Harley Davidson Touring 2004 Service Manual sm08c

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Set/Resume

Switch

110

120

90 100

MPH

RPM

x100

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Cruise Enabled/Engaged Lamp

Tachometer

OME

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.

f2206x8x

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)

2004 Touring: Electrical 8-105

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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)

8-106 2004 Touring: Electrical

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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).

f1555x8x

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

2004 Touring: Electrical 8-107

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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

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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)

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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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