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

HOME

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

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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

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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

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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

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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

HOME

3. Raise the locking bar by pushing up on bottom flange.
With the crimp tails facing upward, insert contact
(socket/pin) through hole of locking bar, so that the
rounded side of the contact barrel rests on the nest (con­cave split level area) of the crimp tool. Use the middle
hole in the locking bar for 16-18 gauge wire, the front
hole for 20 gauge wire.

4. Release locking bar to lock position of contact. If the
crimp tails are slightly out of vertical alignment, the crimp
tool automatically rotates the contact so that the tails
face straight upward. When correctly positioned, the
locking bar fits snugly in the space between the contact
band and the core crimp tails.

5. Strip lead removing 5/32 inch (4.0 mm) of insulation.
Insert wires between crimp tails until ends make contact
with locking bar. Verify that wire is positioned so that
short pair of crimp tails squeeze bare wire strands, while
long pair folds over insulation material.

6. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete. Raise up locking bar and remove contact.

7. Inspect the quality of the core and insulation crimps. Dis­tortion should be minimal.

Mini Terminals

1. Obtain the PACKARD TERMINAL CRIMP TOOL (HD­38125-7).

2. Strip wire lead removing 5/32 inch (4.0 mm) of insula­tion.

3. Compress handles until ratchet automatically opens.

NOTE

Always perform core crimp before insulation crimp.

4. Position the core cr
sure the core crimp tails are facing the forming jaws.

5. Gently apply pressure to handles of tool until crimpers
just secure the core crimp tails.

6. Insert stripped wire between crimp tails. Verify that wire
is positioned so that short pair of crimp tails squeeze
bare wire strands, while long pair is positioned over the
insulation material.

7. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete.

8. Position the insulation cr
tool. Be sure the insulation crimp tails are facing the
forming jaws.

9. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete.

10. Inspect the quality of the core and insulation crimps. Dis­tortion should be minimal.

imp on nest E of the crimping tool. Be

imp on nest C of the crimping

Solid Barrel Contacts

For Size 20, 16 and 12 Contacts
Wire Range 26-12 AWG

1. Obtain the DEUTSCH SOLID BARREL CONTACT
CRIMP TOOL (HD-42879).

2. Squeeze the handles to cycle the crimp tool to the fully
open position.

3. Remove locking pin from selector knob. See Figure 8-

24.

4. Raise selector knob and rotate until selected wire size
stamped on wheel is aligned with “SEL. NO.” arrow. See
upper frame of Figure 8-25.

5. Loosen knurled locknut and turn adjusting screw clock­wise (in) until it stops.

6. Turn tool over and drop contact into indentor cover hole
with the wire end out.

7. Turn adjusting screw counterclockwise (out) until contact
is flush with bottom of depression in indentor cover.
Tighten knurled locknut.

8. Slowly squeeze handles of crimp tool until contact is
centered between indentor points. See middle frame of

Figure 8-25.

9. Strip wire lead removing 1/4 inch (6.4 mm) of insulation.

10. Insert bare wire strands into contact barrel. See lower
frame of Figure 8-25.

11. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete.

12. Remove crimped contact from indentor.

13. Inspect the quality of the crimp. Verify that all wire
strands are in crimp barrel.

Adjusting

Screw

t

o

n

t
s
u

m
l
o

o

t
D
N

A

H
s
i

h

T

d

e

r
e
w

o

p

y
n
a

n

i
d
e

s

u

e

b

y

b
d
e

n
i
f

e

d

s

a

''
S
S

E

R

)

P

6

"

4
(

1

1
2
.

0

1

9

1

R

F

C

A

H

S

O

Locknut

Figure 8-24. Deutsch Solid Barrel Contact Crimp Tool

(Part No. HD-42879)

Locking

Pin

Selector

Knob

f1535x8x

8-18 2004 Touring: Wiring

HOME

Rotate selector knob to align wire size on wheel
with arrow stamped in tool.

Selector

Knob

t

o

n

t

s

u

m

l

o

o

t

D

N

A

H

is

h

T

d

e

r

e

w

o

p

y

n

a

in

d

e

s

u

e

b

y

b

d

e

n

i

f

e

d

s

a

''

S

S

E

R

)

P

6

"

4

(

1

1

2

.

0

1

9

1

R

F

C

A

H

S

O

f1534x8x

Turn adjusting screw as described in text. When
contact is flush with bottom of depression in
indentor cover, squeeze handles to center contact
between indentor points.

Indentor

Cover

Contact

NOTE

Tool must be readjusted when changing contact size/type.

14. Install pin to lock position of selector knob.

HEMET RYAN AIRPORT, P.O. BOX 878

HEMET, CA. 92343-0161 [phone]

IN

D

U

S

T

R

IA

L

P

R

O

D

U

C

T

S

HDT - 48 - 00

D

JDG360-1

Indentor

Points

f1532x8x

Insert bare wire strands into contact barrel.
Squeeze handle of crimp tool until tightly closed.

HEMET RYAN AIRPORT, P.O. BOX 878

HEMET, CA. 92343-0161 [phone]

INDUSTRIAL PRODUCTS DIVISION

HDT - 48 - 00

JDG360-1

f1533x8x

I

V

IS

IO

N

Figure 8-25. Deutsch Solid Barrel Contact

Crimping Procedure

2004 Touring: Wiring 8-19

HOME

1-

PLACE

CABLE CONNECTOR

General

Use the following instructions to service the voltage regulator
cable connector.

Removal

1. Depress external latch and separate pin and socket
halves of connector.

2. Pull rear wire seal from back of housing and slide down
voltage regulator cable to move out of the way.

3. Obtain terminal pick tool (Deutsch® 114008) like that
shown in A of Figure 8-26.

CAUTION

Rough handling or careless storage can result in tool
damage. Exercise care to avoid cracking or breaking the
thin plastic construction.

4. Install terminal pick tool onto voltage regulator cable so
that the tapered end is in the wire end of the housing.
See B of Figure 8-26.

5. Push tool into wire end of housing until it bottoms. Gen­tly tug on housing to pull from terminal. See C of Figure

8-26.

6. Remove tool from voltage regulator cable.

A

7786

B

7787

C

Installation

1. Insert terminal into wire end of housing until it “clicks” in
place. Verify that terminal will not back out of housing. A
slight tug on the voltage regulator cable will confirm that
it is properly locked in place.

2. Fit rear wire seal into back of housing.

3. Mate pin and socket halves of connector.

7788

Figure 8-26. Remove Socket/Pin Housing

8-20 2004 Touring: Wiring

HOME

AMP MULTILOCK ELECTRICAL CONNECTORS 8.3

REMOVING SOCKET/PIN TERMINALS

1. Remove connector from the retaining device, either
attachment or rosebud clip.

2. Depress the button on the socket terminal side of the
connector (plug) and pull apart the pin and socket
halves. See Figure 8-27.

3. Bend back the latch slightly and free one side of second­ary lock, then repeat the step to release the other side.
Rotate the secondary lock outward on hinge to access
terminals in chambers of connector housing.

4. Looking in the terminal side of the connector (opposite
the secondary lock), take note of the cavity next to each
terminal.

5. See Figure 8-28. With the flat edge against the terminal,
insert the pick (Snap-On TT600-3) into the cavity until it
stops. Pivot the end of the pick away from the terminal
and gently tug on wire to pull terminal from chamber. Do
not tug on the wire until the tang is released or the termi­nal will be difficult to remove. A “click” is heard if the tang

Secondary Lock

Open

Pin Terminal

is engaged but then inadvertently released. Repeat the
step without releasing the tang.

NOTE

An Electrical Terminal Crimp Tool (Part No. HD-41609) is
used to install Amp Multilock pin and socket terminals on
wires. If new terminals must be installed, see CRIMPING

INSTRUCTIONS in this section.

INSTALLING SOCKET/PIN TERMINALS

NOTE

For wire location purposes, numbers are stamped into the
secondary locks of both the socket and pin housings. See

Figure 8-30.

1. From the secondary lock side of the connector, insert the
terminal into its respective numbered chamber until it
snaps in place. For proper fit, the slot in the terminal
must face the tang in the chamber.

NOTE

For exploded views of 3-place
and 6-place Amp Multilock
connectors, see Figure 8-31.

Latch

f1292x2x

Pin Housing

Figure 8-27. 10-Place Amp Multilock Connector (Exploded View)

Socket Housing

Latch

Button

Secondary Lock

Open

Secondary Lock

Open

Latch

Socket Terminal

2004 Touring: Wiring 8-21

HOME

Secondary Lock

Open

f1289x2x

Pin Terminal

Socket Terminal

Secondary Lock

Open

4

1

4

Socket Housing

2

Pick Tool

1

3

2

Pick Tool

Pin Housing

1. Open Secondary Lock.

2. Insert Pick into Cavity on Mating End of Connector.

3. Pivot End of Pick to Release Tang.

4. Gently Tug on Wire to Remove Terminal from Housing.

Figure 8-28. Release Tang and Back Out Terminals

NOTE
The tang in the chamber engages the slot to lock the terminal
in position. On the pin side of the connector, tangs are posi­tioned at the bottom of each chamber, so the slot in the pin
terminal (on the side opposite the crimp tails) must face
downward. On the socket side, tangs are at the top of each
chamber, so the socket terminal slot (on the same side as the
crimp tails) must face upward. Up and down can be deter­mined by the position of the release button (used to separate
the pin and socket halves), the button always being the top of
the connector. See Figure 8-29.

2. Gently tug on wire end to verify that the terminal is

locked in place and will not back out of chamber.

3

Pin Housing

f1428x8x

Figure 8-29. Tang Location (Cross Sectional View)

Tang

Tang

Button

Socket Housing

8-22 2004 Touring: Wiring

HOME

f1287x2x

– AMP

123

3-Place Connector 6-Place Connector 10-Place Connector

Figure 8-30. Numbers Stamped on Secondary Locks for Wire Color Locations (Socket Housings Shown)

3-Place Connector

Secondary Locks Open

– AMP

123456

56 78 910

8

9

5

43 21

f1291x2x

7

6-Place Connector

9

7

Socket Side

23. Socket Terminal

24. Secondary Lock (Open)

25. Latch

26. Socket Housing

27. Button

Pin Side

28. Pin housing

29. Latch

30. Secondary Lock (Open)

31. Pin Terminal

6

3

4

3

8

2

1

5

6

3

4

3

2

1

f1288x2x

Figure 8-31. 3-Place and 6-Place Amp Multilock Connectors

2004 Touring: Wiring 8-23

HOME

f1286x2x

PIN TERMINAL SOCKET TERMINAL

Insulation
Crimp Tail

Core

Crimp Tail

Locking Bar

Groove

Tang Slot

Locking Bar

Groove

Tang Slot

Crimp Tail

2.1.

Locking

Bar

Core

Insulation
Crimp Tail

f1290a2x

1. Raise locking bar and seat contact on nest
of crimp tool. Release locking bar.

3.

3. Close and squeeze crimp tool. 4. Raise locking bar and remove contact.

Figure 8-32. Amp Multilock Crimping Procedure

4.

2. Insert stripped lead until it contacts
locking bar.

Gauge

Wire

20 Front

16 Middle

18 Rear

Nest of

Crimp Tool

8-24 2004 Touring: Wiring

HOME

3. Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.

4. Insert the socket housing (plug) into the pin housing
(receptacle) until it snaps in place.

5. Install connector on retaining device, either attachment
or rosebud clip.

CRIMPING INSTRUCTIONS

1. Squeeze the handles to cycle the crimp tool (Part No.
HD-41609) to the fully open position.

2. Raise locking bar by pushing up on bottom flange. With
the crimp tails facing upward, insert contact (socket/pin)
through locking bar, so that the closed side of the con­tact rests on the nest (concave split level area) of the
crimp tool). Use the front nest for 20 gauge wire, the
middle for 16 gauge and the rear for 18 gauge. See Fig-

ure 8-32.

3. Release locking bar to lock position of contact. When
correctly positioned, the locking bar fits snugly in the
space at the front of the core crimp tails.

4. Strip lead removing 5/32 inch (4.0 mm) of insulation.
Insert wires between crimp tails until ends make contact
with locking bar. Verify that wire is positioned so that
short pair of crimp tails squeeze bare wire strands, while
long pair folds over insulation material.

5. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete. Raise up locking bar and remove contact.

6. Inspect the quality of the core and insulation crimps. Dis­tortion should be minimal.

2004 Touring: Wiring 8-25

HOME

PACKARD ELECTRICAL CONNECTORS 8.4

150 METRI-PACK SERIES

General

Use these instructions to service the following connectors:

●

MAP Sensor [80B]
Ignition Coil [83B/130B]

●

●

IAC Actuator [87B]

●

TP Sensor [88B]
ET Sensor [90B]

●

●

IAT Sensor [89B]

Disassembly

1. Remove the connector from the retaining device, if
present.

2. Bend back the external latch(es) slightly and separate
the pin and socket halves of the connector.

3. To free a pull-to-seat terminal from the connector hous­ing, first look into the mating end of the connector to find
the locking tang. See A in Figure 8-34. The tangs are
always positioned in the middle of the chamber and are
on the same side as the external latch. On those con­nectors with locking ears, the tang is on the side oppo­site the ear. See Figure 8-35.

4. At a slight angle, gently insert the point of a one inch
safety pin down the middle of the chamber about 1/8
inch (3.2 mm), and pivot the end of the pin toward the
terminal body. When a click is heard, remove the pin and
repeat the procedure. See B in Figure 8-34. The click is
the sound of the tang returning to the locked position as
it slips from the point of the pin. Pick at the tang in this
manner until the clicking stops and the pin seems to
slide in at a slightly greater depth than it had previously.
This is an indication that the tang has been depressed.

2-Place

AB

IAT Sensor Connector [89B]

2-Place

AB

ET Sensor Connector [90B]

3-Place

ABC

TP Sensor Connector [88B]

4-Place

ABCD

NOTE

On those terminals that have been extracted on a previous
occasion, no clicking sound may be heard when the pin is
pivoted to depress the tang, but proceed as if the clicking is
audible and then push on the wire end of the lead to check if
the terminal is free.

NOTE

When picking multiple terminals, the end of the pin may
become malleable. For best results, continue the procedure
with a new safety pin.

8-26 2004 Touring: Wiring

IAC Connector [87B]

Figure 8-33. Packard External Latch Type Connectors

(Socket Sides)

5. Remove the pin and push on the wire end of the lead to
extract the terminal from the mating end of the connec­tor. See C in Figure 8-34. If necessary, pull back the con­duit and remove the wire seal at the back of the
connector to introduce some slack in the wires.

HOME

f1360x8x

A

Locate tang on latch side of chamber. Push on wire end of lead to remove terminal.

B

Pivot end of pin to depress tang.

Figure 8-34. Depress Tang and Extract Terminal From Mating End of Connector

6. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

Assembly

NOTE

For wire location purposes, alpha characters are stamped
into the socket housings.

C

D

Raise tang and re-install terminal.

2. Gently pull on the lead at the wire end of the connector
to draw the terminal back into the chamber. A click is
heard when the terminal is properly seated.

3. Push on the lead to verify that the terminal is locked in
place.

4. Push the pin and socket halves of the connector
together until the latches “click.”

1. Using a thin flat blade, like that on an X-Acto knife, care­fully bend the tang outward away from the terminal body.
See D in Figure 8-34.

C

AB

Figure 8-35. Packard Pull-to-Seat Terminal Connector

With Locking Ear

280 METRI-PACK SERIES

General

Use these instructions to service the following:

Front/Rear Fuel Injectors [84B/85B]

●

System Fuse Block [64B]

●

Fuel Injectors

Disassembly

1. Depress the wireform and use a rocking motion to
detach the electrical connector.

2. Pry rubber seal from wire end of connector and move
seal down wires toward conduit.

2004 Touring: Wiring 8-27

HOME

A. Insert safety pin at wire end of
connector to depress tang.

B. Push on wire end of lead to
remove terminal.

A

BC D

C. Raise tang with blade of X-Acto
knife.

D. Pull on wire end of lead to draw
terminal back into chamber.

f2012x9x

Figure 8-36. Extract/Install Socket Terminal at Mating End of Connector

3. Hold the connector so that the wireform is facing down,
and looking into the wire end of the connector, insert the
point of a safety pin between the top of the terminal and
the inside chamber wall.

4. Push safety pin completely into chamber while watching
terminal on mating end of connector. When terminal is
observed moving forward slightly, then tang is
depressed. See A in Figure 8-36. Remove safety pin.

NOTE

Repeat steps 3 and 4 as necessary until the desired result is
achieved.

5. Push on wire end of the lead to extract the terminal from

the mating end of the connector. See B in Figure 8-36.

6. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

Assembly

NOTE

For wire color locations, see Section 8.8 WIRING DIA-

GRAMS and then refer to Figure 8-37.

1. Using a thin flat blade, like that on an X-Acto knife, care­fully bend the tang outward away from the terminal body.
See C in Figure 8-36.

2. Gently pull on the lead at the wire end of the connector
to draw the terminal back into the chamber. Be sure that
the tang faces opposite the wireform as it enters the
chamber. A “click” is heard when the terminal is properly
seated. See D in Figure 8-36.

3. Push on lead to verify that terminal is locked in place.

4. Fit rubber wire seal back into wire end of connector.

5. Push the pin and socket halves of the connector
together until the latch “clicks.” The groove in the socket
housing must be aligned with the tab in the pin housing.

AB

Figure 8-37. Fuel Injector Connector [84B/85B]

8-28 2004 Touring: Wiring

HOME

1WARNING1WARNING

Lip of

Locking Wedge

f2205x8x

1. Headlamp

2. Ignition

3. Lighting

4. Instruments

5. Brakes/Cruise

6. Radio Memory

7. Radio Power

8. Accessory

9. Battery

10. Brake Light Relay

11. P&A

11

10

9

1

8

7

6

5

4

3

2

f2204x8x

System Fuse Block

Disassembly

1. Remove system fuses and relay(s) from fuse block.

2. Remove secondary locks as follows:

a. Insert end of small flat blade screwdriver under lip of

locking wedge and gently pry up secondary lock.

NOTE

For best results, start with locking wedge on outboard side of
secondary lock. See Figure 8-38.

3. Remove socket terminals as follows:

a. Looking into chamber at top of fuse block, note the

tang next to each socket terminal.

b. Using a thin flat blade, like that on an X-Acto knife,

gently push tang away from terminal, and then tug
on wire to back terminal out wire end of chamber.

4. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

Figure 8-38. Remove Secondary Locks From Fuse Block

Assembly

1. Install socket terminals as follows:

NOTE

See Section 8.8 WIRING DIAGRAMS, MAIN HARNESS, for
wire colors and locations.

a. With the open side of the socket terminal facing the

tang, push lead into chamber at the wire end of the
fuse block. A click is heard when the terminal is
properly engaged.

b. Gently tug on the wire to verify that the terminal is

locked in place and will not back out of the chamber.

2. Install secondary locks as follows:

a. With the locking wedges positioned above the tangs

in each chamber, slide flat side of secondary lock
into slot (between rows), and push down until it bot­toms. See Figure 8-38.

3. Install system fuses and relay(s) in fuse block.

480 METRI-PACK SERIES

General

Use the following instructions to service the B+ connector.

Figure 8-39. Fuse Block (FLTR, FLHTC/U)

Disassembly

1. Remove seat.

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.

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

2004 Touring: Wiring 8-29

HOME

f2250x8x

B+ Connector

Figure 8-40. Remove Seat

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

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. Cut anchored cable strap to release accessory connec­tor and B+ connector from left side of frame crossmem­ber (in front of battery box). See Figure 8-41.

6. Using small flat blade screwdriver, depress button on pin
housing (red wire) side of the connector and pull apart
the pin and socket halves. See A of Figure 8-41.

7. Bend back the latch slightly and free one side of second­ary lock, then repeat the step to release the other side.
Rotate the secondary lock outward on hinge to access
terminal in chamber of connector housing. See B of Fig-

ure 8-41.

8. On the mating end of the connector, note the tang in the
square shaped opening centered next to the terminal.
Gently insert the point of a stick pin or large safety pin
into the opening between the tang and the chamber wall
until it stops. Pivot the end of the pin toward the terminal
body to depress the tang. Remove the pin and then pull
terminal out wire end of connector housing. See C of

Figure 8-41.

9. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

2. With the tang on the same side as the square shaped
opening in the mating end of the connector housing,
feed terminal into wire end of connector housing until it
“clicks” in place.

3. Verify that terminal will not back out of the chamber. A
slight tug on the cable will confirm that it is locked.

4. Rotate the hinged secondary lock inward until latches
fully engage tabs on both sides of connector housing.

5. Mate pin and socket halves of connector.

6. Install

7. Place battery in battery box, terminal side forward.

f2258x8x

f2259x8x

new

anchored cable strap in lower hole on left
side of frame crossmember (in front of battery box).
Tighten cable strap to capture conduit of both accessory
connector and B+ connector approximately one inch
from connector housings. See Figure 8-41.

A

B

Assembly

1. Carefully bend the tang outward away from the terminal
body.

8-30 2004 Touring: Wiring

f2260x8x

C

Figure 8-41. Remove Socket Terminal

HOME

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.

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

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

10. Rotate hold-down clamp so that the lip (with rubber pad)
rests on the edge of the battery. Using a T40 TORX drive
head, tighten the clamp bolt to 15-20 ft-lbs (20-27 Nm).

11. Install seat.

in-lbs

(6.8-10.9 Nm).

in-lbs

(6.8-10.9 Nm).

630 METRI-PACK SERIES

General

Use these instructions to service the following connectors:

●

Main to Interconnect Harness [15]
Ignition Light/Key Switch [33]

●

Assembly

NOTE

For wire location purposes, alpha characters are molded into
the secondary locks of each connector housing.

1. Using a thin flat blade, like that on an X-Acto knife, care­fully bend the tang outward away from the terminal body.

2. With the tang facing the chamber wall, push the lead into
the chamber at the wire end of the connector. A click is
heard when the terminal is properly seated.

3. Gently tug on the wire end to verify that the terminal is
locked in place and will not back out of the chamber.

4. Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.

5. Push the pin and socket halves of the connector
together until the latches “click.”

6. Install connector on barbed anchor or other retaining
device, if present.

800 METRI-PACK SERIES

General

Use the following instructions to service the maxi-fuse holder.

Disassembly

1. Remove connector from barbed anchor or other retain­ing device, if present.

2. Bend back the external latch slightly and separate pin
and socket halves of the connector.

3. Bend back the latch slightly and free one side of the sec­ondary lock. Repeat the step to unlatch the other side.

4. Rotate the secondary lock outward on hinge to view the
terminals in the chambers of the connector housing. The
locking tang is on the side opposite the crimp tails and
engages a rib in the chamber wall to lock the terminal in
place.

5. Moving to the mating end of the connector, take note of
the small opening on the chamber wall side of each ter­minal.

6. Insert pick (Snap-on® TT600-3) into opening until it
stops. Pivot the end of the pick toward the terminal to
depress the locking tang.

7. Remove the pick and gently tug on the wire to pull the
terminal from the wire end of the connector. Repeat
steps if the terminal is still locked in place.

8. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

Disassembly

1. Remove maxi-fuse.

2. Remove socket terminals as follows:

a. Gently pull sides of secondary lock away from

socket housing to disengage slots from tabs on
socket housing. See A of Figure 8-42. Free second­ary lock from cables and set aside.

b. Take note of the opening on one side of the socket

terminal. Gently insert flat blade of pick (Snap-On
TT600-3) or small screwdriver into opening until it
stops. Pivot the pick toward the terminal body and
hold in position. See B of Figure 8-42.

c. Tug on cable to pull socket from wire end of socket

housing. A firm tug is necessary to overcome the
resistance of the rubber seal.

d. Repeat steps 2(b) and 2(c) to remove remaining

socket terminal.

3. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

2004 Touring: Wiring 8-31

HOME

A

B

Tab

f2245x8x

Secondary

Lock

f2244x8x

d. Repeat steps 1(a) thru 1(c) to install remaining

socket terminal.

e. Install secondary lock onto cables and then push

onto wire end of socket housing until slots engage
tabs on sides of socket housing.

2. Install maxi-fuse.

PACKARD MICRO 64

General

Use the following instructions to service the speedometer
and tachometer connectors.

Disassembly

1. Bend back the external latches slightly and separate the
pin and socket halves of the connector.

NOTE

To differentiate between the speedometer and tachometer
connectors, note that the speedometer connector has a sec­ond length of conduit leading to the odometer reset switch.

C

Figure 8-42. Remove Socket Terminals

Assembly

1. Install socket terminals as follows:
a. Carefully bend tang outward away from the terminal

body. See C of Figure 8-42.

b. Feed socket into wire end of socket housing until it

“clicks” in place. Verify that socket will not back out
of chamber. A slight tug on the cable will confirm
that it is locked.

c. Push rubber seal into wire end of socket housing.

f2246x8x

2. Locate the head of the secondary lockpin on one side of
the connector housing. See Figure 8-44.

3. Insert the blade of a small screwdriver between the cen­ter ear of the lockpin and the connector housing and
gently pry out lockpin. When partially removed, pull lock­pin from connector housing.

4. Obtain the Packard Micro 64 Terminal Remover (HD-

45928). See Figure 8-43. Proceed as follows:

a. Locate small hole between terminals on mating end

of connector. See Figure 8-44.

b. Push the adjacent terminals all the way into the con-

nector housing and then insert tool into hole until it
bottoms. See upper frame of Figure 8-45.

Figure 8-43. Packard Micro 64 Terminal Remover

(Part No. HD-45928).

8-32 2004 Touring: Wiring

HOME

Small

f2202x8x

Hole

Secondary

1

6

Lockpin

23456

1

8

7

10

9

7

12

11

12

Figure 8-44. Mating End of Connector

f2196x8x

f2197x8x

Figure 8-45. Insert Tool and Remove Terminal

NOTE

For wire location purposes, the corners of the socket housing
are stamped with the numbers 1, 6, 7 and 12, representing
terminals 1-6 on one side, and 7-12 on the other. See Figure

8-44.

2. Bottom the terminal in the chamber and then gently tug
on the wire to verify that it is locked in place.

NOTE

Once the terminal is removed it may not lock in place when
first reinstalled. Until the lock engages, move the terminal
back and forth slightly while wiggling the lead.

3. Since the terminal remover tool releases two terminals
simultaneously, repeat step 2 on the adjacent terminal
even if it was not pulled from the connector housing.

4. With the center ear on the head of the secondary lockpin
facing the mating end of the connector, push lockpin in
until head is flush with the connector housing.

5. Push the pin and socket halves of the connector
together until the latches “click.”

Crimping Instructions

1. Strip lead removing 1/8 inch (3.0 mm) of insulation.

2. Obtain the Packard Micro 64 Terminal Crimper (HD-

45929). See Figure 8-46.

3. Squeeze the handles to cycle the tool to the fully open
position.

4. Obtain new contact (socket terminal). Verify that contact
and crimp tails are not bent or deformed.

5. Raise locking bar and barrel holder by pushing up on
bottom tab with index finger. See Figure 8-47.

6. With the crimp tails facing upward, insert contact
through locking bar into front hole in barrel holder (20-22
gauge wire).

7. Release locking bar to lock position of contact. When

correctly positioned, the locking bar fits snugly in the
space at the front of the core crimp tails and the closed
side of the terminal rests on the outer nest of the crimp
tool. See Figure 8-48.

c. Leaving the tool installed, gently tug on wires to pull

either one or both terminals from wire end of con­nector. See lower frame of Figure 8-45. Remove
tool.

5. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions on this page.

Assembly

1. Insert terminal into its respective numbered chamber on
wire end of connector. No special orientation of the ter­minal is necessary.

Figure 8-46. Packard Micro 64 Terminal Crimper

(Part No. HD-45929)

2004 Touring: Wiring 8-33

HOME

11. Inspect the quality of the core and insulation crimps. Dis­tortion should be minimal.

PACKARD 100W

General

Use the following instructions to service the ECM connector.

f2198x8x

Figure 8-47. Raise Locking Bar and Barrel Holder

f2199x8x

Locking

Bar

Figure 8-48. Position Contact in Crimper

Barrel

Holder

Disassembly

1. Gently depress latch on each side of the clear plastic
secondary lock and remove. For best results, release
one side at a time, See Figure 8-50.

2. Carefully cut cable strap to free strain relief collar from
conduit.

3. Using a thin blade, gently pry at seam at back of socket

housing to release three plastic pins from slots in hous­ing. Separate and spread halves of socket housing. See

Figure 8-51.

4. Push on selected wire to free terminal from chamber.

See Figure 8-52.

5. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions on the next page.

f2062x8x

1

2

7

3

f2201x8x

Figure 8-49. Crimp Terminal Onto Wire

8. Insert wires between crimp tails until ends make contact
with locking bar. Verify that wire is positioned so that
wide pair of crimp tails squeeze bare wire strands, while
the narrow pair folds over the insulation material.

9. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete. See Figure 8-49.

10. Raise locking bar and barrel holder to remove contact.

8-34 2004 Touring: Wiring

6

5

1. Latch

2. Rib

3. Secondary Lock

4. Strain Relief Collar

Figure 8-50. Remove Secondary Lock

2

1

4

5. Conduit

6. Cable Strap

7. External Latch

HOME

1-5 A-E F-G

Packard 270

(HD-38125-6)

Packard 271

(HD-38125-7)

Packard 115

(HD-38125-8)

Sealed

Terminals

Non-Sealed

Terminals

Non-Sealed

Terminals

Butt Splices*

*

See Appendix 8.6 SEALED BUTT SPLICE CONNECTORS.

Packard Terminal Crimp Dyes (Nests)

Figure 8-51. Separate Halves of Socket Housing

Pins

f2063x8x

Crimping Instructions

1. Strip wire lead removing 5/32 inch (4.0 mm) of insula­tion.

2. Compress handles until ratchet automatically opens.

NOTE

Always perform core crimp before insulation/seal crimp.

3. See Figure 8-53. Determine the correct dye or nest for
the core crimp.

4. Position the core crimp on the appropriate nest. Be sure
the core crimp tails are facing the forming jaws.

5. Gently apply pressure to handles of tool until crimpers
just secure the core crimp tails.

6. Insert stripped wire between crimp tails. Verify that wire
is positioned so that short pair of crimp tails squeeze
bare wire strands, while long pair is positioned over the
insulation or seal material.

7. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete.

8. See Figure 8-53. Determine the correct dye or nest for
the insulation/seal crimp.

Figure 8-52. Push Wire to Extract Terminal

Assembly

1. From inside socket housing, gently pull on wire to draw
terminal into chamber. See Figure 8-52.

2. Exercising caution to avoid pinching wires, press halves
of socket housing together until three plastic pins fully
engage slots in housing. See Figure 8-51.

3. Install new cable strap in groove of strain relief collar
capturing cable conduit. See Figure 8-50.

4. With the two ribs on the secondary lock on the same
side as the external latch, install over terminals until
latches lock in place.

f2064x8x

Figure 8-53. Packard Terminal Crimp Tools

2004 Touring: Wiring 8-35

HOME

Seal

SEALED TERMINAL

Core Crimp

Seal Crimp

9. Position the insulation/seal crimp on the appropriate
nest. Be sure the insulation/seal crimp tails are facing
the forming jaws.

10. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete.

11. Inspect the quality of the core and insulation/seal
crimps. Distortion should be minimal. See Figure 8-54.

f1006a8x

Insulation

Crimp

Core Crimp

f1005a8x

Insulation

NON-SEALED TERMINAL

Figure 8-54. Inspect Core and Insulation/Seal Crimps

8-36 2004 Touring: Wiring

HOME

8821

AUTOFUSE ELECTRICAL CONNECTOR 8.5

GENERAL

Use these instructions to service the following connector:

● HDI Ignition Light/Key Switch Jumper Harness [33D]

DISASSEMBLY

1. Obtain terminal pick (Snap-on® GA500A) like that
shown Figure 8-55.

2. Insert smallest pair of pins into chamber on mating end
of socket housing to depress tangs on each side of ter­minal simultaneously.

3. Gently pull on wire to remove terminal from wire end of
socket housing.

4. If necessary, crimp new terminals on wires.

Figure 8-55. Depress Tangs and Remove Terminal

ASSEMBLY

1. Using a thin flat blade, like that on an X-Acto knife, care­fully bend tang on each side of terminal outward away
from terminal body.

2. With the open side of the terminal facing rib on wire end
of socket housing, insert terminal into chamber until it
locks in place.

2004 Touring: Wiring 8-37

HOME

SEALED BUTT SPLICE CONNECTORS 8.6

PROCEDURE

Butt splicing may be a necessary procedure for the replace­ment of some components. Proceed as follows:

1. Strip 3/8 inch (9.5 mm) of insulation off the ends of the
wires.

2. Compress the handles of the Packard Crimp Tool (HD­38125-8) until the ratchet automatically opens.

3. Since the size of the connectors vary with the gauge of
the wire, reference the following table to ensure properly
sealed splices are used.

Gauge

Wire

18-20 Red P/N 70585-93

14-16 Blue P/N 70586-93

10-12 Yellow P/N 70587-93

4. Determine the correct dye or nest for the crimping oper­ation. Match the color or gauge wire marked on the butt
splice connector with the corresponding crimp cavity on
the crimp tool. See Figure 8-56.

5. Gently apply pressure to the handles until the crimper
lightly secures one side of the metal insert inside the butt
splice connector. The connector must be crimped in two
stages, one side and then the other.

6. See Figure 8-57. Feed the wire into the butt splice con­nector until the stripped end contacts the wire stop
inside the metal insert.

7. Squeeze the handles of the crimp tool until tightly
closed. The tool automatically opens when the crimping
se-quence is complete.

Connector

Color

Part

Number

8. Repeat steps 5, 6 and 7 on the other side of the butt
splice connector.

NOTE

If adjacent wires are being spliced, stagger the splices so
that the butt splice connectors are spaced at different posi­tions along the length of the wires.

9. Using the UltraTorch UT-100 (HD-39969), Robinair Heat
Gun (HD-25070) with heatshrink attachment (HD-

41183) or other suitable radiant heating device, heat the
crimped splice to encapsulate the butt splice connection.
Apply heat from the center of the crimp out to each end
until the meltable sealant exudes out both ends of the
connector. See Figure 8-57.

Red

Blue

Yellow

Figure 8-56. Packard Crimp Tool (HD-38125-8)

Wire

Stop

Insert stripped wire

ends into connector

f1203b8x

8-38 2004 Touring: Wiring

Metal

Insert

Crimp wire ends

in connector

Figure 8-57. Installing Sealed Butt Splice Connectors

Melted Sealant

Apply heat and allow

connector to cool

HOME

1WARNING1WARNING

Use extreme caution when operating the UltraTorch UT­100 or any other radiant heating device. Read the manu­facturers instructions carefully before use. Always keep
hands away from tool tip area and heat shrink attach­ment. Avoid directing the heat toward any fuel system
component. Extreme heat can cause fuel ignition/explo­sion. Avoid directing heat toward any electrical system
component other than the connectors on which heat
shrink work is being performed. Be sure to turn the “ON/
OFF” switch to the “OFF” position after use. Inadequate
safety precautions could result in death or serious
injury.

NOTE

It is acceptable for the splice to rest against the heat shrink
tool attachment.

10. Heat the center of the splice until the crimp indentations
disappear and the tubing assumes a smooth cylindrical
appearance.

2004 Touring: Wiring 8-39

HOME

AMP ELECTRICAL CONNECTORS 8.7

1-PLACE CONNECTOR

The 1-place Amp MATE-N-LOK connector can be found on
some Touring models.

Socket Terminal

Removal

1. Bend back the ears on the pin housing slightly and sepa­rate the pin and socket halves of the connector.

2. Grasp the lead on the wire end of the socket housing
and push the terminal forward toward the mating end of
the connector until it stops. This will disengage the lock­ing tang from the groove in the connector.

3. Fit the barrel of the Amp Socket Terminal Remover (HD­39621-27) over the socket, and while rotating the tool
slightly, push until it bottoms in the housing. Allow the
plunger to “back out” of the handle. See Figure 8-58.

Install Socket Terminal Remover

A

4. Holding the socket housing while keeping the tool firmly
bottomed, depress the plunger. The terminal pops out
the wire end of the connector.

NOTE

If the terminal is not released from the socket housing, then
the terminal was not pushed forward far enough before
placement of the tool or the tool was not bottomed in the con­nector housing.

Installation

1. Note the lip at the middle of the socket housing. One
side of the lip is flat while the other side is tapered. Insert
the wire terminal into the socket housing on the flat lip
side.

2. Push the lead into the socket housing until it stops. A
click is heard when the terminal is properly seated.

3. Gently tug on the lead to verify that the terminal is locked
in place.

4. Push the pin and socket halves of the connector
together until the latches “click.”

Socket

Housing

Lip

Depress Plunger

B

Figure 8-58. Remove Terminal from Amp Socket Housing

Amp Socket

Terminal Remover

(HD-39621-27)

Plunger

f1364x8x

Pin Terminal

Removal

1. Bend back the ears on the pin housing slightly and sepa­rate the pin and socket halves of the connector.

2. Grasp the lead on the wire end of the pin housing and
push the terminal forward toward the mating end of the
connector until it stops. This will disengage the locking
tang from the groove in the connector.

3. Fit the barrel of the Amp Pin Terminal Remover (HD­39621-28) over the pin, and while rotating the tool
slightly, push until it bottoms in the housing. Allow the
plunger to “back out” of the handle. See Figure 8-59.

4. Holding the pin housing while keeping the tool firmly bot­tomed, depress the plunger. The terminal pops out the
wire end of the connector.

NOTE

If the terminal is not released from the pin housing, then the
terminal was not pushed forward far enough before place­ment of the tool or the tool was not bottomed in the connector
housing.

8-40 2004 Touring: Wiring

HOME

Installation

A

Install Pin Terminal Remover

Pin

Housing

Depress Plunger

B

Figure 8-59. Remove Terminal from Amp Pin Housing

Amp Pin

Terminal Remover

(HD-39621-28)

Plunger

f1366x8x

1. Push the lead into the pin housing until it stops. A click is
heard when the terminal is properly seated.

2. Gently tug on the lead to verify that the terminal is locked
in place.

3. Push the pin and socket halves of the connector
together until the latches “click.”

2004 Touring: Wiring 8-41

HOME

NOTES

8-42 2004 Touring: Wiring

HOME

WIRING DIAGRAMS 8.8

SUBJECT PAGE NO.

FLHT, FLHTC, FLHTCU

Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45

Interconnect Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46

Ignition Harness (Carbureted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47

Electronic Fuel Injection (EFI) Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47

Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

Tail Lamp, Passing Lamps, Fender Tip Lamps, Directional Lamps

and Tour-Pak Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

Starting and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

Handlebar Controls and Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

Fairing Cap Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

Radio, CB/Intercom and Rear Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51

FLTR

Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45

Interconnect Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46

Ignition Harness (Carbureted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47

Electronic Fuel Injection (EFI) Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47

Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

Tail Lamp and Directional Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

Starting and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

Handlebar Controls and Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

Instrument Nacelle Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51

FLHR, FLHRC, FLHRS

Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52

Ignition Harness (Carbureted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53

Electronic Fuel Injection (EFI) Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53

Starting and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

Handlebar Controls, Speedometer, Indicator Lamps, Tail Lamp, Passing Lamps,

Directional Lamps, Fender Tip Lamps and Spot/Accessory Switches . . . . . . . . . . 8-55

TLE Sidecar, TLE Ultra Sidecar

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56

Audio Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56

NOTE

Harness Part No.’s may be included on some wiring diagrams. Use these numbers for reference only.
ALWAYS REFER TO THE PARTS CATALOG WHEN ORDERING WIRING HARNESSES.

2004 Touring: Wiring 8-43

HOME

NOTES

8-44 2004 Touring: Wiring

HOME

TSM/TSSM

VSS/SERIAL DATA LINK

SECURITY INDICATOR

LEFT TURN FEED

RIGHT TURN FEED

RIGHT TURN SW INPUT

LEFT TURN SW INPUT

START RELAY CONTROL

IGNITION ENABLE

ALARM SIGNAL

TURN SIGNAL/

TURN SIGNAL SECURITY

MODULE

TO

IGNITION/EFI

HARNESS

[8A]

(GY)

TO

INTERCONNECT

HARNESS

[1A]

(BK)

TO

INTERCONNECT

HARNESS

[2A]

(GY)

TO

INTERCONNECT

HARNESS

[15A]

12
11
10

2
1

BATTERY

IGNITION

GROUND

BK
LGN/V

9
8
7
6

GY

5

W/GN
4
3

BE/O
W/BK
BN/GY

12
11
10

9
8
7
6
5
4

3
2
1

12
11
10

9
8
7
6
5
4

3
2
1

D
C
B
A

BK
R

[8B]

[1B]

[30A]

O/GY
R

GN/R
W/V
W/BN
O/BE
BN
V
W/BK
O/W
O/R
GY
O/V
O

BK
W/GN
TN
GN/Y
BN/GN
O
Y/BK
Y/W
BN/GY
BE
BK/R
R/BE

[2B]

[15B]

10
11
12

BK
BK/GN
BE
R/O

CARBURETED ONLY

FUEL LEVEL
SENDER

BK

Y/W

[141A]

123

RH GND

STUD

- FRAME GROUND -

LH GND

STUD

OPTIONAL
SECURITY

SIREN

POWER

SIGNAL

A B C

BN/GY

LGN/BN

BKBK/GN

BK

GROUND

BK

[142A]

[142B]

[5B]

MAIN POWER

AT S TARTER

R

40A

MAXI-FUSE

A B

R

R

VOLTAGE
REGULATOR

[77A]

R

O/V
R/Y
R/BE
BK

O

BE

BE

GY

O/V

O/W

O/R

BN/GY

O/BE

4E
3F
3E
4F

1B 1A

1D 1C

1H 1G

1F 1E

4D 4C

2B 2A

2D 2C

2F 2E

3B 3A

R/O

3D 3C

4B 4A

B+

CONNECTOR

[160B]

R

[64B]

3
5
2
1

INSTRUMENTS - 15A

LIGHTS - 15A

HEADLAMP - 15A

IGNITION - 15A

P

&A

IGN - 2A MAX

CRUISE/BRAKE - 15A

ACCESSORIES - 15A

P& A - 15A

RADIO MEM - 15A

BATTERY - 15A

RADIO PWR - 10A

BRAKE

RELAY

TO

IGNITION

SWITCH

[33B]

A

BCD

R/GY

R

R/BK

R/BK

R/BK

R/GY

R

O/GN

R/BK

KEYSWITCH IGN RELAY

[33A]

85

8630

BK

START RELAY

8630 87A

85

TN/GN

87A

R

R/BK

R/BK

O/GN

GN

R/GY

BK/R

[128B]

START

SOLENOID

[126A]

[126B]

[123A]

[123B]

123

12

Y/W

O/GY

123

12

Y/W

O/GY

EFI

[141A]

3

[141B]

BK

3

BK

BK

1

BN/GY

2

GY

3

LGN/V

4

BN/V

5

V

6

BN

7

W/BN
W/V

8

TN/GN

9

LGN/BN

BK

[30B]

(GY)

FUEL
PUMP

FUEL PUMP

ASSEMBLY

IN TANK

AT TO P OF TAN K

70369-02

FUEL TANK

HARNESS

[13B]

[13A]

OIL

PRESSURE

SENDER

[139A]

CRANK POSITION

SENSOR

BK

R

[79A]

[139B]

D C B A

2
1

BN/GN

GN/Y

2
1

[79B]

THROTTLE

ROLL-OFF

SWITCH

[75A]

[75B]

Y/V

[75C]

[75D]

O/V

(BK)

BK

BE

R/Y

321

TOUR-PAK

[12A]

TO INTERCONNECT

BN/V

[156B]

(GY)

V/Y

ABCDEFGHJ

W/BE

BE/BK

R/GN

LGN/V

[156A]

12

3456

ON/OFF

SET/COAST

RESUME/ACCEL

THROTTLE ROLL-OFF

CRUISE CONTROL MODULE

R/BE

BK

BE/O

O/V

GROUND

IGNITION

BRAKE SIGNAL

ENGINE SPEED

GN/R

W/GN

[17B]

K

[17A]

SET LAMP

SPEED SIGNAL

BN

[7A]

12345678

LIGHTING

HORN

[122 ]

Y/BK

BK

[131]

TN

BK

[12B]

NEUTRAL

SWITCH

R/BE

O/W

REAR
STOPLIGHT
SWITCH

[121]

2004 FLHT, FLHTC, FLHTCU and FLTR, DOMESTIC and INTERNATIONAL Models,

Main Harness

BK

BK

O/W

V

TO REAR

[7B]

R/Y

BE

BK

BK

4

O

3

R/Y

O/R

[4A]

ACCESSORY

2

CONNECTOR

1

(BK - LOCATED UNDER

SEAT)

f2227z8x

8-45

HOME

FRONT FENDER

TIP LAMP

[32B]

(BK)

PASSING

LAMPS

HEADLAMP

[

38B]

HDI ONLY

[29B]

TO

RIGHT

HAND

CONTROLS

[22B]

(BK)

GROUND

TO UPPER

TRIPLE
CLAMP

TO

LEFT

HAND

CONTROLS

[24B]

(GY)

TO

RADIO

[27A]

(BK)

FRONT

SPEAKER

(EXCEPT

FRONT

SPEAKER

(EXCEPT

2
1

[32A]

2

[73B]
(WE)

1

LO_BEAM

BK

O/W

[22A]

1
2
3
4
5
6
7
8

9
10
11

12

GROUND EXTENDED ON

FLTR. P/N 70420-98

12
11
10

8
10

11
12
13
14
15
16
17
18
19
20
21
22
23

R/BE
W/BK
BK/R

BN/W
GY/W
PK/W
V/BK
W/BE

BE/BK

[GND3]

BK/GN
BK/GN

O/BK
GY/GN
GN/BE
PK/W

9

BN/BK

8
7

V/BK

6

Y/BK
W/V

5

W

4
3

BE

2

Y

1

O/W

[24A]

[27B]

1

LGN/BK

2

BE/Y

3

PK/W

4

GY/W

5

V/BK

6

BN/W

7

O/BK
BN/BK

9

W/GN

BK/GN
O/BE
BN/O
R/O
V/GY
W/O

LGN/W
GY/R
BK/GN
R/O

V/O

GY/GN
GN/BE

RIGHT

FLHT)

LEFT

FLHT)

[73A]

O/W

GY
W/BN

[34B]

[35B]

BK
BE

GY/BK
GY/BK

Y

HI_BEAM

GND

W

BK

LGN/BK

GY/R

LGN/W
W/O

V/GY

[6B]

ABC

TO AUDIO

HARNESS

[6A]

(BK)

BE/Y

O/V

[156B]

[21A]

TO INDICATOR

12345678

(BK)

BN

W/BE

LGN/V

R/GN

123456

TO MAIN

HARNESS

[156A]

(GY)

[21B]

LAMPS

GN/Y

W

BN/V

BE/BK

9

10

V

O

O

BK

BK

BK

TN

BK

BN

BE

[31R]

12

3

RH FRONT

TURN SIGNAL

FLTRI ONLY

SEPARATE CONNECTORS

FOR FRONT

TURN SIGNALS

[105B]

TO DASH PANEL

SWITCHES

9

11

12

TURN SIGNAL

10

BK/GN

BN/O

V/O

BK

V

12

3

LH FRONT

8

O/BE

BE

[31L]

BK

GY/BK

1234567

[105A]

O/R

BK

Y

R/GN

O/V

O

V

BK

TURN SIGNALS

FLHT/I, FLHTC/I

FLHTCUI ONLY

SINGLE CONNECTOR

FOR FRONT

TURN SIGNALS

(BK)

BE

NOTE: OIL PRESSURE GAUGE AND AIR TEMP GAUGE

NOT INCLUDED ON FLHT AND FLHTP

[116A]

O

FUEL

+

1

O

OIL

[112A]

BK

O

PRESSURE

1

2

+

3

1

2

BK

O

BN/GN

[112B]

[113A]

S

[113B]

[114A]

VOLTMETER

[116B]

1

2

S

[117A]

3

2

[117B]

Y/W

BK

[110A]

BK

+

1

O

[110B]

1

2

[111A]

S

3

2

[111B]

BK

O

AIR

TEMPERATURE

1

2

S

+

3

1

2

O

BE/V

BK

O

BK

BE/V

[114B]

[107B]

BK

[115A]

[115B]

BK

(BK)

1

TEMP SIGNAL

2

GROUND

3

AIR

TEMPERATURE

SENSOR

[107A]

[1A]

[2A]

12
11
10

9
8
7
6
5
4
3
2
1

12
11
10

9
8
7
6
5
4
3
2
1

D
C
B
A

TO

MAIN

HARNESS

(BLACK)

[1B]

TO

MAIN

HARNESS

(GRAY)

[2B]

TO

MAIN

HARNESS

[15B]

(BK)

CIGAR

LIGHTER

[132B]

f2227y8x

GN/R
W/V
W/BN
O/BE
BN

V
W/BK
O/W
O/R
GY

O/V

O

BK
W/GN
TN
GN/Y
BN/GN

O

Y/BK
Y/W
BN/GY
BE
BK/R
R/BE

BK
BK/GN
BE
R/O

[39B]

(BK)

BN

BE

BK

[31A]

3456

(BK)

2

1

BN/V

BN/GY

LGN/V

O

2

1

34

5678

NC

IGNITION

BATTERY

DATABUS

SECURITY LP

SPEEDOMETER

O/W

BK

GROUND

ACCESSORY

TRIP SWITCH

Y/W

91011

12

NC

FUEL LEVEL

TRIP SWITCH

NC

[108B]

(GY)

BK

BK

ODOMETER

RESET

SWITCH

[154A]

O

LGN/V

34

5

2

1

NC

IGNITION

PURSUIT

DATABUS

RPM x 100

TACHOMETER

BN/GY

O/W

67

BATTERY

ACCESSORY

BK

8

GROUND

GN/R

91011

NC

NC

R/GN

12

NC

CRUISE ACTIVE

CRUISE ENABLE

[15A]

O/W

BK

2004 FLHT, FLHTC, FLHTCU and FLTR, DOMESTIC and INTERNATIONAL Models,

Interconnect Harness

8-46

HOME

CARBURETED

VEHICLES

IGNITION CONTROL MODULE

(BLK)

[10A]

RUN/STOP SIGNAL

+5V SENSOR PWR
SENSOR GROUND

MODULE GROUND

CRANK SENSOR (+)

CRANK SENSOR (-)

VEHICLE SPD SIG

BATTERY

COIL FRONT

COIL REAR

MAP SIGNAL

DATALINK

CARBURETED OVERLAY: 32435-04

EFI OVERLAY: 70233-04

[BLK]

[10B]

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

9

9

10

10

11

11

12

12

W/BK
BN/GY

R/W
BK/W
BK
BE/O
Y/BE

R

BK
W/GN
V/W
LGN/V

(GY)

[91A]

DATA

LINK

12

BK

34

LGN/V

GY

IGNITION

COIL

ABC

W/BK

BE/O

[83B]

Y/BE

MAP

SENSOR

ABC

V/W

R/W

BK/W

[80A]

[80B]

R/W

W/GN

BK

[65B]

(BK)

PLUG

ABC

(REAR)

(FRONT)

(+12VDC)

W/GN

R/W

BK
[65B]

(BK)

IGNITION

COIL

(CARB)

REAR SPARK PLUG

A

A

B

B

C

C

[65A]

+5V DC

R

W

BK

OUTPUT

SENSOR

VEHICLE

POWER

COIL RR

ION SENSE

ABCD

GROUND

COIL FRT

[83A]

IGNITION

COIL
(EFI)

+5V DC

R

A

A

B

W

B

C

BK

C

OUTPUT
SENSOR

[65A]

SPEED SENSOR

BK
LGN/V

BK
R
GY
W/GN

BE/O
W/BK
BN/GY

VEHICLE

12
11
10

9
8
7

HARNESS

6
5
4
3
2
1

GROUND

FROM
MAIN

[8B]

[83A]

FRONT SPARK

[8A]

(GY)

SPEED SENSOR

FUEL INJECTED

VEHICLES

ELECTRONIC

CONTROL

MODULE

ALDL & FLASH PIN

CHECK ENG LP

TACH OUTPUT

SYSTEM RELAY

SERIAL DATA LINK

ENGINE TEMPERATURE

INTAKE AIR TEMPERATURE

OXYGEN SENSOR A

ANALOG INPUT

POWER GROUND

CRANK POS. SENSOR (-)

5V SENSOR POWER

FREQUENCY INPUT
IDLE AIR CNTL MOTOR
IDLE AIR CNTL MOTOR

THROTTLE POS SNSR INPUT

OXYGEN SENSOR B

MAP SENSOR INPUT

5V SENSOR GROUND

CRANK POS. SNSR (+)

SWITCH INPUT (unused)

VEHICLE SPEED INPUT

IDLE AIR CNTL MOTOR
IDLE AIR CNTL MOTOR

COIL REAR

SWITCH POWER

DIGITAL GROUND

INJECTOR REAR

OUTPUT (unused)

INJECTOR FRONT

OUTPUT (UNUSED)

ION SENSE

POWER GROUND

COIL FRONT

CONSTANT POWER

DIGITAL POWER

[78A]

REAR

INJECTOR

[85B]

AB

Y/GN

GN/GY

BK/W

SENSOR

[89B]

INTAKE

AIR

TEMP.

AB

LGN/Y

BK/W

[83B]

IGNITION

COIL

ABCD

Y/BE

Y/GN

GY/BE

BE/O

ENGINE

TEMP.

SENSOR

DATA

(GY)

[91A]

[78B]

123456789101112131415161718192021222324252627282930313233343536

123456789101112131415161718192021222324252627282930313233343536

LGN/R

PK

GN/O

LGN/V
PK/Y
LGN/Y

BK
Y/BE

BK+

W/BK

R/W

BK/O

BK/PK
GN/GY

LINK

12

LGN/R

34

BK

GY

LGN/V

[90B]

AB

PK/Y

W/Y

GY/V
V/W

BK/W
GY/BE

BK

BE/O

R

BE/GY

FRONT

INJECTOR

[84B]

AB

Y/GN

W/Y

THROTTLE

POSITION

SENSOR

ABC

R/W

GY/V

BK/W

[88B]

MAP

SENSOR

ABC

R/W

V/W

IDLE AIR

CONTROL ACTUATOR

ABCD

[80B]

BK/W

BK/O

BK/PK

BN/R

[87B]

BE/GN

[119B]

O/GY

BE/GY

Y/GN

BE/GY

GN/O
W/BK

PK

[8A]

12
11
10

9
8
7
6
5
4
3
2
1

FROM

MAIN

HARNESS

[8B]
(GY)

Y/GN

BK

LGN/V

O/GY
R

BK

R

GY

W/GN

W/BK

FUEL PUMP 15A

GH

ECM POWER 15A

AB

SYSTEM RELAY

K

5

T

4

E

3

S

2

U

1

R

(BK)

W/GN
BE/GN

BN/R

f2227x8x

2004 FLHT, FLHTC, FLHTCU and FLTR, DOMESTIC and INTERNATIONAL Models,

Ignition Harness (Carbureted), Electronic Fuel Injection (EFI) Harness

8-47

HOME

RIGHT PURSUIT

LAMP (BLUE)
POLICE ONLY

FENDER TIP

(DOM ONLY)

LEFT PURSUIT

LAMP (RED)

POLICE ONLY

RIGHT

PASSING

LAMP

LAMP

LEFT

PASSING

LAMP

FROM
INTERCONNECT
HARNESS [73A]

12

[73B]

GY/BK

GY/BK

[143B]

BK

1
2

O/W

FROM
INTERCONNECT
HARNESS [32A]

[143A]

1
2

BK

12

O/W

[32B]

V/BN

BK

V/BN

BK

[7B]

[19b]

[18B]

[45B]

12

1
2

1
2

1
2
3

BN

34567

V

BK

O/W

1
2

1
2

1
2
3

[45A]

BE

R/Y

3456

[18a]

[93A]

8

12

123456

[19a]

FROM MAIN

HARNESS [7A]

68772-99

[94B]

BRAKE LIGHT

[94A]

4

4

3

3

2

2

1

1

[93B]

REAR LIGHTING

BK

R/Y

O/W

BEW

RUNNING LIGHT (DOM)

RUNNING LIGHT (HDI)

BK

BK

TAILLAMP

BK
BK

RIGHT REAR

DIRECTIONAL

LAMP

LICENSE

PLATE LAMP

(HDI ONLY)

FENDER TIP LAMP

(DOMESTIC ONLY)

LEFT REAR
DIRECTION

LAMP

RIGHT

DIRECTIONAL

AND DOM

RUNNING LAMP

BLUE WIRES (RUNNING) ARE ONLY

AVAILABLE ON DOMESTIC MODELS

LEFT

DIRECTIONAL

AND DOM

RUNNING LAMP

HARNESS [31A]

[31B]

BK
BE
BN

BK
BE

V

FROM

INTERCONNECT

65

4321

TO MAIN
HARNESS

123

[12B]

[12A]

BE

BK

R/Y

TAIL

STOP

DOM TOUR-PAK HARNESS:
FLHTC P/N
70646-00
FLHTC-U
FLHTCU-I
P/N 70648-00

TOUR-PAK LEFT SIDE

TOUR-PAK RIGHT SIDE

MARKER LIGHTS

[12-2A]

12

BK

BE

12

12

12

BE

[12-3B]

[12-3A]

BK

[12-2B]

BK

BK
BE
BE

BE

BK

MARKER LIGHTS

HDI FLHTC AND FLHTCU MODELS DO NOT HAVE TOUR-PAK LIGHTING

TOUR-PAK NOT INCLUDED ON FLHT OR FLHTP

ULTRA TOUR-PAK

REAR MARKER/

STOP LIGHTS

BK

R/Y

BK

R/Y

BE

BE

NOTE:

DOM FLHTC
DOES NOT INCLUDE
REAR MARKER/STOP

LIGHTS AND

ASSOCIATED WIRING

FROM MAIN

HARNESS [33A]

FROM MAIN

HARNESS [33A]

[33B - HDI]

A
B
C
D

[

33B-DOM

A

R

B

R/GY

C

R/BK

D

IGNITION SWITCH LEGEND (HDI)

"X" INDICATES CONTINUITY

SWITCH

POSITION

LOCK X

]

IGNITION

SWITCH,DOM

BETWEEN LEAD WIRES

IN POSITION INDICATED

RED/

RED

GRAY

OFF X
IGN X X X
ACC X X

R/GY

R

R/BK

IGNITION SWITCH LEGEND (DOM)

SWITCH

POSITION

LOCK X

OFF X
IGN XXX
ACC X X

RED/

BLACK

R/GY

1

1

2

R

2

3

3

R/BK

IGNITION

SWITCH,HDI

"X" INDICATES CONTINUITY

BETWEEN LEAD WIRES

IN POSITION INDICATED

RED/
GRAY

RED/

BLACK

RED

f2227u8x

2004 FLHT, FLHTC, FLHTCU and FLTR, DOMESTIC and INTERNATIONAL Models,

Ignition Switch, Tail Lamp, Passing Lamps, Fender Tip Lamps, Directional Lamps and Tour-Pak Lights

8-48

HOME

+

-

f2227n8x

HAND CONTROLS,
RIGHT

ALL MODELS

EXCEPT

SPARE FUSES

FLHTP

TO INTERCONNECT

HARNESS

[22A]

MAIN FUSE BLOCK COVER

10A

15A

15A

HEADLAMPS

F

H

BRAKE
RELAY

15A

15A

J

15A

G

MAIN FUSE BLOCK

TSM/TSSM

VSS/SERIAL DATA LINK

SECURITY INDICATOR

RIGHT TURN SW INPUT

LEFT TURN SW INPUT

START RELAY CONTROL

TURN SIGNAL/

TURN SIGNAL SECURITY

MODULE

ENGINE OFF/RUN SWITCH
START SWITCH

[22B]

GY

BK/R

BRAKE
RELAY

P&A

IGN

D

BATTERY

IGNITION

LEFT TURN FEED

RIGHT TURN FEED

IGNITION ENABLE

ALARM SIGNAL

GROUND

1
2
3
4
5
6
7
8

9
10
11
12

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

9

9

10

10

11

11

12

12

P&A

IGN

BATTERY

ACCESS.

LIGHTS

B

10A

15A

15A

15A

15A
15A

15A

E

A

C

1
2
3
4
5
6
7
8

9
10
11
12

[8A]

LGN/V

[22A]

GY

BK/R

TO

RIGHT-

HAND

CONTROL

[22B]

RADIO PWR

RADIO MEM

CRUISE/BRK

INSTRUMENTS

4
3

2

1

BN/GY

GY

LGN/V

TN/GN

BK

STATOR

DC

AC

BK

BK

[46A]

A

A
B

B

[46B]

BK

BK

40 A

MAXI-FUSE

BATTERY

86
85
30

87A

87

A
B

IGNITION

C

SWITCH

D

START RELAY

85
86
30

87A

87

[123A]

[123B]

B A

[126A]

[33B]

BK

STARTER

CHARGING SYSTEM

IGNITION SWITCH LEGEND (HDI)

"X" INDICATES CONTINUITY

BETWEEN LEAD WIRES

SWITCH

IN POSITION INDICATED

POSITION

LOCK X

OFF X
IGN X X X
ACC X X

[33B]

R

A
B

R/GY

C

R/BK

D

FROM MAIN

HARNESS [33A]

TO

FROM MAIN

HARNESS [33A]

JUMPER HARNESS

[33B]

A

R

B

R/GY

C

R/BK

D

IGNITION

SWITCH, DOM

IGNITION SWITCH LEGEND (DOM)

SWITCH

POSITION

LOCK X

OFF X
IGN X X X
ACC X X

RED/

RED

GRAY

[33D] [33C]

1
2
3

SWITCH, HDI

"X" INDICATES CONTINUITY

BETWEEN LEAD WIRES

IN POSITION INDICATED

RED/

RED

GRAY

RED/

BLACK

IGNITION

RED/

BLACK

[30B][30A]

BK

BK

[77B] [77A]

RR

BK

POWERTRAIN

R

BK

GROUNDS

MAXI-FUSE

3C

R

R/BK

40 A

B A

R/BK

BK

R

[126B]

KEY SWITCH IGN RELAY

[33A]

R

R/GY
R/BK

TN/GN

BK/R
R/GY

GN

GY

BK/R

TO

MAIN

HARNESS

[1B]

12
11
10

9
8
7
6
5
4
3
2
1

[1A]

12
11
10

9
8
7
6
5
4
3
2
1

[2A]

TO

MAIN

HARNESS

[2B]

(BLACK)

(GRAY)

TO

INTERCONNECT

HARNESS

[1A]

12
11
10

9
8
7
6
5
4
3

GY
2
1

(BK)

[1B]

12

11

10

9
8
7
6
5
4
3
2

BK/R

1

(GY)
[2B]

TO

INTERCONNECT

HARNESS

(2A)

BK

BK

BK

BATTERY

STARTER

BK

[128B]

[128A]

LEFTRIGHT

GND1GND2

3D

BN/GY

1F 1E

GY

R

GN

[64]

BATTERY

IGNITION

2004 FLHT, FLHTC, FLHTCU and FLTR, DOMESTIC and INTERNATIONAL Models,

Starting and Charging

8-49

HOME

LEFT

TURN

BK

-

[21B]

HIGH

NEUTRAL

BEAM

BN

-

GN/Y

TN

N

W

V

LT

HBWBK

12345678

TO INTERCONNECT

HARNESS

[21A]

V

BKOTN

LOW

OIL

RIGHT

TURN

HAND CONTROLS
RIGHT

ALL MODELS

EXCEPT

FLHTP

SWITCH
POSITION

UP X X
MODE X X
DOWN X X

BROWN/
WHITE

PINK/
WHITE

VIOLET/
BLACK

GRAY/
WHITE

RADIO FUNCTION SWITCH
RIGHT DIRECTIONAL SWITCH
ENGINE OFF/RUN SWITCH
START SWITCH
CRUISE SET/RESUME SWITCH

(ULTRA MODELS ONLY)

SWITCH
POSITION

SET

RESUME

BLUE/

ORANGE/
WHITE

BLACK

XX

STOP LAMP SWITCH

[22B]

O/W

R/BE

GY
W/BK
W/BN
BK/R
BN/W
GY/W

PK/W

V/BK

W/BE
BE/BK

1
2
3
4
5

TO INTERCONNECT

6
7
8

9
10
11
12

WHITE/
BLUE

XX

HARNESS

[22A]

BK

10

BK

+

O

RTBNBK

-

GN/Y

+

OP

O

O

9

NOT USED ON FLTR

BK

BN/O

V/O

O/BE

BK/GN

89

10

12

11

TO INTERCONNECT

HARNESS

[105A]

[105C]

Y

GY/BK

7

6

R/GN

5

O/V

"CRUISE" & "SPEAKER" SWITCHES

NOT INCLUDED ON FLHT, FLHTC, OR FLHTC-I

4

4
3

3

2

2

1

1

[105D]

CONNECTOR ONLY ON FLTR

O

BK

O/R

[105B]

2

1

34

DASH PANEL MOUNTED SWITCHES

NOT INCLUDED ON FLHTP-FRG

O/BK
GY/GN
GN/BE
PK/W
BN/BK
V/BK
Y/BK
W/V

ACCYCRUISESPEAKERSPOT

W
BE
Y
O/W

12

11
10

9
8

TO INTERCONNECT

7
6
5
4
3
2
1

HARNESS

[24A]

[24B]

SWITCH
POSITION

+SQ UP (FORE) X X
PTT (PUSH) X X

-SQ DN (AFT) X X

VIOLET/
BLACK

GRAY/
GREEN

ORANGE/
BLACK

BROWN/
BLACK

PTT & SQ

(PUSH TO TALK
(ULTRA MODELS ONLY)

& SQUELSCH)

HORN SWITCH
HEADLAMP HI/LO SWITCH

LEFT DIRECTIONAL SWITCH

LEFT
HAND CONTROLS

ALL MODELS

EXCEPT

FLHTP

RADIO AUDIO CONTROL

SWITCH
POSITION

+VOL X X
AUDI O X X

-VOL X X

PINK/
WHITE

GREEN/
BLUE

BROWN/
BLACK

GRAY/
GREEN

2004 FLHT, FLHTC, FLHTCU and FLTR, DOMESTIC and INTERNATIONAL Models,

Handlebar Controls, Indicator Lamps and Fairing Cap/Instrument Nacelle Switches

f2227w8x

8-50

HOME

TO RADIO

CONNECTOR

(FLHTC/U

P/N 70084-96

ANTENNA

MODELS

[51B]

AM/FM

ANTENNA MAST

FLHTC/U

MODELS ONLY

ONLY)

C.B. MAST ASSY

P/N 76250-98

LOADING COIL ASSY

P/N 76318-98

ANTENNA CABLE PART OF

MAIN HARNESS AND

PRESENT ON ALL MODELS

[51A]

[50B] ULTRA ONLY

1 - RT FRT SPEAKER (+)

2 - PUSH TO TALK (MIC)
3 - R0 (HANDLEBAR MATRIX)
4 - R1 (HANDLEBAR MATRIX)
5 - R2 (HANDLEBAR MATRIX)
6 - C4 (HANDLEBAR MATRIX)
7 - C3 (HANDLEBAR MATRIX)

BASE

RADIO

CONNECTOR

[27A]

(BK)

8 - C2 (HANDLEBAR MATRIX)
9 - VEHICLE SPEED SIGNAL

10 - BATTERY
11 - GROUND
12 - IGNITION
13 - HEADSET SPEAKERS B
14 - N/C
15 - N/C
16 - LFT FRT SPEAKER (+)
17 - LFT FRT SPEAKER (-)
18 - RT FRT SPEAKER (+)
19 - GROUND
20 - BATTERY
21 - HEADSET SPEAKERS A
22 - C1 (HANDLEBAR MATRIX)
23 - C0 (HANDLEBAR MATRIX)

[27A]

RADIO PINOUTS

RT FRONT HEADSET(+) - 1

FRT HEADSET COMMON - 2

LFT RR SPEAKER (-) - 3

RT RR SPEAKER(-) - 4
C4 (RR CNTL MATRIX) - 5
R1 (RR CNTL MATRIX) - 6

RR MIC SHIELD - 7

RR MIC COMMON - 8

LFT FRT HEADSET - 9
LFT RR SPEAKER (+) - 10

RT RR SPEAKER (+) - 11
C3 (RR CNTL MATRIX) - 12
R0 (RR CNTL MATRIX) - 13
R2 (RR CNTL MATRIX) - 14

FRT MIC SHIELD - 15

RT RR HEADSET (+) - 16

LFT RR HEADSET (+) - 17

RR HEADSET COMMON - 18

FRT MIC COMMON -23

N/C - 19
N/C - 20

RR MIC - 21

FRT MIC - 22

BK

[29A]
[29B]

C.B. ANTENNA

BACK OF

ULTRA RADIO

[50A]

(GY)

[28B]

1
2
3
4

TO

5
6
7
8

9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

[28A] ULTRA ONLY

[51B]

ULTRA
RADIO

[28A]

INTERCONNECT

(BK)

ULTRA

RADIO

CONNECTOR

[28A]
(GY)

C0 C1 C2 C3 C4
R0 VOL UP VOL DWN MENU UP TUNE / FF
R1 DWN TUNE / REWIND
R2 SQUELCH UP SQUELCH DWN PUSH TO TALK BAND

R0 RR VOL UP UP TUNE / FF
R1 RR VOL DWN DWN TUNE / REWIND
R2 PUSH TO TALK BAND

RR CONTROL MATRIX

C3 C4

HANDLEBAR MATRIX

Y/R

Y/BK

W/BN

LTG N/BN

BN/W
GY/W

DRAIN

BK

Y/W

BN
GN

O/BK
PK/W
V/BK

DRAIN

GY/Y
GY/O

GY/BK

R
R

BK

[6A]

P/N 70160-04

AUDIO

HARNESS

C
B
A

DRIVER

HEADSET

BE/Y

(BK)

CAV CIR

1

R

2

Y/BK & DRAIN

3

Y/R

4

BK

5

Y/W

6

DRAIN

7

BE/Y

TAB DRAIN

[53A]

[53B]

1

2345

1

2345

6

6

BE/Y

Y/BK

78

78

Y/BK

BE/Y

Y/W

9

10

9

Y/W

Y/R

10

Y/R

BK

1112

1112

R

BK

R

DRAIN

DRAIN

C.B. ANTENNA

INSIDE TOUR-PAK

[50B]

(BK)

1
2
3
4
5
6

[41A]

PK/W
GY/W
V/BK

O/BK

/BN

GN

LTG N

RIGHT REAR

+VOL

PTT

-VOL

[41B]

PK/W
GY/W
V/BK

O/BK

GN

LTG N/BN

1
2
3
4
5
6

SPEAKER &

CONTROLS

[76B]

R

GY/BK

GY/Y
BK
GY/O

DRAIN

(BK)

[42A]

PK/W
GY/W
V/BK
BN/W

BN

W/BN

TAB

1
2
3
4
5
6

1
2
3
4
5
6
7

PASSENGER

HEADSET

[42B]

PK/W

1

GY/W

2

V/BK

3

O/BK

4
5
6

LEFT REAR
SPEAKER &

BN

W/BN

CAV CIR

1 R
2 GY/BK & DRAIN
3 GY/Y
4 BK
5 GY/O
6
7

TAB DRAIN

CONTROLS

UP
MODE

DOWN

LEFT & RIGHT REAR PASSENGER CONTROLS

COLOR

POSITION
UP/+VOL
MODE/PTT
DOWN/-VOL

ORANGE/
BLACK

PINK/
WHITE

VIOLET/
BLACK

GRAY/
WHITE

f2227v8x

2004 FLHTC, FLHTCU and FLTR, DOMESTIC and INTERNATIONAL Models,

Radio, CB/Intercom and Rear Speakers

8-51

HOME

OPTIONAL SECURITY SIREN

POWER
SIGNAL

GROUND

[142A]

[75A] [75C]
[75B] [75D]

ON/OFF

SET/COAST

RESUME/ACCEL

THROTTLE ROLL-OFF

CRUISE CONTROL MODULE

CRUISE CONTROL STANDARD

ON RK CLASSIC ONLY

GROUND

IGNITION
BRAKE SIGNAL
ENGINE SPEED

SET LAMP

SPEED SIGNAL

[17A]

RH CRUISE

CONNECTION

(BLK)

[159B]

LH CRUISE

CONNECTION

[158B]

TO LEFT HAND

CONTROLS

HAND

(GRAY)

[

24B

TO RIGHT

CONTROLS

(BLACK)

[22B]

(GY)

HAND

2
1

2
1

1
2
3
4
5
6

]

1
2
3
4
5
6

A
B
C

O/V
V/Y

[159A]

[158A]

[

24A

Y/BK

[22A]

[142B]

THROTTLE

ROLL-OFF

A
B
C
D
E
F
G
H
J
K

BE/BK

W/BE

R/GN

]

O/W

Y

BE

W

W/V

O/W

R/BE

GY
W/BK
W/BN

BK/R

BN/GY

LGN/BN

BK

SWITCH

R/GN

BE/BK

W/BE

V/Y

BK

O/V
R/BE
BE/O
GN/R
W/GN

[17B]

ODOMETER

RESET

SWITCH

[154]

[39B]

(BK)

SPEEDOMETER

123456 789101112

BK

BK

BK

O

LGN/V

BN/V

BN/GY

O/W

Y/W

GN/R

R/GN

BK

GND

STUD

BK

TO IGNITION/EFI

HARNESS

12

[8B]
(GY)

BN/GY

LH

FRAME GROUND

34567

BE/O

W/GN

W/BK

GY

R

[8A]

89

BK

10

R

11

LGN/V

O/GY

FENDER TIP

LAMP

12

[32A]

BK

BK

RH

GND

STUD

BK

[32B]

(BK)

12

O/W

BK

HEADLAMP

[38B]

BKBK

W

Y

[109A]

PASSING LP

SWITCH

[109B]

34

Y

GY/BK

[73A]
(WE)

PA SSING

LAMPS

[73B]

1212

GY/BK

GY/BK

HDI

POS.

LAMP

[29B]

BK

R/Y
O/V
BK
R/BE

O

BE

BE
GY

O/V

O/W

O/R
BN/GY

R/GY

GN

TN/GN

BK/R

FUEL GAUGE

12

34

[117B]

O

O/W

5

3F
4E

3

4F

1

3E

2

1B

1D 1C

1H 1G

1F 1E

4D 4C

CRUISE/BRAKE - 15A

2B

2D

2F

3D

5

2J

3

3H
3J

1

2H

2

BK

Y/W

[64B]

INSTRUMENTS - 15a

LIGHTS - 15A

HEADLAMP - 15A

IGNITION - 15A

IGN - 2A MAX

P&A

ACCESSORIES - 15A

P&A - 15A

BATTERY - 15A

TO FUEL
SENDER

[141A]

123

BK

Y/W

BRAKE
RELAY

1A

2A

2C

2E

3C

START
RELAY

STARTER

SOLENOID

[128B]

[141B]

O/GY

R/BK

R/BK
R/BK

R/GY

R

CONNECTOR

[160B]

GN

IGNITION SWITCH LEGEND

POSITION

ACCESSORY

LOCK

IGNITION

POWER

RELAY

87A

R

B+

SEE CHARGING SYSTEM FOR

R/GY

ACCESS.

IGNITION SWITCH

[126A]

878685

30

[126B]

R/BK

R/BK

R

BK

R

REGULATOR

[77A]

FURTHER CONNECTIONS

CRANK POSITION

R/BK
IGN.RBATT.

A

R/BK

MAXI-FUSE

40 A

[5B]

B A

R

MAIN POWER

AT S TARTER

SENSOR

[33A]

C

B

[33B]

R/GY

R

R

TURN SIGNAL/SECURITY

MODULE

[30A]

TSM/TSSM

VSS / SERIAL DATA LINK

SECURITY INDICATOR

RIGHT TURN SWITCH INPUT

LEFT TURN SWITCH INPUT

START RELAY CONTROL

IGNITION ENABLE SIGNAL

BATTERY
IGNITION

LEFT TURN FEED

RIGHT TURN FEED

ALARM SIGNAL

GROUND

(BK)

[31A

1

TO FRONT

TURN

SIGNALS

[31B

2
3
4
5

]

6

1
2
3
4
5
6
7
8

9
10
11
12

]
BK

BN
BE
BE
V
BK

BN/GY

GY

LGN/V

BN/V

V

BN

W/BN

W/V

TN/GN
LGN/BN

BK

(GY)

[30B]

R/BE

O/W

TN

[131]

REAR

STOPLIGHT

SWITCH

[121]

NEUTRAL

SWITCH

(BK)

[4A

O

O/R

R/Y

]

234

1

GROUND

IGNITION FEED

BRAKE LP FEED

ACCESS. FEED

GN/Y

[120B]

HORN

[122]

BK

Y/BK

OIL

PRESSURE

SWITCH

[120A]

(BK)

[21A]

12345678

TO INDICATOR

W

V

LAMPS

BN

TN

O

BK

BE

8

7

6

TO REAR

[7B]
(BK)

5

4

12

3

LIGHTS

]

[7A

CONNECTOR

P &A

ACCESSORY

15A MAX

BN

O/W

BK

BK

V

R/Y

BK

2004 FLHR, FLHRC and FLHRS, DOMESTIC and INTERNATIONAL Models,

Main Harness

BK

O

O/R

[67A]

234

1

ACCESSORY

SWITCH

BK

R

[79B]

2

2

1

1

BK

R

[79A]

f2227r8x

8-52

HOME

CARBURETED

VEHICLES

IGNITION CONTROL MODULE

(BLK)

[10A]

RUN/STOP SIGNAL

+5V SENSOR PWR
SENSOR GROUND

MODULE GROUND

CRANK SENSOR (+)

CRANK SENSOR (-)

VEHICLE SPD SIG

BATTERY

COIL FRONT

COIL REAR

MAP SIGNAL

DATALINK

CARBURETED OVERLAY: 32435-04

EFI OVERLAY: 70233-04

[BLK]

[10B]

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

9

9

10

10

11

11

12

12

W/BK
BN/GY

R/W
BK/W
BK
BE/O
Y/BE

R

BK
W/GN
V/W
LGN/V

(GY)

[91A]

DATA

LINK

12

BK

34

LGN/V

GY

IGNITION

COIL

ABC

W/BK

BE/O

[83B]

Y/BE

MAP

SENSOR

ABC

V/W

R/W

BK/W

[80A]

[80B]

R/W

W/GN

BK

[65B]

(BK)

PLUG

ABC

(REAR)

(FRONT)

(+12VDC)

W/GN

R/W

BK

[65B]

(BK)

IGNITION

COIL

(CARB)

REAR SPARK PLUG

A

A

B

B

C

C

[65A]

VEHICLE

+5V DC

R

W

BK

OUTPUT

SENSOR

POWER

COIL RR

ION SENSE

ABCD

GROUND

COIL FRT

[83A]

IGNITION

COIL
(EFI)

+5V DC

R

A

A

B

W

B

C

BK

C

OUTPUT
SENSOR

[65A]

SPEED SENSOR

BK
LGN/V

BK
R
GY
W/GN

BE/O
W/BK
BN/GY

VEHICLE

12
11
10

9
8
7

HARNESS

6
5
4
3
2
1

GROUND

FROM
MAIN

[8B]

[83A]

FRONT SPARK

[8A]

(GY)

SPEED SENSOR

FUEL INJECTED

VEHICLES

ELECTRONIC

CONTROL

MODULE

ALDL & FLASH PIN

CHECK ENG LP

TACH OUTPUT

SYSTEM RELAY

SERIAL DATA LINK

ENGINE TEMPERATURE

INTAKE AIR TEMPERATURE

OXYGEN SENSOR A

ANALOG INPUT

POWER GROUND

CRANK POS. SENSOR (-)

5V SENSOR POWER

FREQUENCY INPUT
IDLE AIR CNTL MOTOR
IDLE AIR CNTL MOTOR

THROTTLE POS SNSR INPUT

OXYGEN SENSOR B

MAP SENSOR INPUT

5V SENSOR GROUND

CRANK POS. SNSR (+)

SWITCH INPUT (unused)

VEHICLE SPEED INPUT

IDLE AIR CNTL MOTOR
IDLE AIR CNTL MOTOR

COIL REAR

SWITCH POWER

DIGITAL GROUND

INJECTOR REAR

OUTPUT (unused)

INJECTOR FRONT

OUTPUT (UNUSED)

ION SENSE

POWER GROUND

COIL FRONT

CONSTANT POWER

DIGITAL POWER

[78A]

REAR

INJECTOR

[85B]

AB

Y/GN

GN/GY

BK/W

SENSOR

[89B]

INTAKE

AIR

TEMP.

AB

LGN/Y

BK/W

[83B]

IGNITION

COIL

ABCD

Y/BE

Y/GN

GY/BE

BE/O

ENGINE

TEMP.

SENSOR

DATA

(GY)

[91A]

[78B]

123456789101112131415161718192021222324252627282930313233343536

123456789101112131415161718192021222324252627282930313233343536

LGN/R

PK

GN/O

LGN/V
PK/Y
LGN/Y

BK
Y/BE

BK+

W/BK

R/W

BK/O

BK/PK
GN/GY

LINK

12

LGN/R

34

BK

GY

LGN/V

[90B]

AB

PK/Y

W/Y

GY/V
V/W

BK/W
GY/BE

BK

BE/O

R

BE/GY

FRONT

INJECTOR

[84B]

AB

Y/GN

W/Y

THROTTLE

POSITION

SENSOR

ABC

R/W

GY/V

BK/W

[88B]

MAP

SENSOR

ABC

R/W

V/W

IDLE AIR

CONTROL ACTUATOR

ABCD

[80B]

BK/W

BK/O

BK/PK

BN/R

[87B]

BE/GN

[119B]

O/GY

BE/GY

Y/GN

BE/GY

GN/O
W/BK

PK

[8A]

12
11
10

9
8
7
6
5
4
3
2
1

FROM

MAIN

HARNESS

[8B]
(GY)

Y/GN

BK

LGN/V

O/GY
R

BK

R

GY

W/GN

W/BK

FUEL PUMP 15A

GH

ECM POWER 15A

AB

SYSTEM RELAY

K

5

T

4

E

3

S

2

U

1

R

(BK)

W/GN
BE/GN

BN/R

f2227x8x

2004 FLHR, FLHRC and FLHRS, DOMESTIC and INTERNATIONAL Models,

Ignition Harness (Carbureted), Electronic Fuel Injection (EFI) Harness

8-53

HOME

BK

POWERTRAIN

GROUND

VOLTAGE

REGULATOR

+
DC AC

-

[77B]

BK

BATTERY

BK

BK

BK

[77A]

[46A]

R

A
B

MAXIFUSE

40 A

B A

R

A
B

BK

STARTER

HAND CONTROLS,

RIGHT

[46B]

BK

BK

CHARGING CIRCUIT

STATO R

RIGHT

BK

LEFT

GROUND

STUDS

BATTERY

BK

MAXIFUSE

40 A

BK

STARTER

B A

R

R

IGNITION

SWITCH

IGNITION SWITCH LEGEND

A RED/

POSITION

GREY

ACCESSORY

OFF

IGNITION

B

A

R

R/GY

BLACK

I RED/

(REAR VIEW)

[33A]

I

[33B]

R/BK

B RED

BN/GY

R/GY

GN

TN/GN

BK/R

GY

3D

1F

2J
3H
3J
2H

[128]

[64]

BATTERY 15A

IGN:

5
3
1
2

START
RELAY

15A

GN

R

3C

R

1E

R/BK

f2227m8x

TURN SIGNAL/SECURITY

MODULE

TS/TSSM

BATTERY
IGNITION
VSS / SERIAL DATA LINK
SECURITY INDICATOR
LEFT TURN FEED
RIGHT TURN FEED
RIGHT TURN SWITCH INPUT
LEFT TURN SWITCH INPUT
START RELAY CONTROL
IGNITION ENABLE SIGNAL
ALARM SIGNAL
GROUND

[30A]

RIGHT DIR SWITCH
ENGINE OFF/RUN SWITCH

START SWITCH

STOPLIGHT SWITCH

[22B]

GY

BK/R

[30B]

1

BN/GY

2

GY
3
4
5
6
7
8

TN/GN

9

10
11
12

2004 FLHR, FLHRC and FLHRS, DOMESTIC and INTERNATIONAL Models,

MAIN FUSE BLOCK COVER

10A

IGN

15A

1
2
3
4
5
6

[22A]

1
2
3

GY

4
5
6

BK/R

BK - Black
BN - Brown
R - Red
O - Orange
Y - Yellow

Wire Color Code Key

GN - Green
BE - Blue
V - Violet
GY - Gray
W - White

LT.GN - Light Green
PK - Pink
TN - Tan
Wire color-XX/XX-Stripe color

PIN CONNECTOR

(A side)

SOCKET CONNECTOR

(B side)

HANDLEBAR

GROUND

P/N 70142-93
P/N 70101-94

FRAME

GROUND

BK

BK

TRIPLE

CLAMP

GROUNDS

15A

SPARE FUSES

START
RELAY

HEADLAMPS

H

3

1

START

RELAY

5

2

J

G

MAIN FUSE BLOCK

Starting and Charging

BRAKE
RELAY

P&A

IGN

F

1

BRAKE
RELAY

5

15A

15A15A

E

64

P&A

BATTERY

ACCESS.

LIGHTS

D

3

2

15A

15A

CRUISE/BRK

INSTRUMENTS

B

15A

15A15A

C

4

3

2

1

A

8-54

HOME

RIGHT
PA SS ING
LAMP

RIGHT

DIRECTIONAL

AND DOM

RUNNING LAMP

FRONT FENDER

TIP LAMP

(DOMESTIC ONLY)

POSITION LAMP

(HDI ONLY)

HEADLAMP

LEFT

DIRECTIONAL

AND DOM

RUNNING LAMP

LEFT
PA SS ING
LAMP

ON

KEYWAY DOWN

OFF

GY/BK

GND

BK

BN

BE

RUNNING

DOM ONLY

O/W

BK

GND

BK

TURN

BE

RUNNING

DOM ONLY

REAR VIEW OF

TOGGLE SWITCH

WITH KEYWAY DOWN

NORMALLY CLOSED
COMMON
NORMALLY OPEN

ACCESSORY/SPOT SWITCH

FROM MAIN

HARNESS [31A]

12

3456

]

[31B

TURN

BK

O/W

HIGH
BEAM

LOW

BEAM

V

BK

BNBEBE

W

Y

BK

GY/BK

FROM MAIN
HARNESS [73A]

12

[ 73B]

GY/BK

GY/BK

12

(WE)

34

V

BK

FROM MAIN HARNESS

[67A] AND [66A]

[66B]

AND/OR

[67B]

BK

BK

BK

FROM MAIN

HARNESS

Y

W

BK

O/W

[39A]

O

[117A]

123

TO MAIN

HARNESS

12

BK

O/W

[32B]

(BK)

BK

LH CRUISE CONTROLS

SPEEDOMETER

DATABUS

IGNITION

23456 789101112

1

ACCESSORY

BATTERY

NC

NC

FUEL LEVEL

GROUND

TRIP SWITCH

FUEL GAUGE

G

S

I

BK

W

EFI ONLY

Y/

4

Y

BK

O

321

[141A]

FUEL PUMP ASSEMBLY IN TANK

O

O

N

F
F

[21B]

(BK)

TRIP SWITCH

CRUISE ACTIVE

CRUISE ENABLE

FUEL

PUMP

FULL: 39.5/27.5 OHMS
1/2: 118.0/97.0 OHMS
EMPTY: 260.0/240.0 OHMS

POWER

RH CRUISE CONTROLS

R

S

E

E

S

T

FROM MAIN
HARNESS

[21A]

12

34567

GN/Y

WVTN

BN

O

8

BK

-

RT

+

+

N

-11

HB

-

LT

CARBURETED ONLY

Y

12

3

[141A]

FUEL LEVEL SENDER IN TANK

RESUME

SET

R/GN

INDICATOR

LAMPS

11

3

10

9OP

10

8

4

11

5

BK

FULL:39.5/27.5 OHMS
1/2: 118.0/97.0 OHMS

EMPTY: 260.0/240.0 OHMS

HANDLEBAR

RIGHT
TURN

OIL
PRESSURE

NEUTRAL

HIGH
BEAM

LEFT
TURN

GROUND

FRAME

GROUND

W/BE

BE/BK

CHASSIS GROUNDS

BK

BK

RH CRUISE

1
2

CONNECTOR

[159B]

LH CRUISE

1

CONNECTOR

2

LIGHTING

REAR

FROM MAIN
HARNESS [7A]

BE

R/Y

BK

[19B]

V/BN

BK

[18B]

V/BN

BK

BK

BK

[45B]

TRIPLE CLAMP

GROUNDS

P/N 70142-93

P/N 70101-94

(BK)

[158B]

(GY)

HARNESS

12345678

BN

V

O/W

FROM MAIN

HARNESS

[94B]

1

1

2

2

1

1

2

2

1

1

2

2

3

3

[45A]

[7B]

[18A]

[19A]

[93A]

[94B]

123456

4
3
2
1

[94A]

1
2
3
4
5
6

BRAKE LIGHT

4
3
2
1

[93B]

HAND CONTROLS

RIGHT

RIGHT DIR SWITCH

ENGINE OFF/RUN SWITCH

START SWITCH

STOPLIGHT SWITCH

[22B

]

R/BE

GY

W/BK

]

y

BE

W

1
2
3
4
5
6

1
2
3
4
5
6

O/W

W/BN

BK/R

[

24B

O/W

W/V

Y/BK

HORN SWITCH
LIGHTS HI/LOW SWITCH

LEFT DIR SWITCH

HAND CONTROLS
LEFT

V/BN

BK

BK
R/Y
O/W

BE

TAI L
HDI ONLY

TAIL
DOM ONLY

FENDERTIP LAMP (DOM)
LICENSE PLATE LAMP (HDI)

BK
BK

TAILLAMP

V/BN

BK

LEFT REAR
DIRECTIONAL
LAMP

f2227q8x

FROM MAIN

HARNESS

[22A]

(BK)

FROM MAIN

HARNESS

]

[24A

(GY)

RIGHT REAR
DIRECTIONAL
LAMP

2004 FLHR, FLHRC and FLHRS, DOMESTIC and INTERNATIONAL Models,

Handlebar Controls, Speedometer, Indicator Lamps, Tail Lamp, Passing Lamps, Directional Lamps, Fender Tip Lamps and Spot/Accessory Switches

8-55

HOME

SIDECAR

LEFT SPEAKER

[SC205]

SIDECAR AUDIO

HARNESS

P/N 88403-98

SIDE CAR

AMPLIFIER

TO
SIDECAR
HEADSET

O/W
BE
R/Y
BK

LBE/W

LBE/BK

[150B]

PA IN T

DOT

[149]

1

LBE/BK

2

W/BN

3

BN

4

LGN/BN

5

GN

6
7

LGN/W

8

LGN/BK

9

LBE/W

10
11
12
13
14
15

PK/W

16

O/BK

17

BN/W
18
19
20

BK
21

O/V

V/BK

22

GY/W

23

[76F]

1

GRAY TWISTED PAIR - R
GY/BK

2

GY/Y

3
4

GRAY TWISTED PAIR - BK
GY/O

5
6
7

TAB

GRAY TWISTED PAIR - SHIELD

1234

1234

[150A]

LGN/W

LGN/BK

LBE/BK

LBE/W

LGN/BK

LGN/W

PA IN T

DOT

SIDE CAR

DIN HARNESS

88401-98

SIDECAR

RIGHT SPEAKER

[SC206]

PK/W
GY/W
V/BK
O/BK
GN
LGN/BN

PK/W
GY/W
V/BK
O/BK
GN
LGN/BN

O/V
W/R
W/V
V/GY
BK
BE/Y
Y/BK
Y/W
Y/R
BK
R
BK

O/V
W/R
W/V
V/GY
BK
BE/Y
Y/BK
Y/W
Y/R
BK
R
BK

PK/W
GY/W
V/BK
BN/W
BN
W/BN

PK/W
GY/W
V/BK
BN/W
BN
W/BN

GRAY TWISTED PAIR - R
GY/BK

GY/Y
GRAY TWISTED PAIR - BK

GY/O

GRAY TWISTED PAIR - SHIELD

GRAY TWISTED PAIR - R
GY/BK

GY/Y
GRAY TWISTED PAIR - BK

GY/O

GRAY TWISTED PAIR - SHIELD

[41D]

[41C]

[53D]

[53C]

[42D]

[42C]

[76C]

[76D]

1
2

MOTORCYCLE

3

AUDI O

4

HARNESS

5
6

1
2

RIGHT SPEAKER

3
4

POD CONNECTOR
5
6

1
2
3
4
5
6

MOTORCYCLE

7

AUDI O

8

HARNESS

9
10
11
12

1

2

3

4

5

CONSOLE

6

CONNECTOR

7

8

9
10
11
12

1
2
3

MOTORCYCLE

4

AUDI O

5

HARNESS

6

1
2
3

LEFT SPEAKER

4

POD CONNECTOR

5
6

1
2
3

MOTORCYCLE

4

AUDI O

5
6

HARNESS

7

TAB

1
2
3
4

PA SS ENGER

5

HEADSET

6
7

TAB

TO

TO

TO

TO

TO

TO

TO

TO

BE

R/Y

O/WBKBK

1
2
3

BK

BK

SIDECAR HARNESS

3456

12

123456

1
2

1
2

1
2
3

[32A][32B]

NOTE: RIGHT REAR
DIRECTIONAL LAMP
BULB MUST BE
REMOVED FROM
MOTORCYCLE WHEN
SIDECAR IS
INSTALLED

P/N 70221-99

4
3
2
1

[93A]

BK BK
BN

[SC18A] [SC18B]

2
1

[94B]

[94A]

[93B]

TA IL

LAMP

4

BK

3

R/Y

2

O/W

1

SIDECAR FRONT

FENDER TIP LAMP

BK
BK

SIDECAR

DIRECTIONAL

LAMP

SIDECAR[84].

2
1

[SC7A]

BN
O/W
V
BK

R/Y
BE
BK

[SC7B]

BN
O/W
V
BK
BK
R/Y
BE
BK

BN

1
2

TO MOTORCYCLE

3

REAR LIGHTING

4

HARNESS

5

CONNECTOR

6
7
8

1
2
3
4
5
6
7
8

[7B]

TO MOTORCYCLE

MAIN HARNESS

CONNECTOR

[7A]

2004 TLE, TLE-U SIDECARS, DOMESTIC AND INTERNATIONAL Models,

Chassis and Audio Harness

8-56