Harley Davidson Touring 2004 Service Manual sm08b

f2115x8x

Socket

Screw

Flat

Washer

Switch

Housing

4-Place

Packard

Connector

Spacer

Collar

Nut

Knob

Tab

Down and Forward

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IGNITION/LIGHT KEY SWITCH AND FORK LOCK 8.18

1WARNING1WARNING

DO NOT modify the ignition/light key switch wiring to disable the automatic-on headlamp feature. High visibility is an important safety consideration for motorcycle riders. Ensure that the headlamp is on at all times. Failure to do so could result in death or serious injury.

FLHT/C/U, FLTR (DOMESTIC)

REMOVAL

1. Remove the outer fairing. See Section 2.29 UPPER

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

2. To remove the ignition switch knob, insert the Ignition Switch key and turn to the UNLOCK position. Leaving the key installed, rotate the knob to ACCESS. Depressing the release button at bottom (left side) with a small screwdriver, push key down and turn an additional 60 degrees in a counter-clockwise direction. Lift and remove knob. See Figure 8-61.

f1240x2x

Button

f1476x8x

Figure 8-61. Ignition Switch Knob Release Button

TOP VIEW

Button

BOTTOM VIEW

Figure 8-62. Ignition Switch Assembly (Domestic)

3. Using a 7/8 inch wrench on ﬂats, loosen switch nut and remove from threaded post of ignition switch housing. Remove collar and spacer. See Figure 8-62.

4. Using a T27 TORX drive head, remove the two screws (with ﬂat washers) that secure fairing cap to left and right sides of inner fairing.

5. Remove the switch position plate by pulling tabs from slots in fairing cap. If necessary, raise the fairing cap slightly to facilitate removal.

2004 Touring: Electrical 8-49

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6. With the forks turned fully to the left, disconnect the Fairing cap switch connector [105], 12-place Multilock (black), from behind right side of fairing cap. Depress the button on the plug side of the connector to pull apart the pin and socket halves.

7. Remove the fairing cap from the motorcycle. See Figure

8-63.

8. Locate the Ignition switch connector [33], 4-place Packard, at bottom of radio. Slide connector off anchor and separate pin and socket halves. See Figure 8-64.

9. Remove the socket screws (with ﬂat washers) and lift the switch housing from the upper fork bracket bore. Route the Ignition switch connector to rear of inner fairing and remove switch housing from the vehicle.

INSTALLATION

1. Slide base of ignition switch into bore of upper fork bracket. Install screws (with ﬂat washers) and tighten to 36-60

in-lbs

(4.1-6.8 Nm).

2. Route the Ignition switch connector [33], 4-place Packard, to front of inner fairing. Mate pin and socket halves of connector and install onto anchor at bottom of radio. See Figure 8-64.

3. Verify that the rubber grommets are installed on each side of the fairing cap. Barbs on cap ﬁt into holes in grommets.

4. Connect the Fairing cap switch connector [105], 12place Multilock (black), on the right side of fairing cap.

5. With the forks turned fully to the left, install fairing cap over ignition switch housing.

f1305b2x

Ignition Switch Connector [33]

f2238x8x

Figure 8-64. Ignition Switch Connector Location

(FLHT/C/U)

6. Install switch position plate ﬁtting tabs in slots of fairing cap. Plate snaps in place when properly installed. Exercise care to avoid breaking tabs. Replace plate if tabs are broken.

7. Using a T27 TORX drive head, start two fairing cap screws (with ﬂat washers). Verify that grommets in fairing cap fully capture handlebar along with throttle and clutch cables.

8. Slide spacer over threaded post of ignition switch housing until it contacts switch position plate. Slide collar over post with the tab side down (and forward). Install nut, and using a 7/8 inch wrench on ﬂats, tighten to 50-70

lbs

(5.7-7.9 Nm).

in-

Fairing Cap

Switch Connector [105]

12-Place Multilock

Figure 8-63. Fairing Cap Assembly (FLHT/C/U)

8-50 2004 Touring: Electrical

9. With the red arrow pointing toward the ACCESS position, install the ignition switch knob. Turn key clockwise to UNLOCK position and then turn knob to OFF.

10. Using a T27 TORX drive head, tighten two fairing cap screws to 25-30

in-lbs

(2.8-3.4 Nm).

11. Verify operation of both the ignition switch and fork lock assemblies.

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

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

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FLHT/C/U, FLTR (INTERNATIONAL)

REMOVAL

1. Remove the ignition switch knob as follows:

a. Insert the ignition switch key and turn to the

UNLOCK position. Leave the key installed in the ignition switch knob.

b. Tu rn the front forks to the left fork stop and rotate

the knob to FORK LOCK.

c. Depressing the release button at bottom (left side)

with a small screwdriver, push key down and turn 60 degrees in a counter-clockwise direction. See Fig-

ure 8-65.

d. Lift and remove knob. Be aware that spring will drop

out of bore at underside of knob when removed.

Figure 8-66. Ignition Switch Alignment Tool

(Part No. HD-45962)

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Button

f2097x8x

Figure 8-65. Ignition Switch Knob Release Button

TOP VIEW

Button

BOTTOM VIEW

Figure 8-67. Bottom Alignment Tool in Threaded Post

and Rotate to Desired Position

NOTE

After removal of the knob, the IGNITION SWITCH ALIGNMENT TOOL (HD-45962) may be used to move the switch to other positions as required. Insert tool until bottom of handle contacts top of threaded post, and then rotate handle in a clockwise direction to the selected position. See Figure 8-67.

2. Turn the front forks to the right fork stop, and using a 7/8 inch open end wrench on ﬂats, remove nut from threaded post of ignition switch housing.

3. Pull collar and spacer from threaded post.

4. Remove the switch position plate by pulling tabs from slots in fairing cap (FLHT/C/U) or instrument nacelle (FLTR).

FLTR:

Remove the instrument nacelle. See Section 2.30

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT NACELLE, REMOVAL.

FLHT/C/U:

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

Remove the fairing cap. See Section 2.29

2004 Touring: Electrical 8-51

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Figure 8-68. Ignition Switch Connector Remover

(Part No. HD-45961)

f2090x8x

8. Disconnect the ignition switch jumper harness connector [33], 3-place Packard, at front of ignition switch housing. Proceed as follows:

a. Obtain the IGNITION SWITCH CONNECTOR

REMOVER (HD-45961). See Figure 8-68.

b. Gently insert end of tool into slot in ignition switch

housing until it stops.

c. Grasping jumper harness conduit and tool, pull both

at the same time to release socket housing from ignition switch housing. See Figure 8-69.

NOTE

For instructions on properly removing and installing jumper harness terminals, see APPENDIX B.4 AUTOFUSE ELEC-

TRICAL CONNECTOR.

INSTALLATION

1. Install Ignition switch jumper harness connector [33], 3place Packard, at front of

2. Slide base of ignition switch housing into bore of upper fork bracket.

new

ignition switch housing.

Figure 8-69. Pull Jumper Harness Conduit and Tool

to Release Socket Housing

1WARNING1WARNING

Always wear proper eye protection when drilling. Flying debris may result in eye injury.

6. Remove the two break-away screws at the base of the ignition switch housing. Proceed as follows:

a. Use a center punch to make a pilot hole at the top of

each break-away screw.

b. Install a 1/8 inch left handed bit in drill and set the

drill to Reverse. Positioning the bit in the pilot hole, spin out the break-away screws.

NOTE

If the above method fails, use a 3/16 inch bit with long shank to carefully drill off heads of break-away screws. Use a pliers to unthread the shafts from the upper fork bracket.

7. Remove ignition switch housing from upper fork bracket bore.

CAUTION

Verify that the threads in the upper fork bracket are clean and in good condition. Dirty and/or damaged threads may cause the heads of the break-away screws to snap off before the switch housing is properly tightened.

CAUTION

Exercise care to avoid losing heads of break-away screws in vehicle. Vibration may cause captured heads to scratch ﬁnished surfaces, chafe wires or cause other damage.

3. Install

5. Install switch position plate ﬁtting tabs in slots of fairing

6. Install spacer over threaded post of ignition switch hous-

new

break-away screws at base of ignition switch housing. Turn screws in a clockwise direction until heads snap off.

FLTR:

Install the instrument nacelle. See Section 2.30

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT NACELLE, INSTALLATION.

FLHT/C/U:

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

cap (FLHT/C/U) or instrument nacelle (FLTR). Plate snaps in place when properly installed. Exercise care to avoid breaking tabs. Replace plate if tabs are broken.

ing until it contacts switch position plate. Orient spacer so that the widest side is forward and the inside tabs ﬁt in slots of post. See Figure 8-70.

Install the fairing cap. See Section 2.29

8-52 2004 Touring: Electrical

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1. Knob

2. Spring

3. Nut

4. Collar

5. Spacer

6. Break-Away Screw

7. Flat Washer

8. Switch Housing

12. Knob was removed in ACCESS or switch may have

been moved out of the FORK LOCK position. Proceed as follows:

a. Insert alignment tool until bottom of handle contacts

top of threaded post, and holding front forks at the left fork stop, rotate handle of tool in a counterclockwise direction until fork locks. See Figure 8-67.

b. Remove tool and repeat step 10.

c. If knob does not install properly, move to step 13.

13. Detent and switch position lugs are misaligned. This can occur when the alignment tool (or ignition switch knob) is rotated before it is properly bottomed in the ignition switch housing. Proceed as follows:

Figure 8-70. Ignition Switch Assembly (International)

7. Slide collar over threaded post until it contacts spacer. Orient collar so that the outside tab is forward and the inside tabs ﬁt in slots of post.

8. Thread nut onto post with the lipped side down and the smaller OD topside. Turn the front forks to the right fork stop, and using a 7/8 inch Open End Crow Foot on ﬂats, tighten nut to 125-150

9. Install spring into bore at underside of knob.

10. With the knob pointing toward the FORK LOCK position, insert shaft into threaded post. Holding the knob down, turn key clockwise to UNLOCK. An audible “click” should be heard when knob and switch are properly engaged. Release knob and then rotate through all four switch positions to verify proper operation.

If knob will not install properly, move to step 11.

11. Proceed as follows:

a. Verify that button at bottom of knob is depressed

and key is turned 60 degrees beyond the UNLOCK

position. See Figure 8-65. b. Repeat step 10. c. If knob does not install properly, move to step 12.

in-lbs

(14.1-16.9 Nm).

f2116x8x

a. Reinstall knob inserting shaft into threaded post and

gently rotate knob until it drops into the partially installed position. Take note of the position of the knob, that is, whether it is pointing toward the rear, or to ACCESS, IGNITION or OFF.

b. Remove knob and insert alignment tool so that the

bottom of the handle is approximately 1/2-3/4 inch (12.7-19.1 mm) from the top of the threaded post, and then hold. See Figure 8-71.

c. Rotate alignment tool in a counter-clockwise

direction the number of positions needed to get to FORK LOCK. For example, if the knob dropped into the partially installed position at IGNITION in step 13(a), rotate the alignment tool two positions in a counter-clockwise direction. Or if the knob was pointing toward the rear when it dropped, rotate the alignment tool four positions in a counter-clockwise direction or one position in a clockwise direction. Repeat step 10.

Figure 8-71. Rotate Alignment Tool Without Bottoming

2004 Touring: Electrical 8-53

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Ignition/Light

Key Switch Connector [33]

Screw

Figure 8-72. Instrument Console (FLHR/C)

f2095x8x

FLHR/C/S

IGNITION/LIGHT KEY SWITCH

Removal

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

1WARNING1WARNING

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

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

3. Carefully cut anchored cable strap securing main harness bundle, instrument console conduit, and fuel vapor vent tube to left side of frame backbone.

6. Raise instrument console and bend back ﬂexible clamp on canopy to release main harness conduit. Depress button on socket side and remove fuel level sender/fuel pump connector [141], 3-place Mini-Deutsch.

7. Lay a clean shop towel on forward part of rear fender. Lift the instrument console from fuel tank and lay upside down on shop towel.

8. Pull external latches outward to disconnect ignition/light key switch connector [33], 3-place Packard. See Figure

8-72.

9. Remove four screws to release switch from console.

Installation

1. Align holes in

ure 8-72.

2. Start four screws and alternately tighten to 20-30 (2.3-3.4 Nm) in a crosswise pattern.

3. Connect ignition/light key switch connector [33], 3-place Packard.

4. Slide head of console mounting bolt into slot at top of canopy.

5. Moving instrument console toward installed position, install fuel level sender/fuel pump connector [141], 3place Mini-Deutsch, at top of canopy. Bend ﬂexible clamp to capture main harness conduit.

6. Align hole in instrument console with console mounting bolt and place into position on fuel tank.

7. Install acorn nut at top of instrument console and tighten to 50-90 Phillips screw and large ﬂat washer (absent on FLHRS models). Tighten screw to 36-60

8. On FLHRS models only, install bolt (with ﬂat washer) to secure rear of fuel tank and instrument console bracket to frame backbone. Tighten bolt to 15-20 ft-lbs (20-27 Nm).

9. Snap anchor of frame backbone. Tighten cable strap capturing main harness bundle, instrument console conduit, and fuel vapor vent tube. Cut any excess cable strap material.

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

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

new

switch with those in console. See Fig-

in-lbs

(5.7-10.2 Nm). If present, also install

in-lbs

(4.1-6.8 Nm).

new

cable strap into hole on left side of

in-lbs

(6.8-10.9 Nm).

in-lbs

4. Remove acorn nut from instrument console. If present, also remove Phillips screw and large ﬂat washer (absent on FLHRS models).

5. On FLHRS models only, remove bolt (with ﬂat washer) to free rear of fuel tank from frame backbone. Removal of rear bolt also releases instrument console bracket.

8-54 2004 Touring: Electrical

FORK LOCK

Removal

1. Remove the handlebar clamp shroud. See Section 2.31

WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S), NACELLE REMOVAL (FLHR/C), steps 1-11, or NACELLE REMOVAL (FLHRS), steps 1-7.

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f2101x8x

Figure 8-73. Fork Lock (FLHR/C/S)

2. Start acorn nuts on both the left and right side fork studs to keep halves of headlamp nacelle on motorcycle.

3. Remove two allen head socket screws (with ﬂat washers) and pull fork lock assembly from upper fork bracket bore. See Figure 8-73.

3. Install the handlebar clamp shroud. See Section 2.31

WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S), NACELLE INSTALLATION (FLHR/C), steps 3-15, or NACELLE INSTALLATION (FLHRS), steps 5-13.

NOTE

On HDI models, use a center punch to make a pilot hole at the top of each break-away screw. Install a 1/8 inch left handed bit in drill and set the drill to reverse. Positioning the bit in the pilot hole, spin out the break-away screws.

Installation

1. Install

2. Install two allen head socket screws (with ﬂat washers)

On HDI models, install clockwise direction until heads snap off. Verify that threads in upper fork bracket are clean and in good condition or heads may break off before fork lock assembly is properly tightened. Avoid losing heads of screws in vehicle as vibration may cause captured heads to scratch ﬁnished surfaces, chafe wires or cause other damage.

new

fork lock assembly into bore of upper fork

bracket. See Figure 8-73.

and alternately tighten to 36-60

NOTE

new

break-away screws and turn in a

in-lbs

(4.1-6.8 Nm).

2004 Touring: Electrical 8-55

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FAIRING CAP SWITCHES (FLHTC/U) 8.19

REMOVAL

1. Partially disassemble domestic ignition switch as follows:

NOTE

For partial disassembly of HDI ignition switch, see Section

8.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U, FLTR (INTERNATIONAL), REMOVAL, steps 1-4.

a. See Figure 8-74. To remove the ignition switch

knob, insert the Ignition Switch key and turn to the UNLOCK position. Leaving the key installed, rotate the knob to ACCESS. Depressing the release button at bottom (left side) with a small screwdriver, push key down and turn an additional 60 degrees in a counter-clockwise direction. Lift and remove knob.

b. Using a 7/8 inch wrench on ﬂats, loosen switch nut

and remove from threaded post of ignition switch housing. Remove collar and spacer.

c. Gently remove the switch position plate by pulling

tabs from slots in fairing cap. If necessary, raise the fairing cap slightly to facilitate removal.

2. Using a T27 TORX drive head, remove the two screws (with ﬂat washers) that secure fairing cap to left and right sides of inner fairing.

3. With the forks turned fully to the left, disconnect the fairing cap switch connector [105], 12-place Multilock (black), from behind right side of fairing cap. Depress the button on the socket terminal side of the connector and pull apart the pin and socket halves.

4. Remove the fairing cap from the motorcycle. See Figure

8-75.

5. Bend back the ﬂexible clamp to release switch wires from the inboard side of the fairing cap. Carefully cut cable straps to free wires from bundles.

f1240x2x

Button

BOTTOM VIEW

f1476x8x

Figure 8-74. Ignition Switch Knob Release Button

10. Remove the appropriate terminals from the socket housing.

NOTE

For instructions on properly removing wire terminals, see APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-

TORS, REMOVING SOCKET/PIN TERMINALS.

TOP VIEW

Button

6. Using a T25 TORX drive head, remove two screws to release switch bracket.

7. Gently pry two latches on bracket outward to release tabs on switch. Remove switch from bracket. See Figure

8-76.

8. If replacing Cruise or Speaker Switch, cut Black/Green wire lead halfway between Cruise and Speaker Switch terminals.

9. Follow the wires of the faulty switch to the socket housing, or reference Figure 8-77 and Table 8-10 for the applicable chamber numbers. For wire location purposes, numbers are stamped into the secondary locks of both the pin and socket housings.

8-56 2004 Touring: Electrical

INSTALLATION

1. Feeding wires through bracket, place position. Engage tabs on switch in slots of latches and then gently bend tabs upward to lock position of switch in bracket.

2. Install terminals into socket housing.

NOTE

For instructions on properly installing wire terminals, see APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-

TORS, INSTALLING SOCKET/PIN TERMINALS.

new

switch into

f1304b2x

Cable

Strap

Switch

Bracket

Tab

Latch

OME

Grommet

Cable

Strap

Socket Housing

12-place Multilock

Fairing Cap Switch Connector [105]

Accessory

Switch

Flexible

Clamp

Cruise Switch

Speaker

Cable

Strap

Switch

Bracket

Spotlight

Switch

Switch Bracket

TORX Screws

f1305b2x

Grommet

Figure 8-75. Fairing Cap (Inboard Side) - Ultra Model Shown

3. If Cruise or Speaker Switch was replaced, butt splice Black/Green wire lead between Cruise and Speaker Switch terminals.

NOTE

For detailed butt splicing information, see APPENDIX B.5

SEALED BUTT SPLICE CONNECTORS.

4. Using a T25 TORX drive head, install two screws to secure switch bracket to fairing cap.

5. Install

new

cable straps to capture wire bundles and then secure switch wires to the fairing cap using the ﬂexible clamp. Route the wires as shown in Figure 8-75.

6. Verify that the rubber grommets are installed on each side of the fairing cap. Barbs on cap ﬁt into holes in grommets.

7. Connect the fairing cap switch connector [105], 12-place Multilock (black), on the right side of fairing cap.

8. With the forks turned fully to the left, install fairing cap over ignition switch housing. Verify that grommets in fairing cap fully capture handlebar along with throttle and clutch cables.

9. Start two fairing cap screws (with ﬂat washers). Using a T27 TORX drive head, alternately tighten screws to 2530

in-lbs

(2.8-3.4 Nm).

Figure 8-76. Bend Latches Outward to Release Tabs

2004 Touring: Electrical 8-57

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10. Assemble domestic ignition switch as follows:

– AMP

7910

Secondary Locks Open

f1287b2x

Figure 8-77. Numbers Stamped on Secondary Locks

(Socket Housing Shown)

Table 8-10. Fairing Cap Switches [105]

Switch

Accessory

Cruise

Ultra Only

Spot

Speaker

Ultra Only

Wire Color

Orange/Red 1

Orange 2

Black 3

Orange/Violet 4

Red/Green 5

Black/Green

(Double Lugged)

Ye llow 6

Gray/Black 7

Black 8

Orange/Blue 9

Violet/Orange 10

Brown/Orange 11

Black/Green

Chamber

Number

Speaker

Switch

To Cruise Switch

NOTE

For assembly of HDI ignition switch, see Section 8.18 IGNI-

TION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U, FLTR (INTERNATIONAL), INSTALLATION, steps 5-10.

a. Install switch position plate ﬁtting tabs in slots of fair-

ing cap. Plate snaps in place when properly installed. Exercise care to avoid breaking tabs. Replace plate if tabs are broken.

b. Slide spacer over threaded post of ignition switch

housing until it contacts switch position plate.

c. Slide collar over post with the tab side down (and

forward).

d. Install nut, and using a 7/8 inch wrench on ﬂats,

tighten to 50-70

in-lbs

(5.7-7.9 Nm).

e. With the red arrow pointing toward the ACCESS

position, install the ignition switch knob. Turn key clockwise to UNLOCK position and then turn knob to OFF.

8-58 2004 Touring: Electrical

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INSTRUMENT NACELLE SWITCHES (FLTR) 8.20

REMOVAL

1. Using a T25 TORX drive head, remove screw on left and right side of instrument bezel.

2. Use thumbs to push tab at rear of bezel from slot in front of ignition switch. Gently raise free side of bezel until tabs at front of instrument nacelle become disengaged from slot at front of bezel (concealed behind decorative adhesive strip).

3. Raising bezel slightly, remove anchor on ambient temperature sensor from hole in bottom inboard ear of speedometer bracket.

4. See Figure 8-78. Disconnect instruments and indicator lamps from interconnect harness as follows:

●

Speedometer connector [39], 12-place Packard.

Tachometer connector [108], 12-place Packard.

●

Indicator lamps connector [21], 10-place Multilock.

●

5. Remove bezel from motorcycle.

6. Partially disassemble domestic ignition switch as follows:

NOTE

For partial disassembly of HDI ignition switch, see Section

8.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U, FLTR (INTERNATIONAL), REMOVAL, steps 1-4.

a. To remove the ignition switch knob, insert the Igni-

tion Switch key and turn to the UNLOCK position. Leaving the key installed, rotate the knob to ACCESS. Depressing the release button at bottom (left side) with a small screwdriver, push key down and turn an additional 60 degrees in a counterclockwise direction. Lift and remove knob. See upper frame of Figure 8-79.

b. Using a 7/8 inch wrench on ﬂats, loosen switch nut

and remove from threaded post of ignition switch housing. Remove collar and spacer. See lower frame of Figure 8-79.

c. Remove the switch position plate from threaded

post of ignition switch housing.

7. Follow instructions based on location of defective switch.

LEFT SIDE SWITCH

a. See Figure 8-78. Disconnect left side switch from

instrument nacelle switch harness as follows:

f2219x8x

Speedometer

Gauge [39]

Clutch

Cable

Speaker

Switch [105]

Indicator

Lamps [21]

Figure 8-78. Instrument Nacelle (Bezel Removed)

Instrument Nacelle

Switches [105]

Tachometer Gauge [108]

Throttle

Cables

Ambient

Temperature

Sensor [107]

2004 Touring: Electrical 8-59

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TOP VIEW BOTTOM VIEW

Button

f1240x2x f1476x8x

f1297b2x

Knob

Nut

Tab

Down and Forward

Collar

RIGHT SIDE SWITCHES

a. See Figure 8-78. Disconnect left side switch from

instrument nacelle switch harness as follows:

●

Speaker Switch connector [105], 4-place Multilock.

b. See Figure 8-78. Disconnect instrument nacelle

switches from interconnect harness as follows: Instrument nacelle switch connector [105], 12-place

●

Multilock.

c. Pull throttle cable clip from hole on right side of

instrument nacelle.

d. Using a T40 TORX drive head, remove two bolts

(with ﬂat washers) to release right side of instrument nacelle from fork side. Move right side of nacelle to bench area leaving left side on motorcycle. See Figure 8-82.

e. Gently bend back molded retainer to release switch

bracket assembly from instrument nacelle.

f. Carefully pry two latches on bracket outward to

release tabs on switch. Remove switch from bracket. See Figure 8-80.

g. Remove the appropriate terminals from the socket

and pin housings. Follow the wires of the faulty switch or reference Table 8-11 for the applicable chamber numbers. For wire location purposes, numbers are stamped into the secondary locks. See

Figure 8-81.

Spacer

Figure 8-79. Ignition Switch Knob (Domestic)

●

Speaker Switch connector [105], 4-place Multilock.

b. Pull clutch cable clip from hole on left side of instru-

ment nacelle.

c. Using a T40 TORX drive head, remove two bolts

(with ﬂat washers) to release left side of instrument nacelle from fork side.

d. Unthread rubber boot from odometer reset switch,

and while carefully removing left side instrument nacelle from motorcycle, pull odometer reset switch from hole. Move left side of nacelle to bench area leaving right side on motorcycle. See Figure 8-82.

e. Gently bend back molded retainer to release switch

bracket assembly from instrument nacelle.

f. Carefully pry two latches on bracket outward to

release tabs on switch. Remove switch from bracket. See Figure 8-80.

Latch

Tab

Switch

Bracket

f2215x8x

Figure 8-80. Bend Latches Outward to Release Tabs

8-60 2004 Touring: Electrical

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Instrument Nacelle Switches

Switch

Accessory

Cruise

Table 8-11. Right Side

Chamber Number

Wire Color

Orange/Red 1

Orange 2

Black 3

Orange/Violet 4

Red/Green 5

Black/Green

(Double Lugged)

– AMP

7910

12-Place

Multilock

Socket

12 4

4-Place

Multilock

b. Snap switch bracket into molded retainer in instru-

ment nacelle.

c. While carefully placing left side of instrument

nacelle on motorcycle, slide odometer reset switch through hole and install rubber boot.

d. See Figure 8-78. Connect left side switch to instru-

ment nacelle switch harness as follows: Speaker Switch connector [105], 4-place Multilock.

●

e. Using a T40 TORX drive head, install two bolts (with

ﬂat washers) to fasten left side instrument nacelle to fork side. Alternately tighten bolts to 15-20 ft-lbs (20-27 Nm).

f. Capture clutch cable in cable clip. Insert cable clip

into hole in left side of instrument nacelle.

g. Move to RIGHT SIDE SWITCHES, step 2.

RIGHT SIDE SWITCHES

a. Place

b. Push terminals through two lengths of conduit to

c. Install terminals into socket or pin housing. See

new

switch into position in bracket. Engaging tabs on switch in slots of latches, gently bend tabs upward to lock position of switch in bracket. See

Figure 8-80.

wire end of socket or pin housing. For best results, push one wire through conduit at a time.

Ta bl e 8-12 and Figure 8-81.

Secondary Locks Open

f1287b2x

Figure 8-81. Numbers Stamped on Secondary Locks

(Socket Housing Shown)

NOTE

For instructions on properly removing wire terminals, see APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-

TORS, REMOVING SOCKET/PIN TERMINALS.

h. Carefully pull wires to draw terminals through con-

duit to backside of switch. For best results, pull one wire at a time.

INSTALLATION

1. Follow instructions based on location of defective switch.

LEFT SIDE SWITCH

a. Place

new

switch into position in bracket. Engaging tabs on switch in slots of latches, gently bend tabs upward to lock position of switch in bracket.

NOTE

For instructions on properly installing wire terminals, see APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-

TORS, INSTALLING SOCKET/PIN TERMINALS.

d. Snap switch bracket into molded retainer in instru-

ment nacelle.

e. Install right side of instrument nacelle on motorcy-

cle.

f. See Figure 8-78. Connect left side switch to instru-

ment nacelle switch harness as follows: Speaker Switch connector [105], 4-place Multilock.

●

g. See Figure 8-78. Connect instrument nacelle

switches to interconnect harness as follows:

●

Instrument nacelle switch connector [105], 12-place Multilock.

h. Using a T40 TORX drive head, install two bolts (with

ﬂat washers) to fasten right side instrument nacelle to fork side. Tighten bolts to 15-20 ft-lbs (20-27 Nm).

i. Capture throttle cables in cable clip. Insert cable clip

into hole in right side of instrument nacelle.

2. Assemble domestic ignition switch as follows:

2004 Touring: Electrical 8-61

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f2214x8x

Throttle

Cable Clip

Speaker

Switch [105D]

4-Place Multilock

LEFT SIDE

CONNECTOR

NUMBER

[105A, 105B] Interconnect to Nacelle Switch Harness

[105]

[105C, 105D] Nacelle Switch Harness to Speaker Switch

DESCRIPTION

[A, C] = Pin [B, D] = Socket

RIGHT SIDE

Clutch

Cable Clip

Instrument Nacelle

Switches [105B]

12-Place Multilock

f2213x8x

Figure 8-82. Instrument Nacelle Halves

NOTE

For assembly of HDI ignition switch, see Section 8.18 IGNI-

TION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U, FLTR (INTERNATIONAL), INSTALLATION, steps 5-10.

a. Install the switch position plate over threaded post

of ignition switch housing. Tabs on plate ﬁt in holes at top of instrument nacelle.

b. Slide spacer over threaded post of ignition switch

housing until it contacts switch position plate. Slide collar over post with the tab side down (and forward). Install nut, and using a 7/8 inch wrench on ﬂats, tighten to 50-70

in-lbs

(5.7-7.9 Nm). See

lower frame of Figure 8-79.

Speaker

Switch [105C]

4-Place Multilock

c. With the red arrow pointing toward the ACCESS

position, install the ignition switch knob. Turn key clockwise to UNLOCK position and then turn knob to OFF.

3. See Figure 8-78. Looking into the instrument nacelle, connect instruments and indicator lamps to interconnect harness as follows:

●

Speedometer connector [39], 12-place Packard. Ta chometer connector [108], 12-place Packard.

●

Indicator lamps connector [21], 10-place Multilock.

4. Install anchor on ambient temperature sensor into hole in bottom inboard ear of speedometer bracket.

8-62 2004 Touring: Electrical

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5. Verify that left and right sides of instrument nacelle are properly mated. Pins on left side of nacelle must fully engage holes on right.

6. Insert tab at rear of bezel into slot of instrument nacelle (just in front of ignition switch). Holding left and right sides of nacelle together, place bezel over instrument nacelle ﬂange. When properly mated, tabs at front of instrument nacelle engage lip in slot at front of bezel (behind decorative adhesive strip).

NOTE

If tabs do not properly engage slot at front of bezel, then a loose ﬁt will result. Remove decorative adhesive strip by gently prying up outer edges, and using a ﬂat bladed screwdriver, carefully raise tabs so that they engage lip in slot. If damaged, install

new

decorative adhesive strip.

7. Using a T25 TORX drive head, install screw on each

side of bezel. Tighten screws to 25-35

in-lbs

(2.8-4.0

Nm).

2004 Touring: Electrical 8-63

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