Harley Davidson Touring 2004 Service Manual sm08c

Download

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Set/Resume

Switch

110

120

90 100

MPH

RPM

x100

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Cruise Enabled/Engaged Lamp

Tachometer

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CRUISE CONTROL (FLHRC, FLTR, FLHTCU) 8.30

GENERAL

The Cruise Control system provides automatic vehicle speed control. The electronics and stepper motor are contained in a control module mounted under the left side cover. The stepper motor actuates the cruise control cable through a gear train and ribbon reel.

SYSTEM OPERATION

To engage and disengage the cruise control system, proceed as follows:

1. While riding in fourth or ﬁfth gear, turn the Cruise ON/ OFF Switch to the ON position. See Figure 8-123. The switch is located on the fairing cap of FLHTCU models, the instrument nacelle of FLTR models, and the left handlebar lower switch housing on FLHRC models. The Cruise Enabled/Engaged lamp in the tachometer face (speedometer on FLHRC models) turns red to indicate that the system is activated. See Figure 8-125. A red lamp in the switch on both FLHTCU and FLTR models also indicates this condition to the rider.

2. Power (12 vdc) is supplied to the cruise control module through a 15 amp fuse located in the fuse block mounted under the left side cover.

3. With the motorcycle traveling at the desired “cruise” speed (30 mph/48 km/h to 85 mph/137 km/h), momentarily push the Cruise SET/RESUME switch to SET. See

Figure 8-124.

Figure 8-124. Right Handlebar Switch Assembly

(FLTR, FLHTCU)

Ignition/Light

Key Switch

Cruise ON/OFF

Switch

Figure 8-125. Instrument Panel (FLHTCU)

The cruise control module “reads” the vehicle speed sensor (VSS) output to establish the desired vehicle speed. The module then sends a signal to the stepper motor which drives the ribbon reel to take up the slack in the cruise cable. The Cruise Enabled/Engaged lamp in the tachometer face (speedometer on FLHRC models) turns from red to green to indicate that the cruising speed is locked in. See Figure 8-125.

4. The cruise control module monitors both the engine RPM and the VSS output speed signal. The module signals the stepper motor to open or close the throttle to keep the speedometer output speed signal constant. The engine RPM is monitored to detect engine

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Figure 8-123. Fairing Cap (FLHTCU)

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DISENGAGE SEQUENCEENGAGE SEQUENCE

CRUISE SWITCH ON

SET/RESUME

SWITCH TO SET

READS VSS

OUTPUT SPEED SIGNAL

STEPPER MOTOR

GEAR TRAIN

& RIBBON REEL

CRUISE ENGAGED

LAMP

THROTTLE

ACTUATION

*Tachometer receives signal from ignition coil on

carbureted models, and from ECM on EFI models.

overspeed, a condition which automatically causes cruise disengagement.

5. The cruise control automatically disengages (stepper motor drives cruise cable to the full-out position) whenever the cruise control module receives one of the following inputs:

a. Front or rear brake is applied. b. Throttle is “rolled back” or closed, thereby actuating

idle cable roll-off (disengage) switch.

c. Motorcycle clutch is disengaged (module senses

too great an increase in RPM).

d. Cruise ON/OFF Switch placed in the OFF position.

The switch is located on the fairing cap of FLHTCU models, the instrument nacelle of FLTR models, and the left handlebar lower switch housing on FLHRC models. The green Cruise Enabled/Engaged lamp in the tachometer face (speedometer on FLHRC models) is extinguished to indicate that the system is deactivated. The red lamp in the fairing cap switch of FLHTCU models and the instrument nacelle switch of FLTR models is also extinguished.

e. Handlebar mounted Engine Stop Switch placed in

the OFF position. (This removes tachometer input signal which results in module disengagement.)

ENGINE RPM MONITORED*

Figure 8-126. Cruise System Diagram

FRONT/REAR BRAKE

IDLE CABLE ROLL-OFF

(DISENGAGE) SWITCH

CRUISE

MODULE

f. Handlebar mounted Cruise SET/RESUME switch is

pushed to SET and held in that position until vehicle speed drops below 30 mph (48 km/h).

If the vehicle speed is above 30 mph (48 km/h) when the Cruise SET/RESUME Switch is released, then the cruise system automatically re-engages.

CRUISE SWITCH OFF

HANDLEBAR

ENGINE STOP

SWITCH OFF

CLUTCH DISENGAGE

(ENGINE RPM)

NOTE

CABLE ADJUSTMENT

NOTE Always adjust the cables in the sequence presented below, that is, throttle and then idle cable. The cruise cable only requires adjustment if the cruise module or cruise cable are removed or replaced, and then it must be adjusted last using the CABLE LASH INITIALIZATION routine on the next page.

THROTTLE CABLE

1. With handlebar in straight ahead position, idle cable

adjusted to full slack and throttle control grip turned to wide open throttle (WOT), adjust pull open cable to obtain full throttle opening at carburetor/induction module.

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2. Twist throttle grip to full closed position. Check that idle stop-screw is touching idle stop with handlebar in straight ahead position, and while turning handlebar from “lock-to-lock”.

NOTE

If idle stop-screw is not touching idle stop, adjust (loosen) pull-open cable just enough so that contact is made through full lock-to-lock handlebar movement. Also check that cruise cable has slack and is not opening throttle. Loosen cruise cable if required.

3. Rotate throttle grip to WOT and release. Throttle must return to idle position freely. If it does not, check for incorrect cable routing, damaged cables or binding in the throttle grip.

IDLE CABLE

1. Remove left side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

2. Gently pull side cover from frame downtubes (no tools required).

3. Lift the locking latch and remove the cruise module connector [17]. With idle cable still adjusted to full slack position, connect ohmmeter to violet/yellow and orange/ violet leads on connector [17A].

4. Ohmmeter must indicate inﬁnity (switch contacts open). If ohmmeter indicates continuity, the roll-off switch may be shorted and entire cable must be replaced.

5. With handlebar in straight ahead position, adjust idle cable until approximately 0.06 inch (1.5 mm) of freeplay exists at the outside diameter (OD) of the throttle grip.

6. With light force, rotate the throttle grip toward the closed position. The ohmmeter must indicate continuity. If it does not, decrease freeplay at throttle grip by adjusting the idle cable to obtain continuity while maintaining some freeplay at the throttle grip.

7. While holding the throttle grip (with light force) in the closed position, turn handlebar from “lock-to-lock”. Ohmmeter must indicate continuity throughout handlebar movement.

8. With handlebar in straight ahead position, rotate throttle grip to WOT and release. Throttle must return to idle position freely.

9. Repeat step 8 with handlebar at full left and right positions. If throttle does not return to idle position freely, loosen idle cable slightly and repeat steps 6-9.

10. Install cruise module connector [17] and engage locking latch.

11. Align barbed studs in side cover with grommets in frame downtubes and push ﬁrmly into place (no tools required).

12. Install left side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

CABLE LASH INITIALIZATION

With the elimination of the mechanical cruise cable adjuster, the tolerance stack-ups are intended to result in a cable that is too long. The extra cable length is then taken up upon execution of the Cable Lash Initialization routine. During the routine, the system calculates the number of “motor steps” the cable is pulled before the throttle plates are moved (a maximum of 200 motor steps equivalent to 1.2 inches or 31 mm). This information is then stored in permanent memory.

NOTE Perform the initialization routine whenever the cruise module, cruise cable or throttle body are removed or replaced. For best results, be sure the engine is at normal operating temperature and throttle and idle cables are correctly adjusted and operational.

To set the correct cable lash, proceed as follows:

a. Push the Cruise Switch on the right handlebar to

RESUME and hold b. Tu rn the Cruise ON/OFF switch to ON. c. Turn the Ignition/Light Key Switch to IGNITION. d. Start the engine. The green Cruise Enabled/

Engaged lamp in the tachometer face (speedometer

on FLHRC models) will illuminate. Wait 3 seconds

for the lamp to go off. e. Release the Cruise Switch from the RESUME posi-

tion. f. Push the Cruise Switch to RESUME and hold

Cruise will pull in cable until change in RPM is

detected. The number of motor steps required to rev

the engine is stored in memory. g. After engine revs and Cruise Enabled/Engaged

lamp is extinguished, release the Cruise Switch

from the RESUME position. h. Turn the Ignition/Light Key Switch to OFF.

THROTTLE/IDLE CABLES

NOTE While the same throttle cable is used on all Touring models, the idle cable of “cruise” models is provided with a cruise rolloff (disengage) switch.

REMOVAL

1. See Section 2.21 THROTTLE CABLES (NON-CRUISE),

REMOVAL, THROTTLE SIDE.

2. Remove the air cleaner and backplate. See Section 4.5

AIR CLEANER, REMOVAL.

3. Raise fuel tank to access cables in area of frame back-

bone. For carbureted models, see Section 4.7 FUEL

TANK (CARBURETED), PA RTIAL REMOVAL, FLHT/C,

or FLHR/S. For fuel injected models, see Section 9.4

FUEL TANK (FUEL INJECTED), PARTIAL REMOVAL, FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

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Insulator

Switch Spade

Contact

Female Spade

External

Step

Main

Harness

Terminal

Cruise Control

Roll-Off Switch

(Under Boot)

Idle Cable

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Figure 8-127. Throttle/Idle Cable Conﬁguration (Right Side View)

4. Locate the cruise control roll-off switch plumbed into the idle cable on the right side of the vehicle. See Figure 8-

127. Push rubber boot on switch forward to access

spade type wire terminals.

5. Remove both female spade type terminals from spade contacts on cruise control roll-off switch.

Carbureted:

Using a needle nose pliers, carefully pull idle cable barrel from upper inboard hole in throttle wheel. Pull throttle cable barrel from remaining hole. Release idle and throttle cables from guides in throttle cable bracket.

Induction Module:

Using a needle nose pliers, carefully pull idle cable barrel from upper hole in throttle wheel. Pull throttle cable barrel from lower hole. Using slots, release idle and throttle cables from guides in throttle cable bracket.

7. Free cables from J-clamp riveted to right side of frame backbone.

8. If present, remove screw (with ﬂat washer) to release Jclamp from wellnut in right side of steering head. Remove J-clamp from cables.

INSTALLATION

1. See Section 2.21 THROTTLE CABLES (NON-CRUISE), INSTALLATION, THROTTLE SIDE.

Throttle Cable

2. Route the throttle and idle cables as follows:

FLHTCU:

Route the cables downward following the brake line to the inner fairing. Pass the cables through the inner fairing grommet and then loop them toward the rear along the right side of the steering head.

FLHRC:

Route the cables downward following the right handlebar to the handlebar clamp shroud. Pass the cables through the opening in the shroud and then loop them toward the rear along the right side of the steering head. Capture cables in J-clamp and then start screw (with ﬂat washer) to fasten J-clamp to wellnut in right side of steering head. Tighten screw to 9-18

in-lbs

(1.0-

2.0 Nm).

3. Route the throttle and idle cables rearward along the right side of the frame backbone. After passing through J-clamp riveted to frame backbone, route cables downward to carburetor/induction module.

4. Use a pliers to straighten spade contacts of cruise rolloff switch if bowed or bent back. The contacts must be parallel and line up perpendicular to the idle cable.

5. Separate the cruise roll-off switch wires up to the point where they enter the wire harness conduit. Now route the leads straight down.

6. Orient the idle cable so that the spade contacts are at the top.

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7. Slide the insulators onto the switch spade contacts (polarity is not a factor). For maximum insertion, be sure that the external step on the insulators face each other. See Figure 8-127.

8. Fit the rubber boot over the cruise control roll-off switch. An oval cut in the boot accommodates the switch spade terminal connections.

9. Position the throttle cable below the idle cable.

10.

Carbureted:

shorter cable guide in throttle cable bracket. Drawing throttle cable downward, ﬁt barrel end into lower outboard hole in throttle wheel. Install sleeve and spring on idle cable housing into longer cable guide inserting barrel end into upper inboard hole in throttle wheel.

Induction Module:

ing into shorter cable guide at top of throttle cable bracket. Drawing throttle cable downward, ﬁt barrel end into lower hole in throttle wheel. Install sleeve and spring on idle cable housing into longer cable guide at bottom of throttle cable bracket inserting barrel end into upper hole in throttle wheel.

11. Verify that cables are fully seated in channel of throttle wheel, and using cable adjusters at handlebar, tighten

Install sleeve on throttle cable housing into

Install sleeve on throttle cable hous-

cables as necessary to keep barrel ends from dislodging. Verify operation by turning throttle grip and observing cable action.

12. Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER PA RTIAL REMOVAL), FLHT/C, or FLHR/S. For fuel

injected models, see Section 9.4 FUEL TANK (FUEL

INJECTED), INSTALLATION (AFTER PARTIAL REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

13. Install backplate and air cleaner assembly. See Section

4.5 AIR CLEANER, INSTALLATION.

14. Adjust the throttle and idle cables. Be sure to use the cable adjustment procedure for Ultra models. See

CABLE ADJUSTMENT, in this section.

CRUISE CABLE

REMOVAL

1. Remove the air cleaner and backplate. See Section 4.5

AIR CLEANER, REMOVAL.

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Cruise Module

Connector [17]

Spare Fuse

Holder

Cruise Cable

Connector

Fuse Block

Cruise Module

Maxi-Fuse

Holder

Figure 8-128. Cruise Control Module (Under Left Side Cover)

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7. Pull the cable out of the connector and remove the cable end bead from the ribbon end eyelet. See Figure 8-130.

8. Pull anchored cable clip from hole in frame crossmember. See Figure 8-131.

9. Carefully pull cruise cable from beneath fuel tank drawing it out through hole in frame crossmember.

INSTALLATION

Wheel Pin

End Fitting

Figure 8-129. Remove End Fitting From Wheel Pin

2. Remove E-clip from sleeve at end of cruise cable housing. Discard E-clip. Using slot, remove cruise cable housing from cable guide in throttle cable bracket.

3. Push the plastic end ﬁtting on the cruise cable to the outboard side to release from wheel pin. See Figure 8-129.

4. Remove left side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

5. Gently pull side cover from frame downtubes (no tools required).

6. Rotate cruise cable connector in a counterclockwise direction to detach from cruise module. See Figure 8-

128.

Flat

1. Draw the cruise cable forward along the left side of the frame backbone, and then route the cable toward the right side of the vehicle in front of the top engine stabilizer bracket.

2. Slide groove in cruise cable end ﬁtting over cap of wheel pin. Push on end ﬁtting until it snaps in place. See Figure

8-129.

3. Using slot, slip cruise cable housing into cable guide in throttle cable bracket. At bottom of bracket, install

new

E-clip on sleeve at end of cruise cable housing.

4. Feed cruise cable and connector through hole in frame crossmember. See Figure 8-131.

CAUTION

Be sure that the ribbon is not twisted. A twisted ribbon may adversely affect performance or even prevent cruise operation.

5. With the hole in the ribbon end eyelet and the ﬂat on the cable connector housing facing outboard, ﬁt cable end bead into ribbon end eyelet. See Figure 8-130.

Ribbon

Cruise Cable

Connector

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Figure 8-130. Remove Cable End Bead From Ribbon End Eyelet

8-104 2004 Touring: Electrical

Cruise

Module

Ribbon End

Eyelet

Cable End

Bead

1WARNING1WARNING

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Mounting

Holes

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Cruise

Cable

Cable Clip

Hole

Figure 8-131. Cruise Cable Routing (Left Side)

6. Verify that bead, eyelet and ribbon are lined up correctly. If necessary, remove plastic end ﬁtting from wheel pin and gently pull on end ﬁtting to remove cable slack. Reinstall end ﬁtting, if removed.

7. Insert cruise cable connector into cruise module and rotate in a clockwise direction until tabs on connector fully engage grooves or detentes in cruise module housing.

8. Capture cruise cable in cable clip and anchor in hole of frame crossmember. See Figure 8-131.

9. Adjust the throttle and idle cables. See CABLE ADJUST-

MENT, in this section.

10. Install backplate and air cleaner assembly. See Section

4.5 AIR CLEANER, INSTALLATION.

11. Align barbed studs in side cover with grommets in frame downtubes and push ﬁrmly into place (no tools required).

12. Install left side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

13. Perform the CABLE LASH INITIALIZATION routine des- cribed in this section.

Always disconnect the negative battery cable ﬁrst. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury.

4. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal.

5. Unthread bolt and remove battery positive cable (red) from battery positive (+) terminal.

6. Using a T40 TORX drive head, loosen bolt to move lip of hold-down clamp off edge of battery. Remove battery from battery box.

7. Lift the locking latch and remove the cruise module connector [17]. See Figure 8-128.

8. Rotate cruise cable connector in a counterclockwise direction to detach from cruise module.

9. From inside battery box, remove three ﬂange bolts. Carefully pull cruise module away from side of battery box exercising caution to avoid losing grommets.

INSTALLATION

1. Install grommets into holes on left side of battery box with the larger OD on the outboard side. See Figure 8-

132.

2. Align threaded holes on inboard side of cruise module with holes in grommets and install ﬂange bolts from inside battery box.

3. Alternately tighten ﬂange bolts to 60-96 Nm). Install cruise module connector [17] and engage locking latch.

in-lbs

(6.8-10.9

CRUISE CONTROL MODULE

REMOVAL

1. Remove the air cleaner and backplate. See Section 4.5

AIR CLEANER, REMOVAL.

2. Push the plastic end ﬁtting on the cruise cable to the outboard side to release from wheel pin. See Figure 8-129.

3. Remove seat. See Section 2.24 SEAT, REMOVAL.

Figure 8-132. Battery Box (Right Side View)

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CAUTION

Be sure that the ribbon is not twisted. A twisted ribbon may adversely affect performance or even prevent cruise operation.

4. With the hole in the ribbon end eyelet and the ﬂat on the cable connector housing facing outboard, ﬁt cable end bead into ribbon end eyelet. See Figure 8-130.

5. Verify that bead, eyelet and ribbon are lined up correctly. If necessary, remove plastic end ﬁtting from wheel pin and gently pull on end ﬁtting to remove cable slack.

6. Insert cruise cable connector into cruise module and rotate in a clockwise direction until tabs on connector fully engage grooves or detentes in cruise module housing.

7. Install the cruise module connector [17] until locking latch engages. See Figure 8-128.

8. Place battery in battery box, terminal side forward. Rotate hold-down clamp so that lip (with rubber pad) rests on edge of battery and tighten clamp bolt.

1WARNING1WARNING

Always connect the positive battery cable ﬁrst. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury.

CRUISE CONTROL SWITCHES

FAIRING CAP

See Figure 8-133. For instructions on replacement of the CRUISE ON/OFF SWITCH, see Section 8.19 FAIRING

CAP SWITCHES (FLHTC/U), Section 8.20 INSTRUMENT NACELLE SWITCHES (FLTR), or Section 8.21 HANDLEBAR SWITCHES (FLHRC).

Cruise ON/OFF

Switch

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Figure 8-133. Fairing Cap (FLHTCU)

9. Insert bolt through battery positive cable (red) into threaded hole of battery positive (+) terminal. Tighten bolt to 60-96

10. Insert bolt through battery negative cable (black) into threaded hole of battery negative (-) terminal. Tighten bolt to 60-96

11. Install seat. See Section 2.24 SEAT, INSTALLATION.

12. Slide groove in cruise cable end ﬁtting over cap of wheel pin. Push on end ﬁtting until it snaps in place. See Figure

8-129.

13. Install backplate and air cleaner assembly. See Section

4.5 AIR CLEANER, INSTALLATION.

14. Perform the CABLE LASH INITIALIZATION routine des- cribed in this section.

in-lbs

(6.8-10.9 Nm).

AUDIO HARNESS

For instructions on replacement of the audio harness, see Section 8.32 WIRING HARNESSES AND CABLES,

AUDIO HARNESS (FLHTCU).

HANDLEBAR

See Figure 8-134. For instructions on replacement of the handlebar mounted CRUISE SET/RESUME switch, see Section 8.21 HANDLEBAR SWITCHES, SWITCH

REPAIR/REPLACEMENT.

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Set/Resume

Switch

Figure 8-134. Right Handlebar Switch Assembly

(FLTR, FLHTCU)

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Radio Antenna

Cable [51]

Radio [27]

Black

CB Antenna

Cable [50]

Ultra Only

Radio [28]

Gray

Ultra Only

1. Main to Interconnect [1]

2. Main to Interconnect [15]

3. Ignition/Light Key Switch [33]

1 2 3

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PREMIUM SOUND SYSTEM (FLHTC/U, FLTR) 8.31

RADIO (FLHTC/U)

REMOVAL

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

1WARNING1WARNING

To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury.

CAUTION

To prevent possible damage to the sound system, always verify that the Ignition/Light Key Switch is in the OFF position before disconnecting the battery negative cable from the battery terminal.

2. Verify that the Ignition/Light Key Switch is in the OFF position. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal.

3. Remove the outer fairing. See Section 2.29 UPPER

FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/ WINDSHIELD, REMOVAL.

NOTE

To separate pin and socket halves of Radio connectors [27] and [28], use thumbnail to pull down external latch before pulling socket from pin side. See Figure 8-135.

4. See Figure 8-136. Separate pin and socket halves of the following connectors:

a. Radio connector [27], 23-place Amp (black).

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Figure 8-136. Radio Connections - FLHTCU

b. Radio antenna cable connector [51]. c. Radio connector [28], 23-place Amp (gray).

models only.

d. CB antenna cable connector [50]. Rotate knurled

nut counterclockwise until free.

Ultra models only.

Ultra

Figure 8-135. Pull Down Latch to Free Radio Connector

Figure 8-137. Release Carrier from Fairing Brackets

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5. Move the following connectors from their ﬁxed locations:

a. Main to interconnect harness connector [1], 12-

place Deutsch (black); T-stud at front of right fairing bracket.

b. Main to interconnect harness connector [15], 4-

place Packard (black); anchor in hole at bottom of radio (right side).

c. Ignition/light key switch connector [33], 4-place

Packard; anchor in hole at bottom of radio (center).

6. Using a long shank ball end socket (Snap-on® FABL6E), remove four screws to release radio from left and right radio support brackets. Use oblong holes in fairing brackets to access screws. See Figure 8-137.

7. Pull radio forward to remove. If radio nose seal gets caught on radio support brackets, rock up and down until free.

INSTALLATION

1. Position radio between radio support brackets and push into approximate position. If radio nose seal gets caught on radio support brackets, rock up and down while pushing. If necessary, spray nose seal with contact cleaner and repeat step.

2. Before pushing radio into cut of inner fairing, verify that nose seal is not distorted, compressed or pinched.

3. Align threaded inserts in radio sides with oblong holes in left and right radio support brackets. Starting with the rear screws, install four socket screws to fasten radio to brackets. Tighten screws to 35-45

4. See Figure 8-136. Mate pin and socket halves of the following connectors:

a. Radio connector [27], 23-place Amp (black).

b. Radio antenna cable connector [51].

c. Radio connector [28], 23-place Amp (gray).

models only.

d. CB antenna cable connector [50]. Insert pin and

rotate knurled nut clockwise until tight.

only.

5. Return the following connectors to their ﬁxed locations:

a. Main to interconnect harness connector [1], 12-

place Deutsch (black); T-stud at front of right fairing bracket.

b. Main to interconnect harness connector [15], 4-

place Packard (black); anchor in hole at bottom of radio (right side).

c. Ignition/light key switch connector [33], 4-place

Packard; anchor in hole at bottom of radio (center).

in-lbs

(4.0-5.1 Nm).

Ultra

Ultra models

6. Install outer fairing. See Section 2.29 UPPER FAIRING/

WINDSHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD, INSTALLATION.

CAUTION

To prevent possible damage to the sound system, always verify that the Ignition/Light Key Switch is in the OFF position before connecting the battery negative cable to the battery terminal.

7. Verify that the Ignition/Light Key Switch is in the OFF position. Insert bolt through battery negative cable (black) into threaded hole of battery negative (-) terminal. Tighten bolt to 60-96

8. Install seat. See Section 2.24 SEAT, INSTALLATION.

in-lbs

(6.8-10.9 Nm).

FRONT FAIRING SPEAKERS

REMOVAL

1. Remove the outer fairing. See Section 2.29 UPPER

FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/ WINDSHIELD, REMOVAL.

2. Carefully pull the socket terminals from the speaker spade contacts.

3. Using a T25 TORX drive head, remove three screws to release the speaker adapter assembly from the inner fairing.

4. Carefully pull speaker from adapter.

INSTALLATION

1. With the speaker spade contacts at the top of the adapter, the top being the side with the widest edge, snap speaker into adapter using ﬁnger pressure.

2. If speaker grille is loose, apply 3M-847 adhesive (HD Part No. 99618-60) to outer edge of adapter ring. Install grille on adhesive.

3. With the widest edge of adapter at the top, align holes in speaker adapter assembly with those in inner fairing.

4. Install two long screws to secure top of speaker adapter assembly to inner fairing. Capturing fairing support brace, install short screw in lower outboard hole (positioning ﬂat washer between adapter and support brace). The screw hole on the lower inboard side is not used.

5. Using a T25 TORX drive head, tighten the lower speaker screw to 22-28 upper speaker screws to 35-50

in-lbs

(2.5-3.2 Nm). Tighten the two

in-lbs

(4.0-5.7 Nm).

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f2192x8x

Console Pod

Cable Conduit

Console Pod

Connector [53]

12-Place Mini-Deutsch

OME

Fuel

Door

Headset

Receptacle

Cap

Console

Figure 8-138. Console Pod Assembly

6. Install the socket terminals onto the speaker spade contacts. Different size spade contacts prevent improper assembly.

7. Install the outer fairing. See Section 2.29 UPPER FAIR-

ING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/ WINDSHIELD, INSTALLATION.

f2019x8x

Pod

CONSOLE POD ASSEMBLY

5. Carefully cut anchored cable strap securing main harness, audio harness, console pod conduit, fuel level sender/fuel pump conduit, and fuel vapor vent tube to left side of frame backbone. Cut cable strap securing console pod conduit and audio harness to left frame tube at front of saddlebag rail.

6. Open fuel door on console. Remove two Allen head screws inboard of rubber bumpers. These screws secure console to clip nuts on the canopy bracket.

7. Remove Allen head screw to detach ﬂange at rear of console from clip nut on fuel tank weldment.

8. Lay a clean shop towel on forward part of the rear fender. Remove ﬁller cap from neck of fuel tank. Remove console and lay upside down on shop towel. Reinstall ﬁller cap.

9. Bend back ﬂexible clamp to release pod cable conduit from bottom of console.

10. Release Console Pod Connector [53], 12-place MiniDeutsch, from attachment clip anchored in hole of frame crossmember (at rear of battery box). See Figure 8-139. Depress external latches and use a rocking motion to separate pin and socket halves.

11. Remove three Phillips screws to release pod from console.

INSTALLATION

1. Feed pin housing and conduit through top of console seating pod in recess. Install three Phillips screws screws to secure pod to console. Alternately tighten screws to 6-11 ﬂexible clamp at bottom of console.

in-lbs

(0.7-1.2 Nm). Capture conduit in

The following instructions may also be used for replacement of the chrome fuel tank console on which the pod is mounted.

REMOVAL

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury.

2. Unthread bolt and remove battery negative cable (black)

3. Remove left side saddlebag. See Section 2.25 SAD-

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

NOTE

1WARNING1WARNING

from battery negative (-) terminal.

DLEBAG, REMOVAL.

required).

Figure 8-139. Disconnect Console Pod Connector

2004 Touring: Electrical 8-109

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Fuel

Tank

Fuel Pump,

Fuel Level

Sender Conduit

Console

Pod

f2007x9x

6. Mate pin and socket halves of Console Pod Connector [53], 12-place Mini-Deutsch. Install connector onto attachment clip anchored in hole of frame crossmember (at rear of battery box).

7. Insert bolt through battery negative cable (black) into threaded hole of battery negative (-) terminal. Tighten bolt to 60-96

8. Install seat. See Section 2.24 SEAT, INSTALLATION.

9. Align barbed studs in side cover with grommets in frame downtubes and push ﬁrmly into place (no tools required).

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

BAG, INSTALLATION.

in-lbs

(6.8-10.9 Nm).

Main

Harness

Bundle

Console

Pod Conduit

Figure 8-140. Console Pod Cable/Hose Routing

Fuel Vapor

Vent Tube

(To Vapor Valve)

Anchored

Cable Strap

(Top View)

Fuel

Overﬂow

Hose

Main

Harness

Bundle

1WARNING1WARNING

Exercise caution to avoid pinching or kinking the fuel overﬂow hose when console is installed. A blocked hose can cause excess gasoline to remain above the ﬁller neck insert, while fuel expansion can cause an overﬁlled tank to overﬂow through the ﬁller cap vent. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

2. Remove ﬁller cap. Place console over ﬁller neck onto canopy. Route cables from beneath console as shown in

Figure 8-140. Be sure that hoses and wires are not

pinched by the console during installation. Reinstall ﬁller cap.

3. Install Allen head screw to fasten rear ﬂange of console to clip nut on fuel tank weldment. Tighten screw to 25-30

in-lbs

(2.8-3.4 Nm).

4. Open fuel door on console. Install two Allen head screws to secure front of console to clip nuts on canopy bracket. Alternately tighten screws to 25-30

5. Snap anchor of frame backbone. Tighten cable strap capturing main harness, audio harness, console pod conduit, fuel level sender/fuel pump conduit, and fuel vapor vent tube. See

Figure 8-140. Install

pod conduit and audio harness to left frame tube at front of saddlebag rail. Cut any excess cable strap material.

new

cable strap into hole on left side of

new

cable strap to secure console

in-lbs

(2.8-3.4 Nm).

FRONT HEADSET RECEPTACLE

REMOVAL

1. Remove console pod. See CONSOLE POD ASSEM-

BLY, REMOVAL, in this section.

2. Remove terminals 6 through 12 from pin housing of 12place Mini-Deutsch connector.

NOTE For instructions on properly removing wire terminals, see APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,

REMOVING/INSTALLING PINS.

3. Raise headset receptacle cap. Place pin punch in either

notch of lock ring and rotate in a counterclockwise direction until loose. See Figure 8-141.

4. Remove lock ring and cap from headset receptacle.

5. Remove headset receptacle from pod.

INSTALLATION

1. From inside pod, insert threaded end of headset recep-

tacle through side hole.

Lock Ring

f2020x8x

Figure 8-141. Remove Lock Ring from Receptacle

Using Pin Punch

8-110 2004 Touring: Electrical

f1492b8x

Speaker

Box

Switch

Bracket

TORX Screw

OME

2. Place receptacle cap over end of headset receptacle so that it seats in recess of pod.

3. Open cap, and with the notches on the outboard side, thread lock ring onto headset receptacle.

4. Place pin punch in either notch of lock ring and rotate in a clockwise direction until tight.

5. Install terminals 6 through 12 into pin housing of 12place Mini-Deutsch connector.

Table 8-16. Front Headset Receptacle

Wire Color

Blue/Yellow 6

Ye llow/Black 7

Yellow/White 8

Yellow/Red 9

Black 10

Red 11

Black (Thick Insulation) 12

NOTE

For instructions on properly installing wire terminals, see APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,

REMOVING/INSTALLING PINS.

6. Install console pod. See CONSOLE POD ASSEMBLY,

INSTALLATION, in this section.

7. Test operation of headset receptacle.

Chamber

Number

REAR HEADSET RECEPTACLE

See Section 8.32 WIRING HARNESSES AND CABLES,

AUDIO HARNESS (FLHTCU).

REAR PASSENGER SWITCHES

REMOVAL

NOTE

Right and left side replacement passenger switch assemblies are interchangeable.

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

MAXI-FUSE, REMOVAL.

2. Open Tour-Pak.

3. Using a T10 TORX drive head, remove four screws and pull speaker grille from speaker box.

Figure 8-142. Remove Passenger Switch Assembly

(Right Side Speaker Box Shown)

4. Remove speaker from speaker box and carefully pull socket terminals from speaker spade contacts.

5. Remove trim ring and gently pull on wire harness to draw 6-place Mini-Deutsch connector out of speaker box.

6. Depress external latch on socket housing side and use a rocking motion to separate pin and socket halves of Mini-Deutsch connector.

7. Draw socket half of Mini-Deutsch connector back into speaker box and pull out through speaker hole.

8. Using a T25 TORX drive head, remove two screws to release switch bracket from inside of speaker box. Remove bracket using slot to free switch wires. See Fig-

ure 8-142.

9. Pull switch housing assembly, wire harness conduit, speaker terminals and Mini-Deutsch socket from speaker box using switch housing hole on outboard side.

10. Carefully pull keycap from switch shaft. Remove switch from switch housing.

11. Remove terminals 1 through 4 from socket housing.

NOTE

For instructions on properly removing wire terminals, see APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,

REMOVING/INSTALLING SOCKETS.

12. Pulling one wire at a time, remove four wires from conduit.

INSTALLATION

1. Pushing one wire at a time, feed four wires of through conduit.

new

switch

2004 Touring: Electrical 8-111

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f1494b8x

Passenger

Cavity

Switch

Slot

Slot faces toward the front on right side switch assembly, toward the rear on left side.

Switch

Housing

Keycap

DISASSEMBLED

Pink/White

Wire

Rib

f1495x8x

ASSEMBLED

Figure 8-143. Install Switch in Housing

2. Install terminals 1 through 4 into socket housing.

f1491x8x

Figure 8-144. Properly Orient Switch Bracket

Speaker

Box

Switch

Bracket

Slot

Forward

Rib

Bottom

Table 8-17. Rear Passenger Switches

Wire Color

Pink/White 1 Gray/White 2 Violet/Black 3

* Orange/Black 4

Mates to O/BK on [41A], BN/W on [42A].

8-112 2004 Touring: Electrical

Chamber

Number

f1492x8x

Figure 8-145. Install Passenger Switch Assembly

(Right Side Speaker Box Shown)

OME

NOTE

For instructions on properly installing wire terminals, see APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,

REMOVING/INSTALLING SOCKETS.

3. With the Pink/White wire at the bottom, place switch in cavity of switch housing. Bottom of the assembly is determined by location of rib on switch housing. See Fig-

ure 8-143.

4. Note lettering for proper orientation and gently push keycap onto switch shaft. When orienting keycap, remember that bottom of assembly is determined by location of switch housing rib.

5. Feed Mini-Deutsch socket connector, speaker terminals and conduit through switch housing hole on outboard side of speaker box until switch housing backplate contacts speaker box. Pull harness out through speaker hole.

6. Reaching into speaker box, align holes in bracket with holes in switch housing. Using a T25 TORX drive head, install two bracket screws. See Figure 8-145.

NOTE

To align bracket and switch housing holes, slot in bracket must face toward the front on right side assembly and toward the rear on left side. See Figure 8-144. Switch also must be square in cavity of switch housing or bracket will not ﬁt.

7. Feed Mini-Deutsch socket through speaker hole into speaker box and pull out through harness hole on inboard side.

REAR SPEAKERS

REMOVAL

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

MAXI-FUSE, REMOVAL.

2. Open Tour-Pak.

3. Using a T10 TORX drive head, remove four screws from speaker grille. Remove speaker grille from speaker box.

4. Remove speaker from speaker box. Carefully pull two socket terminals from speaker spade contacts.

INSTALLATION

1. Install two socket terminals onto speaker spade contacts. Different size spade contacts prevent improper assembly.

2. With spade contacts at bottom, install speaker in speaker box.

3. Align holes in speaker with those in speaker box. Align holes in grille with those in speaker.

4. Install four screws. Aternately tighten screws using a T10 TORX drive head.

5. Close Tour-Pak.

6. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

7. Test speaker for proper operation.

8. Mate pin and socket halves of Mini-Deutsch connector. Feed connector back up into speaker box pressing trim ring into hole.

9. Install socket terminals onto speaker spade contacts. On right side of vehicle, install socket terminal of the solid Green wire onto contact next to the red dot. On left side, install socket terminal of the solid Brown wire onto contact next to the red dot.

10. Align holes in speaker grille with those in speaker and slide four TORX screws through grille and speaker holes.

11. With spade contacts at bottom rear corner, position speaker/grille assembly against speaker box. Thread four screws into speaker box and tighten using a T10 TORX drive head.

12. Close Tour-Pak.

13. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

14. Test switch for proper operation.

CB LOADING COIL

REMOVAL

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

MAXI-FUSE, REMOVAL.

2. Open Tour-Pak. Open map pocket and remove acorn nuts. Remove map pocket and molded liner from TourPak.

3. Disconnect 1-place CB antenna cable connector on right side of Tour-Pak. Release cable from rear clip at bottom of Tour-Pak.

4. Remove Keps nut, ring terminal and ﬂat washer from loading coil stud.

5. Holding Phillips screw, remove ﬂange nut at bottom of Tour-Pak to release loading coil bracket. Remove loading coil from vehicle (with Phillips screw, external tooth lockwasher and ﬂange nut).

2004 Touring: Electrical 8-113

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INSTALLATION

1. Place

2. Mate pin and socket halves of 1-place CB antenna cable

3. Install ﬂat washer, ring terminal and Keps nut onto load-

4. Install molded liner in Tour-Pak. Install map pocket and

5. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,

6. Check SWR and adjust if necessary. Follow the SWR

new

loading coil into position aligning hole in bracket with hole in Tour-Pak. Holding ﬂange nut under To ur-Pak, install Phillips screw with external tooth lockwasher.

connector. Capture antenna cable in rear clip at bottom of Tour-Pak.

ing coil stud. Tighten hex nut.

secure using acorn nuts. Close Tour-Pak.

MAXI-FUSE, INSTALLATION.

Adjustment procedure in Section 6 of the 2004 ELECTRICAL DIAGNOSTIC MANUAL (Part No. 99497-04). Remove SWR meter, plug in antenna connector and tighten antenna connector stud.

AUDIO HARNESS

For removal and installation instructions, see Section 8.32

WIRING HARNESSES AND CABLES, AUDIO HARNESS (FLHTCU).

RADIO ANTENNA CABLE

For removal and installation, see Section 8.32 WIRING HAR-

NESSES AND CABLES, RADIO ANTENNA CABLE (FLHTC/U).

CB ANTENNA CABLE

For removal and installation, see Section 8.32 WIRING HAR-

NESSES AND CABLES, CB ANTENNA CABLE (FLHTCU).

8-114 2004 Touring: Electrical

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WIRING HARNESSES AND CABLES 8.32

MAIN HARNESS

REMOVAL- ALL MODELS (PART I)

1. Remove fuel tank. For carbureted models, see Section

4.7 FUEL TANK (CARBURETED), COMPLETE

REMOVAL, FLHT/C or FLHR/S. For fuel injected mod- els, see Section 9.4 FUEL TANK (FUEL INJECTED), COMPLETE REMOVAL, FLHT/C/U/I, FLTRI or FLHR/C/

S/I.

2. Unthread bolt and remove battery positive cable (red) from battery positive (+) terminal. (Battery negative cable already removed under FUEL TANK, COMPLETE REMOVAL.)

3. Using a T-40 TORX drive head, loosen bolt to move lip of hold-down clamp off edge of battery. Remove battery from battery box.

4. Remove left side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

5. Gently pull left side cover from frame downtubes (no tools required).

6. Repeat steps 4-5 to remove right side saddlebag and side cover.

NOTE

Depending upon model, continue procedure at REMOVAL-

FLHR/C/S (PART II), REMOVAL- FLTR (PART II), or REMOVAL- FLHT/C/U (PART II).

REMOVAL- FLHR/C/S (PART II)

1. Remove the Phillips screw at the bottom of the headlamp door (chrome ring). Remove the headlamp door.

2. Remove the eight Phillips screws to free the headlamp housing from the headlamp nacelle.

3. Squeeze the two external tabs to remove the wire connector at the back of the headlamp bulb. Remove the headlamp housing assembly from the motorcycle.

4. See Figure 8-146. Reaching inside the headlamp nacelle, disconnect main harness as follows:

●

Front fender tip lamp connector [32], 2-place Multilock (black); used on FLHR only. Passing lamps connector [73], 2-place Multilock

●

(white); used on FLHR/C only.

f2212x8x

Right Handlebar

Controls [22]

Passing Lamps

Switch [109]

Used on FLHR/C Only

Cruise Set/Resume

Switch [159]

Used on FLHRC Only

Figure 8-146. Headlamp Nacelle Connectors (FLHR/C/S)

Front Turn

Signals [31]

Passing Lamps [73]

Used on FLHR/C Only

Left Handlebar

Controls [24]

Cruise On/Off

Switch [158]

Used on FLHRC Only

Accessory

Switch [67]

Front Fender

Tip Lamp [32]

Used on FLHR Only

Headlamp [38]

2004 Touring: Electrical 8-115

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f2095x8x

Odometer

Reset Switch

Speedometer

Connector [39]

Figure 8-147. Instrument Console Assembly (FLHR/C)

Passing lamps switch connector [109], 4-place

●

Amp; used on FLHR/C only.

●

Accessory switch connector [67], 4-place Amp.

●

Right handlebar switch controls connector [22], 6place Deutsch (black); T-stud on fork stem nut lock plate (left side).

●

Cruise set/resume switch connector [159], 2-place Deutsch (black); used on FLHRC only.

●

Front turn signal lamps connector [31], 6-place Multilock; anchor in hole of fork stem nut lock plate (left side).

●

Left handlebar switch controls connector [24], 6place Deutsch (gray); T-stud on fork stem nut lock plate (left side).

●

Cruise on/off switch connector [158], 2-place Deutsch (gray); used on FLHRC only.

5. Carefully pull main harness rearward under right side of headlamp nacelle allowing conduit and connectors to hang over top of engine guard.

6. Remove screw and P-clamp to release main harness from right side of steering head.

7. See Figure 8-147. Moving to inboard side of instrument console, disconnect main harness as follows:

Ignition/Light Key Switch connector [33], 3-place

●

Packard. Indicator lights connector [21], 8-place Mini-Deut-

●

sch. Speedometer connector [39], 12-place Packard.

●

Flexible

Clip

Indicator Lights

Connector [21]

Ignition/Light

Key Switch Connector [33]

Flexible

Clip

Flexible

Clip

Plastic

Clip

8. Unthread rubber boot from odometer reset switch and pull switch from hole in instrument console.

9. Bend back ﬂexible clamps on inboard side of instrument console as necessary to release main harness conduit. Set instrument console aside.

10. Moving rearward, carefully cut

eleven

cable straps securing main harness to frame backbone and right and left frame tubes. See Figure 8-148.

NOTE

Continue procedure at REMOVAL- ALL MODELS (PART III).

REMOVAL- FLTR (PART II)

1. Remove the inner fairing. See Section 2.30 UPPER

FAIRING/WINDSHIELD (FLTR), INNER FAIRING, REMOVAL, steps 1-18.

2. Remove screw, two main harness ground ring terminals and P-clamp to release main harness bundle from right side of steering head.

3. Moving rearward, carefully cut securing main harness to frame backbone and right and left frame tubes. See Figure 8-148.

NOTE

Continue procedure at REMOVAL- ALL MODELS (PART III).

eleven

cable straps

8-116 2004 Touring: Electrical

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Frame

Backbone

9 A

3 A

4 A

2 A

2. See Figure 8-149. Disconnect main harness from interconnect harness as follows:

●

Main to interconnect harness connector [1], 12place Deutsch (black); T-stud at front of right fairing bracket.

●

Main to interconnect harness connector [2], 12place Deutsch (gray); T-stud on right fairing support brace.

Main to interconnect harness connector [15], 4-

●

place Packard (black); anchor in hole at bottom of radio (right side).

Main to interconnect harness connector [156], 6-

●

place Deutsch (gray); T-stud on right fairing support brace.

10 A

11 A

f2225x8x

1 Captures main harness, cruise roll-off switch conduit,

audio harness (FLHTCUI only) and frame backbone. 2 Captures ignition/EFI harness only. ANCHORED 3 Captures main harness and audio harness (FLHTCUI

only). ANCHORED 456 Captures main harness, audio harness (FLHTCUI only),

EFI/ignition harness, and conduit to fuel tank harness (all

models except FLHR/C/S). ANCHORED 78 Captures audio harness (FLHTCUI only) and upper frame

tube. 910 Captures main harness and audio harness (FLHTCUI

only). ANCHORED 11 Captures main harness, audio harness (FLHTCUI only),

fuel vapor vent tube and console pod or instrument

console conduit. ANCHORED 12 Captures main harness, audio harness (FLHTCUI only),

console pod or instrument console conduit and upper

frame tube. 13 Captures main harness, audio harness (FLHTCUI only),

console pod conduit (FLHTCUI only) and upper frame

tube.

5 A

6 A

Saddlebag

Guard

Figure 8-148. Cable Strap Locations

REMOVAL- FLHT/C/U (PART II)

1. Remove the outer fairing and windshield. See Section

2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD, REMOVAL.

3. See Figure 8-149. Disconnect ignition switch from main harness. Disconnect radio antenna cable. Proceed as follows:

Ignition switch connector [33], 4-place Packard

●

(black); anchor in hole at bottom of radio (center). Radio antenna cable connector [51]; back of radio

●

(left side).

4. Remove screw to release main harness ground ring terminal and brake line P-clamp from front of upper fork bracket.

5. Carefully pull main harness rearward under right side of fairing cap allowing conduit and connectors to hang over top of engine guard.

6. Remove screw, main harness ground ring terminal and P-clamp to release main harness (and audio harness on FLHTCU models) from right side of steering head.

7. Moving rearward, carefully cut

eleven

cable straps securing main harness to frame backbone and right and left frame tubes. See Figure 8-148. Carefully cut any cable straps securing main harness to audio harness.

NOTE

Continue procedure at REMOVAL- ALL MODELS (PART III).

REMOVAL- ALL MODELS (PART III)

1. If cruise equipped, locate the cruise control roll-off switch plumbed into the idle cable on right side of the steering head. Push rubber boot on switch forward and remove socket terminals from spade contacts.

2. Moving to left side of motorcycle, remove acorn nut to release horn bracket from rubber mount stud. Pull elbow terminals from spade contacts on horn and release conduit from J-clamp.

3. Remove ﬂange nut (10 mm) from left side ground stud on upper frame crossmember. Remove two main harness ground ring terminals. Repeat step to remove two main harness ground ring terminals from right side ground stud.See Figure 8-150.

2004 Touring: Electrical 8-117

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Main to Interconnect

Harness [2]

Main to Interconnect

Harness [156]

Main to Interconnect

Harness [15]

f2238x8x

Main to Interconnect

Harness [1]

Ignition

Switch [33]

Figure 8-149. Inner Fairing - Main Harness Connectors (FLHTC/U)

4. Depress latches on maxi-fuse holder and then slide cover rearward to disengage tongue from groove in fuse block cover.

5. Moving to right side of motorcycle, pull back boot at top of starter housing and remove ﬂange nut and main power cable ring terminal from post. Release cable from clip anchored to T-stud at front of battery tray. Draw main power cable to left side of motorcycle.

6. Carefully cut anchored cable strap to release fuse block conduit from fuse block bracket. Pull fuse block from tabs on bracket.

7. Remove the fuse block cover. Raise lipped side slightly to disengage slots from tabs on fuse block.

8. If cruise equipped, lift the locking latch and remove cruise module connector [17]. From inside battery box, remove three ﬂange bolts. Carefully pull cruise module away from side of battery box exercising caution to avoid losing grommets.

Radio Antenna

Cable [51]

9. Disconnect the rear fender lights connector [7], 8-place Multilock, anchored at front of rear fender. Detach pin housing from anchor.

10. Release ignition keyswitch and starter relays by pulling anchors on rubber molding from holes in frame weldment at rear of battery box. Remove relays and molding from connectors. Push connectors down into space below frame weldment.

11. Locate the turn signal/security module inside hole of frame weldment on opposite side. Depress tab at front of spring clip and lift to release legs from holes in weldment. Remove module and disconnect 12-place Deutsch connector [30]. Push connector down into space below frame weldment.

12. Pull rear fender lights, ignition keyswitch and starter relays, and turn signal/security module conduit and connectors out through opening above rear of fuse block bracket and allow to hang on left side of motorcycle.

8-118 2004 Touring: Electrical

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13. Depending upon model, proceed as follows:

FLHR/C/S: FLTR:

Move to step 14.

a. On left side of motorcycle, remove bolt (with ﬂat

washer) to remove passenger seat strap and saddlebag front mounting bracket. Remove Phillips screw and chrome frame tube cover.

b. Carefully cut cable strap to release radio antenna

cable from shoulder of upper frame tube (just in front of air valve mounting bracket). Cut cable strap to release radio antenna cable from slotted hole in rear fender support.

c. At bottom of radio antenna bracket, rotate knurled

ring to separate pin and socket halves of radio antenna cable connector [51].

d. Draw radio antenna cable forward to area of fuse

block bracket and allow to hang with other main harness branches.

FLHTC/U:

a. Open Tour-Pak and proceed as follows:

FLHTC:

f2250x8x

Remove rubber mat.

FLHTCU:

Open map pocket and remove acorn nuts with ﬂat washers. Remove map pocket and molded liner from Tour-Pak.

b. Depress external latch and remove bulb socket from

left side of Tour-Pak.

c. Rotate knurled ring in a counterclockwise direction

to separate pin and socket halves of radio antenna cable connector [51]. Release cable from two clips at bottom of Tour-Pak.

d. On FLHTCU models, depress button and separate

pin and socket halves of Tour-Pak lights connector [12], 3-place Multilock, inside Tour-Pak.

e. Pull grommet into Tour-Pak and remove from main

harness conduit.

f. Pull Tour-Pak lights and radio antenna cable con-

nectors through hole at front of Tour-Pak. Cut cable strap to release conduit from luggage rack rail.

g. Draw Tour-Pak lights and radio antenna cable con-

nectors forward to area of fuse block bracket and allow to hang with other main harness branches. Remove ﬂange nuts to release passenger hand rail, if necessary.

Main Harness

Ground Ring Terminals (2)

Main Harness

Ground Ring

Terminals (2)

Fuel Tank Harness

Connector [13]

Not Present on FLHR/C/S

B+ Connector [160]

Chassis

Ground Cable

Accessory

Connector [4]

Battery

Positive Cable

Battery

Negative Cable

Figure 8-150. Electrical Connectors - Upper Frame Cross Member (Under Seat)

2004 Touring: Electrical 8-119

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Anchored Cable Strap

Captures Main Harness Conduit,

Neutral Switch Conduit and

Vehicle Speed Sensor Cable

f2276x8x

Battery

Box

See Figure 8-150.

Cable Strap

Captures Main Harness Conduit

and Frame Downtube

Captures Rear Brake Light Switch Wires

Cable Strap

and Lower Frame Tube

Cable Strap Anchor

Captures Main Harness Conduit

and Rear Brake Line

Figure 8-151. Cable Straps (Right Side View)

14. Cut anchored cable strap to release accessory connector [4] and B+ connector [160] from left side of frame crossmember (in front of battery box). See Figure 8-150.

15. Cut cable strap to release vapor valve from mounting bracket. Move vapor valve out of the way to facilitate harness removal.

16. Alternately feed branches of main harness hanging on left side of motorcycle into battery box through opening above front of fuse block bracket. For best results, feed one length of conduit through at a time drawing the fuse block through the opening last. Pulling branches out of battery box, allow conduit and connectors to hang on left side of frame backbone.

17. Moving to front right side of motorcycle, locate crankshaft position sensor connector [79], 2-place Mini-Deutsch, ﬁxed to bracket at bottom of voltage regulator. Push connector toward right side of motorcycle to disengage small end of slot on attachment clip from T-stud on bracket. Lift connector off T-stud. Depress button on socket terminal side and pull apart pin and socket halves.

18. Locate oil pressure sender at the front right side of the crankcase. On FLHR/C/S models, pull elbow from post of oil pressure switch. On FLHT/C/U and FLTR models, pull external latch outward and use rocking motion to remove Packard connector from oil pressure sender.

Cable Strap

Captures Main Harness Conduit,

Voltage Regulator Cables and

Lower Frame Tube

Cable Strap Anchor

Captures Main Harness Conduit,

Voltage Regulator Cables and

Rear Brake Line

19. Cut cable strap to free voltage regulator cables and main harness conduit (leading to oil pressure sender and crankshaft position sensor connectors) from inboard side of rear brake pedal weldment. See Figure 8-151.

20. Cut cable straps from two anchors installed on T-studs at top of lower frame tube.

21. Locate voltage regulator connector [77], 1-place Deutsch, just below the transmission exhaust bracket. Depress external latch to separate pin and socket housings.

22. Depress external latch and pull solenoid connector from top of starter housing.

23. Remove two elbow connectors from neutral switch posts.

24. Pull two socket terminals from spade contacts on rear brake light switch. Cut cable strap to free rear brake light switch wires from lower frame tube.

25. Cut cable strap at rear of rear brake light switch bracket to release main harness conduit from frame downtube.

26. Cut anchored

cable strap in hole of frame downtube (inboard of rear swingarm bracket) to release vehicle speed sensor cable, main harness and neutral switch conduit.

8-120 2004 Touring: Electrical

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8321

Rubber

Boot

OME

27. Pull ignition/EFI harness connector [8] from slot in electrical bracket. Depress external latches and separate pin and socket halves.

28. Remove two ﬂange nuts to release electrical bracket from studs on side of battery box. Release security siren connector and conduit from inboard side of electrical bracket.

29. Pull ignition/EFI harness connector [8] and security siren connector [142] and conduit into battery box through opening at rear of frame crossmember.

30. Draw neutral switch wires out from under starter housing. For best results, move electrical bracket out of the way and reach in under right side of battery box.

31. Carefully pull rear brake light switch, starter solenoid, and neutral switch conduit and connectors rearward and then feed up into battery box through same opening at rear of frame crossmember. See Figure 8-152.

32. Note that main harness runs forward of the front battery box TORX screw. Pull harness to the rear of the screw, and then draw conduit and connectors out of battery box and allow to hang on right side of frame backbone. See lower frame of Figure 8-153.

Figure 8-152. Feed Harness Into Battery Box (Right Side)

CAUTION

Damage to wires can result in electrical problems. Be sure that rubber boot is present on threaded end of battery box TORX screw. Replace rubber boot if absent or damaged. See upper frame of Figure 8-153.

33. Remove main harness from motorcycle.

INSTALLATION- ALL MODELS (PART I)

NOTE

Disregard references to radio antenna cable and starter relay connectors when working on FLHR/C/S models. The connectors are not part of the main harness on these motorcyles.

1. Position main harness on motorcycle as follows:

a. Lay main harness on frame backbone so that front

branches hang over top of right engine guard. On FLHR/C/S models, front branches terminate in headlamp and handlebar switch control connectors (see Figure 8-146). On FLTR and FLHT/C/U models, front branches terminate in the ignition switch, radio antenna cable and interconnect harness connectors (see Figure 8-149).

b. Adjust harness so that left and right side branches

split from main branch at location of anchor at center of frame backbone.

Figure 8-153. Battery Box TORX Screw (Right Side)

NOTE

If reusing the main harness, thread new cable strap through eye in anchor and loosely capture main harness bundle. If installing a new harness, remove and discard old anchor and plug anchor attached to new harness into hole in center of frame backbone.

Left Side

c. Locate left side branch terminating in rear fender

lights, ignition keyswitch and starter relays, turn signal/security module, fuse block, cruise module (if equipped) and radio antenna cable connectors. Feed connectors and conduit into battery box pulling branches out through opening above front of fuse block bracket. Continue drawing harness out through opening until two main harness ground ring terminals are adjacent to left side ground stud on frame crossmember.

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d. Feed rear fender lights, ignition keyswitch and

starter relays, and turn signal/security module conduit and connectors through opening above rear of fuse block bracket to area in front of rear fender.

NOTE

On FLTR and FLHT/C/U models, leave longer conduit of radio antenna cable hanging outboard of fuse block bracket.

Right Side

e. Feed right side connectors and conduit into battery

box pulling voltage regulator, oil pressure sender and crankshaft position sensor connectors and conduit out through opening at rear of frame crossmember. Feed connectors and conduit forward and then downward following front of frame downtube. Continue drawing harness out through opening in side of battery box until two main harness ground ring terminals are adjacent to right side ground stud on frame crossmember.

2. Returning to left side of motorcycle, route horn conduit in front of the top stabilizer link and then under the top engine mounting bracket to back of horn. Install elbow terminals onto horn spade contacts. Capture conduit in J-clamp. Slide horn bracket onto rubber mount stud and install acorn nut with ﬂat washer. Tighten acorn nut to 80-100 in-lbs (9.0-11.3 Nm).

3. Slide two main harness ground ring terminals onto left side ground stud on upper frame crossmember and install ﬂange nut (10 mm). Install chassis ground ring terminal onto right side ground stud and then two main harness ground ring terminals and ﬂange nut (10 mm). Tighten ﬂange nuts to 50-90 in-lbs (5.7-10.2 Nm). See

Figure 8-150.

4. Mate pin and socket halves of rear fender lights connector [7], 8-place Multilock, and attach to anchor at front of rear fender.

5. At front of rear fender, feed ignition keyswitch and starter relay connectors up through rectangular shaped hole in frame weldment. Fit relay connectors into rubber molding and install anchors on molding into holes in frame weldment. Install relays in connectors.

6. Feed turn signal/security module connector [30] up through hole on opposite side of frame weldment and connect to module. Install module into hole in frame weldment. Insert legs of spring clip into holes in weldment and push down until tab at front snaps in place.

7. If cruise equipped, install grommets into holes on left side of battery box with the larger OD on the outboard side. Align threaded holes on inboard side of cruise module with holes in grommets and install ﬂange bolts from inside battery box. Alternately tighten ﬂange bolts to 60-96 in-lbs (6.8-10.9 Nm). Install cruise module connector [17] and engage locking latch.

8. Slide cover over fuse block until slots fully engage tabs on block. Slide fuse block into position on mounting bracket. Tabs on bracket ﬁt into slots on each side of fuse block cover. Install new anchored hole at rear of fuse block bracket. Tighten cable strap to capture fuse block conduit.

9. Route main power cable on maxi-fuse holder through opening above front of fuse block bracket and then forward passing under frame crossmember toward right side of motorcycle. Pull back boot at top of starter housing and install ring terminal on post. Install ﬂange nut and tighten to 70-90 in-lbs (7.9-10.2 Nm). Capture cable in clip anchored to T-stud at front of battery tray.

10. Returning to left side of motorcycle, slide maxi-fuse cover forward to engage tongue in groove of fuse block cover and then insert maxi-fuse holder into cover until latches engage.

11. Install new anchored side of frame crossmember (in front of battery box). Tighten cable strap to capture conduit of both accessory connector [4] and B+ connector [160] approximately one inch from connector housings. See Figure 8-150.

12. Hold vapor valve in position on left side of mounting bracket. From right side of bracket, insert end of small cable strap through hole in arm and then around body of vapor valve. Mate ends of cable strap and pull tight engaging strap in slot of arm. Cut any excess cable strap material.

13. Depending upon model, proceed as follows:

FLHR/C/S: Move to step 14.

FLTR:

a. Feed radio antenna cable and connector rearward

following inboard side of upper frame tube. With the 3-place Multilock connector (unused) positioned about as far rearward as the rear shock air valve, install new cable strap to secure radio antenna cable to shoulder of upper frame tube (just in front of air valve mounting bracket). Using slotted hole, install new cable strap to secure radio antenna cable to rear fender support. See Figure 8-154.

b. At bottom of radio antenna bracket, rotate knurled

ring to mate pin and socket halves of radio antenna cable connector [51].

c. Install chrome frame tube cover on frame tube.

Install Phillips screw. Install bolt (with ﬂat washer) to fasten saddlebag front mounting bracket and passenger seat strap to chrome frame tube cover.

cable strap in lower hole on left

cable strap in

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Figure 8-154. Capture Radio Antenna Cable (FLTR)

FLHTC/U:

a. Feed Tour-Pak lights and radio antenna cable con-

nectors and conduit through hole at front of TourPak. Capture cable and conduit in grommet. Install grommet in hole with the larger OD facing inside.

b. Mate pin and socket halves of Tour-Pak lights con-

nector [12], 3-place Multilock, and tuck into cavity inside Tour-Pak.

c. Rotate knurled ring in a clockwise direction to mate

pin and socket halves of radio antenna cable connector [51]. Capture cable in two clips at bottom of To u r-Pak.

d. Install bulb socket on left side of Tour-Pak. e. Loosely install new cable strap to secure main har-

ness conduit to luggage rack rail.

f. Proceed as follows:

FLHTC: Install rubber mat in Tour-Pak. Close TourPak.

FLHTCU: Install molded liner in Tour-Pak. Install map pocket and secure using acorn nuts (with ﬂat washers). Close Tour-Pak.

14. Returning to right side of motorcycle, feed voltage regulator, oil pressure sender and crankshaft position sensor connectors and conduit downward between rear swingarm and oil ﬁller spout until free ends hang below lower frame tube.

15. Route neutral switch wires under starter housing to transmission top cover. For best results, move electrical bracket out of the way and reach in under right side of battery box. Install two elbow connectors onto posts of neutral switch.

16. Snap solenoid connector to terminal at top of starter housing.

17. Install new anchored

cable strap in hole of frame downtube (inboard of rear swingarm bracket) capturing vehicle speed sensor cable, main harness and neutral switch conduit. See Figure 8-151.

18. Install new cable strap at rear of rear brake light switch

bracket capturing main harness conduit and frame downtube. Cut any excess cable strap material.

19. Install two socket terminals onto spade contacts of rear

brake light switch. Install new cable strap to secure rear brake light switch wires to lower frame tube.

20. Route branch of the main harness (terminating in the voltage regulator, oil pressure sender and crankshaft position sensor connectors) forward to front of motorcycle following inboard side of lower frame tube.

21. Mate pin and socket housings of voltage regulator connector [77], 1-place Deutsch, just below the transmission exhaust bracket.

22. Position main harness conduit over two anchors installed on T-studs at top of lower frame tube. Thread new cable straps through eyelets in anchors to capture conduit. Cut any excess cable strap material.

NOTE

In addition to the main harness conduit, rear cable strap anchor also captures rear brake line, while front anchor captures rear brake line and voltage regulator cables.

23. Route main harness conduit inboard of rear brake pedal weldment. Capturing main harness conduit and lower frame tube, install new cable strap through opening in rear brake pedal weldment. See Figure 8-151. Cut any excess cable strap material.

NOTE

Cable strap also captures voltage regulator cables.

24. Route oil pressure sender and crankshaft position sensor connectors upward at rear of lower frame crossmember.

25. Mate pin and socket halves of crankshaft position sensor connector [79]. Place large end of slot on attachment clip over T-stud on bracket at bottom of voltage regulator. Push connector toward left side of motorcycle to engage small end of slot.

26. Install the oil pressure sender connector at the front right side of the crankcase. On FLHR/C/S models, install elbow connector on post terminal. On FLHT/C/U and FLTR models, install 4-place Packard connector.

27. Returning to area of electrical bracket, feed ignition/EFI harness connector [8] and security siren connector [142] and conduit through opening to outboard side of battery box.

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28. Route siren connector and conduit on inboard side of electrical bracket and install bracket on studs at side of battery box. Install ﬂange nuts on studs and tighten to 36-48 in-lbs (4.1-5.4 Nm).

29. Mate pin and socket halves of ignition/EFI harness connector [8]. Install connector into slot of electrical bracket.

30. Pull up on main harness and tuck conduit into space in front of the battery box TORX screw (along with ignition/ EFI harness). See lower frame of Figure 8-153.

CAUTION

31. At front of top engine stabilizer bracket, install new 14 inch cable strap capturing frame backbone and main harness bundle. Tighten cable strap, but leave loose enough so that one ﬁnger can be inserted between strap and frame backbone. Do not overtighten. Cut any excess cable strap material.

32. If cruise equipped, install cruise roll-off switch as follows: a. Separate the cruise roll-off switch wires up to the

point where they enter the main harness conduit.

b. Orient the idle cable so that the spade contacts are

at the top.

c. Slide the insulators onto the switch spade contacts

(polarity is not a factor). For maximum insertion, be sure that the external step on the insulators face each other.

d. Fit the rubber boot over the cruise control roll-off

switch. An oval cut in the boot accommodates the switch spade terminal connections.

NOTE

Depending upon model, continue procedure at INSTALLA-

TION- FLHR/C/S (PART II), INSTALLATION- FLTR (PART II), or INSTALLATION- FLHT/C/U (PART II).

5. See Figure 8-146. Connect main harness as follows:

● Front fender tip lamp connector [32], 2-place Mul-

tilock (black); used on FLHR only.

● Passing lamps connector [73], 2-place Multilock

(white); used on FLHR/C only.

● Passing lamps switch connector [109], 4-place

Amp; used on FLHR/C only.

● Accessory switch connector [67], 4-place Amp.

● Right handlebar switch controls connector [22], 6-

place Deutsch (black); T-stud on fork stem nut lock plate (left side).

● Cruise set/resume switch connector [159], 2-place

Deutsch (black); used on FLHRC only.

● Front turn signal lamps connector [31], 6-place Mul-

tilock; anchor in hole of fork stem nut lock plate (left side).

● Left handlebar switch controls connector [24], 6-

place Deutsch (gray); T-stud on fork stem nut lock plate (left side).

● Cruise on/off switch connector [158], 2-place Deut-

sch (gray); used on FLHRC only.

6. Install the wire connector at the back of headlamp bulb.

7. Align holes in headlamp housing with those in headlamp nacelle (headlamp door bracket at bottom). Install the eight Phillips screws.

8. Fit the square-shaped portion of the headlamp door spring into the slot at the top of the headlamp housing and then snap the headlamp door (chrome ring) into place. Install Phillips screw at the bottom of the headlamp door and tighten to 9-18 in-lbs (1.0-2.0 Nm).

9. See Figure 8-147. Moving to inboard side of instrument console, connect main harness as follows:

● Ignition/light key switch connector [33], 3-place

Packard.

● Indicator lights connector [21], 8-place Mini-Deut-

sch.

● Speedometer connector [39], 12-place Packard.

INSTALLATION- FLHR/C/S (PART II)

1. Install remaining cables straps as shown in Figure 8-

148.

2. Carefully feed main harness conduit and connectors forward under right side of instrument nacelle (keeping outboard of the front brake line).

3. Install P-clamp on main harness bundle. Install screw to fasten P-clamp to right side of steering head.

4. Moving to front of motorcycle, reach inside headlamp nacelle and install screw to fasten harness ground ring terminal and brake line P-clamp to front of upper fork bracket.

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10. Slide odometer reset switch through hole in instrument console and install rubber boot.

11. Bend ﬂexible clamps on inboard side of instrument console as necessary to capture main harness conduit.

NOTE

Continue procedure at INSTALLATION- ALL MODELS

(PART III).

INSTALLATION- FLTR (PART II)

1. Install remaining cables straps as shown in Figure 8-

148.

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2. Install P-clamp on main harness bundle. Install two main harness ground ring terminals onto screw and fasten Pclamp to right side of steering head.

3. Install the inner fairing. See Section 2.30 UPPER FAIR-

ING/WINDSHIELD (FLTR), INNER FAIRING, INSTAL- LATION, steps 3-20.

NOTE

Continue procedure at INSTALLATION- ALL MODELS

(PART III).

INSTALLATION- FLHT/C/U (PART II)

1. Install remaining cables straps as shown in Figure 8-

148.

2. Install P-clamp on main harness (and audio harness on FLHTCU models). Install main harness ground ring terminal onto screw and fasten P-clamp to right side of steering head.

3. Moving to right engine guard, carefully feed main harness conduit and connectors forward under right side of fairing cap to front of inner fairing.

4. Install screw to fasten harness ground ring terminal and brake line P-clamp to front of upper fork bracket.

5. See Figure 8-149. Standing at front of motorcycle, mate pin and socket halves of the following connectors and ﬁx positions using retaining devices:

● Main to interconnect harness connector [1], 12-

place Deutsch (black); T-stud at front of right fairing bracket.

● Main to interconnect harness connector [2], 12-

place Deutsch (gray); T-stud on right fairing support brace.

● Main to interconnect harness connector [15], 4-

place Packard (black); anchor in hole at bottom of radio (right side).

● Main to interconnect harness connector [156], 6-

place Deutsch (gray); T-stud on right fairing support brace.

6. See Figure 8-149. Connect ignition switch to main harness. Connect radio antenna cable. Proceed as follows:

● Ignition switch connector [33], 4-place Packard

(black); anchor in hole at bottom of radio (center).

● Radio antenna cable connector [51]; back of radio

(left side).

7. Install the outer fairing and windshield. See Section 2.29

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

NOTE

Continue procedure at INSTALLATION- ALL MODELS

(PART III).

INSTALLATION- ALL MODELS (PART III)

1. Place battery in battery box, terminal side forward. Rotate hold-down clamp so that lip (with rubber pad) rests on edge of battery and tighten clamp bolt.

2. Insert bolt through battery positive cable (red) into threaded hole of battery positive (+) terminal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).

3. Insert bolt through battery negative cable (black) into threaded hole of battery negative (-) terminal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).

4. Align barbed studs in left side cover with grommets in frame downtubes and push ﬁrmly into place (no tools required).

5. Install left side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

6. Repeat steps 4-5 to install right side saddlebag and side cover.

7. Install fuel tank. For carbureted models, see Section 4.7 FUEL TANK (CARBURETED), INSTALLATION (AFTER

COMPLETE REMOVAL), FLHT/C or FLHR/S. For fuel injected models, see Section 9.4 FUEL TANK (FUEL

INJECTED), INSTALLATION (AFTER COMPLETE

REMOVAL), FLHT/C/U/I, FLTRI or FLHR/C/S/I.

FRAME GROUND STUD REPLACEMENT

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

2. Locate threaded hole between ground studs. See Figure

8-155. Thoroughly scrape away all paint from around

threaded hole.

3. Moving to front of frame crossmember, thoroughly scrape away all paint on face of threaded boss.

4. Obtain ﬁve parts shown in Figure 8-156.

5. Start hex screw into threaded boss and tighten to 90-120 in-lbs (10.2-13.6 Nm).

6. At rear of frame crossmember, install ﬂat washer and lockwasher onto threaded end of hex screw. Install hex nut and tighten to 90-120 in-lbs (10.2-13.6 Nm).

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Threaded Hole

f2250x8x

Figure 8-155. Remove Seat

Harness Ground

Ring Terminals

7. If replacing left side ground stud, slide two main harness ground ring terminals onto hex screw. If replacing right side ground stud, install chassis ground ring terminal before the two main harness grounds.

8. Install jam nut onto hex screw and tighten to 50-90 in- lbs (5.7-10.2 Nm).

9. Install seat. See Section 2.24 SEAT, INSTALLATION.

Frame

Crossmember

1. Hex Screw, 2551W

2. Flat Washer, 6703

3. Lock Washer, 7036

Figure 8-156. Install New Frame Ground Stud

4. Hex Nut, 7688

5. Jam Nut, 7689W

Boss

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INTERCONNECT HARNESS (FLHTCU)

REMOVAL

NOTE

When referencing inner fairing locations, the term “fairing bracket” refers to either the left or right vertical support, while the term “support brace” refers to either the left or right horizontal support. References to left and right always refers to left and right side of motorcycle.

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

MAXI-FUSE, REMOVAL.

2. Remove the outer fairing and windshield. See Section

2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD, REMOVAL.

3. Release anchors on convoluted tubing of interconnect harness from lower outboard ears of speedometer and tachometer brackets. See Figure 8-157. For best results, squeeze anchor with needle nose pliers before pulling from hole in ear.

4. Remove anchor on convoluted tubing of headlamp connector from hole in left fairing bracket. See Figure 8-160.

5. On opposite side of inner fairing, remove anchor on conduit of fairing cap switch connector from hole in lower wing of right side radio support bracket. See Figure 8-

161.

6. Cut cable strap to release convoluted tubing of interconnect harness, conduit of main to interconnect harness connectors [2] and [156], and housing of main to interconnect harness connector [1] from right fairing bracket. See Figure 8-162.

7. Remove connectors from their retaining devices, if present, and disconnect pin and socket halves. See Fig-

ure 8-158.

a. Main to interconnect harness connector [2], 12-

place Deutsch (gray); T-stud on right fairing support brace (outboard side).

b. Main to interconnect harness connector [156], 6-

place Deutsch (gray); T-stud on right fairing support brace (inboard side).

c. Radio connector [27], 23-place Amp (black); back of

radio (right side).

d. Indicator lamps [21]; 10-place Multilock (black);

above radio (between speedometer and tachometer gauges).

e. Speedometer connector [39]; 12-place Packard

(black); back of speedometer. Unthread rubber boot from odometer reset switch and pull switch from hole in inner fairing.

f. Ta chometer connector [108]; 12-place Packard

(gray); back of tachometer.

Figure 8-157. Anchor Interconnect Harness in Lower

Ears of Speedometer/Tachometer Brackets

g. Ambient temperature sensor connector [107], if

present; 3-place Multilock (black); anchor in hole on outboard side of left fairing bracket.

h. Left handlebar switch controls connector [24], 12-

place Deutsch (gray); T-stud on top of left fairing support brace (inboard side).

i. Front turn signal connector [31], 6-place Multilock

(black); T-stud on top of left fairing support brace (outboard side).

j. Main to interconnect harness connector [1], 12-

place Deutsch (black); T-stud at front of right fairing bracket.

k. Main to interconnect harness connector [15], 4-

place Packard (black); anchor in hole at bottom of radio (right side).

l. Fairing cap switch connector [105], 12-place Mul-

tilock (black); top of upper fork bracket (right side).

m. Right handlebar switch controls connector [22], 12-

place Deutsch (black); T-stud on fork stem nut lock plate (left side).

n. Audio to interconnect harness connector [6], if

present; 3-place Deutsch (black); back of radio.

o. Passing lamps connector [73], 2-place Multilock

(white); below upper fork bracket (left side).

p. Front fender tip lamp connector [32], 2-place Mul-

tilock (black); below upper fork bracket (left side).

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Main to Interconnect

Harness [156]

Main to Interconnect

Harness [2]

Main to Interconnect

Harness [15]

Tac hometer Gauge [108]

Radio [27]

Indicator

Lamps [21]

Speedometer

Gauge [39]

Ambient

Temperature

Sensor [107]

Left Handlebar

Switch Controls [24]

Front Turn

Signals [31]

Main to Interconnect

Harness [1]

Fairing Cap

Switches [105]

f2238x8x

Figure 8-158. Inner Fairing - Interconnect Harness Connectors (FLHTC/U)

8. See Figure 8-159. Remove connectors from spade contacts as follows:

Left side:

● Left speaker

● Fuel gauge and lamp

● Cigarette lighter

Audio to Interconnect

Harness [6]

Front

Fender Tip [32]

Passing

Lamp [73]

Right Handlebar

Switch Controls [22]

9. Feed conduit (with orange tape) terminating in left side speaker, fuel gauge, cigarette lighter and front turn signal connectors to mid section of inner fairing (area between left and right fairing brackets). Also feed conduit terminating in left handlebar switch controls connector [24] to mid section.

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f2238x8x

Gauge and Lamp

Right

Speaker

Oil Pressure

and Lamp

Fuel Gauge

and Lamp

Ambient

Temperature

Gauge and Lamp

Left

SpeakerVoltmeter Gauge

Cigarette

Lighter

Figure 8-159. Inner Fairing - Interconnect Harness Connectors (FLHTC/U)

10. Pull harness ground socket terminal from spade contact fastened to top of upper fork bracket (left side).

11. See Figure 8-159. Remove connectors from spade contacts as follows:

Right side:

● Right speaker

● Voltmeter gauge and lamp

12. Feed conduit (with orange tape) terminating in right side speaker and voltmeter gauge connectors to mid section of inner fairing (area between left and right fairing brackets). Also feed conduit terminating in main to interconnect harness connectors [2] and [156] to mid section.

13. If present, remove connectors from spade contacts as follows:

● Oil pressure gauge and lamp

● Ambient temperature gauge and lamp

14. Remove interconnect harness from motorcycle.

INSTALLATION

NOTE

1. Center interconnect harness on top of radio. To verify proper orientation, be sure that convoluted tubing (with anchor) of headlamp connector is on left side of motorcycle, while conduit (with anchor) of fairing cap switch connector is on the right.

2. Install anchors on convoluted tubing of interconnect harness into lower outboard ears of speedometer and tachometer brackets. See Figure 8-157.

3. If present, install connectors onto spade contacts as follows:

● Oil pressure gauge and lamp

● Ambient temperature gauge and lamp

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4. From mid section of inner fairing (area between left and right fairing brackets), feed conduit (with orange tape) terminating in left side speaker, fuel gauge, cigarette lighter and front turn signal connectors behind left fairing bracket to area of left support brace.

5. Install connectors onto spade contacts as follows:

Left side:

● Left speaker

● Fuel gauge and lamp

● Cigarette lighter; connect the orange/white wire

socket terminal to the socket spade contact, the black wire socket terminal to the shell contact.

6. From mid section of inner fairing (area between left and right fairing brackets), also feed conduit terminating in left handlebar switch controls connector [24] behind left fairing bracket to area of left support brace.

7. Push harness ground socket terminal onto spade contact fastened to top of upper fork bracket (left side).

8. From mid section of inner fairing, feed conduit (with orange tape) terminating in right side speaker and voltmeter gauge connectors behind right fairing bracket to area of right support brace.

9. Install connectors onto spade contacts as follows:

Right side:

● Right speaker

● Vol tmeter gauge and lamp

9421

Anchor

Figure 8-160. Anchor Convoluted Tubing of

Headlamp Connector

9423

Anchor

Oval Shaped

Hole

10. From mid section of inner fairing, also feed conduit terminating in main to interconnect harness connectors [2] and [156] behind right fairing bracket to area of right support brace.

11. Mate pin and socket halves of the following connectors and ﬁx positions using retaining devices, if present:

a. Main to interconnect harness connector [2], 12-

place Deutsch (gray); T-stud on right fairing support brace (outboard side).

b. Main to interconnect harness connector [156], 6-

place Deutsch (gray); T-stud on right fairing support brace (inboard side).

c. Radio connector [27], 23-place Amp (black); back of

radio (right side).

d. Indicator lamps [21]; 10-place Multilock (black);

above radio (between speedometer and tachometer gauges).

e. Speedometer connector [39]; 12-place Packard

(black); back of speedometer. Slide odometer reset switch through hole in inner fairing and install rubber boot.

Figure 8-161. Anchor Conduit of Fairing Cap

Switch Connector

9422

Cable

Strap

Figure 8-162. Cable Strap Convoluted Tubing, Conduit

and Connector to Fairing Bracket

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f. Ta chometer connector [108]; 12-place Packard

(gray); back of tachometer.

g. Ambient temperature sensor connector [107], if

present; 3-place Multilock (black); anchor in hole on outboard side of left fairing bracket.

h. Left handlebar switch controls connector [24], 12-

place Deutsch (gray); T-stud on top of left fairing support brace (inboard side).

i. Front turn signal connector [31], 6-place Multilock

(black); T-stud on top of left fairing support brace (outboard side).

j. Main to interconnect harness connector [1], 12-

place Deutsch (black); T-stud at front of right fairing bracket.

k. Main to interconnect harness connector [15], 4-

place Packard (black); anchor in hole at bottom of radio (right side).

l. Fairing cap switch connector [105], 12-place Mul-

tilock (black); top of upper fork bracket (right side).

m. Right handlebar switch controls connector [22], 12-

place Deutsch (black); T-stud on fork stem nut lock plate (left side).

n. Audio to interconnect harness connector [6], if

present; 3-place Deutsch (black); back of radio.

o. Passing lamps connector [73], 2-place Multilock

(white); below upper fork bracket (left side).

p. Front fender tip lamp connector [32], 2-place Mul-

tilock (black); below upper fork bracket (left side).

13. On opposite side of inner fairing, install anchor on conduit of fairing cap switch connector into hole in lower wing of right side radio support bracket. See Figure 8-

161.

14. Using oval shaped hole in right fairing bracket, install new cable strap capturing convoluted tubing of interconnect harness, conduit of main to interconnect harness connectors [15] and [156], and housing of main to interconnect harness connector [1]. See Figure 8-161 and

Figure 8-162.

15. Install the windshield and outer fairing. See Section 2.29

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

16. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

12. Install anchor on convoluted tubing of headlamp connector into hole in left fairing bracket. See Figure 8-160.

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INTERCONNECT HARNESS (FLTR)

REMOVAL

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

MAXI-FUSE, REMOVAL.

2. Place protective material on top of front fender to protect paint from scratches or other damage.

3. Remove the outer fairing and windshield. See Section

2.30 UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIRING, REMOVAL.

4. Carefully cut two cable straps and allow wire bundles and conduit to hang naturally. See Figure 8-165.

Main to Interconnect

Harness [1]

Radio [27]

5. See Figure 8-163. Disconnect main harness from interconnect harness as follows:

● Main to interconnect harness connector [1], 12-

place Deutsch (black); below radio (right side).

● Main to interconnect harness connector [2], 12-

place Deutsch (gray); below radio (right side).

● Main to interconnect harness connector [15], 4-

place Packard (black); below radio (right side).

● Main to interconnect harness connector [156], 6-

place Deutsch (gray); below radio (right side).

6. See Figure 8-163. Disconnect handlebar switch controls from interconnect harness. Disconnect radio and radio ground. Proceed as follows:

Left Handlebar

Switch Controls [24]

Main to Interconnect

Harness [156]

Main to Interconnect

Harness [2]

Right Turn

Signal [31R]

Main to Interconnect

Harness [15]

Figure 8-163. Inner Fairing Connections (FLTR)

Right Handlebar

Switch Controls [22]

Radio

Ground

Left Turn

Signal [31L]

f2269x8x

8-132 2004 Touring: Electrical

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f2219x8x

Indicator

Lamps [21]

Speedometer

Gauge [39]

Speaker

Switch [105]

Figure 8-164. Instrument Nacelle (Bezel Removed)

● Left handlebar switch controls connector [24], 12-

place Deutsch (gray); T-stud on left side of radio bracket.

● Right handlebar switch controls connector [22], 12-

place Deutsch (black); T-stud on left side of radio bracket.

NOTE

Push on each handlebar connector to disengage small end of slot on attachment clip from T-stud on radio bracket. Lift connector off T-stud.

● Radio connector [27], 23-place Amp (black); back of

radio (right side).

● Radio ground; single spade and socket terminal;

below radio (left side).

7. Remove left side of instrument nacelle. See Section 2.30

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT NACELLE, REMOVAL, steps 1-6.

8. See Figure 8-164. Disconnect instrument nacelle switches and ambient temperature sensor from interconnect harness as follows:

● Instrument nacelle switch connector [105], 12-place

Multilock.

● Ambient temperature sensor connector [107], 3-

place Multilock.

9. See Figure 8-164. Draw branches of interconnect harness (terminating in odometer reset switch and speedometer, tachometer, indicator lamps, instrument nacelle switch and ambient temperature sensor connectors) from instrument nacelle through tunnel of fairing bracket

Instrument Nacelle

Switches [105]

Tachometer

Gauge [108]

Ambient

Temperature

Sensor [107]

to front of inner fairing. Allow the interconnect harness to hang along the left side of the front fender.

10. Remove connectors from spade contacts as follows: Left side:

● Left speaker

● Fuel gauge and lamp

● Ambient temperature gauge and lamp

● Cigarette lighter

Right side:

● Right speaker

● Voltmeter gauge and lamp

● Oil pressure gauge and lamp

11. Free conduit of front turn signal lamp connectors [31L] and [31R], 3-place Multilocks, from ﬂexible clips on sides of inner fairing.

12. Remove interconnect harness from motorcycle. Remove radio antenna cable connector [51] at back of radio (left side) to facilitate removal.

INSTALLATION

1. Center convoluted tubing of interconnect harness above and inboard of hooks on radio bracket. See Figure 8-

165. To verify proper orientation, be sure that long length

2004 Touring: Electrical 8-133

OME

9427

Figure 8-165. Cable Strap Convoluted Tubing

and Conduit

of conduit terminating in socket terminals of cigarette lighter is on left side of motorcycle. Install radio antenna cable connector [51] at back of radio (left side), if removed.

2. Install connectors onto spade contacts as follows: Left side:

● Left speaker

● Fuel gauge and lamp

● Ambient temperature gauge and lamp

● Cigarette lighter; connect the orange/white wire

socket terminal to the socket spade contact, the black wire socket terminal to the shell contact.

Right side:

● Right speaker

● Vol tmeter gauge and lamp

● Oil pressure gauge and lamp

Left side:

● Left speaker

● Fuel gauge and lamp

Right side:

● Right speaker

● Vol tmeter gauge and lamp

3. Find branch of interconnect harness terminating in odometer reset switch and speedometer, tachometer, indicator lamps, instrument nacelle switch and ambient temperature sensor connectors. Feed connectors and conduit from front of inner fairing through tunnel of fairing bracket and then out through opening at top of fairing bracket to instrument nacelle.

4. See Figure 8-164. Connect instrument nacelle switches and ambient temperature sensor to interconnect harness as follows:

● Instrument nacelle switch connector [105], 12-place

Multilock.

● Ambient temperature sensor connector [107], 3-

place Multilock.

5. See Figure 8-163. Connect handlebar switch controls to interconnect harness. Connect radio and radio ground. Proceed as follows:

● Left handlebar switch controls connector [24], 12-

place Deutsch (gray); T-stud on left side of radio bracket.

● Right handlebar switch controls connector [22], 12-

place Deutsch (black); T-stud on left side of radio bracket.

NOTE

Place large end of slot on attachment clip over T-stud on radio bracket and push on each handlebar connector to engage small end of slot.

● Radio connector [27], 23-place Amp (black); back of

radio (right side).

● Radio ground; single spade and socket terminal;

below radio (left side).

6. See Figure 8-163. Connect main harness to interconnect harness as follows:

● Main to interconnect harness connector [1], 12-

place Deutsch (black); below radio (right side).

● Main to interconnect harness connector [2], 12-

place Deutsch (gray); below radio (right side).

● Main to interconnect harness connector [15], 4-

place Packard (black); below radio (right side).

● Main to interconnect harness connector [156], 6-

place Deutsch (gray); below radio (right side).

7. Orient connectors as shown in Figure 8-163. Install two new cable straps outboard of fairing bracket hooks to hold wire bundles together. Cut any excess cable strap material. See Figure 8-165.

CAUTION

To avoid chaﬁng wires of interconnect harness and possible damage to slots of outer fairing during installation, verify that trim strips are installed on hooks of radio bracket.

8. Capture conduit of front turn signal lamp connectors [31L] and [31R], 3-place Multilocks, in ﬂexible clips on sides of inner fairing.

8-134 2004 Touring: Electrical

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9. Install the outer fairing and windshield. See Section 2.30

UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIRING, INSTALLATION.

10. Install left side of instrument nacelle. See Section 2.30

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT NACELLE, INSTALLATION, steps 5-7 and 9-10.

11. Install bezel. See BEZEL, INSTALLATION, in this sec- tion.

12. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

2004 Touring: Electrical 8-135

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RADIO ANTENNA CABLE (FLHTC/U)

REMOVAL

1. Remove fuel tank. For carbureted models, see Section

4.7 FUEL TANK (CARBURETED), COMPLETE

REMOVAL, FLHT/C. For fuel injected models, see Section 9.4 FUEL TANK (FUEL INJECTED), COMPLETE REMOVAL, FLHT/C/U/I, FLTRI.

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

DLEBAG, REMOVAL.

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

4. Remove the outer fairing and windshield. See Section

2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD, REMOVAL.

5. Remove radio antenna cable connector [51] at back of radio (left side). See Figure 8-166. Carefully cut cable where it exits branch of main harness conduit.

6. Remove screw, ground wire ring terminal and P-clamp to release main harness (and audio harness on FLHTCU) from right side of steering head.

7. Carefully cut cable straps securing main harness to

frame backbone, left frame tube and luggage rack rail. See Figure 8-169.

8. Open Tour-Pak and proceed as follows:

FLHTC: Remove rubber mat.

Cable

Clip

Cavity

Tour-Pak Lights

Connector [12]

Radio Antenna

Cable

Figure 8-167. Disconnect Tour-Pak Lights Connector

Tour-Pak

Hole

Grommet

f1466a2x

Radio Antenna

Cable Connector

Radio Antenna

Cable [51]

Figure 8-166. Remove Outer Fairing (FLHTC/U)

f2238x8x

Grommet

Cable

Clip

Figure 8-168. Feed Main Harness Thru Tour-Pak Hole

FLHTCU: Open map pocket and remove acorn nuts

(with ﬂat washers). Remove map pocket and molded liner from Tour-Pak.

9. Depress external latch and remove bulb socket from left side of Tour-Pak.

10. Rotate knurled ring in a counterclockwise direction to separate pin and socket halves of radio antenna cable connector. Release cable from two clips at bottom of To u r-Pak.

f1465a2x

8-136 2004 Touring: Electrical

f2225x8x

4 A

5 A

Frame

Backbone

Saddlebag

Guard

1 Captures main harness, cruise roll-off switch conduit,

audio harness (FLHTCUI only) and frame backbone.

2 Captures main harness and audio harness (FLHTCUI

only). ANCHORED

34 Captures main harness and audio harness (FLHTCUI

only). ANCHORED

5 Captures main harness, audio harness (FLHTCUI only),

fuel vapor vent tube and console pod or instrument console conduit. ANCHORED

6 Captures main harness, audio harness (FLHTCUI only),

console pod or instrument console conduit and upper frame tube.

7 Captures main harness, audio harness (FLHTCUI only),

console pod conduit (FLHTCUI only) and upper frame tube.

2 A

3 A

A = Anchored

OME

11. Depress button and separate pin and socket halves of To ur-Pak lights connector [12], 3-place Multilock, inside To ur-Pak. See Figure 8-167.

12. Pull grommet into Tour-Pak and remove from main harness conduit.

13. Pull Tour-Pak lights and radio antenna cable connectors through hole at front of Tour-Pak. See Figure 8-168.

14. Carefully cut radio antenna cable where it exits main harness conduit.

INSTALLATION

1. Place new radio antenna cable on motorcycle following original routing. Note that the cable follows the branches of the main harness (and audio harness on FLHTCU) routed to the rear left side of the motorcycle.

NOTE

Speciﬁcally, from the front of the inner fairing, the radio antenna cable is routed under the fairing cap where it passes through a P-clamp on the right side of the steering head. The cable then runs along the right side of the frame backbone, where it crosses to the left side at the main harness anchor in the center of the frame backbone. From this point, the cable follows the left side of the frame backbone, runs along the inboard side of the upper frame tube and then continues down the luggage rack rail where it passes through the hole at the front of the Tour-Pak.

2. Feed Tour-Pak lights and radio antenna cable connectors and conduit through hole at front of Tour-Pak. Capture conduit in grommet. Install grommet in hole with the larger OD facing inside.

3. Mate pin and socket halves of Tour-Pak lights connector [12], 3-place Multilock, and tuck into cavity inside TourPak. See Figure 8-167.

4. Rotate knurled ring in a clockwise direction to mate pin and socket halves of radio antenna cable connector. Capture cable in two clips at bottom of Tour-Pak.

5. Install bulb socket on left side of Tour-Pak.

6. Proceed as follows:

FLHTC: Install rubber mat in Tour-Pak. Close Tour-Pak. FLHTCU: Install molded liner in Tour-Pak. Install map

pocket and secure using acorn nuts (with ﬂat washers). Close Tour-Pak.

7. At front of inner fairing, connect radio antenna cable connector [51] to back of radio. See Figure 8-166.

8. On right side of motorcycle, capture radio antenna cable, main harness and audio harness (if present) in P-clamp. Install ground wire ring terminal on screw and fasten Pclamp to right side of steering head.

Figure 8-169. Install Cable Straps

9. At front of top engine stabilizer bracket, install new 14

inch cable strap capturing frame backbone, radio antenna cable, main harness and audio harness (if present). Tighten cable strap, but leave loose enough so that one ﬁnger can be inserted between strap and frame backbone. Do not overtighten. Cut any excess cable strap material.

10. Install remaining cables straps as shown in Figure 8-

169.

2004 Touring: Electrical 8-137

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11. Install the outer fairing and windshield. See Section 2.30

UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIRING, INSTALLATION.

12. Align barbed studs in left side cover with grommets in frame downtubes and push ﬁrmly into place (no tools required).

13. Install left side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

14. Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER

COMPLETE REMOVAL), FLHT/C. For fuel injected models, see Section 9.4 FUEL TANK (FUEL

INJECTED), INSTALLATION (AFTER COMPLETE

REMOVAL), FLHT/C/U/I, FLTRI.

8-138 2004 Touring: Electrical

9425

OME

RADIO ANTENNA CABLE (FLTR)

REMOVAL

1. Remove fuel tank. See Section 9.4 FUEL TANK (FUEL

INJECTED), COMPLETE REMOVAL, FLHT/C/U/I, FLTRI.

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

DLEBAG, REMOVAL.

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

4. Remove the outer fairing and windshield. See Section

2.30 UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIRING, REMOVAL.

5. Remove radio antenna cable connector [51] at back of radio (left side). See Figure 8-170. Carefully cut cable where it exits branch of main harness conduit.

6. Remove screw, ground wire ring terminal and P-clamp to release main harness bundle from right side of steering head.

7. Carefully cut cable straps securing main harness to

frame backbone and left frame tube. See Figure 8-172.

8. On left side of motorcycle, remove bolt (with ﬂat washer) to remove passenger seat strap and saddlebag front mounting bracket. Remove Phillips screw and chrome frame tube cover.

Radio Antenna

Cable [51]

Figure 8-170. Remove Outer Fairing (FLTR)

f2230x2x

Figure 8-171. Capture Radio Antenna Cable

9. Carefully cut cable strap to release radio antenna cable from shoulder of upper frame tube (just in front of air valve mounting bracket). Cut cable strap to release radio antenna cable from slotted hole in rear fender support. See Figure 8-171.

10. At bottom of radio antenna bracket, rotate knurled ring to separate pin and socket halves of radio antenna cable connector [51].

11. Draw radio antenna cable forward to area of fuse block bracket. Carefully cut cable where it exits branch of main harness conduit.

INSTALLATION

1. Place new radio antenna cable on motorcycle following original routing. Note that the cable follows the branches of the main harness routed to the rear left side of the motorcycle.

NOTE

Speciﬁcally, from the front of the inner fairing, the radio antenna cable is routed through an opening on the right side of the fairing bracket where it then passes through a P-clamp on the right side of the steering head. The cable runs rearward along the right side of the frame backbone, where it crosses to the left side at the main harness anchor in the center of the frame backbone. From this point, the cable follows the left side of the frame backbone, runs along the inboard side of the upper frame tube and then down to the radio antenna bracket.

2. Feed radio antenna cable and connector rearward following inboard side of upper frame tube. With the 3place Multilock connector (unused) positioned about as far rearward as the rear shock air valve, install new cable strap to secure radio antenna cable to shoulder of

2004 Touring: Electrical 8-139

OME

upper frame tube (just in front of air valve mounting bracket). Using slotted hole, install new cable strap to secure radio antenna cable to rear fender support. See

Figure 8-171.

3. At bottom of radio antenna bracket, rotate knurled ring to mate pin and socket halves of radio antenna cable connector [51].

4. Install chrome frame tube cover on frame tube. Install Phillips screw. Install bolt (with ﬂat washer) to fasten saddlebag front mounting bracket and passenger seat strap to chrome frame tube cover.

5. At front of inner fairing, connect radio antenna cable connector [51] at back of radio (left side). See Figure 8-

170.

6. On right side of motorcycle, capture radio antenna cable and main harness in P-clamp. Install ground wire ring terminal on screw and fasten P-clamp to right side of steering head.

7. At front of top engine stabilizer bracket, install new 14 inch cable strap capturing frame backbone, radio antenna cable and main harness. Tighten cable strap, but leave loose enough so that one ﬁnger can be inserted between strap and frame backbone. Do not overtighten. Cut any excess cable strap material.

8. Install remaining cables straps as shown in Figure 8-

169.

9. Install the outer fairing and windshield. See Section 2.30

UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIRING, INSTALLATION.

10. Align barbed studs in left side cover with grommets in frame downtubes and push ﬁrmly into place (no tools required).

11. Install left side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

12. Install fuel tank. See Section 9.4 FUEL TANK (FUEL

INJECTED), INSTALLATION (AFTER COMPLETE

REMOVAL), FLHT/C/U/I, FLTRI.

A = Anchored

Frame

Backbone

2 A

3 A

4 A

5 A

Saddlebag

f2225x8x

1 Captures main harness, cruise roll-off switch conduit,

2 Captures main harness and audio harness (FLHTCUI

34 Captures main harness and audio harness (FLHTCUI

5 Captures main harness, audio harness (FLHTCUI only),

6 Captures main harness, audio harness (FLHTCUI only),

7 Captures main harness, audio harness (FLHTCUI only),

audio harness (FLHTCUI only) and frame backbone.

only). ANCHORED

fuel vapor vent tube and console pod or instrument console conduit. ANCHORED

console pod or instrument console conduit and upper frame tube.

console pod conduit (FLHTCUI only) and upper frame tube.

Guard

8-140 2004 Touring: Electrical

Figure 8-172. Install Cable Straps

f2192x8x

Console Pod

Connector [53]

OME

AUDIO HARNESS (FLHTCU)

REMOVAL

1. Remove fuel tank. For carbureted models, see Section

4.7 FUEL TANK (CARBURETED), COMPLETE

REMOVAL, FLHT/C. For fuel injected models, see Section 9.4 FUEL TANK (FUEL INJECTED), COMPLETE REMOVAL, FLHT/C/U/I, FLTRI.

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

DLEBAG, REMOVAL.

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

4. Repeat steps 2 and 3 on left side of motorcycle.

5. Remove the outer fairing and windshield. See Section

2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD, REMOVAL.

6. See Figure 8-173. Disconnect pin and socket halves of the following connectors:

a. CB antenna cable connector [50], back of radio

(right side).

b. Audio to interconnect harness connector [6], 3-

place Deutsch (black); back of radio (right side).

c. Radio connector [28], 23-place Amp (gray); back of

radio (left side).

Interconnect Harness [6]

CB Antenna

Cable [50]

Audio to

Radio [28]

Figure 8-174. Disconnect Console Pod Connector

7. Remove screw, ground wire ring terminal and P-clamp to release main harness and audio harness from right side of steering head.

8. Carefully pull audio harness rearward under right side of fairing cap allowing conduit and connectors to hang over top of engine guard.

9. Carefully cut cable straps securing audio harness to frame backbone, left and right frame tubes, and luggage rack rails. See Figure 8-176. Carefully cut cable straps securing audio harness to main harness, if present.

10. Release console pod connector [53], 12-place MiniDeutsch, from attachment clip anchored in hole at rear of battery box. See Figure 8-174. Depress external latches and use a rocking motion to separate pin and socket halves.

11. Remove trim ring and gently pull on wire harness to draw rear right speaker/passenger controls connector [41], 6-place Mini-Deutsch, out of speaker box. Depress external latch and use a rocking motion to separate pin and socket halves.

12. Open Tour-Pak. Open map pocket and remove acorn nuts. Remove map pocket and molded liner from TourPak.

Figure 8-173. Audio Harness Connectors

f2238x8x

13. Separate pin and socket halves of CB antenna cable connector [50]. Release cable from clip at bottom of Tour-Pak. See Figure 8-175.

14. Pull right side grommet into Tour-Pak and remove from CB antenna cable. Feed CB antenna cable through hole at front of Tour-Pak.

2004 Touring: Electrical 8-141

OME

Grommet

Cable

Clip

a. CB antenna cable connector [50], back of radio

(right side).

b. Audio to interconnect harness connector [6], 3-

place Deutsch (black); back of radio (right side).

c. Radio connector [28], 23-place Amp (gray); back of

radio (left side).

3. On right side of motorcycle, capture audio harness and main harness in P-clamp. Install ground wire ring terminal on screw and fasten P-clamp to right side of steering head.

4. Mate pin and socket halves of console pod connector

[53], 12-place Mini-Deutsch. Install connector onto attachment clip anchored in hole at rear of battery box. See Figure 8-174.

CB Antenna

f1467b2x

Figure 8-175. Disconnect CB Antenna Cable Connector

15. Moving to opposite side of motorcycle, remove trim ring and gently pull on wire harness to draw rear left speaker/ passenger controls connector [42], 6-place Mini-Deutsch, out of speaker box. Depress external latch and use a rocking motion to separate pin and socket halves.

16. Release rear headset receptacle from bracket at bottom of left side speaker box. Release spring from hole in receptacle wire jacket.

17. Remove audio harness from motorcycle.

Cable Connector

INSTALLATION

1. Place new audio harness on motorcycle following original routing. Note that the audio harness follows the branches of the main harness as it is routed to the rear left and right sides of the motorcycle.

NOTE

Speciﬁcally, from the front of the inner fairing, the audio harness is routed under the fairing cap where it passes through a P-clamp on the right side of the steering head. The harness then runs along the right side of the frame backbone, where a branch crosses to the left side at the main harness anchor in the center of the frame backbone. From this point, each branch follows its respective side of the frame backbone, running along the inboard side of the upper frame tubes and then down the luggage rack rails.

2. See Figure 8-173. Standing at front of motorcycle, mate pin and socket halves of the following wire harness connectors:

5. Mate pin and socket housings of rear right speaker/passenger controls connector [41], 6-place Mini-Deutsch. Feed connector back up into speaker box pressing trim ring into hole.

6. Pass CB antenna cable connector [50] through hole at front of Tour-Pak. Capture cable in grommet. Install grommet in hole with the larger OD facing inside. See

Figure 8-175.

7. Mate pin and socket halves of CB antenna cable connector. Capture antenna cable in clip at bottom of TourPak.

8. Moving to opposite side of motorcycle, mate pin and socket housings of rear left speaker/passenger controls connector [42], 6-place Mini-Deutsch. Feed connector back up into speaker box pressing trim ring into hole.

9. Attach spring to rear headset receptacle using hole in wire jacket. Capture headset receptacle in bracket at bottom of left side speaker box.

10. At front of top engine stabilizer bracket, install new 14 inch cable strap capturing frame backbone, audio harness and main harness. Tighten cable strap, but leave loose enough so that one ﬁnger can be inserted between strap and frame backbone. Do not over- tighten. Cut any excess cable strap material.

11. Install remaining cables straps as shown in Figure 8-

176.

12. Install the outer fairing and windshield. See Section 2.29

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

13. Align barbed studs in right side cover with grommets in frame downtubes and push ﬁrmly into place (no tools required).

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

BAG, INSTALLATION.

8-142 2004 Touring: Electrical

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Frame

Backbone

2 A

15. Repeat steps 13 and 14 on left side of motorcycle.

A = Anchored

16. Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER

COMPLETE REMOVAL), FLHT/C. For fuel injected models, see Section 9.4 FUEL TANK (FUEL

INJECTED), INSTALLATION (AFTER COMPLETE

REMOVAL), FLHT/C/U/I, FLTRI.

8 A

9 A

10 A

f2225x8x

1 Captures main harness, cruise roll-off switch conduit,

audio harness (FLHTCUI only) and frame backbone.

2 Captures main harness and audio harness (FLHTCUI

only). ANCHORED

345 Captures main harness, audio harness (FLHTCUI only),

EFI/ignition harness, and conduit to fuel tank harness (all models except FLHR/C/S). ANCHORED

67 Captures audio harness (FLHTCUI only) and upper frame

tube.

89 Captures main harness and audio harness (FLHTCUI

only). ANCHORED

10 Captures main harness, audio harness (FLHTCUI only),

fuel vapor vent tube and console pod or instrument console conduit. ANCHORED

11 Captures main harness, audio harness (FLHTCUI only),

console pod or instrument console conduit and upper frame tube.

12 Captures main harness, audio harness (FLHTCUI only),

console pod conduit (FLHTCUI only) and upper frame tube.

3 A

4 A

5 A

Saddlebag

Guard

Figure 8-176. Install Cable Straps

2004 Touring: Electrical 8-143

OME

CB ANTENNA CABLE (FLHTCU)

Grommet

REMOVAL

1. Remove fuel tank. For carbureted models, see Section

4.7 FUEL TANK (CARBURETED), COMPLETE

REMOVAL, FLHT/C. For fuel injected models, see Section 9.4 FUEL TANK (FUEL INJECTED), COMPLETE REMOVAL, FLHT/C/U/I, FLTRI.

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

DLEBAG, REMOVAL.

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

4. Remove the outer fairing and windshield. See Section

2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD, REMOVAL.

5. Locate CB antenna cable connector [50] at back of radio (right side). Rotate knurled ring in a counterclockwise direction to disconnect. See Figure 8-177. Carefully cut cable where it exits audio harness conduit.

6. Remove screw, ground wire ring terminal and P-clamp to release main harness and audio harness from right side of steering head.

7. Carefully cut cable straps securing audio harness to frame backbone, right frame tube and luggage rack rail. See Figure 8-180. Carefully cut cable straps securing audio harness to main harness, if present.

Cable

Clip

CB Antenna

f1467b2x

Figure 8-178. CB Antenna Cable Connector

8. Open Tour-Pak. Open map pocket and remove acorn nuts (with ﬂat washers). Remove map pocket and molded liner from Tour-Pak.

9. Separate pin and socket halves of CB antenna cable connector [50]. Release cable from clip at bottom of To ur-Pak. See Figure 8-178.

Cable Connector

(Tour-Pak)

CB Antenna

Cable [50]

Figure 8-177. CB Antenna Cable Connector

(Inner Fairing)

f2238x8x

10. Pull right side grommet into Tour-Pak and remove from CB antenna cable. Feed CB antenna cable through hole at front of Tour-Pak.

11. Carefully cut CB antenna cable where it exits branch of audio harness conduit.

INSTALLATION

1. Place new CB antenna cable on motorcycle following original routing. Note that the cable follows the branches of the main harness and audio harness routed to the rear right side of the motorcycle.

NOTE

Speciﬁcally, from the front of the inner fairing, the CB antenna cable is routed under the fairing cap where it passes through a P-clamp on the right side of the steering head. From this point, the cable follows the right side of the frame backbone, runs along the inboard side of the upper frame tube and then continues down the luggage rack rail where it passes through the hole at the front of the Tour-Pak.

8-144 2004 Touring: Electrical

f2225x8x

4 A

5 A

Frame

Backbone

Saddlebag

Guard

1 Captures main harness, cruise roll-off switch conduit,

audio harness (FLHTCUI only) and frame backbone.

2 Captures main harness and audio harness (FLHTCUI

only). ANCHORED

345 Captures main harness, audio harness (FLHTCUI only),

EFI/ignition harness, and conduit to fuel tank harness (all models except FLHR/C/S). ANCHORED

67 Captures audio harness (FLHTCUI only) and upper frame

tube.

2 A

3 A

A = Anchored

OME

2. Pass CB antenna cable connector [50] through hole at front of Tour-Pak. Capture cable in grommet. Install grommet in hole with the larger OD facing inside. See

Figure 8-178.

3. Mate pin and socket halves of CB antenna cable con-

nector. Capture antenna cable in clip at bottom of TourPak.

4. Install two new cable straps to secure CB antenna cable to rear right speaker/passenger controls conduit and luggage rack rail. See Figure 8-179.

5. Install molded liner in Tour-Pak. Install map pocket and secure using acorn nuts (with ﬂat washers). Close TourPak.

6. At front of inner fairing, rotate knurled ring to connect CB antenna cable connector [50] to back of radio. See Fig-

ure 8-177.

7. On right side of motorcycle, capture CB antenna cable, audio harness and main harness in P-clamp. Install ground wire ring terminal on screw and fasten P-clamp to right side of steering head.

8. At front of top engine stabilizer bracket, install new 14 inch cable strap capturing frame backbone, CB antenna cable, audio harness and main harness. Tighten cable strap, but leave loose enough so that one ﬁnger can be inserted between strap and frame backbone. Do not overtighten. Cut any excess cable strap material.

9. Install remaining cables straps as shown in Figure 8-

180.

10. Install the outer fairing and windshield. See Section 2.29

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

9426

Figure 8-179. Secure CB Antenna Cable

Figure 8-180. Install Cable Straps

11. Align barbed studs in right side cover with grommets in frame downtubes and push ﬁrmly into place (no tools required).

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

BAG, INSTALLATION.

13. Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER

COMPLETE REMOVAL), FLHT/C. For fuel injected models, see Section 9.4 FUEL TANK (FUEL

INJECTED), INSTALLATION (AFTER COMPLETE

REMOVAL), FLHT/C/U/I, FLTRI.

2004 Touring: Electrical 8-145

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IGNITION HARNESS (CARBURETED)

REMOVAL

1. Remove fuel tank. See Section 4.7 FUEL TANK (CAR-

BURETED), COMPLETE REMOVAL, FLHT/C or FLHR/S.

2. Unthread bolt and remove battery positive cable (red) from battery positive (+) terminal. (Battery negative cable already removed under FUEL TANK, COMPLETE REMOVAL.)

3. Using a T40 TORX drive head, loosen bolt to move lip of hold-down clamp off edge of battery. Remove battery from battery box.

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

DLEBAG, REMOVAL.

5. Gently pull side cover from frame downtubes (no tools required).

6. Carefully cut cable straps to free ignition harness from right side of frame backbone, upper frame tube and other wire harness bundles. See Figure 8-185.

7. Remove ignition coil connector [83] and manifold absolute pressure sensor connector [80]. Pull external latch outward and use rocking motion to separate pin and socket halves. Draw conduit and connectors to right side of motorcycle as they are disconnected.

f1847x8x

1. Vehicle Speed Sensor [65]

2. P&A Security Siren [142]

Figure 8-182. Electrical Bracket (Inboard Side)

8. Remove ignition control module connector [10]. Depress external latches and use a rocking motion to separate pin and socket halves. See Figure 8-181.

9. Gently pull on data link connector [91] to disengage from arms on electrical bracket.

Main Harness [8]

Data Link [91]

Ignition Control

Module [10]

Figure 8-181. Electrical Bracket (Under Right Side Cover)

f2191x8x

10. Pull main harness connector [8] from slot in electrical bracket. Depress external latches and use a rocking motion to separate pin and socket halves.

11. Remove two ﬂange nuts to release electrical bracket from studs on side of battery box.

12. On inboard side of electrical bracket, disconnect vehicle speed sensor connector [65]. Depress button on socket housing and pull apart pin and socket halves. See Fig-

ure 8-182.

CAUTION

Damage to wires can result in electrical problems. Be sure that rubber boot is present on threaded end of battery box TORX screw. Replace rubber boot if absent or damaged. See Figure 8-183.

13. Note that ignition harness conduit runs forward of the front battery box TORX screw. Pull conduit to the rear of the screw, and then draw connectors and conduit down right side of frame backbone into battery box.

8-146 2004 Touring: Electrical

f2226x8x

Main Harness

[8A]

Data Link

[91A]

Ignition

Control Module

[10B]

Vehicle Speed

Sensor [65B]

Ignition

Coil [83B]

Manifold Absolute

Pressure

Sensor [80B]

14. Pull connectors and conduit out through opening at side

OME

8321

Rubber

Boot

Figure 8-183. Remove Ignition Harness From Vehicle

of battery box to remove ignition harness from motorcycle.

INSTALLATION

1. Locate end of ignition harness terminating in two connectors. See Figure 8-184.

2. Standing on right side of motorcycle, carefully feed connectors and conduit through opening into battery box. Pull up on harness and tuck conduit into space in front of the battery box TORX screw.

Damage to wires can result in electrical problems. Be sure that rubber boot is present on threaded end of battery box TORX screw. Replace rubber boot if absent or damaged. See Figure 8-183.

3. Draw connectors and conduit up along right side of frame backbone just below the main harness bundle.

4. Loosely install new cable straps to secure ignition harness to right side of frame backbone, upper frame tube and other wire harness bundles. See Figure 8-185.

5. Feed ignition coil connector over the top engine stabilizer link to left side of motorcycle. Install ignition coil connector [83] onto left side of ignition coil.

6. Install manifold absolute pressure sensor connector [80].

7. Returning to electrical bracket, mate pin and socket

halves of vehicle speed sensor connector [65]. Route siren and vehicle speed sensor connectors and conduit on inboard side of electrical bracket as shown in Figure

8-182.

CAUTION

Figure 8-184. Ignition Wire Harness Connectors

2004 Touring: Electrical 8-147

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8. Slide electrical bracket onto studs at side of battery box. Be sure that conduit is properly routed on inboard side of electrical bracket or wires may be pinched during installation. Install ﬂange nuts and tighten to 36-48 in-lbs (4.1-5.4 Nm).

9. Install ignition control module connector [10].

A = Anchored

Frame

Backbone

10. Mate pin and socket halves of main harness connector [8]. Install connector into slot of electrical bracket. See

Figure 8-181.

11. Verify that protective plug is installed in data link connector [91]. With the plug side down and in contact with tab, position connector between arms on electrical bracket.

12. Tighten cable straps securing ignition harness to right side of frame backbone, upper frame tube and other wire harness bundles. Cut any excess cable strap material.

13. Place battery in battery box, terminal side forward. Rotate hold-down clamp so that lip (with rubber pad) rests on edge of battery and tighten clamp bolt.

1WARNING1WARNING

14. Insert bolt through battery positive cable (red) into threaded hole of battery positive (+) terminal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).

15. Install fuel tank. See Section 4.7 FUEL TANK (CARBU-

RETED), INSTALLATION (AFTER COMPLETE REMOVAL), FLHT/C or FLHR/S.

16. Align barbed studs in side cover with grommets in frame downtubes and push ﬁrmly into place (no tools required).

1 A

2 A

3 A

4 A

Saddlebag

Guard

f2225x8x

1 Captures ignition harness only. ANCHORED. 234 Captures main harness, audio harness (FLHTCUI only),

ignition harness and conduit to fuel tank harness (all models except FLHR/C/S). ANCHORED

Figure 8-185. Remove/Install Cable Straps

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

BAG, INSTALLATION.

18. Start motorcycle and verify proper operation without setting trouble codes.

8-148 2004 Touring: Electrical

1. Vehicle Speed Sensor [65]

2. P&A Security Siren [142]

f2183x8x

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EFI HARNESS (FUEL INJECTED)

REMOVAL

1. Remove fuel tank. See Section 9.4 FUEL TANK (FUEL

INJECTED), COMPLETE REMOVAL, FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

2. Remove air cleaner and backplate. See Section 4.5 AIR

CLEANER, REMOVAL.

3. Unthread bolt and remove battery positive cable (red) from battery positive (+) terminal. (Battery negative cable already removed under FUEL TANK, COMPLETE REMOVAL.)

4. Using a T40 TORX drive head, loosen bolt to move lip of hold-down clamp off edge of battery. Remove battery from battery box.

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

DLEBAG, REMOVAL.

6. Gently pull side cover from frame downtubes (no tools required).

NOTE

Draw all EFI wire harness connectors to right side of motorcycle as they are disconnected.

7. Carefully cut ﬁve cable straps to free EFI wire harness

from right side of frame backbone, upper frame tube and other wire harness bundles. See Figure 8-190.

[89A]

[87A]

[88A]

f2162x9x

[84A]

[85A]

[80A] Manifold Absolute Pressure Sensor [84A] Front Fuel Injector [85A] Rear Fuel Injector [87A] Idle Air Control [88A] Throttle Position Sensor [89A] Intake Air Temperature Sensor

Figure 8-186. Induction Module Assembly (Top View)

Front

[80A]

Figure 8-187. Electrical Bracket (Inboard Side)

8. Remove idle air control connector [87] and manifold absolute pressure sensor connector [80]. Pull external latch(es) outward and use rocking motion to separate pin and socket halves. See Figure 8-186.

9. Depress wire form to remove front fuel injector connector [84] and rear fuel injector connector [85].

10. Remove throttle position sensor connector [88] and intake air temperature sensor connector [89].

11. Moving to left side of motorcycle, remove ignition coil connector [83] from left side of ignition coil.

12. Pull back boot to reveal engine temperature sensor connector [90] at back of front cylinder. Pull external latch outward and remove connector. Cut cable strap to release conduit from horn bracket.

13. Returning to right side of motorcycle, depress external latch and remove ECM connector [78].

14. Gently pull on data link connector [91] to disengage from arms on electrical bracket.

15. Locate painted white dot on inboard side of fuse block [119]. Pressing on dot, gently tug on conduit to release tabs on fuse block from slots in bracket.

16. Pull main harness connector [8] from slot in electrical bracket. Depress external latches and use a rocking motion to separate pin and socket halves.

17. Remove two ﬂange nuts to release electrical bracket from studs on side of battery box.

2004 Touring: Electrical 8-149

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8321

Rubber

Boot

8319

Figure 8-188. Remove EFI Harness From Vehicle

18. On inboard side of electrical bracket, disconnect vehicle speed sensor connector [65]. Depress button on socket housing and pull apart pin and socket halves. See Fig-

ure 8-187.

CAUTION

19. Note that harness conduit runs forward of the front battery box TORX screw. Pull conduit to the rear of the screw, and then draw sensor connectors and conduit down right side of frame backbone into battery box.

20. Pull connectors and conduit out through opening at side of battery box to remove harness from vehicle. See lower frame of Figure 8-188.

INSTALLATION

1. Standing on right side of vehicle, carefully feed sensor connectors and conduit through opening into battery box. See lower frame of Figure 8-188. Pull up on harness and tuck conduit into space in front of the battery box TORX screw.

CAUTION

2. Draw sensor connectors and conduit up along right side of frame backbone just below the main wire harness bundle.

3. Loosely install ﬁve new cable straps to secure EFI wire harness to right side of frame backbone, upper frame tube and other wire harness bundles. See Figure 8-190.

4. Install front fuel injector connector [84] and rear fuel injector connector [85]. See Figure 8-186.

5. Install manifold absolute pressure sensor connector [80] and idle air control connector [87].

6. Install intake air temperature sensor connector [89] and throttle position sensor connector [88].

7. Feed ignition coil and engine temperature sensor connectors to left side of vehicle, routing the ﬁrst in front of the top engine stabilizer link, the latter to the rear.

8. Install ignition coil connector [83] onto left side of ignition coil.

9. Install engine temperature sensor connector [90] at back of front cylinder. Pull boot over sensor to keep out dirt and debris. Install new cable strap to secure connector conduit to horn bracket.

10. Mate pin and socket halves of vehicle speed sensor connector [65].

11. Install security siren connector [142] and vehicle speed sensor connector [65] on inboard side of electrical bracket as shown in Figure 8-187. Be sure that conduit and cables are properly routed or wires may be pinched during installation.

12. Slide electrical bracket onto studs at side of battery box. Install ﬂange nuts and tighten to 36-48 in-lbs (4.1-5.4 Nm).

13. Mate pin and socket halves of main harness connector [8]. Install connector into slot of electrical bracket.

14. Engage tabs on fuse block [119] with slots in electrical bracket. Slide fuse block up into cavity. Gently tug on conduit to verify that fuse block is locked in place.

15. Install ECM connector [78]. Push connector halves together until latch clicks.

8-150 2004 Touring: Electrical

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[78B]

[65B]

[8A]

Fuel Pump

Fuse

Spare

Fuse

ECM Power

Fuse

EFI System

Relay

[119B]

[89B]

[80B]

[88B]

[85B]

Rubber

Boot

[91A]

[90B]

[8A] Main Harness [65B] Vehicle Speed Sensor [78B] Electronic Control Module (ECM) [80B] Manifold Absolute Pressure Sensor [83B] Ignition Coil [84B] Front Injector [85B] Rear Injector [87B] Idle Air Control

Figure 8-189. EFI Wire Harness Connectors

[88B] Throttle Position Sensor [89B] Intake Air Temperature Sensor [90B] Engine Temperature Sensor [91A] Data Link [119B] EFI Fuse Block

[84B]

[87B]

[83B]

f2224x9x

2004 Touring: Electrical 8-151

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16. Verify that protective plug is installed in data link connector [91]. With the plug side down and in contact with tab, position connector between arms on electrical bracket.

17. Tighten ﬁve cable straps securing EFI wire harness to right side of frame backbone, upper frame tube and other wire harness bundles. Cut any excess cable strap material.

18. Place battery in battery box, terminal side forward. Rotate hold-down clamp so that lip (with rubber pad) rests on edge of battery and tighten clamp bolt.

A = Anchored

Frame

Backbone

1 A

1WARNING1WARNING

19. Insert bolt through battery positive cable (red) into threaded hole of battery positive (+) terminal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).

20. See Section 9.4 FUEL TANK (FUEL INJECTED),

INSTALLATION (AFTER COMPLETE REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I

21. Install backplate and air cleaner. See Section 4.5 AIR

CLEANER, INSTALLATION.

22. Align barbed studs in side cover with grommets in frame downtubes and push ﬁrmly into place (no tools required).

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

BAG, INSTALLATION.

24. Start vehicle and verify proper operation without setting trouble codes.

2 A

3 A

4 A

Saddlebag

Guard

f2225x8x

1 Captures EFI harness only (front injector, idle air control

234 Captures main harness, audio harness (FLHTCUI only),

and ignition coil conduit). ANCHORED

EFI harness and conduit to fuel tank harness (all models except FLHR/C/S). ANCHORED

Figure 8-190. Remove/Install Cable Straps

8-152 2004 Touring: Electrical

Harley Davidson Touring 2004 Service Manual sm08c

Specifications and Main Features

Frequently Asked Questions

User Manual

CRUISE CONTROL (FLHRC, FLTR, FLHTCU) 8.30

GENERAL

SYSTEM OPERATION

CABLE ADJUSTMENT

THROTTLE CABLE

IDLE CABLE

CABLE LASH INITIALIZATION

THROTTLE/IDLE CABLES

REMOVAL

INSTALLATION

CRUISE CABLE

REMOVAL

INSTALLATION

INSTALLATION

CRUISE CONTROL MODULE

REMOVAL

CRUISE CONTROL SWITCHES

FAIRING CAP

AUDIO HARNESS

HANDLEBAR

PREMIUM SOUND SYSTEM (FLHTC/U, FLTR) 8.31

RADIO (FLHTC/U)

REMOVAL

INSTALLATION

FRONT FAIRING SPEAKERS

REMOVAL

INSTALLATION

CONSOLE POD ASSEMBLY

INSTALLATION

REMOVAL

FRONT HEADSET RECEPTACLE

REMOVAL

INSTALLATION

REAR HEADSET RECEPTACLE

REAR PASSENGER SWITCHES

REMOVAL

INSTALLATION

REAR SPEAKERS

REMOVAL

INSTALLATION

CB LOADING COIL

REMOVAL

INSTALLATION

AUDIO HARNESS

RADIO ANTENNA CABLE

CB ANTENNA CABLE

WIRING HARNESSES AND CABLES 8.32

MAIN HARNESS

REMOVAL- ALL MODELS (PART I)

REMOVAL- FLHR/C/S (PART II)

REMOVAL- FLTR (PART II)

REMOVAL- FLHT/C/U (PART II)

REMOVAL- ALL MODELS (PART III)

INSTALLATION- ALL MODELS (PART I)

INSTALLATION- FLHR/C/S (PART II)

INSTALLATION- FLTR (PART II)

INSTALLATION- FLHT/C/U (PART II)

INSTALLATION- ALL MODELS (PART III)

FRAME GROUND STUD REPLACEMENT

INTERCONNECT HARNESS (FLHTCU)

REMOVAL

INSTALLATION

INTERCONNECT HARNESS (FLTR)

REMOVAL

INSTALLATION

RADIO ANTENNA CABLE (FLHTC/U)

REMOVAL

INSTALLATION

RADIO ANTENNA CABLE (FLTR)

REMOVAL

INSTALLATION

AUDIO HARNESS (FLHTCU)

REMOVAL

INSTALLATION

CB ANTENNA CABLE (FLHTCU)

REMOVAL