Harley Davidson 2004 Touring Models. Service Manual — page 52

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3. Using a T27 TORX drive head, loosen the upper screw

SWITCH REPAIR/REPLACEMENT

securing the handlebar clamp to the clutch lever bracket.

Remove the lower clamp screw with flat washer.

RIGHT SIDE HANDLEBAR SWITCHES

4. See SPECIFIC REPAIR PROCEDURES, UPPER

SWITCH HOUSINGS for upper switch housing switches,

DISASSEMBLY

LOWER SWITCH HOUSINGS for lower switch housing

switches.

CAUTION

Do not remove the switch housing assembly without first

placing the 5/32 inch (4.0 mm) cardboard insert between

SPECIFIC REPAIR PROCEDURES

the brake lever and lever bracket. Removal without the

insert may result in damage to the rubber boot and

plunger of the Front Stoplight Switch.

NOTE

Regardless of model or option, all vehicles use the same

NOTE

upper switch housings.

Use the eyelet of an ordinary cable strap if the cardboard

insert is not available.

UPPER SWITCH HOUSINGS

Place the cardboard insert between the brake lever and

lever bracket.

NOTE

2. Using a T25 TORX drive head, remove the upper and

Replace the Engine Stop and Engine Start Switches as a

lower switch housing screws.

single assembly even if only one switch is determined to be

faulty.

If replacing lower housing switches, proceed to step 4. If

replacing upper housing switches, proceed to step 8.

RIGHT SIDE HANDLEBAR (ALL MODELS)

4. Using a T27 TORX drive head, loosen the upper screw

● Engine Stop Switch: OFF/RUN

securing the handlebar clamp to the master cylinder

housing. Remove the lower clamp screw with flat

● Engine Start Switch

washer.

[Continued from RIGHT SIDE HANDLEBAR

Remove the brass ferrules from the notches on the

SWITCHES, DISASSEMBLY, on this page.]

inboard side of the throttle control grip. Remove the fer-

rules from the cable end fittings.

From inside the switch housing, remove the Phillips

screw to release the bracket. Remove the bracket and

Remove the friction shoe from the end of the tension

switch assembly from the housing. See Figure 8-95.

adjuster screw (non cruise equipped models only).

Move cable conduit from beneath wing of bracket. Cut

NOTE

wires 1/4 inch (6.4 mm) from old switches. Discard old

The friction shoe is a loose fit and may fall out or become dis-

switch and bracket assembly.

lodged if the lower switch housing is turned upside down or

Slide conduit forward over severed ends of switch wires

shaken.

and cut off 1/2 inch (12.7 mm) of conduit material. Push

Remove the throttle control grip from the end of the han-

conduit back to access switch wires.

dlebar.

Separate new Engine Stop Switch and Start Switch

See SPECIFIC REPAIR PROCEDURES, UPPER

wires into two bundles.

SWITCH HOUSINGS for upper switch housing switches,

NOTE

LOWER SWITCH HOUSINGS for lower switch housing

switches.

Replacement Stop Switch and Start Switch wires are cut to

length (2-1/2 inches and 2 inches, respectively) and partially

stripped.

LEFT SIDE HANDLEBAR SWITCHES

See GENERAL REPAIR PROCEDURES in this section.

Loop switch wires so that spliced lengths are positioned

DISASSEMBLY

as shown in Figure 8-96. Route wires downstream of

Using a T25 TORX drive head, remove the upper and

splices beneath wing on Engine Stop Switch side of

lower switch housing screws.

bracket as seen in Figure 8-95.

If replacing lower housing switches, proceed to step 3. If

Install a new 7 inch cable strap beneath wing on Engine

replacing upper housing switches, proceed to step 4.

Start Switch side of bracket and capture wire splices.

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f1271x2x

Screw

Splices

Start

Stop

Start

Stop

Switch

Bracket

Wing

Cable

Channel

Conduit

f1272x2x

Conduit

Strap

Figure 8-95. Upper Right Handlebar Switch Housing

Figure 8-96. Upper Right Handlebar Switch Housing

(Without Splices)

(With Splices)

8. Place switch assembly into upper housing aligning hole

Move cable conduit from beneath wing of bracket. Cut

in bracket with threaded hole in boss. Be sure that

wires 1/4 inch (6.4 mm) from old switches. Discard old

bracket is fully seated. The step at the edge of the boss

switch and bracket assembly.

captures the bottom edge of the bracket, while tabs on

Slide conduit forward over severed ends of switch wires

each side of the bracket fit in slots cast into the housing.

and cut off 1/2 inch (12.7 mm) of conduit material. Push

9. Install Phillips screw to secure bracket inside housing.

conduit back to access switch wires.

Verify that wing on Engine Stop Switch side of bracket

captures edge of conduit as shown in Figure 8-95.

Separate new Horn and High/Low Beam Switch wires

into two bundles.

10. Securely tighten cable strap to draw splices to bracket.

Remove any excess cable strap material.

NOTE

11. See RIGHT SIDE HANDLEBAR SWITCHES, ASSEM-

Replacement High/Low Beam Switch and Horn Switch wires

BLY, in this section.

are cut to length (2-1/2 inches and 2 inches, respectively)

NOTE

and partially stripped.

Replace the Horn and High/Low Beam Switches as a single

See GENERAL REPAIR PROCEDURES in this section.

assembly even if only one switch is determined to be faulty.

Loop switch wires so that spliced lengths are positioned

as shown in Figure 8-98. Route wires downstream of

LEFT SIDE HANDLEBAR (ALL MODELS)

splices beneath wing on High/Low Beam Switch side of

bracket as seen in Figure 8-97.

● Hi(gh) and Lo(w) Beam Switch

Install a new 7 inch cable strap beneath wing on Horn

● Horn Switch

Switch side of bracket and capture wire splices.

[Continued from LEFT SIDE HANDLEBAR SWITCHES,

Place switch assembly into upper housing aligning hole

DISASSEMBLY, in this section.]

in bracket with threaded hole in boss. Be sure that

1. See Figure

8-97. From inside the switch housing,

bracket is fully seated. The step at the edge of the boss

remove Phillips screw to release the bracket. Remove

captures the bottom edge of the bracket, while tabs on

the bracket and switch assembly from the housing.

each side of the bracket fit in slots cast into the housing.

2004 Touring: Electrical

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f1269x2x

Screw

Horn

Beam

Horn

Beam

Switch

Bracket

Wing

Cable

f1270x2x

Conduit

Splices

Strap

Figure 8-97. Upper Left Handlebar Switch Housing

Figure 8-98. Upper Left Handlebar Switch Housing

(Without Splices)

(With Splices)

Install Phillips screw to secure bracket inside housing.

● Turn-Right Signal Switch

Verify that wing on High/Low Beam Switch side of

(All Models)

bracket captures edge of conduit as shown in Figure 8-

Cut wires 1-1/2 inches (38.1 mm) from old switch. Dis-

97.

card old switch assembly.

10. Securely tighten cable strap to draw splices to bracket.

Remove any excess cable strap material. See Figure 8-

NOTE

98.

Replacement Turn-Right Signal Switch wires are cut to length

11. See LEFT SIDE HANDLEBAR SWITCHES, ASSEM-

(1-1/2 inches) and partially stripped.

BLY, in this section.

See GENERAL REPAIR PROCEDURES in this section.

See RIGHT SIDE HANDLEBAR, FINAL INSTRUC-

LOWER SWITCH HOUSINGS

TIONS in this section.

RIGHT SIDE HANDLEBAR

PRELIMINARY INSTRUCTIONS

● Front Stoplight Switch

(All Models)

[Continued from RIGHT SIDE HANDLEBAR

Carefully remove the wedge between the switch and

SWITCHES, DISASSEMBLY, in this section.]

switch housing, if present. To remove the switch from the

From inside the switch housing, carefully cut cable strap

housing, depress the plunger and slowly rotate switch

to free conduit from the turn signal switch bracket, if

upward while rocking slightly.

present.

Cut wires 1 inch (25.4 mm) from old switch. Discard old

Remove the Phillips screw to release the turn signal

switch.

switch bracket. Remove the bracket and switch assem-

bly from the housing.

NOTE

Replacement Stoplight Switch wires are cut to length (2-1/2

inches) and partially stripped.

On Classic and Ultra models, pull the conduit back to intro-

duce some slack in the wires or the tight fit of the bundle will

See GENERAL REPAIR PROCEDURES in this section.

prevent removal of the turn signal switch bracket.

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Carefully depress plunger against inside wall of switch

housing. With thumb over plunger bore, move switch into

Lower Bracket

the installed position in the switch housing cavity. When

Screw

Turn Signal Switch

plunger is positioned against thumb, slowly rotate switch

Bracket Screw

downward while rocking slightly. Release the plunger

only after switch is properly positioned in the cavity.

Verify that the plunger is square in the bore and that the

boot is not compressed, collapsed or torn. If necessary,

gently work the plunger in and out until boot is fully

extended.

Push down on switch so that it bottoms against housing

and wires run in groove at base of cavity. With the con-

cave side facing outward, insert wedge between switch

and outboard side of switch housing. See Figure 8-99.

Push wedge down until it also bottoms against housing.

Verify that the plunger is still square in the bore and then

place a drop of RTV Silicone Sealant on upper corner of

wedge.

See RIGHT SIDE HANDLEBAR, FINAL INSTRUC-

TIONS on the next page.

●

Mode Select Switch

(Classic and Ultra Models)

Cable

Pull keycap from switch shaft.

Strap

Remove two lower bracket screws. Pull bracket

and

Lower Bracket

switch from switch housing. See Figure 8-100.

Screw

f1309x2x

Figure 8-100. Lower Right Handlebar Switch Housing

f1280x2x

(Without Splices) - Classic/Ultra Models

Cavity

Wedge

Cut wires 1-1/4 inches (31.8 mm) from old switch. Dis-

card switch assembly.

NOTE

Lower

Replacement Mode Select Switch wires are cut to length (2-

Switch

1/4 inches) and partially stripped.

Housing

See GENERAL REPAIR PROCEDURES in this section.

Stoplight

Fit new switch into cavity so that it sits on edge in a verti-

Switch

cal position (gray/white wire topside). Properly installed,

the switch is captured by blocks cast into the lower hous-

ing. Verify that the switch shaft is aligned for proper key-

cap operation.

Place the lower bracket into the housing (with the weld

nut side down), but keep the splices above the bracket.

Verify that the slots in the upper step of the bracket

engage two tabs on switch body.

Groove

Switch

Install shorter screw to secure front side of lower bracket

Wires

to threaded boss. Install longer rear screw. To engage

threaded hole in casting, use thru hole in lower step of

bracket on Classic models, thru hole in upper step on

Ultra.

Install keycap on switch shaft.

See RIGHT SIDE HANDLEBAR, FINAL INSTRUC-

Figure 8-99. Install Stoplight Switch

TIONS on the next page.

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7. Install shorter screw to secure front side of lower bracket

f1294x2x

7 Inch

to threaded boss. Install longer rear screw. Use thru hole

in upper step of bracket to engage threaded hole in cast-

Cable Strap

ing.

Bracket

8. Note lettering for proper orientation and gently push key-

cap onto switch shaft.

9. See RIGHT SIDE HANDLEBAR, FINAL INSTRUC-

TIONS on this page.

RIGHT SIDE HANDLEBAR

FINAL INSTRUCTIONS

Insert tapered end of new 7 inch cable 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. See Figure 8-101.

NOTE

Right Turn

Be sure that all splices are positioned above the turn signal

Signal Switch

switch bracket.

Place the turn signal switch assembly into the housing

aligning the oblong hole in the bracket with the lower

bracket weld nut (threaded boss on Road King Standard

Figure 8-101. Insert Cable Strap in Switch Bracket

models). Be sure that bracket is fully seated. Tabs on

each side of bracket are captured in slots cast into

switch housing.

●

Cruise Set/Resume Switch

Start Phillips screw to secure bracket inside housing.

(Road King Classic and Ultra Models)

Pull keycap from switch shaft.

CAUTION

Remove two lower bracket screws. Pull bracket and

switch from switch housing.

If routed incorrectly, wires may be pinched by casting or

handlebar resulting in switch failure.

Cut wires 1-1/2 inches (38.1 mm) from old switch. Dis-

card switch assembly.

Loop switch wires so that spliced lengths are positioned

as shown in Figure 8-102.

NOTE

Replacement Cruise Set/Resume Switch wires are cut to

Capturing conduit about 1/4 inch (6.4 mm) from end,

length (2 inches) and partially stripped.

securely tighten cable strap to draw conduit to bracket.

Remove any excess cable strap material.

See GENERAL REPAIR PROCEDURES in this section.

Install second 7 inch cable strap capturing conduit and

Fit new switch into cavity so that it sits in a horizontal

wire splices. Securely tighten cable strap to draw splices

position (blue/black wire towards master cylinder). Prop-

to conduit. Remove any excess cable strap material.

erly installed, the switch is captured by blocks cast into

the lower housing.

Tighten Phillips screw to secure bracket inside housing.

Keeping splices above the bracket, install the lower

Route wire bundle to upper switch housing by gently

bracket (weld nut side down), so that the lower step is

pressing conduit into channel next to angular arm of

positioned over the switch. Slots in the upper step

bracket. Secure bundle to arm using third cable strap.

engage two tabs on the Cruise On Lamp upper housing

(Road King Classic), or the body of the Mode Select

Cut any excess cable strap material. If necessary, bend

Switch (Ultra models).

angular arm of bracket downward to firmly secure Front

Stoplight Switch in installed position.

NOTE

The Mode Select Switch is vertically oriented with the gray/

See RIGHT SIDE HANDLEBAR SWITCHES, ASSEM-

white wire topside.

BLY, in this section.

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f1311x2x

Angular

Arm

Cable Strap

Arm

Cable Strap

(Wire Bundle to Arm)

Splices

Cable Strap

(Conduit to Bracket)

Cable Strap

(Conduit to Bracket)

(Splices to Conduit)

MODE SELECT SWITCH

CRUISE CONTROL SWITCH

Figure 8-102. Lower Right Handlebar Switch Housing (With Splices) - Classic/Ultra Models

LEFT SIDE HANDLEBAR

NOTE

Replacement Turn-Left Signal Switch wires are cut to length

PRELIMINARY INSTRUCTIONS

(1-1/2 inches) and partially stripped.

[Continued from LEFT SIDE HANDLEBAR SWITCHES,

See GENERAL REPAIR PROCEDURES in this section.

DISASSEMBLY, in this section.]

See LEFT SIDE HANDLEBAR, FINAL INSTRUCTIONS

1. From inside the switch housing, carefully cut cable strap

on the next page.

to free conduit from the turn signal switch bracket, if

present.

● Audio Control Switch

2. Remove the Phillips screw to release the turn signal

(Classic and Ultra Models)

switch bracket. Remove the bracket and switch assem-

bly from the housing.

Pull keycap from switch shaft.

NOTE

Remove two lower bracket screws. See Figure 8-105.

Pull bracket and switch from switch housing.

On Classic and Ultra models, pull the conduit back to intro-

duce some slack in the wires or the tight fit of the bundle will

Cut wires 1-1/4 inches (31.8 mm) from old switch. Dis-

prevent removal of the switch bracket.

card switch assembly.

NOTE

● Turn-L(eft) Signal Switch

(All Models)

Replacement Audio Control Switch wires are cut to length (2-

1/4 inches) and partially stripped.

1. Cut wires 1-1/2 inches (38.1 mm) from old switch. Dis-

card old switch assembly.

See GENERAL REPAIR PROCEDURES in this section.

2004 Touring: Electrical

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Stoplight

Switch

Turn Signal Switch

and Bracket

Turn Signal Switch

and Bracket

Lower

Bracket

Lower

Audio Control

Bracket

Switch

Mode Select

Switch

Mode Select

Audio Switch

Keycap

Classic Models

f1327x2x

Classic Models

f1326x2x

Stoplight

Turn Signal Switch

Switch

and Bracket

Cruise

Control Switch

PTT

Switch

Lower

Bracket

Lower

Bracket

Audio

Control

Mode

Switch

Select Switch

Cruise

Switch Keycap

PTT Switch

Keycap

Mode Select

Keycap

Audio Switch

Ultra Models

Keycap

f1329x2x

Ultra Models

f1328x2x

Figure 8-103. Lower Left Handlebar Switch Assemblies

Figure 8-104. Lower Right Handlebar Switch Assemblies

(Exploded View)

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Remove two lower bracket screws. See Figure 8-105.

Pull bracket and switch from switch housing.

Lower Bracket

Turn Signal Switch

Screw

Bracket Screw

Cut wires 1-1/2 inches (38.1 mm) from old switch. Dis-

card switch assembly.

NOTE

Replacement Push-to-Transmit Switch wires are cut to length

(2 inches) and partially stripped.

See GENERAL REPAIR PROCEDURES in this section.

Fit new switch into cavity so that it sits in a horizontal

position (brown/black wire towards clutch lever bracket).

Properly installed, the switch is captured by blocks cast

into the lower housing.

Keeping splices above the bracket, install the lower

bracket (weld nut side down) so that the lower step is

positioned over the Push-to-Transmit Switch (horizon-

tally oriented). Slots in the upper step engage two tabs

on body of Audio Control Switch (vertically oriented with

gray wire topside).

Cable

Install shorter screw to secure front side of lower bracket

Strap

to threaded boss. Install longer rear screw. To engage

threaded hole in casting, use thru hole in upper step of

bracket.

Note lettering for proper orientation and gently push key-

cap onto switch shaft.

Lower Bracket

Screw

f1306x2x

See LEFT SIDE HANDLEBAR, FINAL INSTRUCTIONS

on this page.

Figure 8-105. Lower Left Handlebar Switch Housing

(Without Splices) - Classic/Ultra Models

●

Cruise On/Off Switch

(Road King Classic Models)

Pull keycap from switch shaft.

Fit new switch into cavity so that it sits on edge in a verti-

cal position (gray/green wire topside). Properly installed,

Remove two lower bracket screws. Pull bracket and

the switch is captured by blocks cast into the lower hous-

switch from switch housing.

ing. Verify that the switch shaft is aligned for proper key-

Cut wires 1-1/2 inches (38.1 mm) from old switch. Dis-

cap operation.

card switch assembly.

Place the lower bracket into the housing (with the weld

nut side down), but keep the splices above the bracket.

NOTE

Verify that the slots in the upper step of the bracket

Cut replacement Cruise On/Off Switch wires to 2 inches and

engage two tabs on switch body.

strip 1/2 inch of insulation.

Install shorter screw to secure front side of lower bracket

See GENERAL REPAIR PROCEDURES in this section.

to threaded boss. Install longer rear screw. To engage

Fit new switch into cavity so that it sits in a horizontal

threaded hole in casting, use thru hole in lower step of

position (orange/white wire towards clutch lever bracket).

bracket on Classic models, thru hole in upper step on

Properly installed, the switch is captured by blocks cast

Ultra.

into the lower housing.

Note lettering for proper orientation and gently push key-

Keeping splices above the bracket, install the lower

cap onto switch shaft.

bracket (weld nut side down), so that the lower step is

See LEFT SIDE HANDLEBAR, FINAL INSTRUCTIONS

positioned over the switch. Slots in the upper step

on the next page.

engage two tabs on the Cruise On Lamp upper housing.

Install shorter screw to secure front side of lower bracket

to threaded boss. Install longer rear screw. Use thru hole

●

CB Push-To-Transmit Switch (Ultra Models)

in upper step of bracket to engage threaded hole in cast-

Pull keycap from switch shaft.

ing.

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Loop switch wires so that spliced lengths are positioned

as shown in Figure 8-107.

f1295x2x

7 Inch

Cable Strap

Capturing conduit about 1/4 inch (6.4 mm) from end,

Bracket

securely tighten cable strap to draw conduit to bracket.

Remove any excess cable strap material.

Tighten Phillips screw to secure bracket inside housing.

Route wire bundle to upper switch housing below and

then forward of the main wire harness positioning con-

duit in channel next to angular arm of bracket. See Fig-

ure 8-107. Secure bundle to arm using new cable strap.

Cut any excess cable strap material.

See LEFT SIDE HANDLEBAR SWITCHES, ASSEM-

BLY, which follows.

GENERAL REPAIR PROCEDURES

Left Turn

Signal Switch

To better access wires and avoid damaging conduit with

radiant heating device, push conduit back and secure

with extra 7 inch cable strap in kit.

Figure 8-106. Insert Cable Strap in Switch Bracket

Angular

Note lettering for proper orientation and gently push key-

Arm

Splices

Cable

cap onto switch shaft.

Strap

See LEFT SIDE HANDLEBAR, FINAL INSTRUCTIONS

below.

LEFT SIDE HANDLEBAR

FINAL INSTRUCTIONS

Insert tapered end of new 7 inch cable 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. See Figure 8-106.

NOTE

Be sure that all splices are positioned above the turn signal

switch bracket.

Place the turn signal switch assembly into the housing

aligning the oblong hole in the bracket with the lower

bracket weld nut (threaded boss on Road King Standard

models). Be sure that bracket is fully seated. Tabs on

each side of bracket are captured in slots cast into

switch housing.

Start Phillips screw to secure bracket inside housing.

Cable

Strap

f1310x2x

CAUTION

Figure 8-107. Lower Left Handlebar Switch Housing

If routed incorrectly, wires may be pinched by casting or

handlebar resulting in switch failure.

(With Splices) - Classic/Ultra Models

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f1313x2x

1WARNING

Use extreme caution when operating the UltraTorch UT-

100 or any other radiant heating device. Read the manu-

facturers instructions carefully before use. Always keep

hands away from tool tip area and heat shrink attach-

ment. Avoid directing the heat toward any fuel system

component. Extreme heat can cause fuel ignition/explo-

sion. Avoid directing heat toward any electrical system

component other than the connectors on which heat

shrink work is being performed. Be sure to turn the “ON/

OFF” switch to the “OFF” position after use. Inadequate

safety precautions could result in death or serious

injury.

See Figure 8-109. Using the UltraTorch UT-100, Robinair

Heat Gun with heatshrink attachment or other suitable

radiant heating device, uniformly heat the heat-shrink

tubing to insulate and seal the soldered connections.

Apply heat just until the meltable sealant exudes out

both ends of the tubing and it assumes a smooth cylin-

Figure 8-108. Splice Switch Wires

drical appearance.

CAUTION

Strip 1/2 inch of insulation off switch wires. Twist stripped

Electrically connected solder outside the tubing may

ends of switch wires until all strands are tightly coiled.

cause a short to ground resulting in switch failure.

Cut dual wall heat-shrink tubing supplied in kit into one

Inspect the melted sealant for solder beads. Excess sol-

inch (25.4 mm) segments. Slide tubing over each wire of

der or heat may force some solder out with the melted

new switch assembly.

sealant. Use a small needle nose pliers to remove any

solder found. Briefly heat the connection to reseal the

NOTE

tubing if solder beads were removed. Use less solder or

If absent from kit, obtain heat shrink tubing (Part No. 72266-

reduce heating time or intensity when doing subsequent

94) and two 7 inch cable straps (Part No. 10181).

splices.

4. Matching wire colors, mate old and new switch wires and

splice as follows:

a. Hold the wires so that the stripped ends cross as

shown in A of Figure 8-108. Note that the wire on

the left is on top and two-thirds of its stripped length

lies beyond the point where they intersect. Looking

at the other wire, only 1/3 of its stripped length lies

Ultra Torch UT-100

(HD-39969)

beyond the intersection point.

b. Holding the wires together at their juncture, start the

splice by tightly twisting the top one-third length of

the right hand wire over the left as shown in B of

Figure 8-108.

c. Tightly coil the remaining two-thirds of the left hand

wire around the right with the results shown in C of

Figure 8-108.

Robinair Heat Gun

d. Solder the spliced connections.

Shrink Tool Attachment

(HD-41183))

NOTE

Robinair Heat Gun

(HD-25070)

For best results, do one wire at a time.

5. Center the heat-shrink tubing over the soldered splices.

Figure 8-109. Radiant Heating Devices

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Cut cable strap compressing conduit and move to its

LEFT SIDE HANDLEBAR SWITCHES

original position.

ASSEMBLY

If replacing lower housing switches, proceed to step 2. If

RIGHT SIDE HANDLEBAR SWITCHES

replacing upper housing switches, proceed to step 6.

ASSEMBLY

Install upper and lower switch housings on handlebar.

Be sure that ribs on outboard side of switch housings fit

If replacing lower housing switches, proceed to step 2. If

in grooves molded into grip. Verify that the wire harness

replacing upper housing switches, proceed to step 9.

conduit runs in the depression at the bottom of the han-

With the concave side facing upward, install the friction

dlebar.

shoe so that the pin hole is over the point of the adjuster

Start the upper and lower switch housing screws, but do

screw (non cruise equipped models only).

not tighten.

NOTE

Position the clutch hand lever assembly inboard of the

The friction shoe is a loose fit and may fall out or become dis-

switch housing assembly engaging the tab on the lower

lodged if the lower switch housing is turned upside down or

switch housing in the groove at the bottom of the clutch

shaken.

lever bracket.

Slide the throttle control grip over the end of the right

Align the holes in the handlebar clamp with those in the

handlebar until it bottoms against the closed end. Rotate

clutch lever bracket and start the lower screw (with flat

the grip so that the ferrule notches are at the top. To pre-

washer). Position for rider comfort. Beginning with the

vent binding, pull the grip back about 1/8 inch (3.2 mm).

top screw, tighten the screws to 60-80 in-lbs (6.8-9.0

Position the lower switch housing beneath the throttle

Nm) using a T27 TORX drive head.

control grip. Install the brass ferrules onto the cables so

Using a T25 TORX drive head, tighten the lower and

that the end fittings seat in the ferrule recess. Seat the

upper switch housing screws to 35-45 in-lbs (4-5 Nm).

ferrules in their respective notches on the throttle control

grip. Verify that the cables are captured in the grooves

NOTE

molded into the grip.

Always tighten the lower switch housing screw first so that

Position the upper switch housing over the handlebar

any gap between the upper and lower housings is at the front

and lower switch housing. Verify that the wire harness

of the switch assembly.

conduit runs in the depression at the bottom of the han-

Test the switches for proper operation.

dlebar.

Start the upper and lower switch housing screws, but do

not tighten.

Position the brake lever/master cylinder assembly

inboard of the switch housing assembly engaging the

tab on the lower switch housing in the groove at the top

of the brake lever bracket.

Align the holes in the handlebar clamp with those in the

master cylinder housing and start the lower screw (with

flat washer). Position for rider comfort. Beginning with

the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0

Nm) using a T27 TORX drive head.

Using a T25 TORX drive head, tighten the lower and

upper switch housing screws to 35-45 in-lbs (4-5 Nm).

NOTE

Always tighten the lower switch housing screw first so that

any gap between the upper and lower housings is at the front

of the switch assembly.

10. Remove the cardboard insert between the brake lever

and lever bracket.

11. Test the switches for proper operation.

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STOPLIGHT SWITCHES

8.22

NOTE

FRONT STOPLIGHT SWITCH

The front and rear stoplight switches “trigger” a relay that

connects 12 vdc to the stoplights. The stoplight (brake light)

To replace the front stoplight switch, refer to Section 8.21

relay is located under the seat.

HANDLEBAR SWITCHES, SWITCH REPAIR/REPLACE-

MENT.

NOTE

On Ultra models the stoplight switches also disengage the

REAR STOPLIGHT SWITCH

cruise control when either switch closes.

The switch is mounted in a tee in the rear brake line. The tee

is attached to a frame weldment on the right lower frame

tube. If the stoplight fails to light when the rear brake is

applied, check the bulb. If bulb is OK, check the continuity of

the brake light wires. If brake light wires are good, check the

stoplight switch for continuity with pedal depressed. Replace

the switch if defective. See Section 2.11 REAR BRAKE MAS-

TER CYLINDER, REAR BRAKE LINE, REMOVAL/INSTAL-

LATION.

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NEUTRAL SWITCH

8.23

GENERAL

A two terminal neutral switch (normally closed) is mounted to

the transmission top cover. When the transmission is in NEU-

TRAL and the Ignition/Light Key Switch is in the IGNITION

position, the neutral indicator lamp illuminates to indicate this

condition to the rider.

REMOVAL

O-Ring

f2236x8x

CAUTION

Cover transmission top cover with masking tape to pre-

Figure 8-110. Neutral Switch Assembly

vent damage to chrome.

Using fingers and flat tip screwdriver, remove two elbow

Using 7/8 inch box and open end wrench, install neutral

connectors from neutral switch posts.

switch with O-ring in the transmission top cover. Tighten

to 120-180 in-lbs (13.6-20.3 Nm).

2. Using 7/8 inch box and open end wrench, remove neu-

tral switch and O-ring from transmission top cover.

Using fingers and a flat tip screwdriver, install the two

elbow connectors on neutral switch posts.

NOTE

If neutral switch connector is damaged, replace using Part

NOTE

No.’s 72405-98BK or 72405-98TN with a heat-sealed butt

The neutral switch is not polarity sensitive, so the elbow con-

splice connector. For detailed butt splicing information, see

nectors can be attached to either stud.

APPENDIX B.5 SEALED BUTT SPLICE CONNECTORS.

Test neutral switch for proper operation as follows:

INSTALLATION

a. Turn the Ignition/Light Key Switch to the IGNITION

position.

b. Verify that neutral indicator lamp illuminates.

NOTE

Remove masking tape from transmission top cover.

If transmission top cover has been removed, be sure to install

neutral switch after top cover installation to ensure proper

switch engagement.

1. Roll the vehicle back and forth to verify that the transmis-

sion is in NEUTRAL.

2. Lubricate O-ring with clean transmission oil.

8-82

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OIL PRESSURE SWITCH/SENDER

8.24

REMOVAL

INSTALLATION

1. Locate the oil pressure switch/sender at the front right

NOTE

side of the crankcase.

If reusing oil pressure switch/sender, apply Loctite Pipe Seal-

2. Proceed as follows:

ant with Teflon 565 to threads.

FLHR/C/S: Pull elbow connector [120] from post termi-

Start oil pressure switch/sender into crankcase bore.

nal of oil pressure switch. Use a 15/16 inch Open End

Crow Foot (Snap-On FC30B) to remove switch from

Proceed as follows:

crankcase.

FLHR/C/S: Use a 15/16 inch Open End Crow Foot

FLHT/C/U, FLTR: Pull external latch outward and use

(Snap-On FC30B) to tighten oil pressure switch to 96-

rocking motion to remove 4-place Packard connector

120 in-lbs (11-14 Nm). Install elbow connector [120] on

[139] from oil pressure sender. Use 1-1/16 inch Open

post terminal.

End Crow Foot (Snap-On FC34A) to remove sender

from crankcase.

FLHT/C/U, FLTR: Use 1-1/16 inch Open End Crow Foot

(Snap-On FC34A) to tighten oil pressure sender to 96-

120 in-lbs (11-14 Nm). Install 4-place Packard connec-

tor.

Test oil pressure switch/sender for proper operation.

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HORN

8.25

TROUBLESHOOTING

REMOVAL

Locate the horn below the fuel tank on the left side of the

If the horn does not sound or fails to function satisfacto-

vehicle.

rily, check for the following conditions.

Remove acorn nut and flat washer to free horn assembly

● Discharged battery

from rubber mount stud.

● Loose, frayed or damaged wiring leading to horn

Remove elbow terminals from horn spade contacts.

terminal

Remove flange nut (10mm) from circular recess at back

of horn bracket. Remove horn from chrome horn cover.

If battery has a satisfactory charge and wiring appears

to be in good condition, check for the following:

● Poor ground to frame through mounting hardware or

ground wire (see Steps 3-6 below)

INSTALLATION

● Inoperative horn switch (see Steps 3-6 below)

Fit horn into chrome cover so that stud at back slides

through hole in horn bracket. Apply two drops of LOC-

Disconnect the YELLOW/BLACK wire at the horn. Con-

TITE THREADLOCKER 222 (Purple) to threads of horn

nect a voltmeter as follows:

stud.

● Positive (+) lead to wire terminal

CAUTION

● Negative (-) lead to ground

Overtightening the flange nut can cause permanent horn

Turn ignition switch ON. Depress horn switch. If battery

damage resulting in reduced volume and tone quality.

voltage is present, horn or horn grounding is faulty. If

Install flange nut (10mm) on horn stud and tighten to 80-

battery voltage is not present, either horn switch or wir-

100 in-lbs (9.0-11.3 Nm).

ing to horn is faulty.

Install elbow terminals onto horn spade contacts.

Connect an ohmmeter across the horn terminals. The

resistance measured must be 45-66 ohms. Replace

NOTE

horn if measured resistance is outside range given.

The horn is not polarity sensitive. Elbow terminals may be

If the horn is faulty, then it must be replaced as an

attached to either spade contact.

assembly. The horn is not repairable. If the horn switch is

faulty, replace the switch. See Section 8.21 HANDLE-

Install horn bracket onto rubber mount stud. Install flat

BAR SWITCHES, SWITCH REPAIR/REPLACEMENT.

washer and acorn nut onto stud. Tighten acorn nut to 80-

100 in-lbs (9.0-11.3 Nm).

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CIGARETTE LIGHTER (FLHTCU, FLTR)

8.26

Disconnect the socket terminals from the spade contacts

GENERAL

on the cigarette lighter.

FLHTCU and FLTR models are equipped with a cigarette

Remove lighter from socket. Holding socket, unscrew

lighter. The lighter is located on the left side of the inner fair-

outer shell. Remove socket and outer shell from the fair-

ing.

TROUBLESHOOTING

INSTALLATION

1. Ignition/light key switch must be ON or in ACCESSORY

From rider side of inner fairing, slide socket of new ciga-

position for lighter operation.

rette lighter through bore in fairing. Thread outer shell

onto socket until tight. Install cigarette lighter in socket.

2. If lighter does not work, substitute a known good lighter

element.

Connect the socket terminals onto the spade contacts of

3. If lighter is still inoperative, check for 12 vdc at center

the cigarette lighter. Connect the orange wire terminal to

socket contact and ground at outer shell contact.

the center socket spade contact, the black wire terminal

to the outer shell contact.

4. Refer to applicable Wiring Diagram at rear of manual if

12 vdc or ground are not present. Use voltage checks to

Install the outer fairing. On FLHTCU models, see Sec-

isolate problem.

tion 2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U),

OUTER FAIRING/WINDSHIELD, INSTALLATION. On

FLTR models, see Section

2.30 UPPER FAIRING/

REMOVAL

WINDSHIELD (FLTR), OUTER FAIRING, INSTALLA-

TION.

1. Remove the outer fairing. On FLHTCU models, see Sec-

tion 2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U),

OUTER FAIRING/WINDSHIELD, REMOVAL. On FLTR

models, see Section

2.30 UPPER FAIRING/WIND-

SHIELD (FLTR), OUTER FAIRING, REMOVAL.

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HOME

GAUGES/INSTRUMENTS (FLHT/C/U, FLTR)

8.27

GAUGE/LAMP- 2 INCH DIAMETER

Hex Nut

Lamp

Fuel Level, Ambient Air Temperature, Voltmeter, Oil

Pin Housing

Pressure

REMOVAL

Remove outer fairing. Proceed as follows:

FLHT/C/U: See Section 2.29 UPPER FAIRING/WIND-

Mounting

Bracket

SHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD,

REMOVAL.

Stud

Tab

FLTR: See Section

2.30 UPPER FAIRING/WIND-

SHIELD (FLTR), OUTER FAIRING, REMOVAL.

Gauge

f1345x2x

Pull

2-place and 3-place socket housings to release

interconnect harness from lamp and gauge, respectively.

Figure 8-111. Voltmeter Gauge Assembly

NOTE

To replace lamp, pull pin housing from gauge and then pull

lamp from slot of pin housing. Install new lamp in slot and

GAUGES- 4 INCH DIAMETER

insert pin housing back into gauge. See Figure 8-111.

Remove hex nuts from studs. Remove mounting bracket.

TACHOMETER

Remove gauge from inner fairing.

REMOVAL

Proceed as follows:

INSTALLATION

FLHT/C/U: Remove the outer fairing. See Section 2.29

Install gauge in inner fairing.

UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER

Slide mounting bracket over studs. Verify that tabs on top

FAIRING/WINDSHIELD, REMOVAL.

and bottom of bracket engage slots in inner fairing. See

Figure 8-111.

FLTR: Remove instrument bezel. See Section

2.30

UPPER FAIRING/WINDSHIELD

(FLTR), BEZEL,

Loosely install hex nuts on studs. Verify that gauge is

REMOVAL, steps 1-3.

properly aligned and then tighten nuts to 10-20 in-lbs

(1.1-2.3 Nm).

Bend back the external latches slightly and remove

tachometer connector [108], 12-place Packard, at back

Install 3-place and 2-place socket housings to connect

of tachometer.

interconnect harness to gauge and lamp, respectively.

Remove two allen head socket screws to free tachome-

Install outer fairing. Proceed as follows:

ter bracket from back of tachometer gauge. On FLHT/C/

U models, leave anchors on interconnect harness

FLHT/C/U: See Section 2.29 UPPER FAIRING/WIND-

installed in outboard ears of tachometer bracket.

SHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD,

INSTALLATION.

Push tachometer gauge toward rear of motorcycle to

FLTR: Section

2.30 UPPER FAIRING/WINDSHIELD

remove from inner fairing

(FLHT/C/U) or bezel bore

(FLTR), OUTER FAIRING, INSTALLATION.

(FLTR).

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2004 Touring: Electrical

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INSTALLATION

f2183x8x

1. Insert tachometer gauge into inner fairing (FLHT/C/U) or

bezel bore (FLTR).

2. Align holes in tachometer bracket with those at back of

tachometer gauge and start two allen head socket

screws.

3. Rotate tachometer gauge until tabs at top and bottom of

bracket engage slots in inner fairing (FLHT/C/U) or bezel

(FLTR).

NOTE

On FLHT/C/U models, both the speedometer and tachome-

ter brackets are oriented with the ears on the outboard side.

On FLTR models, the brackets are oriented with the ears

inboard.

4. Verify that gauge is properly aligned and tighten two

allen head socket screws to 10-20 in-lbs (1.1-2.3 Nm).

5. Install tachometer connector [108], 12-place Packard, at

1. Vehicle Speed Sensor [65]

back of tachometer.

2. P&A Security Siren [142]

6. Proceed as follows:

Figure 8-112. Electrical Bracket (Inboard Side)

FLHT/C/U: Verify that anchors on interconnect harness

are installed in lower outboard ears of both the speed-

7951

ometer and tachometer brackets. Install outer fairing.

See Section

2.29 UPPER FAIRING/WINDSHIELD

(FLHT/C/U), OUTER FAIRING/WINDSHIELD, INSTAL-

LATION.

Starter

FLTR: Install instrument bezel. See Section

2.30

Speed

UPPER FAIRING/WINDSHIELD

(FLTR), BEZEL,

Sensor

INSTALLATION, steps 2-5

VEHICLE SPEED SENSOR

Bolt

REMOVAL

1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

Engine Oil Fill

MAXI-FUSE, REMOVAL.

Plug/Dipstick

2. Remove right side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

Figure 8-113. Vehicle Speed Sensor Location

3. Gently pull side cover from frame downtubes (no tools

required).

NOTE

4. Remove two flange nuts to release electrical bracket

For instructions on properly removing wire terminals, see

from studs on side of battery box.

APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,

REMOVING/INSTALLING PINS.

Disconnect vehicle speed sensor connector [65], 3-place

Deutsch, on the inboard side of the electrical bracket.

Carefully cut anchored cable strap inboard of rear pas-

See Figure 8-112.

senger footboard screw to release cable from frame

6. Remove terminals from pin housing.

downtube.

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HOME

Locate the vehicle speed sensor mounted next to the

10. Install right side saddlebag. See Section 2.25 SADDLE-

starter on the right side of the transmission case.

BAG, INSTALLATION.

Remove the bolt to free the sensor from the case. See

11. Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

Figure 8-113.

MAXI-FUSE, INSTALLATION.

Draw sensor and cable forward to remove from motorcy-

cle.

SPEEDOMETER

INSTALLATION

REMOVAL

Inspect the vehicle speed sensor O-ring for cuts, tears or

general deterioration. Replace as necessary.

Proceed as follows:

Insert the sensor into the transmission case and install

FLHT/C/U: Remove the outer fairing. See Section 2.29

the bolt. Tighten the bolt to 84-108 in-lbs (9-12 Nm).

UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER

FAIRING/WINDSHIELD, REMOVAL.

Feed cable rearward under and inboard of the chrome

starter cover. Running cable up the frame downtube,

FLTR: Remove instrument bezel. See Section

2.30

capture cable in new cable strap anchored in hole of

UPPER FAIRING/WINDSHIELD

(FLTR), BEZEL,

frame downtube.

REMOVAL, steps 1-2. Raising bezel slightly, remove

anchor on ambient temperature sensor from bottom

NOTE

inboard ear of speedometer bracket.

Anchored cable strap also captures the main harness and

Bend back the external latches slightly and remove

neutral switch conduit.

speedometer connector [39], 12-place Packard, at back

of speedometer.

Draw cable rearward between frame downtube and side

of battery box to area of electrical bracket.

Remove two allen head socket screws to free speedom-

eter bracket from back of speedometer gauge. On FLHT/

Referencing the following table, install terminals into pin

C/U models, leave anchors on interconnect harness

housing of 3-place Deutsch.

installed in outboard ears of speedometer bracket.

Push speedometer gauge toward rear of motorcycle to

Table 8-13. Vehicle Speed Sensor [65]

remove from inner fairing

(FLHT/C/U) or bezel bore

(FLTR).

Wire Color

Chamber Number

Red

White

INSTALLATION

Black

Insert speedometer gauge into inner fairing (FLHT/C/U)

or bezel bore (FLTR).

NOTE

Align holes in speedometer bracket with those at back of

For instructions on properly installing wire terminals, see

speedometer gauge and start two allen head socket

APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,

screws.

REMOVING/INSTALLING PINS.

Rotate speedometer gauge until tabs at top and bottom

Mate pin and socket halves of vehicle speed sensor con-

of bracket engage slots in inner fairing (FLHT/C/U) or

nector. Route connector and cable on inboard side of

bezel (FLTR).

electrical bracket as shown in Figure 8-112. Be sure that

NOTE

cable is properly routed or wires may be pinched during

installation of bracket.

On FLHT/C/U models, both the speedometer and tachome-

ter brackets are oriented with the ears on the outboard side.

Slide electrical bracket onto studs at side of battery box.

On FLTR models, the brackets are oriented with the ears

inboard.

Install flange nuts on studs and tighten to 36-48 in-lbs

(4.1-5.4 Nm).

Verify that gauge is properly aligned and tighten two

allen head socket screws to 10-20 in-lbs (1.1-2.3 Nm).

Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

Install speedometer connector [39], 12-place Packard, at

required).

back of speedometer.

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2004 Touring: Electrical

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Release four paddles to free indicator bulb housing from

f2254x8x

lense assembly. See Figure

8-115. Remove lense

assembly from inner fairing (FLHT/C/U) or bezel (FLTR),

if damaged.

To replace indicator lamp bulbs, carefully remove rubber

boot from bulb housing. Remove bulb from socket in

boot.

INSTALLATION

Install new bulb in socket. Install boot in bulb housing.

Place lense assembly in inner fairing (FLHT/C/U) or

bezel (FLTR), if removed. Note position of oil icon to be

sure that lense is right side up.

Engage all four paddles on lense assembly with tabs on

indicator bulb housing. Be sure that flange on bulb hous-

Figure 8-114. Anchor Interconnect Harness in Lower

ing faces upward.

Ears of Speedometer/Tachometer Brackets

Mate pin and socket halves of indicator lamps connector

[21], 10-place Multilock.

6. Proceed as follows:

On FLHT/C/U models, install tachometer gauge. See

FLHT/C/U: Verify that anchors on interconnect harness

GAUGES-

4 INCH DIAMETER, TACHOMETER,

INSTALLATION, in this section.

are installed in lower outboard ears of both the speed-

ometer and tachometer brackets. See Figure 8-114.

Proceed as follows:

Install outer fairing. See Section 2.29 UPPER FAIRING/

WINDSHIELD

(FLHT/C/U), OUTER FAIRING/WIND-

FLHT/C/U: Install outer fairing. See Section

2.29

SHIELD, INSTALLATION.

UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER

FAIRING/WINDSHIELD, INSTALLATION.

FLTR: Install anchor on ambient temperature sensor into

bottom inboard ear of speedometer bracket. Install

FLTR: Install instrument bezel. See Section

2.30

instrument bezel. See Section 2.30 UPPER FAIRING/

UPPER FAIRING/WINDSHIELD

(FLTR), BEZEL,

WINDSHIELD (FLTR), BEZEL, INSTALLATION, steps

INSTALLATION, steps 1-2.

3-5.

Indicator Lamp

Connector [21]

INDICATOR LAMPS

10-Place Multilock

REMOVAL

Bulb

1. Proceed as follows:

Housing

FLHT/C/U: Remove the outer fairing. See Section 2.29

UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER

FAIRING/WINDSHIELD, REMOVAL.

FLTR: Remove instrument bezel. See Section

2.30

UPPER FAIRING/WINDSHIELD

(FLTR), BEZEL,

Rubber

REMOVAL, steps 1-2.

Boot

2. Disconnect indicator lamps connector

[21],

10-place

Multilock. Depress button on plug side of connector and

Paddle

pull apart pin and socket halves.

Lense

f2262x8x

3. On FLHT/C/U models, remove tachometer gauge to

access indicator lamp assembly. See GAUGES- 4 INCH

DIAMETER, TACHOMETER, REMOVAL, in this section.

Figure 8-115. Indicator Lamp Assembly

2004 Touring: Electrical

8-89

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