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Harley Davidson 2008 Touring Models. Service Manual - page 28

into pin housing until it "clicks." To avoid stressing wires,
verify that tail lamp conduit is positioned on the outboard
side of the rear fender tip lamp and left turn signal lamp
conduit as shown

Figure 8-53

10. Place tail lamp into position against chrome base.

11. Install two screws and alternately tighten to 20-24 in-

lbs (2.3-2.7 Nm).

NOTE

Over tightening screws can crack the lens or result in scratching
of the fender paint.

12. Turn the Ignition/Light Key Switch to IGNITION and test

lamp for proper operation.

13. Install saddlebag. See

2.27 SADDLEBAGS

Removal: FLHX, FLTR

NOTE

This procedure entails replacement of the rear turn signal lamp
socket/ isolator assembly. To remove and install the turn signal
lamps bracket, see

8.14 TURN SIGNAL LAMPS, Rear Turn

Signal Lamps Bracket

in this section.

Remove chrome base and circuit board assembly. See

8.12 TAIL LAMP

Remove terminals from socket housing of rear turn signal
lamp connector.

NOTE

For instructions on removing terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Reaching inside rear fender, release conduit from cable
clip anchored on T-stud.

Draw conduit and terminals through hole to outboard side
of fender.

Remove socket/isolator assembly as follows:

Insert blade of small screwdriver into slot at bottom
of lens. Gently rotate end of screwdriver to unsnap
lens from lamp.

Push grommet at end of conduit into lamp housing.
Lightly lubricate grommet with glass cleaner, if
necessary.

Push in bulb and rotate in a counterclockwise direction
to remove.

Inserting blade of small screwdriver between outer
edge of rubber isolator and inside of lamp housing,
gently pry up socket assembly until free.

Pull socket assembly to draw conduit and terminals
into lamp and then out through lens opening.

Remove rubber isolator from lamp if still installed.

Installation: FLHX, FLTR

Place new socket/isolator assembly next to discarded unit
and cut wires to proper length. Crimp new socket terminals
onto wires.

NOTE

For instructions on crimping terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Install socket/isolator assembly as follows:

Seat socket assembly in rubber isolator aligning tab
on socket with slot in isolator.

Feed terminals and conduit into lamp through lens
opening and then out through unthreaded hole.

Exercising caution to avoid pulling on wires, carefully
pull grommet out through hole in lamp. For best res-
ults, grasp edge of grommet with needle nose pliers.
Lightly lubricate grommet with glass cleaner, if
necessary.

Install socket assembly aligning tab on socket with
slot inside lamp.

Using thumbs of both hands, apply even pressure
around outer edge of socket assembly until fully
seated.

Liberally apply dielectric grease to contacts in socket
and at bottom of bulb. Push in bulb and rotate in a
clockwise direction to install.

Install lens in lamp and gently apply thumb pressure
until it snaps into place. Rotate lens to position slot
at bottom of lamp.

Feed socket terminals through hole to inboard side of
fender.

Install terminals into socket housing. See

Table 8-11

NOTE

For instructions on installing terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Reaching inside rear fender, capture conduit in cable clip
anchored on T-stud.

Install chrome base and circuit board assembly. See

8.12 TAIL LAMP

REAR TURN SIGNAL LAMPS BRACKET

Removal: FLHR/C, FLHT/C/U

Remove chrome base and circuit board assembly. See

8.12 TAIL LAMP

Remove rear turn signal lamps from bracket. See

8.14 TURN SIGNAL LAMPS, Rear Turn Signal Lamp

this section.

Remove two screws to free rear turn signal lamps bracket
from rear fender.

Installation: FLHR/C, FLHT/C/U

Apply one drop of Loctite High Strength Threadlocker 271
(red) to two screws.

Install screws to fasten rear turn signal lamps bracket to
rear fender. Alternately tighten screws to 84-144 in-
lbs (9.5-16.3 Nm).

Install rear turn signal lamps to bracket. See

8.14 TURN

SIGNAL LAMPS, Rear Turn Signal Lamp

in this section.

Install chrome base and circuit board assembly. See

8.12 TAIL LAMP

2008 Touring Service: Electrical 8-41

Removal: FLHX, FLTR

NOTE

To remove the rear turn signal lamps bracket on FLHX models,
see

8.15 LICENSE PLATE LAMPS AND BRACKET: FLHX

Remove circuit board and chrome base. See

8.12 TAIL

LAMP

Reaching inside rear fender, release left and right rear
turn signal lamp conduit from respective cable clips
anchored on T-studs.

Remove two screws to release rear turn signal lamps
bracket.

Pull rear turn signal lamps bracket away from motorcycle
drawing socket housings out through fender holes.

Installation: FLHX, FLTR

NOTE

To install the rear turn signal lamps bracket on FLHX models,
see

8.15 LICENSE PLATE LAMPS AND BRACKET: FLHX

Feed socket housings of left and right rear turn signal
lamps through respective holes to inboard side of fender.

Apply one drop of Loctite High Strength Threadlocker 271
(red) to two screws.

Install screws to fasten rear turn signal lamps bracket to
rear fender. Alternately tighten screws to 84-144 in-
lbs (9.5-16.3 Nm).

Install chrome base and circuit board assembly. See

8.12 TAIL LAMP

8-42 2008 Touring Service: Electrical

8.15

LICENSE PLATE LAMPS AND BRACKET: FLHX

BULB REPLACEMENT

Removal

Remove two screws to release lens of license plate lamp
from rear turn signal lamps bracket.

See

Figure 8-55

. Exercising caution to avoid stressing

wires, carefully pull down lamp assembly only as far as
necessary to access bulbs. Remove bulbs from sockets.

Installation

Liberally apply dielectric grease to contacts in sockets and
at bottom of new bulbs. Install bulbs in sockets. For correct
bulb type, see

1.4 BULB REQUIREMENTS

Install two screws to fasten lens of license plate lamp to
rear turn signal lamps bracket.

LICENSE PLATE LAMPS

Removal

Remove two screws to release lens of license plate lamp
from rear turn signal lamps bracket.

See

Figure 8-55

. Exercising caution to avoid stressing

wires, carefully pull down lamp assembly only as far as
necessary to access bulbs.

Remove circuit board and chrome base. See

8.12 TAIL

LAMP

Remove terminals from socket housing of license plate
lamps connector [45].

NOTE

For instructions on removing terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Reaching inside rear fender, release conduit from left side
cable clip anchored on T-stud.

Draw conduit and socket terminals through hole to out-
board side of fender, and then down through slot in center
of turn signal lamps bracket. See

Figure 8-56

sm03656

Figure 8-55. Release Lamp Assembly

sm03657

Figure 8-56. Draw Wires Through Fender Hole

Installation

Place new lamp assembly next to discarded unit and cut
wires to proper length.

Crimp new socket terminals onto license plate lamp wires.

NOTE

For instructions on crimping terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Feed socket terminals and conduit up through slot in center
of turn signal lamps bracket, and then through hole to
inboard side of fender. See

Figure 8-56

Install terminals into socket housing.

Table 8-12. FLHX License Plate Lamps [45]

CHAMBER NUMBER

WIRE COLOR

Black

Not Used

Black

NOTE

For instructions on installing terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Install two screws to fasten lens to rear turn signal lamps
bracket.

Reaching inside rear fender, capture conduit in cable clip
anchored on T-stud. Reaching inside rear fender, capture
conduit in cable clip anchored on T-stud.

Install chrome base and circuit board assembly. See

8.12 TAIL LAMP

LICENSE PLATE BRACKET

Removal

Remove circuit board and chrome base. See

8.12 TAIL

LAMP

2008 Touring Service: Electrical 8-43

Remove terminals from socket housing of license plate
lamps connector [45].

NOTE

For instructions on removing terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Reaching inside rear fender, release license plate lamps
conduit from left side cable clip anchored on T-stud.

Draw socket terminals through hole to outboard side of
fender. See

Figure 8-56

Reaching inside rear fender, release left and right rear
turn signal lamp conduit from respective cable clips
anchored on T-studs.

Remove two screws to release rear turn signal lamps
bracket.

Pull rear turn signal lamps bracket away from motorcycle
drawing socket housings out through fender holes.

Remove two screws to release license plate bracket from
rear turn signal lamps bracket. See

Figure 8-57

Installation

Install two screws to fasten license plate bracket to rear
turn signal lamps bracket. See

Figure 8-57

Feed socket housings of left and right rear turn signal
lamps through respective holes to inboard side of fender.

Apply one drop of Loctite High Strength Threadlocker 271
(red) to two flange bolts.

Install screws to fasten rear turn signal lamps bracket to
rear fender. Alternately tighten screws to 84-144 in-
lbs (9.5-16.3 Nm).

Feed socket terminals of license plate lamp connector [45]
through left side hole to inboard side of fender. See

Figure 8-56

Install terminals into socket housing. Refer to

Table 8-12

NOTE

For instructions on installing terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Reaching inside rear fender, capture conduit of rear turn
signal lamps connectors in respective cable clips anchored
on T-studs. Also capture license plate lamps conduit in
left side cable clip.

Install chrome base and circuit board assembly. See

8.12 TAIL LAMP

sm03658

Figure 8-57. Remove License Plate Bracket

8-44 2008 Touring Service: Electrical

8.16

TSM/HFSM

REMOVAL

NOTE

If equipped with the optional "Harley-Davidson Smart Security
System," verify that the security status lamp in speedometer
face is not flashing before proceeding (security system dis-
armed).

Remove seat. See

2.26 SEAT

Depress tab at front of spring clip and lift to release index
pins from holes in frame crossmember. See

Figure 8-58

Remove module from hole in frame crossmember and
disconnect TSM/HFSM connector [30], 12-place Deutsch.

If equipped, disconnect HFSM antenna jumper harness
connector [208], 4-place Deutsch.

INSTALLATION

Connect TSM/HFSM connector [30], 12-place Deutsch,
to module.

If equipped, connect HFSM antenna jumper harness
connector [208], 4-place Deutsch.

Install module into hole on right side of frame cross-
member.

Insert index pins on spring clip into holes in frame cross-
member and push down until tab at front snaps in place.

Install seat. See

2.26 SEAT

Test all turn signal functions. Test all security system
functions, if equipped.

sm05252

Spring clip

TSM/HFSM

Rubber boot

Figure 8-58. Frame Crossmember (Under Seat)

HFSM ANTENNA

Removal

Remove seat. See

2.26 SEAT

Release groove on HFSM antenna from tongue at front
of top caddy.

Disconnect HFSM antenna connector [209], 2-place Molex,
from jumper harness. See

Figure 8-59

Remove HFSM antenna jumper harness as follows:

Remove HFSM module. See

8.16 TSM/HFSM,

Removal

Disconnect jumper harness connector [208], 4-place
Deutsch, from HFSM module.

Draw jumper harness below frame crossmember thru
empty slot of rubber boot on left side, and then pull
back up and out thru right side opening.

Installation

Install HFSM antenna jumper harness as follows:

Connect jumper harness connector [208], 4-place
Deutsch, to HFSM module.

Feed jumper harness down through opening on right
side of frame crossmember, and then pull back up
and out thru empty slot of rubber boot on left side.

Install HFSM module. See

8.16 TSM/HFSM, Installa-

tion

Connect HFSM antenna connector [209], 2-place Molex,
to jumper harness.

Routing jumper harness conduit along inboard side of left
upper frame tube, engage groove on HFSM antenna on
tongue at front of top caddy.

Install seat. See

2.26 SEAT

Test all security system functions.

2008 Touring Service: Electrical 8-45

sm05254

HFSM

Jumper harness

HFSM antenna

Figure 8-59. HFSM/HFSM Antenna and Jumper Harness

8-46 2008 Touring Service: Electrical

8.17

IGNITION/LIGHT KEY SWITCH AND FORK LOCK

FLHX, FLHT/C/U, FLTR

TOOL NAME

PART NUMBER

IGNITION SWITCH CONNECTOR
REMOVER

HD-45961

IGNITION SWITCH ALIGNMENT TOOL

HD-45962

Removal

Remove maxi-fuse. See

8.5 SYSTEM FUSES AND

RELAYS

Remove the ignition switch knob as follows:

Insert the ignition switch key and turn to the UNLOCK
position. Leave the key installed in the ignition switch
knob.

Turn the front forks to the left fork stop and rotate the
knob to FORK LOCK.

Depressing the release button at bottom (left side)
with a small screwdriver, push key down and turn 60°
in a counterclockwise direction. See

Figure 8-60

sm03678

Figure 8-60. Ignition Switch Knob Release Button (Top

and Bottom Views)

sm03679

Figure 8-61. Ignition Switch Alignment Tool (HD-45962)

sm03680

Figure 8-62. Bottom Alignment Tool in Threaded Post and

Rotate to Desired Position

Lift and remove knob. Be aware that spring will drop out
of bore at underside of knob when removed.

NOTE

After removal of the knob, the IGNITION SWITCH ALIGNMENT
TOOL (Part No. 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 8-62

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

Pull collar and spacer from threaded post.

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

2008 Touring Service: Electrical 8-47

FLHX, FLHT/C/U:

Remove outer fairing. See

2.35 UPPER FAIRING

AND WINDSHIELD: FLHX, FLHT/C/U

Using a long shank ball end socket (Snap-on®
FABL6E), remove four socket head screws to release
radio (storage box on FLHT) from left and right radio
support brackets. Use oblong holes in fairing brackets
to access screws. Lift radio slightly.

Carefully cut anchored cable strap to release main
harness conduit from bottom right corner of radio.

Remove fairing cap. See

2.36 FAIRING CAP: FLHX,

FLHT/C/U

FLTR: Remove instrument nacelle. See

2.41 INSTRU-

MENT NACELLE: FLTR

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

Obtain the IGNITION SWITCH CONNECTOR
REMOVER (Part No. HD-45961). See

Figure 8-63

Gently insert end of tool into slot in ignition switch
housing until it stops.

Grasping main harness conduit and tool, pull both at
the same time to release socket housing from ignition
switch housing. See

Figure 8-64

sm03681

Figure 8-63. Ignition Switch Connector Remover (HD-45961)

sm03682

Figure 8-64. Pull Main Harness Conduit and Tool to Release

Socket Housing

sm03683

Knob

Spring

Nut

Collar

Spacer

Break-away screw (international only)

Flat washer

Switch housing

Figure 8-65. Ignition Switch Assembly (International)

10. Remove upper handlebar clamp. Support handlebars out

of the way. See

2.24 HANDLEBARS, Removal

11. Domestic: Remove two screws (with flat washers) at base

of ignition switch housing.

Always wear proper eye protection when drilling or
grinding. Flying debris could cause serious eye injury.
(00402e)

12. International: Remove two break-away screws (with flat

washers) as follows.

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.

8-48 2008 Touring Service: Electrical

sm03684

Figure 8-66. Rotate Alignment Tool Without Bottoming

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.

13. Remove ignition switch housing from bore of upper fork

bracket. See

Figure 8-65

Installation

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

Domestic: Install two screws (with flat washers) at base
of ignition switch housing. Alternately tighten screws to
36-60 in-lbs (4.1-6.8 Nm).

International: Install two new break-away screws (with
flat washers) as follows.

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 prop-
erly tightened.

NOTE

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

Rotate break-away screws in a clockwise direction
until heads snap off.

Install handlebars. See

2.24 HANDLEBARS, Installation

Install ignition switch connector [33], 3-place Packard, at
front of ignition switch housing.

Install anchor of new cable strap in hole at bottom right
side of radio. Tighten cable strap capturing main harness
conduit (to ignition switch).

FLHX, FLHT/C/U:

Install fairing cap. See

2.36 FAIRING CAP: FLHX,

FLHT/C/U

Using oblong holes in fairing brackets and a long
shank ball end socket (Snap-on® FABL6E), install
four socket head screws to fasten radio (storage box
on FLHT) to left and right radio support brackets.
Alternately tighten screws to 35-45 in-lbs (4.0-5.1
Nm).

Install outer fairing. See

2.35 UPPER FAIRING AND

WINDSHIELD: FLHX, FLHT/C/U

FLTR: Install instrument nacelle. See

2.41 INSTRUMENT

NACELLE: FLTR

Install switch position plate fitting tabs in slots of fairing
cap (FLHX, 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.

10. Install spacer over threaded post of ignition switch housing

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 8-65

11. 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.

12. 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 in-lbs (14.1-16.9 Nm).

13. Install spring into bore at underside of knob.

14. 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 pos-
itions to verify proper operation. If knob will not install
properly, proceed as follows:

Verify that button at bottom of knob is depressed and
key is turned 60° beyond the UNLOCK position. See

Figure 8-60

Repeat this step.

If knob does not install properly, move to previous
step.

15. Knob was removed in ACCESS or switch may have been

moved out of the FORK LOCK position. Proceed as fol-
lows:

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 counter-clock-
wise direction until fork locks. See

Figure 8-62

Remove tool and repeat previous step.

If knob does not install properly, move to next step.

16. Detent and switch position lugs are misaligned. This can

occur when the alignment tool (or ignition switch knob) is

2008 Touring Service: Electrical 8-49

rotated before it is properly bottomed in the ignition switch
housing. Proceed as follows:

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.

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 8-66

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 16(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 counterclockwise direction or one
position in a clockwise direction. Repeat step 14.

17. Install maxi-fuse. See

8.5 SYSTEM FUSES AND RELAYS

FLHR/C

Ignition/Light Key Switch: Removal

Remove maxi-fuse. See

8.5 SYSTEM FUSES AND

RELAYS

Remove seat. See

2.26 SEAT

Remove socket screw to release front of console from fuel
tank weldment.

Remove hex screw to release rear console bracket from
clip nut on rear fuel tank bracket.

Lay a clean shop towel on forward part of rear fender.
Remove console and lay upside down on shop towel.

Disconnect ignition switch connector [33], 3-place Packard.
See

Figure 8-67

. Release ignition switch conduit from

plastic clip, if necessary.

Remove four screws to release ignition switch from con-
sole.

Ignition/Light Key Switch: Installation

Align holes in new ignition switch with those in console.
See

Figure 8-67

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

Connect ignition connector [33], 3-place Packard. Capture
ignition switch conduit in plastic clip, if removed.

Exercising caution to avoid pinching wire harness and vent
tube, position console on fuel tank.

Start socket screw to fasten front of console to fuel tank
weldment.

sm03685

Ignition switch connector [33]

Screw (4)

Plastic clip

Figure 8-67. Instrument Console (FLHR/C)

Start hex screw to fasten rear console bracket to clip nut
on rear fuel tank bracket.

Alternately tighten socket/hex screws to 36-60 in-lbs (4.1-
6.8 Nm).

Install seat. See

2.26 SEAT

Install maxi-fuse. See

8.5 SYSTEM FUSES AND RELAYS

Fork Lock: Removal

Remove handlebar clamp shroud. See

2.45 HEADLAMP

NACELLE: FLHR/C

, steps 1-11.

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

Remove two socket screws (with flat washers) and pull
fork lock assembly from upper fork bracket bore. See

Figure 8-68

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.

Fork Lock: Installation

Install new fork lock assembly into bore of upper fork
bracket. See

Figure 8-68

Install two socket screws (with flat washers) and alternately
tighten to 36-60 in-lbs (4.1-6.8 Nm).

8-50 2008 Touring Service: Electrical

sm03686

Figure 8-68. Fork Lock (FLHR/C)

NOTE

On HDI models, install new break-away screws and turn in a
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 motorcycle as vibration may
cause captured heads to scratch finished surfaces, chafe wires
or cause other damage.

Install handlebar clamp shroud. See

2.45 HEADLAMP

NACELLE: FLHR/C

, steps 3-15.

2008 Touring Service: Electrical 8-51

8.18

FAIRING CAP SWITCHES: FLHTC/U

REMOVAL

Partially disassemble ignition switch: remove ignition
switch knob, spring, nut, collar, spacer and switch position
plate. See

8.17 IGNITION/LIGHT KEY SWITCH AND

FORK LOCK

Remove two screws (with flat washers) to release fairing
cap from left and right sides of inner fairing.

With the front forks turned to the left fork stop, reach
behind right side of fairing cap and disconnect the fairing
cap switch connector [105], 12-place Multilock.

Remove fairing cap from motorcycle. See

Figure 8-69

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.

Remove two screws to release switch bracket from fairing
cap.

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

Figure 8-70

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

Follow the wires of the faulty switch to the socket housing,
or reference

Figure 8-71

and

Table 8-13

for the applicable

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

10. Remove the appropriate terminals from the socket housing.

NOTE

For instructions on properly removing wire terminals, see

A.2 AMP MULTILOCK CONNECTORS

sm03687

Auxiliary lamp switch

Fairing cap switch connector [105]

Cable strap

Speaker switch

Cruise switch

Flexible clamp

Switch bracket screws

Accessory switch

10.

Grommet

Switch bracket

Figure 8-69. FLHTCU Fairing Cap (Inboard Side)

INSTALLATION

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

Install terminals into socket housing.

NOTE

For instructions on properly installing wire terminals, see

A.2 AMP MULTILOCK CONNECTORS

8-52 2008 Touring Service: Electrical

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

A.18 SEALED

SPLICE CONNECTORS

Install two screws to secure switch bracket to fairing cap.

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 8-69

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

sm03688

Switch bracket

Latch

Tab

Figure 8-70. Bend Latches Outward to Release Tabs

Table 8-13. Fairing Cap Switches [105]

CHAMBER

NUMBER

WIRE COLOR

SWITCH

Orange/Red

Accessory

Orange

Black

Orange/Violet

Cruise

Ultra Only

Red/Green

To Speaker Switch

Black/Green

(Double Lugged)

Yellow

Auxiliary Lamp

Gray/Black

Black

Orange/Blue

Speaker

Ultra Only

Violet/Orange

Brown/Orange

To Cruise Switch

Black/Green

5 5

– AMP

sm03689

Figure 8-71. Socket Housing (Secondary Locks Open)

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

With the front forks turned to the left fork stop, install fairing
cap over ignition switch housing. Verify that grommets in
fairing cap fully capture handlebar, handlebar switch con-
duit, and brake line from front master cylinder reservoir
(right side).

Start two screws (with flat washers) to fasten fairing cap
to left and right sides of inner fairing. Alternately tighten
screws to 25-30 in-lbs (2.8-3.4 Nm).

10. Assemble ignition switch: install switch position plate,

spacer, collar, nut, spring and knob. See

8.17 IGNITION/LIGHT KEY SWITCH AND FORK LOCK

2008 Touring Service: Electrical 8-53

8.19

INSTRUMENT NACELLE SWITCHES: FLTR

REMOVAL

Partially disassemble ignition switch: remove ignition
switch knob, spring, nut, collar, spacer and switch position
plate. See

8.17 IGNITION/LIGHT KEY SWITCH AND

FORK LOCK

Remove screw on each side of bezel.

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).

See

Figure 8-72

. Raising bezel slightly, disconnect

instruments and indicator lights from interconnect harness
as follows:

Speedometer connector [39], 12-place Packard.

Tachometer connector [108], 12-place Packard.

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

Remove bezel from motorcycle.

Follow instructions based on location of defective switch.

Left Side Switch

See

Figure 8-72

. Disconnect speaker switch connector

[105], 4-place Multilock.

Pull clutch cable clip from hole on left side of instrument
nacelle.

Remove two screws (with flat washers) to release left side
of instrument nacelle from upper and lower fork brackets.

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 8-72

Gently bend back molded retainer to release switch
bracket assembly from instrument nacelle.

Carefully pry two latches on bracket outward to release
tabs on switch. Remove switch from bracket. See

Figure 8-73

sm02877

Speaker switch [105C/D]

Indicator lights [21]

Speedometer gauge [39]

Tachometer gauge [108]

Clutch cable

Instrument nacelle switches [105A/B]

Figure 8-72. Instrument Nacelle (Bezel Removed)

8-54 2008 Touring Service: Electrical

Right Side Switches

See

Figure 8-72

. Disconnect speaker switch connector

[105], 4-place Multilock.

See

Figure 8-72

. Disconnect instrument nacelle switch

connector [105], 12-place Multilock.

Remove two screws (with flat washers) to release right
side of instrument nacelle from upper and lower fork
brackets. Move right side of nacelle to bench area leaving
left side on motorcycle. See

Figure 8-72

Gently bend back molded retainer to release switch
bracket assembly from instrument nacelle.

Carefully pry two latches on bracket outward to release
tabs on switch. Remove switch from bracket. See

Figure 8-73

Remove the appropriate terminals from the socket and/or
pin housings. Follow the wires of the faulty switch or refer-
ence

Table 8-14

for the applicable chamber numbers. For

wire location purposes, numbers are stamped into the
secondary locks. See

Figure 8-74

NOTE

For instructions on properly removing wire terminals, see

A.2 AMP MULTILOCK CONNECTORS

Carefully pull wires to draw terminals through conduit to
backside of switch. For best results, pull one wire at a
time.

sm03688

Switch bracket

Latch

Tab

Figure 8-73. Bend Latches Outward to Release Tabs

Table 8-14. Right Side Instrument Nacelle Switches

CHAMBER NUMBER

WIRE COLOR

SWITCH

4-PLACE

PIN

12-PLACE

SOCKET

Orange/Red

Accessory

Orange

Black

Orange/Violet

Cruise

Red/Green

Black/Green

(Double

Lugged)

5 5

– AMP

sm03689

Figure 8-74. Socket Housing (Secondary Locks Open)

INSTALLATION

Left Side Switch

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.

Snap switch bracket into molded retainer in instrument
nacelle.

While carefully placing left side of instrument nacelle on
motorcycle, slide odometer reset switch through hole and
install rubber boot. See

Figure 8-75

See

Figure 8-72

. Connect speaker switch connector [105],

4-place Multilock.

Install two screws (with flat washers) to fasten left side
instrument nacelle to upper and lower fork brackets.
Alternately tighten screws to 15-20 ft-lbs (20-27 Nm).

Capture clutch cable in cable clip. Insert cable clip into
hole in left side of instrument nacelle.

Right Side Switches

See

Figure 8-73

. 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.

2008 Touring Service: Electrical 8-55

sm00051

Wire lead in metal insert

Crimp metal insert

Center of crimp

Melted sealant

Figure A-55. Sealed Splice Connector

2008 Touring Service: Appendix A Connector Repair A-37

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