Harley Davidson FLHRC 2006. Maintenance & Repair Manual — page 25
HOME
NOTE
For instructions on installing terminals, see APPENDIX B.2
9403
MULTILOCK ELECTRICAL CONNECTORS, INSTALLING
SOCKET/PIN TERMINALS.
6.
Connect front turn signal lamps connector. Install anchor
on connector into hole of fork stem nut lockplate (left
side).
7.
Install two cable clips into holes at bottom of handlebar
after capturing handlebar switch and turn signal lamp
conduit.
8.
Install new cable strap to secure handlebar switch and
turn signal lamp conduit to lower handlebar clamp. Cut
any excess cable strap material.
9.
Install handlebar clamp shroud/wind deflector. See Sec-
tion 2.32 WINDSHIELD/HEADLAMP NACELLE (FLHR/
C/S), NACELLE INSTALLATION (FLHRS), steps 5-13.
10. Adjust mirror as necessary and tighten acorn nut to 60-
96 in-lbs (6.8-10.8 Nm).
11. Turn Ignition/Light Key Switch to IGNITION and test for
Figure 8-62. Front Turn Signal Lamp (FLHX)
proper operation.
12. Adjust front turn signal lamp if necessary. See ADJUST-
MENT which follows.
ADJUSTMENT
1.
Using a 1/4 inch allen head socket, loosen set screw in
turn signal lamp bracket. See Figure 8-59.
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
fuel tank or any other components. Loosen set screw
and readjust lamp as required.
9405
4.
Tighten set screw to 50-60 in-lbs (5.7-6.8 Nm).
Figure 8-63. Route Conduit Thru Mounting Bracket
and Chrome Skirt Reliefs (FLHX)
FLHX
NOTE
REMOVAL
For instructions on removing terminals, see APPENDIX B.2
1.
Remove outer fairing. See Section 2.30 UPPER FAIR-
MULTILOCK ELECTRICAL CONNECTORS, REMOVING
ING/WINDSHIELD (FLHX, FLHT/C/U), OUTER FAIR-
SOCKET/PIN TERMINALS.
ING/WINDSHIELD, REMOVAL.
b. Pull mounting bracket from conduit.
2.
Disconnect the left or right front turn signal lamp connec-
c. Remove socket/isolator assembly from lamp. See
tor [31L/R], 4-place Multilock. Connector is attached to T-
FLHRS, REMOVAL, in this section, steps 8(e) thru
stud at top of left or right fairing support brace (outboard
8(i).
side). See Figure 8-56.
3.
Remove two T40 TORX screws to release turn signal
lamp mounting bracket from upper and lower fork brack-
INSTALLATION
ets. See Figure 8-62.
NOTE
4.
To remove socket/isolator assembly, proceed as follows:
If turn signal lamp is already assembled, begin procedure at
a. Remove terminals from socket housing.
step 2.
2006 Touring: Electrical
8-47
HOME
1.
To install socket/isolator assembly, proceed as follows:
FLTR
a. Seat socket assembly in rubber isolator aligning tab
REMOVAL
on socket with slot in isolator.
1.
Remove outer fairing and front turn signal lamp. See
Section 2.31 UPPER FAIRING/WINDSHIELD (FLTR),
b. Feed terminals and conduit into lamp through lense
opening and then out through unthreaded hole.
OUTER FAIRING, REMOVAL. See Figure 8-64.
2.
To remove socket/isolator assembly, proceed as follows:
c. Complete installation of socket assembly. See
a. Remove terminals from socket housing.
FLHRS, INSTALLATION, in this section, steps 1(d)
thru 1(g).
NOTE
d. Feed terminals and conduit through triangular
For instructions on removing terminals, see APPENDIX B.2
shaped hole in mounting bracket.
MULTILOCK ELECTRICAL CONNECTORS, REMOVING
SOCKET/PIN TERMINALS.
e. Align thru hole in mounting bracket with threaded
hole in lamp and start hex screw. Tighten hex screw
b. Pull lamp from mounting bracket.
to 15-20 ft-lbs (20-27 Nm).
c. Remove socket/isolator assembly from lamp. See
FLHRS, REMOVAL, in this section, steps 8(e) thru
NOTE
8(i).
For instructions on installing terminals, see APPENDIX B.2
MULTILOCK ELECTRICAL CONNECTORS, INSTALLING
SOCKET/PIN TERMINALS.
INSTALLATION
NOTE
f.
Install terminals into socket housing as follows:
If turn signal lamp is already assembled, begin procedure at
Table 8-10. Front Turn Signal Lamp [31L/R]
step 2.
1.
Assemble front turn signal lamp as follows:
FLHX, 4-Place
a. Seat socket assembly in rubber isolator aligning tab
Left Side [31L]
Right Side [31R]
on socket with slot in isolator.
b. Feed terminals and conduit into lamp through lense
Wire Color
Chamber
Wire Color
Chamber
opening and then out through unthreaded hole.
Blue
1
Blue
1
c. Complete installation of socket/isolator assembly.
Violet
2
Brown
2
See FLHRS, INSTALLATION, in this section, steps
Black
3
Black
3
1(d) thru 1(g).
Empty
4
Empty
4
d. Install lamp onto mounting bracket. See Figure 8-
64.
2.
Start two T40 TORX screws to fasten turn signal lamp
mounting bracket to upper and lower fork brackets.
3.
To avoid pinching wires, verify that conduit is routed for-
ward through relief at front of mounting bracket, and then
inboard using relief in upper outboard corner of chrome
skirt. See Figure 8-63.
4.
Alternately tighten T40 TORX screws to 15-20 ft-lbs (20-
27 Nm).
5.
Connect front turn signal lamp connector. Install connec-
tor on T-stud at top of left or right fairing support brace
(outboard side). See Figure 8-56.
6.
Install outer fairing. See Section 2.30 UPPER FAIRING/
9408
WINDSHIELD (FLHX, FLHT/C/U), OUTER FAIRING/
WINDSHIELD, INSTALLATION.
Figure 8-64. Front Turn Signal Lamp (FLTR)
8-48
2006 Touring: Electrical
HOME
NOTE
For instructions on installing terminals, see APPENDIX B.2
[18]
[19]
MULTILOCK ELECTRICAL CONNECTORS, INSTALLING
[93]
SOCKET/PIN TERMINALS.
e. Install terminals into socket housing. For correct ter-
minal locations refer to Table 8-10.
2.
Install outer fairing and front turn signal lamp. See Sec-
tion
2.31 UPPER FAIRING/WINDSHIELD
(FLTR),
OUTER FAIRING, INSTALLATION.
3.
Turn Ignition/Light Key Switch to IGNITION and test for
proper operation.
REAR TURN SIGNAL LAMP
FLHR/C, FLHT/C/U
f2172x8x
REMOVAL
[18] Left Turn Signal Lamp
[19] Right Turn Signal Lamp
1.
Remove saddlebag on same side of motorcycle. See
[93] Tail Lamp
Section 2.26 SADDLEBAG, REMOVAL.
2.
Remove two Phillips screws to release tail lamp assem-
Figure 8-65. Release Tail Lamp Socket
bly from chrome base.
3.
Disconnect tail lamp connector [93], 4-place Multilock.
f1497x8x
Set tail lamp assembly aside. See Figure 8-65.
4.
Disconnect turn signal lamp assembly, 2-place Multilock.
For best results, use a pick or small screwdriver to
depress release button as shown in Figure 8-66.
5.
Feed socket housing through opening in chrome base to
inboard side of rear fender.
6.
Reaching under rear fender, release conduit from cable
clip anchored on T-stud.
7.
Draw conduit and socket housing out through fender
hole just below chrome base. See Figure 8-66.
8.
Draw socket housing through channel on inboard side of
rear turn signal lamp bracket, so that length of conduit
hangs below turn signal lamp.
9.
Inserting a long shank ball end socket
(Snap-on®
FABL5) through channel in bracket, remove two socket
head screws to release turn signal lamp assembly.
10. Remove terminals from socket housing.
Opening
NOTE
Fender Hole
For instructions on removing terminals, see APPENDIX B.2
Figure 8-66. Use Pick Tool to Release
MULTILOCK ELECTRICAL CONNECTORS, REMOVING
Left Turn Signal Lamp Socket
SOCKET/PIN TERMINALS.
INSTALLATION
1.
Place new turn signal lamp assembly next to discarded
2.
Crimp new socket terminals onto turn signal lamp wires.
unit and cut wires to proper length.
2006 Touring: Electrical
8-49
HOME
NOTE
FLHRS, FLHX, FLTR
For instructions on crimping terminals, see APPENDIX B.2
NOTE
MULTILOCK ELECTRICAL CONNECTORS, CRIMPING
INSTRUCTIONS.
This procedure entails replacement of the rear turn signal
lamp socket/isolator assembly. To remove and install the turn
3.
Install terminals into socket housing.
signal lamps bracket, see REAR TURN SIGNAL LAMPS
BRACKET in this section.
Table 8-11. Rear Turn Signal Lamps [18/19]
REMOVAL
Chamber
Wire Color
1.
Remove chrome base and circuit board assembly. See
Number
Section 8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/
CHROME BASE, REMOVAL.
Violet/Brown
1
2.
Remove terminals from socket housing of rear turn sig-
Black
2
nal lamp connector.
NOTE
NOTE
For instructions on removing terminals, see APPENDIX B.2
For instructions on installing terminals, see APPENDIX B.2
MULTILOCK ELECTRICAL CONNECTORS, REMOVING
MULTILOCK ELECTRICAL CONNECTORS, INSTALLING
SOCKET/PIN TERMINALS.
SOCKET/PIN TERMINALS.
3.
Reaching inside rear fender, release conduit from cable
4.
Align holes in turn signal lamp assembly with those in
clip anchored on T-stud.
rear turn signal lamp bracket and start two socket head
screws. For best results, insert a long shank ball end
4.
Draw conduit and terminals through hole to outboard
socket (Snap-on® FABL5) through channel on inboard
side of fender.
side of bracket. Alternately tighten screws to 30-50 in-
5.
Remove socket/isolator assembly as follows:
lbs (3.4-5.6 Nm).
a. Insert blade of small screwdriver into slot at bottom
5.
Route socket housing through channel in bracket, and
of lense. Gently rotate end of screwdriver to unsnap
then feed through fender hole just below chrome base.
lense from lamp.
See Figure 8-66.
b. Push grommet at end of conduit into lamp housing.
6.
Reaching under rear fender, capture conduit in cable clip
Lightly lubricate grommet with glass cleaner, if nec-
anchored on T-stud.
essary.
7.
Feed socket housing through opening in chrome base to
c. Push in bulb and rotate in a counterclockwise direc-
outboard side of rear fender.
tion to remove.
8.
Orient socket housing so that the release button is at the
d. Inserting blade of small screwdriver between outer
top and insert into pin housing/circuit board.
edge of rubber isolator and inside of lamp housing,
gently pry up socket assembly until free.
9.
To install tail lamp assembly, orient 4-place Multilock
socket so that the release button is at the bottom and
e. Pull socket assembly to draw conduit and terminals
insert into pin housing until it “clicks.” To avoid stressing
into lamp and then out through lense opening.
wires, verify that tail lamp conduit is positioned on the
f.
Remove rubber isolator from lamp if still installed.
outboard side of the rear fender tip lamp and left turn
signal lamp conduit as shown Figure 8-65.
10. Place tail lamp into position against chrome base.
INSTALLATION
1.
Place new socket/isolator assembly next to discarded
CAUTION
unit and cut wires to proper length. Crimp new socket
terminals onto wires.
Over tightening screws can crack the lense or result in
scratching of the fender paint.
NOTE
11. Install two Phillips screws and alternately tighten to 20-
For instructions on crimping terminals, see APPENDIX B.2
24 in-lbs (2.3-2.7 Nm).
MULTILOCK ELECTRICAL CONNECTORS, CRIMPING
INSTRUCTIONS.
12. Turn the Ignition/Light Key Switch to IGNITION and test
lamp for proper operation.
2.
Install socket/isolator assembly as follows:
13. Install saddlebag. See Section
2.26 SADDLEBAG,
a. Seat socket assembly in rubber isolator aligning tab
INSTALLATION.
on socket with slot in isolator.
8-50
2006 Touring: Electrical
HOME
b. Feed terminals and conduit into lamp through lense
INSTALLATION
opening and then out through unthreaded hole.
1.
Apply one drop of LOCTITE THREADLOCKER 271
c. Exercising caution to avoid pulling on wires, care-
(Red) to two flange bolts.
fully pull grommet out through hole in lamp. For best
2.
Install flange bolts to fasten rear turn signal lamps
results, grasp edge of grommet with needle nose
bracket to rear fender. Alternately tighten bolts to 84-144
pliers. Lightly lubricate grommet with glass cleaner,
in-lbs (9.5-16.3 Nm).
if necessary.
3.
Install rear turn signal lamps to bracket. See REAR
d. Install socket assembly aligning tab on socket with
TURN SIGNAL LAMP, INSTALLATION, in this section,
slot inside lamp.
steps 4-6.
e. Using thumbs of both hands, apply even pressure
4.
Install chrome base and circuit board assembly. See
around outer edge of socket assembly until fully
Section 8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/
seated.
CHROME BASE, INSTALLATION.
f.
Liberally apply dielectric grease to contacts in
socket and at bottom of bulb. Push in bulb and
rotate in a clockwise direction to install.
FLHRS, FLHX, FLTR
g. Install lense in lamp and gently apply thumb pres-
sure until it snaps into place. Rotate lense to posi-
REMOVAL
tion slot at bottom of lamp.
NOTE
3.
Feed socket terminals through hole to inboard side of
To remove the rear turn signal lamps bracket on FLHX mod-
fender.
els, see Section 8.17 LICENSE PLATE LAMPS/BRACKET
(FLHX), LICENSE PLATE BRACKET, REMOVAL.
4.
Install terminals into socket housing. See Table 8-11.
1.
Remove circuit board and chrome base. See Section
NOTE
8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/
For instructions on installing terminals, see APPENDIX B.2
CHROME BASE, REMOVAL.
MULTILOCK ELECTRICAL CONNECTORS, INSTALLING
2.
Reaching inside rear fender, release left and right rear
SOCKET/PIN TERMINALS.
turn signal lamp conduit from respective cable clips
anchored on T-studs.
5.
Reaching inside rear fender, capture conduit in cable clip
anchored on T-stud.
3.
Remove two flange bolts to release rear turn signal
lamps bracket.
6.
Install chrome base and circuit board assembly. See
Section 8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/
4.
Pull rear turn signal lamps bracket away from motorcycle
CHROME BASE, INSTALLATION.
drawing socket housings out through fender holes.
INSTALLATION
REAR TURN SIGNAL LAMPS
NOTE
BRACKET
To install the rear turn signal lamps bracket on FLHX models,
see Section
8.17 LICENSE PLATE LAMPS/BRACKET
(FLHX), LICENSE PLATE BRACKET, INSTALLATION.
FLHR/C, FLHT/C/U
1.
Feed socket housings of left and right rear turn signal
REMOVAL
lamps through respective holes to inboard side of fender.
1.
Remove chrome base and circuit board assembly. See
2.
Apply one drop of LOCTITE THREADLOCKER 271
Section 8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/
(Red) to two flange bolts.
CHROME BASE, REMOVAL.
3.
Install flange bolts to fasten rear turn signal lamp bracket
2.
Remove rear turn signal lamps from bracket. See REAR
to fender. Alternately tighten bolts to 84-144 in-lbs (9.5-
TURN SIGNAL LAMP, REMOVAL, in this section, steps
16.3 Nm).
6-9.
4.
Install chrome base and circuit board assembly. See
3.
Remove two flange bolts to free rear turn signal lamps
Section 8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/
bracket from rear fender.
CHROME BASE, INSTALLATION.
2006 Touring: Electrical
8-51
HOME
LICENSE PLATE LAMPS/BRACKET (FLHX)
8.17
BULB REPLACEMENT
9296
REMOVAL
1.
Using a
7/32 inch allen head wrench, remove two
screws to release lense of license plate lamp from rear
turn signal lamps bracket.
2.
See Figure 8-67. Exercising caution to avoid stressing
wires, carefully pull down lamp assembly only as far as
necessary to access bulbs. Remove bulbs from sockets.
INSTALLATION
1.
Liberally apply dielectric grease to contacts in sockets
and at bottom of new bulbs. Install bulbs in sockets. For
correct bulb type, see Section 8.2 BULB CHART.
Figure 8-67. Release Lamp Assembly
2.
Using a 7/32 inch allen head wrench, install two screws
to fasten lense of license plate lamp to rear turn signal
9303
lamps bracket.
LICENSE PLATE LAMPS
REMOVAL
1.
Using a
7/32 inch allen head wrench, remove two
screws to release lense of license plate lamp from rear
turn signal lamps bracket.
2.
See Figure 8-67. Exercising caution to avoid stressing
Figure 8-68. Draw Wires Through Fender Hole
wires, carefully pull down lamp assembly only as far as
necessary to access bulbs.
3.
Remove circuit board and chrome base. See Section
INSTALLATION
8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/
CHROME BASE, REMOVAL.
1.
Place new lamp assembly next to discarded unit and cut
4.
Remove terminals from socket housing of license plate
wires to proper length.
lamps connector [45].
2.
Crimp new socket terminals onto license plate lamp
NOTE
wires.
For instructions on removing terminals, see APPENDIX B.2
NOTE
MULTILOCK ELECTRICAL CONNECTORS, REMOVING
SOCKET/PIN TERMINALS.
For instructions on crimping terminals, see APPENDIX B.2
MULTILOCK ELECTRICAL CONNECTORS, CRIMPING
5.
Reaching inside rear fender, release conduit from left
INSTRUCTIONS.
side cable clip anchored on T-stud.
6.
Draw conduit and socket terminals through hole to out-
3.
Feed socket terminals and conduit up through slot in
center of turn signal lamps bracket, and then through
board side of fender, and then down through slot in cen-
hole to inboard side of fender. See Figure 8-68.
ter of turn signal lamps bracket. See Figure 8-68.
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2006 Touring: Electrical
HOME
4.
Install terminals into socket housing.
INSTALLATION
Table 8-12. License Plate Lamps [45]
1.
Install two allen head socket screws to fasten license
plate bracket to rear turn signal lamps bracket. See Fig-
Chamber
ure 8-69.
Wire Color
Number
2.
Feed socket housings of left and right rear turn signal
Black
1
lamps through respective holes to inboard side of fender.
Not Used
2
3.
Apply one drop of LOCTITE THREADLOCKER 271
Black
3
(Red) to two flange bolts.
4.
Install flange bolts to fasten rear turn signal lamps
NOTE
bracket to fender. Alternately tighten bolts to 84-144 in-
lbs (9.5-16.3 Nm).
For instructions on installing terminals, see APPENDIX B.2
MULTILOCK ELECTRICAL CONNECTORS, INSTALLING
5.
Feed socket terminals of license plate lamp connector
SOCKET/PIN TERMINALS.
[45] through left side hole to inboard side of fender. See
Figure 8-68.
5.
Using a 7/32 inch allen head wrench, install two screws
to fasten lense to rear turn signal lamps bracket.
6.
Install terminals into socket housing. Refer to Table 8-12.
6.
Reaching inside rear fender, capture conduit in cable clip
anchored on T-stud.
NOTE
7.
Install chrome base and circuit board assembly. See
For instructions on installing terminals, see APPENDIX B.2
Section 8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/
MULTILOCK ELECTRICAL CONNECTORS, INSTALLING
CHROME BASE, INSTALLATION.
SOCKET/PIN TERMINALS.
7.
Reaching inside rear fender, capture conduit of rear turn
signal lamps connectors in respective cable clips
LICENSE PLATE BRACKET
anchored on T-studs. Also capture license plate lamps
conduit in left side cable clip.
8.
Install chrome base and circuit board assembly. See
REMOVAL
Section 8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/
1.
Remove circuit board and chrome base. See Section
CHROME BASE, INSTALLATION.
8.14 TAIL LAMP ASSEMBLY, CIRCUIT BOARD/
CHROME BASE, REMOVAL.
2.
Remove terminals from socket housing of license plate
lamps connector [45].
9305
NOTE
For instructions on removing terminals, see APPENDIX B.2
MULTILOCK ELECTRICAL CONNECTORS, REMOVING
SOCKET/PIN TERMINALS.
3.
Reaching inside rear fender, release license plate lamps
conduit from left side cable clip anchored on T-stud.
4.
Draw socket terminals through hole to outboard side of
fender. See Figure 8-68.
5.
Reaching inside rear fender, release left and right rear
turn signal lamp conduit from respective cable clips
anchored on T-studs.
6.
Remove two flange bolts to release rear turn signal
lamps bracket.
Figure 8-69. Remove License Plate Bracket
7.
Pull rear turn signal lamps bracket away from motorcycle
drawing socket housings out through fender holes.
8.
Remove two allen head socket screws to release license
plate bracket from rear turn signal lamps bracket. See
Figure 8-69.
2006 Touring: Electrical
8-53
HOME
TSM/TSSM
8.18
REMOVAL
NOTE
If equipped with the optional “Harley-Davidson Factory Secu-
rity System,” verify that the security status lamp in speedom-
eter face is not flashing before proceeding (security system
disarmed).
1.
Remove seat. See Section 2.25 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.
See Figure 8-70.
3.
Remove module from cavity and disconnect TSM/TSSM
Spring
connector [30], 12-place Deutsch.
Clip
TSM/TSSM
f2013x8x
INSTALLATION
Figure 8-70. TSM/TSSM
1.
Connect TSM/TSSM connector [30], 12-place Deutsch,
to new module. Install module in cavity of frame cross-
3.
Install seat. See Section 2.25 SEAT, INSTALLATION.
member at rear of battery box.
4.
Test all turn signal functions. Test all security system
2.
Insert legs of spring clip into holes in frame crossmem-
functions, if so equipped.
ber and push down until tab at front snaps in place.
8-54
2006 Touring: Electrical
HOME
IGNITION/LIGHT KEY SWITCH AND FORK LOCK
8.19
FLHX, FLHT/C/U, FLTR
REMOVAL
1.
Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
2.
Remove the ignition switch knob as follows:
a. Insert the ignition switch key and turn to the
UNLOCK position. Leave the key installed in the
ignition switch knob.
Figure 8-72. Ignition Switch Alignment Tool
(Part No. HD-45962)
b. Turn the front forks to the left fork stop and rotate
the knob to FORK LOCK.
c. Depressing the release button at bottom (left side)
with a small screwdriver, push key down and turn 60
degrees in a counterclockwise direction. See Figure
8-71.
f2080x8x
f2086x8x
Figure 8-73. Bottom Alignment Tool in Threaded Post
and Rotate to Desired Position
d. Lift and remove knob. Be aware that spring will drop
out of bore at underside of knob when removed.
TOP VIEW
NOTE
After removal of the knob, the IGNITION SWITCH ALIGN-
MENT TOOL (HD-45962) may be used to move the switch to
other positions as required. Insert tool until bottom of handle
contacts top of threaded post, and then rotate handle in a
clockwise direction to the selected position. See Figure 8-73.
3.
Turn the front forks to the right fork stop, and using a 7/8
inch open end/box wrench on flats, remove nut from
threaded post of ignition switch housing.
4.
Pull collar and spacer from threaded post.
BOTTOM VIEW
5.
Remove the switch position plate by pulling tabs from
f2097x8x
slots in fairing cap
(FLHX, FLHT/C/U) or instrument
nacelle (FLTR).
Figure 8-71. Ignition Switch Knob Release Button
6.
Proceed as follows:
2006 Touring: Electrical
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HOME
a. Obtain the IGNITION SWITCH CONNECTOR
REMOVER (HD-45961). See Figure 8-74.
b. Gently insert end of tool into slot in ignition switch
housing until it stops.
c. Grasping main harness conduit and tool, pull both
at the same time to release socket housing from
ignition switch housing. See Figure 8-75.
8.
Proceed as follows:
Domestic: Remove two socket head screws (with flat
Figure 8-74. Ignition Switch Connector Remover
washers) at base of ignition switch housing.
(Part No. HD-45961)
International: Remove two break-away screws (with flat
washers) as follows.
f2110x8x
a. Use a center punch to make a pilot hole at the top of
each break-away screw.
1WARNING
Always wear proper eye protection when drilling. Flying
debris may result in eye injury.
b. Install a 1/8 inch left handed bit in drill and set the
drill to Reverse. Positioning the bit in the pilot hole,
spin out the break-away screws.
NOTE
Figure 8-75. Pull Main Harness Conduit and Tool
If the above method fails, use a 3/16 inch bit with long shank
to Release Socket Housing
to carefully drill off heads of break-away screws. Use a pliers
to unthread the shafts from the upper fork bracket.
FLHX, FLHT/C/U:
9.
Remove ignition switch housing from bore of upper fork
a. Remove outer fairing. See Section 2.30 UPPER
bracket. See Figure 8-76.
FAIRING/WINDSHIELD
(FLHX,
FLHT/C/U),
OUTER FAIRING/WINDSHIELD, REMOVAL, step
2.
INSTALLATION
b. Using a long shank ball end socket
(Snap-on®
FABL6E), remove four socket head screws to
1.
Slide base of ignition switch housing into bore of upper
release radio (storage box on FLHT) from left and
fork bracket.
right radio support brackets. Use oblong holes in
fairing brackets to access screws. Lift radio slightly.
2.
Proceed as follows:
c. Carefully cut anchored cable strap to release main
Domestic: Install two socket head screws
(with flat
harness conduit from bottom right corner of radio.
washers) at base of ignition switch housing. Alternately
d. Remove fairing cap. See Section
2.30 UPPER
tighten screws to 36-60 in-lbs (4.1-6.8 Nm).
FAIRING/WINDSHIELD (FLHX, FLHT/C/U), FAIR-
ING CAP, REMOVAL, steps 2-4.
International: Install two new break-away screws (with
flat washers) as follows.
FLTR:
a. Remove instrument nacelle. See Section
2.31
CAUTION
UPPER FAIRING/WINDSHIELD (FLTR), INSTRU-
MENT NACELLE, REMOVAL, steps 2-9.
Verify that the threads in the upper fork bracket are clean
and in good condition. Dirty and/or damaged threads
7.
Disconnect ignition switch connector [33], 3-place Pack-
may cause the heads of the break-away screws to snap
ard, at front of ignition switch housing. Proceed as fol-
off before the switch housing is properly tightened.
lows:
8-56
2006 Touring: Electrical
HOME
1.
Knob
1
2.
Spring
3.
Nut
4.
Collar
5.
Spacer
6.
Break-Away Screw
(International Only)
7.
Flat Washer
8.
Switch Housing
2
f2087x8x
3
Figure 8-77. Rotate Alignment Tool Without Bottoming
4
b. Using oblong holes in fairing brackets and a long
shank ball end socket (Snap-on® FABL6E), install
5
four socket head screws to fasten radio (storage box
6
on FLHT) to left and right radio support brackets.
Alternately tighten screws to 35-45 in-lbs (4.0-5.1
Nm).
c. Install outer fairing. See Section 2.30 UPPER FAIR-
7
ING/WINDSHIELD
(FLHX, FLHT/C/U), OUTER
FAIRING/WINDSHIELD, INSTALLATION, step 1.
8
f2116x8x
FLTR:
a. Install instrument nacelle. See Section 2.31 UPPER
Figure 8-76. Ignition Switch Assembly (International)
FAIRING/WINDSHIELD
(FLTR), INSTRUMENT
NACELLE, INSTALLATION, steps 1-10.
6.
Install switch position plate fitting tabs in slots of fairing
CAUTION
cap (FLHX, FLHT/C/U) or instrument nacelle (FLTR).
Plate snaps in place when properly installed. Exercise
Exercise care to avoid losing heads of break-away
care to avoid breaking tabs. Replace plate if tabs are
screws in motorcycle. Vibration may cause captured
broken.
heads to scratch finished surfaces, chafe wires or cause
other damage.
7.
Install spacer over threaded post of ignition switch hous-
ing until it contacts switch position plate. Orient spacer
a. Rotate break-away screws in a clockwise direction
so that the widest side is forward and the inside tabs fit
until heads snap off.
in slots of post. See Figure 8-76.
8.
Slide collar over threaded post until it contacts spacer.
3.
Install ignition switch connector [33], 3-place Packard, at
Orient collar so that the outside tab is forward and the
front of ignition switch housing.
inside tabs fit in slots of post.
4.
Install anchor of new cable strap in hole at bottom right
9.
Thread nut onto post with the lipped side down and the
smaller OD topside. Turn the front forks to the right fork
side of radio. Tighten cable strap capturing main harness
stop, and using a 7/8 inch Open End Crow Foot on flats,
conduit (to ignition switch). Cut any excess cable strap
material.
tighten nut to 125-150 in-lbs (14.1-16.9 Nm).
10.
Install spring into bore at underside of knob.
5.
Proceed as follows:
11.
With the knob pointing toward the FORK LOCK position,
FLHX, FLHT/C/U:
insert shaft into threaded post. Holding the knob down,
turn key clockwise to UNLOCK. An audible “click” should
a. Install fairing cap. See Section 2.30 UPPER FAIR-
be heard when knob and switch are properly engaged.
ING/WINDSHIELD
(FLHX, FLHT/C/U), FAIRING
Release knob and then rotate through all four switch
CAP, INSTALLATION, steps 1-4.
positions to verify proper operation.
2006 Touring: Electrical
8-57
HOME
If knob will not install properly, move to step 12.
Ignition/Light
12.
Proceed as follows:
Key Switch Connector [33]
a. Verify that button at bottom of knob is depressed
and key is turned 60 degrees beyond the UNLOCK
position. See Figure 8-71.
b. Repeat step 11.
c. If knob does not install properly, move to step 13.
13.
Knob was removed in ACCESS or switch may have
been moved out of the FORK LOCK position. Proceed
as follows:
a. Insert alignment tool until bottom of handle contacts
top of threaded post, and holding front forks at the
left fork stop, rotate handle of tool in a counter-
clockwise direction until fork locks. See Figure 8-73.
b. Remove tool and repeat step 11.
c. If knob does not install properly, move to step 14.
14.
Detent and switch position lugs are misaligned. This can
occur when the alignment tool (or ignition switch knob) is
Screw
f2095x8x
rotated before it is properly bottomed in the ignition
switch housing. Proceed as follows:
Figure 8-78. Instrument Console (FLHR/C)
a. Reinstall knob inserting shaft into threaded post and
gently rotate knob until it drops into the partially
installed position. Take note of the position of the
knob, that is, whether it is pointing toward the rear,
1WARNING
or to ACCESS, IGNITION or OFF.
To protect against shock and accidental start-up of vehi-
b. Remove knob and insert alignment tool so that the
cle, disconnect the negative battery cable before pro-
bottom of the handle is approximately 1/2-3/4 inch
ceeding. Inadequate safety precautions could result in
(12.7-19.1 mm) from the top of the threaded post,
death or serious injury.
and then hold. See Figure 8-77.
c. Rotate alignment tool in a counter-clockwise
2.
Unthread bolt and remove battery negative cable (black)
direction the number of positions needed to get to
from battery negative (-) terminal.
FORK LOCK. For example, if the knob dropped into
the partially installed position at IGNITION in step
3.
Remove acorn nut from instrument console. If present,
also remove Phillips screw and large flat washer (absent
14(a), rotate the alignment tool two positions in a
on FLHRS models).
counterclockwise direction. Or if the knob was
pointing toward the rear when it dropped, rotate the
4.
On FLHRS models only, remove bolt (with flat washer) to
alignment tool four positions in a counterclockwise
free rear of fuel tank from frame backbone. Removal of
direction or one position in a clockwise direction.
rear bolt also releases instrument console bracket.
Repeat step 11.
5.
Raise instrument console and bend back flexible clamp
15.
Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
on canopy to release main harness conduit. Remove
MAXI-FUSE, INSTALLATION.
fuel level sender/fuel pump connector
[141],
4-place
Packard, at top of canopy.
6.
Lay a clean shop towel on forward part of rear fender.
Lift the instrument console from fuel tank and lay upside
FLHR/C/S
down on shop towel.
7.
Pull external latches outward to disconnect ignition/light
IGNITION/LIGHT KEY SWITCH
key switch connector [33], 3-place Packard. See Figure
8-78.
Removal
8.
Remove four screws to release switch from console.
1.
Remove seat. See Section 2.25 SEAT, REMOVAL.
8-58
2006 Touring: Electrical
HOME
Installation
1.
Align holes in new switch with those in console. See Fig-
f2101x8x
ure 8-78.
2.
Start four screws and alternately tighten to 20-30 in-lbs
(2.3-3.4 Nm) in a crosswise pattern.
3.
Connect ignition/light key switch connector [33], 3-place
Packard.
4.
Slide head of console mounting bolt into slot at top of
canopy.
5.
Moving instrument console toward installed position,
install fuel level sender/fuel pump connector [141], 4-
place Packard, at top of canopy. Bend flexible clamp to
capture main harness conduit.
6.
Align hole in instrument console with console mounting
bolt and place into position on fuel tank.
Figure 8-79. Fork Lock (FLHR/C/S)
7.
Install acorn nut at top of instrument console and tighten
to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
Phillips screw and large flat washer (absent on FLHRS
Installation
models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).
1.
Install new fork lock assembly into bore of upper fork
8.
On FLHRS models only, install bolt (with flat washer) to
bracket. See Figure 8-79.
secure rear of fuel tank and instrument console bracket
to frame backbone. Tighten bolt to 15-20 ft-lbs (20-27
2.
Install two allen head socket screws (with flat washers)
Nm).
and alternately tighten to 36-60 in-lbs (4.1-6.8 Nm).
9.
Insert bolt through battery negative cable (black) into
NOTE
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
On HDI models, install new break-away screws and turn in a
clockwise direction until heads snap off. Verify that threads in
10.
Install seat. See Section 2.25 SEAT, INSTALLATION.
upper fork bracket are clean and in good condition or heads
may break off before fork lock assembly is properly tightened.
Avoid losing heads of screws in motorcycle as vibration may
FORK LOCK
cause captured heads to scratch finished surfaces, chafe
wires or cause other damage.
Removal
3.
Install the handlebar clamp shroud. See Section 2.32
1.
Remove the handlebar clamp shroud. See Section 2.32
WINDSHIELD/HEADLAMP NACELLE
(FLHR/C/S),
WINDSHIELD/HEADLAMP NACELLE
(FLHR/C/S),
NACELLE INSTALLATION (FLHR/C), steps 3-15, or
NACELLE REMOVAL
(FLHR/C), steps
1-11, or
NACELLE INSTALLATION (FLHRS), steps 5-13.
NACELLE REMOVAL (FLHRS), steps 1-7.
2.
Start acorn nuts on both the left and right side fork studs
to keep halves of headlamp nacelle on motorcycle.
3.
Remove two allen head socket screws (with flat wash-
ers) and pull fork lock assembly from upper fork bracket
bore. See Figure 8-79.
NOTE
On HDI models, use a center punch to make a pilot hole at
the top of each break-away screw. Install a 1/8 inch left
handed bit in drill and set the drill to reverse. Positioning the
bit in the pilot hole, spin out the break-away screws.
2006 Touring: Electrical
8-59
HOME
FAIRING CAP SWITCHES (FLHTC/U)
8.20
7.
Gently pry two latches on bracket outward to release
REMOVAL
tabs on switch. Remove switch from bracket. See Figure
8-81.
1.
Partially disassemble ignition switch. See Section 8.19
IGNITION/LIGHT KEY SWITCH AND FORK LOCK,
8.
If replacing Cruise or Speaker Switch, cut Black/Green
FLHX, FLHT/C/U, FLTR, REMOVAL, steps 1-5.
wire lead halfway between Cruise and Speaker Switch
2.
Remove two T27 TORX screws (with flat washers) to
terminals.
release fairing cap from left and right sides of inner fair-
9.
Follow the wires of the faulty switch to the socket hous-
ing.
ing, or reference Figure 8-82 and Table 8-13 for the
3.
With the front forks turned to the left fork stop, reach
applicable chamber numbers. For wire location pur-
behind right side of fairing cap and disconnect the fairing
poses, numbers are stamped into the secondary locks of
cap switch connector [105], 12-place Multilock (black).
both the pin and socket housings.
4.
Remove the fairing cap from the motorcycle. See Figure
10. Remove the appropriate terminals from the socket hous-
8-80.
ing.
5.
Bend back the flexible clamp to release switch wires
NOTE
from the inboard side of the fairing cap. Carefully cut
cable straps to free wires from bundles.
For instructions on properly removing wire terminals, see
6.
Remove two T25 TORX screws to release switch bracket
APPENDIX B.2 MULTILOCK ELECTRICAL CONNECTORS,
from fairing cap.
REMOVING SOCKET/PIN TERMINALS.
f1305b2x
9
5
10
8
7
6
2
10
1
3
2
1.
Fairing Cap Switch Connector [105]
6.
Auxiliary Lamp Switch
4
2.
Cable Strap
7.
Speaker Switch
3.
Flexible Clamp
8.
Cruise Switch
4.
Switch Bracket TORX Screws
9.
Accessory Switch
5.
Switch Bracket
10. Grommet
Figure 8-80. Fairing Cap (Inboard Side) - Ultra Model Shown
8-60
2006 Touring: Electrical
HOME
INSTALLATION
Table 8-13. Fairing Cap Switches [105]
Chamber
1.
Feeding wires through bracket, place new switch into
Switch
Wire Color
Number
position. Engage tabs on switch in slots of latches and
then gently bend tabs upward to lock position of switch
Orange/Red
1
in bracket.
Accessory
Orange
2
2.
Install terminals into socket housing.
Black
3
NOTE
Orange/Violet
4
For instructions on properly installing wire terminals, see
Cruise
Red/Green
5
APPENDIX B.2 MULTILOCK ELECTRICAL CONNECTORS,
Ultra Only
Black/Green
To
INSTALLING SOCKET/PIN TERMINALS.
12
Speaker
(Double Lugged)
Switch
3.
If Cruise or Speaker Switch was replaced, butt splice
Yellow
6
Black/Green wire lead between Cruise and Speaker
Auxiliary
Gray/Black
7
Switch terminals.
Lamp
Black
8
NOTE
Orange/Blue
9
For detailed butt splicing information, see APPENDIX B.6
SEALED BUTT SPLICE CONNECTORS.
Speaker
Violet/Orange
10
Ultra Only
Brown/Orange
11
4.
Install two T25 TORX screws to secure switch bracket to
fairing cap.
Black/Green
To Cruise Switch
5.
Install new cable straps to capture wire bundles and
then secure switch wires to the fairing cap using the flex-
ible clamp. Route the wires as shown in Figure 8-80.
6.
Verify that the rubber grommets are installed on each
side of the fairing cap. Barbs on cap fit into holes in
grommets.
2
– AMP
6
7
8
9
10
11
12
3
Secondary Locks Open
f1287b2x
Figure 8-82. Numbers Stamped on Secondary Locks
(Socket Housing Shown)
1
7.
Connect the fairing cap switch connector [105], 12-place
Multilock (black), on the right side of fairing cap.
1.
Switch Bracket
2.
Latch
8.
With the front forks turned to the left fork stop, install fair-
3.
Tab
ing cap over ignition switch housing. Verify that grom-
4.
Cable Strap
mets in fairing cap fully capture handlebar along with
throttle and clutch cables.
4
9.
Start two T27 TORX screws (with flat washers) to fasten
fairing cap to left and right sides of inner fairing. Alter-
nately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).
f1304b2x
10. Assemble ignition switch. See Section 8.19 IGNITION/
LIGHT KEY SWITCH AND FORK LOCK, FLHX, FLHT/
C/U, FLTR, INSTALLATION, steps 6-15.
Figure 8-81. Bend Latches Outward to Release Tabs
2006 Touring: Electrical
8-61
HOME
INSTRUMENT NACELLE SWITCHES (FLTR)
8.21
7.
Follow instructions based on location of defective switch.
REMOVAL
1.
Partially disassemble ignition switch. See Section 8.19
LEFT SIDE SWITCH
IGNITION/LIGHT KEY SWITCH AND FORK LOCK,
FLHX, FLHT/C/U, FLTR, REMOVAL, steps 1-5.
a. See Figure 8-83. Disconnect left side switch from
instrument nacelle switch harness as follows:
2.
Remove T25 TORX screw on left and right side of instru-
ment bezel.
● Speaker Switch connector [105], 4-place Multilock.
3.
Use thumbs to push tab at rear of bezel from slot in front
b. Pull clutch cable clip from hole on left side of instru-
of ignition switch. Gently raise free side of bezel until
ment nacelle.
tabs at front of instrument nacelle become disengaged
c. Remove two T40 TORX bolts (with flat washers) to
from slot at front of bezel (concealed behind decorative
release left side of instrument nacelle from upper
adhesive strip).
and lower fork brackets.
4.
Raising bezel slightly, remove anchor on ambient tem-
d. Unthread rubber boot from odometer reset switch,
perature sensor from hole in bottom inboard ear of
and while carefully removing left side instrument
speedometer bracket.
nacelle from motorcycle, pull odometer reset switch
5.
See Figure 8-83. Disconnect instruments and indicator
from hole. Move left side of nacelle to bench area
lamps from interconnect harness as follows:
leaving right side on motorcycle. See Figure 8-86.
● Speedometer connector [39], 12-place Packard.
e. Gently bend back molded retainer to release switch
● Tachometer connector [108], 12-place Packard.
bracket assembly from instrument nacelle.
● Indicator lamps connector [21], 10-place Multilock.
f.
Carefully pry two latches on bracket outward to
release tabs on switch. Remove switch from
6.
Remove bezel from motorcycle.
bracket. See Figure 8-84.
[21] Indicator Lamps
[39] Speedometer Gauge
[105A/B]
[21]
[105A/B] Instrument Nacelle Switches
[105C/D] Speaker Switch
[107] Ambient Temperature Sensor
[108]
[108] Tachometer Gauge
Throttle
Cables
[39]
Clutch
Cable
[105C/D]
[107]
f2219x8x
Figure 8-83. Instrument Nacelle (Bezel Removed)
8-62
2006 Touring: Electrical
HOME
RIGHT SIDE SWITCHES
Table 8-14. Right Side
Instrument Nacelle Switches
a.
See Figure 8-83. Disconnect left side switch from
instrument nacelle switch harness as follows:
Chamber Number
●
Speaker Switch connector [105], 4-place Multilock.
Switch
Wire Color
12-Place
4-Place
b.
See Figure 8-83. Disconnect instrument nacelle
Multilock
Multilock
switches from interconnect harness as follows:
Socket
Pin
●
Instrument nacelle switch connector [105], 12-place
Orange/Red
1
Multilock.
Accessory
Orange
2
c.
Pull throttle cable clip from hole on right side of
instrument nacelle.
Black
3
d.
Remove two T40 TORX bolts (with flat washers) to
Orange/Violet
4
release right side of instrument nacelle from upper
and lower fork brackets. Move right side of nacelle
Red/Green
5
Cruise
to bench area leaving left side on motorcycle. See
Black/Green
Figure 8-86.
12
4
(Double Lugged)
e.
Gently bend back molded retainer to release switch
bracket assembly from instrument nacelle.
f.
Carefully pry two latches on bracket outward to
release tabs on switch. Remove switch from
bracket. See Figure 8-84.
g.
Remove the appropriate terminals from the socket
and/or pin housings. Follow the wires of the faulty
switch or reference Table 8-14 for the applicable
chamber numbers. For wire location purposes,
numbers are stamped into the secondary locks. See
Figure 8-85.
– AMP
6
7
8
9
10
11
12
Secondary Locks Open
f1287b2x
2
Figure 8-85. Numbers Stamped on Secondary Locks
(Socket Housing Shown)
3
NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.2 MULTILOCK ELECTRICAL CONNECTORS,
REMOVING SOCKET/PIN TERMINALS.
1
h. Carefully pull wires to draw terminals through con-
duit to backside of switch. For best results, pull one
wire at a time.
1.
Switch Bracket
INSTALLATION
2.
Latch
3.
Tab
1.
Follow instructions based on location of defective switch.
LEFT SIDE SWITCH
f2215x8x
a. Place new switch into position in bracket. Engaging
tabs on switch in slots of latches, gently bend tabs
Figure 8-84.
Bend Latches Outward to Release Tabs
upward to lock position of switch in bracket.
2006 Touring: Electrical
8-63
HOME
f2214x8x
CONNECTOR
DESCRIPTION
NUMBER
[A, C] = Pin
[B, D] = Socket
LEFT SIDE
[105A, 105B]
Interconnect to Nacelle Switch Harness
[105]
[105C, 105D]
Nacelle Switch Harness to Speaker Switch
Clutch
Cable Clip
RIGHT SIDE
Speaker
Switch [105D]
4-Place Multilock
Throttle
Cable Clip
Instrument Nacelle
Switches [105B]
12-Place Multilock
Speaker
Switch [105C]
4-Place Multilock
f2213x8x
Figure 8-86. Instrument Nacelle Halves
b. Snap switch bracket into molded retainer in instru-
f.
Capture clutch cable in cable clip. Insert cable clip
ment nacelle.
into hole in left side of instrument nacelle.
c. While carefully placing left side of instrument
g. Move to RIGHT SIDE SWITCHES, step 2.
nacelle on motorcycle, slide odometer reset switch
through hole and install rubber boot.
d. See Figure 8-83. Connect left side switch to instru-
RIGHT SIDE SWITCHES
ment nacelle switch harness as follows:
a. Place new switch into position in bracket. Engaging
● Speaker Switch connector [105], 4-place Multilock.
tabs on switch in slots of latches, gently bend tabs
upward to lock position of switch in bracket. See
Figure 8-84.
e. Install two T40 TORX bolts (with flat washers) to fas-
ten left side instrument nacelle to upper and lower
b. Push terminals through two lengths of conduit to
fork brackets. Alternately tighten bolts to 15-20 ft-lbs
wire end of socket or pin housing. For best results,
(20-27 Nm).
push one wire through conduit at a time.
8-64
2006 Touring: Electrical
HOME
c. Install terminals into socket or pin housing. See
2.
See Figure 8-83. Looking into the instrument nacelle,
Table 8-14 and Figure 8-85.
connect instruments and indicator lamps to interconnect
harness as follows:
NOTE
● Speedometer connector [39], 12-place Packard.
For instructions on properly installing wire terminals, see
APPENDIX B.2 MULTILOCK ELECTRICAL CONNECTORS,
● Tachometer connector [108], 12-place Packard.
INSTALLING SOCKET/PIN TERMINALS.
● Indicator lamps connector [21], 10-place Multilock.
d. Snap switch bracket into molded retainer in instru-
3.
Install anchor on ambient temperature sensor into hole
ment nacelle.
in bottom inboard ear of speedometer bracket.
e. Install right side of instrument nacelle on motorcy-
4.
Verify that left and right sides of instrument nacelle are
cle.
properly mated. Pins on left side of nacelle must fully
f.
See Figure 8-83. Connect left side switch to instru-
engage holes on right.
ment nacelle switch harness as follows:
5.
Insert tab at rear of bezel into slot of instrument nacelle
● Speaker Switch connector [105], 4-place Multilock.
(just in front of ignition switch). Holding left and right
sides of nacelle together, place bezel over instrument
g. See Figure
8-83. Connect instrument nacelle
nacelle flange. When properly mated, tabs at front of
switches to interconnect harness as follows:
instrument nacelle engage lip in slot at front of bezel
(behind decorative adhesive strip).
● Instrument nacelle switch connector [105], 12-place
Multilock.
NOTE
h. Install two T40 TORX bolts (with flat washers) to fas-
If tabs do not properly engage slot at front of bezel, then a
ten right side instrument nacelle to upper and lower
loose fit will result. Remove decorative adhesive strip by gen-
fork brackets. Alternately tighten bolts to 15-20 ft-lbs
tly prying up outer edges, and using a flat bladed screwdriver,
(20-27 Nm).
carefully raise tabs so that they engage lip in slot. If dam-
aged, install new decorative adhesive strip.
i.
Capture throttle cables in cable clip. Insert cable clip
into hole in right side of instrument nacelle.
6.
Install T25 TORX screw on each side of bezel. Alter-
nately tighten screws to 25-35 in-lbs (2.8-4.0 Nm).
7.
Assemble ignition switch. See Section 8.19 IGNITION/
LIGHT KEY SWITCH AND FORK LOCK, FLHX, FLHT/
C/U, FLTR, INSTALLATION, steps 6-15.
2006 Touring: Electrical
8-65
HOME
HANDLEBAR SWITCHES
8.22
NOTE
GENERAL
Use the eyelet of an ordinary cable strap if the cardboard
insert is not available.
The basic switch configuration is the “Road King.” The Road
King switches have no specialized functions. Other switches,
1.
Place the cardboard insert between the brake lever and
referred to as the Road King Classic, Classic and Ultra, have
lever bracket. See Figure 8-87.
additional functions, such as cruise control, sound system
2.
Remove the two T27 TORX screws with flat washers
controls, etc., which cause them to differ from the Road King
securing the handlebar clamp to the master cylinder
switches. To accommodate these added functions, special
housing. Remove the brake lever/master cylinder
lower switch housings are provided.
assembly and clamp from the handlebar.
NOTE
3.
Using a T25 TORX drive head, remove the upper and
Regardless of model or option, all motorcycles use the same
lower switch housing screws.
upper switch housings. The motorcycles and their switch con-
4.
Remove the friction shoe from the end of the tension
figurations are as follows:
adjuster screw (non cruise equipped models only).
Table 8-15. Handlebar Switches
NOTE
The friction shoe is a loose fit and may fall out or become dis-
Road King
lodged if the lower switch housing is turned upside down or
FLHR
FLHRI
FLHRS
FLHRSI
shaken.
Road King Classic
5.
Remove the brass ferrules from the notches on the
inboard side of the throttle control grip. Remove the fer-
FLHRCI
rules from the cable end fittings.
Classic
6.
Remove the throttle control grip from the end of the han-
dlebar.
FLHX
FLHXI
FLHT
FLHTI
FLHTC
FLHTCI
7.
Pull the crimped inserts at the end of the throttle and idle
Ultra
control cable housings from the lower switch housing.
FLTRI
FLHTCUI
For best results, use a rocking motion while pulling.
Place a drop of light oil on the retaining rings, if neces-
NOTE: See Figures 8-95 thru 8-98 for illustrations.
sary. Remove the cables from the switch housing.
8.
Cut two cable straps to release wire harness conduit
NOTE
from handlebar.
To replace or repair individual switches in either the right or
left handlebar switch assemblies, see SWITCH REPAIR/
REPLACEMENT in this section.
7959
REMOVAL
NOTE
While there are four different switch configurations for Touring
models (Road King, Road King Classic, Classic and Ultra),
the removal procedures are the same. To simplify these
instructions, only the Road King switch configuration is repre-
sented in the photographs and illustrations which follow.
RIGHT HANDLEBAR CONTROLS
CAUTION
5/32 Inch
(4.0 mm)
Do not remove the switch housing assembly without first
Cardboard
placing the 5/32 inch (4.0 mm) cardboard insert between
Insert
the brake lever and lever bracket. Removal without the
insert may result in damage to the rubber boot and
Figure 8-87. Install Cardboard Insert
plunger of the Front Stoplight Switch.
8-66
2006 Touring: Electrical
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