Harley Davidson FLHRC 2006. Maintenance & Repair Manual — page 26

HOME

LEFT HANDLEBAR CONTROLS

7958

Remove the two T27 TORX screws with flat washers

Upper

securing the handlebar clamp to the clutch lever bracket.

Switch Housing

Remove the clutch hand lever assembly and clamp from

Cable

the handlebar.

End

Fittings

Using a T25 TORX drive head, remove the upper and

lower switch housing screws.

Cut two cable straps to release wire harness conduit

from handlebar.

Remove hand grip from handlebar, if damaged. See

Section

2.23 HANDLEBARS, LEFT HAND GRIP,

REMOVAL.

INSTALLATION

Figure 8-89. Route Cable to Upper Switch Housing

NOTE

While there are four different switch configurations for Touring

Note the different diameter inserts crimped into the end

models (Road King, Road King Classic, Classic and Ultra),

of the throttle and idle control cable housings. See Fig-

the installation procedures are the same. To simplify these

ure 8-88.

instructions, only the Road King switch configuration is repre-

Push the larger diameter insert (silver) on the throttle

sented in the photographs and illustrations which follow.

cable housing into the larger hole in front of the tension

adjuster screw.

RIGHT HANDLEBAR CONTROLS

Push the smaller diameter insert (gold) on the idle cable

housing into the smaller hole at the rear of the tension

With the concave side facing upward, install the friction

adjuster screw.

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

screw (non cruise equipped models only).

NOTE

To aid assembly, place a drop of light oil on the retaining

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

rings of the crimped inserts. Always replace the retaining

lodged if the switch housing is turned upside down or

rings if damaged or distorted.

shaken.

Route the cable to the upper switch housing as shown in

Push the throttle and idle control cables into the lower

Figure 8-89.

switch housing until they snap in place. Proceed as fol-

lows:

Slide the throttle control grip over the end of the right

handlebar until it bottoms against the closed end. Rotate

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

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

7961

Position the lower switch housing beneath the throttle

control grip. Install the brass ferrules onto the cables so

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

ferrules in their respective notches on the throttle control

grip. Verify that the cables are captured in the grooves

molded into the grip. See Figure 8-90.

Position the upper switch housing over the handlebar

and lower switch housing.

Throttle

Cable Insert

Verify that the wire harness conduit runs in the depres-

(Silver)

sion at the bottom of the handlebar. Be sure that the

Idle

upper switch housing harness will not be pinched under

Cable Insert

the handlebar when the switch housing screws are tight-

(Gold)

ened.

Start the upper and lower switch housing screws, but do

Figure 8-88. Install Throttle/Idle Control Cables

not tighten.

in Lower Switch Housing

2006 Touring: Electrical

8-67

HOME

CAUTION

See Figure 8-91. Do not remove the 5/32 inch (4.0 mm)

cardboard insert (or cable strap eyelet) wedged between

the brake lever and lever bracket. Removal will result in

damage to the rubber boot and plunger of the Front

Stoplight Switch during installation of the master cylin-

der assembly.

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. See Figure 8-92.

10. Align the holes in the handlebar clamp with those in the

master cylinder housing and start the two T27 TORX

screws (with flat washers). Position for rider comfort.

Beginning with the top screw, tighten the screws to 60-

80 in-lbs (6.8-9.0 Nm).

11. 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

f1474x2x

of the switch.

Throttle Grip

Groove

12. Remove the cardboard insert between the brake lever

Idle Cable

Notch

and lever bracket.

Throttle Cable

Ferrule

The completed assembly appears as shown in Figure 8-

95.

Figure 8-90. Install Throttle/Idle Cables

13. Secure wire harness conduit to handlebar using two

new cable straps. Position first cable strap approxi-

mately 4-5 inches (102-127 mm) from handlebar clamp.

f1225x2x

Cut any excess cable strap material.

14. Test the switches for proper operation.

Groove

f1785x8x

5/32 Inch

(4.0 mm)

Cardboard

Insert

Tab

Switch Housing Assembly

Groove

Brake Lever Bracket

Figure 8-91. Leave Cardboard Insert in Place

Figure 8-92. Fit Brake Lever/Master Cylinder to

Right Handlebar Switch Housings

8-68

2006 Touring: Electrical

HOME

7964

7966

Tab

Groove

Switch

Grip

Clutch

Housing

Sleeve

Assembly

Ribs

Lever

Bracket

Figure 8-94. Fit Clutch Lever Bracket to

Left Handlebar Switch Housings

Grooves

Using a T25 TORX drive head, tighten the lower and

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

Figure 8-93. Install Left Handlebar Switch Housings

NOTE

Always tighten the lower switch housing screw first so that

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

LEFT HANDLEBAR CONTROLS

of the switch.

Install new hand grip, if removed,. See Section 2.23

The completed assembly appears as shown in Figure 8-

HANDLEBARS, LEFT HAND GRIP, INSTALLATION.

95.

Install upper and lower switch housings on handlebar.

Secure wire harness conduit to handlebar using two

Be sure that ribs on outboard side of switch housings fit

new cable straps. Position first cable strap approxi-

in grooves molded into grip. See Figure 8-93.

mately 4-5 inches (102-127 mm) from handlebar clamp.

Cut any excess cable strap material.

Verify that the wire harness conduit runs in the groove at

Test the switches for proper operation.

the bottom of the handlebar. Be sure that the upper

switch housing harness will not be pinched under the

handlebar when the switch housing screws are tight-

ened.

Start the upper and lower switch housing screws, but do

not tighten.

Position the clutch hand lever assembly inboard of the

switch housing assembly engaging the tab on the lower

switch housing in the groove at the bottom of the clutch

lever bracket. See Figure 8-94.

Align the holes in the handlebar clamp with those in the

clutch lever bracket and start the two T27 TORX screws

(with flat washers). Position for rider comfort. Beginning

with the top screw, tighten the screws to 60-80 in-lbs

(6.8-9.0 Nm).

2006 Touring: Electrical

8-69

HOME

f1228a2x

Right Handlebar Switch Housings

Upper Switch Housing:

● Engine Start Switch

● Engine Stop Switch: Off/Run

Lower Switch Housing:

● Turn-Right Signal Switch

● Front Stoplight Switch

Left Handlebar Switch Housings

Upper Switch Housing:

● Horn Switch

● Light Switch: Hi(gh) and Lo(w) Beam

Lower Switch Housing:

● Turn-Left Signal Switch

f1227a2x

Figure 8-95. Road King Handlebar Switch Assemblies

Right Handlebar Switch Housings

f2158x8x

Upper Switch Housing:

● Engine Start Switch

● Engine Stop Switch: Off/Run

Lower Switch Housing:

● Turn-Right Signal Switch

● Front Stoplight Switch

● Cruise Control Switch: Set/Res(ume)

Left Handlebar Switch Housings

Upper Switch Housing:

● Horn Switch

● Light Switch: Hi(gh) and Lo(w) Beam

Lower Switch Housing:

● Turn-Left Signal Switch

f2157x8x

● Cruise Control Switch: On/Off

Figure 8-96. Road King Classic Handlebar Switch Assemblies

8-70

2006 Touring: Electrical

HOME

f1370a8x

Right Handlebar Switch Housings

Upper Switch Housing:

● Engine Start Switch

● Engine Stop Switch: Off/Run

Lower Switch Housing:

● Turn-Right Signal Switch

● Front Stoplight Switch

● Mode Select Switch: UP/DN

Left Handlebar Switch Housings

Upper Switch Housing:

● Horn Switch

● Light Switch: Hi(gh) and Lo(w) Beam

Lower Switch Housing:

f1369a8x

● Turn-Left Signal Switch

● Audio Control Switch: +/-

Figure 8-97. Classic Handlebar Switch Assemblies

f1368a8x

Right Handlebar Switch Housings

Upper Switch Housing:

● Engine Start Switch

● Engine Stop Switch: Off/Run

Lower Switch Housing:

● Turn-Right Signal Switch

● Front Stoplight Switch

● Mode Select Switch: UP/DN

● Cruise Control Switch: Set/Res(ume)

Left Handlebar Switch Housings

Upper Switch Housing:

● Horn Switch

● Light Switch: Hi(gh) and Lo(w) Beam

Lower Switch Housing:

● Turn-Left Signal Switch

● Audio Control Switch: +/-

f1367a8x

● Squelch Control and Driver P(ush)

T(o) T(ransmit) Switch: SQ-/PTT/SQ+

Figure 8-98. Ultra Handlebar Switch Assemblies

2006 Touring: Electrical

8-71

HOME

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

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 motorcycles 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

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

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

faulty.

replacing upper housing switches, proceed to step 8.

RIGHT SIDE HANDLEBAR (ALL MODELS)

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 8-99.

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 8-100. 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 8-99.

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.

8-72

2006 Touring: Electrical

HOME

f1271x2x

Screw

Splices

Start

Stop

Start

Stop

Switch

Bracket

Wing

Cable

Channel

Conduit

f1272x2x

Conduit

Strap

Figure 8-99. Upper Right Handlebar Switch Housing

Figure 8-100. Upper Right Handlebar Switch Housing

(Without Splices)

(With Splices)

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

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

Slide conduit forward over severed ends of switch wires

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

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 8-99.

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

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

See GENERAL REPAIR PROCEDURES in this section.

Loop switch wires so that spliced lengths are positioned

as shown in Figure 8-102. Route wires downstream of

LEFT SIDE HANDLEBAR (ALL MODELS)

splices beneath wing on High/Low Beam Switch side of

bracket as seen in Figure 8-101.

● 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

See Figure 8-101. 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.

2006 Touring: Electrical

8-73

HOME

f1269x2x

Screw

Horn

Beam

Horn

Beam

Switch

Bracket

Wing

Cable

f1270x2x

Conduit

Splices

Strap

Figure 8-101. Upper Left Handlebar Switch Housing

Figure 8-102. 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-

101.

card old switch assembly.

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

Remove any excess cable strap material. See Figure 8-

NOTE

102.

Replacement Turn-Right Signal Switch wires are cut to length

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

11. See LEFT SIDE HANDLEBAR SWITCHES, ASSEM-

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

NOTE

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

inches) and partially stripped.

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.

8-74

2006 Touring: Electrical

HOME

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 8-103.

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 8-104.

Screw

f1309x2x

Figure 8-104. 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 8-103. Install Stoplight Switch

TIONS on the next page.

2006 Touring: Electrical

8-75

HOME

Install shorter screw to secure front side of lower bracket

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

f1294x2x

7 Inch

Cable Strap

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

ing.

Bracket

Note lettering for proper orientation and gently push key-

cap onto switch shaft.

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 8-105.

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 8-105. 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 8-106.

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.

8-76

2006 Touring: Electrical

HOME

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 8-106. 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

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

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 8-109.

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.

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

card old switch assembly.

See GENERAL REPAIR PROCEDURES in this section.

2006 Touring: Electrical

8-77

HOME

f1327x2x

f1326x2x

Left Side

Right Side

Left Turn Signal Switch and Bracket

Right Turn Signal Switch and Bracket

Lower Bracket

Stoplight Switch

Audio Control Switch

Mode Select Switch

Audio Switch Keycap

Mode Select Keycap

Figure 8-107. Lower Handlebar Switch Assemblies (Classic)

f1329x2x

f1328x2x

Left Side

Right Side

Left Turn Signal Switch and Bracket

Right Turn Signal Switch and Bracket

Lower Bracket

Stoplight Switch

Audio Control Switch

Cruise Control Switch

Audio Switch Keycap

10. Cruise Switch Keycap

PTT Switch

11. Mode Select Switch

PTT Switch Keycap

12. Mode Select Keycap

Figure 8-108. Lower Handlebar Switch Assemblies (Ultra)

8-78

2006 Touring: Electrical

HOME

Remove two lower bracket screws. See Figure 8-109.

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

See LEFT SIDE HANDLEBAR, FINAL INSTRUCTIONS

f1306x2x

on this page.

Figure 8-109. 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.

2006 Touring: Electrical

8-79

HOME

Loop switch wires so that spliced lengths are positioned

as shown in Figure 8-111.

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 8-111. 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 8-110. 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 8-110.

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 8-111. 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

8-80

2006 Touring: Electrical

HOME

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 8-113. 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-

drical appearance.

Figure 8-112. Splice Switch Wires

CAUTION

Electrically connected solder outside the tubing may

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

cause a short to ground resulting in switch failure.

ends of switch wires until all strands are tightly coiled.

Inspect the melted sealant for solder beads. Excess sol-

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

der or heat may force some solder out with the melted

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

sealant. Use a small needle nose pliers to remove any

new switch assembly.

solder found. Briefly heat the connection to reseal the

tubing if solder beads were removed. Use less solder or

NOTE

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

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

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 8-112. 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

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 8-112.

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

wire around the right with the results shown in C of

Figure 8-112.

d. Solder the spliced connections.

Ultra Torch UT-100 (HD-39969)

Robinair Heat Gun (HD-25070)

NOTE

Robinair Heat Gun Shrink Tool Attachment

For best results, do one wire at a time.

(HD-41183)

Center the heat-shrink tubing over the soldered splices.

Figure 8-113. Radiant Heating Devices

2006 Touring: Electrical

8-81

HOME

reduce heating time or intensity when doing subsequent

LEFT SIDE HANDLEBAR SWITCHES

splices.

ASSEMBLY

Cut cable strap compressing conduit and move to its

original position.

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

replacing upper housing switches, proceed to step 6.

Install upper and lower switch housings on handlebar.

RIGHT SIDE HANDLEBAR SWITCHES

Be sure that ribs on outboard side of switch housings fit

ASSEMBLY

in grooves molded into grip. Verify that the wire harness

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

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

dlebar.

replacing upper housing switches, proceed to step 9.

Start the upper and lower switch housing screws, but do

With the concave side facing upward, install the friction

not tighten.

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

screw (non cruise equipped models only).

Position the clutch hand lever assembly inboard of the

switch housing assembly engaging the tab on the lower

NOTE

switch housing in the groove at the bottom of the clutch

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

lever bracket.

lodged if the lower switch housing is turned upside down or

shaken.

Align the holes in the handlebar clamp with those in the

clutch lever bracket and start the lower screw (with flat

Slide the throttle control grip over the end of the right

washer). Position for rider comfort. Beginning with the

handlebar until it bottoms against the closed end. Rotate

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

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

Nm) using a T27 TORX drive head.

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

Position the lower switch housing beneath the throttle

Using a T25 TORX drive head, tighten the lower and

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

control grip. Install the brass ferrules onto the cables so

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

NOTE

ferrules in their respective notches on the throttle control

grip. Verify that the cables are captured in the grooves

Always tighten the lower switch housing screw first so that

molded into the grip.

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

Position the upper switch housing over the handlebar

of the switch assembly.

and lower switch housing. Verify that the wire harness

Test the switches for proper operation.

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

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.

8-82

2006 Touring: Electrical

HOME

STOPLIGHT SWITCHES

8.23

FRONT STOPLIGHT SWITCH

REMOVAL/INSTALLATION

See Section

8.22 HANDLEBAR SWITCHES, SWITCH

REPAIR/REPLACEMENT.

REAR STOPLIGHT SWITCH

9658

REMOVAL

Figure 8-114. Rear Stoplight Switch

CAUTION

DOT 4 brake fluid will damage painted and molded-in

color surfaces it comes in contact with. Always use cau-

Using a

11/16 inch open end/box wrench on flats,

tion and protect surfaces from spills whenever brake

tighten rear stoplight switch to 12-15 ft-lbs (16.3-20.3

work is performed. Failure to comply can result in cos-

Nm).

metic damage. (00239a)

Fill and bleed rear brake system. See Section

2.14

BLEEDING HYDRAULIC BRAKES.

IMPORTANT NOTE

Verify proper operation of tail lamp/rear brake light.

Immediately wipe up any brake fluid spillage with a

clean, dry, soft cloth. Follow up by thoroughly wiping

affected area with a clean, damp, soft cloth (small spills)

or washing with a large quantity of soapy water (large

spills).

Remove bleeder valve cap on rear brake caliper. Install

end of a length of clear plastic tubing over caliper

bleeder valve, while placing free end in a suitable con-

tainer. Open bleeder valve about 1/2-turn. Pump brake

pedal to drain brake fluid. Close bleeder valve.

Using a

11/16 inch open end/box wrench on flats,

remove rear stoplight switch from rear brake line. See

Figure 8-114.

INSTALLATION

Apply Loctite Pipe Sealant with Teflon 565 to threads of

rear stoplight switch.

Install rear stoplight switch into rear brake line. See Fig-

ure 8-114.

2006 Touring: Electrical

8-83

HOME

NEUTRAL SWITCH

8.24

REMOVAL

CAUTION

Cover transmission top cover with masking tape to pre-

vent damage to chrome.

Using fingers and flat tip screwdriver, remove two elbow

connectors from neutral switch posts.

O-Ring

Using a 7/8 inch open end/box wrench on flats, remove

neutral switch and O-ring from transmission top cover.

f2236x8x

NOTE

Figure 8-115. Neutral Switch Assembly

If neutral switch connector is damaged, replace using Part

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

splice connector. For detailed butt splicing information, see

APPENDIX B.6 SEALED BUTT SPLICE CONNECTORS.

Using a 7/8 inch open end/box wrench on flats, install

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

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

INSTALLATION

Using fingers and a flat tip screwdriver, install the two

elbow connectors on neutral switch posts.

NOTE

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

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

neutral switch after top cover installation to ensure proper

nectors can be attached to either stud.

switch engagement.

Test neutral switch for proper operation as follows:

Roll the motorcycle back and forth to verify that the

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

transmission is in NEUTRAL.

position.

Lubricate O-ring with clean transmission oil.

b. Verify that neutral indicator lamp illuminates.

Remove masking tape from transmission top cover.

8-84

2006 Touring: Electrical

HOME

OIL PRESSURE SWITCH/SENDER

8.25

REMOVAL

INSTALLATION

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-

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

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

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

use rocking motion to remove 4-place Delphi 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.

FLHX, 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 Del-

phi connector.

Test oil pressure switch/sender for proper operation.

2006 Touring: Electrical

8-85

HOME

HORN

8.26

TROUBLESHOOTING

REMOVAL

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

Remove acorn nut and flat washer to free horn assembly

rily, check for the following conditions.

from rubber mount stud.

Remove elbow terminals from spade contacts and

● Discharged battery

release main harness conduit from J-clamp.

● Loose, frayed or damaged wiring leading to horn

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:

INSTALLATION

● Poor ground to frame through mounting hardware or

ground wire (see Steps 3-6 below)

Fit horn into chrome cover so that stud at back slides

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

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

TITE THREADLOCKER 222 (Purple) to threads of horn

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

stud.

nect a voltmeter as follows:

● Positive (+) lead to wire terminal

CAUTION

● Negative (-) lead to ground

Overtightening the flange nut can cause permanent horn

damage resulting in reduced volume and tone quality.

Turn ignition switch ON. Depress horn switch. If battery

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

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

100 in-lbs (9.0-11.3 Nm).

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

ing to horn is faulty.

Install elbow terminals onto spade contacts.

Connect an ohmmeter across the horn terminals. The

NOTE

resistance measured must be 45-66 ohms. Replace

horn if measured resistance is outside range given.

The horn is not polarity sensitive. Elbow terminals may be

attached to either spade contact.

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

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

Capture main harness conduit in J-clamp and install

faulty, replace the switch. See Section 8.22 HANDLE-

horn bracket onto rubber mount stud. Install flat washer

BAR SWITCHES, SWITCH REPAIR/REPLACEMENT.

and acorn nut. Tighten acorn nut to 80-100 in-lbs (9.0-

11.3 Nm).

8-86

2006 Touring: Electrical

Была ли эта страница вам полезна?

Да!Нет

3 посетителя считают эту страницу полезной.

Harley Davidson FLHRC 2006. Maintenance & Repair Manual — page 26

Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.