal/Security Module
INSTALLATION
3. Install seat. See Section 2.24 SEAT, INSTALLATION.
1.
Connect turn signal/security module connector [30], 12-
4. Test all turn signal functions. Test all security system
place Deutsch, to new module. Install module in cavity
functions, if so equipped.
of frame crossmember at rear of battery box.
2.
Insert legs of spring clip into holes in frame crossmem-
ber and push down until tab at front snaps in place.
8-48
2004 Touring: Electrical
HOME
IGNITION/LIGHT KEY SWITCH AND FORK LOCK
8.18
1WARNING
Knob
DO NOT modify the ignition/light key switch wiring to
disable the automatic-on headlamp feature. High visibil-
ity is an important safety consideration for motorcycle
riders. Ensure that the headlamp is on at all times. Fail-
ure to do so could result in death or serious injury.
FLHT/C/U, FLTR (DOMESTIC)
Nut
REMOVAL
Collar
Tab
1. Remove the outer fairing. See Section 2.29 UPPER
Down and Forward
FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/
WINDSHIELD, REMOVAL.
2. To remove the ignition switch knob, insert the Ignition
Switch key and turn to the UNLOCK position. Leaving
Spacer
Socket
the key installed, rotate the knob to ACCESS. Depress-
Screw
ing the release button at bottom (left side) with a small
screwdriver, push key down and turn an additional 60
degrees in a counter-clockwise direction. Lift and
Flat
remove knob. See Figure 8-61.
Washer
f1240x2x
Switch
Housing
4-Place
Button
TOP VIEW
Packard
Connector
f2115x8x
Figure 8-62. Ignition Switch Assembly (Domestic)
3.
Using a 7/8 inch wrench on flats, loosen switch nut and
remove from threaded post of ignition switch housing.
Button
Remove collar and spacer. See Figure 8-62.
4.
Using a T27 TORX drive head, remove the two screws
(with flat washers) that secure fairing cap to left and right
sides of inner fairing.
5.
Remove the switch position plate by pulling tabs from
f1476x8x
BOTTOM VIEW
slots in fairing cap. If necessary, raise the fairing cap
slightly to facilitate removal.
Figure 8-61. Ignition Switch Knob Release Button
2004 Touring: Electrical
8-49
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