Harley Davidson 2004 Touring Models. Service Manual - page 60
HOME
14. Obtain the remaining mounting block (with 2 holes), two
long Phillips and two flat washers from kit.
Front
15. See Figure 8-38. Install flat washers to Phillips screws
Air Tank
Mounting
and position screws above two holes near front center of
Mounting
Block
Tour-Pak above front mounting block position.
Bracket
16. Position block (with holes running vertical) between Tour-
Pak and air tank mounting bracket. Install screws
through Tour-Pak and mounting block and thread into air
tank mounting bracket. Tighten screws to 22 in-lbs (2.5
Nm).
17. Return to mounting hardware installed in Steps
9
through 15 and alternately tighten to 60-84 in-lbs (6.8-
9.5 Nm).
i03737
18. See Figure 8-39. Reposition power supply onto mounting
plate and reinstall the three nuts removed in step 3 to
provide access for mounting Tour-Pak. Obtain two more
Figure 8-38. Install Tour-Pak Front Mounting Block
nuts from kit and install to remaining mounting plate
studs. Tighten nuts to 80 in-lbs (9.0 Nm).
i03738
Nut
19. Reconnect the strobe head (male to female) connectors
disconnected in step 4.
NOTE
Nut
When performing the next few steps, install battery mounting
bracket, battery strap and battery only. Do NOT connect bat-
Nut
tery terminals at this time.
20. See Figure 8-40. Loosely assemble battery mounting
bracket with bolt, washers and nut obtained from kit.
21. Orient and position battery behind mounting bracket as
shown. Loosely install battery strap using two bolts, four
Strobe
washers and two nuts from kit.
Connectors
22. Make sure battery is centered and mounting bracket is
Nut
positioned properly. While pushing mounting bracket for-
ward, tighten bracket hardware to 120-144 in-lbs (13.6-
Figure 8-39. Install Power Supply Mounting Plate and
16.3 Nm). Return to battery strap hardware and tighten
Reconnect Strobe Heads
to 120-144 in-lbs (13.6-16.3 Nm).
Battery
i03739
Battery
Strap
Mounting
Bracket
Nut
Nut
Washer
Washer
Figure 8-40. Install Battery Mounting Bracket and Battery
8-26
2004 FLT Police: Electrical
HOME
23. See Figure 8-41. Locate positive and negative battery
cables in Tour-Pak. Make sure cables are not touching
each other or anything metal in the Tour-Pak.
Negative
24. See Figure 8-42. Route control harness (from Tour-Pak)
Cable
Positive
along left upper frame tube to PNA accessory connector
Cable
in space immediately in front of motorcycle battery.
25. Connect control harness to PNA accessory connector.
26. Locate the two-pin connector originally routed to pole
lamp and connect to the two-pin connecter coming from
Tour-Pak.
NOTE
Prior to installing positive battery terminal to battery post,
locate insulated end of positive battery cable (directly after
maxi-fuse) and bend a 90 degree radius into the cable as
i03739
shown. This will keep the terminal from kinking when install-
ing terminal to battery post.
Figure 8-41. Positive and Negative
Tour-Pak Battery Cables
1WARNING
Always connect the positive battery cable first. If the pos-
2-Pin
itive cable should contact ground with the negative cable
Connector
PNA
installed, the resulting sparks may cause a battery explo-
Accessory
sion which could result in death or serious injury.
Connector
(00068a)
27. See Figure 8-43. Route the positive battery cable with
Maxi-fuse as shown and loosely install positive battery
terminal over existing terminal to battery positive post.
Tuck the Maxi-Fuse along with the pole lamp harness
down into the space between the battery and the left
upper frame tube as shown. Tighten terminal to 30 in-lbs
(3.4 Nm).
28. Route the negative battery cable around the front of the
Control
battery and install terminal over existing terminal to neg-
Harness
i03741
ative battery post. Tighten terminal to 30 in-lbs (3.4 Nm).
Figure 8-42. Install Tour-Pak Harness and
2-Pin Connectors
i03742
Maxi-Fuse
Positive Cable
Radius to Prevent
Terminal Kinking
Pole Lamp
Harness
Connector
Figure 8-43. Install Tour-Pak Battery Cables
to Motorcycle
2004 FLT Police: Electrical
8-27
HOME
29. See Figure 8-44. Install cable strap to secure Tour-Pak
Harness to mounting rail.
i03743
30. See Figure 8-45. Reinstall trim panel to fender using nuts
and washers saved from step 7.
31. Reinstall trim panel cover to protect battery and wiring.
32. Pivot seat downward and lower until it engages seat pin
completely. Install quick release seat pin clip to fully
secure seat.
1WARNING
Cable
After installing seat, pull upward on front of seat to be
Tour-Pak
Strap
sure it is locked in position. If seat is loose, it could shift
Harness
position during vehicle operation and startle the rider,
causing loss of control and death or serious injury.
(00070a)
Figure 8-44. Secure Tour-Pak Harness to Mounting Rail
1WARNING
Always connect the positive battery cable first. If the pos-
Trim Panel
itive cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion which could result in death or serious injury.
(00068a)
33. See Figure 8-46. Return to Tour-Pak and locate positive
and negative battery cables. Route positive battery ter-
minal to battery and install terminal to battery post.
Tighten terminal to 30 in-lbs (3.4 Nm).
34. Route negative battery terminal to negative battery post
and install terminal. Tighten terminal to 30 in-lbs (3.4
Nm).
35. Close Tour-Pak and test strobe lights for proper opera-
i03744
tion.
Figure 8-45. Reinstall Trim Panel
Positive Post
Negative Post
and Terminal
and Terminal
i03740
Figure 8-46. Install Tour-Pak Battery Terminals
8-28
2004 FLT Police: Electrical
HOME
ELECTRICAL CONNECTOR LOCATIONS
8.14
Table 8-7. FLHTP Wire Harness Connectors
No.
Description
Type
Location
Fig.
Left Handlebar Controls-
[24]
12 - Place Deutsch (Gray)
Inner Fairing - Left Fairing Support Brace
8-47
Air Horn Option
[57]
Siren/PA Speaker
2 - Place Deutsch
Top Rail of Engine Guard (Right Side)
-
[59]
Rear Pole Lamp
2 - Place Deutsch
Under Luggage Rack (Left Side)
-
[69]
Pursuit Flasher
Relay Connector
Inner Fairing - Inboard of Left Fairing Bracket
8-47
[70]
Siren Amplifier Harness
12 -Place Deutsch
Inner Fairing - Left Fairing Support Brace
8-47
[72]
Siren Amplifier
18 - Place Packard
Top Rail of Saddlebag Guard (Left Side)
-
[73]
Pursuit Lamps
2 - Place Multilock (White)
Inner Fairing - Next to Top Fork Bracket
8-47
[108]
Tachometer
6 - Place Packard
Inner Fairing - Back of Tachometer
8-47
1. Tachometer [108]
2. Left Handlebar Controls [24]
3. Siren Amplifier Harness [70]
4. Pursuit Flasher [69]
5. Pursuit Lamps [73] (White)
3
2
1
4
p0058x8x
5
Figure 8-47. Inner Fairing (FLHTP)
2004 FLT Police: Electrical
8-29
HOME
Table 8-8. FLHP Wire Harness Connectors
No.
Description
Type
Location
Fig.
Left Handlebar Controls
[24]
12 - Place Deutsch (Gray)
Inside Headlamp Nacelle
8-48
Air Horn Option
[57]
Siren/PA Speaker
2 - Place Deutsch
Top Rail of Engine Guard (Right Side)
-
[59]
Rear Pole Lamp
2 - Place Deutsch
Under Luggage Rack (Left Side)
-
[69]
Pursuit Flasher
Relay Connector
Under Left Side Cover
-
[72]
Siren Amplifier
18 - Place Packard
Top Rail of Saddlebag Guard (Left Side)
-
[73]
Pursuit Lamps
2 - Place Multilock (White)
Inside Headlamp Nacelle
8-48
[108]
Tachometer
3 - Place Deutsch
Inside Headlamp Nacelle
8-48
p0118x8x
Left Handlebar Controls [24] (Gray)
Air Horn Option
Pursuit Lamps [73]
Tachometer [108]
Figure 8-48. Headlamp Nacelle (FLHP)
8-30
2004 FLT Police: Electrical
HOME
WIRING DIAGRAMS
8.15
SUBJECT
PAGE NO.
FLHTP
Main Harness
8-33
Interconnect Harness
8-34
Electronic Fuel Injection (EFI) Harness
8-35
Ignition Switch
8-36
Tail Lamp, Pursuit Lamps, Directional Lamps and Fender Tip Lamps
8-36
Starting and Charging
8-37
Handlebar Controls, Speedometer, Tachometer and Indicator Lamps
8-38
Siren Amplifier and Strobe Harness
8-39
Optional Strobe System
8-44
FLHP, FLHPE
Main Harness
8-40
Electronic Fuel Injection (EFI) Harness
8-41
Starting and Charging
8-42
Handlebar Controls, Indicator Lamps, Tail Lamp, Pursuit Lamps,
Directional Lamps, Accessory/Spot Switch, Speedometer and Tachometer
8-43
Siren Amplifier and Strobe Harness
8-39
Optional Strobe System
8-44
NOTE
Harness Part No.’s may be included on some wiring diagrams. Use these numbers for
reference only. ALWAYS REFER TO THE 2004 FLT POLICE MODELS PARTS CATALOG
(Part No. 99545-04) WHEN ORDERING WIRING HARNESSES.
2004 FLT Police: Electrical
8-31
HOME
NOTES
8-32
2004 FLT Police: Electrical
HOME
TSM/TSSM
EFI
40A
BATTERY
1
BN/GY
OPTIONAL
MAXI-FUSE
IGNITION
2
GY
TO
VSS/SERIAL DATA LINK
3
LGN/V
SECURITY
IGNITION
KEYSWITCH IGN RELAY
SECURITY INDICATOR
4
BN/V
FUEL
SIREN
SWITCH
LEFT TURN FEED
5
V
PUMP
[33B]
RIGHT TURN FEED
6
BN
VOLTAGE
B+
RIGHT TURN SW INPUT
7
W/BN
REGULATOR
CONNECTOR
A B C D
[126A]
LEFT TURN SW INPUT
8
W/V
FUEL PUMP
[141A]
START RELAY CONTROL
9
TN/GN
ASSEMBLY
[142A]
[5B]
A B
[33A]
IGNITION ENABLE
10
IN TANK
1
2
3
85863087A
ALARM SIGNAL
11
LGN/BN
GROUND
12
BK
AT TOP OF TANK
1
2
3
A B C
[77A]
[160B]
[126B]
[141B]
MAIN POWER
[30A]
[30B]
TURN SIGNAL/
[142B]
AT STARTER
(GY)
TURN SIGNAL SECURITY
70369-02
MODULE
[13B]
FUEL TANK
HARNESS
1
2
3
12
BK
11
LGN/V
1
2
3
10
O/GY
TO
9
R
[13A]
IGNITION/EFI
8
BK
7
R
HARNESS
6
GY
[8A]
5
W/GN
(GY)
4
[64B]
3
BE/O
2
W/BK
1
BN/GY
O/V
4E
3
RH GND
R/Y
3F
5
[8B]
BK/GN
STUD
BK
BRAKE
R/BE
3E
2
RELAY
- FRAME GROUND -
BK
4F
1
12
GN/R
11
BK
LH GND
BK
W/V
10
STUD
1B
INSTRUMENTS - 15A
1A
W/BN
TO
9
O
R/BK
O/BE
INTERCONNECT
8
BN
1D
LIGHTS - 15A
1C
HARNESS
7
V
BE
6
W/BK
1H
HEADLAMP - 15A
1G
[1A]
5
O/W
BE
R/BK
(BK)
4
O/R
1F
IGNITION - 15A
1E
START RELAY
3
GY
GY
2
O/V
4D
P&A IGN - 2A MAX
4C
1
O
R/BK
[123A]
2B
BRAKE/PURSUIT - 15A
2A
[1B]
O/V
R/GY
85863087A
2D
ACCESSORIES - 15A
2C
O/W
12
BK
[123B]
2F
P&A - 15A
2E
11
W/GN
O/R
10
TN
TO
3B
RADIO MEM - 15A
3A
9
GN/Y
INTERCONNECT
R/O
R
8
BN/GN
3D
BATTERY - 15A
3C
HARNESS
7
O
BN/GY
[2A]
6
Y/BK
(GY)
5
Y/W
SIREN - 10A
4B
4A
4
BN/GY
O/BE
O/GN
3
BE
2
BK/R
1
R/BE
[2B]
[128B]
TO
D
BK
INTERCONNECT
C
BK/GN
START
HARNESS
B
BE
[15A]
A
R/O
SOLENOID
[15B]
CRANK POSITION
SENSOR
BK
4
O
3
ACCESSORY
R/Y
2
CONNECTOR
O/R
1
(BK)
BK
2
2
[12B]
[4A]
R
1
1
BK
32 1
(BK - LOCATED UNDER SEAT)
[79A]
[79B]
NEUTRAL
SWITCH
TOUR-PAK
[12A]
BN/GN
GN/Y
[131]
[17B]
THROTTLE
ROLL-OFF
[75C]
HORN
[139B]
SWITCH
D C B A
[7A]
REAR
[17A]
OIL
[75A]
[156A]
1 2 3 4 5 6 7 8
PRESSURE
[75D]
STOPLIGHT
SENDER
SWITCH
TO REAR
O/V
6 5
4
3
2 1
[139A]
[122 ]
[121]
LIGHTING
Y/V
TO INTERCONNECT
[7B]
[75B]
[156B]
(GY)
f2227o8x
CRUISE CONTROL MODULE
2004 FLHTP, DOMESTIC and INTERNATIONAL Models,
Main Harness
8-33
HOME
PURSUIT
FLASHER
TO MAIN HARNESS
TO MAIN HARNESS
VOLTMETER
[2B]
FUEL
[1B]
[116A] [116B]
[110A] [110B]
P L X
1211109 8
7 6 5 4
3
2
1
[2A]
1211109 8
7 6 5 4
3 2 1
[1A]
(GY)
(BK)
1
2
1
2
+
S
+
S
(BK)
[117A]
[111A]
1
3
1
3
[22A]
2
2
1
O/W
2
[117B]
[111B]
R/BE
3
G/Y
4
W/BK
5
W/BN
TO
6
BK/R
RIGHT-HAND
7
O/V
CONTROLS
8
GY/BK
9
GN/R
[22B]
10
11
12
(GY)
(BK)
[24A]
[70A]
1
O/W
O/PK
1
2
Y
TN/BK
2
3
BE
PK/BK
3
4
W
Y/PK
4
TO
TO
5
W/V
5
SIREN
LEFT-HAND
6
Y/BK
GN/R
6
7
AMPLIFER
CONTROLS
BK/R
7
8
BK/R
8
HARNESS
[24B]
9
PK/BK
9
[70B]
10
TN/BK
10
11
Y/PK
BK
11
12
BK
12
[21A]
(BK)
1
BN
2
GN/Y
A
3
W
BE
B
TO MAIN
TO
4
V
C
HARNESS
INDICATOR
5
BK
BK
D
[15B]
LAMPS
6
O
[21B]
7
TN
[15A]
8
O
(BK)
9
BK
10
BK
O/W
BK
[38]
CIGAR LIGHTER
LO-BEAM
[132B]
Y
(BK)
(GY)
(BK)
HI-BEAM
[39B]
[108B]
[31A]
W
[73A]
[156B]
1 2 3 4 5 6
[32A]
BK
1
2
1 2
1 2 3
4
1
2
3
4
5
6
7
8
9 10 1112
1
2
3
4
5
6
7
8
9 10 11 12
GND
FRONT
TURN SIGNALS
PURSUIT
FENDER
MAIN
LAMPS
TIP LIGHT
HARNESS
(WE)
(BK)
(GY)
HEADLAMP
RPM x 100
TRIP
RESET
SWITCH
[154A]
f2227c8x
TACHOMETER
SPEEDOMETER
2004 FLHTP, DOMESTIC and INTERNATIONAL Models,
Interconnect Harness
8-34
HOME
C B A
IGNITION
COIL
[83A]
(CARB)
ABCD
[83A]
FRONT SPARK
IGNITION
REAR SPARK PLUG
COIL
PLUG
(EFI)
+5V DC
R/W
A
A
R
W/GN
B
B
W
BK
C
C
BK
OUTPUT
[65B]
SENSOR
(BK)
[65A]
GROUND
VEHICLE
SPEED SENSOR
REAR
FRONT
INTAKE
FUEL INJECTED
ENGINE
AIR
INJECTOR
INJECTOR
IDLE AIR
TEMP.
TEMP.
VEHICLES
CONTROL ACTUATOR
SENSOR
SENSOR
THROTTLE
MAP
BK
12
POSITION
LGN/V
11
EFI OVERLAY: 70233-04
SENSOR
SENSOR
O/GY
10
R
9
FROM
DATA
IGNITION
BK
8
MAIN
LINK
R
7
COIL
GY
6
HARNESS
(GY)
1
2
3
4
AB
AB
ABCD
W/GN
5
[8B]
[91A]
4
ELECTRONIC
DCB A
PK
3
(GY)
[83B]
AB
AB
CB A
CBA
[87B]
CONTROL
[90B]
[89B]
W/BK
2
MODULE
[85B]
1
[84B]
[88B]
[80B]
[78A]
[78B]
[8A]
ALDL & FLASH PIN
LGN/R
CHECK ENG LP
TACH OUTPUT
PK
SYSTEM RELAY
GN/O
SERIAL DATA LINK
LGN/V
ENGINE TEMPERATURE
PK/Y
INTAKE AIR TEMPERATURE
LGN/Y
OXYGEN SENSOR A
ANALOG INPUT
POWER GROUND
BK
COIL REAR
Y/BE
[119B]
CRANK POS. SENSOR (-)
BK+
SWITCH POWER
W/BK
FUEL PUMP 15A
5V SENSOR POWER
R/W
G
H
DIGITAL GROUND
O/GY
Y/GN
FREQUENCY INPUT
IDLE AIR CNTL MOTOR
BK/O
ECM POWER 15A
IDLE AIR CNTL MOTOR
BK/PK
A
B
INJECTOR REAR
GN/GY
BE/GY
R
OUTPUT (unused)
INJECTOR FRONT
W/Y
SYSTEM RELAY
(BK)
OUTPUT (UNUSED)
OXYGEN SENSOR B
Y/GN
K
5
THROTTLE POS SNSR INPUT
GY/V
T
4
MAP SENSOR INPUT
V/W
BE/GY
E
3
5V SENSOR GROUND
BK/W
GN/O
S
2
ION SENSE
GY/BE
W/BK
U
1
POWER GROUND
BK
COIL FRONT
BE/O
CRANK POS. SNSR (+)
R
CONSTANT POWER
BE/GY
SWITCH INPUT (unused)
VEHICLE SPEED INPUT
W/GN
DIGITAL POWER
IDLE AIR CNTL MOTOR
BE/GN
IDLE AIR CNTL MOTOR
BN/R
f2227b8x
2004 FLHTP, DOMESTIC and INTERNATIONAL Models,
Electronic Fuel Injection (EFI) Harness
8-35
HOME
1 2
3 456 78
FROM MAIN
HARNESS [7A]
REAR LIGHTING
[7B]
RIGHT PURSUIT
LAMP (BLUE)
RIGHT REAR
POLICE ONLY
FROM
FROM
DIRECTIONAL
INTERCONNECT
INTERCONNECT
68772-99
LAMP
HARNESS [73A]
HARNESS [32A]
RIGHT
PASSING
2 1
2 1
LAMP
[73B]
[32B]
BK
TAILLAMP
R/Y
O/W
BEW
[94B] BRAKE LIGHT
654 3
2
1
654 3
2
1
FENDER TIP LAMP
[143B]
[143A]
[19b]
(DOM ONLY)
[94A]
[19a]
O/W
1
1
V/BN
1
1
BK
2
2
BK
2
2
RUNNING LIGHT (DOM)
LICENSE
[18a]
[18B]
PLATE LAMP
RUNNING LIGHT (HDI)
(HDI ONLY)
V/BN
1
1
BK
2
2
4
4
1
1
3
3
BK
2
2
2
LEFT
2
FENDER TIP LAMP
3
3
1
BK
PASSING
1
(DOMESTIC ONLY)
LAMP
[93B]
[45B]
[45A]
[93A]
LEFT PURSUIT
LAMP (RED)
LEFT REAR
POLICE ONLY
DIRECTION
LAMP
IGNITION SWITCH LEGEND (HDI)
"X" INDICATES CONTINUITY
FROM
BETWEEN LEAD WIRES
SWITCH
IN POSITION INDICATED
INTERCONNECT
POSITION
RED/
RED/
RED
HARNESS [31A]
GRAY
BLACK
LOCK
X
6 5 4 3 2 1
OFF
X
IGN
X
X
X
[31B]
ACC
X
X
RIGHT
R/GY
1
1
R/GY
BK
[33B - HDI]
DIRECTIONAL
R
2
2
R
BE
R/BK
3
3
AND DOM
R/BK
BN
RUNNING LAMP
IGNITION
A
FROM MAIN
SWITCH,HDI
B
HARNESS [33A]
C
D
BLUE WIRES (RUNNING) ARE ONLY
AVAILABLE ON DOMESTIC MODELS
IGNITION SWITCH LEGEND (DOM)
"X" INDICATES CONTINUITY
BETWEEN LEAD WIRES
SWITCH
IN POSITION INDICATED
LEFT
POSITION
RED/
RED/
BK
[ 33B-DOM]
RED
DIRECTIONAL
GRAY
BLACK
BE
LOCK
X
AND DOM
V
OFF
X
RUNNING LAMP
A
R
FROM MAIN
IGN
X
X
X
B
R/GY
ACC
X
X
HARNESS [33A]
C
R/BK
D
IGNITION
f2227a8x
SWITCH,DOM
2004 FLHTP, DOMESTIC and INTERNATIONAL Models,
Ignition Switch, Tail Lamp, Pursuit Lamps, Directional Lamps and Fender Tip Lamps
8-36
HOME
STATOR
[46A]
[46B]
+
BK
A
DC
A
BK
-
AC
TSM/TSSM
BK
B
B
BK
BATTERY
1
BN/GY
IGNITION
2
GY
VSS/SERIAL DATA LINK
3
LGN/V
SECURITY INDICATOR
4
LEFT TURN FEED
5
RIGHT TURN FEED
6
40 A
RIGHT TURN SW INPUT
7
MAXI-FUSE
LEFT TURN SW INPUT
8
START RELAY CONTROL
9
TN/GN
IGNITION ENABLE
10
ALARM SIGNAL
11
GROUND
12
BK
B A
[30A]
[30B]
TURN SIGNAL/
TURN SIGNAL SECURITY
[77B]
[77A]
MODULE
BK
R
R
[8A]
1
2
3
BK
BK
4
5
6
7
8
9
10
11
LGN/V
12
POWERTRAIN
STARTER
BATTERY
BATTERY
GROUNDS
BK
BK
CHARGING SYSTEM
40 A
FLHTP
MAXI-FUSE
RIGHT HAND
STARTER
R
CONTROLS,
[22R]
[128A]
[128B]
ENGINE OFF/
R
IGNITION SWITCH LEGEND (HDI)
RUN SWITCH
"X" INDICATES CONTINUITY
STARTER SWITCH
GN
B A
SWITCH
BETWEEN LEAD WIRES
POSITION
IN POSITION INDICATED
RED
RED/
RED/
GRAY
BLACK
BK
LOCK
X
OFF
X
IGN
X
X
X
ACC
X
X
TO
TO
MAIN
INTERCONNECT
[22A]
HARNESS
[22B]
HARNESS
[1A]
[33D] [33C]
(BLACK)
1
1
[1B]
(BLACK)
[33B]
2
2
RIGHT
LEFT
GY
3
3
GY
12
W/BK
4
4
11
12
GND2
GND1
BK
R/BK
86
1
5
5
10
11
BK
85
A
R
2
BK/R
6
6
BK/R
10
R
30
B
R/GY
3
7
7
9
9
87A
C
R/BK
8
8
8
8
[64]
7
7
87
D
IGNITION
9
9
JUMPER HARNESS
6
6
[126B]
[126A]
SWITCH, HDI
10
10
TO LEFT-HAND
5
5
3D
BATTERY
3C
TO INTERCONNECT
11
11
CONTROL [22B]
4
4
BN/GY
R
FROM MAIN
12
12
GY
3
3
GY
HARNESS [33A]
HARNESS
KEY SWITCH IGN RELAY
2
2
1
1
[24B]
[33A]
[24A]
[1A]
[1B]
(BK)
(GRAY)
1
1
A
2
2
IGNITION
R
TO
3
3
12
12
1F
1E
R/GY
B
IGNITION
4
4
11
11
GY
R/BK
R/BK
C
SWITCH
[33B]
5
5
10
10
D
[33B]
6
6
9
9
BK/R
7
7
BK/R
8
8
BK/R
8
8
BK/R
7
7
START RELAY
A
R
9
9
6
6
B
R/GY
10
10
5
5
FROM MAIN
C
R/BK
11
11
4
TN/GN
85
D
4
86
HARNESS [33A]
12
12
3
3
BK/R
IGNITION
TO RIGHT-HAND
BK/R
2
2
R/GY
30
CLUTCH
BK/R
87A
SWITCH, DOM
LOCKOUT SWITCH
CONTROL [24B]
1
1
(GY)
GN
87
[2A] (GRAY)
IGNITION SWITCH LEGEND (DOM)
[2B]
"X" INDICATES CONTINUITY
TO
SWITCH
IN POSITION INDICATED
BETWEEN LEAD WIRES
TO
[123B]
[123A]
POSITION
MAIN
INTERCONNECT
RED
RED/
RED/
GRAY
BLACK
HARNESS
HARNESS
LOCK
X
[2B]
[2A]
OFF
X
IGN
X
X
X
FLHTP
ACC
X
X
LEFT HAND
FUSE BLOCK COVER
CONTROLS,
[24L]
10A
15A
P&A
IGN
SIREN
10A
BRAKE
BRAKE
15A
RELAY
RELAY
15A
15A
BATTERY
RADIO MEM
15A
15A
15A
SPARE FUSES
P&A
ACCESS. BRK/PURSUIT
15A
15A
15A
15A
HEADLAMPS IGN
LIGHTS
INSTRUMENTS
f2227d8x
[64]
FUSE BLOCK
2004 FLHTP, DOMESTIC and INTERNATIONAL Models,
Starting and Charging
8-37
HOME
HAND CONTROLS,
RIGHT
CONNECT TO MAIN HARNESS
[ 22R ]
OFF/AUX
PURSUIT SWITCH
[39B]
RIGHT DIRECTIONAL
(BK)
[108B]
SWITCH
1
2 3 4 5 6 7 8 9101112
(GY)
ENGINE OFF/
1
2
3 4 5 6 7 8 910 1112
RUN SWITCH
STARTER SWITCH
STOPLAMP SWITCH
(BLACK)
[22B]
O/W
1
R/BE
2
GY
3
RPM x 100
W/BK
4
W/BN
5
FROM
BK/R
6
MAIN
ODOMETER
O/V
7
HARNESS
RESET
GY/BK
8
[22A]
SWITCH
GN/R
9
[154A]
10
11
MOVE Y/BK WIRE TO CAVITY
12
SPEEDOMETER
11 IF USING WHELEN SIREN
TACHOMETER
AMPLIFIER
& 'AIR HORN'
FUNCTION IS DESIRED
[24B]
(GRAY)
O/W
1
Y
2
LEFT
HIGH
RIGHT
BE
3
LOW
TURN
BEAM
NEUTRAL
W
4
FROM
OIL
TURN
W/V
5
MAIN
Y/BK
6
HARNESS
BK/R
7
[24A]
BK/R
8
BK
V
HB
BK TN
+
GN/Y
+
RT
BK
PK/BK
9
TN/BK
10
-
LT
W
O
OP
O
BN
Y/BK
11
- N
-
12
CLUTCH
LOCKOUT SWITCH
SIREN OFF/RUN
SWITCH
HEADLAMP HI/LO
SWITCH
[21B]
LEFT
DIRECTIONAL
SWITCH
HORN/SIREN
1 2 3 4 5 6 7 8 9 10
SWITCH
HAND CONTROLS,
TO INTERCONNECT
LEFT
HARNESS
[ 24L]
[21A]
f2227e8x
2004 FLHTP, DOMESTIC and INTERNATIONAL Models,
Handlebar Controls, Speedometer, Tachometer and Indicator Lamps
8-38
HOME
f2227f8x
[72B]
[72A]
[72B]
1B
GY/R
3C
GY/R
3A
2A
2B
R/PK
2D
MICROPHONE
2C
W/PK
1E
JACK
2E
BE/PK
3F
R/PK
3B
3D
W/PK
SIREN
3E
AMPLIFIER
BE/PK
[72A]
[68]
2F1F1D1A1C
[72B]
FLHTP-FRG
SIREN AMPLIFIER HARNESS
12
BK
P/N 70177-97
11
BK
10
9
8
TO
7
INTERCONNECT
6
GN/R
HARNESS
5
[70A]
4
Y/PK
3
PK/BK
2
TN/BK
1
O/PK
[70B]
REF: SIREN WIRES
ARE NOT POLARITY
SENSITIVE
[57A]
[57B]
SIREN/PA
1
1
GY/R
GN/R
2
TO OPTIONAL
SPEAKER
2
2
GY/R
BK
1
POLE LAMP
[59B]
BK
BK
PIN CONNECTOR
W/GN
W/GN
(A side)
TO OPTIONAL
W
W
DEALER INSTALLED
TO OPTIONAL
R
SOCKET CONNECTOR
R
STROBE POWER
DEALER INSTALLED
(B side)
GN
GN
SUPPLY
STROBE LIGHTS
O
O
Wire Color Code Key
FLHTP-FRG STROBE HARNESS
BK - Black
GN - Green
LT.GN - Light Green
P/N 70175-94
BN - Brown
BE - Blue
PK - Pink
R - Red
V - Violet
TN - Tan
O - Orange
GY - Gray
Wire color-XX/XX-Stripe color
Y - Yellow
W - White
2004 FLHTP, DOMESTIC and INTERNATIONAL Models,
Siren Amplifier and Strobe Harness
8-39
HOME
OPTIONAL
SECURITY
f2227h8x
TACH ASSEMBLY
POLE LAMP
IGNITION SWITCH LEGEND
SIREN
FUNCTION/
HEADLAMP
TRIPOMETER
1
2
3
4
5
6
1
2
R/GY
R/BK
R
TO FENDER
POSITION
RESET
ACCESS.
IGN.
BATT.
POWER
A
BN/GY
[39B]
IGNITION
TIP LAMP
[38B]
SWITCH
SPEEDOMETER
[108A]
ACCESSORY
SIGNAL
B
LGN/BN
(BK)
HARNESS
1
2
[59B]
FUEL GAUGE FUEL
C
(BK)
(BK)
SENDER
LOCK
GROUND
1 2 3 4 5 6 7 8 9101112
1 2 3 4
1
2
3
45
6
7
8
9 101112
3
2
1
IGNITION
[142A]
[142B]
(BK)
(BK)
[8B]
[32A]
[117B]
POWER
(GY)
[141B]
IGNITION SWITCH
RELAY
[57B]
[72B]
[72B]
(BK)
[33A]
SIREN/
1B
1
GY/R
3C
[126A]
P&A
2
GY/R
3A
[72A]
2A
2B
SPEAKER
2D
87a 87 86 85 30
1E
2C
3F
2E
[33B]
3B
SIREN
3D
[64B]
[126B]
AMPLIFIER
3E
R/Y
3F
5
O/V
4E
3
BRAKE
2F1F1D 1A1C
BK
4F
1
RELAY
MICROPHONE
[72B]
R/BE
3E
2
JACK
1B INSTRUMENTS 15A
1A
O
R/BK
[68B]
1D
LIGHTS 15A
1C
BE
1H
HEADLAMP 15A
1G
40A
PURSUIT
2
BE
MAXIFUSE
1
LAMPS
1F
IGNITION 15A
1E
[73A]
GY
R/BK
4D
P&A IGN 2A MAX
4C
(WE)
BK
BK
R/BK
LH
RH
2B
BRAKE/PURSUIT 15A
2A
[69A]
[69B]
GND
GND
O/V
FRAME GROUND
X
GY/BK
STUD
STUD
ACCESSORY 15A
[5B]
B A
PURSUIT
2D
2C
L
O/W
FLASHER
P
BK
BK
2F
P&A 15A
2E
O/R
R/GY
BATTERY
15A
3C
[24A]
3D
BN/GY
R
12
SIREN
10A
11
Y/PK
4B
4A
O/PK
R/GY
10
TN/BK
TO LEFT
9
PK/BK
HAND
8
BK/R
7
BK/R
R/GY
2J
5
CONTROLS
6
Y/BK
GN
3H
3
START
[77A]
(GRAY)
5
W/V
[160B]
[24B]
4
W
TN/GN
3J
1
RELAY
3
BE
BK/R
2H
2
2
Y
B+
REGULATOR
MAIN POWER
1
O/W
CONNECTOR
AT STARTER
(10A MAX)
[22A]
12
11
[SEE CHARGING
10
SYSTEM FOR
TO RIGHT
9
GN/R
FURTHER
8
GY/BK
DETAILS]
HAND
7
O/V
CONTROLS
6
BK/R
[22B]
5
W/BN
(BLACK)
4
W/BK
3
GY
CRANK POSITION
2
R/BE
SENSOR
1
O/W
[30A]
[30B]
(GY)
[121]
TSM/TSSM
BATTERY
1
BN/GY
[131]
BK+
2
2
BK+
IGNITION
2
GY
R+
1
1
R+
VSS / SERIAL DATA LINK
3
LGN/V
(BK)
SECURITY INDICATOR
4
BN/V
[79B]
[79A]
LEFT TURN FEED
5
V
[4A]
RIGHT TURN FEED
6
BN
REAR
RIGHT TURN SWITCH INPUT
7
W/BN
1 23
4
LEFT TURN SWITCH INPUT
8
W/V
STOPLIGHT
FUSE BLOCK
START RELAY CONTROL
9
TN/GN
SWITCH
NEUTRAL
IGNITION ENABLE SIGNAL
10
SWITCH
LGN/BN
10A
ALARM SIGNAL
11
GROUND
12
BK
GN/Y
[67A]
15A
P & A IGN
[128B]
SIREN
10A
15A
BRAKE
BRAKE
HORN
1 234
RELAY
RELAY
15A
[21A]
BATTERY
STARTER
START
[31A]
(BK)
ACCESSORY
START
[120B]
SOLENOID
SPARE FUSES
RELAY
RELAY
15A
15A
15A
1
BK
(BK)
SWITCH
P&A
ACCESS
BRAKE/PURSUIT
TO FRONT
2
BN
1
2
3
4
5
6
7 8
P&A
8
7
6
5
4
3
2
1
[7A]
15A
15A
15A
15A
TURN
3
BE
ACCESSORY
OIL
4
BE
TO INDICATOR
REAR LIGHTS
HEADLAMPS
IGN
LIGHTS
INSTRUMENTS
SIGNALS
[122]
CONNECTOR
5
V
PRESSURE
[31B]
LAMPS
(15A MAX)
6
BK
[64]
SWITCH
(BK)
2004 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models,
Main Harness
8-40
HOME
C B A
IGNITION
COIL
[83A]
(CARB)
ABCD
[83A]
FRONT SPARK
IGNITION
REAR SPARK PLUG
COIL
PLUG
(EFI)
+5V DC
R/W
A
A
R
W/GN
B
B
W
BK
C
C
BK
OUTPUT
[65B]
SENSOR
(BK)
[65A]
GROUND
VEHICLE
SPEED SENSOR
REAR
FRONT
INTAKE
FUEL INJECTED
ENGINE
AIR
INJECTOR
INJECTOR
IDLE AIR
TEMP.
TEMP.
VEHICLES
CONTROL ACTUATOR
SENSOR
SENSOR
THROTTLE
MAP
BK
12
POSITION
LGN/V
11
EFI OVERLAY: 70233-04
SENSOR
SENSOR
O/GY
10
R
9
FROM
DATA
IGNITION
BK
8
MAIN
LINK
R
7
COIL
GY
6
HARNESS
(GY)
1
2
3
4
AB
AB
ABCD
W/GN
5
[8B]
[91A]
4
ELECTRONIC
DCB A
PK
3
(GY)
[83B]
AB
AB
CB A
CBA
[87B]
CONTROL
[90B]
[89B]
W/BK
2
MODULE
[85B]
1
[84B]
[88B]
[80B]
[78A]
[78B]
[8A]
ALDL & FLASH PIN
LGN/R
CHECK ENG LP
TACH OUTPUT
PK
SYSTEM RELAY
GN/O
SERIAL DATA LINK
LGN/V
ENGINE TEMPERATURE
PK/Y
INTAKE AIR TEMPERATURE
LGN/Y
OXYGEN SENSOR A
ANALOG INPUT
POWER GROUND
BK
COIL REAR
Y/BE
[119B]
CRANK POS. SENSOR (-)
BK+
SWITCH POWER
W/BK
FUEL PUMP 15A
5V SENSOR POWER
R/W
G
H
DIGITAL GROUND
O/GY
Y/GN
FREQUENCY INPUT
IDLE AIR CNTL MOTOR
BK/O
ECM POWER 15A
IDLE AIR CNTL MOTOR
BK/PK
A
B
INJECTOR REAR
GN/GY
BE/GY
R
OUTPUT (unused)
INJECTOR FRONT
W/Y
SYSTEM RELAY
(BK)
OUTPUT (UNUSED)
OXYGEN SENSOR B
Y/GN
K
5
THROTTLE POS SNSR INPUT
GY/V
T
4
MAP SENSOR INPUT
V/W
BE/GY
E
3
5V SENSOR GROUND
BK/W
GN/O
S
2
ION SENSE
GY/BE
W/BK
U
1
POWER GROUND
BK
COIL FRONT
BE/O
CRANK POS. SNSR (+)
R
CONSTANT POWER
BE/GY
SWITCH INPUT (unused)
VEHICLE SPEED INPUT
W/GN
DIGITAL POWER
IDLE AIR CNTL MOTOR
BE/GN
IDLE AIR CNTL MOTOR
BN/R
f2227b8x
2004 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models,
Electronic Fuel Injection (EFI) Harness
8-41
HOME
VOLTAGE
STATOR
REGULATOR
[46A]
[46B]
ELECTRONIC
ALDL & FLASH PIN
+
CONTROL
DC AC
BK
A
A
MODULE
CHECK ENG LP
BK
TACH OUTPUT
-
BK
B
B
BK
SYSTEM RELAY
SERIAL DATA LINK
LGN/V
ENGINE TEMPERATURE
INTAKE AIR TEMPERATURE
RED BAND
BATTERY
OXYGEN SENSOR A
BK
ANALOG INPUT
POWER GROUND
BK
MAXI-FUSE
COIL REAR
40 AMP
CRANK POSITION SENSOR (-)
SWITCH POWER
[119B]
5V SENSOR POWER
DIGITAL GROUND
CHARGING SYSTEM
FREQUENCY INPUT
IDLE SPEED CONTROL MOTOR
STARTER
IDLE SPEED CONTROL MOTOR
INJECTOR REAR
B A
OUTPUT (unused)
INJECTOR FRONT
[128A]
[128B]
OUTPUT (UNUSED)
ECM POWER 15A
GN
OXYGEN SENSOR B
A
B
[77B]
[77A]
THROTTLE POS. SENSOR INPUT
R
MAP SENSOR INPUT
BK
R
5V SENSOR GROUND
ION SENSE
POWER GROUND
COIL FRONT
CRANK POSITION SENSOR (+)
CONSTANT POWER
40A
BK
BK
BE/GY
SWITCH INPUT (unused)
MAXI-FUSE
VEHICLE SPEED INPUT
DIGITAL POWER
IDLE SPEED CONTROL MOTOR
IDLE SPEED CONTROL MOTOR
B A
[78A]
[78B]
BATTERY
STARTER
POWER RELAY
(LOCATED UNDER SEAT)
POWERTRAIN
TURN SIGNAL / SECURITY
GROUND
MODULE (TSM/TSSM)
[8B]
12 1110 9 8
7
6 5 4
3
2
1
12 1110 9 8
7
6
5
4
3
2
1
[126A]
HAND CONTROLS
RIGHT
[8A]
87A 87 86 85 30
[ 22R ]
[30A]
[126B]
12 11 10 9
8
7
6
5
4
3
2
1
BK
ENGINE OFF/
KEY SWITCH
IGNITION
[30B]
LH
RH
(REAR VIEW)
RUN SWITCH
GND
GND
STARTER SWITCH
STUD
STUD
CONN.
[33A]
FUSE BLOCK
BK
BK
INDEX
[22B]
[22A]
RIB
A
B
I
FRAME GROUND
10A
(BLACK)
[33B]
1
1
15A
P & A IGN
SIREN
2
2
15A
BRAKE
GY
3
3
GY
RELAY
4
4
BATTERY
5
5
START
BK/R
6
6
BK/R
SPARE FUSES
7
7
RELAY
P&A
ACCESS
BRAKE/PURSUIT
8
8
9
9
10
10
BATTERY
HEADLAMPS
IGN
LIGHTS
INSTRUMENTS
11
11
BN/GY
I
J
R
12
12
(GRAY)
[24B]
[24A]
1
1
10A
BRAKE
2
2
RELAY
3
3
15A
4
4
START
5
5
RELAY
15A
15A
6
6
15A
BK/R
7
7
BK/R
IGNITION 15A
BK/R
8
8
BK/R
GY
G
H
R/BK
15A
15A
15A
15A
9
9
10
10
11
11
12
12
[64]
CLUTCH
LOCKOUT SWITCH
Wire Color Code Key
[64]
R/GY
TN/GN
BK - Black
GN - Green
LGN - Light Green
PIN CONNECTOR
BK/R
(A side)
[62B]
BN - Brown
BE - Blue
PK - Pink
HAND CONTROLS
GN
R - Red
V - Violet
LEFT
TN - Tan
SOCKET CONNECTOR
E S U K T
O - Orange
GY - Gray
Wire color-XX/XX-Stripe color
(B side)
[24L]
30 85 86 87 87A
Y - Yellow
W - White
[62A]
f2227k8x
START
RELAY
2004 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models,
Starting and Charging
8-42
HOME
HAND CONTROLS,
TACHOMETER
[108B]
[73R]
RIGHT
IGNITION
O
[ 22R ]
DATABUS
LGN/V
NC
PURSUIT
GN/R
RIGHT
RPM x 100
BN/GY
REAR LIGHTING HARNESS
BATTERY
OFF/AUX
PURSUIT
ACCESSORY
O/W
GROUND
BK
CHASSIS GROUNDS
PURSUIT SWITCH
LAMP
NC
HANDLEBAR
TRIPLE CLAMP
FROM MAIN
RIGHT DIRECTIONAL
(BLUE)
NC
BK
HARNESS [7A]
CRUISE ACTIVE
GROUND
GROUNDS
SWITCH
NC
8 7 6 5
4
3
2 1
ENGINE OFF/
CRUISE ENABLE
P/N 70142-93
FRAME
BK
RUN SWITCH
P/N 70101-94
[7B]
GROUND
TACH. HARNESS
STARTER SWITCH
PART NO. 68912-04
STOPLAMP SWITCH
GY/BK
[20B]
(BLACK)
TURN
[22B]
1 2 3 4 5 6
[94B]
O/W
1
RIGHT
BK
BROWN TAPE
TO
R/BE
2
DIRECTIONAL
V/BN
MAIN
HARNESS
1
GY
3
BE
[31B]
AND RUNNING
2
W/BK
4
LAMP
3
FROM MAIN
4
W/BN
5
FROM
1
HARNESS
RUNNING
BK
FROM
SPEEDOMETER
5
BK/R
6
MAIN
2
[21A]
6
V/BN
MAIN
O/V
7
HARNESS
BE
3
1 2
3 4 5 6 7 8
[31R]
HARNESS
GY/BK
8
[22A]
BE
4
[21B]
GN/R
9
V/BN
5
[31A]
(BK)
10
BK
6
11
MOVE Y/BK WIRE TO CAVITY
RUNNING
VIOLET TAPE
INDICATOR
12
11 IF USING WHELEN SIREN
LAMPS
LEFT
BK
AMPLIFIER & 'AIR HORN'
BE
-
11
FUNCTION IS DESIRED
[24B]
(GRAY)
DIRECTIONAL
RIGHT
V/BN
AND RUNNING
TURN
RT
3
O/W
1
LAMP
TURN
Y
2
+
10
OIL
BE
3
[31D]
PRESSURE
OP
9
W
4
FROM
GY/BK
W/V
5
MAIN
+
10
NEUTRAL
Y/BK
6
HARNESS
N
8
BK/R
7
[24A]
BK/R
8
[73L]
-
11
[39A]
HIGH
PK/BK
9
BEAM
10
HB
4
TN/BK
Y/BK
11
LEFT
-
11
1
2
3
4
5
6
7
8
9
10 11 12
LEFT
12
PURSUIT
TURN
LT
5
LAMP
CLUTCH
(RED)
RIGHT REAR
LOCKOUT SWITCH
[73B]
DIRECTIONAL
SIREN OFF/RUN
2
1
FUEL GAUGE
LAMP
SWITCH
HEADLAMP HI/LO
TO
G
V/BN
SWITCH
MAIN
S I
BK
FROM MAIN
LEFT
HARNESS
HARNESS
BRAKE LIGHT
DIRECTIONAL
[94B]
SWITCH
HORN/SIREN
6543
2
1
BK
EFI ONLY
R/Y
SWITCH
[19B]
O/W
[19A]
BE
V/BN
1
1
HAND CONTROLS,
FROM MAIN HARNESS
[117A]
2
2
[94A]
BK
LEFT
[67A] AND [66A]
TAIL
[66B]
1234
HDI ONLY
[ 24L]
AND/OR
1234
[18B]
TO MAIN
[18A]
TAIL
REAR VIEW OF
[67B]
V/BN
1
1
DOM ONLY
TAILLAMP
HARNESS
BK
2
2
TOGGLE SWITCH
FUEL
PUMP
WITH KEYWAY DOWN
4
4
BK
1
1
3
3
2
2
2
2
ON
NORMALLY CLOSED
BK
3
3
1
1
FENDERTIP LAMP (DOM)
BK
FULL: 39.5/27.5 OHMS
COMMON
1/2: 118.0/97.0 OHMS
LICENSE PLATE LAMP (HDI)
NORMALLY OPEN
123
EMPTY: 260.0/240.0 OHMS
[93B]
BK
[141A]
[45B]
[45A]
[93A]
BK
OFF
KEYWAY DOWN
BK
FUEL PUMP ASSEMBLY IN TANK
ACCESSORY/SPOT SWITCH
V/BN
BK
LEFT REAR
DIRECTIONAL
f2227j8x
LAMP
2004 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models,
Handlebar Controls, Indicator Lamps, Tail Lamp, Pursuit Lamps, Directional Lamps, Accessory/Spot Switch, Speedometer and Tachometer
8-43
HOME
Right front
UPS 54C / UPS 64C
strobe bulb (blue)
Use terminals and terminal
POWER SUPPLY
housings supplied by Whelen
GN
for connections at power supply
BK
R
CONTROL INPUT
1
2 3
4
1-4
GND
2-3
H/L
+12VDC
"X" Indicates unterminated
F
#22 Ga. wires supplied by Whelen
strobe harness wires in fairing
U
Route through spotlight stems
cavity on FLHTP models or
S
Existing pole lighting wire
E
headlight nacelle on FLHP/I
located at left rear side of
models
motorcycle
BK
Left front
strobe bulb (red)
V
GN
R
GN R
Power down circuit
GN
optional
R
R
BK
BK
W
W
V
W
Existing strobe
GN
harness (routed
"XX" indicates
Ground to left ground
under tank)
unterminated strobe
stud in front of battery
Remove GY/BK wire from terminal
harness wires located
"X" of the pursuit flasher and terminate
under left side cover
O
Connect to O/R
it to W/GN wire of the strobe harness
O
wire of ACC. fuse
located under left
Not used
side cover
GY BK
W
GN
Cable color
XX XX
Stripe color
W
R
RED
BE
BLUE
BK
TN
TAN
BK
BLACK
R
V
BN
VIOLET
BROWN
Pursuit flasher is located in
Extra wire and terminals
W
GN
GREEN
WHITE
fairing on FLHTP models and
may be required to connect
Y
YELLOW
GY GRAY
under left side cover on
harness to power supply
PK
PINK
FLHP/I models
O ORANGE
f2227g8x
2004 FLHTP, FLHP and FLHPE, DOMESTIC AND INTERNATIONAL Models,
Optional Strobe System
8-44
HOME
HYDRAULIC CLUTCH
1.1
GENERAL
8834
4
2
The clutch is hydraulically actuated. A hand lever actuated
master cylinder creates pressure in a clutch fluid line that
activates a secondary clutch actuator mounted in the clutch
release cover. The secondary clutch actuator piston extends
and contacts a pushrod which releases the clutch.
3
1
CAUTION
D.O.T. 5 SILICONE BRAKE FLUID is used for the hydrau-
lic clutch and is referred to as clutch fluid in this manual.
Do not use other types of fluid as they are not compati-
ble.
CHECKING AND CORRECTING
CLUTCH FLUID LEVEL
1.
Clutch Master Cylinder Reservoir
2.
Reservoir Cover
3.
Cover Gasket
Even though a clear sight glass in the reservoir cover indi-
4.
Screws (2) @ 6-8 in-lbs (0.68-0.90 Nm)
cates a low clutch fluid, it is also possible to remove the cover
to verify fluid level.
Figure 1-1. Clutch Master Cylinder Reservoir (Typical)
1WARNING
8835
D.O.T. 5 silicone hydraulic brake fluid is used in the
hydraulic clutch. Do not use other types of fluids as they
are not compatible and could cause equipment damage.
(00204a)
1WARNING
Do NOT allow dirt or debris to enter the clutch master cyl-
inder reservoir. Dirt or debris in the reservoir can cause
improper operation of the clutch and equipment damage.
(00205a)
1WARNING
Figure 1-2. Fill Level (reservoir cover removed as viewed
Direct contact of D.O.T. 5 brake fluid with eyes can cause
from front of motorcycle)
eye irritation, swelling, and redness. Avoid eye contact. In
case of eye contact flush with large amounts of water and
get medical attention. Swallowing large amounts of D.O.T.
CAUTION
5 brake fluid can cause digestive discomfort. If swal-
Clutch fluid volume actually increases with clutch wear.
lowed, obtain medical attention. Use in well ventilated
Do NOT overfill reservoir.
area. KEEP OUT OF REACH OF CHILDREN. (00144a)
5. If necessary, add D.O.T. 5 SILICONE BRAKE FLUID,
1. Stand motorcycle upright (not leaning on jiffy stand) on a
(HD-99902-77) to master cylinder reservoir. Fluid level
level surface. Turn handlebars to the right if necessary,
should not exceed FILL LEVEL.
so top of clutch master cylinder reservoir is level.
6. Carefully place cover gasket and cover on clutch master
2. See Figure 1-1. Clean and remove reservoir cover.
cylinder reservoir and secure with two cover screws.
7. Tighten reservoir cover screws to 6-8 in-lbs
3. Remove two clutch master cylinder screws, cover and
(0.68-0.90 Nm).
cover gasket.
4. See Figure 1-2. Verify fluid level in the clutch master cyl-
inder is at FILL LEVEL mark at top of ledge on rear
inside wall of reservoir.
2004 FLHTCSE: Maintenance
1-1