Harley Davidson 2004 Touring Models. Service Manual — page 59
HOME
c. Moving to the inner fairing side, reach in under the
i04384
fairing cap and slide the screw through the holes in
the metal plate and power supply. Returning to the
front, loosely install lockwasher and locknut.
d. Carefully pull out the two strobe harnesses, the red
(power) wire and the black (ground) wire, so that it is
free of the power supply and other wiring.
7. Obtain ring terminal from kit. Strip 3/8 inch (9.5 mm)
Screws
insulation from end of black (ground) wire exiting power
supply. Using a wire crimpers, install and crimp ring ter-
minal to wire.
8. See Figure 8-9. While holding the power supply and
mounting screw in position, remove the locknut and lock-
washer loosely installed. Install black (ground) wire ring
terminal onto screw and reinstall lockwasher and locknut.
Not Used
Tighten locknut securely.
Figure 8-5. Headlamp Housing Mount (FLHP)
1
3
2
Storage Box
50
60
70
30
40
50
3040
80
90
20
60
20
100
10
70
10
0
MPH
120
110
0
RPM x100
80
TI
D
D
Metal Plate
i04390
4
7
Figure 8-7. Locate Metal Mounting Plate
(FLHTP)
f1755d8x
6
5
Metal Plate
Figure 8-6. Remove Outer Fairing (FLHTP)
NOTE
Locknut and
Lockwasher
When installing the power supply, note that it is not an exact
fit. It may be necessary to manipulate the power supply into
various positions to obtain the optimal alignment and posi-
tion. Also note that the hole in the metal plate is slightly larger
than the hole in the power supply mount. While the overall fit
Power Supply
may appear less than perfect, the power supply will be secure
once the hardware is fully tightened.
Strobe
b. See Figure 8-8. Obtain the power supply (with wir-
Harnesses
ing), screw, lockwasher and locknut from kit. Posi-
i04391
tion the power supply, so that the mounting hole on
the left side is aligned with the hole in the metal
Figure 8-8. Mount Strobe Power Supply (FLHTP)
plate.
8-6
2004 FLT Police: Electrical
HOME
d. Moving to the inner fairing side, use a T27 TORX
drive head to start the two fairing screws (4 and 7)
Ground Wire
just above the wind deflectors on both the left and
From Power Supply
right side.
e. Turn the handlebar to the left and reaching in below
Locknut
the fairing cap, start the right side fairing screw (6).
Turn the handlebar to the right and start the fairing
screw (5) on the left side.
f.
Alternately tighten the four fairing screws on the
inner fairing side to 20-30 in-lbs (2.7-3.4 Nm).
g. Moving to the front of the vehicle, tighten the outer
fairing screws below the windshield to 25-30 in-lbs
(2.8-3.4 Nm).
11.
Obtain the new strobe headlamp assembly from the kit.
Ring Terminal
Reaching in through the headlamp opening of the fairing,
and Lockwasher
i04392
retrieve the two headlamp strobe harnesses. Mate the
harnesses to the connectors at the back of the head-
lamp.
Figure 8-9. Install Ground Wire Ring Terminal
12.
See Figure 8-4. Align holes in new headlamp assembly
with those in fairing (headlamp door bracket at bottom).
Install the four TORX screws.
9. Route the red (power) wire upward toward the right side
13.
See Figure 8-3. Fit the square-shaped portion of the
of the plastic storage box and proceed as follows:
headlamp door spring into the slot at the top of the head-
lamp housing and then snap the headlamp door (chrome
NOTE
ring) into place. Install the Phillips screw at the bottom of
The flasher is cable strapped to the fairing on the right side of
the headlamp door.
the storage box.
1WARNING
a. Locate the flasher and remove the three-place con-
nector. Cut the gray/black wire at a point about 4-5
Always connect the positive battery cable first. If the pos-
inches (101.6-127.0 mm) from the connector.
itive cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
b. Strip 3/8 inch (9.5 mm) of insulation from both ends
sion which could result in death or serious injury.
of gray/black wire. Strip 3/8 inch (9.5 mm) of insula-
(00068a)
tion from red (power) wire from power supply.
14. Install battery cables, positive cable first.
c. Obtain the sealed butt splice connector from the kit.
15. Test strobe headlamp for proper operation.
Butt splice the red (power) wire to the gray/black
wire. See Section B.5 SEALED BUTT SPLICE
CONNECTORS in the 2004 Touring Models Service
Manual (Part No. 99483-04). See Figure 8-10.
d. Connect the three-place connector to the flasher
Flasher
and carefully tuck the wiring in and around the exist-
Gray/Black
ing wiring.
Wire
e. Obtain cable strap from kit and fix location of wiring.
Be sure wiring is positioned so that it will not be
pinched or kinked when outer fairing is installed.
10.
Install outer fairing as follows:
a. Place the outer fairing on the motorcycle.
Sealed Butt
b. Place the windshield in position on the inner fairing
Splice Connector
aligning the slots with the threaded inserts.
Red (Power)
c. See Figure 8-6. Using a T27 TORX drive head, start
Wire
i04393
the three outer fairing screws (1, 2 and 3) and flat
washers just below the windshield.
Figure 8-10. Flasher and Flasher Connector
2004 FLT Police: Electrical
8-7
HOME
f.
See Figure 8-12. While holding the power supply,
Metal Plate
i04394
remove the locknut. Remove screw and lockwasher
allowing power supply to seat inside the nacelle.
Route black (ground) wire to the rear of the metal
plate. Install ring terminal and lockwasher on screw.
Slide the screw through the metal plate and power
Locknut and
supply and install locknut. Tighten locknut securely.
Lockwasher
g.
Locate the white two-place connector inside the
headlamp nacelle (pursuit switch) and carefully pull
Strobe
both connector and wiring free. Cut the gray/purple
Harnesses
wire at a point about 2-3 inches from the connector.
h.
Strip 3/8 inch of insulation from both ends of gray/
Power
purple wire. Strip
3/8 inch of insulation from red
Supply
(power) wire from power supply.
i.
Obtain the sealed butt splice connector from the kit.
Butt splice the red (power) wire to the gray/purple
Figure 8-11. Mount Strobe Power Supply (FLHP)
wire. See Section B.5 SEALED BUTT SPLICE
CONNECTORS in the 2004 Touring Models Service
Manual (Part No. 99483-04).
j.
Carefully tuck the wiring in and around the existing
16. FLHP: Install the power supply as follows:
wiring. Obtain cable strap from kit and fix location of
wiring. Be sure wiring is positioned so that it will not
NOTE
be pinched or kinked when headlamp housing is
installed.
When installing the power supply, note that it is not an exact
fit. It may be necessary to manipulate the power supply into
various positions to obtain the optimal alignment and posi-
17.
See Figure
8-13. Obtain the new strobe headlamp
tion. Also note that the hole in the metal plate is slightly larger
assembly from the kit. Reaching into the headlamp
than the hole in the power supply mount. While the overall fit
nacelle, retrieve the two headlamp strobe harnesses.
may appear less than perfect, the power supply will be secure
Mate the harnesses to the connectors at the back of the
headlamp.
once the hardware is fully tightened.
18.
Align holes in headlamp housing with those in headlamp
a. See Figure 8-11. Locate the metal plate on which
nacelle (headlamp door bracket at bottom). Install the
the power supply will be mounted. Remove the black
seven Phillips screws.
plastic wire retainer (Christmas Tree) from the hole
in the plate.
b. Obtain the power supply (with wiring), screw, lock-
washer and locknut from kit. Install lockwasher on
i04395
screw. Position the power supply, so that the upper
mounting hole is aligned with the hole in the metal
plate.
c. Moving to the rear of the handlebars, reach in under
the headlamp nacelle and slide the screw through
the holes in the metal plate and power supply.
Returning to the front of the motorcycle, loosely
install locknut.
d. Carefully pull out the two strobe harnesses, the red
Screw with
(power) wire and the black (ground) wire, so that it is
Ground Wire
free of the power supply and other wiring.
Ring Terminal
and Lockwasher
Metal Plate
e. Obtain ring terminal from kit. Strip 3/8 inch insulation
from end of black (ground) wire exiting power supply.
Using a wire crimpers, install and crimp ring terminal
to end of wire.
Figure 8-12. Install Ground Wire Ring Terminal
8-8
2004 FLT Police: Electrical
HOME
19. Fit the square-shaped portion of the headlamp door
spring into the slot at the top of the headlamp housing
and then snap the headlamp door (chrome ring) into
Strobe
place. Install the Phillips screw at the bottom of the head-
Harness
lamp door. See Figure 8-3.
Connectors
1WARNING
Always connect the positive battery cable first. If the pos-
itive cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion which could result in death or serious injury.
Headlamp
(00068a)
Assembly
20. Install battery cables, positive cable first.
21. Test strobe headlamp for proper operation.
i04396
Figure 8-13. Install Strobe Harness to Headlamp
2004 FLT Police: Electrical
8-9
HOME
STROBE KIT (PAR-36)
8.4
GENERAL
i03977
The Strobe Kit Par-36 (Part No. 69172-01) is designed for
Push Wire Down
installation on both FLHP and FLHTP model motorcycles
Through Stem
when equipped with the H-D Police Tour-Pak, and is available
from your Harley-Davidson Dealer.
1WARNING
The rider’s safety depends on the correct installation of
this kit. If the following installation procedures are not
within your capabilities, or if you do not have the correct
Tuck Ground Wire
tools, have your Harley-Davidson dealer perform this
Back Into Bucket
installation. Failure to do the installation correctly could
Cut Terminal
result in death or serious injury.
From Wire
Figure 8-14. Modify Existing Wiring
INSTALLATION
Black
Harness
1WARNING
Wires
To protect against shock and accidental start-up of vehi-
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury. (00048a)
White
Red
1WARNING
Always disconnect the negative battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
i03978
explosion which could result in death or serious injury.
(00049a)
Figure 8-15. Route Harness Wiring into Lamp Bucket
1. Disconnect battery cables, negative battery cable first.
7. Push the wire down through the mounting bracket stem
2. Remove fuel tank. See Section 9.4 FUEL TANK (FUEL
while carefully pulling it out the opposite side. Cut the
INJECTED) in the 2004 Touring Models Service Manual
wire where it exits the conduit. Tape the end of the wire
(Part No. 99483-04).
and tuck inside conduit.
3. Remove two socket head screws to free the left turn sig-
NOTE
nal assembly from the mounting bracket.
Tuck the black (ground) wire with terminal into the lamp
bucket so it is out of the way.
4. Remove Phillips screw to release chrome ring from
bucket of passing/pursuit lamp. Carefully pull the sealed
8. Obtain one of the strobe harnesses from kit and locate
beam unit out of the bucket.
the open end (3 wires, no connector).
5. Disconnect the wire terminals from the sealed beam unit.
9. Starting inside Tour-Pak, push the open end of the har-
ness through the right side straight fitting at the bottom of
6. See Figure 8-14. Locate the passing/pursuit lamp power
the Tour-Pak. Route harness along frame tube, under
wire (gray/black) and cut the terminal off.
fuel tank and along existing turn signal lamp conduit up
to front of motorcycle.
8-10
2004 FLT Police: Electrical
HOME
10. See Figure
8-15. Push the three harness wires up
Socket Head
through the mounting bracket stem and into the lamp
Screw
Recessed
bucket following the route used to remove the original
Area
power wire.
11. Obtain three socket terminals and one 3-place socket
housing from kit.
12. Install sockets on wires. See Section B.2 AMP MUL-
TILOCK ELECTRICAL CONNECTORS in the 2004 Tour-
ing Models Service Manual (Part No. 99483-04).
Turn Signal
13. Taking note of the numbers stamped on the socket hous-
Assembly
ing, install the terminals into their respective chambers.
Table 8-3. Terminal Location
i03979
TERMINAL WIRE COLOR
CHAMBER
Red
1
Figure 8-16. Install Turn Signal to Mounting Bracket
Black
2
White
3
i03980
NOTE
The red Par-36 Strobe is typically installed on the left side of
the motorcycle, while the blue strobe is installed on the right.
Strobe
Harnesses
14.
Obtain the red Par-36 strobe lamp from kit and mate the
harness connector with the left side strobe connector.
15.
Position the strobe within the lamp bucket and reinstall
the chrome ring using Phillips screw. Tighten securely.
Power Supply
16.
See Figure 8-16. Make sure conduit rests in the recess
Control Harness
of the clamp area as shown. Install the left turn signal
assembly to the mounting bracket using two socket head
screws. Tighten screws securely.
Figure 8-17. Connect Strobes to Power Supply Outlets
17.
Using the blue Par-36 strobe, perform steps 3-16 on the
right side of the motorcycle.
18.
Route the left and right strobe harnesses under the fuel
21. Obtain the power supply control harness and Instruction
tank then toward the rear of the motorcycle following the
Sheet J02192 from kit. Install harness following instruc-
same paths as the conduit for the left and right turn sig-
tions. Connect control harness to power supply.
nal lamps. Continue along the frame tubes and then back
into the opening in the Tour-Pak.
22. Install fuel tank. See Section 9.4 FUEL TANK (FUEL
INJECTED) in the 2004 Touring Models Service Manual
19.
Obtain three cable straps from kit and secure the strobe
(Part No. 99483-04).
harness to the frame (or turn signal lamp conduit) at suit-
able locations. Repeat step for the other harness.
1
WARNING
20.
See Figure 8-17. Connect the strobe harness connectors
Always connect the positive battery cable first. If the pos-
to the power supply as shown.
itive cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
NOTE
sion which could result in death or serious injury.
(00068a)
Depending on which of the four outlets are chosen, the flash
pattern can be set so lamps flash alternately or simulta-
23. Install battery cables, positive cable first.
neously. You may want to experiment with the various outlets
until the desired flash pattern is obtained.
24. Close Tour-Pak and test strobe lights for proper opera-
tion.
2004 FLT Police: Electrical
8-11
HOME
POLE LAMP
8.5
GENERAL
6105
Harley-Davidson police model motorcycles are shipped from
the factory with the brackets necessary to mount a police pole
lamp.
INSTALLATION
1.
Rotate knurled rings to remove from pole lamp.
Knurled Ring
(Bevel Up)
Lower
2.
Cut all but approximately 14 inches (356 mm) of wire off
Bracket
pole lamp.
3.
Crimp terminals on wires and install in pin side of 2-place
Deutsch connector. See Section B.1 DEUTSCH ELEC-
TRICAL CONNECTORS, in the 2004 Touring Models
Service Manual (Part No. 99483-04).
Knurled Ring
(Bevel Down)
NOTE
The black wire must go to the black and the green/red wire
must go to the red. The lamp will not work if wires are not
matched correctly.
4.
Slide pole through grommet in luggage rack. Spray glass
Figure 8-18. Install Pole Lamp
cleaner on pole to lubricate surfaces, if necessary.
5.
Install knurled ring at bottom of pole with the beveled
6106
side up. See Figure 8-18.
6.
Insert pole through lower bracket and install second
Connector
knurled ring with the beveled side down.
7.
Alternately tighten knurled rings to lock position of pole.
8.
Mate pin and socket halves of 2-place Deutsch connec-
tor. Secure connector and conduit to saddlebag guard
and saddlebag support bracket using new cable straps.
See Figure 8-19.
Cable
Strap
Figure 8-19. Install Cable Straps
8-12
2004 FLT Police: Electrical
HOME
SIREN AND PUBLIC ADDRESS SYSTEM
8.6
GENERAL
TROUBLESHOOTING
The siren and public address (PA) system consists of: ampli-
If siren and/or PA system are inoperative, refer to the trouble-
fier, speaker, microphone, microphone jack, siren, horn/siren
shooting chart below.
switches and connecting wiring.
The Whelen 100 watt siren amplifier, WS-320, (Part No.
91156- 93) uses a waterproof connector.
Table 8-4. Troubleshooting
PROBLEM
CAUSE
SOLUTION
Siren and PA not
Connector not properly installed.
Be sure connector is properly oriented and screw is tight.
operational.
Apply wheel bearing grease to connector pins and sockets
to reduce corrosion.
Siren and PA not
Faulty amplifier or speaker.
Substitute a known good amplifier and check system func-
operational.
tion. If system is still inoperative, substitute a known good
speaker and check for system operation.
NOTE
If neither an amplifier nor speaker is available, see Section
8.8 SPEAKER, TROUBLESHOOTING in this manual. If
speaker checks “good”, continue at Section 8.7 VOLTAGE
CHECKS, RESISTANCE AND CONTINUITY CHECKS.
Siren functions, PA
PA gain control not properly
See Section 8.10 SIREN AMPLIFIER, GAIN ADJUST-
not operational.
adjusted.
MENT.
Inoperative microphone.
Substitute a known good microphone. If known good micro-
phone is not available, see Section 8.11 MICROPHONE
AND JACK.
Microphone jack or connecting
leads do not provide good electri-
See Section 8.11 MICROPHONE AND JACK.
cal connection.
Wrong microphone.
Some Whelen microphones are electrically different and
cannot be interchanged.
NOTE
Microphones used with WS-320 amplifiers should be
marked 010245648-00.
2004 FLT Police: Electrical
8-13
HOME
VOLTAGE CHECKS
8.7
ALL MODELS
Table 8-5. Voltage Checks at
Motorcycle Siren Harness
See Figure 8-20, Table 8-5, and the appropriate wiring dia-
gram in Section 8.15 WIRING DIAGRAMS. Measure the volt-
VOLTAGE MEASURED AT
Switch
ages at the motorcycle siren harness connector (pins 1C, 2F,
PINS
Switch
Position
and 1F) as listed in Table 8-5. The Ignition/Light Key Switch
1C
2F
1F
must at IGNITION while checking voltages. Connect common
or negative lead of voltmeter to a good ground. If voltages
Do Not
Do Not
Ignition
ON
12 Vdc
specified in Table 8-4 are not present, refer to applicable wir-
Measure
Measure
ing diagram to diagnose the problem.
Siren
OFF
Do Not
0 Vdc
12 Vdc
Measure
Siren/Horn
ON
Siren
ON
Do Not
12 Vdc
0 Vdc
p0011a8x
Siren/Horn
OFF
Measure
Siren/Horn
ON
Do Not
12 Vdc
12 Vdc
Measure
Siren
ON
To Motorcycle Harness
Pin
Description
1A
Ground (-) to motorcycle
3A
Speaker (+)
12 Vdc supply to amplifier.
1C
Present when ignition is on.
3C
Speaker (-)
Air horn enabled - 12 Vdc is present when
1D
connected to horn circuit and button is
pushed. See Section 8.12 AIR HORN.
2D
Push-to-talk (mic)
1E
Mic (-)
Yelp, 12 Vdc is present when siren/horn
1F
switch is ON.
Wail, 12 Vdc is present when siren switch
2F
is ON.
3F
Mic (+)
Figure 8-20. Pin Connector
8-14
2004 FLT Police: Electrical
HOME
RESISTANCE AND CONTINUITY
CAUTION
CHECKS
Do not connect ohmmeter probes to a “live” circuit or
ohmmeter will be damaged.
See Figure 8-20 and Table 8-6 below. Perform checks with
both battery cables removed.
If ohmmeter readings in Table 8-5 are not obtained, refer to
Section 8.15 WIRING DIAGRAMS and diagnose the problem
using the appropriate schematic.
Table 8-6. Resistance/Continuity Checks (Battery Cables Disconnected)
OHMMETER PROBE
OHMETER
COMPONENT AND WIRE BEING CHECKED
LOCATION (PINS)
3A & 3C
6-10 Ohms
Speaker coil voice and leads from pin connector to speaker.
3F & 1E
Infinity
Verifies microphone circuit is not shorted.
Verifies PTT switch is functioning and two microphone leads from
connector have continuity.
Press and hold PTT switch
0-1 Ohms
with probes on pins 2D & 1E.
For microphone jack connections, see Figure 8-28. To check third
lead, place one probe on pin 3F and the other probe on tip terminal of
microphone jack.
Common probe to ground,
0-1 Ohms
Checks amplifier to motorcycle ground.
other probe to pin 1A.
2004 FLT Police: Electrical
8-15
HOME
SPEAKER
8.8
TROUBLESHOOTING
Connector
If speaker is inoperative, check voice coil impedance as fol-
Bolt
lows:
1. Disconnect speaker leads and measure impedance by
connecting ohmmeter leads to speaker leads.
2. Measured resistance must be 6-10 ohms.
3. Replace speaker if resistance is not within specification.
NOTE
A binding voice coil or torn speaker cone could also cause
speaker to be inoperative. To check for these conditions, con-
nect speaker to shop stereo. If speaker works, it’s functional.
Screw
4579p
REMOVAL
Figure 8-21. Speaker (Rear View)
1. Cut two cable straps to release 2-place Deutsch connec-
tor and cable from top rail of right side engine guard. Dis-
4578p
connect pin and socket halves. See Figure 8-21.
2. Reaching into speaker horn, remove flange locknuts, flat
washers and rubber washers from top and side bolts.
Pull bolts from speaker horn and mounting bracket.
Remove flat washers and rubber washers between horn
and mounting bracket.
3. Remove bolt to release back of speaker from mounting
bracket.
Drain
INSTALLATION
Hole
1. Position speaker in mounting bracket aligning holes in
speaker with those in bracket.
2. Loosely install bolt to fasten mounting bracket to back of
speaker. See Figure 8-21.
Figure 8-22. Speaker (Bottom View)
3. Position rubber washers and flat washers between holes
in horn and mounting bracket, rubber washers against
horn.
6.
Mate pin and socket halves of 2-place Deutsch connec-
NOTE
tor. Install two new cable straps to secure connector and
Be sure the speaker voice coil drain hole is facing down to
cable to top rail of right side engine guard.
provide good drainage. Hole is located 180° from “Made in
USA” logo. See Figure 8-22.
CAUTION
4. Slide bolts through mounting bracket, flat washers, rub-
Use of a high pressure washer on or near speaker can
ber washers and horn. Reaching into speaker horn,
result in damage.
install rubber washers, flat washers and flange locknuts
on bolts.
NOTE
5. Alternately tighten all fasteners. Rubber washers should
If speaker center cone is removed to make installation easier,
deform slightly when flange locknuts are properly tight-
apply 2-3 drops of Loctite 242 (blue) on center cone screw
ened.
and then tighten until snug.
8-16
2004 FLT Police: Electrical
HOME
HANDLEBAR SWITCHES
8.9
6. While holding down the ramp, pull both switches from the
HORN/SIREN YELP SWITCH
housing.
7. Cut the wires from the old switches as follows:
NOTE
● Yellow/Black wire: 1-1/4 inches (32 mm)
Consult the 2004 Touring Models Service Manual (Part No.
● Orange/White wires: 1-7/8 inches (48 mm)
99483-04) for assembly/disassembly instructions and general
repair procedures.
● Brown/Black wire: 1-1/2 inches (38 mm)
NOTE
Removal
Replacement Horn/Siren Yelp Switch wires are cut to length
and partially stripped (Yellow/Black wire: 3-3/4 inches (95
1.
See LEFT SIDE HANDLEBAR SWITCHES, DISASSEM-
mm); Orange/White wires: 3-1/2 inches (89 mm); Brown/
BLY, page 8-70 of the 2004 Touring Models Service Man-
Black wire: 3-3/8 inches (86 mm).
ual (Part No. 99483-04).
8.
See GENERAL REPAIR PROCEDURES, page 8-78 of
2.
From inside the switch housing, carefully cut cable strap
the
2004 Touring Models Service Manual
(Part No.
to free conduit from the turn signal switch bracket.
99483-04).
3.
Remove the Phillips screw (with lockwasher) to release
the turn signal switch bracket. Remove the switch
NOTE
assembly from the housing.
If the ramp and spring mechanism becomes loose, install as
follows: Using the blade of a small screwdriver, compress
4.
Remove the two T8 TORX screws and the Phillips screw
spring and place in wider portion of channel at bottom of
(with lockwasher) to release the lower bracket. Carefully
ramp. Verify that spring is evenly compressed and is not
lift out the bracket so as not to disturb the spring-loaded
cocked or skewed. Push spring so that it bottoms in channel.
ramp on the inboard side of the housing.
With tab side of ramp facing inboard and hook end on switch
5.
Carefully remove the keycap disengaging slot from hook
side of casting, install ramp so that narrow channels engage
on ramp.
pins cast into housing.
f1237a2x
Right Handlebar Switch Housings
Upper Switch Housing:
● Engine Start Switch
● Engine Stop Switch: Off/Run
Lower Switch Housing:
● Turn-Right Signal Switch
● Front Stoplight Switch
● Pole and Pursuit Lamp Switch:
Off/Aux(iliary)/Purs(uit)
Left Handlebar Switch Housings
Upper Switch Housing:
● Siren Switch: On/Off
● Light Switch: Hi(gh) and Lo(w) Beam
Lower Switch Housing:
● Turn-Left Signal Switch
● Horn/Siren Yelp Switch
● Clutch/Starter Interlock Switch
f1236a2x
Figure 8-23. Police Handlebar Switch Assemblies
2004 FLT Police: Electrical
8-17
HOME
Installation
from end of conduit. Cut any excess cable strap material.
If necessary, bend angular arm of bracket downward to
1.
Install the switches in the housing with contacts facing
firmly secure Clutch Interlock Switch in installed position.
tabs on ramp. For best results, install one switch at a
14. See LEFT SIDE HANDLEBAR SWITCHES, ASSEMBLY,
time. Ribs cast in lower housing hold switches in posi-
page 8-80 of the 2004 Touring Models Service Manual
tion.
(Part No. 99483-04).
The Horn switch with the Yellow/Black lead (pivot point
towards rider) is installed at the bottom, while the Siren
Yelp switch with the Brown/Black lead
(pivot point
towards the front) is at the top. Route switch wires in
CLUTCH INTERLOCK SWITCH
channel on the outboard side of the ribbed area.
2.
Install the keycap engaging slot with hook on ramp.
NOTE
3.
Install lower bracket sliding pin through keycap and
All Police models have a Clutch Interlock Switch that prevents
engaging hole in lower casting.
the motorcycle from starting (even in Neutral) if the clutch
lever is not pulled in.
4.
Slide T8 TORX screws through holes in lower bracket
and switches and thread into lower casting until snug.
Removal
5.
Install Phillips screw (with lockwasher), to secure lower
bracket to threaded boss in housing. Verify operation of
1.
See LEFT SIDE HANDLEBAR SWITCHES, DISASSEM-
Horn and Siren Yelp switches to ensure that both are
BLY, page 8-70 of the 2004 Touring Models Service Man-
spring returned.
ual (Part No. 99483-04).
6.
Install Clutch Interlock Switch in bore of lower switch
2.
From inside the switch housing, carefully cut cable strap
housing, if loose.
to free conduit from the turn signal switch bracket.
7.
Insert tapered end of new 7 inch cable strap into round
3.
Remove the Phillips screw (with lockwasher) to release
hole in turn signal switch bracket and then feed back
the turn signal switch bracket. Remove the switch
through using the adjacent hole. Reserve the oblong
assembly from the housing.
hole for the bracket screw.
4.
Remove the Clutch Interlock Switch from the housing.
NOTE
5.
Cut wires 1/4 inch (6 mm) from old switch. Discard switch
Be sure that all splices are positioned above the turn signal
assembly.
switch bracket.
NOTE
8.
Place the turn signal switch assembly into the housing
aligning the oblong hole in the bracket with the lower
Replacement Clutch Interlock Switch wires are cut to length
bracket weld nut. Be sure that bracket is fully seated.
(looking at backside, left side switch wire is 2-1/4 inches (57
Tabs on each side are captured in slots cast into switch
mm), right side is 2-3/4 inches (70 mm) and partially stripped.
housing.
6.
See GENERAL REPAIR PROCEDURES, page 8-78 of
9.
Install Phillips screw (with lockwasher) to secure bracket
the
2004 Touring Models Service Manual
(Part No.
inside housing.
99483-04).
CAUTION
Installation
If routed incorrectly, wires may be pinched by casting or
1.
Install Clutch Interlock Switch in bore of lower switch
handlebar resulting in switch failure.
housing.
10. Loop switch wires so that spliced lengths are positioned
2.
Insert tapered end of new 7 inch cable strap into round
directly over bracket screw.
hole in turn signal switch bracket and then feed back
11. Capturing conduit about
1/4 inch
(6 mm) from end,
through using the adjacent hole. Reserve the oblong
securely tighten cable strap to draw conduit to bracket.
hole for the bracket screw.
Remove any excess cable strap material.
NOTE
12. On opposite side, install second 7 inch cable strap cap-
Be sure that all splices are positioned above the turn signal
turing conduit and wire splices. Securely tighten cable
switch bracket.
strap to draw splices to conduit. Remove any excess
cable strap material.
3.
Place the turn signal switch assembly into the housing
13. Route wire bundle to upper switch housing below and
aligning the oblong hole in the bracket with the lower
then forward of the main wire harness positioning conduit
bracket weld nut. Be sure that bracket is fully seated.
in channel next to angular arm of bracket. Secure bundle
Tabs on each side are captured in slots cast into switch
to arm placing new cable strap 1/4 inch (6 mm)
housing.
8-18
2004 FLT Police: Electrical
HOME
PURSUIT/AUXILIARY SWITCH
Clutch Interlock
Switch
Removal
1. See RIGHT SIDE HANDLEBAR SWITCHES, DISAS-
SEMBLY, page 8-70 of the 2004 Touring Models Service
Manual (Part No. 99483-04).
2. From inside the switch housing, carefully cut cable strap
to free conduit from the turn signal switch bracket.
3. Remove the Phillips screw (with lockwasher) to release
the turn signal switch bracket. Remove the switch
assembly from the housing.
4. Remove the two T8 TORX screws and the Phillips screw
(with lockwasher) to release the lower bracket. Remove
the bracket from the housing.
5. Pull both switches from the housing.
6. Cut the wires from the old switches as follows:
● Gray/Black wire: 1-1/2 inches (38 mm)
● Orange/Violet wires: 1-7/8 inches (48 mm)
p0040a8x
● Green/Red wire: 1-1/4 inches (32 mm)
NOTE
Figure 8-24. Lower Switch Housing
Replacement Pursuit/Auxiliary Switch wires are cut to length
and partially stripped (Gray/Black wire: 2 inches (51 mm);
Orange/Violet wires: 1-7/8 inches (48 mm); Green/Red wire:
4.
Install Phillips screw (with lockwasher) to secure bracket
1-3/4 inches (45 mm).
inside housing.
7. See GENERAL REPAIR PROCEDURES, page 8-78 of
the
2004 Touring Models Service Manual
(Part No.
CAUTION
99483-04).
If routed incorrectly, wires may be pinched by casting or
8. Move keycap to the OFF position. Install the switches in
handlebar resulting in switch failure.
the housing with contacts facing the recessed area on
the ramp. Ribs cast in lower housing hold switches in
5. Loop switch wires so that spliced lengths are positioned
position.
directly over bracket screw.
The Auxiliary switch with the Gray/Black lead is installed
6. Capturing conduit about
1/4 inch
(6 mm) from end,
at the bottom, while the Pursuit switch with the Green/
securely tighten cable strap to draw conduit to bracket.
Red lead is at the top. Route switch wires into corner
Remove any excess cable strap material.
space outside of the ribbed area.
NOTE
7. On opposite side, install second 7 inch cable strap cap-
turing conduit and wire splices. Securely tighten cable
If the keycap and ramp mechanism requires replacement,
strap to draw splices to conduit. Remove any excess
install as follows: Slide ramp upward to remove from keycap
cable strap material.
shaft. Remove keycap from switch housing. Install spring into
hole on inboard side of new keycap. Position ball on end of
8. Route wire bundle to upper switch housing below and
spring. Use a small amount of grease to hold ball in place.
then forward of the main wire harness positioning conduit
Install keycap so that ball engages detente in switch housing.
in channel next to angular arm of bracket. Secure bundle
Slide ramp over keycap shaft so that tongues on ramp
to arm placing new cable strap 1/4 inch (6 mm) from end
engage grooves in keycap shaft.
of conduit. Cut any excess cable strap material. If neces-
sary, bend angular arm of bracket downward to firmly
secure Clutch Interlock Switch in installed position.
Installation
9. See LEFT SIDE HANDLEBAR SWITCHES, ASSEMBLY,
1.
Install lower bracket with the weld nut side down.
page 8-80 of the 2004 Touring Models Service Manual
2.
Slide the T8 TORX screws through holes in lower bracket
(Part No. 99483-04).
and switches and thread into lower casting until snug.
2004 FLT Police: Electrical
8-19
HOME
3.
Install Phillips screw (with lockwasher), to secure lower
bracket to threaded boss in housing. Work Auxiliary and
Pursuit switches to ensure smooth operation.
7 Inch
Cable Strap
4.
See Figure 8-25. Insert tapered end of new 7 inch cable
Bracket
strap into round hole in turn signal switch bracket and
then feed back through using the adjacent hole. Reserve
the oblong hole for the bracket screw.
NOTE
Be sure that all splices are positioned above the turn signal
switch bracket.
5. Place the turn signal switch assembly into the housing
aligning the oblong hole in the bracket with the lower
bracket weld nut. Be sure that bracket is fully seated.
Tabs on each side are captured in slots cast into switch
housing.
Right Turn
6. Install Phillips screw (with lockwasher) to secure turn sig-
Signal Switch
nal switch bracket inside housing.
f1294x2x
CAUTION
If routed incorrectly, wires may be pinched by casting or
Figure 8-25. Insert Cable Strap in Switch Bracket
handlebar resulting in switch failure.
7.
Loop switch wires so that spliced lengths are positioned
10.
Route wire bundle to upper switch housing in channel
directly over bracket screw.
next to angular arm of bracket. Secure bundle to arm
8.
Capturing conduit about
1/4 inch
(6 mm) from end,
placing new cable strap 1/4 inch (6 mm) from end of con-
securely tighten cable strap to draw conduit to bracket.
duit. Cut any excess cable strap material. If necessary,
Remove any excess cable strap material.
bend angular arm of bracket downward to firmly secure
Front Stoplight Switch in installed position.
9.
On opposite side, install second 7 inch cable strap cap-
turing conduit and wire splices. Securely tighten cable
11.
See RIGHT SIDE HANDLEBAR SWITCHES, ASSEM-
strap to draw splices to conduit. Remove any excess
BLY, page 8-80 of the 2004 Touring Models Service Man-
cable strap material.
ual (Part No. 99483-04).
8-20
2004 FLT Police: Electrical
HOME
SIREN AMPLIFIER
8.10
AMPLIFIER
4577p
Part No. /Description
91156-93
Whelen 100 Watt (WS-320) Siren Amplifier
REMOVAL
See Figure 8-26. The Whelen amplifiers are mounted to the
mounting bracket in front of the left saddlebag with screws
and washers.
1.
Pull back rubber boot.
2.
Loosen connector screw and disconnect connector.
3.
Remove mounting screws.
INSTALLATION
1. Position amplifier as shown in Figure 8-26.
2. Install mounting screws and tighten to 6 ft-lbs (8 Nm).
Figure 8-26. Whelen Amplifier Mounting
3. Plug in the connector and tighten connector screw.
4. Install rubber boot.
GAIN ADJUSTMENT
NOTE
The Public Address (PA) amplifier gain is set at the manufac-
turer and normally does not require adjustment. If it has feed-
back, low volume or distortion, adjust the gain as follows:
1. Remove access screw to expose the internal adjusting
screw. See Figure 8-27.
2. Press Push-To-Talk switch on microphone, speak into
microphone in normal manner and while speaking, care-
fully turn internal adjusting screw, with a proper size
screwdriver, to obtain maximum distortion free output.
Adjustment Screw
(Under Access Hole Screw)
3. Replace access screw.
4575p
Figure 8-27. PA Gain Adjustment Screw
2004 FLT Police: Electrical
8-21
HOME
MICROPHONE AND JACK
8.11
FLHP: Remove headlamp assembly. See HEADLAMP
MICROPHONE
ASSEMBLY, REMOVAL, page 8-25 of the 2004 Touring
Models Service Manual (Part No. 99483-04).
Troubleshooting
2. Remove nut and washer to release microphone jack.
1.
To verify that Push-To-Talk (PTT) switch is functioning
3. Unsolder leads from jack terminals.
properly, connect probes of ohmmeter to tip and ring of
microphone plug. See Figure 8-28.
2.
With PTT switch off (not depressed) there must be no
INSTALLATION
continuity.
3.
Depress PTT switch. Ohmmeter must read 0-1 ohm.
1.
Solder leads to jack terminals as shown in Figure 8-28.
Replace microphone if there is no continuity.
2.
Install microphone jack and secure with washer and nut.
3. FLHTP: Install outer fairing. See OUTER FAIRING/
WINDSHIELD, INSTALLATION, page 2-120 of the 2004
REMOVAL
Touring Models Service Manual (Part No. 99483-04).
1. FLHTP: Remove outer fairing. See OUTER FAIRING/
FLHP: Install headlamp assembly. See HEADLAMP
WINDSHIELD, REMOVAL, page 2-120 of the 2004 Tour-
ASSEMBLY, INSTALLATION, page 8-25 of the 2004
ing Models Service Manual (Part No. 99483-04).
Touring Models Service Manual (Part No. 99483-04).
4
5
p0013a8x
R
W
To Pin Connector
3
BE
2
Microphone Jack
1
6
Microphone Plug
1.
Sleeve
2.
Ring
3.
Tip
Microphone Jack
Microphone Plug
4.
Ring
5.
Sleeve
6.
Tip
Figure 8-28. Microphone and Jack Connections
8-22
2004 FLT Police: Electrical
HOME
AIR HORN
8.12
ENABLING AIR HORN
Left Handlebar Controls [24]
(Gray)
1. FLHTP: Remove outer fairing. See OUTER FAIRING/
WINDSHIELD, REMOVAL, page 2-120 of the 2004 Tour-
ing Models Service Manual (Part No. 99483-04).
FLHP: Remove headlamp assembly. See HEADLAMP
ASSEMBLY, REMOVAL, page 8-25 of the 2004 Touring
Models Service Manual (Part No. 99483-04).
2. Locate the gray 12-place Deutsch connector for the left
side handlebar switch controls [24]. See Figure 8-29 for
FLHTP models, Figure 8-30 for FLHP models.
3. Remove the secondary lock from the socket half of the
connector and proceed as follows:
a. Pull seal pin from cavity 11.
b. Remove Y/BK wire from cavity 6.
c. Install Y/BK wire in cavity 11. See Figure 8-31.
d. Push seal pin into cavity 6.
p0118x8x
NOTE
Figure 8-30. Headlamp Nacelle (FLHP)
For instructions on properly removing and installing wire ter-
minals, see APPENDIX B.1, DEUTSCH ELECTRICAL CON-
NECTORS, REMOVING/INSTALLING SOCKETS, page B-1
MOVE Y/BK WIRE TO CAVITY
of the 2004 Touring Models Service Manual (Part No. 99483-
11 IF USING WHELEN SIREN
04).
AMPLIFIER & AIR HORN
FUNCTION IS DESIRED
[24B]
(GRAY)
4. Place a rag in the speaker cone to reduce volume. Turn
O/W
1
the Ignition/Light Key Switch to IGNITION and test oper-
Y
2
BE
3
ation of air horn.
W
4
FROM
W/V
5
MAIN
Y/BK
6
HARNESS
BK/R
7
[24A]
BK/R
8
PK/BK
9
Left Handlebar Controls [24]
TN/BK
10
(Gray)
Y/BK
11
12
CLUTCH
LOCKOUT SWITCH
SIREN OFF/RUN
SWITCH
HEADLAMP HI/LO
SWITCH
LEFT
DIRECTIONAL
SWITCH
HORN/SIREN
SWITCH
p0042c8x
Figure 8-31. Enabling the Air Horn (All Models)
5. FLHTP: Install outer fairing. See OUTER FAIRING/
WINDSHIELD, INSTALLATION, page 2-120 of the 2004
Touring Models Service Manual (Part No. 99483-04).
p0058x8x
FLHP: Install headlamp assembly. See HEADLAMP
ASSEMBLY, INSTALLATION, page 8-25 of the 2004
Figure 8-29. Inner Fairing (FLHTP)
Touring Models Service Manual (Part No. 99483-04).
2004 FLT Police: Electrical
8-23
HOME
TOUR-PAK
8.13
GENERAL
i03730
Phillips Screws
The Tour-Pak Kit (White- Part No. 53238-01; Black- Part No.
with Washers
53239-01) is designed for installation on both FLHP and
FLHTP model motorcycles and is available from your Harley-
Davidson Dealer.
1WARNING
The rider’s safety depends on the correct installation of
this kit. If the following installation procedures are not
within your capabilities, or if you do not have the correct
tools, have your Harley-Davidson dealer perform this
installation. Failure to do the installation correctly could
Luggage
Hex Head
result in death or serious injury.
Rack Spacer
Screws
Figure 8-32. Remove Radio Tray and Hardware
INSTALLATION
1.
See Figure 8-32. Remove the five hex head cap screws
i03731
Strobe Head
and two smaller Phillips screws (with washers) securing
Connectors
existing radio tray to mounting rail. Leave the two rectan-
Nut
gular license plate spacers and set aside three remain-
ing spacers. Discard screws and washers, but save nuts
for installation later. Discard radio tray.
Nut
2.
See Figure 8-33. Carefully remove Tour-Pak assembly
and hardware from shipping container. Open Tour-Pak.
Remove the three nuts securing the power supply
mounting plate to the bottom of the Tour-Pak. Save for
reinstallation.
3.
Note connector locations for reinstallation and discon-
nect the strobe head connectors from the power supply.
Nut
4.
See Figure 8-34. Set power supply aside temporarily.
Raise and position (lean) the mounting plate up against
Figure 8-33. Remove Plate Securing Power Supply
the front side of Tour-Pak to provide access to the Tour-
Pak permanent mounting holes. If necessary, use a
cable strap to hold plate in place. Temporarily set Tour-
i03732
Pak assembly aside.
Power Supply
Mounting Plate
Leaning Toward
Front of Tour-Pak
Figure 8-34. Provide Room For Mounting Tour-Pak
8-24
2004 FLT Police: Electrical
HOME
5. See Figure 8-35. Remove the quick release seat pin clip
from the seat pin and pivot the seat forward as far as
i03733
Seat Pin
possible. It may be necessary to tie or brace seat in the
full forward position.
6. Remove the two nuts and washers securing the trim
panel assembly to the fender and remove panel. Save
hardware and panel for reinstallation.
Cut Cable
1WARNING
Straps
Securing
To protect against shock and accidental start-up of vehi-
Pole Lamp
cle, disconnect the negative battery cable before pro-
Harness
Trim Panel
ceeding. Inadequate safety precautions could result in
Nuts
death or serious injury. (00048a)
1WARNING
Figure 8-35. Remove Trim Panel
Always disconnect the negative battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
i03734
explosion which could result in death or serious injury.
(00049a)
7.
Disconnect battery cables, negative battery cable first.
Tour-Pak Mounting
8.
Cut the two cable straps securing the pole lamp harness
Bolts (with Washers)
to the support rail. Discard cable straps. Route pole lamp
harness away from Tour-Pak mounting area.
9.
See upper frame of Figure 8-36. Return to the Tour-Pak.
Using parts from kit, pre-install four long hex head bolts
with washers from inside bottom of Tour-Pak at four per-
Luggage
License Plate
manent mounting holes.
Rack Spacer
Bracket Spacer
10.
Raise the Tour-Pak up and position onto rack with four
mounting bolts aligned with four holes in support rail (two
on each side).
See lower frame of Figure 8-36. Make sure the two
license plate bracket spacers remain in position and
bolts can pass through them. Obtain the two rectangular
Washers
luggage rack spacers and four nuts saved from step 2.
and Nuts
i03735
Obtain four new washers from kit and loosely install
washers and nuts to secure Tour-Pak to support rail.
Figure 8-36. Install Tour-Pak Mounting Hardware
11.
Obtain rear mounting block (with1 hole), hex head bolt
and two flat washers from kit. Also obtain rectangular
spacer and nut saved from step 1.
i03736
Mounting
Block
12.
See Figure 8-37. Install washer to bolt and position bolt
above hole at rear center Tour-Pak above rear block
mounting position.
13.
Orient rear mounting block (with hole running vertical)
and position between recessed area of Tour-Pak (near
center) and rail support. Install bolt through Tour-Pak,
rear block and rail, then loosely Install spacer followed by
Spacer
washer and nut.
Washer
and Nut
Figure 8-37. Install Tour-Pak Mounting Block
2004 FLT Police: Electrical
8-25
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