Harley Davidson Touring 2004 Service Manual fe08a
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ELECTRICAL CONNECTOR LOCATIONS 8.1
FLHT/C/U WIRE HARNESS CONNECTORS
No. Description Type Location Fig.
[1] Main to Interconnect Harness 12 - Place Deutsch (Black) Inner Fairing - Right Fairing Bracket 1
[2] Main to Interconnect Harness 12 - Place Deutsch (Gray) Inner Fairing - Right Fairing Support Brace 1
[4] Accessory 4 - Place Deutsch Upper Frame Cross Member (Under Seat) 6
[5] Maxi-Fuse 2 - Place Packard Under Left Side Cover 3
[6] Audio to Interconnect Harness 3 - Place Deutsch (Black) Inner Fairing - Back of Radio (Right Side) 1
[7] Rear Fender Lights Harness 8 - Place Multilock Top of Rear Fender (Under Seat) 9
[8] Ignition Harness (EFI Harness on Fuel Injected Models) 12 - Place Deutsch (Gray) Under Right Side Cover 5
[10] Ignition Control Module **** 12 - Place Deutsch (Black) Under Right Side Cover 8
[12] Tour-Pak Lights 3 - Place Multilock Inside Tour-Pak 2
[13] Fuel Tank Harness 3 - Place Multilock Behind Fuel Tank (Under Seat) 12
[15] Main to Interconnect Harness 4 - Place Packard Inner Fairing - Bottom of Radio (Right Side) 1
[17] Cruise Control Module ** 10 - Place Packard Under Left Side Cover 3
[18] Left Rear Turn Signal 2 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
[19] Right Rear Turn Signal 2 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
[21] Indicator Lamps 10 - Place Multilock Inner Fairing - Above Radio 1
[22] Interconnect to Right Handlebar Switch Controls 12 - Place Deutsch (Black) Inner Fairing - Fork Stem Nut Lock Plate (Left Side) 1
[24] Interconnect to Left Handlebar Switch Controls 12 - Place Deutsch (Gray) Inner Fairing - Left Fairing Support Brace 1
[27] Radio * 23 - Place Amp (Black) Inner Fairing - Back of Radio (Right Side) 1
[28] Radio ** 23 - Place Amp (Gray) Inner Fairing - Back of Radio (Left Side) 1
[30] Turn Signal/Security Module 12 - Place Deutsch Cavity in Crossmember at Rear of Battery Box (Under Seat) 7
[31] Front Turn Signals 6 - Place Multilock Inner Fairing - Left Fairing Support Brace 1
[32] Front Fender Tip Lamp (DOM) 2 - Place Multilock (Black) Inner Fairing - Above Chrome Skirt (Left Side) 1
[33] Ignition/Light Key Switch 4 - Place Packard Inner Fairing - Bottom of Radio 1
[38] Headlamp Headlamp Connector Inner Fairing -
[39] Speedometer 12 - Place Packard Inner Fairing (Back of Speedometer) 1
[41] Rear Right Speaker/Passenger Controls ** 6 - Place Mini-Deutsch Inside Rear Right Speaker Box -
[42] Rear Left Speaker/Passenger Controls ** 6 - Place Mini-Deutsch Inside Rear Left Speaker Box -
[45] Rear Fender Tip Lamp (DOM) 3 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
Stator 2 - Place Packard Bottom of Voltage Regulator
[46]
[50] CB Antenna Cable ** - Inner Fairing - Back of Radio (Right Side) 1,2
[51] Radio Antenna Cable * - Inner Fairing - Back of Radio (Left Side) 1
[53] Console Pod ** 12 - Place Mini-Deutsch Rear of Battery Box (Under Seat) 7
[64] Fuse Block Packard Under Left Side Cover 4
[65] Vehicle Speed Sensor 3 - Place Deutsch Under Right Side Cover (Behind Electrical Bracket) 5
[73] Passing Lamps 2 - Place Multilock (White) Inner Fairing - Above Chrome Skirt (Left Side) 1
[75] Cruise Roll-Off Switch Spade Contacts Right Side of Steering Head -
[76] Passenger Headset 7 - Place DIN Below Rear Left Speaker Box -
[77] Voltage Regulator 1 - Place Deutsch Right Lower Frame Tube (Below Transmission Bracket) -
[78] Electronic Control Module (ECM) *** 36 - Place Packard Under Right Side Cover 5
[79] Crankshaft Position (CKP) Sensor 2 - Place Mini-Deutsch Bottom of Voltage Regulator 11
[80] Manifold Absolute Pressure (MAP) Sensor 3 - Place Packard Top of Intake Manifold/Induction Module -
[83] Ignition Coil 4 - Place Packard Below Fuel Tank (Left Side) -
[84] Front Injector *** 2 - Place Packard Below Fuel Tank (Left Side) -
[85] Rear Injector *** 2 - Place Packard Below Fuel Tank (Left Side) -
[87] Idle Air Control (IAC) *** 4 - Place Packard Below Fuel Tank (Right Side) -
[88] Throttle Position Sensor (TP Sensor) *** 3 - Place Packard Below Fuel Tank (Right Side) -
[89] Intake Air Temperature Sensor (IAT Sensor) *** 2 - Place Packard Below Fuel Tank (Right Side) -
11
Continued ...
2004 Touring: Wiring 8-1
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Main to Interconnect
Harness [156]
Main to Interconnect
Harness [15]
Lamps [21]
Tac hometer
Gauge [108]
Indicator
Speedometer
Gauge [39]
Ambient
Temperature
Sensor [107]
Left Handlebar
Switch Controls [24]
Main to Interconnect
Harness [2]
Main to Interconnect
Harness [1]
Radio [27]
Radio [28]
Front Turn
Signals [31]
Radio Antenna
Cable [51]
Fairing Cap
Switches [105]
CB Antenna
Cable [50]
f2238x8x
8-2 2004 Touring: Wiring
Ignition
Switch [33]
Right Handlebar
Switch Controls [22]
Lamp [73]
Figure 8-1. Inner Fairing Connectors (FLHT/C/U)
Audio to Interconnect
Harness [6]
Front
Fender Tip [32]
Passing
HOME
FLHT/C/U WIRE HARNESS CONNECTORS (Continued)
No. Description Type Location Fig.
[90] Engine Temperature Sensor (ET Sensor) *** 2 - Place Packard Back of Front Cylinder (Left Side) -
[91] Data Link 4 - Place Deutsch Under Right Side Cover 5
[93] Tail Lamp 4 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
[94] Rear Fender Lights Harness to Circuit Board 6 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
[105] Fairing Cap Switches 12 - Place Multilock Inner Fairing - Below Upper Fork Bracket (Right Side) 1
[107] Ambient Air Temperature Sensor * 3 - Place Multilock Inner Fairing - Left Fairing Bracket (Outboard Side) 1
[108] Tachometer 12 - Place Packard Inner Fairing (Back of Tachometer) 1
[110] Voltmeter Lamp Spade Connector Inner Fairing -
[111] Voltmeter Spade Connector Inner Fairing -
[112] Oil Pressure Gauge Lamp Spade Connector Inner Fairing -
[113] Oil Pressure Gauge Spade Connector Inner Fairing -
[114] Air Temperature Gauge Lamp Spade Connector Inner Fairing -
[115] Air Temperature Gauge Spade Connector Inner Fairing -
[116] Fuel Gauge Lamp Spade Connector Inner Fairing -
[117] Fuel Gauge Spade Connector Inner Fairing -
[119] EFI Fuses *** Fuse Terminals Fuse Block (Under Right Side Cover) 5
[121] Rear Brake Light Switch Spade Terminals Beneath Transmission (Right Side) -
[122] Horn Spade Terminals Between Cylinders (Left Side) -
[123] Starter Relay Relay Connector Rear of Battery Box (Under Seat) - Left Side 7
[124] Brake Light Relay Relay Connector Fuse Block (Under Left Side Cover) 4
[126] Ignition Keyswitch Relay Relay Connector Rear of Battery Box (Under Seat) - Left Side 7
[128] Starter Solenoid Spade Terminals Top of Starter -
[129] Harness Grounds Ring Terminals Upper Frame Cross Member (Under Seat) 6
[131] Neutral Switch Post Ter minals Transmission Top Cover -
[132] Cigarette Lighter * Spade Terminals Inner Fairing -
[135] EFI System Relay *** Relay Connector Fuse Block (Under Right Side Cover) 5
[139] Oil Pressure Sender 4 - Place Packard Front Right Crankcase -
[141] Fuel Level Sender (and Fuel Pump on EFI models) 3 - Place Mini-Deutsch Top of Canopy (Under Console) -
[142] Security Siren (Optional) 3 - Place Packard Under Right Side Cover (Behind Electrical Bracket) 5
[156] Main to Interconnect Harness 6 - Place Deutsch Inner Fairing - Right Fairing Support Brace 1
[160] B+ 1 - Place Packard Upper Frame Cross Member (Under Seat) 6
* Classic and Ultra ** Ultra Only *** Fuel Injected Models **** Carbureted Models
f1466a2x f1467b2x
Cavity
CB Antenna
Tour-Pak Lights
Connector [12]
LEFT SIDE
RIGHT SIDE
Cable Connector
[50C/D]
Figure 8-2. Tour-Pak Connectors
2004 Touring: Wiring 8-3
HOME
f2206x8x
Cruise Module
Connector [17]
Spare Fuse
Holder
Cruise Cable
Connector
Fuse Block
Cruise Module
Maxi-Fuse
Holder
f2203x8x
10
11
1
1. Headlamp
2. Ignition
3. Lighting
4. Instruments
5. Brakes/Cruise
6. Radio Memory*
Figure 8-3. Control Control Module (Under Left Side Cover)
f1917x9x
7
8
9
6
*P&A
Security Siren
[142]
5
4
2
7. Radio Power*
8. Accessory
9. Battery
10. Brake Light Relay
11. P&A
3
*Vehicle Speed
Sensor [65]
Data Link
[91]
Electronic
Control
Module [78]
Main Harness to
EFI Harness [8]
EFI Fuse
Block
*Absent from FLHR/C/S models.
Figure 8-4. Fuse Blocks - FLTR, FLHTC/U
(Under Left Side Cover)
8-4 2004 Touring: Wiring
* Under Bracket
Figure 8-5. Electrical Bracket - Fuel Injected Models
(Under Right Side Cover)
HOME
f2191x8x
Ignition Control Module
Connector [10]
f2250x8x
Main Harness
Ground Ring
Terminals (2)
Main Harness
Ground Ring
Terminals (2)
Chassis
Ground Cable
Fuel Tank Harness
Connector [13]
Not Present on FLHR/C/S
B+ Connector [160]
Starter
Relay [123]
Console Pod [53]
Accessory
Connector [4]
Battery
Positive Cable
Battery
Negative Cable
Figure 8-6. Electrical Connections - Upper Frame Cross Member (Under Seat)
Ignition Keyswitch
Relay [126]
Turn Signal/Security
Module [30]
f2192x8x
Figure 8-7. Electrical Connectors/Relays (Under Seat)
Under Crossmember
Figure 8-8. Ignition Control Module - Carbureted Models
(Under Right Side Cover)
2004 Touring: Wiring 8-5
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f2013x8x
Fender Tip
Lamp [45]
Tail Lamp
[93]
Rear Fender
Lights Connector [7]
Figure 8-9. Rear Fender (Under Seat)
Right Turn
Signal Lamp
[19]
Left Turn
Signal Lamp
[18]
Fender Lights
Harness to
Circuit Board
f2256x8x
Stator
Connector [46]
Crankshaft
Position Sensor
Connector [79]
Figure 8-11. Voltage Regulator (Left Side View)
f1924x8x
[94]
Figure 8-10. Rear Fender Lights Assembly
f2172x8x
Fuel Tank
Fuel Vapor
Vent Tube
To Vapor Valve
Fuel Tank Harness
Connector [13]
Not Present on FLHR/C/S
Figure 8-12. Rear of Fuel Tank (Under Seat)
8-6 2004 Touring: Wiring
HOME
FLHR/C/S WIRE HARNESS CONNECTORS
No. Description Type Location Fig.
[4] Accessory 4 - Place Deutsch Upper Frame Cross Member (Under Seat) 6
[5] Maxi-Fuse 2 - Place Packard Under Left Side Cover 3
[7] Rear Fender Lights Harness 8 - Place Multilock Top of Rear Fender (Under Seat) 9
[8] Ignition Harness (EFI Harness on Fuel Injected Models) 12 - Place Deutsch (Gray) Under Right Side Cover 5
[10] Ignition Control Module **** 12 - Place Deutsch (Black) Under Right Side Cover 8
[18] Left Rear Turn Signal 2 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
[19] Right Rear Turn Signal 2 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
[21] Indicator Lamps 8 - Place Mini-Deutsch Under Console 14
[22] Right Handlebar Controls 6 - Place Deutsch Inside Headlamp Nacelle - Fork Stem Nut Lock Plate (Right Side) 13
[24] Left Handlebar Controls 6 - Place Deutsch Inside Headlamp Nacelle - Fork Stem Nut Lock Plate (Left Side) 13
[30] Turn Signal/Security Module 12 - Place Deutsch Cavity at Rear of Battery Box (Under Seat) 7
[31] Front Turn Signals 6 - Place Multilock Inside Headlamp Nacelle - Fork Stem Nut Lock Plate (Left Side) 13
[32] Front Fender Tip Lamp (DOM) 2 - Place Multilock (Black) Inside Headlamp Nacelle 13
[33] Ignition/Light Key Switch 3 - Place Packard Under Console 14
[38] Headlamp Headlamp Connector Inside Headlamp Nacelle 13
[39] Speedometer 12 - Place Packard Back of Speedometer (Under Console) 14
[45] Rear Fender Tip Lamp (DOM) 3 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
Stator 2 - Place Packard Bottom of Voltage Regulator
[46]
[64] Fuse Block Packard Under Left Side Cover 4
[65] Vehicle Speed Sensor 3 - Place Deutsch Under Right Side Cover (Behind Electrical Bracket) 5
[67] Accessory Switch 4 - Place Amp Inside Headlamp Nacelle 13
[73] Passing Lamps 2 - Place Multilock (White) Inside Headlamp Nacelle 13
[75] Cruise Roll-Off Switch ** Spade Contacts Right Side of Steering Head -
[77] Voltage Regulator 1 - Place Deutsch Right Lower Frame Tube (Below Transmission Bracket) -
Continued ...
11
f2212x8x
Right Handlebar
Controls [22]
Passing Lamps
Switch [109]
Used on FLHR/C Only
Cruise Set/Resume
Switch [159]
Used on FLHRC Only
Front Turn
Signals [31]
Passing Lamps [73]
Used on FLHR/C Only
Figure 8-13. Headlamp Nacelle Connectors (FLHR/C/S)
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: Wiring 8-7
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FLHR/C/S WIRE HARNESS CONNECTORS (Continued)
No. Description Type Location Fig.
[78] Electronic Control Module (ECM) *** 36 - Place Packard Under Right Side Cover 5
[79] Crankshaft Position (CKP) Sensor 2 - Place Mini-Deutsch Bottom of Voltage Regulator 11
[80] Manifold Absolute Pressure (MAP) Sensor 3 - Place Packard Top of Intake Manifold/Induction Module -
[83] Ignition Coil 4 - Place Packard Below Fuel Tank (Left Side) -
[84] Front Injector *** 2 - Place Packard Below Fuel Tank (Left Side) -
[85] Rear Injector *** 2 - Place Packard Below Fuel Tank (Left Side) -
[87] Idle Air Control (IAC) *** 4 - Place Packard Below Fuel Tank (Right Side) -
[88] Throttle Position Sensor (TP Sensor) *** 3 - Place Packard Below Fuel Tank (Right Side) -
[89] Intake Air Temperature Sensor (IAT Sensor) *** 2 - Place Packard Below Fuel Tank (Right Side) -
[90] Engine Temperature Sensor (ET Sensor) *** 2 - Place Packard Back of Front Cylinder (Left Side) -
[91] Data Link 4 - Place Deutsch Under Right Side Cover 5
[93] Tail Lamp 4 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
[94] Rear Fender Lights Harness to Circuit Board 6 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
[108] Optional Tachometer 1 - Place Amp Inside Headlamp Nacelle -
[109] Passing Lamps Switch 4 - Place Amp Inside Headlamp Nacelle 13
[117] Fuel Gauge 4 - Place Multilock Below Fuel Tank (Left Side) -
[119] EFI Fuses *** Fuse Terminals Fuse Block (Under Right Side Cover) 5
[120] Oil Pressure Switch Post Terminal Front Right Crankcase -
[121] Rear Brake Light Switch Spade Terminals Beneath Transmission -
[122] Horn Spade Terminals Between Cylinders (Left Side) -
[123] Starter Relay Relay Connector Fuse Block (Under Left Side Cover) -
[124] Brake Light Relay Relay Connector Fuse Block (Under Left Side Cover) 4
[126] Ignition Keyswitch Relay Relay Connector Rear of Battery Box (Under Seat) - Left Side 7
[128] Starter Solenoid Spade Terminals Top of Starter -
[129] Harness Grounds Ring Terminals Upper Frame Cross Member (Under Seat) 6
[131] Neutral Switch Post Terminals Top of Transmission -
[135] EFI System Relay *** Relay Connector Fuse Block (Under Right Side Cover) 5
[141] Fuel Level Sender (and Fuel Pump on EFI models) 3 - Place Mini-Deutsch Top of Canopy (Under Console) -
[142] Security Siren (Optional) 3 - Place Packard Under Right Side Cover (Behind Electrical Bracket) 5
[158] Left Handlebar Controls (Cruise Switches) ** 2 - Place Deutsch (Gray) Inside Headlamp Nacelle 13
[159] Right Handlebar Controls (Cruise Switches) ** 2 - Place Deutsch (Black) Inside Headlamp Nacelle 13
[160] B+ 1 - Place Packard Upper Frame Cross Member (Under Seat) 6
** FLHRC Only *** Fuel Injected Models **** Carbureted Models
Speedometer
Gauge [39]
f2095x8x
8-8 2004 Touring: Wiring
Ignition/Light
Key Switch [33]
Indicator Lights [21]
Figure 8-14. Instrument Console Connectors (FLHR/C)
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FLTR WIRE HARNESS CONNECTORS
No. Description Type Location Fig.
[1] Main to Interconnect Harness 12 - Place Deutsch (Black) Inner Fairing - Below Radio (Left Side) 16
[2] Main to Interconnect Harness 12 - Place Deutsch (Gray) Inner Fairing - Below Radio (Left Side) 16
[4] Accessory 4 - Place Deutsch Upper Frame Cross Member (Under Seat) 6
[5] Maxi-Fuse 2 - Place Packard Under Left Side Cover 3
[7] Rear Fender Lights Harness 8 - Place Multilock Top of Rear Fender (Under Seat) 9
[8] Ignition Harness (EFI Harness on Fuel Injected Models) 12 - Place Deutsch (Gray) Under Right Side Cover 5
[10] Ignition Control Module **** 12 - Place Deutsch (Black) Under Right Side Cover 8
[13] Fuel Tank Harness 3 - Place Multilock Behind Fuel Tank (Under Seat) 12
[15] Main to Interconnect Harness 4 - Place Packard Inner Fairing - Inside Fairing Bracket Tunnel (Left Side) 16
[17] Cruise Control Module 10 - Place Packard Under Left Side Cover 3
[18] Left Rear Turn Signal 2 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
[19] Right Rear Turn Signal 2 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
[21] Indicator Lamps 10 - Place Multilock Inside Instrument Nacelle (Under Bezel) 15
[22] Interconnect to Right Handlebar Switch Controls 12 - Place Deutsch (Black) Inner Fairing - Right Side of Radio Bracket 16
[24] Interconnect to Left Handlebar Switch Controls 12 - Place Deutsch (Gray) Inner Fairing - Left Side of Radio Bracket 16
[27] Radio 23 - Place Amp (Black) Inner Fairing - Back of Radio (Right Side) 16
[30] Turn Signal/Security Module 12 - Place Deutsch (Gray) Cavity at Rear of Battery Box (Under Seat) 7
[31L] Front Turn Signals - Left Side 3 - Place Multilock Inner Fairing - Left Side 16
[31R] Front Turn Signals - Right Side 3 - Place Multilock Inner Fairing - Right Side 16
[33] Ignition/Light Key Switch 4 - Place Packard Inner Fairing - Inside Fairing Bracket Tunnel (Right Side) 16
[38] Headlamp Headlamp Connector Inner Fairing 16
[39] Speedometer 12 - Place Packard Inside Instrument Nacelle (Back of Speedometer) 15
[45] Rear Fender Tip Lamp (DOM) 3 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
Stator
[46]
[51] Radio Antenna Cable - Inner Fairing - Back of Radio (Left Side) 16
[64] Fuse Block Packard Under Left Side Cover 4
[65] Vehicle Speed Sensor 3 - Place Deutsch Under Right Side Cover (Behind Electrical Bracket) 5
2 - Place Packard Bottom of Voltage Regulator
Continued ...
11
f2219x8x
Speedometer
Gauge [39]
Clutch
Cable
Speaker
Switch [105]
Indicator
Lamps [21]
Figure 8-15. Instrument Nacelle Connectors (FLTR)
Instrument Nacelle
Switches [105]
Tachometer
Gauge [108]
Throttle
Cables
Ambient
Temperature
Sensor [107]
2004 Touring: Wiring 8-9
HOME
FLTR WIRE HARNESS CONNECTORS (Continued)
No. Description Type Location Fig.
[75] Cruise Roll-Off Switch Spade Contacts Right Side of Steering Head -
[77] Voltage Regulator 1 - Place Deutsch Right Lower Frame Tube (Below Transmission Bracket) -
[78] Electronic Control Module (ECM) *** 36 - Place Packard Under Right Side Cover 5
[79] Crankshaft Position (CKP) Sensor 2 - Place Mini-Deutsch Bottom of Voltage Regulator 11
[80] Manifold Absolute Pressure (MAP) Sensor 3 - Place Packard Top of Intake Manifold/Induction Module -
[83] Ignition Coil 4 - Place Packard Below Fuel Tank (Left Side) -
[84] Front Injector *** 2 - Place Packard Below Fuel Tank (Left Side) -
[85] Rear Injector *** 2 - Place Packard Below Fuel Tank (Left Side) -
[87] Idle Air Control (IAC) *** 4 - Place Packard Below Fuel Tank (Right Side) -
[88] Throttle Position Sensor (TP Sensor) *** 3 - Place Packard Below Fuel Tank (Right Side) -
[89] Intake Air Temperature Sensor (IAT Sensor) *** 2 - Place Packard Below Fuel Tank (Right Side) -
[90] Engine Temperature Sensor (ET Sensor) *** 2 - Place Packard Back of Front Cylinder (Left Side) -
Continued ...
Radio [27]
Radio
Ground
Main to Interconnect
Harness [156]
Right Turn
Signal [31R]
Right Handlebar
Switch Controls [22]
Ignition
Switch [33]
Radio Antenna
Cable [51]
Left Handlebar
Switch Controls [24]
Main to Interconnect
Harness [1]
Left Turn
Signal [31L]
8-10 2004 Touring: Wiring
Main to Interconnect
Harness [15]
Headlamp [38]
Figure 8-16. Inner Fairing Connectors (FLTR)
Main to Interconnect
Harness [2]
f2230x2x
HOME
FLTR WIRE HARNESS CONNECTORS (Continued)
No. Description Type Location Fig.
[91] Data Link 4 - Place Deutsch Under Right Side Cover 5
[93] Tail Lamp 4 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
[94] Rear Fender Lights Harness to Circuit Board 6 - Place Multilock Circuit Board Under Tail Lamp Assembly 10
Instrument Nacelle Switches
[105]
[105A, 105B] Interconnect to Nacelle Switch Harness 12 - Place Multilock Inside Instrument Nacelle (Under Bezel) 15
[105C, 105D] Nacelle Switch Harness to Speaker Switch 4 - Place Multilock Inside Instrument Nacelle (Under Bezel) 15
[107] Ambient Air Temperature Sensor 3 - Place Multilock Inside Instrument Nacelle (Under Bezel) 15
[108] Tachometer 12 - Place Packard Inside Instrument Nacelle (Back of Tachometer) 15
[110] Voltmeter Lamp Spade Connector Inner Fairing -
[111] Voltmeter Spade Connector Inner Fairing -
[112] Oil Pressure Gauge Lamp Spade Connector Inner Fairing -
[113] Oil Pressure Gauge Spade Connector Inner Fairing -
[114] Air Temperature Gauge Lamp Spade Connector Inner Fairing -
[115] Air Temperature Gauge Spade Connector Inner Fairing -
[116] Fuel Gauge Lamp Spade Connector Inner Fairing -
[117] Fuel Gauge Spade Connector Inner Fairing -
[119] EFI Fuses *** Fuse Terminals Fuse Block (Under Right Side Cover) 5
[121] Rear Brake Light Switch Spade Terminals Beneath Transmission (Right Side) -
[122] Horn Spade Terminals Between Cylinders (Left Side) -
[123] Starter Relay Relay Connector Rear of Battery Box (Under Seat) - Left Side 7
[124] Brake Light Relay Relay Connector Fuse Block (Under Left Side Cover) 4
[126] Ignition Keyswitch Relay Relay Connector Rear of Battery Box (Under Seat) - Left Side 7
[128] Starter Solenoid Spade Terminals Top of Starter -
[129] Harness Grounds Ring Terminals Upper Frame Cross Member (Under Seat) 6
[131] Neutral Switch Post Terminals Transmission Top Cover -
[132] Cigarette Lighter Spade Terminals Inner Fairing -
[135] EFI System Relay *** Relay Connector Fuse Block (Under Right Side Cover) 5
[139] Oil Pressure Sender 4 - Place Packard Front Right Crankcase -
[141] Fuel Level Sender (and Fuel Pump on EFI models) 3 - Place Mini-Deutsch Top of Canopy (Under Console) -
[142] Security Siren (Optional) 3 - Place Packard Under Right Side Cover (Behind Electrical Bracket) 5
[156] Main to Interconnect Harness 6 - Place Deutsch Inner Fairing - Front of Right Fairing Bracket 16
[160] B+ 1 - Place Packard Upper Frame Cross Member (Under Seat) 6
*** Fuel Injected Models **** Carbureted Models
2004 Touring: Wiring 8-11
HOME
NOTES
8-12 2004 Touring: Wiring
HOME
f1049a8x
DEUTSCH ELECTRICAL CONNECTORS 8.2
GENERAL
Attachment clips are attached to the pin housings of some
connectors. The clips are then attached to T-studs on the
motorcycle frame. T-studs give positive location to electrical
connectors and wire harnesses. Consistent location reduces
electrical problems and improves serviceability.
To become familiar with the Deutsch connector, read the
parts description below while referencing the 12-place connector illustrated in Figure 8-19.
Soc
ket housing: alignment tabs and/or external latch, sec-
ondary locking wedge, internal seal, wire seal, seal pin.
NOTE
Seal pins or plugs are installed in the wire seals of unused
chambers. If removed, seal pins must be replaced to maintain the integrity of the environmental seal.
Pin housing
secondary locking wedge, wire seal, seal pin.
: alignment grooves and/or external latch cover,
REMOVING/DISASSEMBLING
1. Push the connector to disengage small end of slot on
attachment clip fromT-stud. Lift connector off T-stud.
2. Depress the external latch(es) on the socket housing
side and use a rocking motion to separate the pin and
socket halves. Two-, three-, four- and six-place Deutsch
connectors have one external latch, while eight- and
twelve-place connectors have two, both of which must
be pressed simultaneously to separate the connector
halves.
4566
Figure 8-18. Depress Terminal Latches/Back Out Pins
NOTE
With few exceptions, the socket housing can always be found
on the accessory side, while the pin side of the connector is
plumbed to the wiring harness.
REMOVING/INSTALLING SOCKETS
1. See Figure 8-17. Remove the secondary locking wedge.
Insert the blade of a small screwdriver between the
socket housing and locking wedge inline with the groove
(inline with the pin holes if the groove is absent). Turn the
screwdriver 90 degrees to pop the wedge up.
2. Gently depress terminal latches inside socket housing
and back out sockets through holes in rear wire seal.
See Figure 8-18.
NOTE
If new terminals must be installed, see CRIMPING
INSTRUCTIONS in this section.
Figure 8-17. Remove Secondary Locking Wedge
3. Fit rear wire seal into back of socket housing, if removed.
Grasp socket approximately 1 inch (25.4 mm) behind the
contact barrel. Gently push sockets through holes in wire
seal into their respective chambers. Feed socket into
chamber until it “clicks” in place. Verify that socket will
not back out of chamber; a slight tug on the wire will confirm that it is properly locked in place.
4. Install internal seal on lip of socket housing, if removed.
Insert tapered end of secondary locking wedge into
socket housing and press down until it snaps in place.
The wedge fits into the center groove within the socket
housing and holds the terminal latches tightly closed.
2004 Touring: Wiring 8-13
HOME
Terminal
Pin
Latch Cover
Wire Seal
Alignment
Grooves
f1915x8x
Pin
Housing
Locking Wedge
(Pin Side)
Locking Wedge
(Socket Side)
Internal
Seal
Socket
Housing
Wire
Seal
NOTE
For exploded views of 2-place,
3-place and 4-place Deutsch
connectors, see Figure 8-21.
Figure 8-19. 12-Place Deutsch Connector (Exploded View)
NOTE
While rectangular wedges do not require a special orientation, the conical secondary locking wedge of the 3-place connector must be installed with the arrow pointing toward the
external latch. See Figure 8-20.
NOTE
If the secondary locking wedge does not slide into the
installed position easily, verify that all terminals are fully
installed in the socket housing. The lock indicates when terminals are not properly installed by not entering its fully
installed position.
REMOVING/INSTALLING PINS
Alignment
Tabs
Housing
Socket
Housing
Seal
Pin
External
Latch
Socket
Terminal
Pin
Arrow Points to
External Latch
1. Remove the secondary locking wedge. Use the hooked
end of a stiff piece of mechanics wire, a needle nose pliers or a suitable pick tool (HD-41475-100). See Figure
8-22.
8-14 2004 Touring: Wiring
f1515x8x
Figure 8-20. 3-Place Locking Wedge Orientation
HOME
f1510x8x
11
11
10
8
7
6
5
9
2-Place Connector
4
2
3
10
8
1
7
6
9
5
3-Place Connector
4
11
Socket Side
12. Socket Terminal
13. Wire Seal
14. Socket Housing
15. External Latch
16. Internal Seal
17. Locking Wedge
DEUTSCH
9
10
Pin Side
18. Locking Wedge
19. Latch Cover
20. Pin Housing
21. Wire Seal
22. Pin Terminal
2
3
1
8
7
6
5
4-Place Connector
4
2
1
DEUTSCH
3
Figure 8-21. 2-Place, 3-Place and 4-Place Deutsch Connectors
2004 Touring: Wiring 8-15
HOME
Figure 8-22. Deutsch Connector Pick Tool
(Part No. HD-41475-100)
2. Gently depress terminal latches inside pin housing and
back out pins through holes in wire seal.
NOTE
If new terminals must be installed, see CRIMPING
INSTRUCTIONS on this page.
3. Fit wire seal into back of pin housing. Grasp crimped pin
approximately 1 inch (25.4 mm) behind the contact barrel. Gently push pins through holes in wire seal into their
respective numbered locations. Feed pin into chamber
until it “clicks” in place. Verify that pin will not back out of
chamber; a slight tug on the wire will confirm that it is
properly locked in place.
4. Insert tapered end of secondary locking wedge into pin
housing and press down until it snaps in place. The
wedge fits in the center groove within the pin housing
and holds the terminal latches tightly closed.
click (latch), press on one side of the connector until that
latch engages, then press on the opposite side to
engage the other latch.
NOTES
Deutsch connectors are colored coded for location pur-
●
poses. Those connectors associated with
accessories, such as the front and rear
are
gray
. All other connectors, including those associ-
ated with right side accessories, are black.
If it should become necessary to replace a plug or
●
receptacle, please note that the 8-place and 12-place
gray and black connectors are not interchangeable.
Since location of the alignment tabs differ between the
black and gray connectors, plugs or receptacles must be
replaced by those of the same color. If replacing both the
socket and pin halves, then the black may be substituted
for the gray, and vice versa. The socket and pin halves of
all other connectors are interchangeable, that is, the
black may be mated with the gray, since the alignment
tabs are absent and the orientation of the external latch
is the same.
2. Fit the attachment clip to the pin housing, if removed.
Place large end of slot on attachment clip over T-stud on
frame. Push assembly forward to engage small end of
slot.
left
turn signals,
left
side
NOTE
While rectangular wedges do not require a special orientation, the conical secondary locking wedge of the 3-place connector must be installed with the arrow pointing toward the
external latch. See Figure 8-20.
NOTE
If the secondary locking wedge does not slide into the
installed position easily, verify that all terminals are fully
installed in the pin housing. The lock indicates when terminals are not properly installed by not entering its fully
installed position.
ASSEMBLING/INSTALLING
1. Insert socket housing into pin housing until it snaps in
place. Two-, three-, four- and six-place Deutsch connectors have one external latch on the socket half of the
connector. To fit the halves of the connector together, the
latch on the socket side must be aligned with the latch
cover on the pin side.
For those connectors with two external latches (8-place
and 12-place), a different system is used to prevent
improper assembly. Align the tabs on the socket housing
with the grooves on the pin housing. Push the connector
halves together until the latches “click.” If latches do not
CRIMPING INSTRUCTIONS
Use the Deutsch Terminal Crimp Tool (HD-39965) to install
standard size terminals with crimp tails, as described under
STANDARD TERMINALS below. To install the mini-Deutsch
terminals with crimp tails, see MINI TERMINALS, which follows. To install those terminals without crimp tails, both standard and mini-Deutsch, use the Deutsch Solid Barrel Contact
Crimp Tool (HD-42879) as described under SOLID BARREL
CONTACTS.
NOTE
A Deutsch Connector Service Kit (HD-41475) contains a
selection of wire seals, internal seals, seal plugs, secondary
locking wedges, attachment clips and socket/pin terminals.
Also included is a compartmented storage box, carrying case
and pick tool (HD-41475-100) used for the removal of all
types of locking wedges.
Standard Terminals
1. Obtain the DEUTSCH TERMINAL CRIMP TOOL (HD-
39965).
2. Squeeze the handles to cycle the crimp tool to the fully
open position. See Figure 8-23.
8-16 2004 Touring: Wiring
HOME
f1516x8x
2.1.
Gauge
Wire
20 Front
16-18 Middle
Locking
Bar
1. Insert contact through hole of locking bar
so that barrel rests on nest of crimp tool.
3.
Nest of
Crimp Tool
2. Insert stripped lead until it contacts
locking bar.
4.
3. Close and squeeze crimp tool. 4. Raise locking bar and remove contact.
Insulation crimp Core crimp
5.
f1558x8x
5. Inspect quality of core and insulation crimps.
Figure 8-23. Deutsch Crimping Procedure
2004 Touring: Wiring 8-17
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